f e a t u r e d !
Packaging processes in the automotive industry High quality packaging plays a major role in the automotive industry, and so the focus of the latest Auto Motor Sport Auto Salon in Geneva was not just on new models of cars, but increasingly also on automotive accessories, an area that is clearly gaining in importance. Not only do the required parts need to undergo the best possible processing, but it is also vital that they should be efficiently packaged to allow trouble-free handling in inbound and outbound logistics. Container-optimised packaging and secure shipping are seen as vital requirements for a smooth supply chain in the automotive industry.
Optimised processes for automotive components Vehicle components have long been be produced outside the manufacturer’s premises. Instead, international carmakers increasingly use third-party modules that require customised shipping and storage methods, for which the packaging industry provides suitable solutions. Thanks to special containers, it is possible to warrant secure transportation by ship and by rail, followed by economical storage on factory premises. Stackable trays are available so that each vehicle component is easy to handle, regardless of the product type. High-quality materials such as VCI film for corrosion protection and corrugated cardboard for greater stability ensure that each item can be packaged and secured to suit its specific requirements, whether such items are engines, bulbs, pumps, transmissions or various small parts.
Product protection and safety thanks to foamed plastic solutions High-quality foamed plastic provides additional protection against heat impact and subzero temperatures. Whether it’s body parts, aluminium cases, plastic boxes or tools, customised cutting and trimming of the relevant plastic foam inserts help to ensure full functionality of the packaged components even after a number of years. Another bonus point is that CFC-free foam has no environmental impact during the manufacturing process and allows recycling after use. Moreover, the use of wood, steel and metal makes it possible to produce custom-fit packaging systems for electronic accessories and on-board instruments while also preventing potential damage.
Vol.2 No.2 | March-April 2014 | New Delhi, India
ANNUAL SUBSCRIPTION: US$100
I n T h e P a g e s 4 New dimensions in in-house recycling 8 ArabiaMold 2014 – EuroMold goes to Sharjah 10 CHINAPLAS 2014 to Drive the Evolution of Sustainability 14 Beverage&Packaging at Interpack 2014 20 AMUT: Multipurpose Extrusion Solutions 22 Huge exhibitor demand for interpack 2014 28 Changes and Trends in Blow Moulding Technology 36 InterPlas Thailand 2014 - The Future is Here! 41 Technical Report - Hi-Q Shaping 43 Interior design of the Airbus A380 super jumbo 48 Upward trends in organic food containers 54 Saving energy – soon a duty for all?
Editorial: Reny, Sarvjit, Vishwapreet & Amrita (India), Anna (Sweden), Mike (UK), Liza (Singapore), Upi (Indonesia), Ying & Adrian (China), Arvi (Australia). Public Relations Director: Winnie. Advisor: Rajiv Sanghavi. Production: Rakesh. Design, Art & Web Development: Diamond Infomedia. Publisher: Milinia Inc. Founded by: Late Mr N.S. Kanwar. B-2-B Group Publications: PRINTING REVIEW, Medical Device ASIA, autoASIA, Hotels & Culinary ASIA, Electronics & Electrical ASIA, Beauty & Fashion World. Contacts: To advertise: advertise@ plasticsandrubberreview.com, to submit a press release: email@example.com, to subscribe: firstname.lastname@example.org, for any other enquiries: info@ plasticsandrubberreview.com. Head Office: D-182, PR House, Anand Vihar, 110092 New Delhi, India. Tel: +91 11 22141542 | Fax: +91 11 22160635. Published, printed, & owned by S. Singh on behalf of Milinia Inc. at , D-182, PR House, Anand Vihar, 110092, New Delhi, India and printed by him at Technical Press, D-182/C, Anand Vihar, 110092, New Delhi, India. Views expressed in this magazine are of the contributors, authors and companies and not necessarily of the publisher and/or editors’ and they do not take any responsibility for the errors and/or accuracy of the information published in this publication. No part or design of this magazine can be reproduced without prior permission of the publisher, who reserves the right to use the information published in this magazine in any manner whatsoever.
New dimensions in in-house recycling Exclusive world premiere at interpack 2014: INTEREMA® K of the INTAREMA® generation. The result is the fully automatic INTAREMA® K recycling system – with the new, patented core technology Counter Current, the energy-saving ecoSAVE® system including direct drive and, for the first time, a touchscreen, the new Smart Start System for even more user-friendliness through a high degree of automation. INTAREMA® K is designed above all for the processing of edge trim and enables an up to 100% return to the production process. EREMA sets the new standard in production efficiency in plastics recycling The proven EREMA cutter/compactor/extruder combination has always ensured the efficient processing of plastic production waste – especially in the packaging industry which, in particular, has very high quality requirements for re-usable pellets. With the innovations of the new INTAREMA® plant generation, such as the Counter Current system, EREMA now sets another milestone in the field of in-house and industrial waste recycling.
World premiere at interpack 2014: EREMA presents for the first time INTAREMA® K. The model 504 K will be on show as an exhibit.
EREMA, the global market leader in plastic recycling systems, will be presenting the new INTAREMA® K system for the first time at interpack 2014. The new model is the successor of the KAG system designed especially for the recycling of PE edge trim – a fully automatic recycling system which ensures materialfriendly processing through a short extruder, i.e. minimal thermomechanical stress and excellent material properties as a result. With the additional integration of the innovative technologies of the new INTAREMA® plant generation it will now be known as INTAREMA® K and promises a further boost in efficiency. The model 504 K will be presented to the industry for the first time from 8 to 14 May 2014 as an exhibit on the EREMA stand D70 in Hall 11. The development and production of high-performance and application-oriented recycling solutions for production waste in the fields of in-house and industrial waste is a core competency of EREMA. The new plant generation INTAREMA® was launched in 2013, with which the T and TE systems (for PE, PE-LD, PP, BOPA, PA/PET, PLA etc. edge trim) and TVEplus® (heavily printed materials and strongly contaminated post-consumer waste) have already experienced an enormous boost in efficiency. The plant system known previously as KAG now also features the innovations 4 | March-April 2014 | Plastics & Rubber Review
Rajoo Upholds The Custom Of Being A Pacesetter:
Rajoo’s Labex - Lamina– Nano Five Layer Barrier Sheet Line Awarded ‘Pride is not in achieving honors, but in be worthy of getting it’, Says Sunil Jain, President, Rajoo Engineers. ‘We are delighted at this honour bestowed by IPMMI; especially for this revolutionary designed product that has created history and will now carve a niche for itself in the world markets’, says Khushboo Chandrakant Doshi. New polymers, newer materials, newer machines for trial runs…the challenges are enormous for the process development laboratory, raw material manufacturers and large processors to ensure process or application development on one side with a production like feel on the other. Estimates and guesstimates should surely be a thing of the past, quite surely so, the industry deserves this convenience. With this accomplishment, Rajoo once again pays tribute to its Mentor & Founder Mr. Chandrakant N.Doshi. LabEX …addresses the challenges in sheet extrusion of a process development laboratory, raw material manufacturers and large sheet producers …wins a national award and also gets award by IPMMI. LabEX-Lamina– Nano Five Layer barrier sheet Line is equipped with one 30 mm extruder for inner layers three - 20 mm extruder for skin and middle layers , with 300mm width and maximum output 40 kg/hr. It is the world’s smallest five layer barrier sheet line, thus helping simulate commercial scale sheet extrusion process on a lab-scale. Onn 7th February, 2014, Institute of Packaging Machinery Manufacturers of India, Mumbai ( IPMMI) identified Rajoo Engineers Limited as an innovator in extrusion when it recognized its development in Labex – Lamina – Nano 5 layer barrier sheetline. This marvel was awarded with the IMDIR-2013 under the award category – IPMMI – Machinery Design / Development / Innovation. Rajoo Engineers received the award from Mr. Suresh Gupta ( MD of Huhtamaki India) , Mr. S.S.Cooper (President IPMMI) and Mr. V. Krishnan (Vice President-IPMMI). 6 | March-April 2014 | Plastics & Rubber Review
About Rajoo Based in Rajkot, Rajoo Engineers Limited, having made a modest beginning in 1986, has today emerged as an undisputed global player in blown film, sheet ( both solid and foam) extrusion lines, thermoformers and non-woven fabric manufacturing machines. PVC/CPVC Pipe and Drip irrigation pipe manufacturing machines are the latest addition to the portfolio. Owing to its focused efforts.in the Company enjoys premium market position in this segment. Being a technology driven Company, product innovations, world-class quality, state-of-the-art workmanship, increased energy efficiency and high levels of sophistication and automation have become the hallmark of Rajoo products during all these years, positioning the Company’s products on a global platform, competing with the established world leaders. With representations in many countries of the world and customers in over 52 countries, the Company’s exports have multiplied after its debut in the international market in 1990. (www.rajoo.com)
ArabiaMold 2014 – EuroMold goes to Sharjah
3D giants to showcase their excellence in Arabiamold 2014
Jacky’ Business Solutions - the B2B solution-based arm of the Jacky’s Group of Companies, will be showcasing for the first time some its products for the industrial business solutions in Arabiamold 2014. The 2nd ArabiaMold will be held by DEMAT, organiser of EuroMold – world fair for Moldmaking and Tooling, Design and Application Development- and Expo Centre Sharjah, with the inestimable collaboration of the Sharjah Chamber of Commerce & Industry. Sharjah – at the croccroad of Middle East Business Uniquely located on world trade routes and the only Emirate with direct access to both the Arabian Gulf and the Gulf of Oman, Sharjah has developed from a small trading town, relying on fishing and pearl diving, to one of the most modern, dynamic commercial and trade centres, as well as one of the leading tourist destinations in the Arabian Gulf. Expo Centre Sharjah, the exhibition wing of the Sharjah Chamber of Commerce and Industry (SCCI), is the UAE’s first-etablished Trade Exhibition Centre. Sharjah, is among the top ten business cities in the Gulf region and the UAE’s leading industrial and manufacturing capital with 19 industrial subdivisions. Sharjah is home to approximately 45% of all industry based in the UAE with goods being manufactured across the entire spectrum. Industrial areas have been developed in specified locations and Sharjah has two world-class free zones. Exhibiting in ArabiaMold with us offers you an excellent option to step into this well-known market. Your Success is our focus! Do not miss the opportunity and benefit from the synergy effects of the ArabiaMold. Contacts, Partnerships and favourable deals for you. This exhibition is the perfect platform that will position your company in a market full of new chances, will help you establishing local and international partnerships and also gain insight into the Near and Middle East markets. Here ends your search for a perfect Exhibition…. And, here begins the mutually beneficial business relationships! Be part of ArabiaMold, the gateaway for the Middle East market. Please join us in Sharjah in Apri 2014. We look forward to welcoming you to ArabiaMold. 8 | March-April 2014 | Plastics & Rubber Review
Visit their stand to learn about the world’s most advanced 3D printing technologies: Fused Deposition Modeling (FDM) for durable thermoplastic parts that withstand tough testing; and PolyJet, for precise models that look and feel like the final product. Making the leap to world-class 3D printing at such a low cost is a revolution on its own. From individual designer through product development collaboration to the manufacturing department, Jacky’s offers FDM and PolyJet 3D printers designed for you. Jacky’s will display Stratasys 3D FDC and Polyjet printers, Makerbot desktop 3D printers & Artec 3D scanner. Samples printed in metal on Concept Laser 3D printers and wax on SolidScape 3D printers will also be on display. Maptec - Professional solution oriented company, totally dedicated to Rapid Prototyping, Rapid Manufacturing, and 3D printing in Middle East market place will be part of Arabiamold exhibition for the second time. Maptec established its strong presence in Middle East’s Dental & Jewelry industry. They have wide presence in Middle East with offices in UAE and Saudi Arabia. Visit their stand to experience the new technology and products from one of world’s biggest manufacturers of 3D printers and scanner. Maptec represents 3D Systems - a leading provider of 3D content-to-print solutions including 3D printers, print materials and cloud sourced ondemand custom parts for professionals and consumers alike with materials including plastics, metals, ceramics and edibles. The company also provides integrated software and hardware tools including scan to CAD and inspection. Its expertly integrated solutions replace and complement traditional methods and reduce the time and cost of designing new products by printing real parts directly from digital input. These solutions are used to rapidly design, create, communicate, prototype or produce real parts, empowering customers to manufacture the future. Come with an idea and return with a finished product!
c h i n a | e v e n t
CHINAPLAS 2014 to Drive the Evolution of Sustainability
any enterprises have well-recognized the importance of building a sustainable future through resources management, recycling and energy saving. With its durable, lightweight and versatile features, plastic products make a significant contribution to the global sustainability. Lightweight vehicles reduce fossil fuel energy consumption and reduce carbon emissions, whereas innovative plastic packaging protects food in shipment and keeps it fresher and longer. High-tech plastic insulation reduces energy consumption in buildings. Energy and resources efficiencies have drawn plastics and rubber practitioner’s attention as it becomes ever more pressing issues for many enterprises to stay competitive in the world with scarcity of resources. Green technologies and industrial processes have become the promising ways leading the world to a more sustainable future. Echoing the increasing demand for more sustainable business practices, CHINAPLAS 2014, held at Shanghai New International Expo Centre, PR China from April 23 - 26, 2014, will promote sustainability under the theme of “Greenovation - Solution to Sustainability”, with “The City of Tomorrow” and “Green Conference” as two featured events. “The City of Tomorrow” will feature a circular shape structure at Central Square of the
10 | March-April 2014 | Plastics & Rubber Review
exhibition centre to showcase a comprehensive sustainability model which covers the sustainability concept in four aspects, namely Green and Alternative Raw Materials, Energy-efficient Machinery, Plastics and Rubber Applications, and Recycling. Visitors can explore the latest green messages and trends from manufacturing till the end of the life of the products through interactive displays and game booths in a fun and relaxing manner. Green Conference, another remarkable event of CHINAPLAS 2014, is a 2-day conference co-hosted by Adsale Exhibition Services Ltd, Plastics Information Europe (PIE) and Association of Green Molding Solutions (AGMS). It will be held on the second and third day of the event (April 24-25), covering the sessions of “Innovative Solutions for Plastic Recycling” and “Green Molding to Halve the Cost and Double the Wealth” respectively. The conference will highlight a range of forward thinking topics such as green molding, 3D printing, plastics recycling as well as various solutions for end-of-life plastic wastes, etc.
