BP&R Sept 2022 by BP&R Magazine

Helping UK processors navigate challenging times

A AT 75: Duncan Wood, CEO, Rapid News Group on the show's past, present and future

— pg 07 sept 2022 bp&r

CAREER IN PLASTICS: Dr Sally Beken K2022 The ultimate guide CONTRACT MOULDERS AND TOOLING: Thinking of reshoring? and RubberPlasticsBritish INTERPLAS

...and at STV, we’re engineers who speak your language. Call us for a chat on 01933 27 27 47 or find out more at www.stvmachinery.co.uk These machines simply re-write the class/specification rule book: • Wider tie bar spacing • Increased platen size • Longer opening stroke • Mould cooling piped to the platens • Supplied ‘robot-ready’ with extended guarding • Dosing signal as standard • Greater choice of injection units • Fully employed dedicated UK service team • Plus more NOW WITH A 3 YEAR GUARANTEE Brought to you by REVISE YOUR EXSPECTATIONS. YIZUMISERIESA5-EUInjection Moulding Machines from 30T – 8000T Visit Yizumi, K HallShow,13,C77

have a great guide to everything to look forward to at K this year. And if you can’t make it, be sure to check out the Interplas Insights podcast. I’ll be interviewing some of the major players about their new launches. And of course, don’t forget to subscribe to receive news from InterplasInsights.com, to follow the action as it happens.

E: sam.hamlyn@rapidnews.com

www.interplasinsights.com

head of content: dave gray

Incorporating0307-6164Polymer

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that the BPF’s six-monthly Business Conditions Surveys are a good weather vane for the state of play in UK plastics. A lot can happen in six months, so they’re always worth a look. Past surveys are available to the public on the BPF website, and the current one is available to members.

Advertising Manager: Gareth Jones

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Group portfolio sales manager: MANDY O’BRIEN

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While every attempt has been made to ensure that the information contained within this publication is accurate the publisher accepts no liability for information published in error, or for views expressed. All rights for British Plastics & Rubber are reserved. Reproduction in whole or in part without prior written permission from the publisher is strictly prohibited.

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On the positive side, capacity utilisation is high across the board – suggesting there’s no shortage of business for many in the trade.

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Recyclers in particular have been working at full pelt, as have the compounders. This is likely the beginnings of a new economy for recyclate. Who wants to pay the Plastics Packaging Tax after all – there is only so much cost that can be passed along to the customer. This perception that the UK plastics industry is, despite its many challenges, running at high capacity right now, is the reason why we’ve chosen to incorporate a guide to some of the fantastic British moulding and toolmaking services on offer on domestic shores inside this issue. Let’s make hay while the sun shines, as they

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editor: rob coker

British Plastics & Rubber is published monthly (8 times/year) by Rapid Plastics Media Ltd, Carlton House, Sandpiper Way, Chester Business Park, CH4 9QE

Advertising Manager: Kelley Jo Gwatkin

Head of studio: SAM HAMLYN

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That’s a good indicator that adoption of new technology is starting to happen – perhaps as a last resort, for some. I think of it like getting my car serviced. I know it’s going to cost an arm and a leg, which is the last thing I need when fuel prices and the cost of parts are already eating up my motoring budget, and yet I also know if I don’t act now, I’ll regret it in 12 months when the cambelt goes.

Enjoy! Head of Content

Perhaps as you’d expect, there’s a lot of caution out there. The energy crisis is starting to really bite, which is reflected in the 50% of companies who gave it as their main reason for predicting a decrease in profit margin over the next 12 months. We’ve been spreading the word on social media and in print about the importance of investing in new technology before things get too much more severe. Not surprising then, that equipment suppliers are one of only three groups surveyed to post that sales for 2022 so far have been ahead of budget.

E: gareth.jones@rapidnews.com

WHAT’S THE STATE OF PLAY?

