Plastics & Rubber Review

Vol.3 No.4 | July-August 2015 | New Delhi | India

Welcome to

Arburg’s Freeformer at T-Plas

K 2016 –

Innovation takes

centre stage

High Quality Rubber Components with Modern Vacuum Technology

Plastics from greenhouse gases Eliminating shortages of skilled staff

Polymer chemistry meets biotechnology: PLASTICS FROM SEAFOOD

Process concept for a zero-emission route to clean middle-distillate fuels from coal A novel process configuration has been developed for producing clean middle-distillate fuels from coal with minimal emissions.

The EMS Energy Institute at Penn State University has developed and tested a solvent extraction process for making liquids from bituminous coals, and has shown the successful use of these fuels in small jet engines, a diesel-engine pickup truck, and a solid oxide fuel cell. The core of the process involves extracting coals with light cycle oil, a refinery byproduct, separating the residual solids, hydrotreating the liquid to remove sulfur, hydrogenating to eliminate aromatic compounds, and finally distilling to obtain the fuel products, which represent the majority of the liquid yield. The optimum yield of the raw extract, after three stages of extraction, is as high as 75%. The recovery of middle-distillate fuels from the hydrotreated and hydrogenated extract is up to 80%. A solvent stream would be recycled back to the front end of the process.

Vol.3 No.4 | July-August 2015 | New Delhi, India

ANNUAL SUBSCRIPTION: INDIA: RS.2000 | OVERSEAS: US$150

I n T h e P a g e s 4 AMUT SOLAR LINES PRODUCING EVA FOILS 6 ARBURG AT THE T-PLAS 10 K 2016 – INNOVATION TAKES CENTRE STAGE

The liquid product is of particular interest as an aviation fuel. It appears to be suitable as a potential drop-in replacement for Jet A or JP-8 fuels. In addition, it has a much greater resistance to pyrolytic breakdown at high temperatures than either Jet A or JP-8. The fuel could be considered for thermal management on high-performance aircraft such as the F-35. The middle-distillate is also fully compatible with conventional petroleum-derived diesel for light-duty applications such as in light road vehicles. It has not yet been tested in other diesel applications.

Coal conversion to liquid fuels has many potential environmental issues. A conceptual process design has been developed in which the successfully-demonstrated core processes of extraction, separation, hydrotreating and hydrogenation, and distillation have been augmented with other operations selected to reduce total process emissions nearly to zero. Most of the hydrogen needed for the hydrotreating and hydrogenation steps would be produced by electrolysis of water using non-carbon electricity, e.g. from photovoltaics. Hydrotreating the extract inevitably produces hydrogen sulfide.

New catalytic processes for H2S splitting are recommended for destruction of this material, recycling the hydrogen back into the process, and recovering the sulfur as a marketable byproduct. Additional hydrogen could be produced by gasifying the residual partially extracted coal recovered after the final extraction step. Gasification at high temperature would melt the mineral constituents of the coal, allowing the resulting slag to be vitrified into a glassy product that could be used as, e.g. fill material for road construction. Heavy distillation residua or biomass material from CO2 capture could also be co-fed to the gasification unit.

Likely sources of CO2 include emissions from fired process heaters and from the gasification unit, after shifting the raw gas to a CO2-H2 mixture and separating the desired hydrogen. The intended approach for carbon capture would use algae photobioreactors. Algae would be harvested for production of a bio-oil that could be blended with the coal-derived oil product. “Spent” algae would be consumed in the gasification unit.

Overall inputs to the process would be coal, water, non-carbon electricity, and make-up solvent for extraction. The outputs would be clean liquid fuel, with a bio- component, suitable for use in jet or diesel engines; sulfur for sale to various chemical applications, and a vitrified slag. Other emissions would be minimal.

12 TPLAS - GAIN A COMPETITIVE EDGE AND VISIT THAILAND’S LEADING PLATFORM FOR THE PLASTICS AND RUBBER INDUSTRIES! 19 THE NEW KUBE RANGE TO GO ON SHOW AT SCANPACK 2015 23 25 YEARS OF ARBURG IN THE USA 26 ELIMINATING SHORTAGES OF SKILLED STAFF 28 INTERPLAS SHOW REPORT - THE ABSOLUTE PLATFORM FOR PLASTICS MANUFACTURING! 30 HIGH QUALITY RUBBER COMPONENTS WITH MODERN VACUUM TECHNOLOGY 34 FOAM INJECTION MOLDING 2.0 BY WITTMANN BATTENFELD. 41 JINMING GETS “FAST AND FURIOUS” WITH A NEW DELIVERY MODE FOR BLOW FILM LINE 44 LATEST SACMI INNOVATIONS FOR CAPS AND LABELS TO GO ON SHOW IN SHANGHAI 47 HIGHLIGHTS OF THE LATEST PRODUCTS AND TECHNOLOGIES AT PACK PRINT INTERNATIONAL 2015 50 PLASTICS FROM GREENHOUSE GASES 52 POLYMER CHEMISTRY MEETS BIOTECHNOLOGY: PLASTICS FROM SEAFOOD

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. Contacts: To advertise: advertise@plasticsandrubberreview.com, to submit a press release: editorial@plasticsandrubberreview.com, to subscribe: subscribe@plasticsandrubberreview.com, for general 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.

Plastics & Rubber Review | July-August 2015 | 3

AMUT SOLAR LINES PRODUCING EVA FOILS EVA, Ethylene-Vinyl-Acetate, is the type of material produced with AMUT’s extrusion foil line and it is especially reserved for the production of solar-photovoltaic panels. EVA foil protects the photovoltaic cell, encapsulating and wrapping the silicon cells, and enables a perfect sealing and a high adherence with the outer glass sheet and with the back-sheet (lower layer).

The calender has 3 rolls with special surface treatment to handle EVA material and to avoid the stickiness of the foil on the rolls. The calender, equipped with independent drives, has a further special stabilization unit system. The cooling phase must be progressive to reduce the tension at minimum level.

A sophisticated thermoregulation system

is

essential,

for

both

extrusion and cooling processes.

The innovative winding system can wind-up, directly in-line, the foil in reels or permit to laminate in-line a separating film sheet (mask film) or a silicone paper foil to protect EVA foil completely. There is also the possibility to emboss on one sheet side allowing the adherence with the glass sheet during the solar cells The EVA foil delivered with AMUT

All units of the line are purposely

lines assures:

designed

- the maximum light transmission;

and to not compromise the foil

- the absence of deformations or

dimensional stability.

for

this

application

shrinkages; - a great capacity to achieve a good

The

cross-linking level (necessary to end

extrusion/die units can process

the panel lamination very

both liquid and solid additives thus

quickly);

assuring an optimal melting of the

- the satisfaction of TĂœV or CEI EN

Polymers in order to give the foil the

50086 certificates requirements.

necessary resistance to UV rays and

gravimetric

dosing

and

avoid the yellowing effect (it causes The foil produced has a width from

a lack of efficiency in the energy

1050 mm up to 2100 mm, with a

production). There is not cross-

thickness range from 0,3 to 0,8 mm.

linking during extrusion process.

4 | July-August 2015 | Plastics & Rubber Review

manufacturing.

ThE ART Of pRODUcTION EffIcIENcy

Finding the decisive perspective – that is true art. Around 3.5 billion high-quality plastic parts are produced every day worldwide on ALLROUNDER machines. If you want to produce efficiently, we are the perfect choice. We ensure your economic success. And your future perspectives!

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Arburg at the T-Plas: Freeformer and high-speed injection moulding machine • • •

Complete product range: Plastic parts produced as one-off items and in high volumes Additive manufacturing: Freeformer on view live in Thailand for first time Injection moulding highlight: Hybrid Allrounder produces 24 closures in only three seconds

From 26 to 29 August, at the T-Plas 2015 in Bangkok, Thailand (Hall 101, stand C01), Arburg will present a high-end injection moulding machine as well as the Freeformer for additive manufacturing to cover the entire production spectrum from one-off parts to mass-produced items. While a high-speed Allrounder will demonstrate the cost-effective production of drinks bottle closures, a Freeformer will show the potential of the industrial additive manufacturing of functional parts as one-off items or in multivariant small batches.

“With a hybrid Allrounder 570 H in the “Packaging” version, we will be presenting an injection moulding application designed for high volume production in the packaging industry at the T-Plas 2015. This efficient high-speed machine produces 24 water bottle closures in only three seconds,” explains David Chan, Managing Director of Arburg Singapore and responsible for the entire ASEAN region. “The highlight on our exhibition stand this year will be the Freeformer. Using the Arburg Plastic Freeforming process, the innovative system additively manufactures design and functional samples from standard plastics based on 3D CAD data, without the need for a mould. We will demonstrate this based on the example of spray heads and gear cards.”

Freeformer additively processes two components The Freeformer initially melts conventional granulates in a plasticising cylinder, similarly to injection moulding. A second discharge unit can be used for an additional component, for example to produce a part in different colours, with special tactile qualities, or as a hard/soft combination.

At the T-Plas 2015, the Freeformer will, for example combine a standard ABS granulate with a special support material. The supporting structures used during the additive manufacturing of the gear cards and spray heads for cosmetics containers can be subsequently removed in a water bath.

6 | July-August 2015 | Plastics & Rubber Review

Packaging technology: Allrounder “Packaging” version Specially for the production of screw caps, Arburg will present a hybrid Allrounder in the “Packaging” version at the T-Plas 2015. This efficient highspeed machine from the Hidrive series offers high productivity and reduced energy requirements for applications in the beverage industry. The exhibit, which features a clamping force of 1,800 kN and a size 800 injection unit, operates with a 24 cavity mould from Z-moulds. The high-quality closures weighing 1.25 grams are produced in a cycle time of around three seconds.

PACKAGING • INGREDIENTS • MACHINERY • PRIVATE LABELS • RAW MATERIALS • CONTRACT MANUFACTURING

MARCH 2016

17TH-20THCOSMOPACK 18TH-21STCOSMOPROF BOLOGNA (ITALY) FAIR

DISTRICT

WWW.COSMOPROF.COM/COSMOPACK

Organiser - BolognaFiere Cosmoprof S.p.a. - Milan - Italy ph. +39.02.796.420 - fax +39.02.795.036 - info@cosmoprof.it - company of

in cooperation with

Two hoses for specialists: AIRDUC® PUR 352 SE RAILWAY and AIRDUC® PUR 352 SE RAILWAY PLUS

NORRES Schlauchtechnik: new flame retardant hoses for the automotive industry

NORRES Schlauchtechnik has just introduced two new hose products: flame-retardant hoses for the automotive industry – the AIRDUC® PUR 352 SE RAILWAY and the AIRDUC® PUR 352 SE RAILWAY PLUS, and these immediately supplement the NORRES range of polyurethane hose products of the manufacturer from Schalke, Gelsenkirchen, Germany.

Both these certified suction- and conveying- hose types can installed particularly for use in rail vehicles and heavy goods vehicles and in public transport systems, such as for example in busses or ships.

installed for purposes of: ventilation, heating, roof drainage, brake sand conveyance as well as for sanitary equipment. The hose products are designed to resist temperature ranges of: – 40°C to +90°C, are flexible, internally smooth and microbe- and hydrolysis -resistant. These new flame-retardant hoses for the automotive industry, are convincing for their resistance to oils, fuels, chemicals as well as their ‘UV’- and ozone –stability. The Special Premium Polyurethane Pre-PUR® with a flame-retardant additive renders the hoses highly abrasion-proof and they therefore have a particularly long service life. The two types of flame-resistant industrial hoses meet the requirements of German Industrial DIN- and European Standard: DIN EN 45545-2 R23 HL1. As a result also of a thermal-insulation coating, the AIRDUC® 352 SE RAILWAY PLUS can also be employed for installations meeting the requirements of the German Industrial DIN- and European Standards: DIN EN 45545-2; R1 HL1, HL2, HL3; R22 HL1, HL2 and R23 HL2.

Tested and certified: Special fire prevention regulations are in force for rail vehicles

Heavy-duty flame-resistant hoses for the automotive industry

such as train sets or tramcar sets, as well as for public transport

The AIRDUC® PUR 352 SE RAILWAY and the AIRDUC® PUR

systems. These new industrial hose products from NORRES are

352 SE RAILWAY PLUS hose products are the heavy-duty

particularly intended to meet these regulations completely. The

flame-resistant hoses from NORRES for the automotive industry.

installation of the tested and certified AIRDUC® 352 SE RAILWAY

These polyurethane type hoses can be installed in a variety

and AIRDUC® 352 SE RAILWAY PLUS products is absolutely

of transportation vehicles, such as for example, rail vehicles,

possible as these comply with latest guidelines and meet the

busses or ships. The transportation vehicle hoses from NORRES

German Industrial DIN- and European Standards: DIN 5510 and

also meet a variety of German Industrial DIN standards for

DIN EN 45545-2. The new polyurethane hose products of the

the automotive industry and are suitable for a great variety of

AIRDUC® range provide for a great variety of use and can be

purposes.

8 | July-August 2015 | Plastics & Rubber Review

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K 2016 – Innovation takes centre stage Interview with Werner Matthias Dornscheidt, President and CEO, Messe Düsseldorf GmbH Q: Mr. Dornscheidt, the registration period for participation in K 2016 closed a few weeks ago. How would you rate the response from the global plastics and rubber industry?

A: Extremely positive! The demand for exhibition space has risen once again and all of the 19 halls at the Düsseldorf exhibition centre are completely booked up. More than 3,000 exhibitors from all five continents will be taking part and presenting their innovations. The spectrum of participating companies ranges from globally operating industrial groups to start-ups and covers all segments of the world market for polymers. K 2016 will be presenting a panorama of unmatched breadth and depth.

Will all of the companies who have registered actually be able to take part?

We will keep our promise: all companies that registered by 31st May and whose exhibits meet the K 2016 nomenclature will be allocated a stand. In some cases, it might be necessary to compromise on the stand size, but I am confident that we will find a good solution for everyone.

What is so special about K in Düsseldorf?

Other industry events have large numbers of exhibitors too.

K is the premiering platform for the plastics and rubber industry. No other trade fair sparks off so many new ideas. Right now, companies throughout the industry are already working hard to make sure they present themselves in the best light when the date comes around in October 2016. And “in the best light” stands for “with interesting innovations”. Because innovative products are the most important asset in a competitive environment. Only those who can offer new technologies that bring real benefits to their customers will be able to hold their own against strong competition.

Another unique feature of K is its high degree of

10 | July-August 2015 | Plastics & Rubber Review

internationalism, both on the exhibitor and on the visitor side.

This guarantees that trade visitors will find world-class products and services in every area covered. And it gives the exhibitors the opportunity to meet industry experts from over 100 countries and establish contacts with potential customers that they might not have been able to reach in other ways.

So innovation will take centre stage at K 2016.

Will there be additional offerings providing insights

into new developments and perspectives alongside what the exhibitors will be showcasing?

Enterprises from the industry and research institutes will be taking advantage of K 2016 to spotlight developments and future prospects in the plastics and rubber industry.

This will be done not only at the exhibitors’ stands but also in the extensive supporting programme which offers the trade visitors another range of interesting topics.

To mention just two:

The global events calendar for the plastics and rubber industry has seen quite an upheaval recently regarding shifting of dates. How does this affect K 2016?

The special show in Hall 6 gives insights into how plastics can shape the future and solve tomorrow’s challenges – in functional, aesthetic and sustainable ways. Topics like resource efficiency, lightweight construction, new materials and Industry 4.0, and even the controversial marine litter, will be addressed in panel discussions and presented in multiple media. The special show is organised by the German plastics industry under the auspices of PlasticsEurope Deutschland and Messe Düsseldorf.

While the special show is directed at industry decision-makers and also reaches the general public through multipliers and the media, the Science Campus is the meeting place for the scientific community. This is where institutions, universities and other establishments present their latest research results in the complex field of plastics and rubber and dialogue with industrial users.

With such a broad array of offerings, will the trade visitors be able to find all the highlights at the trade fair?

Yes, of course! K 2016 offers huge variety, but at the same time it is very clearly structured. The exhibition halls are dedicated to the specific areas of • raw materials, auxiliaries • semi-finished products, technical parts and reinforced plastics • machinery and equipment, and • services This structure ensures that each visitor can easily locate the exhibitors most likely to match his or her professional interests.

An extensive range of web-based services makes planning very easy before and during visits to the trade fair. As an additional resource, the Innovation Compass is being optimised to allow even better identification of the new developments presented by exhibitors.

Thanks to its scope and the unrivalled internationality, K has a very special standing in the world. It is seen as the heart of the industry and the starting point for major decisions regarding products, processes and solutions. One of the key reasons why K is so successful is its concept, which we designed from the very beginning in consultation with manufacturers and processers and their industry associations and have continued to develop jointly with them ever since. This interaction has proved to be a winning combination and ensured that the trade fair has remained the undisputed leader for decades. And right now we are hearing that suppliers and decision-makers have a very high preference for Düsseldorf. People in the industry are rescheduling their events calendar worldwide to ensure that nothing clashes with K.

K 2016- The World’s No. 1 Trade Fair for Plastics and Rubber 19 to 26 October 2016

The world’s premier trade fair for the plastics and rubber industry will once again be presenting the entire range of products and services that the industry has to offer, from the latest state of the art to groundbreaking innovations to visionary developments. At K 2013, a total of 3,220 exhibitors from 59 countries showcased their capabilities, and 218,000 trade visitors from over 100 countries used this event as a business platform for information and investments. 82% of visitors at K 2013 were directly involved in investment decisions. The visitors categories at K are manufacturers of plastic and rubber products as well as developers, designers and manufacturing specialists from user industries, such as the automotive, consumer goods, electrical and electronics, aerospace and construction sectors.

K 2016 will be occupying all 19 halls of the Düsseldorf exhibition grounds.

Suppliers of machinery and equipment are traditionally the largest group among the exhibitors, and their live presentations of sophisticated production units offer a globally unique experience. The producers of raw materials, semi-finished products and technical parts will be focusing on novel products and applications in addition to energy-efficient and environmentally sustainable solutions.

K 2016 will be open from 10 a.m. to 6.30 p.m. daily from Wednesday, 19 October, to Wednesday, 26 October. All the details can be found at www.konline.com Plastics & Rubber Review | July-August 2015 | 11

Gain a competitive edge and visit Thailand’s Leading Platform for the Plastics and Rubber Industries!

Mirroring the most recent industry patterns, T-PLAS 2015 will present a complete showcase of new technologies, state-of-the-art machineries and insightful conferences, represented by more than 300 global companies and key players who are experts in their field. Trade visitors can look forward to an integrated exhibition of market-driven solutions from 20 countries as well as synergistic concurrent conferences and seminars that will shape the future across the rubber and plastics sector, from raw materials and auxiliaries to semi-finished products to machine technology and applications.