The Organizer expected that the conference will attract experts and decision makers in plastics and rubber industries from manufacturers, converters, end users, institutes, machinery suppliers and media to grasp the latest developments of green technologies, inventions and practices from manufacturing methods, to waste management and renewable resources in the plastics and rubber industries. The conference, presented in technical presentations and case sharing format, has invited international brand names and global market leaders across various sectors to share their experiences and insights, making it an unmissable event in CHINAPLAS 2014. For more details on the concurrent events, please visit: www. ChinaplasOnline.com/Event CHINAPLAS 2014, Asia’s no. 1 and world’s no. 2 plastics and rubber trade fair, will gather more than 2,900 exhibitors, occupying an exhibition area of over 220,000 sqm, with 14 international pavilions and more than 3,200 sets of machineries. For more information about CHINAPLAS 2014, please visit the official website at www.ChinaplasOnline.com. v
CHINAPLAS 2014 Brings in a Series of Concurrent Activities to Embrace Sustainability Sustainability is now the hottest trend that is highly sought-after by many forward-looking companies which see it as the way to improve their competitive strengths and the road to a better future. In recent years, plastics and rubber industries are transforming themselves to embrace greener manufacturing methods, technologies and products and taking sustainability at the heart of their corporate governance, in attempts to achieve considerable cost and resource savings as well as to fulfill social responsibility. Likewise, the user community also starts to realize the potentials of plastics, which are lightweight, durable and versatile, as an irreplaceable alternative in terms of energy and resource inputs when comparing side-byside with other materials like metal, steel and paper.
CHINAPLAS 2014 (The 28th International Exhibition on Plastics and Rubber Industries) will take place on 23-26 April at Shanghai New International Expo, Shanghai, PR China. To promote sustainability within the plastics and rubber industries, the show sets the theme as “Greenovation – Solution to Sustainability” and features two events, namely “The City of Tomorrow” and “Green Conference” in echoing to the theme. Ada Leung, Assistant General Manager at Adsale Exhibition Services Ltd, the organizer of CHINAPLAS, noted, “The word “greenovation” is a combination of the meaning of “green and innovation”. When companies evaluate their business five years from now, sustainability shouldn’t be the things for them to neglect. The two events give the opportunities for visitors to learn the latest trends on green solutions from market leaders. They also create
a perfect synergy complementing with the exhibition that brings together many new eco-friendly technologies and raw materials for the plastics, rubber, automotive, building & construction, E&E, IT & telecommunications and packaging industries at the fairground.” The City of Tomorrow “The City of Tomorrow” features an open semi-spherical structure located at Central Square of the exhibition centre which will portray a sustainability model encompassing four aspects of manufacturing cycle, namely Green & Alternative Raw Materials, Energy-efficient Machinery, Green Solutions for Customers & Products and Recycling. Visitors can wander inside the structure, personally interact with each of the exhibits displayed in various formats for visitors to see and touch while exploring the latest green technologies and trends in the plastics and rubber industries in a fun-filled atmosphere. Bayer MaterialScience, the leading producer of polymer and hi-tech plastics, is the exclusive sponsor for this event. Ms. Holly Lei, Vice President, China – Polycarbonates Business Unit at Bayer MaterialScience said, “Sustainability, as part of Bayer’s corporate strategy, is an integral part of our day-to-day work routines. By applying our scientific know-how, we deliver innovations that help meet the global challenges of our time.” She continued “We sponsor “The City of Tomorrow” is to raise the awareness of sustainability at where we can get all parties in the
industry and society involved and this show is the place to be. The sustainability is something we need to do it together and create social benefits for all stakeholders.” The company will display various kinds of exhibits ranging from electrical vehicle charging station, solar panel, eco window frame to notebook housings and soccer ball to tell the stories about sustainability contributed by plastics technology in different aspects of people’s daily life. Furthermore, Bayer’s participation at “The City of Tomorrow” demonstrates not only the green properties of plastics, but also its innovative solutions which contribute significantly in energyefficiency and climate protection. Other companies such as Arburg, W&H, Matsui and Trexel will also showcase green manufacturing with energy efficient machinery of injection, extrusion, auxiliaries and molding. With the growing problem of waste plastics, effective recycling and the use of bioplastics are highly sought after by the industry. Good practices in Europe and America and the applications of NatureWorks’ bioplastics will be shared at the event. Green Conference Green Conference is the half-day event running on 24-25 April in conjunction with CHINAPLAS 2014, covering industry’s hottest topics across green molding, 3D printing, plastics recycling as well as various solutions for end-of-life plastic wastes, etc. Eminent and influential speakers from Austria, China, Germany, Italy, Japan, USA,
Plastics & Rubber Review | March-April 2014 | 11
and Taiwan will share their invaluable experiences and insights. Conference session on 24 April on “Innovative Solutions for Plastic Recycling” will delve into the latest developments of green raw materials, waste treatment methods and recycling technologies for post-consumer plastic materials. Michael Heitzinger, Chief Technology Officer at EREMA will reveal a new technology to boost recycling efficiency of difficult treated waste plastics in a just single working step. Ms. Kim Holmes, Director of Recycling & Diversion at SPI: The Plastics Industry Trade Association will present about how the new treatment technologies changing the landscape of solid waste management and how it can be used in tandem with the existing mechanical recycling infrastructure. Additionally, executives from Plastics Recycling Committee of China Plastics Processing Industry Association, Plastics Recyclers Europe (PRE) and Bayer MaterialScience will also be speaking in the conference. “Green Molding to Halve the Cost and Double the Wealth” will be the theme of the second day conference on 25 April which will discuss about how green molding and 3D printing technologies can achieve cost and resources savings. Mr. Paris Ba at Shanghai Matsui Machinery will talk about how molding companies can harness the potentials of green molding to enhance competitiveness and productivity with less resource used. Mr. Yan Chin, Vice General Manager, Risemold Laser will share cases of how metal 3D printing technology can help manufacture precision 12 | March-April 2014 | Plastics & Rubber Review
injection mold. Member companies from the Association of Green Molding Solutions (AGMS), e.g. Frigel, Trexel and Moldex3D will also exchange their experiences in the conference. In the light of the growing number of enterprises in China looking for opportunities to venture out to other Asian countries, CHINAPLAS organizer will hold a seminar entitled “Key to Open Up ASEAN Market” on 26 April, Saturday morning to provide audience useful information on business environment, investment information, as well as challenges and opportunities in entering the markets in ASEAN countries. Representatives of the ASEAN Federation of Plastics Industries and overseas experts will be invited to share their experiences. With the total exhibition area spanning over 220,000 sqm, CHINAPLAS 2014 will house exhibits from 3,000 exhibitors coming from 39 countries and regions. 3,200 sets of machinery will be in display with 14 pavilions organized from Austria, Canada,
France, Germany, Hong Kong, Italy, Japan, Korea, Switzerland, Turkey, UK, USA, PR China & Taiwan. Building on the past success of CHINAPLAS, the show affords a truly international sourcing platform as a prime destination converging professional buyers and decision makers in plastics and rubber industries from around the world. It is expected to attract 120,000 visitors for this year. Leading endusers such as L’Oreal, Nike, New Balance, Toyota, BMW, Dongfeng Nissan, Geely, Lenovo, Foxconn, Samsung, TCL, Midea, HITACHI, COCA-COLA, Wahaha, DANONE, Mattel along with other buyers have already registered to the show. Pre-registration is now open until 18 April, 2014. Visitors who successfully pre-registered at www.ChinaplasOnline.com/ prereg will enjoy free and speedy admission to the fair. Besides, pre-registered visitors can also enjoy the function of “My Exhibitor” which is available at the official website and CHINAPLAS’ app to help visitors to mark their interested exhibitors and take notes of each.
Sacmi solutions for Beverage&Packaging at Interpack 2014 Latest CCM developments to be presented together with new COLORA CAP decorating system and quality control solutions for caps and preforms. Innovative FORMSLEEVE + by Sacmi Verona and new TF 12 tray forming machine by Sacmi Packaging also to be showcased.
Innovative Made-in-Sacmi technology will soon be showcased at the Interpack fair in Düsseldorf. Sacmi will, of course, be attending this important three-annual event, to be held in this German city from 8th to 14th May 2014, with its own 540 m2 display area (hall 8, stand 8AE03), allowing visitors get a close look at the very latest solutions developed for the beverage and packaging production processes. The displayed machines will include the 32-cavity CCM, a compression press for the manufacture of plastic caps, characterised – just like the rest of the CCM range – by the low temperatures at which the extrusion process takes place, thus ensuring considerable advantages on the energy-saving and productivity fronts. Equipped with an innovative ‘COOL+’ mould designed to enhance the efficiency of the cooling process even further, at the fair the CCM32 will be making soft drink closures with cycle times of approximately 2 seconds, a speed that makes this the most competitive cap production solution in the world. A Sacmi-made 2-camera Sacmi CVS3000 Quality Control system integrated on the CCM ensures 100% guaranteed cap quality. 14 | March-April 2014 | Plastics & Rubber Review
A global pioneer that is revolutionising closure products and processes (at present, 40% of the world beverage market uses Made-in-Sacmi compression technology), Sacmi will also be making the very most of the opportunities presented by Europe’s biggest packaging fair to showcase COLORA CAP, the new on-cap digital printing system that allows high-definition images to be printed directly on the production line without having to store the caps; the user can also effect real-time decoration changeovers simply by switching to a different graphics file: a major competitive advantage for manufacturers, then, in terms of both output flexibility – the machine can carry out any type of on-cap decoration (e.g.
promo campaigns, events, prizes etc.) – and stock management, allowing HD images to be printed on caps in just a few minutes, even on small production runs. The Sacmi CVS3000 Quality Control system, stationed both upstream and downstream from COLORA CAP, ensures that only flawless caps are decorated and only those with fault-free images are used in bottling. Moving on to labelling: Sacmi will also be heading to Düsseldorf with the latest plant engineering solutions from Sacmi Verona. Following an extensive overhaul in 2013, the Sacmi labelling range now includes the flagship FORMSLEEVE+, the new modular labeller offering outstanding output versatility and unique levels of flexibility in the choice and control of materials. The machine is designed, in fact, to form the sleeve directly in the machine from the roll using natural bonding liquids, cutting label costs by over 20%. Product quality is guaranteed by the LVS360 which, thanks to innovative software, unrolls the 3-D image provided by the 4 cameras to form a 2-D image that allows inspection of 100% of the label. On the quality control front, Sacmi will be presenting the PVS and CHS vision systems at the fair. Designed for direct installation on the line, next to the press, the PVS system can test an impressive quantity of preforms – up to 36,000 an hour – at set time intervals, either feeding them back into the production cycle or, should they fail to respond to set quality parameters, tripping an alarm: an efficient solution that eliminates potential defects and, thanks to high levels of system automation
and reliability, minimises line downtimes. Alongside the PVS, Sacmi also offers the new CHS cap control system: equipped with HD video cameras (series CVS 3000) and capable of effecting ultrareliable inspection of every side of the cap, the result is, again, better line efficiency and overall output quality. To complete the picture, this fair - the last edition of which attracted 160,000 visitors and 2,700 exhibitors from 59 countries - will also be showcasing the TF 70 modular tray former designed by Sacmi Packaging; this machine has won widespread market acclaim thanks to outstanding production flexibility with all tray types. As the name implies, the machine offers excellent modularity. The different base modules (magazine, press and corner) are used to
create the new TF 70 tray former, currently the most competitive, highest-performing solution for corner trays on the market. A major strong point of the solution – in addition to excellent output rates of up to 50 pieces per minute thanks to the dual feel track and other technical devices – is the
possibility of working in line with the new stacker, redesigned by Sacmi to keep pace with the outstanding productivity of the new machine and so manage two trays in parallel, up to a maximum length of 800 mm, and make stacks of unlimited height.
The latest solutions from Sacmi also have plenty of other winning features such as, to name just a few, lower maintenance requirements, user-friendliness and fast size changeovers: features that have, over the years, kept us several steps ahead of our closest competitors.
RadiciGroup at CHINAPLAS Nylon Specialties Take Centre Stage trong® - Radiflam® -Heramid®), PBTs (Raditer®), TPEs (Heraflex®) and POMs (Heraform®).
RADICI PLASTICS (SUZHOU) CO., LTD. will participate in CHINAPLAS 2014, the 28th International Exhibition on Plastics and Rubber Industries, which will be held on April 23-26, 2014 at Shanghai New International Expo Centre, Pudong, PR China. Specialties are going to be the main attraction for visitors to the RadiciGroup Plastics stand at CHINAPLAS 2014 is the 28th International Exhibition on Plastics and Rubber Industries. Today RadiciGroup is one of the world’s leading manufacturers of nylon engineering plastics (Radilon® - Radis-
The spotlight will be on: RADILON® nylon specialties with enhanced heat resistance - the HHR (High Heat Resistant) and new RADILON® XTreme lines; RADISTRONG® PA6 and PA6.6 long-fiber plastic specialties, ideal for use as metal replacement; and the RADILON® DT PA6.12 and RADILON® D PA6.10 long-fiber polyamide families. RADILON® HHR AND NEW RADILON® XTREME LINES RadiciGroup nylon high heat resistant specialties with enhanced performance: the new RADILON® XTreme line has joined the RADILON® HHR line. The leading RadiciGroup players at Chinaplas 2014 are going to be the high heat resistant nylon special-
ties: Radilon® HHR and RADILON® XTreme. Radilon® HHR nylon 6.6 engineering plastics feature excellent high heat ageing resistance at temperatures of up to 210°C.They are suitable for injection and blow molding, and are available in 15%, 20% and 35% glass-fiber-filled versions. Moreover, they have a high safety factor and can thus be used as metal or special polymer (PPS, PPA, and PA46) replacements. The recent addition of the new RADILON® XTreme specialty line to the already existing RadiciGroup HHR line has extended the application temperature range of this class of products. RADILON® XTreme materials were developed for hotair applications at continuous operating temperatures of up to 230°C, through a synergistic collaboration of the RadiciGroup Plastics and Chemicals Business Areas. The base
nylon polymer used to produce these innovative engineering plastics at the RadiciGroup Plastics production sites was developed and produced by Radici Chimica SpA, a RadiciGroup polymerization plant in Novara, Italy. This vertically integrated polyamide production capability is a distinctive feature of RadiciGroup. RADILON® XTreme engineering plastics are mainly used in automotive (turbo air ducts, EGR head exchanger components and resonators) and electrical applications (high-temperature electrical insulation components and leadfree soldering components). Key Radilon® XTreme characteristics: melting temperature 280°C (+20°C compared to PA6.6); glass transition temperature 90°C (+20°C compared to PA6.6); moisture absorption at saturation 7% (-25°C compared to PA6.6); viscosity grades suitable for injection and blow molding.