E: robert.coker@rapidnews.com

PUBLISHER: duncan wood

miss this pull-out special featuring the machinery and materials on display at K 2022 34

4 www.interplasinsights.comwww.interplasinsights.com 17 RUBBER AND TPES

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News Group CEO

INTERPLAS7

Rapid Duncan

Kevin

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Wood on the past, present and future of the UK’s biggest plastics and rubber trade event 37 A Top 10 run-down of the must-see K 2022 highlights, according to Rob Coker

The

Sepro Group CEO makes the case for automated robotics in injection moulding COMMENT3 Dave Gray 59Regulars INDUSTRY NEWS 60 MACHINERY NEWS 62 MATERIALS NEWS 64 BUYERS GUIDE contents POLYMERMAN52 Mike Boswell on the reality Europeanbehindgasshortages FROM66 THE BPF Philip DISCUSSESLaw the ongoing energy crisis and its eﬀect on business WOMEN25 PLASTICSIN Dr Sally Beken on sustainability and inclusivity FOCUS:COUNTRY54INDIA Rob Coker spoke to RSWM Ltd CMD Riju Jhunjhunwala

Bradford, Hexopol TPE, on becoming independent from fossil-based feedstocks 21 ON THE COVER Plastribution is tackling modern political challenges head on 27 K 2022 PREVIEW

COMPOSITES43

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Brownsill, Intertronics, explores the considerations when specifying an optically clear compound. CONTRACT46 MANUFACTURING AND RESHORING Dave Gray takes a look at the logic behind the growing trend 25

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DG: What do you attribute the success of Interplas to since RN took over? The simple answer is hard graft from an amazing team and consistent investment in the areas that matter. It is, of course, much more nuanced than that but the original decision to invest in the event was housed in a belief we could positively impact the plastics industry by bringing an event that was in the doldrums back to life.

DG: There’s no denying that the Interplas of recent years is a far cry from where the event was back in 2008. What are your abiding memories of that period?

Specialists in technical polymers | www.cjpsales.co.uk interplas: Q&A

ince Rapid News Group took over running Interplas in 2010, the UK’s leading plastics event has been on a considerable journey of rebirth and growth. In 2023, the show will be back with new and exciting features, bringing together perspectives from all corners of the industry. This continued investment in the show by the organisers is set to further cement its position as the leading UK event for the international plastics industry for the short-, medium- and long-term.

7www.interplasinsights.com

INTERPLAS, INVESTMENT, INNOVATION, INTERACTION, INSIGHTS

Dave Gray, Head of Content at British Plastics & Rubber/InterplasInsights.com sat down with Duncan Wood, Chief Executive of Rapid News Group to find out more about the journey the show has been on and what to look forward to in 2023.

In the end it is important to recognise that we are custodians of a show that existed long before any of the current team were born! So, our memories of the last twelve years are only a small part of the Interplas story. As we approach the seventyfifth anniversary of the show it is important that we reflect on that history, but stay focused on the future of the UK’s plastics event. Our legacy will be what we do next. It is THE industry show and every decision we have ever made has always been framed by the question: does it move the UK plastics industry forward?

Since the acquisition from Reed Exhibitions, Interplas has seen a resurgence in the key metrics that trade shows use to benchmark themselves by. Visitor numbers, quantity of exhibitors and stand space are all up. Perhaps the most visible indicator is that what was just half of one hall at the NEC in 2008 has now expanded across two halls... who said manufacturing in the UK was dead?

The numbers for the show over the years in terms of visitors, exhibitors and floor space would suggest by any measure we have achieved that

lockdown events in the UK with the postponed edition in September 2021, it’s been quite a journey. I would say a mainly positive experience for everyone who has been involved at RN. Although I don’t think anyone on our side would willingly go through the 395 floorplan iterations and 1000 budget revisions we had to handle in the run up to 2021!

From 2010, when we first took over, all the way through to running as one of the first post

TRAJECTORYCONTINUESINTERPLASGROWTHWITHNEWFEATURESFOR75THANNIVERSARYEDITION

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aim, in some cases spectacularly and in some cases against everyone’s expectations.

For sure, Dave, but given we were one of the first shows post COVID, with the uncertainty that still existed around mass gatherings, added to an unexpected fuel crisis and you have the perfect storm for lower attendance – but in the end the feedback we had onsite blew us away, the quality of attendee was extremely high as those who came, came to do business. So, if we can deliver in the chaos of that situation, I am excited about what we can do with a nine-month visitor campaign that will start in January 2023.

interplas: Q&A

DG: Do you think that there are any long-term effects for live events post pandemic?

DG: It’s brilliant that the rebooks were so strong, but you can’t deny that visitor numbers took a hit?

The most important thing is what we have learned through this period and one thing is for sure, live events are not going to be the same in the future.

We run events across Asia and North America as well as having our interests in Europe, so our view is not restricted to the UK or to the plastics industry only. Long before COVID appeared we had recognised that content needs to be really engaging, relevant and offer clear takeaways, that attendees valued an ability to pre-arrange meetings and to plan their time at the show in advance, and that show floor features needed to excite and offer useful information – not merely be places to sit and rest your feet.