T

aking place at a time of economic transitioning to a unified ASEAN Economic Community that is expected to outgrow the European Union within a decade, Southeast Asia is producing tremendous growth and investment opportunities to the international market. The dynamic region is one of the top exporters of plastic products and producers of rubber worldwide, with Thailand alone accounting for 40 % of the world’s rubber production together with 5,000 plastic companies.

Coupled with a growing demand such as car and aircraft tyres, that will require millions of hectares of additional rubber plantations alone, as well as an increased demand in plastic products due to growing populations and economies around the world, has fuelled the region with an abundance of opportunities for companies in the plastics and rubber sector, positioning Bangkok as the perfect platform to drive your business forward.

“T-PLAS 2015 will see a 20% increase in exhibitors and international participation up by some 15%, as well as a range of new initiatives which will raise the value of business the trade fair facilitates. With the major industry sectors represented on the show floor, trade visitors can expect to see more machinery and equipment for the plastics and rubber sectors and with a focus on the key growth areas, we are very optimistic of a very strong showing and a marked increase in trade visitors this year,” - Gernot Ringling, Managing Director, Messe Düsseldorf Asia

12 | July-August 2015 | Plastics & Rubber Review

At a Glance

Date: Opening hours:

Venue:

Dress Code:

Admission:

26 – 29 August 10.30 – 6.30pm Bangkok International Trade & Exhibition Centre (BITEC) www.bitec.co.tht Office / Work attire Admits business and trade visitors by registration only.

Pre-register your visit now at www.tplas.com Be among the first 1,000 to pre-register and receive a gift when you visit! In addition, stand a chance to own the latest iPhone in our daily lucky draw.

Reflecting the latest industry trends, T-PLAS 2015 will feature special highlights in high-value manufacturing sectors such as medical plastics, 3D printing technology and automotive applications.

SPECIAL HIGHLIGHTS IN HIGH-VALUE MANUFACTURING SECTORS

MEDICAL PLASTICS With today’s manufacturing technology, medical manufacturers are turning to durable and safe plastics to boost their production to meet the strong demand for medical products. Exhibitors will showcase the latest technologies

and applications in 3D printing and plastic injection moulding, catered specifically for the high speed and high precision required in medical manufacturing.

AUTOMOTIVES

About ARBURG Group: ARBURG is one of the world’s leaders of injection moulding machines with clamping forces between 125 and 5,000kN, complemented by robotic systems, turnkey solutions and further peripherals.

Plastic is often the preferred material for automobile parts and components because of their lightweight, durability and cost effectiveness. In Thailand, the plastics industry alone accounts for US$897 million in automobile production. Catered to professionals from this key sector, the Plastics in Automotive conference will focus on Lightweighting and Sustainability, providing latest development updates in plastics materials, design and processing.

Product to be launched: ARBURG will be launching the Freeformer, with a live demonstration of additive manufacturing right here in Thailand for the first time.

3D PRINTING TECHNOLOGY (ADDITIVE MANUFACTURING)

Demonstration

Additive manufacturing is hardly a new trend in the plastics industry. As it rapidly becomes the preferred technique among manufacturers, Thailand and the region is expected to become the key region ready for 3D printing adoption. Benefits of additive manufacturing includes flexibility to create complex parts, weight reduction through building parts with internal cavities and lattice structures, waste minimisation, and speed in product development.

Using both the Freeformer and a high-speed injection moulding machine, ARBURG will demonstrate the entire production spectrum from one-off parts to mass-produced items. The Freeformer will, for example combine a standard ABS granulate with a special support material.

Featured at T-PLAS 2015 are some of the players at the forefront of this technology, such as ARBURG and STRATASYS, showcasing the latest products and technologies in this key sector.

Using the ARBURG Plastic Freeforming process, the innovative Freeformer system additively manufacturers design and functional samples from standard plastics based on 3D CAT data, without the need for a mould.

About WITTMANN Group: The WITTMANN Group is a worldwide leader in the manufacturing of injection moulding machines, robots and peripheral equipment for the plastics industry.

Business Matching

Product to be launched: The SmartPower, a servo-hydraulic machine, will be shown for the first time in Thailand.

Benefit from the pre-event Business Matching Service and stand a chance to win a FREE trip* to K Düsseldorf when you use the Business Matching service to connect with relevant exhibitors prior to your visit. To register, go to www.tplas.com *Terms and conditions apply

The new SmartPower, model from WITTMANN’s servo-hydraulic machine series, is benchmarked primarily by its intelligent, economical use of energy.

Available in clamping force sizes from 25 to 120 t, this new machine boasts of precision, efficiency, compact dimensions and user-friendliness.

UNVEILING OF NEW PRODUCTS AND TECHNOLOGIES AT T-PLAS 2015 Be among the first to see new products launched by ARBURG and WITTMAN Group. The world leading manufacturers in 3D printing and injection moulding machinery respectively will unveil their latest products and technology for the industry at the exhibition!

Demonstration For the onsite demonstration, trade visitors can see the manufacturing of a PET blood tube with a 16-cavity mould. Later, a W818 servo traverse robot from WITTMANN will be used to demonstrate the removal of the parts.

Plastics & Rubber Review | July-August 2015 | 13

Concurrent Events Explore the Future of Plastics and Rubber with these Industry-driven Conferences and Seminars: (All conferences will be conducted in Thai, with the exception of “Plastics in Automotive”, which will be in English) 26 Aug (Wed) Composite - Reinforced Plastic for the Future Thai Composite Association - Packaging with In Mould Labeling (IML) - Competitive advantages through innovative production technology - “Freeformer” and Plastic Freeforming (3D Printing) Arburg (Thailand) Co Ltd. Plastics in Automotive Asian Plastics News 27 Aug (Thur) Plastics in Automotive Asian Plastics News Rubber Mould and Plastic Mould Tool & Die Industry Association Seminar on Medical Plastics Plastics & Rubber Asia Packaging with In Mould Labeling (IML) Competitive advantages through innovative production technology “Freeformer” and Plastic Freeforming (3D Printing) Arburg (Thailand) Co Ltd. 28 Aug (Fri) Mould Efficiency Improvement Thai German Institute Plastic for Medical Industry Plastic Institute of Thailand Rubber Mould and Plastic Mould Tool & Die Industry Association Essential Techniques to Succeed in the Plastic Injection Moulding Thai German Institute Coating Technology Kurz (Thailand) Ltd 14 | July-August 2015 | Plastics & Rubber Review

Product Features at T-PLAS Machineries and Equipment AEDICE CO LTD - The company has over 10 years of technological experience, and the product quality to take the industry into the future.

AEDICE offers plastic injection moulding machine, vertical type injection moulding machine and plastic injection mould.

ANUPAM HEATERS & CONTROLS PVT LTD - One of India’s leading manufacturers in quality heating elements for plastic and other allied industries, their product range includes: band heaters, high watt density cartridge heaters, micro tubular heaters, nozzle heaters, coil heaters, tubular heating elements and hot runner elements.

BLUE AIR SYSTEMS GMBH - An Austrian based company with 20 years of experience, BLUE AIR SYSTEMS supply the plastics industry with innovative technology. Their core subject is climate technology with solutions for extremely dry and cold air for energy efficient processing in the plastics industry.

C.S. MACHINERY CO LTD - Developer of plastic sheet extrusion lines through the experience of actual manufacturing and know-how. The company has over two decades of PET and PP sheet production experience.

CHIP HUA EQUIPMENT & TOOLS PTE LTD - With 60 years of experience for the provision of products for Static Control and Corona Surface Treatment services, CHIP HUA specialises in the implementation of static eliminators and corona surface treating machines to enhance their customers product’s quality and reliability.

CIRWIND MACHINE MFG CO - One of India’s leading manufacturer of machines for the raffia woven sack industry (HDPE/PP tapes) since 1986. Additionally, they also specialise in manufacturing circular looms and cheesewinders.

DAVIS-STANDARD LLC - Recognised as the global leader in highperformance plastic and rubber extrusion and converting systems, DAVIS-STANDARD supplies technologically-advanced extrusion solutions to the global polymer and rubber processing industries, with capabilities that go beyond

extrusion technology and extruder processing equipment.

ENGEL AUSTRIA GMBH - With the highly integrated and automated systems solutions for injection moulding, ENGEL helps their customers in the automotive, teletronics, medical, technical moulding and packaging industries to make their production processes highly efficient and cost effective and thus increasing their competitiveness.

EREMA ENGINEERING RECYCLING MASCHINEN UND ANLAGEN GMBH - Specialised in the development and production of plastics recycling systems and technologies for the plastics processing industry. As a global market and innovation leader, they have achieved numerous patents, particularly in energy-saving and environmentally-friendly systems.

EVERPLAST MACHINERY CO LTD Specialises in the manufacturing of machinery for producing pipes, profiles, soft pipes, door, compounding, WPC, and tooling.

They provide the professional extrusion lines based on market demand and the diversified characteristics of resin material.

EXTRUNET GMBH - A pioneering leader in energy and extrusion technology in tooling- and machine building. They supply customertailored extrusion lines and tooling - from co-extruders, single and double screw extruder, guillotine cutters, retrofit, extrusion lines and tooling to development of individual window systems.

FOMTEC PLASTIC MACHINERY (GUANGZHOU) CO LTD - A leading enterprise in VERTICAL injection moulding machine. The FOMTEC Injection Moulding Machine has a clamping force of 13-750 tons, and injection weight of 15-8000g. Their machines range includes plastic, engineer-plastic, thermoset plastic (Bakelite, BMC) and liquid silicone rubber.

FORMATIVE TECH PTE L TD - Babyplast UAI converts a standard machine to multi-colour machine with fast ROI. FORMATIVE TECH will showcase a customised injection press + rotary table + three Babyplast UAI as well as micro and high precision parts produced by Babyplast.

GCM - Specialises in seamless PE tube production lines. GCM will showcase the 5-Layers Extrusion Line / GCE05.

Specifications: Extrusion speed: Max.23M/ min -Cutting capa.: Max.200pcs/min -Tube dia.:16~60mm -Tube length:50~220mm

HAO YU PRECISION MACHINERY INDUSTRY CO LTD - An experienced manufacturer of PP and HDPE woven bag machinery and whole-plant equipment. They also provide ISO-9001 and CE international quality standard equipment to more than 450 plants in over 60 countries.

HTW FORMEN - UND FERTIGUNGSTECHNIK GMBH - Specialised in the production of high performance injection moulding for screw caps. They are also able to produce and deliver 1-cavity pilot moulds as well as 96- cavity series moulds in a very short period of time.

JET ENGINE AUTOMATION CO LTD - Based in Taiwan, JET ENGINE AUTOMATION is dedicated to auto equipment design and development. They specialise in Post Mould Cooling Robot Systems and IML Robot Systems.

LIMAX INDUSTRIES SDN BHD - A leading manufacturer of plastic bag converting machines.

The Limax Gapa 1100 machine is the fastest clamp stack bottom seal machine in the market, with speed up to 200cpm, converting bags from 5 micron/layer to 150 micron x 4 layers.

MAGUIRE PRODUCTS ASIA PTE LTD - A global leader in material management systems for plastics moulding, extrusion and compounding. They offer a full range of flexibility in weigh scale blending and mixing from 9 series of blender to 120 models for most of the industrial application.

MASTERFLEX ASIA PTE LTD - With over 25 years of experience, MASTERFLEX is a specialist in superior connection and hose systems made of innovative high-tech plastics. Their high-tech hoses can be applied in aviation, automotive, energy segment, food manufacturing, pharmaceutical products and medical industry.

MATILA INDUSTRIAL CO LTD - The company offers mono layer, double layer, and up to five layer blown film machines for all kinds of HDPE /LDPE /LLDPE /PP /PA / EVOH film. The film width is from 30mm reaching to 10M, with a film output of 10kg up to 800kg/hr.

Plastics & Rubber Review | July-August 2015 | 15

MORETTO S.p.A. - The company supplies automation for the plastic processing industry including machines for feeding, conveying, hot-air drying, dehumidifying, grinding, micro-dosing, gravimetric and volumetric dosing, storage, temperature control and cooling.

RIECKERMANN (THAILAND) CO LTD - A group of companies that is a competent, internationally acting industrial service partner for selected markets and industries.

They provide complete industrial solutions from master planning and conceptual design, engineering, procurement and construction management up to equipment installation, training, service and maintenance.

NEXT GENERATION ANALYTICS GMBH - The leading manufacturer for laboratory equipment and pilot systems for processing polymers. They offer roll mills and calenders, platen presses, single and twin screw extruders, mono and co-extrusion lines, systems for qc and stretching lines and equipment for medical applications.

SML MASCHINENGESELLSCHAFT MBH - An internationally recognised as a reliable turn-key supplier of custom-made coex-castfilm lines, coex-calendering-lines, extrusioncoating-lines and multifilaments pinning- lines. They also offer holistic and reliable concepts to support customers in the realisation of complex products

NGR - NEXT GENERA TION RECYCLINGMASHINEN GMBH Manufactures machines for recycling of thermoplastics.

The machine-series combine the shredding of the plastic input (fibres, films, flakes, and even thick-walled parts or lumps), the extrusion and the pelletizing in one single step.

Other features include central control units and automatic filtration systems.

NICHO THAI PLAST LIMITED PARTNERSHIP - The company provides spare parts of the plasticising unit (barrel, screw, screw tip) for all brands of injection moulding machines. All products are made in Italy by Brixia Plast using fine raw material from Germany.

ORRECA SARL - A company that provides technical solutions for packaging, such as bag placing, big bag extractors, ultrasound welding and thermal welding, compactor, conveyors, scaling on line, palettes distributor, drums distributor, crimper, palletiser, lining machine, warping machine, press for pallets.

PASS CARD CO LTD - Specialised in plastic injection mould related to food/medical packaging items. Moulds are well presented with multi cavities and with high speed performance, including PET preform mould, cap and closure mould, thin-wall mould, PET blood test tube mould and turnkey production line solution.

RAJOO ENGINEERS LIMITED - Excellence in Extrusion™ is the origin, path and destination defining solutions by RAJOO ENGINEERS. Their solutions include - mono and multilayer blown film lines, sheet lines, water quenched downward extrusion lines, lines for PE and PS foamed film and sheets and end-to-end thermoforming solutions.

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STAR FLEX INTERNATIONAL - A group of leading manufacturers and exporters of flexographic and rotogravure printing machines roll to roll in India.

STARLINGER RECYCLING TECHNOLOGY - With the pioneering machine concept of the recoSTAR dynamic line, STARLINGER showcases an energyefficient production process with a high degree of automation. It ensures reliable and constant production, higher output, and great flexibility regarding input materials.

STRATASYS SINGAPORE PTE LTD - A leading global provider of 3D printing and additive manufacturing solutions, the company’s patented FDM® and PolyJet™ 3D printing technologies produce prototypes and manufactured goods directly from 3D content. Systems include 3D printers for idea development, prototyping and direct digital manufacturing.

TAIZHOU JOBO MACHINERY MOULD CO LTD - The company has developed a cap compression moulding machine with a whole set of hydraulic reciprocating transmission, characterised by stable transmission in mould lifting, low noise, easy operation and energyefficient. The machine is also equipped with automatic temperature control devices.

TECHPLAS MACHINERY CO LTD - Specialised in PVC extrusion machinery for pipe/hose, profiling products and pelletizing, and providing complete turnkey solutions for the industry.

TOHOKU ELECTRONIC INDUSTRIAL CO LTD - The Chemiluminescence Analyser by TOHOKU ELECTRONIC INDUSTRIAL is the most sensitive photon counting device and the only spectrometer with that sensitivity in the world. It detects down to 50 photons/cm2/sec (about 1/10000 of a firefly) 10-15 Watts.

TOZAI BOEKI KAISHA (THAILAND) LTD - KUBOTA is the leading manufacturer of gravimetric feeders and pellet screening systems and provides process industries with advanced gravimetric feeding technology and pellet screening systems to meet customers’ process requirements.

WELL SHYANG MACHINERY CO LTD - A leading machine manufacturer for rubber, silicone and plastics processing machines in Taiwan, WELL SHYANG’s main products include dispersion kneader, intensive hydraulic pressurized kneader, intermesh mixer, cold feed extruder, strainer, hot feed extruder and other support units.

YICHEEN TECHNOLOGY CO LTD - Formed in 1979, YICHEEN specialise in high speed slitting machine, die cutting machine, sheet cutting machine, auto planar oil pressure cutting machine, rubber cooling machine and core cutter.

ZERMA (THAILAND) CO LTD - One of the leading manufacturers of high quality size reduction machinery- From the small GSL slow speed granulators to the versatile GSH heavy duty granulators including small and compact granulators with integrated blower and soundproofing.

Raw Materials & Auxilliaries, Semi-Finished Products & Services ABLE-SPEED SDN BHD - A manufacturer of EVA Foam, CR Foam, EPDM Foam blocks and multi-component parts, lamination with adhesive multi-layer and custom made, die-cutting and punching, rubber and rubber foam moulding. A Thai/ German trading company representing leading machine manufacturers from Germany and Italy, they provide complete lines, technical assistance and spare part service for all products.

ADVANCED PLASTIC INTERTRADE CO LTD - A Thai/ German trading company representing leading machine manufacturers from Germany and Italy, they provide complete lines, technical assistance and spare part service for all products.

ARMSTRONG - Established in 1980, Stitchman supplies ARMSTRONG brand industrial sewing machines in India and internationally. Their products include PP / HDPE woven sack big bags (FIBC’S) sewing machine, needle looms, printing machine and bale press machine supplier.

antioxidants. They also manufacture flame retardants and other processing additives.

CHAIYABOON BROTHERS CO LTD - The company offers a variety of screen printing products and tools as well as emulsions and screen printing products related to chemical substances such as printing machines, coating machines, pad printing machines and plasma treatment machines.

CHIAO FU MATERIAL TECHNOLOGY CO LTD - Specialised in resin colouring, extrusion, injection moulding, mould design and manufacture. CHIAO FU also strengthen, refine, and colour plastic materials such as PA6, PA66, PLA, and PP. CHS PACKAGING CO LTD - Specialised in plastic products for packaging, CHS manufactures various types of products such as pp corrugated, plastic film products, protection tape products as well as flexible packaging PE foam and air bubble, insulation hose and tubes.

DONGGUAN HIGH GRADE CHEMICAL CO LTD - A well-known enterprise specialising in the production and sale of ultramarine blue pigment, the company manufactures Ultramarine Blue(PB:29), Carbon Black(PBK:7), Titanume Brown(PBR:24) and Titanume Yellow(TY:53).

IMCD - A leading international distributor of high-quality additives and compounds, specialising in the fields of additives and compounds for the plastics and rubber industries.

MIRAE P&T - Korea’s no. 1 PE / PP foam and machine manufacturer. They specialise in electron beam cross-linked PE/PP foams, chemically cross-linked PE foams, PE foams and PE film and air-cap.

M.P.I. SRL - Ultra Purge by M.P. I. is a chemical and hybrid purging compound designed to purge screws, barrels and hot runners during colour changes, material changes and machine shutdowns. It can be used for injection moulding machines, extrudes, blow moulding machines and blow film machines.