Plastics & Rubber Review | March-April 2014 | 15
Red Bull’s Mark Webber launches furious attack on Pirelli as tyre debate starts to wear thin A furious Mark Webber reignited the debate over Pirelli’s fast-degrading tyres on Sunday night, accusing the Italian manufacturer of not caring about drivers in producing tyres that “explode a bit” and fall apart after a handful of laps. The Australian was incensed after enduring a puncture caused by debris from the front-right tyre of Sergio Perez’s McLaren, which blew spectacularly as the Mexican was flying down the straight on lap 31 of the Korean Grand Prix on Sunday. Webber was later forced to retire after a collision with Adrian Sutil’s Force India, his misery complete when his Red Bull car caught fire thanks to a burst oil radiator. After returning to the paddock it is understood that Webber went to see Pirelli’s director of motorsport, Paul Hembery, to remonstrate with him over the current formula of racing. Drivers currently spend much of their time nursing their tyres to make them last rather than going flat out as Webber would like. There have also been plenty of blowouts this year, most notably at Silverstone where the race was almost called off after some catastrophic high-speed failures. “That is how it is. The drivers aren’t super important – it is what other people want,” said Webber, who is quitting Formula One for sports cars next year. “The tyres are wearing a lot and they also explode a bit. But that is for Pirelli to sort out.
TECHNOPLASTIC PET STRAP LINES TECHNO PLASTIC TIGHT STRAP WINDER is a full electronic winder machine for plastic strapping band designed to wrap all kinds of plastic strapping band made of PET and PP starting from 4mm up to 32mm in width. It allows a simply perfect quality in winding on spools of any size on the market, thanks to its capacity of absorbing the winding temporary phases and a linear winding process due to the uncoupling of the speed ramping in the packaging area. The head winder is equipped with a PLC for memorizing and managing the various “recipes” for winding. Via a 10” touch-screen, the programming and management of the production can be carried out for various parameters: meters of strapping band to wrap, inversion angle, stop angle, kind of winding (2pts, 3pts and 4pts), winding step, gap, and traverse up to 300mm (12”), setting to point zero (traverse starting point), width and thickness of strapping band, progressive tensioning on the spool. The winders appointed to the one ahead can be programmed by using the control panel in a singular way or in a multiple way. Furthermore, all models are equipped with a knot-detection system, pneumatic equalizer input for fast winding in case of new tube, motorized pulley, electronic equalizer, adjustable strapping band guide, complete with roll input, air chuck with radial expansion rack inserts, fast recovery pedal and digital counter.
“Pirelli will put the puncture of Perez down to a lock-up but the reason the drivers are locking up is because there’s no tread left.” Hembery hit back, saying that the lock-up was entirely predictable as Perez was 21 laps into a stint on a set of tyres that were only designed to last for 20 laps. He said that the Perez blowout was not linked to the tyre structure issues which had caused the Silverstone failures, Pirelli having switched back to old tyre structures in the wake of the British Grand Prix. “There are two issues here that Mark is conflating,” Hembery told The Telegraph. “Firstly the situation with Sergio’s tyre. It was nothing to do with delaminations earlier in the season. He had a major lock-up and flatspotted. “The other issue about degradation is the same old story. You can have a philosophical difference of opinion – as Michael [Schumacher] had last year – but we are only doing what we were asked to do, which is to create two to three stops per race. If they want tyres to last all race we can do that, too.” 16 | March-April 2014 | Plastics & Rubber Review
For More Details please contact: Satellite Plastic Industries 2A2, Court Chambers, 35, New Marine Lines, Mumbai 400 020 Phone: 022-22006477, 66346816, Fax: 022-22006556 Email : email@example.com, Website: www.technoplastic.it
BOY Announces Program Expansion at CHINAPLAS this BOY innovation are an energy reduction of 50 % during the melting phase, a more precise and faster barrel heating as well as shorter start and heating times. The high wear-resistant plasticizing units have convinced more and more users because of the material-savings and the reduced friction while processing various materials.
Ultra compact, reliable and highly precise
DR. BOY GMBH & CO. KG will participate in CHINAPLAS 2014, the 28th International Exhibition on Plastics and Rubber Industries, which will be held on April 2326, 2014 at Shanghai New International Expo Centre, Pudong, PR China. Only a few weeks since K 2013, the preparations for Chinaplas (April 23 – 26 2014 / Shanghai) are already at full speed. BOY will present two injection moulding machines during the internationally important fair in hall E1 / booth J 41. Besides a BOY 35 E (350 kN clamping force) equipped with a servo-motor pump drive and the multi-patented Procan ALPHA ® 2 control, a BOY XS, the most compact BOY injection moulding machine, will be shown.
Highest precision for close tolerances The space-saving cantilevered clamping unit design characterizes the BOY 35 E. This four-tie bar machine provides generously spaced tie bars and platen distances and a foot print of only 1.9 m². With a torsion resistant clamping system and highly efficient injection unit, this highly acclaimed injection moulding machine is particularly suitable for the production of precision moulded parts with close tolerance requirements. All E-Series BOY injection moulding machines from the 24 mm screw diameter can be optionally equipped with the new EconPlast units. The main advantages of 18 | March-April 2014 | Plastics & Rubber Review
The BOY XS enables maximum performance in the smallest space. With a footprint of only 0,74 m² and stroke volumes from 0,1 cm³ up to 8,0 cm³, parts can be produced in a continuous industrial environment with the highest precision. A pneumatically operated sprue picker, which is integrated under the safety gate, makes clear that even the smallest injection moulding machines can be equipped with peripheral devices. The machine manufacturer provides compact conveying and pigment mixing units for the BOY XS, which do not increase the space requirement of the machine. The BOY 2C XS – an advancement of the BOY
XS without the clamping unit – represents an efficient and flexible introduction into multi-component technology (up to 76,5 cm³ injection volume) in tandum with a conventional injection moulding machine. “Like we already demonstrated during K 2013,” states Wolfgang Schmidt, BOY Export Manager, we also offer complex automation equipment for our BOY injection moulding machines as per customer requirements. We are now able to respond even better to customer requirements through the addition of these devices. Besides feeding and removal devices, e.g. the BOY picker which is shown on the BOY XS, we now also offer BOY handling units equipped with servo motors. Everything from a single source including the CEcompliant safety housing”. The local and Northern China BOY distributor Andeli Co.,Ltd., Wolfgang Schmidt, as well as the other BOY Chinese distributor, Trillion Machinery, are all looking forward to promising contacts in the BOY booth.
Arburg’s electric Allrounders at Expo Plasticos 2014 • • •
Electric: From the Edrive entry-level model to the high-performance Alldrive machine Complete: Exhibits from Arburg and sales partner Axiomatek produce bowls and covers Important: Mexican market connects North and South America
Arburg presented its range of electric machines and automation solutions at the Expo Plasticos 2014 held in Mexico recently. An electric Allrounder 520 E with a Multilift Select robotic system will demonstrate the production of a bowl at stand number 800. The matching cover will be produced on an electric Allrounder 320 A with robotic system from Sepro Robotique on the Sepro stand, which is also where Arburg’s sales representative Axiomatek can be found. Over the past ten years, the Expo Plasticos has established itself as an important event for the plastics processing industry in Mexico and Central America. Guillermo Fasterling, Managing Director of the Mexican Arburg subsidiary in Querétaro, explains the importance of the fair: “Thanks to the good infrastructural links with the markets in North, Central and South America, Mexico has succeeded in building an excellent reputation as a location for trade fairs in recent years. At the same time, the local plastics industry has developed well, thanks in part to the increased demand from regional automotive suppliers. The industry finds itself confronted with some complex challenges in this context. The automation solutions exhibited on the high-tech electric machines from Arburg at the Expo Plasticos 2014 show that we are well able to meet these demands.” Two electric Allrounders with automation solutions Arburg has come up with a special campaign for visitors with the demonstration parts produced there. On Arburg’s 90 square metre stand (no. 800), bowls will
be produced in a cycle time of 12 seconds on an Allrounder 520 E with a clamping force of 1,500 kN and a size 400 injection unit. The 36 gram moulded parts are removed by a Multilift Select robotic system and set down on a conveyor belt, where they can be collected by visitors, who can then obtain a matching cover at the Sepro Robotique stand (no. 913). There, in conjunction with Arburg’s sales representative Axiomatek, an Allrounder 320 A with Sepro robotic system will be on display. This exhibit has a clamping force of 600 kN and a size 170 injection unit and produces the 16 gram cover in a cycle time of 10 seconds. Electric Allrounder range The electric machines from Arburg cover a clamping force range between 350 and 5,000 kN. The Edrive machine series offers customers the perfect entry to the world of electric machines, while the high-precision Alldrive can be used to produce high-end injection moulded parts in large
volumes. The entry-level Edrive model is a cost-efficient alternative to standard hydraulic machines, while the high-end Alldrive series is predestined for the accurate and fast production of precision parts, for example in the areas of optics or medical technology. Playfree, direct acting spindle drives achieve maximum reproducibility and consistent part quality, while special versions of the machines are also available for packaging applications. The advantages of the electric Allrounder series includes efficiently reduced energy requirements in comparison with hydraulic machines, as well as lowemission servo-electric drives. The machines are also convenient to use, thanks to the Selogica control system which is standard on all machine series. First class support from Mexican subsidiary Visitors to the Arburg stand can look forward to personal discussions with the relevant advisors relating to the performance range of the Allrounder machines and the service offerings of Arburg’s Mexican subsidiary in Querétaro. The subsidiary’s facilities include a showroom with a floorspace of some 215 square metres, which provides sufficient space for five Allrounder injection moulding machines. In addition to presentations of the latest Arburg technology, mould prototyping and training also take place here. In addition, there is a well-stocked spare parts store, enabling Arburg to offer its customers in Mexico comprehensive pre- and after-sales service. Further information about Arburg can be found at www.arburg.com.
Plastics & Rubber Review | March-April 2014 | 19
AMUT: Multipurpose Extrusion Solutions AMUT GROUP, headquartered in Novara, Italy, is a global leader in plastics extrusion field, since 1958. Starting with the production of different kind of extruders, the company has continued its technological improvement up to manufacturing complete lines. AMUT stands for innovative process engineering as well as flexibility and high quality production. Extruders and dies are still own design and production.
AMUT GROUP has premises in North America and in Brasil (AMUT WORTEX) and two special divisions: AMUT COMI, dedicated to the thermoforming industry and AMUT ECOTECH, producer of waste sorting and disposal equipments. AMUT production range is wide and suitable for a large number of different applications: plastic extrusion lines for foils, sheets and multicellular panels, with nominal width from 400 to 3300 mm, thickness from 150 microns to some centimeters, configuration up to 9 layers and output over 4000 kg/h. Thermoplastic materials used are PET, PS, PE, PP, EVA, EVOH, PVC, TPO, HDPE, F/ PVC, ABS, PMMA, PC. Furniture industry AMUT overcomes the mass production limits providing lines for the production of profile and panels made by single and multilayer sheets, with thickness range from 0,3 to 3 mm and width from 350 to 700 mm. Depending on the material and on the Customerâ€™s requirements, the extrusion section can be equipped 20 | March-April 2014 | Plastics & Rubber Review
with single-screw, counter-rotating twin-screw or co-rotating twinscrew extruders. The embossing process can be done directly in the calender, by means of a purposely embossed roll fitted with extra quick-change supports, or in a post-calender embossing station. This second option enables a quicker change of the embossing rolls permitting frequently changes of the finishing surface (these operations can be carried out also while the line is in production). The lines can be set up with unwinding systems suitable for warm lamination of sheets or textiles in the calendar, whilst the end-ofline is characterized by a winding system equipped with cantilever
shafts. Construction industry AMUT is also dedicated to providing solutions to produce WPC, with the special range EasyWood, which covers lines with output from 250 up to 600 kg/h. WPC is obtained melting polymers (PE, PP, PVC) with up to 80% natural fibers (such as wood flours coming from rice husk, sugar cane, hemp,â€Ś) and some additives. The finished product has a wood like appearance and its main applications are in construction, building exteriors and interiors field (decking, fencing, skirting, panels, wall and ceiling claddings, door applications).
to adopt an Environment Friendly attitude: in fact the WPC polymeric mixture can consist of material coming from industrial scraps or post-consumer waste. Moreover, the extruded products are 100% recyclable. AMUT EasyWood lines, with direct extrusion or compounding, are equipped with gravimetric dosing system for materials and are based on plasticizing, mixing and extrusion with counter-rotating twin screw extruder as main unit.
Compared to wood, WPC needs a low maintenance, has a good ageing and heat resistance, weather resistant, fungi free and flame retardant. The WPC market demand is growing worldwide, especially in that countries where the government wants
Frozen bakery goods: portioning made easy Freezing Institute (dti) reports that this is more than 3.3 million metric tonnes per year. Last year’s total turnover was over 12 billion euros.
The frozen food market is growing, and baked and parbaked products are gaining in popularity. What challenges does this pose for the functions and design of packaging? Compared with other food products, the frozen food market is growing above average. In Germany alone annual per-capita consumption over 41 kg of frozen food. The German Deep
Although, according to dpi, some frozen bakery goods are developing “slightly below average”, there are nevertheless two trends: Cakes and pastries are still very much in demand, and the upward trend in frozen pizzas is also continuing. “The consumer very much appreciates the benefits of frozen food, so that the industry has every reason to be optimistic about the future,” says dti. Making frozen bakery goods portionable Frozen bakery goods, including parbaked products, such as chips, croquettes and bread rolls, are selling increasingly
Healthcare industry AMUT offers solutions as well as for the healthcare field: extrusion lines producing nontoxic PVC foil to medical sacks (thickness from 200 to 500 micron) and equipment for medical tubing. Both types satisfy well, so that their packaging needs to be adjusted to suit consumer preferences. This also means that a growing number of consumers want to portion frozen food in exactly the same way as other products. The trend is matched by a development towards more single and two-person households who prefer smaller packaging units or units which allow more convenient portioning. Resealable frozen food packaging The special challenge for packaging designers is to create frozen food packaging that can be resealed, and the first products for this purpose are now on the market – for instance from the packaging manufacturer A&R Carton. A&R’s solution is a strip of plastic, integrated directly into the carton. It is a clearly visible resealing strip which makes it easy to open the carton – and above all to put it together again and reseal it. Easy
medical industry requirements: dimensional precision, reduced tolerance in production, clear or mat surface and absolutely no contamination allowed. Pipes industry AMUT is involved in line concepts to extrude pipes: PVC pipe lines with diameter of 16-1200 mm for rigid pipes and 8-63 mm for the flexible, PE pipe lines (monolayer) with diameter of 16-1600 mm and special pipes multilayer such as PE-X, PA (fuel pipe), PP (hot water, internal glass fiber), flexible PVC reinforced hoses, irrigation, foam core, corrugated, bi-oriented and automotive pipes. For more information, please contact:
Ms Pamela Provera firstname.lastname@example.org recognisable pictograms are displayed on the package, explaining how the new method works. A GFK survey, commissioned by the German Deep-Freeze Institute (dti), shows that the portioning of frozen bakery goods is set to become more important. Small one and two-person households are now especially frequent among young consumers – customers who are particularly keen to have small packaging units or portionable packages. And it is precisely this young consumer group that plays a major role on the frozen food market. Between 2011 and 2013 frozen food sales displayed higher growth figures among the age range up to 29 than on the overall German market. Having gone up 4.9 per cent, this age group was clearly above the general trend in the country as a whole.