Equally, long before COVID appeared we had decided that an aim of being the biggest show in the world in any sector was a bit silly, and quite frankly unsustainable when you consider the carbon footprint of flying people half way round the world to see what they can see in their own country.

Even the 2021 edition, with a twelve-month postponement due to COVID that meant it was one of the first post pandemic events (with all the uncertainty that brought) was topped off with a fuel crisis on the same week. And yet we still had a record rebook rate in the immediate quarter after the show. Testament that sticking to doing the basics like marketing the event well, even in tough times, will yield results for our clients... and in the end that’s who we do it for.

I do want to take a moment here to thank the industry for their support in 2021. It was fraught for everyone, but we were blown away by the support we received. It was a challenging period that made us stronger, and I genuinely believe our team is more robust and better equipped than ever to operate in challenging conditions. We always take the positives!

9www.interplasinsights.com Specialists in technical polymers | www.cjpsales.co.uk

But let’s also be clear, that’s not just a COVID thing. That’s a direction of travel that had emerged long before we all stopped getting on planes in early 2020.

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The second really exciting new play that links preshow and the live event together is a significant technology investment that we have made. Our new web platform and event app mesh visitor

The feedback we had relating to 2021 was great but we’ve never simply repeated the last edition... this time we get to deploy some very cool ideas that have been bubbling since 2018.

I think the third really big investment is in the content at the event, we’ve tried a number of formats over the years but we’ve never really nailed a high-level conference, so for 2023 that’s precisely what we are going to do. We are creating a purpose-built closed theatre on the show floor and inside that for three days there will be a programme of the highest quality... but don’t think ‘Death by PowerPoint’, the format of the programming will be as innovative as the topics under discussion. We’ll take on the issues that matter to our industry including Circular Economy, Reshoring, Energy, Diversity, Equity and Inclusion, Sustainability and

planning and exhibitor lead generation together brilliantly. For visitors it means once registered they can start to review the AI recommended exhibitors (who have full featured profile pages), setting meetings, assembling check-lists of who to visit, products to review. It is a gamechanger in enabling visitors to plan to make the most of their time at the

What visitors want and need are events that are valuable to them…and what is valuable and useful about spending two days in Düsseldorf trekking around seventeen halls in the hope of some inspiration and serendipity in an encounter?

11www.interplasinsights.com

DG: OK, so that’s ahead of the show... what can expect we when we get there?

are not only a show organiser, we are embedded in the industry with our media plays including the highly regarded magazine British Plastics & Rubber, our ability to use our connections to wire together a programme of the highest quality is unrivalled in the UK. I can’t wait to reveal some of the speakers and formats

DG: So, on that subject, looking ahead to 2023, what will be different?

The first new element is in the planning phase. We are currently in the process of recruiting an Exhibitor Advisory Board to ensure we have a range of industry perspectives in our planning process. We’ve worked hard to win the trust of the major industry brands since we took over the show and it is essential that these important organisations have a voice in the direction of their industry event. Our first meeting is in November and we are excited by the composition of this group and the industry knowledge we’ll now be able to tap into to ensure we create a must attend event.

reverse side, the exhibitor dashboard captures and shows all of these interactions, and enables exhibitors to reach out to registered visitors and set meetings ahead of the show.

Our new technology investment also means we have the capability to bring the content to life in a digital environment ahead of the event, showcasing what exhibitors are bringing and signposting the most exciting sessions for registered visitors.

The other very cool, and financially beneficial aspect to this investment for exhibitors, is that the app enables every exhibitor team member to scan visitors and therefore gather leads on their own smartphones... all for free. So, no more expensive data scanners needed and what’s more, the data loads instantly to the dashboard so no waiting at the end of the day for the leads to be downloaded from the scanners.

Onevent.the

I say that with a smile on my face because for the foreseeable future K Show is always going to be important. But there is a shift in thought process for attendees: they are more discerning today than five years ago and organisers must adapt.

So COVID helped us hone and reinforce our thinking, we watched lots of organisers fail miserably with virtual exhibitions. Digital solutions can enhance live events but they will never replace the face-to-face encounter, and Interplas 2023 will be the first time we can bring together all our developments and ideas without restrictions.

BecauseDigitisation.we

Specialists in technical polymers | www.cjpsales.co.uk

interplas: Q&A

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the food, drinks and entertainment for everyone, creating the platform for the biggest informal get-together of the British plastics industry. These socials are our way of saying thank you to the event stakeholders, in particular the exhibitors, who make the show the brilliant vehicle for the UK plastics industry that it is.