OMEGA PLASTO COMPOUNDS PVT LTD - POLYCOM Modifier is a revolution in the entire plastic industries. This technology includes woven sack, blown film, lamination, blow/injection moulding, rotational moulding, HDPE/PP/PPR pipes, PP non-woven, HIPS thermoforming and PE foaming industries.

BIORAY CHEMICAL CO L TD - A Chinese firm specialised in manufacturing and supplying polymer additives, such as UV stabilisers and Plastics & Rubber Review | July-August 2015 | 17

PHON TECH INDUSTRIAL COMPANY - One of the leading companies for thermoplastic elastomers (TPEs) in Taiwan, specialising in SEBS, SEPS compounds, and sold under the trademark PHOENIX.

POLYCELL KOREA CORPORATION - A Korean manufacturer of PE foam extruder, PS foam extruder, air bubble sheet extruder, physical cross linked PE foam plant and chemical cross linked PE foam plant. Their products are sold domestically and overseas.

SHAOYANG TIANTANG ADDITIVES CHEMICAL CO LTD - A professional plastic stabiliser manufacturer. Their main products are metallic stearates, calcium stearate, zinc stearate, magnesium stearate, lead stearate, hydrotalcite, one pack PVC stabiliser.

SHENZHEN CHUANGHUIXINYE PLASTIC TRYPTOPHANE CO LTD - The company is dedicated to plastic masterbatches, such as food grade black, white and different colour masterbatch, with specified base/polymer for special application, and different types functional additives.

SUNNINGDALE TECH PTE LTD - A one-stop precision plastic engineering company, SUNNINGDALE provides services in product design improvement / design conceptualisation, mould design and fabrication, ultraprecision high cavitation tooling and precision injection moulding through to precision assembly of complete products.

ULTRA PLAST ASIA CO LTD - The leading manufacturer of purging compounds for plastic processing machines. ULTRA PLAST ASIA’s products are not abrasive and can be cleaned with an immediate chemical reaction without any waiting time.

VIETNAM QUICKLIME, HYDRATED LIME, PCC & NANO PCC Hong Hai Group is the first and exclusive manufacturer of high quality quicklime (CaO-95%), hydrated lime (Ca(OH)2-96%), precipitated calcium carbonate (PCC) (CaCO2-99%) and Nano PCC, licensed by the Government of Vietnam.

WACKER CHEMICALS (SOUTH ASIA) PTE LTD - A globally-active chemical company specialising in silicones, polymers, biosolutions and polysilicon. WACKER CHEMICALS have a global network of 25 production sites and 52 sales offices worldwide.

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ZOTEFOAMS PLC - The world’s leading manufacturer of cross-linked block foams. ZOTEFOAMS PLC specialises in a range of closed cell cross-linked polyolefin foams using a unique, environmentally friendly, clean, noncontaminating, nitrogen expansion process.

More details on exhibitor and product highlights available on www.tplas.com

All the latest from the new KUBE range to go on show at Scanpack 2015

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n innovative, modular labeller with outstanding application flexibility, efficiency and user-friendliness, designed to meet every possible packaging requirement with maximum versatility, precision and low running costs. These, then, are the key characteristics of the Sacmi solution being showcased at the Gothenburg fair (20-23 October 2015).

Sacmi labelling technology will be playing a pivotal role at Scanpack, northern Europe’s biggest international packaging fair that will – following the success of the 2012 edition with 13,000 visitors – be back from 20 to 23 October in the city of Gothenburg, Sweden.

The Group’s stand (hall B02, n° 09) will be displaying the new range of SACMI KUBE labellers; these feature extremely innovative cold-glue or hotmelt self-adhesive labelling solutions that have been designed to meet the needs of a market ever-more demanding as regards product changes.

The labeller presented at Gothenburg will be equipped with two selfadhesive stations and a cold-glue station and can be used to apply up to 9,000 labels and hour: an ideal, effective system, then, suitable for a variety of labelling solutions and systems. The machine is made entirely of stainless steel and, as the labelling stations are positioned outside the machine, workers find it easy to perform size changeover and maintenance tasks.

One of the key features of the KUBE range is robotized axes adjustment, the patented Sacmi bottle orientation system (that allows, with just one camera or sensor, correct orientation of sparkling wine caps, raised onglass logos or glass moulding seams), and the robotized universal screw feeder for flexible, efficient control of all bottle types without any need for screw changeovers.

The electronic control system (of the touchscreen type) includes advanced user-friendly software, allowing simple yet effective control (also remotely and via mobile devices such as tablets and smartphones) of all process parameters.

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Fakuma 2015: Arburg presents itself as system supplier • • •

Additive manufacturing: freeformer-customised injection-moulded mass-production parts Industry 4.0: automated and networked shear production for one-off designs Innovative process: Lightweight construction, LSR processing, packaging technology and more

Arburg is to present itself beyond machine technology as a production system supplier for plastic part production at the Fakuma trade fair in Friedrichshafen from 13 to 17 October 2015. Eight allrounders and three freeformers, the ARBURG host computer system ALS and integrated automation will be on view in Hall A3, Stand 3101. Production-efficient applications indicate current industry trends. One highlight is the customisation of mass-production parts by combining injection moulding and additive manufacturing, including integration with Industry 4.0 technologies.

Innovative lightweight construction processes, multi-component injection moulding, LSR processing, practical examples for medical and packaging technology and a micro production system round off our trade fair presentation. Another eight allrounders can be found at the stands of our partners.

“We have been working on the subject of Industry 4.0 for some time now.

With automated allrounders, the freeformer for additive manufacturing and IT solutions, we are increasingly developing ourselves into a production system supplier for integrated production in the digital factory”, stresses Arburg’s Managing Partner Juliane Hehl. “In Friedrichshafen we are going to show how mass-production parts can be customised and traced back in a part-specific way in practice using industrial additive manufacturing with the freeformer. The other exhibits at our exhibition stand, every single one of which is a highlight, will also astonish visitors”.

Combined: allrounder, freeformer and Industry 4.0 Three freeformers will be on show at Fakuma which produce complex components from common plastic granules without a mould through industrial additive manufacturing, which customise injection-moulded mass-production parts, and which showcase the subject of Industry 4.0.

Exhibition stand visitors can make unique versions of various office scissors, for example. Firstly, an electrical Allrounder 370 E first moulds plastic handles onto the stainless-steel blades, onto which a particular code is then lasered, and optionally customised 2D or 3D lettering is applied with the laser or Freeformer.

A Multilift V robotic system inserts the scissors into the workpiece carrier and transports them out of the production cell via a conveyor belt. A scanner then checks whether the scissors are to be issued to the visitor directly or if 3D lettering made from additive plastic is to be applied using the Freeformer in a further step.

As a première, Arburg is to present a highly flexible automation solution in combination with the Freeformer for the first time at the Fakuma 2015: a six-axis robot mounted on a mobile platform from Kuka designated ‘iiwa’ (intelligent industrial work assistant) handles automatic loading and unloading of the Freeformer. In addition to its mobility, and the associated high degree of flexibility, the main advantage of this automation is the possibility of direct, autonomous cooperation between human and robot.

The robot will hand out the finished, individualised 2D and 3D scissors ‘personally’ to the visitors at Fakuma.

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A second practical example of networked production is provided by a Freeformer enhancing injection-moulded rocker-type light switches with a customised symbol/name combination in large volumes. Here too, the product itself becomes an information carrier with a code applied by laser. All the components for this networked production are supplied by system supplier Arburg.

The Arburg host computer system (ALS) seamlessly documents all relevant process parameters and forwards these to a web server.

A web page displaying all the relevant process data can be opened via the unique code using mobile devices. Each individual part can be seamlessly tracked in this way.

Beyond the Industry 4.0 applications, all exhibits at the Arburg exhibition stand are linked via ALS. Visitors can experience the performance of the host computer system, which is optimised for injection moulding operations, with regard to machine and operational data logging ‘live’ at the stand and also receive advice from experts.

Innovative: the Profoam lightweight construction process With an innovative application for the automotive industry, Arburg will present the physical foaming of thermoplastics. The innovative Profoam lightweight construction process has been researched and developed together with the Institute for Plastics Processing

“We have been addressing the subject of Industry 4.0 for some time now and are increasingly developing into a production system supplier for networked production in the digital factory”, says Arburg Managing Partner Juliane Hehl, referring to Arburg’s main focus at the Fakuma 2015.

(IKV). It enables significant material savings in automotive plastic parts and thus a reduction in fleet consumption and CO2 emissions.

Due to the reduction in volume and weight, the process also saves cooling time, minimises the occurrence of sink marks, shrinkage and distortion and does not require any additional peripheral devices. Conventional injection moulding machines can be employed in this way and also used for other applications.

The latest stage of development of Profoam will be presented at the Fakuma 2015 on a hydraulic Allrounder 630 S. An injection unit with normal screw geometry is used. The plastic granules are first mixed with motive fluid in a granulate lock between the refill container and material feed. During plastification the

propellent is dissolved in the melt and only escapes again when pressure is reduced during the injection process in the form of microcellular ‘bubbles’. The result is a light, robust and low-distortion component with homogeneous foam structure. Further advantages of Profoam are the simple process control, the material-friendly melt temperature and the conservation of long fibres when preparing the melt, as the process requires no shear or mixing element in the melt.

Double soft: push-buttons from LSR / LSR compound An electrical two-component Allrounder 470 A with a clamping force of 1,000 kN, a size 170 injection unit and a second size 30 injection unit in an L-arrangement manufactures buttons for car interiors from liquid silicone rubber (LSR). The diaphragm of the moulded part is manufactured from coloured LSR with a Shore hardness of 50; the inner disc from transparent LSR with a Shore hardness of 80. Because silicones, unlike thermoplastics, do not perish or turn yellow, they enable a particularly pleasant texture and unvarying appearance over the entire life cycle.

The exhibit operates with a 32+32-cavity mould from Trelleborg and an electric rotary unit. The shot weights are especially small at just 2.04 and 0.98 grams. A vertically-operating Multilift V robotic system removes the finished parts from the mould, conducts a visual inspection using a thermal imaging camera and sets them down according to cavity.

Refined manufacture: handles, fruit basket and Y-joint The fact that hydraulic, hybrid and electrical Allrounder injection moulding machines are suitable for a wide range of uses will be

demonstrated at the Fakuma with industry-specific applications.

For example, a hydraulic twocomponent Allrounder 570 S with a clamping force of 2,000 kN and size 400 and 170 injection units will produce handles for garden saws from 40 percent glass fibre-reinforced PP and haptically appealing TPE. The machine is complemented by a mobile robotic cell. A small Agilus six-axis robot, which moves on an additional linear axis transversely to the machine, removes the finished handles, subjects them to pad printing and then sets them down on a conveyor belt. The flexible automation is characterised by dynamic movements and quick entry into the mould. This results in short cycle times and high productivity.

A hybrid Allrounder 820 H has been specially configured in the “Packaging” version for applications in the packaging industry. The highspeed machine with a clamping force of 3,700 kN and a size 1300 injection unit will produce small folding baskets (175 x 175 x 85 mm) for fruit from PP in a cycle time of around five seconds. IML labels are attached using automation from Campetella. Depending on the requirement, the fruit baskets are set down on different conveyor belts folded together or opened out.

An electrical Allrounder 470 A with a clamping force of 1,000 kN will be on view for the field of medical technology, producing connecting pieces (Y-connectors) for infusion therapy with an 8-cavity mould from Männer. The cycle time is around 15 seconds.

The highlight of this application is the side injection through a needle-type shut-off nozzle and the demoulding from three sides of PMMA moulded parts each weighing 1.1 grams. The exhibit has an extended conveyor belt

with a tunnel cover for docking with the clean room. By placing the machine and extensive peripheral equipment outside and only transporting the clean, produced parts inside, the clean room can be operated with a high level of costeffectiveness. A clean-air module with ionisation above the clamping unit ensures the required clean atmosphere (ISO class 7) during series production.

Special: system solution for micro components Also on view at the Fakuma 2015 will be a micro production system based on an electric Allrounder 270 A, equipped with a new micro injection unit and a compact, horizontal Multilift H 3+1 for the reliable separation of micro component and sprue. A clean-air module with ionisation ensures a constant, controlled production environment and effectively prevents the adhesion of micro components in the working area.

The micro injection unit is specially designed for precision control over short travel strokes in conjunction with high filling dynamics. It combines a choice of 18 or 15-millimetre screw for melting the material with an 8-millimetre screw for the injection. This enables normal granule sizes, and therefore all common materials to be processed problem-free and the smallest shot weights can be achieved precisely and with short travel strokes.

The micro production system manufactures four micro counter wheels in a cycle time of twelveseconds. Nine components weigh as much as a single granule of PBT material. The specially designed double-armed robot removes the sprue and the delicate 0.004 gram-light micro counter wheels simultaneously and sets them down carefully, separately and according to cavity.

About Arburg German machine manufacturer Arburg is one of the world’s leading manufacturers of injection moulding machines with clamping forces between 125 and 5,000 kN. This is complemented by robotic systems, customerand sector-specific turnkey solutions and further peripherals.

An innovative additive manufacturing system was added to the plastic processing range in 2013.

The company places the topic of production efficiency at the centre of all its activities, taking into account the entire valueadded chain. The objective is to enable Arburg’s customers to manufacture their plastic products, whether one-off parts or high-volume production, in optimal quality and at minimum unit cost – e.g. for the automotive and packaging industries, communication and entertainment electronics, medical technology, or the white goods sector.

An international sales and service network guarantees first-class, local customer support. Arburg is represented by its own organisations at 32 locations in 24 countries and by trading partners in more than 50 countries.

The machines are produced exclusively at the parent factory in Lossburg, Germany. From a total of around 2,400 employees, around 2,000 work in Germany.

About 400 further employees work in Arburg’s organisations around the world. In 2012, Arburg became one of the first companies to gain triple certification: to ISO 9001 (Quality), ISO 14001 (Environment) and ISO 50001 (Energy).

Further information about Arburg can be found at www.arburg.com.

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Expansion at the Arburg Spanish subsidiary • • •

More space: relocation to new premises in Montcada i Reixac (Barcelona) Inaugural celebration: events with over 110 guests Sales launch: Freeformers for customers in Spain

On 1 July 2015, the Arburg Spanish subsidiary in Montcada i Reixac celebrated the official opening of its new home in Barcelona in the presence of Arburg Managing Partner Renate Keinath. This event and the open house on the following day attracted over 110 guests from Spain and Portugal, who came to see for themselves what the new location in Barcelona has to offer. Another highlight was the Freeformer, which was presented live for the first time in Spain and which is now also available for purchase in the country.

The showroom provides space for up to five Allrounder injection moulding machines and a freeformer for testing is also available.

machines and turnkey systems, spare parts, practical tests and intensive training. The show room measures 320 square metres and has enough room for up to five Allrounder injection moulding machines or production cells, as the automation sector is set for further expansion. In addition a freeformer is available for testing.

Official inauguration of the new building in Montcada i Reixac (Barcelona): Managing Partner Renate Keinath (centre) with Martín Cayre (right) and Stephan Doehler, European Sales Director.

The over 30 VIP guests who attended the inaugural celebration were greeted by Arburg Managing Partner Renate Keinath, who, together with Stephan Doehler, Arburg’s European Sales Director, represented the German parent company.

Successful for more than 25 years In her speech, Renate Keinath emphasised: “The new subsidiary building is evidence of the important role our Spanish subsidiary has played for us over more than 25 years. Our success here is thanks to our highly committed local team and to our customers. Without them, we would not be what we are today: one of the market leaders in Spain and Portugal.

The new building confirms that we made the right choice decades ago and that our continuous investments in the Iberian market have paid off.”

She explained that the aim is always to offer the customer an even better product range and a much improved service offering.

800 square metres dedicated to customer support in Barcelona The new building in Montcada i Reixac (Barcelona) will ensure that Arburg can continue to offer comprehensive support to customers in Catalonia, the largest and most important market in Spain, long into the future.

With an area of 800 square metres, it offers significantly more space for 22 | July-August 2015 | Plastics & Rubber Review

Freeformer now available in Spain Another highlight was the official sales launch of the Freeformer in Spain.

Guests were impressed with the options offered by the innovative system for industrial additive manufacturing, which can cost-effectively produce one-off parts or small-volume batches from commercially available plastic granulates. There were also experts on hand from the AKF team to answer the many questions posed about the Freeformer and Arburg Plastic Freeforming (AKF).

In order to present the entire Arburg production range, the efficient production of large batches was demonstrated on an electric twocomponent Allrounder 520 A with Multilift Select robotic system, producing covers for the iPhone 6.

Arburg well positioned in Spain With the Arburg Technology Centers in Madrid and Barcelona, the company is extremely well positioned in Spain. The subsidiary in Sabadell (Barcelona) was founded as long ago as 1989. In 1997, Arburg S.A. additionally took on the task of supporting the customers in Portugal. In 1998, the subsidiary’s headquarters was then moved to Arganda del Rey (Madrid), as the central location of the Spanish capital made it easier to support the entire region. Today, the Arburg team in Spain numbers 27 employees, including 14 service technicians, who ensure the best possible support at local level.

To mark the 25th anniversary of Arburg Inc., Managing Partner Michael Hehl (right) presented the Arburg commemorative sculpture to subsidiary manager Friedrich Kanz on 16 June 2015.

25 years of Arburg in the USA • • •

Official inauguration of new building with Partners, Management Team and customers Arburg success story in the US Expansion in the turnkey sector and entry into additive manufacturing

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rburg’s US subsidiary had two good reasons to celebrate on 16 and 17 June 2015: Together with 245 customers and guests, the company marked the 25th anniversary of Arburg Inc. and also officially inaugurated the new premises for the US headquarters in Rocky Hill, Connecticut.

A high-ranking delegation from the parent company was on hand to join in the celebrations in the person of Managing Partner Michael Hehl, as well as Managing Directors Heinz Gaub (Technology & Engineering) and Helmut Heinson (Sales).

As part of the opening ceremony, Michael Hehl, Managing Partner and Spokesperson for the Arburg Management Team, offered congratulations on behalf of the entire parent company: “North America is Arburg’s largest foreign market, in which we have installed more than 12,000 machines.

Our new headquarters in Rocky Hill represents a

further milestone in our success story in the US. In addition to the Arburg Inc. subsidiary founded in the US in 1990, we are also represented in North America with the Arburg Technology Centers in California (1993) and the Midwest (2007).” In this context, Michael Hehl expressed his thanks to the company’s customers for the trust they have placed in the family-run company and for the successful cooperation. In recognition of the American team’s great commitment over the past 25 years, the Managing Partner presented a commemorative sculpture and certificate to Friedrich Kanz, Managing Director of Arburg

Inc. “Our new US headquarters, our infrastructure and our highly motivated team of experts will enable us to further intensify our collaboration with our customers,” said Friedrich Kanz, adding: “We are perfectly positioned to enjoy another 25 successful years in the US.” Representing the US plastics industry, William (Bill) R. Carteaux, CEO and President of the SPI industry association, gave a keynote address in which he offered detailed insights into the contribution made by the SPI and the plastics processing industry to the US economy.