Plastics & Rubber Review | March-April 2014 | 21
Huge exhibitor demand for interpack 2014 Extensive supporting programme with new COMPONENTS event, SAVE FOOD Congress, INNOVATIONPARC PACKAGING and METAL PACKAGING PLAZA
Once again in 2014, interpack is emphasising its role as the world’s most important trade fair for the packaging sector and related processing industries. At the official deadline for registration at the end of February 2013, all the available spaces in the Düsseldorf exhibition centre with its 19 halls were already booked out (as at the previous fair in 2011), so that not all exhibitor wishes could be met. From 8 to 14 May 2014 about 2,700 exhibitors are therefore again expected from industries ranging from food and beverages, confectionary and baked goods to pharmaceuticals and cosmetics, non-food consumer goods, industrial goods and related services. The companies are coming to Düsseldorf from about 60 countries and are occupying about 174,000 square metres of net space. 22 | March-April 2014 | Plastics & Rubber Review
New parallel event:“components for processing and packaging” interpack is reinforcing its leading role by offering visitors innovative special topics alongside the extensive range of offerings provided by exhibitors. “components for processing and packaging” is an event being staged for the first time in 2014 as an additional exhibition for suppliers to the packaging industry. Companies who are engaged in drive, control and sensor technology, products for industrial image processing, handling technology, industrial software and communication, and complete automation systems for packaging machinery, are exhibiting in the Düsseldorf “Stadthalle” in Congress Center South (CCD Süd). Plus manufacturers of machine parts, components, accessories and peripherals as well as those who manufacture components and auxiliaries for packaging means. About 75 companies are taking part overall. The event is accompanied by a daily lecture forum. Visitors can find the current programme at www. packaging-components.de.
doors, the SAVE FOOD Congress will already commence in the Congress Center South (CCD Süd). This two-day event is directed at both non-profit organisations and industry. It highlights the topics of global food loss and food waste and explores the aspects involved, addressing a broad public audience. Building on the foundation established in 2011,
interpack will thus again provide a unique international platform for exchanges between all those concerned with this critical issue. The SAVE FOOD initiative is a co-operation between the Food and Agriculture Organisation of the United Nations (FAO) and Messe Düsseldorf. It was originally launched in 2011 with a very successful congress staged parallel
“components” is taking place during the first three days of interpack from 8 to 10 May in the direct vicinity of the lead fair in the Stadthalle at the Congress Center South (CCD Süd). interpack visitors and exhibitors have direct access to “components for processing and packaging”. And, of course, the same applies vice versa. SAVE FOOD Congress On 7 May 2014, one day before interpack opens its Plastics & Rubber Review | March-April 2014 | 23
to interpack and is now being supported by the United Nations Environment Programme (UNEP). Among other things, the 2014 event will present the results of new FAO studies conducted in developing and emerging countries to investigate local food losses. In addition, companies from the entire food value chain will be presenting best practices. The congress supports the fundamental aims of the initiative, which seeks to network key actors in business, politics and research to instigate a constructive dialogue between all parties. The ultimate goal is to develop solutions that will reduce food loss and waste along the food value chain. â€œAll the industries involved in the food, packaging and logistics sectors have an especially important role to play in the SAVE FOOD initiative. Ultimately, it is the products developed by 24 | March-April 2014 | Plastics & Rubber Review
these companies which offer concrete approaches to solving the problems we all face. We want SAVE FOOD to act as a catalyst for establishing contact with other enterprises and organisations to carry these approaches further,â€? explains Director Jablonowski, the author of this initiative. INNOVATIONPARC PACKAGING and the SAVE FOOD theme Now a regular feature at interpack, the special show INNOVATIONPARC PACKAGING (IPP) 2014 will therefore also be staged under the motto of SAVE
FOOD. The over 20 participating SAVE FOOD members, companies and associations from all stages along the value chain are showcasing their solutions for avoiding food loss and food waste. The special show presents practical approaches from areas such as food processing, packaging design, packaging materials and machine construction to fight the problem in concrete ways. An additional exhibition highlights the dimensions of international food losses along the food value chain. Since early 2012, the SAVE FOOD initiative has been
open to corporate members and private individuals who wish to support its aims both through financial sponsorship and by providing new ideas. Alongside individual companies in the packaging industry, almost all the leading trade associations in the sector have joined this initiative. The IPP will be staged in a prestige marquee on an area of around 2,500 square metres on the outdoor space between Halls 2 and 3. Throughout the fair, a programme of lectures will be held on an integrated stage. In the catering zone, which is also available, the foods provided have been selected in cooperation with Tristam Stuart. Stuart is the initiator of the â€œFeeding the 5,000â€? project, which has made a name for itself by organising several public and free feeding events for several thousand people using food that would otherwise be disposed of. Visitors can find the Innovationsparc lecture programme and a stand plan at www.interpack.de. METAL PACKAGING PLAZA 2014 interpack 2014 will again feature the METAL
PACKAGING PLAZA in Hall 11. This special theme also premiered at interpack 2011 where its metal-inspired stand concept created a new meeting point for the international metal packaging community and its supplier industry. The proven concept of this special exhibition will be continued at interpack 2014 by the organisers VMV (the German Metal Packaging Association) and Empac (the European Metal Packaging association). For the first time, exhibitors here will include packaging steel manufacturers such as ThyssenKrupp Rasselstein and ArcelorMittal under the umbrella of APEAL, the Association of European Producers of Steel for Packaging. In addition to the showings of the roughly 40 exhibitors, the METAL PACKAGING
PLAZA 2014 offers an information platform with a forum, bar-lounge and meeting points. Online services covering every aspect of a trade fair visit The interpack website, www. interpack.com, has been completely reorganised and given a facelift. At this site, visitors can find useful tools to help them plan their trade fair agenda efficiently. Examples include the exhibitor database where they can generate a personalised hall floorplan, a matchmaking function for establishing contact with exhibitors, and information on all new developments being presented by the participating companies. The interpack services can also be accessed by mobile via http://mobile.interpack.com.
Plastics & Rubber Review | March-April 2014 | 25
Visitors will appreciate the downloadable iPhone and Android apps. These offer daily updated exhibitor and event databases, graphically optimised halls maps and exhibitor data, including contact details, product information, forms for arranging meetings and a possibility to compose notes on individual exhibitors. Visitors can also use the app to synchronise their trade fair planning between a desktop computer and their handheld device. All individual editing, such as personalised display of favourites in the hall floorplan or notes made about companies, will then be available on both platforms no matter where it was originally done. The interpack home page additionally offers the possibility to arrange hotel bookings as well as providing tips on cultural attractions in Düsseldorf to plan one’s stay in the city. Opening hours and prices interpack will be open daily from 10 a.m. to 6 p.m. from 8 to 14 May 2014. Tickets are on sale via online presales at www.interpack.com, a one-day admission ticket costs €49 (€60 at the gate). Schoolchildren, students and apprentices/ trainees pay a reduced rate of €13 at the gate. A three-day ticket can be purchased via online 26 | March-April 2014 | Plastics & Rubber Review
presales for €99 (€120 at the gate). Visitors can print out all eTickets they purchase online from their own computer. All admission tickets and exhibitor passes to interpack 2014 entitle the bearer to free travel to the trade fair and back on the buses, trains and trams of the regional public transport network VRR (Verkehrsverbund Rhein-Ruhr) which also serves towns in a large radius around Messe Düsseldorf.
EXCLUSIVE Interview with Andreas Kandt (CEO of BEKUM Maschinenfabriken GmbH, Berlin) by Mr Reny, Associate Editor PRR
So, what’s ahead, Mr. Kandt? Changes and Trends in Blow Moulding Technology Blow moulding has always been characterised by technological advances and dynamic market trends. For decades, the food and packaging sectors have been influencing numerous plastics applications, with the expectation that the blow moulder can find the solutions. However, it is also true that there is a constant demand for blow moulded technical parts and fuel tanks for the automotive industry. Bekum, a pioneer and technological leader in these processes, adapts to these changes, but also views them as opportunities. We spoke to Andreas Kandt, the new CEO of this traditional company, about what the processors call “The World of Extrusion Blow Moulding.” PRR Editor: Mr. Kandt, since 1959 Bekum has shaped the world of blow moulding technology like no other company. Numerous developments are closely linked to its founder, Gottfried Mehnert. How do you feel about being 28 | March-April 2014 | Plastics & Rubber Review
a trendsetter and technological leader? Andreas Kandt: The task of being a technological pioneer is challenging. When it comes to excellence in terms of output quantity and high quality, everyone knows us. However, there are many other competitors out there offering attractive solutions that represent good value for the money. For us, this means we need to focus on the areas in which we are particularly strong: providing the best service and quality available on the worldwide market. PRR Editor: What will you be setting as your main focuses and emphases? Andreas Kandt: Bekum’s annual sales volume at the moment is around €80 million, with 370 employees. Within 24 months, we hope to have it up to €100 million. To this end, we have set ourselves a variety of goals across all areas of the business. They cover a number measures aimed at improving our processes, optimising our purchasing, making project management more efficient and coordinating better between our subsidiaries in the USA and Brazil and our European plants in Berlin and Traismauer. We have brought new
experts on board, who are able to offer us the necessary experience. Kornelia Kern, in her new role as commercial director, is overseeing all of these important tasks. This is where we see potential to simultaneously credibly bridge the gap between wanting to be able to offer competitive yet technologically high-quality products. PRR Editor: A sales volume of €100 million seems a rather bold target. What does that mean in terms of the market? Andreas Kandt: The target is ambitious, but eminently achievable given our resources. My commercial focuses will enable that dream to become a reality. This is exactly why intensifying customer relations is at the top of the “To Do” list. We have a two-fold approach
to putting Bekum’s already strong relationships with our customers on a new footing. Up until now, we have been recognised as machine suppliers. Cooperative efforts with selected partner companies are no longer an issue when seen in the context of forging ahead with our project business. Today, our high-performance machinery operates in a largely automated environment with constantly changing market demands. For our worldwide customers, not only our own contribution to the system, but also the entire concept has to be correct. In a global context, the Bekum Group, therefore, needs efficient and reliable partners in project business. The second aspect is directly related to this. In the future, our consulting team must be able to show its expertise with regard to product development. When developing packaging or
Plastics & Rubber Review | March-April 2014 | 29
technical parts for the automotive industry, we want to be involved in product development at as earlyas possible; not only to consult on the machine solution, but also for the entire concept of production cell, materials and design. Brand owners in the packaging sector need a consultant who fully understands how to make packaging functional and appealing. The trend continues strongly toward customer-specific solutions and blow moulding, as a process, can point the way. An open-minded approach to design allows us to help creating product-specific solutions, which lead to strong brand differentiation in the marketplace. In terms of marketing, this is a classic argument in favour of our technology. For example, an interesting niche is the dairy market, but also other segments. The automotive industry has always demanded close development partnerships. In the future, our expertise must always exceed what other suppliers can offer as partners in this industry. In the long term, both approaches mean we can present ourselves as the partner of choice and, therefore, do justice to the Bekum brand. PRR Editor: Bekum has a long tradition of regionally successful, independent plants in America and Europe. What about demand across Asia? Andreas Kandt: I think one needs to view the Asian 30 | March-April 2014 | Plastics & Rubber Review
markets in terms of marketing and location. It goes without saying that in the future we want to be able to offer our customers in the western market a service equal to, if not better than, the one we already do. With this is mind, new marketing opportunities are arising in Russia, Eastern Europe, Turkey and India, to name just a few regions in the east. China is naturally an extremely dynamic market with great volume. For this reason we are looking into the possibility of a location â€œeastâ€? of Berlin. We need to investigate whether this is something that we could do in cooperation with China or in Asia generally. We do know that we will be expanding into the east soon in order to be able to supply the regional markets there. However, we also know that our future development will not change how we approach the technological demands of the entire company or the brand.
PRR Editor: How is blow moulding distributed across the different sectors? Andreas Kandt: Initially, we need to turn our attention to the packaging sector. It is vibrant and of worldwide interest. We differentiate between customers in the consumer goods and industrial packaging. In the USA, co-polyester plays a significant role; globally, it is solutions in PP and LDPE or HDPE that make up about 85% of the applications. As I have already said, when it comes to the brand differentiation of our customersâ€™ products, blow moulding technology is of particular appeal. There is a catchphrase: Individualise the packaging; move away from the perception of mass production. An effective, energy-efficient production for medium-sized production lots is required, shaped by frequent mould changes
and production change-overs. Approximately 25% of applications are co-extruded moulded parts, as multilayer packaging with up to 6 layers extending the shelf life of the packages’ contents. These applications form part of our core competencies, as, on the machine side, our own extruders, extrusion heads, spiral distributors or, for high-output production, our Tandem Blow, allow us to stand out from the competition. A Bekum blow moulding machine stands for longevity, currently in its 7th generation series. The clamping unit with the so-called C-frame, patented in 2010, is the most advanced system of its kind on the market. The wide spectrum of machine sizes allows for attractive individual solutions from our modular systems for sectors such as food, pharmaceuticals or medical. Sectors in which, by the way, our electrical blow moulding machine, EBLOW, will become increasingly important.
automotive industry well, this will become a fundamental focus. We have the right technology to go after the market. PRR Editor: Is there not already established competition in this area... Andreas Kandt: Yes, and that’s the way we like it. It means that we can stand out amid argumentation through a clear technological statement. It promises to be very exciting.
PRR Editor: ...and nothing to say about the automotive industry?
PRR Editor: What can we expect in terms of machine technology from Bekum at K 2016?