Then we have the inaugural Exhibitor Advisory Board meeting and then the important step of registration opening will happen in January and at that point we want everyone reading this to register to join us in September... it will be a birthday to remember!

Obviously, sustainability is at the heart of the industry’s challenges right now, with energy costs reaching concerning levels for manufacturers. So we’re dedicating time on the conference stage to explore strategies for dealing with that.

Beyond 2023 we also have something new coming for the plastics community but more on that at the show next year.

The final element at the event, and frankly the real stars of the show, are the exhibitors. Despite only having two years between shows this time I am pleased to say the floorplan is looking fantastic. August was a superb month with over 30 companies signing up, both halls are filling up nicely.

interplas: Q&A

The most significant part of the celebration will be the announcement on the evening of Day 1 of the 75 most influential people in the UK plastics industry. We’ll be opening the nomination process for this in the coming weeks and anyone from the industry will be able to nominate those individuals who they feel are most deserving of recognition for their contribution to the industry. We hope to see as many of the 75 individuals there in person as possible, where they’ll be able to catch up with connections old and new.

13www.interplasinsights.com Specialists in technical polymers | www.cjpsales.co.uk

The plastics industry is a social bunch, so social events play a huge part in the all-round event package. In 2021 we hosted our exhibitors on two nights, seizing the opportunity to get together again after the pandemic. It went so well we’ll be hosting our exhibitors, speakers, advisors and VIPs again on both the evenings of Day 1 and Day 2 next

We’ll also have the Knowledge Hub back on the show floor, alongside a new VIP Buyer programme which we’ll be rolling out in Q1 next year when registration opens. Every feature is designed with a clear thread running through it.

Then of course the supply chain challenges of recent years have given many brand owners pause for thought. More and more we’re hearing from contract manufacturers who are seeing tooling and processing being re-shored as a result of inconsistencies in the supply chain, as well as varying levels of quality. We’ll be making sure we profile the best of British contract service providers.

DG: And of course, it’s going to be a huge year for the show as it celebrates its 75th Anniversary. How are you planning to mark the event? We’ve got plenty of ideas, but one appeal I’d like to make to all readers is that we are looking to collect as much Interplas memorabilia as possible to display at the show. We’ve found and acquired some amazing old show guides, but we would love to see, and display at the event, any photos, tickets or Interplas related things from times past.

DG: How else do you go about creating the right environment for networking at a show like Interplas?

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We operate in an industry that is worth over £25bn to the UK. We don’t expect to have this space all to ourselves! There is always room for great events that are capable of pushing the industry forward and that are demonstrably different to what is in the market already. To be fair, we’ve always had smaller shows operating in the gaps between Interplas editions, whether it was PDM or others that came and went before. It’s all good.

DG: So, a lot a lot of exciting things planned... what’s next for the team? Yes, lots going on, but we still have huge ambition and the event has even more potential so it’s easy to stay motivated when you look at it like that.

Next for us is to open up nominations for the 75 Most Influential awards. We’ll all be at the K-Show in October, and we’ll be hosting our regular Reception aboard the BPF boat on Thursday 20th October on the banks of the Rhine... any BP&R readers who would like to come to that, please drop us a line.

DG: Recently we’ve seen a new entrant into the space, with the inaugural edition of Plastics Live taking place earlier this year. How do you see that?

LEARN

AmyLEFT:Brackin, Vice President, Sustainability & Market Development for Liberty Tire with Tony Wibbeler, and Michael Murray of Bolder Industries, touring the Bolder Industries Maryville facility in July 2022.

rubber

How has the American public reacted to or embraced the concepts of sustainability and circularity?

With motorsport such a huge part of the US leisure economy, how are motorsports industry stakeholders involved in such initiatives? We’ve had incredible success within the motorsports and automotive industries and their supply chains. While the adoption of sustainable carbon black in passenger tyres has been slow, there’s been a significant and growing appetite for BolderBlack in other automotive applications such as weatherstripping, gaskets, motor mounts and, due to growing demand and the exceptional technical performance and consistency of BolderBlack, our product is now in a number of tyres with major tyre manufacturers – and that list is growing.

Bolder Industries has forged important partnerships with several industry-leading companies including Liberty Tire, Tauber Oil, Pirelli, and more. We’ve expanded our facilities to Terre Haute, Indiana, and the Port of Antwerp, in addition to doubling our output in our Maryville, Missouri, plant. We have the support of those local governments, who are aligned with our sustainability efforts and appreciate our impact on local jobs and economies.