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NEW NYLON 6/6 COMPOUND PROVIDES OUTSTANDING LOWTEMPERATURE TOUGHNESS FOR A WIDE RANGE OF INJECTION MOLDED APPLICATIONS On 16 June 2015, Arburg Managing Partner Michael Hehl (middle) opened the new US headquarters in Rocky Hill jointly with Managing Director Helmut Heinson, subsidiary manager Friedrich Kanz, SPI President and CEO William R. Carteaux and Managing Director Heinz Gaub (from left).

At -40 °C, Chemlon® 109 HBK778 from Teknor Apex Provides 50% Greater Toughness than a Standard HighImpact Nylon 6/6 for Automotive and Other Industrial Parts

New 2,500 square metre US headquarters The new Arburg building covers a total floorspace of 2,500 square metres (27,000 square feet) and boasts state-of-theart infrastructure. The centrepiece of the new building is the showroom, which has sufficient space for seven Allrounder injection moulding machines that can be used for testing and training purposes, for example. There is also plenty of space for setting up and dismantling complete turnkey systems, which are experiencing rapid growth in demand in the US. The building also features a comprehensive spare parts store, a machine store as well as a special area for the Freeformer. This industrial additive manufacturing system has been available in the US since its launch at the NPE trade fair in March 2015.

The anniversary event offered customers plenty of opportunities to see for themselves the extensive facilities available for them at the new location in Rocky Hill. Over the two days, a total of 245 guests learned about the latest trends during presentations and live demonstrations involving the exhibits. There was a great deal of interest in industrial additive manufacturing with the Freeformer, automated production cells, as well as the presentation by Managing Director Technology & Engineering, Heinz Gaub on “Innovative Lightweight Construction Processes”.

Successful in the US for 25 years Arburg Inc. is one of the German machine manufacturer’s first subsidiaries and was established in 1990 as part of the effort to expand international sales activities.

To ensure regional support nationwide, Arburg has established two Technology Centers in Elgin, Illinois, and Irvine, California, for its customers in the Midwest and on the West Coast respectively, in addition to its location in Rocky Hill, Connecticut. A total of around 75 Arburg employees provide comprehensive support in the USA. Arburg is represented by its own organisations at 32 locations in 24 countries and by trading partners in more than 50 countries. From a total of some 2,400 employees, around 2,000 work in Germany.

About 400 further employees work in Arburg’s organisations around the world.

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eknor Apex Company has increased the low-temperature impact strength of a standard toughened nylon 6/6 compound, providing enhanced cold-weather performance for injection molded applications as diverse as fasteners, fuel can nozzles, cable ties, living hinges, and sports equipment.

New Chemlon® 109 HBK778 exhibits 50% greater notched Izod impact strength at -40 °C than the company’s standard Chemlon 109 product, a toughened nylon 6/6 compound. At -10 °C, it still provides nearly as much impact resistance as it exhibits at room temperature, whereas that of standard Chemlon 109 has fallen by 75% (see graph).

Among the key physical properties of Chemlon 109 HBK778 are notched Izod impact strength of 18 kJ/m2 at – 40 deg. C., and flexural strength of 52 MPa (see table).

Good flow properties make Chemlon 109 HBK778 suitable for intricate parts such as clips and fasteners, where the flexural strength of the material enables it to withstand the stresses of assembly and end use.

“Aside from its outstanding low-temperature toughness, Chemlon 109 HBK778 provides physical properties comparable to those of standard Chemlon 109, which has been used successfully in many applications and has received automotive specifications from Chrysler, Ford, and General Motors,” said Michael Roberts, vice president of the Nylon Division of Teknor Apex. “Teknor Apex is prepared to supply this new product worldwide.”

Bosch highlights complete systems capabilities for pharmaceutical applications Seamless System for product handling and packaging • Gentle product handling and accurate placement with feed placer • Horizontal flow wrapper with hermetic sealing ensures product protection • Flexibility to suit different layout and production requirements Hermetic sealing for a wide range of products

T

o meet pharmaceutical and medical manufacturers’ needs for increased productivity, Bosch Packaging Technology, a leading provider of processing and packaging solutions, highlights its complete line capabilities at Achema 2015. As part of its Seamless Systems portfolio, Bosch will exhibit the Sigpack LDF feed placer for flexible handling of products such as blow-fill-seal (BFS) cards, blister packs, ampoules, syringes, inhalers or medical devices.

At the show, the BFS robotic handling will be combined with the Sigpack HSL horizontal flow wrapper for hermetically sealed packaging at production speeds of up to 300 packages per minute.

Precise placement for continuous production flow The Sigpack LDF feed placer

displayed at the show will demonstrate the gentle handling and accurate placement of eye drop vial cards by picking and placing them into the infeed chain of the Sigpack HSL flow wrapper. Based on proven Delta robot technology, the Sigpack LDF features an advanced gripper design that can be adapted to suit different production requirements. Products arrive in an upright position and are then laid flat, get verified by a vision system and stacked in sets of twos, ready to be wrapped. The precise placement ensures the correct product orientation, closes gaps and enables continuous production for maximum uptime. With optimized gripper technology, the feed placer offers high flexibility for different product sizes and applications and can be implemented with single or multiple robots cells.

At Achema 2015, the BFS vial cards are hermetically packaged by a Sigpack HSL flow wrapper equipped with long dwell heat sealing technology. Different sealable compound materials qualify for usage. Products packaged in aluminium compound film offer optimum protection from water vapor and light exposure. The wrapper can be easily adjusted to accommodate a wide range of sizes, counts and product shapes.

Alternatively, the machine can be fitted with ultrasonic sealing technology. Also, a hybrid version using e.g. heat cross sealing and ultrasonic length sealing is available.

This suits specifically well to high packaging speed as well as sensitive pharmaceutical products.

Broad range of options to suit every requirement Bosch’s Seamless Systems for pharmaceutical packaging offer a wide range of features to ensure specific demands can be easily met. The Achema line features a vision system for enhanced quality control. The cameras monitor data such as inline-printed lot numbers, expiration dates, manufacturing dates, 2D code bar which ensures the correct product orientation into the flow wrapper infeed. The flow wrappers can also be expanded to accommodate modified atmosphere packaging (MAP). All components

in contact with the product, such as belts and grippers, can be cleaned quickly and easily. Moreover, all line configurations can be combined with additional inspection devices, handling equipment and secondary packaging solutions.

Layout flexibility and productivity with a single-source solution provider “Every manufacturer has different needs with regards to layout and production goals. This is why we customize solutions to offer the flexibility and capabilities needed to cater for even the most complex applications,” said Joerg Kleiner, product manager at Bosch Packaging Technology. “In addition, our Seamless Systems meet the need for a single-source solution supplier and streamlines processes, eliminates bottlenecks and optimizes line productivity. This ensures that our customers have the optimized technology that will help them achieve business goals.”

Thanks to a single HMI for the whole system, operators can easily and safely use the production line.

The uniform design and philosophy allow for additional components to be easily integrated, ensure optimum accessibility throughout the line and provide a good system overview for line clearances. The robust and flexible design allows for quick changeover and maximum uptime while providing consistently high product protection.

Plastics & Rubber Review | July-August 2015 | 25

Eliminating shortages of skilled staff Bachelor degree in mechanical engineering without A-levels via distance learning Although companies are in desperate need of suitably qualified skilled staff, they often overlook the fact that potential candidates are already available – often in their own ranks.

All they lack is appropriate training. As our example demonstrates, this training can be provided while employees continue in their jobs. of proven employees and are adept at motivating them to take the plunge: by making sure that the overall conditions make it feasible to combine career, studying and family.

The summer holidays are beginning soon all over Europe and young people are leaving their schools to start an apprenticeship or a university course in the autumn.

There are not enough of them apparently, however, because otherwise companies in Germany and elsewhere would not be in desperate need of suitably qualified skilled staff. It is, on the other hand, often overlooked that potential candidates for skilled jobs are already available – among companies’ own personnel. All they lack are the appropriate qualifications. They can be acquired while continuing to work, however – via distance learning courses, with or without A-levels.

Is it possible to combine student life with a family and job?

It is not easy to have both a family and a job and to study as well. What are needed to make this possible are a great deal of personal motivation and employers who provide incentives and succeed in encouraging employees to tackle the challenge of distance learning, who have an eye for the professional potential

When he applied to Studiengemeinschaft Darmstadt (SGD) to do the distance learning course “Geprüfter Industriemeister IHK, Fachrichtung Metall mit AEVO” in 2005, Simon Köhler’s aim was to obtain further training and to take the next step in his career. It was not to be his only distance learning course. Although he sometimes found the learning process tough – giving up was never an option for him. The 36-year-old from Esslingen, who describes himself as inquisitive and keen to learn, explains: “I complete whatever I start”. He found distance learning to be the best way for him to study. “I was technically minded even as a child and I already knew while still in school that I wanted to work in a technical field. The training courses I have completed alongside my job have therefore been a logical step in my career”, Köhler says. Three years after finishing his master craftsman course at SGD, he started a distance learning bachelor degree course in mechanical engineering (B.Eng) at Wilhelm Büchner Hochschule.

Shift work + distance learning =

26 | July-August 2015 | Plastics & Rubber Review

Bring jobs and training under one roof? Distance learning can be the solution. (Image: istockphoto)

promotion On leaving school after taking his GCSEs, Simon Köhler started an apprenticeship to become a construction mechanic in 1995.

When the temporary contracts with his first employer ended, he switched fields: he was offered a job as a machinist and accepted it. “Even then, I was already keen to acquire new skills and improve myself”, Köhler says. In October 2005, he then decided to complete training to become a master craftsman in metalworking – while continuing to work at the same time. He completed a distance learning course in this area at SGD. In June 2008, Simon Köhler finished the course within the standard time. His explanation: “By opting for the master craftsman qualification, I deliberately chose a course that is recognised

and in demand in the business community”. The crucial reason why Köhler selected a distance learning course while continuing to work at his job was the freedom he had to plan his learning times and to learn wherever he was: “At this time, I was working in shifts.

I would not have been able to attend normal lessons at evening school.” The training paid off, as Köhler remembers: “Six months before the course ended, I was already promoted to a position as application technician.”

From master craftsman to mechanical engineer Once you have developed a taste for something, you want more and more: Simon Köhler’s thirst for learning had not been quenched yet. In January 2011, the newly promoted application technician

Distance learning offers the possibility to take into account family aspects. (Image: istockphoto)

decided to join the academic world too and start a standard distance learning course – which was possible even though he did not have A-levels. He chose the bachelor of mechanical engineering degree course at Wilhelm Büchner Hochschule. Köhler completed his university course successfully three years later. In order to reach his goal of becoming an engineer, Köhler generally did his learning during the evening after work, at weekends or during the time he had available when he was away on business trips.

Strong practical relevance has always had high priority for Simon Köhler. He focussed on specific mechanical engineering issues not only during his course but also in his bachelor thesis. Simon Köhler explains: “In my graduation thesis, I investigated the conditions under which the smoothing cycle time on a 5-axis machining centre can be reduced with the help of circular segment milling tools. I decided to study this topic, because it involves a new technology in tool manufacturing and is directly connected to the work I do in my job”. As was the case with his master craftsman course, he was again promoted on graduation.

He now works as an application technician for 5-axis and milling/

turning machining centres at Gebrüder Heller Maschinenfabrik GmbH, one of the leading German manufacturers of machine tools that is based in Nürtingen.

Professional training is a sign of motivation and perseverance Blickt Simon Köhler auf seine bisherige Bildungskarriere per The conclusions Simon Köhler draws from the distance learning courses he has completed to date are as follows: “What have given me motivation again and again have been particularly difficult exams that I passed and other students with whom I have been able to swap ideas. It has also proved to be good at regular intervals to stop looking at the course papers and to focus on something else instead.” Simon Köhler is proof of the fact that professional training is worthwhile: “Today I am in a position to say that I have been able to benefit not just personally but also and above all professionally from the training courses.” Because: commitment to training is evidence to employers of motivation, dedication and perseverance. Characteristics that go down well and lead to promotion opportunities, more demanding assignments and greater responsibility. Simon Köhler has not reached the end of his

Commitment to training is evidence to employers of motivation, dedication and perseverance.

Characteristics that go down well and lead to promotion opportunities, more demanding assignments and greater responsibility. (Image: istockphoto)

training “career” by a long way yet. At the moment, he is considering whether or not to continue with a master degree course.

What can be said by way of conclusion is: Simon Köhler completed his training and his university course successfully – most certainly with the help of strong personal motivation. However, he has only managed to climb the career ladder by changing his employer. The question is whether this is the only alternative: employers invest huge amounts in the basic and advanced training of their staff; every qualified employee proves to be an investment with a large return for the company – if both parties cooperate bilaterally and with determination on improving the qualifications and careers of employees within the company.

Find your distance learning course too Practically all universities offer distance learning courses, including such subjects as plastics engineering. Distance learning courses enable those who are unable to attend conventional on-campus courses at a university for various reasons to complete an initial or further university course. For many people who have jobs, it is the opportunity for them to improve their professional skills and obtain a university degree while continuing to work.

The programmes are carried out mainly via written and audiovisual media – trained mentors are available to answer questions and to help the students. This means that distance learning students are largely independent of time and place constraints, even if on-campus events are included in some programmes at regular intervals.

Success through vocational and continuous training – blueprint for success. (Image: istockphoto)

Plastics & Rubber Review | July-August 2015 | 27

The Absolute Platform for Plastics Manufacturing!

S

miles have been exchanged all around at the closing of the 2015 edition of InterPlas Thailand at BITEC, Bangkok, Thailand on 12July 2015. 15,953 attendants have found the right technology they were looking for and formed new business alliances. Exhibitors were happy to meet target customers and distribute their products. The plastics manufacturing industries have been fired up to evolve with a strong force.

Increasingly confident from the networks they established and knowledge they have gained, industrialists here are more ready for the coming of larger business following AEC by the end of this year.

Technology providers found more sale leads and information from potential clients so they have confirmed to return in the 2016 edition to present even more powerful technologies and solutions!

Manufacturers, agents and industrial specialists have bonded and expand their networks here. This industrial circle keeps expanding year after year!

Thank You All Participants!

All of this is possible because of all of you and your kind supports, so we would like to take this opportunity to thank supporters, exhibitors, coorganizers of seminars and activities, visitors, seminar delegates, members 28 | July-August 2015 | Plastics & Rubber Review

of the press, and everyone involved in this show for your trusts and for your collaborations in advancing the industries together.

See you again on 7 – 10 July 2016 at BITEC, Bangkok, Thailand!

Stay tuned at www.interplasthailand.com for movements and updates on plastics and petrochemical manufacturing industry and the show.

Plastics & Rubber Review | July-August 2015 | 29

High Quality Rubber Components with Modern Vacuum Technology

Blood collection tubes

The main products of Datwyler Pharma Packaging Italy Srl. are small rubber components for medical equipment. The output of the company’s production facility in Montegaldella (VI) is primarily rubber parts for syringe plungers and sealing caps for sterile products. Datwyler’s thermoforming machines rely on screw vacuum technology

by Busch. A vacuum system with four COBRA screw vacuum pumps ensures high product quality, as air and gas bubbles are removed from the rubber during the moulding process.

30 | July-August 2015 | Plastics & Rubber Review

D

atwyler Pharma Packaging Italy Srl. is part of the international Datwyler Sealing Solution Group, which is owned by the Datwyler corporation.

Datwyler Pharma Packaging Italy Srl. operates two production sites in Italy. At the Montegaldella (VI) facility, components such as stoppers for blood collection tubes and parts for single-use syringes are manufactured. The site employs 140 staff and operates around the clock in a 3-shift system. The manufacturing process includes all stages of production, from mixing of raw materials to preparing the finished sterile rubber components for shipment.

Datwyler’s customers are medical technology companies throughout

the world.

The first production stage is the mixing of rubber with additives and chemicals to form strips of base material, which are then coiled. The composition of this base material is dependent on its later application, and is prepared to customer specifications. Two production lines of twelve thermoforming machines each cut the base material strips to size automatically.

The trimmed sections are then pressed into a mould under vacuum, after which the individual components are stamped, vulcanised, tested, washed and packed.

The moulding process takes

Screw vacuum pump COBRA NC

place under high mechanical pressure, at temperatures between 175°C and 180°C, and in a vacuum of 1 mbar (-999 mbar). This vacuum level is necessary to exclude air bubbles from the finished component, and to remove vapour generated by the high temperature and pressure of the process. The moulding machines were originally equipped with oil-lubricated rotary vane vacuum pumps, which soon developed a serious problem: the vacuum pump oil reacted with the process vapour, causing emulsions and greasy deposits to accumulate in the vacuum pumps. These deposits reduced the vacuum output, so the required level and pumping speed could no longer be achieved. Costly measures to keep these vacuum pumps running were attempted, including changing the oil every two weeks.

In 2009 Datwyler signed a maintenance agreement with Busch, in which Busch agreed to carry out third-party servicing of the vacuum equipment.

After Busch vacuum specialists had studied the problem in depth, they presented their recommendations to Alessandro Piccoli, the maintenance manager of the Montegaldella (VI) site. Their solution: replace the oil-lubricated rotary vane vacuum pumps with Busch dry screw technology. Consequently, a COBRA screw

Centralised vacuum generation outside of the production rooms

Rubber plugs

vacuum pump was subjected to extensive testing. These vacuum pumps operate without compression chamber fluids, which means there is no contact between the extracted vapour and any other medium in the vacuum pump. In addition, COBRA vacuum pumps run at a working temperature which allows vapour to pass through the pump without condensing. The COBRA test system proved to be highly satisfactory, so Alessandro Piccoli ordered two COBRA vacuum pumps to supply a line of six moulding machines. Both vacuum pumps incorporated Panda Roots vacuum pumps as boosters. This arrangement permitted the vacuum system to be installed away from the production buildings, with vacuum for the thermoforming machines supplied by a pipework system. An upstream vacuum reservoir ensures that the required vacuum level and pumping speed are constantly available. In 2012 two additional vacuum units were ordered and installed – also with COBRA fore pumps and Panda Roots booster pumps – to supply a complete line of twelve thermoforming machines. All the vacuum units are equipped with a fully automatic control system, which monitors the vacuum level and activates the minimum number of vacuum pumps required to meet the

current demand from the twelve thermoforming machines. This means that all the vacuum pumps run only when the entire line is operating at maximum capacity. In everyday use, only three COBRA/ Panda combinations are required.

For Alessandro Piccoli, whose goal is maximum energy efficiency, this is another important argument in favour of COBRA dry screw technology and the centralisation of the vacuum supply. Plans to extend the vacuum system to supply all 24 moulding machines have been made, and will be implemented shortly.