Andreas Kandt: For a long time, the automotive industry was the step-child on the marketing side of things. This is something that I would like to change. For one thing, we have the best technology for the industry. Our solutions are – thanks to our head technology, advanced clamping units and sophisticated measuring and control technology – more cost-effective, more innovative, and technologically more ambitious than those of our competitors. There is nothing to indicate that we shouldn’t actively pursue these markets in Europe and across Asia. And as I know all of the important partners in the
Andreas Kandt: Well, you know I can’t really go into too much detail! We are currently working on the technology to expand platforms. The electric blow moulding machine will be a definite, considerable focus. Here, we will expand our leadership role with regard to technology and market presence. No one has such a persuasive electrical drive
technology concept as we do. We will continue grow and strengthen in this area. We will also reorganise our staffing. At the turn of the year, a new technical director joined us. His responsibilities are to increase our portfolio, integrate system partners, and further develop control and sensor technology. The focus of the new technical management at Bekum is rheology, extrusion technology, and head technology. In agreement with the Service Department, we will be focusing on the area of retrofitting. Hardly any other used machines in the plastic industry are as sought after as those from Bekum. Even after 25 years of service, the purchase of a second-hand machine is still a good investment. Companies in emerging markets start out with a used Bekum blow moulding machine and then, when they have made enough money, move on to a new Bekum. It fits in very well with long-term marketing strategies. PRR Editor: Many thanks for your time.
Plastics & Rubber Review | March-April 2014 | 31
The individualist among the two-stage ejectors The use of two-stage ejectors is one of the ways in which complex undercuts can be demoulded on plastic articles. This seemingly straightforward mechanism, with its force-controlled and low-play movement, even permits the release of undercuts located inside the part.
Visualisation on the process monitor facilitates setting up of the hot runner unit and offers many additional features for quality assurance: HASCO Z12402/… A new touch-screen process monitor Z12402/... has now been introduced to accompany the successful Z1240/... generation of hot runner control units. It considerably facilitates not only the setting up and monitoring process, but also the diagnosis of hot runner systems. Especially when a hot runner control unit is operated with a large number of control zones, handling of the settings can be very complicated. The setting of temperatures and group functions is then very time-intensive. Furthermore, it is very difficult to obtain an overall view of the current status of the respective control zones. All the zones of the connected control unit are now displayed on a clearly arranged, intuitively operated 15” monitor. The colour highlighting of the affected zones enables allocation of the individually defined groups and any deviations from the set target values to be recognised at a glance. The clarity can be further improved by incorporating a picture of the hot runner system or the injection moulding tool. The displays of the control zones are positioned on the picture in such a way that they provide a clear, unambiguous allocation for the user. Target values can be altered for entire groups with one single entry. Specific settings can be saved for each injection moulding tool. Actual values are recorded versus time. They can be depicted and evaluated in protocols and diagrams. This enables processes to be conveniently analysed, problems localised and settings optimised. To incorporate them into protocols, the data can be exported or, for example, printed for documentation. The process monitor can be connected to all control units of the Z1240/… and Z1246/… series. It can thus also be operated if desired with the particular control unit for which the offered features are currently required in order to set up, monitor or document processes. If necessary, the process monitor can be positioned as a decentralised unit. Our technical consultants and application experts can provide you with detailed information on the broad fields of application for the Z12402/… process monitor. 32 | March-April 2014 | Plastics & Rubber Review
A further use for two-stage ejectors is in moulds incorporating a stripper plate, or for the separate demoulding of the sprue and the article. HASCO supplies the Z1692/… to implement special series sequences, such as those required for underground slides or inclined sliding carriage elements. These advancing two-stage ejectors, which are designed for central installation, make it possible to define the two strokes that are required completely independently of each other. This independence is achieved because the stroke of the three standard sizes, with maximum stroke lengths of up to 180mm, can be adjusted by means of a simple modification. HASCO also supplies the two-stage ejector Z1692/… as a special, customized version with pre-set strokes. The functional surfaces of all HASCO two-stage ejectors have a DLC coating to allow these products to be used in clean rooms and for the production of articles for medical technology and the food industry. With its high hardness and outstanding slip properties, the DLC layer helps to avoid abrasive and adhesive wear. This results in the required freedom from lubricant, which also directly reduces maintenance costs and downtime.
Mr. René Eisenring named as new General Manager at HASCO America Inc. HASCO America, a member of the Berndorf Group, based in North Carolina has named Mr. René Eisenring as the new General Manager. A mechanical engineer graduate, born in Switzerland, who lived and worked in Europe, Africa, Asia and since 1990 is at home in the US. Today as a proud US citizen he brings the understanding of multiple cultures and languages, which will enhance the HASCO global strategy. In his last function, Mr. Eisenring was responsible for the Customer Sales and Service in the field of extrusion and die casting. He brings to HASCO America a wealth of know-how in Management, Sales and Customer Service, which supports our new organization. HASCO America as a competence partner for the tool and mold industry has seen a tremendous growth over the last few years and timing could not have been better to build on this success by growing the Sales and Service portion. We welcome Mr. Eisenring to the whole North American HASCO Team.
EXPERTISE & TECHNOLOGY
Successful relationship in Malaysia Upgrading and modernizing existing equipment is essential to not only keep the machine performance at the highest level but also to decrease operating costs or debottleneck systems. The ever increasing price pressure that most companies will face at some stage forces pellet producers to keep an eye on their equipment. This is of importance due to the fact that polymer pumps and pelletizing equipment are key elements in polymer production. It is particularly the wear of the moving elements in the pelletizer (rotors incl. counter knives and infeed rollers) that has a considerable influence on the operating costs since choosing the wrong profile or material for the rotor and the wrong adjustments for the pelletizer will impact the end product quality as well as the waste rate of the material. Therefore an intensive cooperation and information exchange with the machine supplier will help in most cases to reduce costs and extend the equipment life time.
A very good example of the above is illustrated in the relationship between Recron Malaysia, Automatik Malaysia and Maag Singapore. Recron Malaysia, a member of the Reliance Group, is the world’s largest polyester and textile manufacturing company with production facilities in Nilai and Malaka. Using Maag’s new bearing material featuring an improved clearance for existing polymer pumps, during debottlenecking projects at Recron, a higher production capacity of approx. 15% was achieved. The latter was made possible without changing other auxiliary equipment such as universal drive shafts and drive units. The solution was devised jointly by the machine user (Recron) and the gear pump supplier (Maag). Thanks to Maag Singapore, and the professional consulting it provided, we discovered together the best way
to increase production. With the changes implemented, our plant is now producing more than before with less problems. ”Of particular notice is the fact that the positive results yielded have been achieved with little investment; Mr Balasubramanian, Technology Manager, explains”. Further down the process, in addition to Maag’s pumps, Automatik Plastics Machinery‘s under water strand pelletizer also played an important role, with a view to further increase the pellet quality and to reduce the consumable costs. Potential improvements were identified during initial discussions and a subsequent inspection of machines and production processes. New start up devices were put in place to reduce waste during start up periods. A number of old devices were also replaced to both avoid twin pellets and optimize the existing tools such
34 | March-April 2014 | Plastics & Rubber Review
as rotors and bedknives in relation to the actual product needs. The changes implemented on the machines combined with the necessary training of the operator and the maintenance staff helped us to increase productivity with the added resulting benefits of lower maintenance time and costs. “We were particularly impressed by the high quality and competence of the support provided by Maag and Automatik’s team in this region. As a result, we are very pleased as this is very important for us”, said Mr. Balasubramanian. “Beside the technical competence of the local employees and also the superb grinding service for the cutting rotors including the bedknives, we are now able to achieve lifetimes which could not have been obtained if working with other grinding service suppliers for such tools”, Mr. Balasubramanian continues. “The close cooperation with our customers and the level of technical support provided make Maag and Automatik a truly unique supplier of services in this industry for this region”, Chew Phenghuat and Seah Poh Siang explain. Maag Singapore was established in 2000 whereas Automatik Plastics Machinery opened its service centre in Malaysia in 2009.
Mr Balasubramanian, Technology Manager, Recron
About Maag & Automatik Plastics Machinery Maag is the worldwide leading manufacturer of gear pumps, pelletizing systems, and filtration systems for demanding applications in the plastics, chemical, petrochemical, and food industries. Maag develops, manufactures, and distributes innovative, customized solutions for complete pump and pelletizing systems – with the expertise based on its long-term industrial tradition since 1910. Automatik Plastics Machinery has been manufacturing innovative pelletizing systems of the highest quality for several decades. It is the world leader in underwater strand pelletizing systems. That leadership position is founded on state-of-the-art technology and on comprehensive know-how in all pelletizing techniques and pellet forms. The company’s longstanding tradition in development, production and global sales and distribution is complemented by comprehensive advice and service backup. Automatik Plastics Machinery is a subsidiary of Maag. The whole company employs more than 500 staff at its headquarters in Switzerland and its production sites and sales offices in Germany, France, Italy, Singapore, Taiwan, Malaysia, China, Brazil, and the USA and is represented in the markets with its brands ”Maag Pump Systems“, ”Automatik Pelletizing Systems“, and ”Maag Filtration Systems“. Maag, a Dover Corporation Company (NYSE:DOV), is a part of the Pump Solutions Group, itself a business unit of Dover Engineered Systems.
InterPlas Thailand 2014 - The Future is Here! ASEAN is soon becoming a single market. The continual demand for automotive parts, packaging, design products and general appliances will drive the needs for production further. Institute of Thailand in collaboration with PTT, SCG & IRPC. • “Japan Plastic Technology”: a special pavilion to promote exclusive Japanese Plastic Technology to specific target of Japanese visitors. • “Composite Thailand” Profile: Add more value to your products with composite materials, technology and know-hows to increase your business potentials. • “Taiwan Mold & Die Pavilion” : meet with the mold & die makers of Taiwan and discuss on possible business collaboration. “InterPlas Thailand 2014”, the only international plastics & rubber manufacturing machinery and technologies exhibition in Thailand, is proud to be an arena that offers business opportunities to industrialists in the plastics and rubber industries throughout the region. Moreover, InterPlas Thailand has been certified by a world-class exhibition organization called UFI as an “UFI Approved Event” so that is a proof that the event is high standard and a genuinely international event which participants can benefit from. The exhibition will be held from 19 – 22 June 2014, at BITEC, Bangkok, Thailand. With innovations from 260 brands from 14 countries including Japan, South Korea, China, Germany, Italy, visitors will find here the technologies that represent a various segments of plastics and rubber manufacturing, as well as endless number of potential suppliers and partners to strengthen your business! Meet these special featured zones at the show: InterPlas Thailand will provide more than trade exhibition as visitors will also get to attend forums, asks for advices from the specialists, as well as joining in activities that will further their experience and enable their productivity development. • “Chemical & Raw Materials Zone” : a unique venue where leading suppliers will offer their high-performance materials for more efficient plastics production • “Innovation & Consultancy Center” : Professional advices will be provided by the experts from PETROMAT and the Plastic Institute of Thailand. Visitors will also learn new knowledge from the conferences organized by the Plastic 36 | March-April 2014 | Plastics & Rubber Review
A part of “Manufacturing Expo 2014,” Thailand’s Largest Manufacturing and Supporting Industries Event Manufacturing Expo 2014 incorporates three other UFI
approved events: Automotive Manufacturing (for auto parts manufacturing), InterMold Thailand (for mold and die) and Assembly Technology (on industrial automation). The Show will put up bigger scale, wider ranges of technologies, more insightful conferences and seminars, and more beneficial onsite activities to show the complete convergence of technology, know-how, network and products through value chain. Come grab the abundant opportunities, enhance your brand images, expand your business connections, and increase your production efficiency with innovative machinery and technologies only available at InterPlas Thailand 2014 from 19 – 22 June 2014, at BITEC, Bangkok, Thailand. For more information, please visit www.interplasthailand.com
Objective China: Sacmi to play starring role in Chinaplas 2014 Made-in-Sacmi technological solutions to be showcased at this key international plastic and rubber fair (Shanghai, 23-26 April 2014). The star of the Sacmi stand will be the CCM48, the world’s most competitive singlepiece cap manufacturing press
acmi will be playing a prominent role at Chinaplas, the most important international fair for the plastic and rubber industry which, this year, will be held in Shanghai from 23 to 26 April. The world’s leading manufacturer of complete plastic cap manufacturing lines, Sacmi will be in China with the CCM 48S: developed by the Closures & Containers Division, this is the very latest in a series of presses that is gaining customer approval all over the globe. The CCM48 has already been exhibited at the Kappa and Drinktech 2013 fairs where it generated excellent feedback from industry specialists. At Shanghai, it will play a central role on the Sacmi stand (hall E2, stand E2B45). Designed and developed specially for this market, the machine can produce up to 2000 plastic caps per minute with just 48 moulds, making it today’s most competitive solution on the single-piece CSD, water, hot filling and cold aseptic filling cap-making market. The CCM48S presented at the fair will be equipped with a mould suitable for manufacturing single-piece AB29W caps in HDPE (high density polyethylene) with a diameter of 29 mm and a weight of just 1.35 grams.
38 | March-April 2014 | Plastics & Rubber Review
This will also be an opportunity, then, for the Division to illustrate the general competitive advantages compression technology can offer manufacturers of plastic drink caps. Moreover, of course, there is the added value Sacmi provides in terms of low consumption, process constancy, reduced cycle times, low maintenance costs and outstanding management flexibility (i.e. ultra-short colour changeover times and excellent repeatability of the production process). Featuring an extremely compact design that ensures excellent user-friendliness, the CCM48S can be smoothly integrated with the innovative CVS in-line quality control vision system; made by Sacmi’s Automation & Inspection System Division, the latter ensures, thanks to advanced software and a high resolution camera system, total cap control, thus eliminating potential defects. In addition to this innovative machine, visitors to the stand will also find helpful personnel from Sacmi Closures&Containers, Sacmi Automation & Inspection Systems, Sacmi Hong Kong, Sacmi Nanhai, Sacmi Shanghai and Negri Bossi. Sacmi Automation & Inspection Systems will be presenting multiple inspection solutions, one of the most noteworthy being the CHS Lean. This modular solution offers excellent inspection rates (up to 2,500 caps per minute, 150,000 caps per hour) and has been developed for installation downstream from compression and injection lines. Especially recommended for post-slitting, printing or pre-packaging checks, the CHS offers the perfect solution for complete cap inspection (inside and out) thanks to a modular structure that allows personalised configurations to meet customers’ specific
quality control needs. Chinaplas 2014, also offers an opportunity to showcase the results achieved – just two years after its market launch – by the innovative IPS220, the preform injection press that combines the very best of Sacmi’s experience and technology with outstanding PET preform production solutions and the know-how developed on the closures front with the CCM series. Right from the very first installations, the IPS 220 won extensive market acclaim thanks to its performance (productivity and energy consumption), flexibility and user-friendliness (fast format changeover) A tangible demonstration, then, of Sacmi’s capacity – shared by very few others in the industry – to lead the way in different businesses and technologies. Also heading for Shanghai will be Negri Bossi, the Sacmi Group company that is a European leader in the design and production of plastic processing machines; they’ll be presenting new products in their integrated moulding and postprocessing solution range. Chinaplas continues to be a notto-be-missed event for the Sacmi Group. In recent years the Group has taken on a decisive role in developing product and process innovation, especially as regards cap-making technology; such innovations are leading the world on account of both their outstanding productivity and quality and their flexibility and low energy consumption. These solutions boost the customer’s competitiveness, a factor especially important in an emerging economy like China’s where tough competition is the flip side of the enormous opportunities offered by a continuously expanding market.