AUGUST, US-BASED PROVIDER OF SOLUTIONSCIRCULARFORTHERUBBERINDUSTRYBOLDERINDUSTRIESINC.ANNOUNCEDASTRATEGICPARTNERSHIPWITHLIBERTYTIRERECYCLINGTHATWOULDGIVENEWLIFETOOLDMOTORSPORTTYRES.

More than three million annually, starting in 2023 at the Bolder Industries Terre Haute facility – which is expected to increase to six million in the coming years. The total number of tyres diverted will increase dramatically upon further expansion of our facilities to other states that are ideal for the Liberty Tire partnership, based on supply and other factors.

ROB COKER SPOKE TO BOLDER INDUSTRIES CEO FOUNDERAND

TONY WIBBELER TO HOW.

Bolder Industries’ proprietary process turns endof-life tyres into circular raw materials for the rubber, plastics, and petrochemical industries. Our primary products consist of a sustainable carbon black, BolderBlack, used in the manufacturing of consumer goods, automotive applications, and industrial materials. BolderBlack is now in over 3,000 product applications – everything from phone cases to conveyor belts, and from tyres to bumpers. Our sustainable petrochemical, BolderOil, is used in solvents, renewable fuels, and for industrial manufacturing.

It’s great news that US-based rubber industry stakeholders are taking more and more steps towards recycling and circularity. How many used tyres do you estimate will be diverted from landﬁll/ incineration due to this partnership alone?

America has embraced sustainability and circularity in the last 10 years. With rising consumer demand for more sustainable processes and products, it’s becoming an important part of business for brands, regardless of their size or location.

To which industries/applications would the rubber recyclate then go?

Which other industrial/governmental bodies are involved in the collaboration and how do you anticipate expanding the consortium?

14 www.interplasinsights.com

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How can we Enable the Shift from Virgin and Fossil Materials?

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to be used in demanding areas such as automotive interiors. Materials have been tested for odour and emissions performance. A representative Dryflex Circular TPE grade, a 65 Shore A material for inlay mats with a recyclate content of 20%, showed a very low amount of VOC (60 μg/g) and FOG (594 μg/g).

o create a real system change there needs to be a shared value between us, our customers, and our supply chains. We’re working to build that value from a support package which combines our materials and R&D capabilities, as well as knowledge around carbon literacy and sustainability practices, and importantly providing evidence such as product carbon footprints.

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One of our latest technology pillars to enable a shift away from fossil feedstocks is to use the concept of mass balance.

One our technology fossil

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This chain of custody model makes it possible to mix fossil with recycled and/or biobased raw materials whilst keeping close track of the respective quantities. Mass balance allows for a gradual increase of the sustainable share using existing infrastructure with the target to reduce the use of fossil raw materials step by step.

We’re

pillars to enable a shift away from

We’ve also recently added a series of TPE materials containing recyclate from post-use maritime ropes. We’re working with PLASTIX A/S, a Danish plastic recycling company specialising in sorting and recycling plastic fibre waste from the maritime industry. They convert used fishnets, trawls and ropes that would previously have ended up in the ocean or on landfill into high-grade and virgin-like raw materials. The Dryflex Circular MWR TPEs are available in 40 Shore A to 50 Shore D hardnesses with 10-60% recycled content. They are available in black, blue, green and mint colours.

WHAT IS THE MASS BALANCE APPROACH FOR POLYMER COMPOUNDING?

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I remember when we first launched the Dryflex Green Biobased TPEs back in 2015. At the time, it felt that we were a front-runner and initial demand was fairly niche. Bioplastics weren’t new, but as most of the raw materials were quite hard on their own, it had been a challenge to develop soft materials with high renewable content and low hardness, all while maintaining mechanical properties.

feedstocks is to use the concept of mass balance.

hard to source reliable post-industrial (PIR) and post-consumer (PCR) recyclates, diverting materials from potential landfill or very and well-controlled from hygienic and opens up possibilities for the TPEs

17www.interplasinsights.com

DECOUPLING FROM FOSSIL AND SWITCHING TO RENEWABLE FEEDSTOCKS

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Since then, interest in renewables and biomaterials has grown exponentially as companies look to decrease fossil-based dependency. Constant investigation into potential raw material sources and R&D activities testing new polymer combinations has allowed us to expand what is possible. Now Dryflex Green Biobased TPEs are available with amounts of renewable content to over 90% (ASTM D 6866) with hardnesses from 15 Shore A to 60 Shore D. The portfolio includes grades based on Styrenic Block Copolymer (TPS), Thermoplastic Polyolefin (TPO), and we’ve just added Thermoplastic Vulcanisate (TPV) technologies.