For Alessandro Piccoli, the Busch solution has brought the following advantages: • No reaction between extracted vapour and operating fluids, due to dry screw vacuum technology • No accumulation of condensates in the vacuum pumps, due to the even temperature distribution throughout COBRA units • Considerable energy savings, due to vacuum supply centralisation and automatic demand-driven control • An extremely reliable vacuum supply • Significantly reduced maintenance effort and consequently lower costs for servicing, replacement parts and production downtime • Easy access to the vacuum system even if thermoforming machines are operating, maintenance possible during production • No noise emissions in the production building or at workstations, due to external location of centralised vacuum system For more details, please contact: www.buschvacuum. com

Plastics & Rubber Review | July-August 2015 | 31

Talk to Cannon @ Fakuma 2015!

Numerous Carbon-reinforced automotive parts are produced in Germany using dedicated Cannon fibre preformers (left) and polymerisation presses (right).

The 24th edition of Fakuma – the

International trade fair for plastics

processing taking place in Friedrichshafen, Germany – will be held from 13 to 17

October, 2015. The twelve halls of the

Friedrichshafen Exhibition Centre on Lake Constance are fully booked out since the

end of February, with 1700 exhibitors from more than 30 countries. Cannon will be

present as usual at this important event – Fakuma holds the second place in the

overall ranking of international trade fairs

for plastics – with a stand in Hall 1 managed

by Cannon Deutschland.

32 | July-August 2015 | Plastics & Rubber Review

The Cannon Group – present in Germany since 1983 with Cannon Deutschland GmbH (www.cannondeutschland.de ) a technicalcommercial subsidiary based in Hanau – will present the latest developments in the processing technologies for Polyurethanes and Composites: • High-Pressure Mixing Heads: advanced solutions for general purpose foams up to specialised applications such as filled and reinforced formulations, multi-component and multihardness foaming, high-output, cavity filling, Clear Coating.

• The Vacuum-based foaming technology, Cannon V.A.I. (Vacuum Assisted Injection), a major achievement in the field

of domestic refrigerators and sandwich panels.

A new kit for the conversion of existing polymerisation presses for discontinuous foaming of sandwich panels will be presented.

• The range of Cannon solutions per Polyurethane and Epoxy Resin formulations dedicated to the Automotive and transportation industries, in particular for flexible seats, car interior parts and Carbon fibre reinforced components.

• The complete moulding solution for Epoxy-based fast HP-RTM process designed for the production of Carbon- and Glass-reinforced composites for automotive, leisure and sport parts.

CRESIM - the Cannon R&D project aiming at the industrialisation of the use of recycled Carbon fibres –has been used to manufacture this skateboard (left) using ESTRIM LLD Liquid Lay Down technology (right). With ESTRIM LLD – Liquid Lay Down resin application – the Epoxy resin is deposited over the Carbon reinforcement: this method significantly reduces the pressure required to keep the mould closed during the polymerisation phase, with significant containment of the relevant tonnage and investment.

All the above mentioned machines and turnkey solutions are today available for parts manufacturers based across the five continents: Cannon extended network of direct offices and agencies guarantees prompt local service, availability of spare parts, technical and marketing assistance.

On top of dedicated preformers, polymerisation clamps and moulds, Cannon offers the E-System, high-pressure metering and mixing equipment that guarantees very fast demoulding times and perfect distribution of the resin across the entire mould surface.

• The innovative EU-funded project named CRESIM (Carbon Recycling by Epoxy Special Impregnation), finally aimed at the development of proper processing methods for the manufacture of CFRP parts using recycled Carbon fibres.

This Life+ EU-sponsored project addresses fully the waste reuse issue by demonstrating a new innovative manufacturing process which will potentially reuse up to 100% of the Carbon fibre waste

and scraps from different industrial sectors, transforming a costing environmental problem of today in an opportunity of greening the production processes and getting economic benefit for tomorrow.

• The equipment for the wind-power industry, that is rewarding Cannon with growing volumes of business worldwide, thanks to the availability of dedicated low-pressure resin dispensers for the infusion of Epoxy formulations in the largest blades, manufactured for off-shore and conventional wind turbines.

A number of new developments (including innovative de-gassing systems, a dedicated gluing machine, a third-component metering device) will be illustrated.

• A complete range of industrial Thermoforming machines

The new Cannon JL 32 mixing head, designed for high-output applications with rigid foams, provides laminar flow and superior mixing performances with all modern blowing agents.

The new Cannon FPL SR mixing head, specifically designed for the injection of rigid foam in the cabinet of domestic refrigerator and freezers, features superior mixing efficiency and laminar flow of the blended chemical components in the mould. It is available now in three sizes: 18, 24 and 26 mm.

designed to fulfil the productivity and flexibility demands of the producers of formed parts for automotive interiors and fuel tanks, for refrigerator cabinet and door liners, for large parts for the aerospace and the wind power industry, for technical and leisure parts.

All the above mentioned machines and turn-key solutions are today available for parts manufacturers based across the five continents: Cannon extended network of direct offices and agencies guarantees prompt local service, availability of spare parts, technical and marketing assistance.

An innovative, patented fullyadjustable frame named TRIPLO will be presented, a system designed for minimum set up time and elimination of reduction plates.

A qualified team of specialists in Polyurethane and Composites technologies will welcome all the interested visitors at the Cannon stand 1434 in Hall 1.

Plastics & Rubber Review | July-August 2015 | 33

Foam injection molding 2.0 Lightweight design is a trend increasingly pervading all sectors of the manufacturing industry. In this domain, plastics play a vital part thanks to their favorable relation between performance data and low specific weight. But their lightweight potential can be increased even further by foaming, for example by foam injection molding. One of the pioneers in this field is the Austrian injection molding machine manufacturer WITTMANN BATTENFELD. Its CELLMOULD® high-pressure process offers comparatively superior performance parameters together with a less complex and consequently more robust system technology by comparison with competitors. It is a 100% in-house development and serves as the basis for a number of new, innovative applications, such as solutions for improvement of the surface quality including high gloss, for partial combination of compact with foamed components in a single molded part and for foaming of thermoplastic elastomers. These solutions have been developed in cooperation with the Bavarian technology company Schaumform (Fig. 1).

CELLMOULD®: the machine concept

Fig.1: Structured foam parts with high-gloss surfaces are the result of a joint development project of the companies WITTMANN BATTENFELD / Kottingbrunn, Austria and Schaumform / Hutthurm, Germany

Foam injection molding technology is not a new process. Applications in which chemical substances such as azodicarbonamide or phenyltetrazole are blended into the plastic granulate and plasticized with it, which release propellant gases following injection into the cavity of the mold, have been known and used in production for some 50 years. Since the expansion pressure of these chemically released gases is no more than about 15 to 40 bar, their use is limited to relatively thick-walled parts with short flow paths.

To further extend the application boundaries for foam injection molding, foaming by the addition of an inert gas, usually nitrogen, was developed about 40 years ago. The main advantage is that higher expansion pressures in the region of 100 to 200 bar can be reached with nitrogen. This enables exploitation of the lightweight design potential in foam injection molding for thin-walled components and components with long flow paths as well. The advantages in addition to weight reduction are a reduction of the specific injection pressure required to fill the cavities and consequently the clamping force, and compensation of shrinkage and warpage effects. Both processes are used in thermoplastic resin processing, all the way from PP to engineering plastics such as PC, PA or PBT. Most recent, promising developments aim to extend the fields of application to include thermoplastic elastomers as well.

34 | July-August 2015 | Plastics & Rubber Review

The essential task of a foam injection molding line is to generate a onephase polymer-gas solution dispersed as homogeneously as possible during the plasticizing process. The technology used by all suppliers for this purpose is very similar. Nevertheless there are some differences in the details of technical design. Dipl.-Ing.(FH) Wolfgang Roth, Head of Application Technology at WITTMANN BATTENFELD, puts it this way: “The more than 40 years of practical experience with the technology developed at our predecessor company BATTENFELD/Meinerzhagen provided a solid foundation for us to build on. Our goal was to reduce the complexity of the system while simultaneously expanding the fields of application and thus make it more reliable. Therefore we have designed our CELLMOULD® foam injection unit to come as close as possible to the standard injection unit. Accordingly, our machine operates with a 20 D standard screw, which has been extended at the front by adding a 5 D mixing section.”

The specific BATTENFELD feature of the CELLMOULD® technology is the separation between the plasticizing and gas injection sections of the screw, which is provided by a fixed, cylindrical barrier on the screw. It is the alternative to using an additional sleeve-type check valve. Wolfgang Roth adds: “The effort involved in adjusting two check valves to the operating conditions in every case to make them fail-safe, i.e. wearresistant, motivated us to seek a simpler solution, which we have ultimately

Fig.2: The CELLMOULD® plasticizing unit: its core components are a 25 D barrel with a 20 D 3-zone plasticizing screw and subsequent 5D gas injection and mixing zone. The two functional zones of the screw are separated by a cylindrical retention ring (barrier).

found in the barrier between the plasticizing and gas injection sections of the screw. This solution has been proven in production for all machine sizes. In this way, the wear problem could be eliminated without having to compromise to a significant extent on gas density in the direction of the screw’s plasticizing section.”

In the mixing section of the plasticizing unit, liquefied nitrogen (pressurized with up to 300 bar) is added into the plastic melt by an injector in during a metering stroke and subsequently diffuses into the melt. In the mixing section of the screw, the nitrogen distribution is intensified by dividing the melt flow into many separate currents.” (Fig.2) Since the barrel is kept closed by a needle shut-off valve in the direction of the mold during plasticizing and gas injection, the melt-and-gas mixture is kept under pressure inside the plasticizing unit. Consequently, a single-phase polymer/ gas solution is achieved by the end of the mixing process. During injection into the cavity, it is subjected to pressure decrease, which reduces the solubility of the gas in the plastic melt. The finely distributed gas nucleates in the melt and thus provides the ingredient to form a foam structure with just as finely distributed cells.

Fig.5: High user-friendliness and process transparency were top priorities in process development. Accordingly, all process parameters can be set, monitored and recorded via the machine’s control system.

one gas supply system (Fig.4). A gas flow regulator is placed between the pressure generator and the gas injector on the plasticizing unit. Via its controllable valve system, the gas flow is controlled and coordinated with the process by the CELLMOULD® software (Fig.5). The CELLMOULD® equipment package is available for the entire portfolio of WITTMANN BATTENFELD machines.

Fig.3a: The CELLMOULD® line components are available in identical configuration for the entire range of WITTMANN BATTENFELD machines, illustrated here by the example of a 110 t machine model. A gas injector connected with a compact gas flow control module is placed on top of the barrel.

Fig.3b: In addition to the gas injector and gas flow control module, the CELLMOULD® equipment package also includes an injection accumulator on the machine (center of the photo) and a central nitrogen generator combined with a compressor unit.

The formation of this structure depends on the specific conditions of the injection molding process. These include the viscosity of the plastic melt, the injection speed (the higher the speed, the finer the foam) and finally the pre-set degree of foaming (material reduction). The latter is set either by injecting a corresponding underdosage into a fixed cavity, or by filling a cavity completely and subsequently opening it with a pre-set high-precision stroke. In order to reach the high injection speed which favors an even foam distribution, an injection accumulator is supplied as a part of the CELLMOULD® equipment package (Fig. 3a+3b).

Fig.4: The CELLMOULD® line configuration.

The concept is designed to have one or several plasticizing units supplied with gas by one central nitrogen generator including compressor unit. One gas flow controller controlled by the CELLMOULD® software and one gas injector are connected to each plasticizing unit to meter the liquid nitrogen into the barrel.

The nitrogen is either drawn from a battery of pressure cylinders or extracted from the ambient air by a nitrogen generator. In both cases, the gas is subsequently passed on to the gas injector via a pressure generator such as is also used in AIRMOULD® gas injection lines.

A part of the BATTENFELD line concept is that several machines can be supplied simultaneously by

Fig. 6a+b: Lightweight plastic parts with a compact outer shell and structured foam core, here shown by the example of a housing component made of PP with 3 mm wall thickness.

What potentials does high-pressure foam injection molding have to offer?

Inside the mold cavity, the formation of foam in the outer shell of the melt is largely suppressed due to its contact with the cooled cavity wall and the resulting increase in viscosity, while the hotter core area favors the formation of the cell structure. In this way, “sandwich structures” are formed in major parts of the molded part, consisting of covering layers with a high density and core parts, whose bulk density is 5 to 20% lower Plastics & Rubber Review | July-August 2015 | 35

(Fig. 6a+b).

The possible density reduction in the molded part shows a direct correlation with the flow path/wall thickness ratio for all commonly available types of plastic materials. In PP processing, for example, a density reduction of 15 per cent can be achieved at a ratio of 100 : 1, while at 150 : 1 a density reduction of only 10 per cent can be expected.

Quite apart from weight reduction, foam injection molding offers additional potential for improvement in the quality of molded parts, primarily with regard to shrinkage and warpage, thanks to the uniform effect of the expansion pressure inside the foam core. This effect is so strong that sink marks and warpage caused by shrinkage can be virtually eliminated to 100 per cent, thus increasing the overall dimensional accuracy. Processors will also benefit from several significant process technology advantages, such as a reduction in the required clamping force by up to 50 per cent due to a decrease in melt viscosity and consequently the injection pressure, as well as commercial advantages by a reduction in cycle time, in particular cooling time, thanks to the lower mass of the molded part which needs to be cooled.

High-gloss surfaces through dynamic mold tempering In spite of exploiting the full range of parameter variations offered by the foam injection molding process, light-weight parts still show characteristic striations or grey fogging on the surface as a common attribute. This surface effect is due to gas bubbles penetrating into the flow front of the melt during the injection process. This structure then solidifies when coming into contact with the cooler cavity wall and subsequently remains unchanged. Polished surfaces, such as are required for visual parts of housing components, cannot be achieved with standard technology.

However, a substantial improvement in surface quality can be achieved by a combination of foam injection molding with cyclical, dynamic mold tempering, as is offered, for example, by WITTMANN BATTENFELD in the form of BFMOLD® and VARIOMOULD® technology. These variants use a cooling system integrated in the mold to improve the visible surface of the molded part, following the part’s contour and operating cyclically with hot/cold temperature controllers. This system controls the temperature of limited mold areas close to the cavity. By heating the cavity wall, for example with pressurized water heated up to 180°C immediately before injection of the melt with gas content, the material does not come into contact with a cold cavity wall at first, so that a closed surface can form before it solidifies Fig.7: Mold with dynamic variothermic cool(Fig. 7). In this way, excellent ing system to produce a housing panel from a PC/ABS blend with a high-gloss surface. surface quality can be achieved, which is on a par with that of compact plastic parts. The comparison between parts with and without dynamic cooling, as illustrated in Fig. 8, shows how strongly the effect of dynamic mold tempering can influence the quality of the surface.”

Elastomers are also suitable for foaming Foam injection molding can also be extended to thermoplastic elastomers.

While good foam structures can be achieved by chemical as well as physical foaming, for example, with polypropylene and polyamide, our test series have revealed that most types of TPE can only be foamed by 36 | July-August 2015 | Plastics & Rubber Review

Fig.8: Decorative panel made of a PC/ABS blend, on the left manufactured with active dynamic cooling, on the right without activating dynamic mold tempering.

physical foam injection molding. And only TPEs based on thermoplastic polyester show acceptable results in terms of foam structure, fineness of cells and evenness. Tests have shown that the softer a TPE formulation, the more strongly surface problems will show up in foaming, especially if foam injection molding is combined with high-precision mold opening.

Especially when the cavity is draw polished or even high-gloss polished, the surface often shows numerous dents. Several different explanations have been proposed for this phenomenon. One is that air is already enclosed between the molded part and the cavity wall while the cavity is being filled, which cannot escape. An alternative assumption is that highprecision opening leads to a separation of the foam part from the cavity wall, and that the expanding foam part, when it comes into contact with the cavity wall again, encloses air or plastic gas in some places, which then causes the dents.”

Test series have shown that, in contrast to rigid and solid technical thermoplastic materials, the surface problems in TPE processing can be significantly reduced by using medium to low injection speeds. Equally positive effects can be obtained by structuring the cavity wall. A textured, bead blasted or grained surface allows any potential gas or air bubbles to escape via micro channels in the contact surface between the molded part and the cavity wall.

As to striations on the surface, the same principles generally apply as in foam injection molding with engineering plastics. Here, the solution is also to use dynamic tempering around the contours of the visible side. If high-precision opening is applied simultaneously, high-quality soft foam padding, for example for arm rests in vehicle construction, or shock absorbers for hand-held appliances which must be protected from damage dropped, can be produced at low cost. This will be further discussed in a separate report in one of the next issues.

With innovative mold and machine technology for broad application It has already been mentioned in connection with surface improvement that innovative mold technology plays a vital part in foam injection molding. Another area of mold and machine technology specially geared to foam injection molding is the system of partial mold opening via the injection molding machine, which enables the combination of compact with foamed components in a single injection-molded part.

This is necessary whenever functional elements made of rather compact material, such as hooks, springs or bolts, must be combined with panel components made of foamed material. To realize this, the part of the cavity to be foamed around the foaming stroke is made movable. In a first step, the entire cavity for the molded part is filled as is done for a

compact molded part. Subsequently, only the part to be foamed is opened by a high-precision stroke. In this way, housing components with complex mechanical interfaces to partner components can also be realized in light-weight design.

Mechanical key values can be predicted reliably High-pressure foamed injection molded parts have a characteristic sandwich structure with compact covering layers and a foamed core layer. The borderline between the covering layer and the core is relatively abrupt. In low-thickness components, the core layer has a virtually constant density throughout the entire width of the core, while in the case of large total thickness a characteristic density profile is present. The process implementation has just as little influence on the density of the compact covering layer as the type of gas injection chosen. Consequently, the most important design parameters are the reduction of density designed for the core part and the wall thickness. These can be clearly defined by measurement results and serve as key figures for a calculation model developed by Dr. Norbert M端ller, the founder of Schaumform, as part of his dissertation to predict the mechanical attributes of components.

Process design based on a model calculation The starting point for the model calculation is a symmetrical sandwich structure, in which, in slightly simplified terms, the specific material values of the compact material are assumed for the covering layers. For the foamed core, key values close to reality are assumed for the E module and fracture strain (yield strain for ductile materials). The behavior of the foamed core is derived from the behavior of the entire sandwich component, which functions well if the thickness of the covering layers is known. Tests in which the foamed core is extracted from a component and subsequently tested mechanically are possible, but lead to strongly scattered measurement results, which consequently have only a very limited significance.

Theory and practice are consistent The optimal method to test rigidity and strength is by using standard test rods produced from injection-molded structured foam sheets.

Alternatively, if this option is not available, standard test rods with a 4 x 10 mm cross-section (e.g. campus tension rods) can be used. However, when analyzing the measurement values, it must be taken into account that not only the 10 mm-wide covering layers of the standard rods are compact, but also the 4 mm-deep lateral surfaces. Consequently, a foamed standard tension rod is comparable to a small rectangular tube (10 x 4 mm) with approx. 0.4 to 1.0 mm wall thickness and a foamed core.