More than 800 experts at IKV in Aachen Seamless Vacuum Roll to be New structure of 27th International Colloquium introduced at CHINAPLAS 2014 Plastics Technology 2014 highly successful
New Vacuum Roll Features an Ultra-fine, Seamless Surface for Thin Film Coatings
The next colloquium will take place in Aachen on February 24 and 25, 2016.
WEBEX, INC. will participate in CHINAPLAS 2014, the 28th International Exhibition on Plastics and Rubber Industries, which will be held on April 23-26, 2014 at Shanghai New International Expo Centre, Pudong, PR China. Webex, inc., a leader in precision rolls for the plastics industry, will introduce its new seamless vacuum roll design at CHINAPLAS 2014. The innovative seamless design will be on display in the Maxcess booth in Hall C4, Booth C01. Webex Vacuum Rolls provide the ideal tension isolation and control point ahead of floater ovens and can be used at any other location where nips are neither possible nor desired. The new vacuum pull roll design incorporates a unique system that allows the customer to have a smooth, ultra-fine, seamless nickel screen in contact with their web. In addition, the sleeve is drum tight and customer replaceable on site. Webex Vacuum Rolls have proven themselves in some of the harshest environments while continuing to maintain accurate and delicate web control. Applications include the production of ultra thin film coatings for aerospace, biomedical or pharmaceutical industries, pressure sensitive papers, decorative products, adhesive tapes and optical film. About Maxcess Maxcess helps the web handling industry maximize productivity with convenient access to innovative products and services worldwide. By bringing together the leading brands of Webex, Fife, Tidland and MAGPOWR, Maxcess has built an unrivaled network of application experts with more than 200 years combined experience to help customers improve efficiency and production quality anywhere in the world.
About CHINAPLAS 2014 CHINAPLAS 2014 is organized by Adsale Exhibition Services Ltd. and co-organized by China National Light Industry Council - China Plastics Processing Industry Association, China Plastics Machinery Industry Association, Messe Düesseldorf China Ltd., the Plastic Trade Association of Shanghai and Beijing Yazhan Exhibition Services Ltd. The event is also supported by various plastics and rubber associations in China and abroad. First introduced in 1983, CHINAPLAS is China’s only plastics and rubber trade show approved by UFI (The Global Association of the Exhibition Industry). CHINAPLAS has been exclusively sponsored by the Europe’s Association for Plastics and Rubber Machinery Manufacturers (EUROMAP) in China for the 25th time. CHINAPLAS is currently Asia’s No. 1 and the world’s No. 2 plastics and rubber trade fair. CHINAPLAS 2014 is expected to have 2,900 exhibitors from 39 countries and regions, together with14 pavilions from Austria, Canada, France, Germany, Italy, Japan, Korea, PR China, Taiwan, Singapore, Switzerland, Turkey, UK and USA, occupying an exhibition area of over 220,000 sqm, to showcase their diversified chemicals and raw materials and over 3,200 sets of plastics and rubber machineries. The 4-day exhibition is expected to attract over 120,000 trade visitors from 130 countries or regions. Online pre-registration is available now till April 18, 2014. Pre-registered visitors can enjoy free admission. For more details, please visit the official website at http://www.ChinaplasOnline.com.
More than 800 plastics experts from 19 nations and some 300 companies and institutions attended the 27th IKV International Colloquium Plastics Technology in Aachen on March 19 and 20. The content, the speakers, the new programme concept, over 40 exhibitors and many other new features created lively interest and very good feedback from the participants. IKV, VDMA and PlasticsEurope presented Dipl.-Ing. Günter Hofmann, Managing Director of Hofmann Innovation Group based in Lichtenfels, Germany, with the Georg Menges Prize 2014. The Georg Menges Prize has been awarded since 1999 and aims to promote dialogue and partnership between companies and research institutions. The sponsors of the prize emphasised that Günter Hofmann’s achievements have helped to shape the future of plastics processing in an outstanding manner. The “Study prize for fibre-reinforced plastics”, donated by Dr.-Ing. Peter Ehrentraut, was won this year by IKV scientists Regina Riedel, M.Sc., and Nicolai Lammert, M.Sc. On the second day of the event, the management of the Institute dedicated a session to Professor em. Georg Menges on the occasion of his 90th birthday. The former head of the Institute delighted the Colloquium delegates with a presentation of his own, in which he described how IKV has basically been carrying out research on the now very topical subject of Industry 4.0 since the late 1960s.
The IKV Colloquium The International Colloquium Plastics Technology is the cradle of the Institute of Plastics Processing (IKV) in Industry and the Skilled Crafts at RWTH Aachen University. It was at the first plastics processing colloquium, on October 28, 1950, that IKV was founded. The Colloquium has been taking place regularly every two years since 1966. About IKV IKV, the Institute of Plastics Processing at RWTH Aachen University, is Europe-wide the biggest research and education institute engaged in the field of plastics processing enjoying outstanding reputation. More than 300 staff are employed in finding solutions to problems connected with processing, materials technology and part design in the plastics and rubber industries. IKV’s close contacts with industry and science, together with its outstanding facilities, enable cutting-edge research in plastics technology and ensure that students benefit from a comprehensive, practically oriented course of study. Plastics engineering graduates from IKV are thus sought after experts in industry. In organisational terms, IKV is divided up into the four specialist departments of Injection Moulding, Extrusion and Rubber Technology, Part Design and Materials echnology, and Composites and Polyurethane Technology. The Institute also takes in the Centre for Analysis and Testing of Plastics, and the Training and Further Education department. IKV is run by an Association of Sponsors, which currently has a membership of more than 230 plastics companies from all over the world. Univ.-Prof. Dr.-Ing. Christian Hopmann is Head of the Institute and Managing Director of the Association of Sponsors. He also holds the Chair of Plastics Processing at the Faculty of Mechanical Engineering at RWTH Aachen University.
Plastics & Rubber Review | March-April 2014 | 39
Heinz Gaub joins as New Managing Director of Technology & Engineering at Arburg
Expo 2015 Milan: Germany begins construction of its pavilion Construction work began earlier today on the German Pavilion for Expo Milano 2015. This means that the Federal Republic of Germany is the first participant country to commence construction work on the EXPO grounds. Dietmar Schmitz, Commissioner General of the German Pavilion and Head of the Division for Trade Fair Policy and EXPO Participation at the Federal Ministry of Economics and Technology (BMWi), performed the symbolic groundbreaking ceremony together with Giuseppe Sala, General Commissioner of EXPO Milano 2015. Schmitz: “It is a great pleasure for me to make the first cut of the spade on behalf of the Federal Republic of Germany. As of today, the German Pavilion will take shape more and more every day.”
The new Managing Director Technology & Engineering, Heinz Gaub (right) has been preparing intensively for his new duties at the side of his predecessor, Herbert Kraibühler (left).
On April 1 2014, Heinz Gaub takes up his duties as Managing Director Technology & Engineering at Arburg. He succeeds Herbert Kraibühler, who has retired after 50 years of service to the company. The handover was planned long in advance, enabling Heinz Gaub to spend nine months of intensive preparation for his new responsibilities. In Heinz Gaub Arburg has found a new Managing Director Technology & Engineering who is a perfect fit for the company. For one thing, he has always had a soft spot for internationally active, medium-sized family-run industrial companies. Moreover his career to date has equipped him perfectly for this position, as does his expertise in machine manufacturing. He studied mechanical engineering, specialising in production technology, at the Technical University of Berlin, as well as completing an MSc at the Massachusetts Institute of Technology (USA). He has since gained 15 years of experience in executive positions at medium-sized industrial companies, four years in management at the German Standardisation Institute (DIN) in Berlin, as well as providing consulting to holding companies as an independent industry expert. During his nine-month induction period, Heinz Gaub had the opportunity to familiarise himself with his area of responsibility, which includes Development, Materials Administration, Quality Management and Production with a total of 1,100 employees, and was able to work closely with his predecessor Herbert Kraibühler, who spent 50 years at Arburg. In 1964, Herbert Kraibühler began training as a machine fitter and subsequently studied precision engineering in Karlsruhe, specialising in plastics technology, thanks to a scholarship from Arburg. In 1972, he joined the company’s Development Department. His further professional path led him via various posts until he assumed the position of Managing Director Technology & Engineering in 1996. Over the course of the five decades, he continuously furthered the development of injection moulding technology, extending the product portfolio to include additive manufacturing with the freeformer. 40 | March-April 2014 | Plastics & Rubber Review
In Milan, Germany will be represented by one of the largest buildings. Sala: “We have no doubt that the German Pavilion will once again deliver an excellent performance in 2015. The concept is firmly rooted in the Expo theme of “Feeding the Planet, Energy for Life” and offers a whole new experience that I am sure will appeal greatly to visitors.” Now that construction work on the pavilion has commenced, the topping-out ceremony has been scheduled for the coming autumn. The Federal Ministry of Economic Affairs and Energy has commissioned Messe Frankfurt with the task of organising and running the German Pavilion. The company has extensive international experience and has its own subsidiary in Milan. The German Pavilion will be built by a consortium of companies consisting of Milla & Partner (Stuttgart), Schmidhuber (Munich) and Nüssli Deutschland (Roth, near Nuremburg). Within the consortium, Milla & Partner will be responsible for the overall concept and for exhibition and media design, Schmidhuber for architecture and general planning, and Nüssli for implementation and project management. Background information on the German Pavilion at the 2015 World Exhibition in Milan Large-scale, universal world exhibitions are held every five years in rotation with smaller expos. The upcoming World Expo in Milan follows Shanghai (2010), Aichi (2005) and Hanover (2000). Expo 2015 showcases the theme “Feeding the planet, energy for life”. It dispenses with prestigious monumental buildings, presenting itself rather as a sustainable Agrofood Park. The German Pavilion has the motto “Fields of Ideas”. On behalf of the Federal Ministry of Economic Affairs and Energy, Messe Frankfurt has been entrusted with the organisation and running of the German Pavilion at EXPO 2015 in Milan. The design, planning and realisation of the German Pavilion have been taken on by the ARGE, a consortium made up of Milla & Partner (Stuttgart), Schmidhuber (Munich) and Nüssli Deutschland (Roth near Nuremberg). Milla & Partner is responsible for the content concept as well as the design of the exhibition and media. Schmidhuber is responsible for the pavilion’s spatial concept, its architecture and general planning and Nüssli for project management and construction. The Expo site is being built close to the existing Milan exhibition centre. The world exhibition will remain open for six months – from 1 May to 31 October 2015. For more information, please visit our website at www. expo2015-germany.de
Hi-Q Shaping –
injection embossing further developed mold halves. Here, two different processes are in common use: • complete filling of the cavity • partial filling of the cavity
Fig. 1: The MicroPower – ideal for a dynamic injection embossing process
ue to its complete automatability, high reproduction accuracy and minimal need for downstream finishing of molded parts, injection molding ranks among the most important manufacturing processes in plastics processing, and serves as the basis for many specialized variants of this technology. But particularly strong directional orientation must normally be expected in injection-molded parts, since in this process shaping is accompanied by major deformation, high deformation speeds and high-speed cooling; consequently, some of the molecules solidify with an orientation in the direction of the deformation. This leads to significant anisotropy in the attributes of injection-molded parts .
However, components with attributes as isotropic as possible are increasingly required, in order to achieve the best possible surface quality and highest accuracy in shape and dimensions on the one hand, and on the other hand to keep warpage, internal tension and orientation at a low level. Optical parts are particularly sensitive to anisotropy, since internal tension and orientation strongly diminish the optical brilliance due to the effect of birefringence. This can only be remedied by applying a special form of injection molding, i.e. injection embossing. In this special process, the plastic melt is injected into a mold with a pre-defined embossing gap, then shaped by means of a preset compression stroke of the
Due to the high cooling speed inside the mold, injection embossing of thin-walled components and micro parts is largely restricted to the process with complete filling of the cavity. A compression stroke with partial cavity filling and an already frozen melt front would lead to surface defects and to the internal tension and orientation which should actually be prevented. Injection embossing is characterized above all by low material shearing and orientation. As the holding pressure is not applied via the gating, but becomes effective across the entire projected surface of the component, this leads to a reduction in sink marks. An improved venting effect due to injection into the open cavity can also be observed. Of course this requires a higher amount of capital investment in custom-built molds and a specially adapted process control system. The decisive processing step in injection embossing is primarily the application of the compression stroke. In conventional embossing processes, this stroke is time- or path-controlled, which leads to relatively low precision of the entire process in the area of micro parts, since time and path settings only allow a rigid process without information feedback from the molded part. Information about the thermodynamic states of the material inside the cavity and information feedback from the mold would make it possible to use a process specially adapted to
the material processed. In this way, adjustments can be made to the specific behavior of each material during the embossing phase in order to ensure a dynamic, flexible and material-preserving process. The micro injection molding department of WITTMANN BATTENFELD has been engaged in developing such a dynamic injection embossing process for some time, in order to provide the improvement in quality demanded by the market. Thanks to its flexibility, reproduction accuracy and dynamism, the MicroPower machine model serves as an ideal platform for studies and tests in this field (Fig. 1). The main goal of this latest development is to implement an extremely rapid, optimized injection-embossing process, in order to establish low-cost mass production of parts with nanostructured surfaces and improved material attributes. Development of Hi-Q Shaping at WITTMANN BATTENFELD With these objectives in view, Hi-Q Shaping was developed at WITTMANN BATTENFELD under the FP7 EU research program “Cotech” in cooperation with Microsystems UK, the Karlsruhe Institute of Technology KIT, the University of Bradford, the Technical University of Denmark DTU and the Department of Microsystems Engineering IMTEK at the University of Freiburg. For this purpose, a new software was created and adapted to the MicroPower injection molding machine. Hi-Q Shaping by WITTMANN BATTENFELD is a process in which, similar to conventional injection embossing, the active movement of the clamping unit
Plastics & Rubber Review | March-April 2014 | 41
during the injection process plays a major part. In this innovative process, the reference input variable or reference value is extended by adding temperature and pressure values, which enables specific regulation of the embossing pressure (holding pressure) for every process via the closing stroke (Fig. 2).
optically anisotropic media to split a light beam into two beams polarized perpendicular to each other. A birefringent material is identified, for example, by using a polarization microscope. When the specimen is rotated between crossed polarization filters, the light intensity and/ or color of a birefringent object will change, while optically isotropic materials show no change in their appearance (Fig. 4).