KEEPING VALUABLE MATERIALS IN CIRCULATION

One circular economy principle particularly relevant to our role as polymer compounders is to circulate materials as long as possible. This helps to reduce the demand for virgin fossil-based materials and is why we created the Dryflex Circular TPE

SOFT, SAFE, SUSTAINABLE

Working with the various technologies; bio, recycled content and mass balance, allows us to widen the scope of what’s possible. For example, we would not offer a TPE with PCR content for a medical device. But it becomes possible to meet medical requirements with a TPE material with biocircular feedstock allocated via the mass balance approach, as there is no change of properties. A toy manufacturer may take the biobased TPE route to meet toy or food contact regulations, while an automotive Tier 1 will work with a TPE containing recycled content to reduce the product carbon footprint of their part.

How can we know that what we do is making a positive change? As an organisation, as individuals and with the products we make?

with organisations such as EcoVadis, which provide an independent assessment that evaluates our sustainability performance. Their methodology is based on international standards such as the Global Reporting Initiative (GRI) and the United Nations Global Compact (UNGC). Our UK site received the Platinum medal, putting them in the top one per cent of companies in our industry.

I’mlens?sure

And with proposals such as the Ecodesign for Sustainable Products Regulation (ESPR) to consider, we and our industry will need to continue this work on calculating and communicating environmental impact data for our materials and operations. To give our customers and us the knowledge necessary to make informed choices and enable that shift in how we use, value and respect our natural resources.

is an example of systems transformation. Ensuring the required traceability standards needs engagement with our supply chain and a co-ordinated approach from our purchasing, production, R&D, sales, logistics and IT teams. But the result is that we’re proud to be one of the first TPE compounders to achieve ISCC PLUS certification and to bring further possibilities for our customers to reach their sustainability goals.

Our goal is to do what’s right, not necessarily what’s easy – meaning we challenge ourselves to create robust systems and in-depth assessments. For the last twelve months, we’ve been building the HEXPOL TPE methodology for calculating cradle-to-gate Product Carbon Footprints, which we can now offer to We’recustomers.alsoworking

EVIDENCE-BASED APPROACH TO SUSTAINABLE DEVELOPMENT

So far, this has been adopted by our Swedish site, which received the International Sustainability and Carbon Certification (ISCC PLUS) earlier this year. ISCC PLUS is a global certification scheme providing traceability along the supply chain and guaranteeing correct and transparent use of the mass balance approach. Certified companies must meet specific environmental and social standards, creating a chain of custody. Each company along the chain needs to be certified, and sustainability declarations follow the Massmaterial.balance

When developing our TPEs, we need a deep understanding of regulatory and industry standards and international and national legislation. We must carefully manage each step of the process, from sourcing the correct raw materials and suppliers, managing production to the knowledge about the final application requirements and end-of-life. After all, if a material doesn’t serve its purpose or isn’t compliant with the standards required of it, it’s not the right material for the job.

How do we design our TPEs to meet performance and aesthetic requirements while ensuring regulatory status and, at the same time, supporting ecodesign principles and under a carbon footprint reduction

18 www.interplasinsights.com

my product safety colleagues would explain how working with recycled and bio feedstocks has brought new challenges. Indeed, transparency about material sources and regulatory compliance is needed more than ever throughout the supply chain. But our product safety approach and standards remain the same.

For more information visit www.mauserpackaging.com You can also email mauserpackaging.comInfo@or call +44 1706 754 980 to find out how much CO2 you can save by switching to the Infinity Series.

not have to compromise on quality and safety.

Investment in multi-layer plastic drum machine expands capacity for growing demand of Infinity Series products manufactured with recycled resin.

As more regulations, such as the PPT in the United Kingdom, are introduced around the world to encourage the use of recycled plastic, Mauser Packaging Solutions’ Infinity Series of products offers companies the most comprehensive portfolio of

in a state-ofthe-art multi-layer plastic drum machine at its plant in Littleborough, UK, global company Mauser Packaging Solutions is at the forefront of meeting the growing demand for products containing recycled resin, helping your business to be more sustainable too. The new extrusion blow molding machine can produce a much more sustainable 3-layer tight-head plastic drum (also known as an L-ring drum) using recycled resin in the middle layer of the drum.