Fig.9: Change in tensile strength, impact resistance and fracture strain of PP-SGS 40 depending on percentage of foaming (0, 5, 10, 15 per cent)

As can be expected, the evaluation of tensile strain tests shows that as the proportion of foam increases, the tensile elastic modulus and tensile strength decrease accordingly. This is due to the fact that only the quantity of material still contained in the component can withstand mechanical stress or contribute to load bearing. So foamed injection-molded products show a higher expansion rate

when exposed to the same load and break under a lower maximum load.

Added to this are notching effects caused by foam cells close to the covering layer. The measurement results regularly show that the decline in tensile strength invariably at least equals the reduction in part weight.

(Fig.9)

Fig.10: The change in flexural resistance, the most important attribute for housing components. The flexural resistance in relation to weight of the test samples decreases only slightly with 5% foaming, while it remains equal to the compact part with 10% foaming, and shows even a noticeable increase with a 15% reduction in density.

Fig.11: A comparison between the weightrelated flexural resistance according to the model calculation (Schaumform) and the results of measurements on injection-molded bending rods with 10 x 7 mm cross-section shows good to excellent congruence.

Under bending load, the absolute values of flexural resistance and flexural strength are also reduced. However, since sandwich structures are much more resistant to this type of load, the loss of strength here is significantly less than for tensile strain. The flexural resistance falls by a lower percentage than the part weight. In figures 10 and 11 it is documented that, for instance, with a foaming degree of 15% the rigidity in relation to weight has increased by 4.8 per cent compared to the compact part without foam or, in other words, it is possible to realize rigid components with a lower weight.

Summary Foam injection molding technology has received a new innovative boost due to the progressively increasing trend towards lightweight applications.

The most recent innovations concern methods to improve the surface quality in the direction of high gloss, as well as the combination of compact with foamed segments in a single molded part. The most important contributions have been made by further developments in process and mold technology, ranging from dynamic mold tempering to high-precision opening of entire molds or cavity segments in one or several steps. The proven model calculations, which are now generally available, offer additional potential for assistance in parts design and layout. All in all, the foam injection molding process has thus reached a similarly high degree of maturity as conventional processing by injection molding. It delivers precise, repeatable density reductions and sandwich structures for a constantly growing range of plastic materials, including thermoplastic elastomers.

About WITTMANN BATTENFELD WITTMANN BATTENFELD, a member company of the WITTMANN group, is a leading manufacturer of injection molding machines for the plastics industry, with its headquarters and production plant in Kottingbrunn / Lower Austria and its own network of sales and service companies and agencies in 60 countries worldwide. Its production program comprises the complete range of injection molding machinery from micro injection molding machines to large machines with 1,600 tons clamping force, including vertical machine models and machines for multi-component injection molding.

Extensive application technology equipment packages round off the product portfolio, which is supplemented by the range of robots and peripheral equipment from WITTMANN. More information on www.wittmann-group.com

Plastics & Rubber Review | July-August 2015 | 37

Honorary doctorate for Herbert Kraibühler • • •

Former Arburg Managing Director Technology & Engineering recognised by Technical University of Munich Outstanding achievements in research and development honoured Ceremony attended by the Arburg Partners Ceremony The Dean of the Faculty of Mechanical Engineering, Prof. Tim Lüth, described the cooperation as “an exemplary partnership between an innovative, family-run company and an elite technical university”. Herbert Kraibühler’s outstanding technical and scientific achievements have now been rewarded with the honorary doctorate. Also present at the conferment ceremony with Herbert Kraibühler were his wife Ellen and son Mathias, Arburg Partners Eugen Hehl, Juliane Hehl, Michael Hehl and Renate Keinath as well as the Director Research & Development Dr. Eberhard Duffner and his wife Eva.

Half a century at Arburg

Dr.-Ing. E.h. Herbert Kraibühler (centre) with Prof. Tim Lüth (left), Dean of the Faculty of Mechanical Engineering and Prof. Wolfgang A. Herrmann, President of the TUM.

On 10 July 2015, the former Arburg Managing Director Technology & Engineering, Herbert Kraibühler, was awarded an honorary doctorate by Technical University of Munich (TUM) for his outstanding achievements and ideas in research and development for plastics processing in the areas of injection moulding and additive manufacturing.

These developments are frequently used today in industrial production.

In awarding Herbert Kraibühler the right to use the title “Dr.-Ing. E.h.”, TUM cited the further development of injection moulding technology as one of his achievements.

He promoted the integration and automation of injection moulding technology and optimised production. In doing so, he pre-empted a development which today goes by the name of Industry 4.0. Herbert Kraibühler also realised early on the central role that interaction between human and machine would play in modern production. This resulted in the development of an innovative machine controller, the Selogica, which to this day enables full control over increasingly complex injection moulding processes.

Herbert Kraibühler was also a visionary in the field of additive manufacturing. He spent many years working on joint research projects with the TUM, investigating fundamental questions in this area. The topics covered included polymers, dosage methods and optimum filling strategies. The result was an innovative system for industrial additive manufacturing which had much more to offer than simple 3D printers.

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In total, Herbert Kraibühler spent 50 years at Arburg. He started his apprenticeship as a machine fitter at the company in 1964. He then studied precision engineering specialising in plastics technology in Karlsruhe, before returning to the company as a development engineer in 1972. His career ultimately led him to the position of Managing Director Technology & Engineering, which he held for 18 years.

About Arburg German machine manufacturer Arburg is one of the world’s leading manufacturers of injection moulding machines with clamping forces between 125 and 5,000 kN. This is complemented by robotic systems, customer- and sector-specific turnkey solutions and further peripherals. An innovative additive manufacturing system was added to the plastic processing range in 2013.

The company places the topic of production efficiency at the centre of all its activities, taking into account the entire value-added chain.

The objective is to enable the Arburg customers to manufacture their plastic products, whether one-off parts or high-volume production, in optimal quality and at minimum unit costs – e.g. for the automotive and packaging industries, communication and entertainment electronics, medical technology, or the white goods sector.

An international sales and service network guarantees first-class, local customer support. Arburg is represented by its own organisations at 32 locations in 24 countries and by trading partners in more than 50 countries. The machines are produced exclusively at the parent factory in Lossburg, Germany. From a total of around 2,400 employees, around 2,000 work in Germany. About 400 further employees work in Arburg’s organisations around the world. In 2012, Arburg became one of the first companies to gain triple certification: to ISO 9001 (Quality), ISO 14001 (Environment) and ISO 50001 (Energy).

Further information about Arburg can be found at www.arburg.com.

High-raking delegation from Canada finds out all about “Industry 4.0” • • •

Canadian delegation and Siemens visit German machine manufacturer in Lossburg Arburg presents activities relating to Industry 4.0 Guests impressed by networked process chain and high level of vertical integration

Arburg Senior Partner Eugen Hehl (5th from left) and Managing Director Sales, Helmut Heinson (4th from left) welcomed a Canadian delegation in Lossburg on 22 June 2015, who learned about the topic of Industry 4.0 on-site.

On 22 June 2015, a Canadian delegation together with Siemens visited the headquarters of family-owned company Arburg in Lossburg. Senior Partner Eugen Hehl and Managing Director Sales Helmut Heinson welcomed the high-ranking guests. Control technology expert Michael Vieth and André Amon, Deputy Manager Machining, then demonstrated how the German machine manufacturer implements the topic of “Industry 4.0” in theory and practice.

Arburg regularly receives guests and customers from around the world at its headquarters in Lossburg (Northern Black Forest). The fact that a Canadian business delegation visited jointly with Siemens to find out on-site how the German machine manufacturer approaches the topic of Industry 4.0, however, was still something really special.

Industry 4.0 as main focus of interest The Canadian delegation included, for example, Philip Jennings, Assistant Deputy Minister, Industry Sector, Industry Canada, Jayson Myers, President and CEO of Canadian Manufacturers & Exporters, as well as Consul Steven

Goodinson. The representatives from the worlds of business and science had responded to an invitation from Siemens to visit innovative German companies closely involved in the Industry 4.0 initiative.

The Canadians learned about how Arburg covered the topic with a fully networked process chain at the world’s leading industrial trade fair in Hanover and how large-volume parts were individualised with Industry 4.0 technologies and a combination of Allrounder injection moulding machines and the Freeformer for industrial additive manufacturing.

Highly automated production at Arburg The Canadians were particularly impressed at how the machine manufacturer has also for many years implemented technologies at its own production facilities, which today fall within the scope of Industry 4.0.

Examples here range from a suspended monorail conveying system which finds its own way around the approx. 148,000 square-metre production halls, covering some 250 kilometres a day, automatic machining centres and high-bay warehouses which operate unmanned overnight, through to Arburg’s proprietary host computer system, ALS. At around 60 percent, the level of vertical integration is extremely high. In this context, the guests were highly impressed by the fact that Arburg develops and builds its own machine control system and operates an in-house circuit board production line.

Plastics & Rubber Review | July-August 2015 | 39

FEEC High Speed Paper Coating and Laminating Aseptic Packaging Line Model LSMH1450 Total system remote fault diagnosis and maintenance process With IT and automatic shared network, the engineer may access the machine control system at any time, and check the parameters of all network devices (not only PLC and touch screen, but also frequency converters and remote IO stations, thus achieving online modification of procedures and parameters).

Shantou Far East Equipment Co., Ltd., owned by Jinming, is a well-known and the first supplier to manufacture plastic extrusion, coating and laminating equipment in China. As early as 2003, FEEC cooperated with world-famous paper companies to manufacture the leading high-speed dual-host paper coating machines for the production of paper packaging materials. After that, it manufactured several sets of high speed paper coating units for Hangzhou Nanda Group, Shanghai Jinye Packing Material Co. Ltd., Dongying Xinhua Printing House, etc.

Over the last two years, FEEC has developed new environment-friendly polylactic coating machines for Hangzhou Nanda Group and Hefei Hengxin Printing Co., Ltd. with the development of the market, high speed, high precision, environment-friendly paper coating machines will receive more and more attention from customers.

To meet the efficiency and quality requirements on coating machines by the market and customers, FEEC, by virtue of internationally advanced technology and the research and development strength of Jinming Group, has produced a 300m/min high speed paper coating and laminating aseptic packaging line, which has the main features as follows:

Fully functional powerful control system The system adopts a common DC bus. All frequency converters (PowerFlex 750 series) are connected to the DC bus, thus realizing energy recovery, energy saving and environmental protection, and improving system stability.

High efficient intelligent temperature control system The signals are collected in a distributed mode, but controlled and set in a centralized mode to streamline the system, reduce failure points and signal interference, and improve performance. Furthermore, advanced algorithms are adopted to enable excellent temperature control and easy operation, while providing current measurements, heating circuit abnormality alarm, and other functions.

Automatic tension control system The drive system adopts the centralized PID tension control technology, which allows the tension shaft to use the feed-forward of the upper system to achieve coordinated production line control, thus finally achieving real-time synchronization, faster speed, higher precision, and easier adjustment.

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Device Level Ring (DLR) technology to address communication jamming issues The 100M high speed ring network communication can perfectly solve the communication jamming problem. Any network outage will not affect the system operation. Furthermore, it has extensive diagnostic capabilities, which can display the failure points in the ring network, and timely conduct troubleshooting.

Intelligent information system The smart alarm and prompt system can keep track of equipment operation all the time, and help the operator make a timely and effective response. It is unnecessary to install software when replacing hardware.

The system automatically records the parameters, and can be extended to the intelligent corporate manufacturing platform. The line introduces 2 sets of automatic die heads from the United States, and uses the NDC automatic thickness measurement technology from the United States to automatically feed back the thickness data online, thus achieving real-time adjustment of die lip clearance of die head as well as transmission of extrusion laminating line, and achieving higher precision of the product composite film.

Highly efficient online thickness measurement system The system displays the thickness of coated film and the deviation of uniformity on the Human Machine Interface (HMI) in real time by graphics and data through continuous scanning of the probe, controls the power of the heating bolt of the die lip of the automatic die head to change the opening degree of the corresponding die head through automatic horizontal thickness control system (APC), thus controlling the deviation of horizontal uniformity of film thickness and hence greatly improving the quality and stability of the products, and displays online monitoring directly on the HMI in real time by graphics and data, which also can facilitate saving and printout. In this way, the system greatly improves the quality and stability of the products and the consistency of the thickness, and also intuitively and effectively controls the costs of the customers’ materials.

With the successful launch of the 300m/min high speed paper coating and laminating aseptic packaging line, Model LSMH1450, it is believed that FEEC’s share in the Chinese extrusion lamination market will increase more rapidly.

Jinming Gets “Fast and Furious” with a New Delivery Mode for Blow Film Line - Delivery within One Week after Order Confirmation Valuex models (referred to as “V” series), which results in both dramatic reduction of production cost and great optimization of production process, thus ensuring shorter delivery cycle and lower equipment investment.

Advantages of the Valuex series are as follows:

Equipment delivery within 1 week The core components of Jinming V series are modular equipment. Based on the current market enthusiasm for the product, Jinming makes efforts for better optimization of the production to ensure the products are manufactured and delivered within 1 week after the order contracts are confirmed by customers. Jinming also helps customers organize production within 1 month to increase their return speed and efficiency on investment.

Higher cost performance As Jinming’s classic models, the models in V series have an obviously higher cost performance ratio. Compared to similar domestic products, their productivity increases by more than 20%. Since launched in 2014, the models have gained the trust of customers. The optimized production structure and technology design ensures cost control, and Jinming’s technological strength ensures the quality of V-series.

Better equipment versatility In the plastics machinery industry, compared with other plastics machinery, the multi-layer blown film line becomes one of the plastic machinery products with the longest processing time and delivery cycle due to its huge structure, large number of spare parts, complex assembly processes and other factors. Such a long delivery cycle brings challenges to production of customers’ orders and return on investments in equipment, and also restricts the development of the film equipment manufacture industry.

During the manufacture and delivery of multi-layer co-extrusion blown film line, the delivery time for an order is commonly 3 months in the industry; for equipment with special requirements, the delivery period may even be longer than 6 months. In the current efficiency-oriented competitive environment where “the Fast Fish Eat the Slow Fish”, the delivery cycle will also put customers into agonizing ordeals from the market. Taking innovation as the driving force for its development, Jinming gradually launched various models in three series (Superex series, Classicx series and Valuex series) in 2014, and then conducted modular design of the

Jinming V series use the latest low-temperature extrusion system. This technology can effectively reduce energy consumption, and can achieve good machining for such materials as HDPE, LDPE, LLDPE/LDPE, and mLLDPE, thus suitable for production of various films, such as composite films and heat shrinkable films. The equipment is widely used in processing of food packaging films, commodity packaging films and other films.

Equipment categories for fast delivery The models in V series now available for fast delivery include three series, i.e., M3B-1700Q-V, M3B-2000Q-V, and M3B-2300Q-V. If you are interested, please contact 0086-0754-8820 7788 for more details.

About Jinming: Jinming (stock code: 300281), established in 1987, is not only a world-famous film equipment manufacturer who integrates development, design, production and sales, but also one of the leading brands that have the strength to provide a full range of film equipment and solutions in the industry. Jinming products cover blown film line, cast film line and stretch film line. By 2014, Jinming had provided thousands of sets of professional equipment and services for users from over 40 countries and regions, which makes Jinming one of the world’s largest film equipment manufacturers.

Plastics & Rubber Review | July-August 2015 | 41

IKV at the International Motor Show in Frankfurt IKV to present its research on automotive design on a joint NRW stand

moulding for outstanding surface quality on interior and exterior parts - Integrated design and production of hybrid plastic/metal structural parts, based on the example of a near-series front end - Integrative simulation of the mechanical behaviour of short and long fibrereinforced thermoplastic parts - Predicting the damage behaviour and designing fibre-reinforced plastics in the event of a crash and under fatigue load The open-plan exhibition area will offer the visitors an insight into current research topics and their implementation in practice. IKV will present a holistic view of the entire value chain, from design and simulation, via material technology and production engineering, to the analysis and testing of plastic parts for automotive construction.

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ightweight construction, functional integration, production efficiency and simulation are the topics currently dominating plastics research in the field of automotive design. For the first time, the Institute of Plastics Processing (IKV) in Industry and the Skilled Crafts at RWTH Aachen University will present these topics at the 66th International Motor Show (IAA), due to be held in Frankfurt am Main/Germany on September 15 – 27, 2015.

The federal state of North Rhine-Westphalia, represented by the state’s Ministry for Economic Affairs, Energy, Industry, SMEs and Crafts, will organise the joint NRW stand under the motto “Mobility connects” in cooperation with AutoCluster.NRW. At the 66th IAA, IKV will show the latest developments and research results with the focus on automotive applications.

Because of their outstanding range of properties, plastics have already become firmly established in automotive construction.

They also offer consistently high potential for innovation. The main focus of the IKV presentation will be on: - New processes for the large-volume production of fibrereinforced plastic parts, based on the example of the production of an engine hood by the gap impregnation process - Interactive repair workshop of the future for electric vehicles with CRP materials as part of the project “Leading technologies for SMEs” - Efficient production of complex composite parts by 3D fibre spraying and process integration through laser-based functionalisation - Production of complex plastic optics taking the examples of an LED focus lens made of liquid silicone rubber (LSR) and the multi-layer process - Physical foam injection moulding process “ProFoam” - Variothermal mould temperature control in injection

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IKV experts will be available on the stand for intensive discussions and talk about current issues. You can find the Institute on the joint NRW stand in Hall 4.

More information: www.ikv-aachen.de, www.autocluster.nrw.de, www. mweimh.nrw.de About IKV IKV, the Institute of Plastics Processing at RWTH Aachen University, is Europewide 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 soughtafter 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 Technology, 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.

Contact: Institut für Kunststoffverarbeitung (IKV) in Industrie und Handwerk an der RWTH Aachen Dr.-Ing. Maximilian Schöngart Head of Materials Technology and Part Design Seffenter Weg 201, 52074 Aachen, Germany Phone: +49 (0) 241 80-28359, Fax: +49 (0) 241 80-22316 E-mail: max.schoengart@ikv.rwth-aachen.de

The new FEEDMAX S3 net

Easy to handle, and fit for the hardest applications

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or more than a decade now, the single material loaders of the FEEDMAX series have an important place within the WITTMANN product range. Quality of construction and extraordinary user-friendliness have been the defining hall marks of production. The new FEEDMAX S3 net shows all of these virtues and more – with plenty of added features into the bargain.

The FEEDMAX S3 net material loader has a powerful collector motor, and is designed for a throughput of up to 150 kg/hr. This unit executes a 100% trouble-free conveying of synthetic granules and any sort of regrind to dryers, dosing devices, and processing machines.