Fig. 2: B6 program page for extended injection embossing and relevant evaluation
The aim is to apply the embossing pressure to the entire surface of the part above the glass transition temperature with a high degree of dynamism and precision. In this way, a drastic reduction in material tension becomes possible, since the deformation proceeds at significantly lower shear speeds. High dynamism combined with ultimate precision is necessary, because micro parts solidify much faster than larger parts due to their small size/thickness, which reduces the time window for the compression stroke to a fraction. Therefore the viscosity of the melt is automatically taken into account at every stage. Thanks to its extremely rigid toggle design, which is free of play but still permits high precision, the MicroPower is able to perform extremely accurate movements of the clamping plates and consequently precise compression strokes. Where micro structures are involved, the precision of the clamping stroke has an enormous influence on the pressure behavior inside the part. Due to the lower volume and small surfaces, the temperature conditions are much more critical than for larger parts. This is a highly dynamic embossing process which can only be implemented with adequate software, control technology and machine performance.
Fig. 4: Internal tension and orientation made visible with polarization filters
Conclusions about the surface quality of parts produced can be drawn by using comparative light microscopy. Summary of results This new, innovative process makes it possible to produce parts with a constant weight, minimal shrinkage, excellent surface quality and a low level of orientation and internal tension. The following main factors influencing the quality of the molded parts have been established: â€˘ mold temperature â€˘ compression force â€˘ compression time The tests have revealed that this process yields a higher degree of precision than standard embossing. Moreover, it was possible to reduce the internal tension and thus to achieve a significant improvement in translucency (Fig. 5).
In the tests, flashlight lenses were used as exemplary trial specimens, since these require high quality standards for the optical attributes and surface properties of the molded parts (Fig. 3). These lenses were manufactured from the polymer Makrolon LED 2045, a polycarbonate with extremely high light transmission.
Fig. 5: Birefringence effects and microscope photographs in standard injection embossing and Hi-Q Shaping
Fig. 3 Trial specimen flashlight lens
Besides the PVT phase diagram, the effective temperature conductivity aeff and the glass transition temperature TG must be considered as additional important material parameters, since they make it possible to calculate the actual melt temperature at any point in time and thus make the process controllable in the first place. Specification of the final part dimensions and the desired density is also required. Birefringence effects were used to obtain information about internal tensions and orientations. Birefringence designates the proneness of 42 | March-April 2014 | Plastics & Rubber Review
Moreover, the cycle times in Hi-Q Shaping are virtually on a par with those in conventional injection molding and consequently ten times as fast as those in similar variothermic processes. This fact makes the process extremely economical and energy-efficient, as no high capital investment in a complex heating and cooling system for any comparable parts quality is necessary. Use of the injection embossing process generally leads to an improvement of both optical attributes and surface quality. WITTMANN BATTENFELD, a company of the WITTMANN group based in Kottingbrunn, Austria is a leading manufacturer of injection molding machines for the plastics industry. With its own sales and service companies as well as representations in about 60 countries, WITTMANN BATTENFELD provides optimal support to its customers in all matters concerning injection molding technology. Its innovative strength, highest precision and strong focus on maximum customer benefit make WITTMANN BATTENFELD a valuable partner for its customers.
Rapid Prototyping in Aviation and Aerospace
Interior design of the Airbus A380 super jumbo
Plastics & Rubber Review | March-April 2014 | 43
Some orders are extraordinary challenges, even for experienced model builders like Modellbau Robert Hofmann. The order for the Airbus Showroom in Toulouse (F), for which cabin elements, or “mock-ups”, needed to be created in a 1:1 scale, was such an “exotic”. The task was to design 28 Business Class seats along with 6 individual cabins and a lounge for First Class in close collaboration with designers from Design Investment. In the Airbus Showroom, the airlines’ buyers can let themselves be inspired about what long-haul flight luxury can look like, in advance of purchasing a wide-body aircraft like the A380.
Anyone who is familiar with a 12-hour long-haul flight from Zurich to Hong Kong knows how strenuous travelling can be, particularly when flying Economy Class. Even in Business Class, the seats are not necessarily luxurious for such a long-haul route. The same route in First Class of an A380 has a high price compared to Business Class, however, the interior fittings and passenger service are extremely pleasant. The mock-ups are seat modules and sleeping modules, which ensure as much relaxation as possible through restful comfort with integrated entertainment. The First Class fittings are regarded as image carriers and brand messengers for airlines, even if the majority of passengers tend to only be able to afford lower-priced classes. Objective for the model builder As is customary for experienced model builders, the design of the mock-ups needed to be indistinguishable from a series version, in terms of impression, function and feel. In order to achieve this, Modellbau Robert Hofmann pulled out all the stops in process engineering, with regard to mould making, rapid prototyping and refinements. In this case, also special third-party services, such as covering with fine leather. Particularly the highquality finishing of plastic parts at economical unit prices and form-fitting assembly are included in the disciplines in which Modellbau Robert Hofmann ranks among the world’s leading companies in the industry. In view of the huge modules, many individual components needed to be coordinated to fit precisely – from development,
44 | March-April 2014 | Plastics & Rubber Review
to production, right up to the finish. Not only were the time constraints set by the client, Airbus, tight, but the designer’s aesthetic requirements also needed to be fulfilled. In close collaboration with the client and designer, Project Manager Ingo Güttler coordinated the respective teams of model builders and external partners. A “truly mammoth task,” says Ingo Güttler now. The major advantage for the model builder, based in Lichtenfels, was its experience with clients from the aviation and aerospace scene. The Hofmann Group supplies prototypes, tools and series parts to Diehl Aerosystems, B-E Aerospace Systems, Airbus Group, Latécoere and AOA Avionics Dresden. Therefore, the preferences regarding safety concepts, material selection and execution are known. In terms of series parts, components are sent to Hamburg-Finkenwerder or Toulouse for the Airbus series A320, A340, A380 and the newly developed A350. Safe and light in the air Assemblies for passenger aviation must meet the criteria for lightweight construction, as known from motor racing. However, in addition to this, extremely high safety requirements apply, which can only be fulfilled using high-temperature-resistant high-performance plastics, such as PEEK or PEI. For the production of tools and processing of these materials, this requires a great deal of experience and, particularly, process know-how. Through intelligent engineering design and material selection, many components can be configured in a weight-optimised manner, which leads to enormous cost savings over the long product lifetime of an aircraft. With its modernly equipped injection moulding centre, Hofmann offers its clients run-in capacities for parts in single-component and multi-component technology,
right up to 3K parts. Machines are available with special fitting packages of between 500kN and 16,000kN of clamping force, which can take on virtually any task. Modern 3D printing technologies in aviation Particularly for the Hofmann Group, it also applies that specific technologies, such as LaserCUSING with metal powder, can be included. A laser builds up generative components layer by layer from titanium powder, for example. The extremely hard and durable material is extremely popular in the industry, as well as in aviation. The laser melting process with metals allows extreme geometry freedoms and functional integration for developers. Application examples include bionic holders for connecting the outer skin of the aircraft with the cabin or filling connections for oxygen supply. “LaserCUSING sets completely new benchmarks for the development of components. Generative processes, such as 3D printing, must be seen completely separately from the boundaries of tool and mould engineering. This way solutions become possible that seemed impossible a few years ago using classic casting methods,” says Jens Henzler, Managing Director of Robert Hofmann GmbH.
Mock-ups require full service under one roof Hofmann took over the true-toscale production of the mock-up modules, right up to installing them in the aircraft fuselage, which can be found in the Airbus Showroom in Toulouse. For the interior fittings, Modellbau Robert Hofmann employed its entire engineering expertise for the process chain, product development, right up to production and implementation. In detail, this means draft designs and concepts, 3D constructions, assessment of variant engineering designs, product analysis (e.g. FEM analysis), simulation, stress tests and functional tests. With complex assemblies like mock-ups, these services are very advantageous for the client, as he receives the required products from a single source with the certainty that they are in no way inferior to series parts in functional terms. The “one-stop shop” not only saves Airbus time, but also offers potential for supply reliability. The example makes a clear impression The project is among the prestige projects of the Hofmann Group; on the one hand, as a highly complex planning task, and on the other hand, under the aspect of process and method combination. “The tasks of model construction for such presentation applications are diverse. In addition to aircraft engineering, this is an interesting option for the initial presentation of fittings options. Model construction and small series are interesting for the utility vehicle sector, for passenger transport systems, such as buses and railway vehicles, right up to boat building and the caravan sector,” explains Jens Henzler. After having mastered such a task for the demanding aviation industry, his statement can absolutely be believed.
Plastics & Rubber Review | March-April 2014 | 45
Innovative drive concept activeDrive enables energy savings of up to 60 % compared with standard hydraulics
Sumitomo (SHI) Demag already delivers every second hydraulic machine with an energy-saving drive Energy efficient injection moulding is actively driven by the energy-saving drive activeDrive of the Systec hydraulic series from Sumitomo (SHI) Demag Plastics Machinery GmbH. A reduction in energy usage of up to 60 % is possible according to application. As ever, hydraulically driven injection moulding machines represent a large market. Sumitomo (SHI) Demag offers its multifunction machine Systec at a clamping force from 350 to 1,200 kN with a fully hydraulic clamping unit, and from 1,600 to 20,000 kN with a toggle clamping unit. Numerous production-efficient building blocks are available for the Systec, which support the processor in the realisation of the best possible production efficiency. The energy-saving drive activeDrive guarantees a dynamic performance adjustment to the respective requirements and in doing so ensures the optimum degree of efficiency and minimum loss, especially in the partial load area and when idling. The combination of a high-dynamic, frequency-controlled servomotor and a constant pump enables energy-savings of 30 - 60 per 46 | March-April 2014 | Plastics & Rubber Review
cent compared with a standard hydraulic drive. When investing, many companies decide on sustainable solutions, which offer the greatest degree of efficiency even under future production conditions. The increasing pressure of costs for power, water and other operating materials can be met through investment in new technologies. Therefore, Sumitomo (SHI) Demag already delivers every second machine with the hybrid concept activeDrive. “We are in the meantime seeing a huge increase in activeDrive drives, even in the small hydraulic machines, and this although here the return on investment (ROI) for our customers
takes somewhat longer than for machines with greater tonnages”, states Marketing Manager Bernd Tröger, and continues: “Sustainability is shifting increasingly into focus during investment. Here we are providing exactly the right answers with our “Blue Technolution” system solutions.” activeDrive and activeMotionControl increase performance and lower energy usage As a manufacturer of technical plastic injection-moulded parts for vehicle construction, Borscheid + Wenig GmbH in Diedorf by Augsburg has been operating several Systec machines for many years. A further Systec 50-310 with
the technology building blocks activeDrive and active MotionControl will be delivered shortly and support the company in the framework of its environmental management. The managing partners Norbert and Sven Borscheid and Carlo Wenig are extremely satisfied with both the performance of the hybrid machines with activeDrive and activeMotionControl as well as with the energy-saving. â€œThe Systec machine offers a good price/performance ratio and, with the energy-efficiency building block activeDrive we additionally save energy and can considerably reduce the cycle time further thanks to activeMotionControlâ€?, say the partners. Summit (SHI) Demag Plastics Machinery GmbH Sumitomo (SHI) Demag has consistently shaped the plastics industry from its inception. As a specialist for injection moulding machines for polymer processing, Sumitomo (SHI) Demag and its Japanese parent company are among the leading companies in this sector globally. The Japanese-German company was formed in the spring of 2008 by merging the injection moulding activities of Sumitomo Heavy Industries (SHI) and those of Demag Plastics Group. The global development and production network of Sumitomo Heavy Industries and Sumitomo (SHI) Demag consists of four plants in Japan, Germany and China with more than 3,000 employees. The product portfolio encompasses all-electric, hydraulic and hybrid injection moulding machines with clamping forces of between 180 and 20,000 kN. With over 100,000 machines installed, Sumitomo
(SHI) Demag is present in all important markets throughout the world. With more than 5,000 machines sold each year, the Plastics Machinery Business of Sumitomo Heavy Industries counts as one of the largest Global manufacturer of injection moulding machines. The main Sumitomo plant in Chiba produces machines with low and medium clamping forces. Around 95 % of all machines supplied by Japan have an all-electric drive. The main Demag facility in Schwaig/Germany focuses on the hydraulic Systec and the hybrid high performance, high-speed El-Exis machines. Recognising the increasing importance of electric drive technology for injection moulding machines, Sumitomo (SHI) Demag has expanded the former Demag factory in Wiehe/ Germany into an international centre of competence for electric machines. Thanks to the new production capacities, Wiehe now supplies all electric injection moulding machines worldwide with its IntElect series with clamping forces up to 4,500 kN and also the hydraulic Systec series with clamping forces of up to 1,200 kN.
Sumitomo (SHI) Demag continues to operate the former Demag plant in Ningbo/China which has been active since 1998. Since 2007 the subsidiary located there, Demag Plastics Machinery (Ningbo) Co., Ltd, had its own, newly built plant and after reaching full capacity, moved to a larger factory with a production area of 11,000 sqm. Injection moulding machines from the Systec C product line with clamping forces of between 500 and 10,000 kN are produced here for Asian markets. In addition to injection moulding machines, Sumitomo (SHI) Demag offers customised and standardised systems for the automated handling of moulded parts, technical solutions for special applications in process engineering, tailor-made service concepts and various forms of financing for investments in injection moulding machines. With its seamless sales and service network of subsidiaries and representations, Sumitomo (SHI) Demag is present in all major industrial markets. www.sumitomo-shi-demag.eu
Plastics & Rubber Review | March-April 2014 | 47
Upward trends in organic food containers
Bekum and Polykemi’s organic plastic EcoScan, made from calcium carbonate (chalk) and PE for the extrusion blow-moulding process In the past 35 years, more non-renewable resources were consumed on earth than civilisation had ever required before. Current climatic changes are a warning: new standards must be set for the production and consumtion of resources. The plastics industry has therefore already begun to turn its attention to renewable materials: The “bio plastics”. Bekum and Polykemi are presenting applications from the food sector with a material combining polyethylenes (PE) and chalk. Within the framework of a cooperative venture, the Swedish raw material manufacturer Polykemi AB (Ystad – Sweden www.polykemi.se) will be presenting a new bio-plastic: a polyethylene with a chalk (calciuim carbonate) constituent as a filler. This Swedish granulate calls itself “EcoScan” (formerly: “ScanFill”) and replaces conventional HDPE as a constituent of foodstuff containers. Efficient alternatives The material demonstrates outstanding barrier properties, an improved UV protective function and its high cost effectiveness makes a pleasant surprise. In addition, advantages arise from its processability in extrusion blow-moulding: The first fully electric blow moulding machine Eblow 206 D is being tested as a dual-station unit for 3-layer extrusion. 5,220 units of a 200 ml milk bottle can be blow-moulded per hour using the EcoScan material on a Bekum. Depending on the material used for comparison, up to 30% high production quantities are feasible. EcoScan in blow moulding technology – an ecological contribution EcoScan has of course received FDA certification as foodstuff-safe and its extended shelf life is also assured. The physical and functional advantages are just the start: methods of production and refinement of the material, 48 | March-April 2014 | Plastics & Rubber Review
as well as recycling after packaging use, result in a positive environmental balance. This way, EcoScan is already conserving energy and water during its production. Both companies are confident that this contribution to matters of enviromental responsibility will be well received in the marketplace.