By using the UN-certified PCR drums, you can reduce the consumption of virgin plastic and CO2 emissions. The 220-litre drums are part of Mauser Packaging Solutions’ Infinity Series which includes IBCs, medical waste containers, plastic pails, tight-head containers, and lube oil cans, offering the most comprehensive portfolio of industrial packaging made from recycled resin.

is committed to supporting you in moving from the linear rawcarbonSeriesthatAnothercircularpackagingtheequipmentinvestmodel“reduce-reuse-recycle”model“take-make-dispose”tothecircularandwillcontinuetointechnologiesandthatextendslifecycleofindustrialandsupportstheeconomy.positiveaspectisbyusingtheInfinityyoureduceyourfootprintandsavematerials.Youalsodo

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MAUSER PACKAGING SOLUTIONS

This investment does not only boost UK manufacturing and support global sustainability efforts, but it is also helping to solve the very real issue of PCR supply (which is itself recyclable). The high-quality, recycled resin, used in the drums is manufactured in-house at a Mauser Packaging Solutions facility. The resin, called Recolene®, is made from empty industrial packaging that has been collected, shredded, washed, sorted by colour and extruded on-site at one of the company’s six recycling centres as part of its global packaging return programme. This unique closed-loop process ensures a consistent, high-quality supply of recycled resin that gives plastic materials new life, reduces industrial waste, conserves raw materials, and has a smaller carbon Mauserfootprint.Packaging Solutions

industrial packaging made from recycled resin to help meet these regulations.

With the increased demand for post-consumer recycled plastic (PCR), the introduction of the Plastic Packaging Tax (PPT) in the UK, and companies making highly visible commitments to cutting back on virgin plastics, businesses are looking for a reliable, quality supply of packaging solutions manufactured from ByPCR.investing

invests to revolutionise sustainable plastic drum manufacture

Create | Engage | Inspire Webinars

Webinars

o er a multi-layered marketing outcome, enabling you to tell your story to a global audience, deﬁne your organisation as a thoughtleader and simultaneously deliver a healthy number of leads for your sales team to get to work on. TO FIND OUT MORE CONTACT Mandy O’Brien | t: +44 (0) 1244 952 519 | e: mandy.obrien@rapidnews.com www.interplasinsights.com/discoverwebinars

Despite the backdrop of increasing uncertainties facing the European plastics sector, historically the UK plastics processing sector is robust, adaptable and capable of meeting changing demand needs. Aligned to this optimism and having been operating at the top of its game for over 40 years, leading polymer distributor Plastribution believes that it is well placed to provide trusted support for processors even in the most uncomfortable of commercial situations.

customers come to Plastribution because they have problems that they need to resolve, whether that be commercial, productivity, support or process,” said Mike Boswell, Plastribution’s Managing Director. “Over the years, we have become very good at interpreting situations that could impact our customers and developing strategies to help them navigate difficult times. This in turn has allowed us to build trust and forge strong relationships.”

on the cover

HELPING UK PROCESSORS

In the current challenging scenario, the company has been considering innovative ways that it can help processors deal with their biggest outlays - typically energy and inflationary raw material costs.

igher-than-expected inflation, specifically in the UK and major European economies, is prompting a tightening of global financial conditions. China’s slowdown has been worse than initially expected amid COVID-19 outbreaks and lockdowns, and there have been further negative spillovers from the war in Ukraine, such as the constraints on Russian gas supply to continental Europe.

WITH

COST-EFFICIENT PROCESSING SOLUTIONS

Technical support - Plastribution’s technical team not only provide sound technical advice across a number of areas, covering the initial design through to the end of the manufacturing process, they can also advise on optimising processes to help processors ensure that they’re using the most cost-effective material for their application.

www.plastribution.co.uk

SUSTAINABLE MATERIAL CHOICES

Helping UK processors navigate challenging times

GRANIC mineral masterbatches are seven times more thermally conductive than polymer. This results in faster melting and mixing in an extruder. The material also enhances processability by keeping a more homogeneous melting temperature, resulting in less power consumption and less melt pressure. It will also help reduce CO2 emissions, as this material has an inherently lower carbon footprint than

21www.interplasinsights.com

SUPPLY CHAIN VOLATILITY

Disruption to the supply chain continues to be a major concern, much due to congestion or global issues that affect material availability. Through extensive warehousing, Plastribution has undertaken measures to mitigate supply chain disruption, with the main focus being on the availability of a significant physical inventory for delivery at short notice to create a buffer between producers and converters.