For the first time, the loader deploys a second filter: This security filter prevents the motor from getting dusty in case the main filter is not FEEDMAX S3 net with ambiLED, correctly re-installed after being the variegated light signal for the display of cleaned. The cylindrical part of the different operating conditions conveying unit is made of stainless steel. In order to keep the quality standard on the highest level, the respective stainless steel sheets are machined in-house. The material inlet also consists of stainless steel, and is composed of two parts; a stainless steel cast part of about 5 mm wall thickness, and secondly a stainless steel reduction. This part is connected to the cast part via a clamping ring, and it serves as the connector for the conveying tube.

When the FEEDMAX S3 net is supplied with electricity and compressed air, the unit starts the conveying process immediately after having operated the on/ off switch. Using a potentiometer scale, the conveying times can be exactly defined. The net part of the new FEEDMAX S3 net expresses the possibility of controlling several loaders using only one touch screen remote control. The selfexplanatory color display of the control has a status indication. It FEEDMAX S3 net with open flap lid. The right enables the setting of conveying picture shows the material inlet inside the times, dosing proportions, and unit.

dedusting cycles for up to six units.

A special characteristic of the FEEDMAX S3 net is the new all around visible status display, the so-called ambiLED. This feature allows the status of the unit to be seen from any point of view in the production hall.

This display alerts the user to the lack of material within the conveying process – which may happen when the material bin has to be filled again or replaced. Through this visual management, machine downtime or loss of production can be easily avoided. The cleaning of a loader should take only a little time, and it should also be possible to execute the procedure without having to use special tools. Cleaning the filter of the FEEDMAX S3 net is easy. A self-securing fixture needs to be manually loosened. The foldaway lid can then be opened, and the filter can be removed.

The WITTMANN Group is a worldwide leader in the manufacturing of injection molding machines, robots and peripheral equipment for the plastics industry. Headquartered in Vienna/Austria, the WITTMANN Group consists of two main divisions, WITTMANN BATTENFELD and WITTMANN, which operate 10 production facilities in 7 countries, including 30 direct subsidiary offices located in all major plastics markets around the world.

WITTMANN BATTENFELD focuses on the independent market growth in the manufacturing of state-of-the-art injection molding machines and process technology, providing a modern and comprehensive range of machinery in a modular design that meets the actual and future requirements of the plastic injection molding market.

WITTMANN’s product range includes robots and automation systems, material handling systems, dryers, gravimetric and volumetric blenders, granulators, mold temperature controllers and chillers. With this comprehensive range of peripheral equipment, WITTMANN can provide plastics processors with solutions that cover all production requirements, ranging from autonomous work cells to integrated plant-wide systems.

The syndication of the WITTMANN Group has led to connectivity between all product lines, providing the advantage plastics processors have been looking for in terms of a seamless integration of injection molding machines, automation and auxiliary equipment – all occurring at a progressive rate.

Please contact for more details: WITTMANN Robot Systeme GmbH, Am Tower 2, 90475 Nuremberg GERMANY Tel.: +49 9128 7099-0 Fax: +49 9128 7099-500 Email: info.de@wittmann-group.com Website: www.wittmann-group.com Plastics & Rubber Review | July-August 2015 | 43

Latest SACMI innovations for caps and labels to go on show in Shanghai

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t CBST 2015 (4-6 November) Sacmi will be presenting the latest additions to the range, the CCM 48 SC, equipped with moulds for the production of ultra-light caps, and the ARENA RF labeller, produced directly by Sacmi Nanhai and specifically designed to meet the needs of the Chinese market.

Over 20,000 professional visitors are expected to attend the seventh edition of the China International Beverage Industry Exhibition on Science & Technology (CBST), to be held at the new International Expo Centre of Shanghai from 4 to 6 November 2015.

The country’s biggest such event, it is held every two years and showcases trends and technologies within the beverage industry. CBST 2015 will see Sacmi play a pivotal role with its CCM 48SC, a compression press that stands out on account of high specific productivity, excellent cap quality and optimised energy consumption.

The CCM 48SC presented at CBST (hall W1, stand 1D02) will, more specifically, be equipped with a mould suitable for the manufacture

of S30W3-type HDPE (high density polyethylene) single-piece caps for still water: with a diameter of 29 mm and weighing just 1.85 g, they have specially been designed for this market. This design is part of the Sacmi range developed, in recent years, to allow the manufacture of ever-lighter caps and containers as part of a green packaging policy that aims to optimise energy and raw material consumption while lowering transport costs.

The press on show at the fair will also be equipped with COOL+, the innovative ‘enhanced cooling’ mould which features a dual cooling circuit that acts closer (and therefore more effectively) to where it’s needed (i.e. on the tamper band and plug). Launched on the market in 2013, dozens of COOL+ mould sets have already been installed all around the globe. On the one hand COOL+ gives manufacturers, alongside the intrinsic advantages of all CCM machines, capsules of excellent quality with very short cycle times (35% less than with alternative technologies); on the other hand it offers productivity that, in the case of the caps being made at the fair,

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can reach 1,600 caps per minute with just 48 moulds (cycle time 1.8 seconds).

In addition to the innovative cap manufacturing line, visitors to CBST will be able to take a close look at the Group’s range of integrated beverage & packaging solutions, which enjoy close support in China thanks to local companies Sacmi Shanghai and Sacmi Nanhai; both the latter have their own production facilities and spare parts/after-sales services and constitute the main in-country support hub. Sacmi Nanhai, in fact, is where the Arena RF labeller, specifically designed for the Chinese market, is made. Soon to be showcased on the Group stand, the labeller features the rollfed technology in which Sacmi is the undisputed market leader with highly innovative, high performance solutions. The advantages of this machine – on the market for just two years and already setting the standard for the local beverage industry – are outstanding flexibility of use and output, which can reach 36,000 bottles/containers an hour.

Further advantages include excellent access to machine

parts (thus making maintenance tasks easier and allowing for fast size changeovers), a userfriendly operator interface and the innovative self-cleaning labelling station equipped with devices designed to optimise and reduce glue consumption.

Designed, as is the Sacmi tradition, to the most exacting quality and reliability standards, the ARENA RF labeller provides an effective response to the requirements of local producers. It does this by combining maximum productivity and extensive flexibility plus the reliability one expects from European technology, not to mention the enormous logistical and sales advantages that stem from direct in-China production.

The Sacmi strategy is, then, a farsighted one: while its technological heart remains in Italy, for decades it has been operating globally with local production facilities and branches capable of providing close customer support from the design stage and throughout the working life of the machine or plant; moreover, added value and assurance is provided by the Group’s Research & Development Center, certified by the top international players in the industry.

Joly.

The following table of properties compares two Monprene IN23000 Series compounds with a Sarlink® TPV compound (also available from Teknor Apex) for use in the flexible seal segment of coextruded window gaskets.

In addition to such compounds, Teknor Apex supplies highermodulus Monprene IN-23000 Series grades, as well as Sarlink grades, for the supporting segment.

“In offering styrenic TPEs alongside TPVs, Teknor Apex has taken a ‘polymer-neutral’ approach to the market for window profiles,

expanding the range of options for building product manufacturers so that they can select precisely the best compound for their requirements,” said Stef Hordijk, senior market manager.

Teknor Apex can produce Monprene IN-23000 Series compounds at all of its TPE manufacturing locations worldwide, ensuring dependable and steady supply in any region around the globe. “As a custom compounder, we are well prepared to accommodate customers who require rapid sampling, small lots, or pre-colored compounds,” noted Mr. Hordijk.

Styrenic Tpes For Window Seals Perform Like Widely Used Tpvs While Providing New Supply And Processing Alternatives Monprene® IN-23000 Series Compounds from Teknor Apex Are Available in Small and Pre-Colored Lots, Can Be Run in PVC Tooling, Need No PreDrying, and Avoid Paint Staining

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RI, U.S.A. and operates thirteen facilities worldwide in the United States, the Netherlands, the United Kingdom, China and Singapore. To learn more visit: www.teknorapex.com.

new series of styrenic block copolymer elastomers from Teknor Apex Company exhibits performance comparable to that of thermoplastic vulcanizates (TPVs) widely used in window gaskets while offering new options for building product manufacturers.

In introducing the compounds at Fakuma 2015 (Stand B5-5315), Teknor Apex will highlight its multi-material capability as a supplier of both TPVs and styrenic TPEs. Unlike most TPVs used for weatherproof seals in metal, wood, or PVC window frames, Monprene® IN-23000 Series styrenic block copolymer compounds are readily available in small lots and pre-colored grades and require no pre-drying.

Some grades in the new Monprene IN-23000 series can be processed with the same tooling used for PVC profiles at similar throughput rates and die pressures. “We have adjusted the viscosity and melt strength of Monprene IN-23000 Series TPEs to increase throughput while reducing or eliminating the common problem of die drool,” said Gert Joly, European R&D manager for the TPE Division of Teknor Apex.

In the coextruded structures widely used for window gaskets, Mr. Joly added, all of the new compounds exhibit excellent adhesion to the polypropylene or high-modulus TPE substrate that serves as the rigid supporting component. They provide sufficient stiffness to facilitate window assembly and, unlike most TPVs, resist staining from paints.

Like TPVs, Monprene IN-23000 Series TPEs exhibit the end-use properties essential for air- and moisture-proof window gaskets, including rubberlike seal recovery, low-temperature toughness, and UV resistance, noted Mr.

About Teknor Apex. Teknor Apex Company, a privately held firm founded in 1924, is one of the world’s leading custom compounders of plastics.

Teknor Apex produces flexible and rigid vinyl, thermoplastic elastomers, nylons, toll and specialty compounds, color masterbatches, specialty chemicals, bioplastics and hoses. The company is headquartered in Pawtucket,

The Thermoplastic Elastomer Division of Teknor Apex Company offers the broadest portfolio of TPE compounds available from a single source. The division compounds TPEs at eight locations in the U.S., Europe, and Asia under the brands: Elexar® (electrical and electronics applications), Medalist® (medical devices), Monprene® (consumer and industrial products), and Sarlink® (transportation).

Plastics & Rubber Review | July-August 2015 | 45

Sacmi “Total integration” for the beverage supply chain in the ‘Food & Beverage Plastic Day’ Appointment on 15 September 2015 in Sacmi, Imola with a day dedicated to the technological solutions and integrated plants for the beverage industry, in the name of productivity, versatility and energy saving.

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xtremely dynamic and competitive, the beverage industry is continuously seeking solutions that can combine productivity and efficiency to flexibility and versatility of the machines, to respond in real time to the requirements of the market, all accompanied by a pressing and constant requirement for optimisation of consumptions and costs.

Sacmi, the only global player capable of proposing integrated cap-preform-bottle solutions, next 15 September 2015 promotes the first “Food & Beverage Plastic Day”, to illustrate to the specialised operators project H.E.R.O. (High Efficiency Resource Optimisation) applied to the beverage supply chain.

From integration between blowing and filling to the compression presses for the production of caps,

Sacmi takes the opportunity of the first Food & Beverage Plastic Day to display to the operators the latest development of the IPS (Injection Preform Moulding) range, IPS400, the machine for the production of preforms designed to handle moulds up to 128 cavities.

Characterised by the lowest cycle times in the industry, IPS 400 backs up, to the recognised advantages of the previous range, significant innovations such as the automated unloading of the preform system, the different circuitry inside the plasticising unit - to guarantee the best quality of the PET - and the particular configuration of the cooling station of the preforms, where the kinetic energy of the gripper plate is recovered, in the deceleration stage, and reconverted into electrical energy.

Also in this case, Sacmi accompanies the technological innovation with a complete

46 | July-August 2015 | Plastics & Rubber Review

proposal from the point of view of process integration: Sacmi CPB LINK is the new high automation dynamic buffer that enables the integration of production of caps and preforms in the bottling line, in view of energy savings (H.E.R.O.) and logistics, while increasing at the same time the hygienic safety of the process.

Among the focuses of the day of work, there are also the developments of the Colora Cap system for high definition digital press, of caps and closures, now usable, after years of developments and researches, even on coloured caps. The fast loading of graphic files and the instant quick change of images makes the system suitable for the decoration of capsules for promotional campaigns, events and award ceremonies.

To complete the picture, the CBF (Compression Blow Forming)

technology, studied in view of the green packaging, that is, reduction of weights – at equal performance – of containers up to 500 ml for the dairy industry, and the solutions for inspection developed for the different businesses, machines and plant solutions of the Group.

The day of work - followed by a gala dinner - will end with a visit to the R&S Beverage laboratory, where are developed and tested

by Sacmi the solutions later industrialised and proposed to the market. A certified structure by the top global players in the beverage chain industry, capable to accompany the customer right from the design stage by combining the guarantee on the final result to the high capacity of customisation of solutions, in line with the most modern and diversified needs of the customer and the market.

Be sure to check out leading-edge machinery, solutions and services by 300 internationally prominent exhibitors, including Bobst Group, Heidelberg Graphics, Fuji Xerox, Hewlett-Packard and Kohoku Seiko.

HIGHLIGHTS OF THE LATEST PRODUCTS AND TECHNOLOGIES AT PACK PRINT INTERNATIONAL 2015 BOBST GROUP Booth: P15

FUJI XEROX Booth: X02 Color 1000i Press, the company’s latest production color press and the industry’s first xerographic production press to offer both metallic Gold and Silver Dry Inks, will be on display at the exhibition.

Targeted at the high-end professional printing market, the Color 1000i Press will be available in Thailand. FUJI XEROX Color 1000i Press Grand Opening Ceremony Date: 26 Aug 2015 Time: 1130hrs

HEWLETT-PACKARD (ASIA PACIFIC) Booth: L01 Bobst will be introducing the Novacut 106 ER - Autoplaten® die-cutter at the trade fair. The new die-cutting machine comes with efficient in-line blank separation and application capabilities. Another product on display is the new Bobst folder -gluer for high quality micro flute lamination box.

HEIDELBERG GRAPHICS Booth: Q01

HP will showcase the broadest and most complete range of industry changing products across the commercial and industrial graphics printing space HP PageWide Printers: First time in Thailand!

HP 8000XL – world’s fastest large format inkjet printer HP Indigo ws6800 – a high-capacity, high-quality narrow-web labels and packaging solution HP Latex L370 – most advanced ‘green’ printers in the commercial large format print space

KOHOKU SEIKO Booth: T25

A partnership between Heidelberg and Masterwork Machinery Co., Ltd presents new competiveness for Post press packaging.

On display is the MK Easymatrix 106 CS die cutter - ideal for short to medium production, it offers a wide range of other user-friendly features. Others include MK 1060ERSL, a hot foil stamping die cutter is capable of both longitudinal and transverse servo foil feeding to improve foil usage, and MK550Qmini – the full automatic sheet inspection machine.

Kohoku Seiko specializes in the creation of machinery and equipment using cutting-edge mechatronics. 80% of its products are custom-made to suit customers’ needs for design to processing, assembly and installation. Its product range includes bottle cap printers, labelers as well as inspection machines and packing machines. At the exhibition, the company will conduct in-booth demonstrations of the cap transfer air chute, the inking unit for cap printer and the mechanical cam system demonstration machine.

Plastics & Rubber Review | July-August 2015 | 47

PMMI Releases Innovation Stage Schedules for PACK EXPO Las Vegas 2015 and Pharma EXPO

More than 40 free, educational sessions address flexible packaging, OEE and workforce engagement and more critical topics in processing and packaging

PACK EXPO owner and organizer PMMI, The Association for Packaging and Processing Technologies, has released the preliminary schedule for Innovation Stage at PACK EXPO Las Vegas and the co-located Pharma EXPO 2015 (Sept. 28–30; Las Vegas Convention Center). More than 40 sessions will give visitors a glimpse of cutting edge technology presented by industry leaders.

The education sessions — on the show floor at PACK EXPO and Pharma EXPO — provide free, convenient access to insights into processing and packaging trends as well as challenges in food safety regulatory compliance, workforce development and measuring line efficiency.

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“

One of the greatest benefits offered by our on-floor educational programming is the opportunity for a ‘cross pollination’ of ideas,” says Maria Ferrante, vice president, Education & Workforce Development, PMMI. “This enables attendees to tap the potential of practices and applications proven in one industry but unexplored in their own.”

The presentations are a valuable opportunity to understand cutting-edge technologies, with subject matter experts, including industry consultants, exhibitors and association partners, describing specific applications and benefits. Subjects range from explorations of the latest innovations and regulations in flexible packaging to ways to engage the workforce. Other topics include: • Impact of serialization on the pharmaceutical industry • Advanced simulation software for packaging lines • Anti-counterfeiting technologies for packaging • Transforming automated packaging with reusability • Roadmap for creating a highly engaged workforce • The latest snacking trends and their impact on packaging • The next evolution of metal detection The OpX Leadership Network will also be among presenters, discussing the latest in one voice solutions for workforce engagement, total cost of ownership and factory acceptance testing. OpX Leadership Network is a dynamic community of manufacturing, engineering and operations professionals dedicated to operational excellence.

“PACK EXPO Las Vegas and Pharma EXPO is where the industry will go this fall to find winning solutions from top-tier suppliers,” Ferrante says.

“The value of the Innovation Stage presentations is that they provide context attendees need to put those solutions into action at their plants.”

The 30-minute long presentations will run hourly between 10:00 a.m.–3:00 p.m. on Sept. 28 and Sept. 29; sessions end at noon on Sept. 30. There will be three adjacent locations of the Innovation Stage on the PACK EXPO Las Vegas show floor, in Booths C-1041, C-1045 and C-1049, and a fourth stage in Booth N-559 on the Pharma EXPO show floor.

The preliminary schedule of Innovation Stage presentations is available at packexpolasvegas.com andpharmaexpo.com.

This year marks Pharma EXPO’s first year in Las Vegas. PMMI owns and produces Pharma EXPO in partnership with the International Society for Pharmaceutical Engineering (ISPE). PACK EXPO Las Vegas and Pharma EXPO will bring together more than 2,000 exhibitors showcasing their processing and packaging innovations to 30,000 attendees in over 800,000 net square feet of exhibit space. Prospective attendees are encouraged to register early by visiting packexpolasvegas.com. Registration is $30 through Sept. 14, 2015, and includes admission to both PACK EXPO Las Vegas and Pharma EXPO. After September 14, registration increases to $100. In addition to the Pharma EXPO Innovation Stage, attendees can register for Pharma EXPO Conference sessions, curated by ISPE. Separate fees apply, ranging from $90 per session to $350 for access to all 15 sessions until September 14th. Following this date, fees will increase. Visit pharmaexpo. comto find a registration option that works for you.

About PMMI PMMI, The Association for Packaging and Processing Technologies, is a trade association representing more than 700 companies that provide a full range of processing and packaging machinery, materials, components and containers. PMMI actively brings buyers and sellers together through initiatives such as packexpo.com, educational programs and world-class events, connecting participants in the processing and packaging supply chain with their customers around the world. PMMI produces the PACK EXPO portfolio of trade shows that include PACK EXPO Las Vegas 2015 (Sept.