Record: 6,900 visitors at Arburg Technology Days 2014 • • •
Technology Days 2014: Four days, 40 exhibits, 52 countries, 6,900 guests Unique event: Customers from around the world experience innovative plastics processing in Lossburg Efficiency Arena: Innovative manufacturing examples – from one-off parts to mass production
The Arburg Technology Days 2014 were more popular than ever before: approx. 6,900 invited guests attended the unique industry event in Lossburg from 19 to 22 March. With an emphasis on production efficiency at the Efficiency Arena, they witnessed how plastic products, from one-off parts through to mass produced items can be manufactured cost-effectively. Furthermore, with more than 40 Allrounder injection moulding machines, Arburg presented innovations and a representative crosssection of its current product range covering a wide range of industries and applications. Further highlights included the Freeformer Technology Centre for additive manufacturing, expert presentations and the new Evolution exhibition featuring multimedia content on the history of Arburg.
“Our Technology Days have been a major attraction for the international plastics world for many years. This year, the interest has been absolutely overwhelming: approx. 6,900 trade visitors from 52 countries have learned about our innovative and production-efficient solutions for plastic part production at first hand in Lossburg. That’s nearly a quarter more than in the previous record year 2013,” says Michael Hehl, Managing Partner and Spokesperson for the Arburg Management Team. “Despite the huge numbers, what counts for us at this
event is and remains quality rather than quantity. Our employees from Lossburg and the subsidiaries worldwide are therefore in action during the four-day industry event to provide individual support to our customers.” Around 45 percent of the visitors travelled from abroad. The largest groups of visitors came from Europe, primarily from France (265 participants), Switzerland (260) and Poland (180). Very large groups from overseas included the US (260 guests) and China (185).
Plastics & Rubber Review | March-April 2014 | 49
off parts and small-volume batches. One and two-component parts were manufactured on an additive basis, including an ABS connector housing as a spare part for an Allrounder injection moulding machine and a housing for the main switch of the Freeformer itself.
Focus on the topic of production efficiency At the Efficiency Arena, both current and visionary technologies for the efficient production of plastic parts were on display. The spectrum ranged from the manufacture of one-off parts and small-volume batches, the interaction of human and machine, through to mass-produced items. Each of the five stations covered a different aspect of production efficiency based on a practical example, depending on the required unit volumes: • Individuality: The unique Freeformer performed additive manufacturing, i.e. building up spare parts for in-house use, layer-by-layer, based on 3-D files in small unit volumes – without a mould, from tiny plastic droplets. • Flexibility: During the production of a toy buggy, operatives and a robotic system work handin-hand. Complex feed systems are dispensed with. This renders an automation solution worthwhile, even for small and medium-sized batches. • Data integration: Based on the example of the buggy with an individual QR code, the topic of Industry 4.0 was also presented. Here, the machine, order information and process data are networked and each part can be traced online. • Speed: A Multilift V demonstrated how cycle times can be reduced in the case of large unit volumes: Equipped with a dynamic mould-entry axis, the robotic system reduces the action time by 25 percent. • Productivity: 137,000 parts per hour for an irrigation solution, i.e. 64 flat drippers produced in 1.68 seconds by an electric Allrounder. Here, the high-performance machine and mould are perfectly matched. 50 | March-April 2014 | Plastics & Rubber Review
Freeformer delights visitors The Freeformer, on which Arburg provided information in the form of an expert presentation as well as exhibits in the Efficiency Arena and the new Technology Centre, attracted a great deal of interest among the guests. The new system for the additive manufacturing of functional components made from standard granulates, which celebrated its global premiere at the K 2013 trade fair, could now be examined at first hand and generated a great deal of enthusiasm. This is because plastics processors are faced with the challenges of rapid technical developments, short product life cycles, increasing variant diversity and the demand for customised products. One complete production step can be omitted in comparison with injection moulding because there is no need to design and build an expensive mould. Moreover, product starts can be achieved in a very short space of time. Based on various product examples, Arburg demonstrated how the Freeformer fits into the product range and how it offers new opportunities for product design and for the efficient production of one-
Sophisticated products, processes and applications The highlights with regard to injection moulding machines, process and applications technology included: • An electric Allrounder 820 A featuring a new 4,000 kN toggle-type clamping unit and size 2100 electric injection unit, completing the Alldrive machine series. In a cycle time of around 5 seconds, 48 teaspoons were produced before being automatically packaged ready-for-use and marked with a QR code. • Extremely sophisticated processing of liquid silicone was demonstrated with the example of a transparent magnifying glass produced by an electric Allrounder 470 A. • Also interesting for the optics sector was an innovative two-component application running on an Allrounder 520 A: Equipped with a multi-timed mould, the electric injection moulding machine produced four lenses with a thickness of 25 millimetres in only 55 seconds. The mould rotated by increments of 45°, with injection, cooling and removal steps performed simultaneously at the eight stations. The cycle times were thereby reduced several times over. • As a medical technology application, a stainless steel version of the electric Allrounder 370 A was presented, which produced syringe barrels made from the glass substitute COP. • A hybrid Allrounder Hidrive 570 H in a packaging version demonstrated how high productivity can be combined with
reduced energy requirements based on the example of thin-walled IML containers. â€˘ A servo-hydraulically driven Allrounder 820 S produced a 200 g lever reinforced with organic sheet and long glass fibres for the automotive industry. Versatile range In addition to innovative applications and product innovations, the visitors also had the opportunity to see injection moulding production for themselves in Lossburg and to participate in extensive factory tours. In total, some 1,750 guests attended 232 Germanspeaking tours through the plant. Furthermore, all groups of foreign visitors visiting the Technology Days under the auspices of the Arburg subsidiaries and trading partners were given presentations of the company in their own language.
In order to round off their practical day at Arburg with theory, some 3,200 visitors took advantage of the opportunity to listen to expert presentations in German and English. In-house and external speakers provided information on additive manufacturing using Arburg Plastic Freeforming, the innovative long-fibre direct injection moulding lightweight construction process, the Industry 4.0 future project and tips and tricks for the Selogica control system, for example. Valuable know-how was also shared by the Arburg experts in numerous individual discussions.
In the Service area, the guests obtained comprehensive information on product training courses, spare parts management and preventive maintenance. New maintenance packages are available, for example, containing lubricants and tools accommodated in machine-specific cases. It was also demonstrated how the service life of the Allrounder injection moulding machines can be extended through regular maintenance and proper care. Plastics & Rubber Review | March-April 2014 | 51
In Line Production Of Two-Colour Disposable Cups Made Of Multi-Layer Polypropylene feeds a rimming unit (a WM production) with three rotating screws. This turns up the upper edge of the cups and then send the rods to the accessory counting and packing units. The waste or the residual perforated polypropylene sheet from which the cups are made, is sent in line to a soundproof grinding mill, which reduces the scrap to flakes and, by means of a blower group, sends it to the dosing/mixing unit located above the extrusion unit. This creates a closed loop from the raw material to the finished product, with the direct in line recycling of waste materials. The INTEC 900/3 system can produce up to 120,000 pcs of 200 cc cups per hour, minimising energy consumption and significantly reducing necessary personnel. Recently, WM Wrapping Machinery SA from Stabio (Switzerland) completed the successful testing of a complete line for the production of two-colour disposable cups made of multi-layer polypropylene. The plant destination is a leading extra European manufacturer of disposables items, to whom is currently being delivered another WM complete in line system dedicated to the production of plates made of co-extruded polystyrene HIPS. The line subjected to testing and named by the Swiss company INTEC FT 900/3 consists of a unit for the automatic dosing and feeding of the raw material in granules, including a system of management and recycling of the ground line waste. An extrusion group, provided always by WM Wrapping Machinery Sa and including a main extruder with a screw diameter of 120 mm and two co-extruders with
a diameter of 80 mm. The total extrusion capacity of the group is 1,096 kg/h. The flat die head of the extrusion feeds a vertical laminating calender with three rolls creating a sheet with a width of 930 mm and a thickness ranging from 0.2 to 2 mm. The extruded sheet is then sent in line to the transport system with toothed chains of the thermoforming machine model FT 900, with a tilting lower platen and a servo-assisted plugging unit. The forming tool can accommodate moulds with a maximum size of 880x520 mm and has a clamping force of 75,000 DaN. The tilting system of the movable lower platen is based on an innovative double DESMODROMIC system of cams and levers operated by a servomotor. The mould has 51 cavities for the production of cups with a finished border diameter
52 | March-April 2014 | Plastics & Rubber Review
of 73 mm and a height of 95 mm. Once thermoformed and cut (an operation that occurs simultaneously in the same mould) the cups are removed from the bottom half-mould which tilts at 75 degrees by a plate with aspirating spindles and automatically transported to a collection cage, which automatically unloads the various rows of stacked cups on a conveyor belt and continuously
As mentioned, WM Wrapping Machinery SA designs and manufactures INLINE systems dedicated to the production of disposable plates made of co-extruded polystyrene as well as systems for yogurt, butter, margarine and ice cream containers, made of polypropylene, polystyrene or a multi-layer barrier.
EREMA expands global trial centres and technical support
With seven systems in the EREMA Customer Centre and three more in the R&D Centre at the company’s headquarters in Austria, two at the EREMA North America (ENA) Trial Centre in Ipswich and a plant at the trial centre in the Middle East, EREMA customers now have a total of 13 facilities at their disposal for trial runs with the test materials they choose to provide. Additionally, the trial centres feature the world’s very latest technology thanks to the installation of the new plant generation INTAREMA® with patented Counter Current technology (presented for the first time at K 2013). The test runs on these systems are carried out in realistic production conditions and thus provide the results with which the customer’s machine configuration is optimised on an individual basis. CEO Manfred Hackl explains: “Our customers benefit from the fact that the systems can be configured exactly in line with their concrete application.” Currently some 400 tests are already carried out every year with a wide variety of customer materials. This number of test runs will continue to increase with the expansion of the trial centres.
EREMA recognised years ago the trend of being able to produce recycled pellets with a property profile customised to the specific end application, to continuously increase on the one hand not only the recyclate share in innovative products but also on the other hand the general market value of plastics recycling. In order to be able to realise such specific recycled pellet grades it is necessary to analyse the problems in the recycling processes in detail. For this reason the global market leader soon decided to invest in its own R&D Centre with dedicated plastics analysis laboratory featuring a wide range of equipment with state-of-the-art engineering.
EREMA offers another unique service with additional technical support centres around the world to assist customers on site. Teams of qualified service engineers are stationed in the respective regions (Europe, North and South America, China, Japan, Vietnam, Korea and the rest of Asia, Africa and the Middle East) for technical support and on-site visits – close to the customer at all times. With the three trial centres, over 50 representatives and the 10 regional technical support centres, EREMA not only offers its customers global after-sales expertise which saves time and money, it once again sets new standards in customer service.
Plastics & Rubber Review | March-April 2014 | 53
Saving energy – soon a duty for all? BOY sees itself best positioned in the market gies. Since K 2013, EconPlast increases the saving potential even more. The new BOY heating technology makes the plasticizing of plastics much more efficient, is energy-saving and material friendly. For example, with a BOY 60 E operating in a three-shift operation with a material throughput of 14 kg/h per year, the use of the EconPlast unit saves about EUR 3.500 in energy costs. BOY, the manufacturer of injection moulding machines up to 1,000 kN clamping force, has provided on its website (www.econplast.de) the ability to perform an online calculation. “Besides the pure energy advantages, EconPlast also provides a much more precise and more direct regulation of the temperature supply. Especially with heat-sensitive materials, this can be a deciding influence on the part quality,” explains Michael Kleinebrahm, BOY Manager Process Engineering.
BOY 100 E with EUROMAP classification 9+
In parts of the BENELUX countries and in Switzerland this duty already exists – to save energy. This means that the governments of these countries have called for a commitment from manufacturers, dealers as well as operators to offer and use only the most energy-efficient products available in the market. In Poland, users can receive favorable investment money through the PolSEFF support program if they build and sell injection moulding machines that are certified as energy-saving. Soon, perhaps there will be a program like this for all of us? In atmosphere of departure If so, “a golden time,” will begin for those products which use the latest technologies and save a lot of energy (costs). This applies especially to the plastics industry. Their machines, for some time now, have required a decreasingly amount of energy to process one kilogram of plastic. BOY recognized this trend very early. Since 2008, the BOY E-Series servo drive saves about 50 % operating power compared with previous technolo54 | March-April 2014 | Plastics & Rubber Review
Euromap 60.1 – just a beginning? For a few months, the energy classification of injection moulding machines according to Euromap 60.1 is valid. This comparability, which became transparent through the norm, helps users to choose and use the most efficient machines. Was this just the beginning? Will Germany establish a similar energy regulation like those in the Netherlands and Switzerland or a support project such as the one in Poland? Users who already use machines with the latest technologies and efficiencies have done more than just carrying out their duty. They have already benefited from the energy savings – and this with each shot.
About BOY Dr. Boy GmbH & Co. KG is one of the leading worldwide manufacturers of injection moulding machines with clamping forces up to 1,000 kN. The very compact, durable machines work precise, energy-saving and therefore highly economical. BOY continually sets new standards in our industry with innovative concepts and solutions. Since the company was founded in 1968, over 40,000 injection moulding machines have been delivered worldwide. The privately owned company continues to put special emphasis on engineered performance and high-class “made in Germany” workmanship. For further information visit http://www.dr-boy.de.