28–30, Las Vegas Convention Center); Pharma EXPO, co-located with PACK EXPO Las Vegas 2015; EXPO PACK México 2016, May 17–20, (Mexico City, Expo Bancomer Santa Fe); PACK EXPO International 2016, Nov. 6–9 (McCormick Place, Chicago, Ill.); Pharma EXPO, co-located with PACK EXPO International 2016; PACK EXPO East 2017, Feb. 27– March 1, (Pennsylvania Convention Center, Philadelphia) and EXPO PACK Guadalajara 2017, June 13–15, 2017(Guadalajara, Jalisco, Mexico). PMMI owns the PMMI Media Group, a market-leading B2B media company that produces information for processing and packaging professionals, bringing together solution providers and end-users and facilitating connectivity throughout the supply chain. Its world class media brands Packaging World, Automation World, Healthcare Packaging, Contract Packaging and Packaging + Processing OEM- are proven leaders in covering this diverse and dynamic marketplace, and its digital products incorporate leading edge media technologies to deliver informed, actionable business intelligence to the industry. PMMI Media Group also produces The Automation Conference, an annual education and networking forum, taking place in Chicago each spring.

More information at PMMI.org and Packexpo.com and pmmimediagroup.com.

Plastics & Rubber Review | July-August 2015 | 49

Plastics from greenhouse gases The world is experiencing an unprecedented summer. There is talk of the hottest July since weather records began.

Is this pure chance or is it a consequence of climate change instead? It is time to rethink, regardless of the causes.

What is vital is to reduce greenhouse gas emissions or to make useful things from them – plastic, for example!

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arbon dioxide is a chemical compound that occurs naturally and is produced in the course of oxidation and/or combustion processes. We breathe in oxygen and breathe out carbon dioxide (CO2). Green plants – including algae – absorb carbon dioxide and use it to produce the oxygen that is so essential to us. An efficient recycling process. Everything would be wonderful if we were not so successful at meddling with Mother Nature.

Are we facing climatic catastrophes?

The effect of excessive combustion of fossil fuels is that the proportion of carbon dioxide in the air will be continuing to increase in the foreseeable future – in spite of all the political promises that have been made and the objectives that have been agreed about climate protection. This increase in greenhouse gas concentration has consequences: The temperature in the atmosphere is increasing, the polar caps and glaciers are melting and the sea level is rising. Habitats are changing. There is a real danger that entire areas of land will be flooded. Oceans are acidifying and deserts are expanding. Dry periods are increasing, precipitation and storms are becoming more ferocious. Reductions in crop levels must be expected, people are experiencing severe problems and are losing the whole basis for their existence. The same is true of animals too; many species will probably die out.

50 | July-August 2015 | Plastics & Rubber Review

A point must come when everyone asks himself if we can continue in the same vein for ever and where our modern lifestyle is leading us.

Perhaps into a catastrophe of the kind Roland Emmerich has presented to us in his blockbusters “The Day After Tomorrow” or “2012”: the earth buried under metres of ice or flooded by endless masses of water? Just fiction – or might it be more than just that?

Action rather than mere words It is time to stop paying lip service.

It is time to take action. The solution is plain to see: harmful greenhouse gas emissions need to be reduced quickly and sustainably. One step in the right direction is the obtainment of energy from renewable sources – on a large scale.

Another is to develop and apply technical processes with which harmful greenhouse gases can be “harvested” and put to good use.

Because there is no dispute about one thing: CO2 is not just a greenhouse gas; it is also an interesting source of carbon, which is needed for the production of high-quality polymers.

It is, however, proving to be a challenge to implement such concepts in practical and efficient process technology that can be employed effectively in largescale production. Bayer Material Science appears to have found one attractive and practicable approach. The company reports that it plans to use carbon dioxide to manufacture plastic from 2016 onwards.

ZA production line is currently being built at the Dormagen location for this purpose. The central element, a chemical reactor weighing 25 tonnes, was installed only recently. “We are right on schedule”, reports Project Manager Dr Karsten Malsch. A carbon dioxide tank is apparently to be added in the autumn and the line

chemical level – to react efficiently with other substances. The partners co-operating on the project discovered such an appropriate catalyst.

Interesting combination for interesting applications

will then be almost complete after a construction phase lasting a good year and involving investment of about EUR 15 million. Malsch predicts that the line will be ready to operate in early 2016, if everything continues to go so smoothly.

Malsch reveals that there are already specific production plans: Bayer Material Science intends to use carbon dioxide as a raw material source for the first time on a commercial scale in the context of the “Dream Production” project and incorporate it in polyols – central base products that are needed to manufacture such materials as foam plastic. The line is said to be designed for a production volume of 5,000 tonnes per year. The innovative new polyol, which will be containing about 20 per cent CO2, is evidently formulated in such a way that it can be used initially to manufacture mattresses made of flexible polyurethane foam.

Carbon dioxide as a substitute for mineral oil The tests are said to have demonstrated that the material containing CO2 has comparable properties to conventionally manufactured plastic. This means that the carbon dioxide is replacing some of the mineral oil that is generally the sole basis for polyols and polyurethanes. “For a long time now, the plastics industry has been looking for alternative raw materials, in order to eliminate fossil sources, which are in shorter supply in the meantime,” says Malsch. He adds that demand for sustainable products is increasing among consumers. “We think that we are in a position to provide a comprehensive solution with our new processes.”

A considerable amount of research and development work has been needed so that CO2 can be used in plastics production. Bayer Material Science has received assistance from Aachen University scientists in this context. The main challenge was to find a catalyst that incites carbon dioxide – which is very inert at the

It is the objective of US scientists to make sure that power stations no longer discharge carbon dioxide (CO2) into the atmosphere from their chimneys but feed it directly into a production plant instead.

In the magazine Angewandte Chemie, they recently presented a process with which carbon dioxide and epoxides can be used to manufacture polycarbonate block copolymers that combine water-soluble and water-repellent areas and can aggregate to form nanoparticles or micelles.

Carbon dioxide and epoxides – highly reactive compounds with a three-atom ring consisting of two carbon atoms and one oxygen atom – can be polymerised into polycarbonates with the help of specially developed catalysts.

These processes are proving to be a more environmentally sound alternative to common manufacturing processes and have already been introduced by some companies. Since the carbon dioxide-based polycarbonates produced to date are water-repellent and do not have any functional groups, applications for them are limited, however. Biomedical applications in particular, an area in which biocompatible polycarbonates have already established themselves, have left out up to now.

Sustainable chemical process engineering A team of scientists headed by Donald J. Darensbourg from Texas A&M University is now providing a solution. The research scientists

have succeeded for the first time in producing amphiphilic polycarbonate block copolymers, i.e. compounds that combine both water-repellent and hydrophilic properties. Not only the waterrepellent areas but also the water-soluble areas are based on carbon dioxide. Darensbourg and his colleagues have also managed to incorporate various functional and charged groups in the polymers, i.e. components that have a strong impact on the chemical properties of a molecule and/or a polymer. Acid and/or alkaline groups can, for example, be attached that have a positive or negative charge in the appropriate pH range. Some of the amphiphilic polycarbonates manufactured in this way are in a position to grow into particles or micelles by themselves. This characteristic combined with the ability to attach bioactive substances as well creates numerous interesting new prospects for biomedical applications.

And, by way of conclusion ...

The German government is planning to invest billions of euros in innovative technologies that concentrate on sustainable development. The implementation of carbon dioxide and other greenhouse gases like methane in polymer materials is proving to be both worthwhile and promising.

Above and beyond this, the polymer industry is well-known for innovative and creative solutions.

It is therefore the ideal partner to respond effectively to the tough challenges that society faces.

Guido Deußing Source [1] Bayer Material Science [2] Yanyan Wang, Jingwei Fan andProf. Donald J. Darensbourg, Construction of Versatile and Functional Nanostructures Derived from CO2-based Polycarbonates, Angewandte Chemie 127 (2015) 1-6 (DOI: 10.1002/ anie.201505076)

Plastics & Rubber Review | July-August 2015 | 51

Polymer chemistry meets biotechnology: plastics from seafood Not that long ago, it was possible to make clear distinctions between chemistry, process engineering, biotechnology and mechanical engineering. However, the requirements that are being made today and – even more importantly – that will be made in future encourage and demand elimination of the distinctions between the natural science and technical faculties. The development and production of bioplastics based on renewable resources are an outstanding example of this. Current developments present a more varied and also more sustainable picture, as this Topic of the Month report impressively demonstrates.

Up to now, renewable raw materials – starch should be mentioned primarily here – have been used in most cases to produce biobased polymers, with the aim of replacing oil-based plastics.

The world is full of polymers. Life would be inconceivable without them.

The word polymer is of Greek origin: the first syllable “poly” means “many”, while the second syllable “mer” comes from “meros” and means “parts”. Polymers consist of numerous chain-like macromolecules that are cross-linked with each other to some extent.

The most important natural polymers Cellulose is such a macromolecule, that forms the structure of plant cell walls together with lignin and pectins. Cellulose consists of thousands of glucose units, i.e. simply structured sugar molecules. Cellulose is a polymer, the most commonly occurring natural polymer, and is the main component of wood, paper, pulp, cotton, flax, line and hemp. Cellulose forms the basis for the production of viscose fibres, from which yarns for the textile and furniture industry can be manufactured. Viscose is used to produce thermoplastics. Tool handles, keyboards, steering wheels, ball-point pens and many other products are manufactured from cellulose-based plastic.

Plastic films too, as is easy to deduce from the name cellophane. Movie and photographic films used to be recorded on celluloid – the very first thermoplastic to be produced industrially. Cellulose-based plastics were used to make billiard balls and piano keys, where they were practically indistinguishable from ivory. The plastic was, in addition, more resistant and rolled predictably thanks to its consistent material density – in contrast to ivory. Merely for the sake of completeness, it should be added that billiard balls are made from phenolic resin, a thermosetting plastic, nowadays.

Important natural polymers can be found in both the human and animal world. Proteins are the animal counterpart to cellulose. Proteins consist of amino acids. Hair is formed from fibre proteins, out of which wool or non-woven fabrics can be made. Silk, which is obtained from silkworm cocoons and is a key raw material for sophisticated textiles, is the only endless textile fibre that occurs in nature; its main component: proteins.

Leather, which is of course still in widespread use, is produced from the skin of mammals, that incorporates connective tissue and muscles – and is thoroughly polymer cross-linked.

Bioplastics based on natural polymers According to Fachagentur Nachwachsende Rohstoffe e.V., proteins have only played a minor role in the production of biobased plastics in 52 | July-August 2015 | Plastics & Rubber Review

the past: “The bioplastics made from animal proteins include casein, which already had some significance at the beginning of the plastics age. In the production process, the casein that is obtained from skimmed milk and plastified is cross-linked to form a plastic under the influence of formaldehyde and with the discharge of water.

The term casein formaldehyde is commonly used in this context.

Casein plastics are only used in smaller niche markets nowadays because of their comparatively inferior properties. Gelatin is a protein-based bioplastic in the broader sense of the word. In addition to its familiar application areas as a food additive, it is used – for example – as a bonding agent or as capsules for tablets. Gelatin is produced mainly from collagen.”

[1] Up to now, renewable raw materials – starch should be mentioned primarily here – have been used in most cases to produce biobased polymers, with the aim of replacing oil-based plastics. It will definitely be quite a long time until this aim can be reached on a large scale and petrochemical products disappear from the market – there are plenty of critics who doubt whether it is even possible. One reason is that there has been a lack of technically suitable raw materials so far. In most cases, vegetable biomass is used, such as cellulose and lignin from wood, starch from corn, wheat and potatoes, sugar from sugar beet or sugar cane, oil from rapeseed, sunflowers and soybeans or from such exotic oil plants as oil and coconut palms. The earliest bioplastics included celluloid (cellulose

When shrimp and crabs are processed, large quantities of shells are left over that contain chitin and are both laborious and expensive to dispose of as waste. Source: Fraunhofer IGB

nitrate, developed in 1856) – as has already been mentioned – from which films used to be made and table tennis balls are still made, as well as cellophane (regenerated cellulose), which has developed from being a simple sweet wrapper to being a modern, multifunctional packaging film – which is biologically degradable too – in the past hundred years. [2] Scientists are still working intensively on finding further attractive raw material sources. Some of them are scientists from the Fraunhofer Institute for Interfacial Engineering and Biotechnology (IGB), to some extent in liaison with Evonik. In connection with the research project ChiBio that is funded by the EU, the Fraunhofer IGB has come up with a remarkable approach: instead of concentrating on renewable raw materials which can also be used in food production, so that any other use is criticised, the Fraunhofer IGB focusses on waste – specifically waste that

Overview above the “ChiBio” project: Develop improved pretreatment-methods for European (and Asian/African) shell wastes with respect to eco-efficiency and sustainability. Identify and evolve new enzymes for the depolymerisation of chitin/chitosan to monomeric units. Develop cheap separation processes for proteinogenic and lipoid by-products. Evaluate the potential of energy-rich by-products as feed for anaerobic biogas-production. Establish a novel chemo-enzymatic/microbial route to synthesize N-containing bifunctional monomers starting from glucosamine. Develop a fermentative production route for bifunctional olefins starting from glucosamine and/or N-Acetylglucosamine. Upscaling of the full process chain to make needed enzymes/ microbial strains available in kg-scale. Separation of new monomers to polymer grade (minimum of 10 g for initial testing).

Synthesis of novel “sustainable” polymers and characterization of their physical properties. Study the technical feasibility of new biotechnological methods and synthesise prototypes of the novel polymers for demonstration activities. Perform process analysis, feasibility study and cradle-to-product life cycle analysis (LCA) of the entire process chain. Establish a scientific advisory board including members from European fishery companies, peeling factories and enzyme producers. In addition, ChiBio is aiming towards: broadcasting and dissemination of gained knowledge beyond the consortium to the public and other industrial communities. (Source: Fraunhofer IGB)

occurs in large amounts in the fishing industry.

project funded by the EU intends to make changes.

Plastics from seafood

At the end of 2011, an international team of partners from the scientific, research and industrial communities headed by the Fraunhofer IGB bio-, electro- and chemocatalysis project group (BioKat) started its work in this context in Straubing.

Lars O. Wiemann and Volker Sieber outline the aim of this project as follows in the 2015 Annual Report of the Fraunhofer IGB: “The objective was to establish a multi-stage process based on the biorefinery principle, with which valuable biobased monomers can be obtained for the plastics industry from the chitin of crab shells” [5].

When shrimp and crabs are processed, large quantities of shells are left over that contain chitin and are both laborious and expensive to dispose of as waste. More than six to ten million tonnes of these crustacean shells are thrown away around the world every year, approximately several hundred thousand tonnes of them within the European Union (EU) alone [3]. A small proportion of this biogenic marine resource is, however, already being used – in Asia, for example – to produce chitosan, which is used for biomedical purposes or acts as a food supplement [4]. Due to their higher calcium content, it has up to now been less economic and therefore uncommon to use the shells produced in Europe. It is, however, an important point to note that the proper disposal of waste shells is laborious and expensive because of EU and national regulations.

This is exactly where the “ChiBio”

Preliminary treatment of crab waste and biogas generation Appropriate preliminary treatment of the waste was necessary in order to stop the natural process of decay and to prevent contamination of the shells by micro-organisms that are harmful to health. Meat residue had to

be removed from the shells and the chitin contained in the shells had to be released. Enzymatic transformation (fermentation) using two strains of bacteria that were discovered by Irish ChiBio partners proved to be an efficient way to do this. Lars O. Wiemann and Volker Sieber report in the 2014/15 Annual Report of the Fraunhofer IGB [5] that the optimised process included a combination of chemical and biotechnological operations; they are said to lead to chitin yields that vary from 13 to 14 per cent in the case of European shell waste to 6 to 18 per cent with Asian shells that contain less calcium. The exact composition of the shell components is apparently largely dependent on the species and is subject to seasonal fluctuations. The chitin content determined in the project is said to have averaged between 14 and 30 per cent.

Optimum exploitation of available resources The protein and lipid fraction that was separated in the first operation of the process was not discarded; instead of this it was tested in the environmental biotechnology and bioprocess technology department at the headquarters of the Fraunhofer IGB in Stuttgart to determine its potential for the generation of biogas. Lars O. Wiemann and Volker Sieber: “Fermentation of the organic waste fraction (...) produced good biogas yields of 460 to 900 millilitres per gram of organic dry mass within one to two weeks.”

Suitable micro-organisms and enzymes were needed to separate the macromolecular chitin and to release saccharide monomers (sugar components); there was a shortage of them. As is the case in the production of biopolymers from cellulose too, fine-tuned enzymatic separation is essential, however. Scientists from a Norwegian research group headed by Professor Vincent Eijsink from the molecular biotechnology department at the Fraunhofer IGB – who participated in this

project – succeeded in obtaining and providing suitable (chitinolytic) enzymes (chitinases, chitobioases, hexosaminidases, deacetylases), using new bacterial strains too (e.g. Amantichitinum ursilicas and Andreprevotiaripae) [6].

A certain amount and certain blends of these enzymes were, however, needed, which it was only possible to produce biotechnologically. This was done in co-operation with the Czech company Apronex, which has developed suitable processes for this purpose. Lars O. Wiemann and Volker Sieber: “With the help of co-ordinated enzyme cocktails, chitin from European shell waste was degraded purely enzymatically to form N-acetylglucosamine and/ or glucosamine.” The scientists are working on the assumption that “an environmentally sound and economically viable version for chemical chitin separation is therefore likely to become available via further process optimization.”

Biobased monomers for the polymer industry This does not mean that the development work has already been completed, however. In order to be able to manufacture technically relevant polymers, the sugar components obtained from chitin need to be converted first of all into molecules that have two reaction-specific functional groups per molecule. The scientists are pursing different strategies here.

Time will have to tell which of them will in the final analysis prove to be most effective. It is a fact, however, that chitin-based plastics can be manufactured on an industrial scale, e.g. by the project partner Evonik. A film report provides an impressive insight into this.

Source and further information [1] biopolymernetzwerk.fnr.de/biobasierte-werkstoffe/ werkstoffe/protein-basierte-kunststoffe/ [2] biopolymernetzwerk.fnr.de/netzwerk/ hintergrundinformation-zu-biokunststoffen/1-was-sindbiokunststoffe/<1A> [3] FAOSTAT, FAO statistical databases, fisheries data (2001) Food and Agriculture organization of the United Nations, Rome, Italy (www.fao.org) [4] Kandra, P.; Challa, M. M.; Jyothi, H. K. P. (2012) Efficient use of shrimp waste: present and future trends, Appl Microbiol Biotechnol 93: 17-29 [5] 2014/2015 Annual Report of the Fraunhofer IGB, P. 90/91 [6] Moss, K. S.; Hartmann, S. C.; Müller, I.; Fritz, C.; Krügener, S.; Zibek, S.; Hirth, T.; Rupp, S. (2012) Amantichitinum ursilacus gen. nov., sp nov., a chitin-degrading bacterium isolated from soil. IJSEM 63: 98–103

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