With material selection, Plastribution’s solution is the use of GRANIC by GCR Group, the drop-in mineral masterbatch that can assist in reducing processors’ energy consumption in production

NAVIGATE CHALLENGING TIMES

To assist further, Plastribution also provides:

GLOBALPANDEMICSTILLMARKETSTRYINGTORECOVERFROMTHEANDTHEONGOINGCONFLICTINUKRAINE,THEECONOMYISFACINGANINCREASINGLY

Market intelligence - Plastribution say that they are always trying to support its customers in better understanding the markets through its monthly Price knowhow report, and helping them decide when is the best time to buy. The company also produces Price know-how ‘Snippets’ - video commentary which provides supply and demand trends together with qualified insights to help their customers’ decision-making process.

Amongst the commercial uncertainties being currently faced, environmental issues are ever present and the ongoing development of sustainable materials is a hot topic. Working with the world’s best sustainable materials producers, Plastribution was the first polymer distributor to provide processors with a portfolio of materials to suit their environmental “Mostambitions.prospective

22 www.interplasinsights.com FROM END-OF-LIFE TO NEW LIFE MATERIALS ONLY LINDNER CLIENTS CAN TRULY SAY: WITH LINDNER’S INNOVATIVE PLASTICS RECYCLING TECHNOLOGY. Hauke Grabau Senior Associate Recycling AST Kunststoffverarbeitung GmbH Germany #WASTETRANSFORMER K 2022 HALL 9, BOOTH B17 / B19 & CIRCULAR ECONOMY FORUM CE02 13745 Distrupol Advert - The Positives of Plastic 190x124mm - Q1 2022-Final.indd 1 09/02/2022 09:47

Asked how Romi has been able to deliver such a large project in a short window of time, Bathard explained: “Romi’s, manufacturing site in Brazil has the latest processes in place to produce machines quickly and efficiently. Couple that with the fact that Romi UK is one of the largest whollyowned subsidiaries in the UK, it means we have the space to stock a larger number of machines, enabling highly competitive delivery times.”

“They can also still benefit from the Superdeduction Tax, which enables companies to claim up to 130% of asset value within the first 12 months” he added.

This latest machinery upgrade is another positive sign of growth for the UK’s plastic and manufacturing sectors. Machinery suppliers are reporting increasing enquiries, in some cases as a result of renewed interest in reshoring after the supply chain challenges seen in the last couple of

“Romi Machines UK can help in the control of cashflow and manufacturing costs by supplying our range of hybrid energy efficient machines with the latest design technology. Our machines from 70T to 450T single pump are 8+ (“+” meaning our machines consume less than 1kW when idle), under Euromap 60:1 and 9+ for 600-2000T. I believe hybrid machines are the future, offering greater long-term savings on maintenance than other technologies.”

he recent investment in new tech from Romi will see the manufacturer, which serves the building products market, benefit from the latest energy saving technology – a shrewd move against the backdrop of rapidly increasing energy costs.

Bathard added that the customer will now be able to benefit from over 85% in energy savings

Increased costs on energy now and in the very near future make it vitally important for plastic moulders to invest in the latest technology which will help them save on their future costs.

overall for both of its sites. Investment in the latest technology will also see the firm benefit from reduced downtime and lower costs for

“We have seen a renewed interest in the domestic market for our new machines, due to reshoring and increased taxes brought about by Brexit. Companies are fuelling the growth of British manufacturing. The high-quality products the UK market is capable of producing gives investors peace of mind, not to mention control over their supply chains, and, of course, over their cashflow.

costs on energy now and in the very near future make it vitally important for plastic moulders to invest in the latest technology which will help them save on their future costs, with the added benefit of increasing their productivity while reducing/keeping their maintenance costs to a minimum,” said Bathard.

UK MANUFACTURER UPGRADES IMM FLEET TO ROMI’S EN SERIES FOR +85% ENERGY SAVINGS

A further order of two EN100T machines will be installed in the coming weeks, as well as a further five machines to one of the company’s other manufacturing sites (consisting of an EN220T, an EN300T, an EN450T, an EN800T and an EN70T). The entire project will be completed within the month of August.

The project began with the purchase of an EN300T from Romi’s EN Series machines. Machines in the EN Series, which range from 75 to 1500 tonne, are powered by a Siemens servo pump system. Bathard explained that Romi always use European specified part. The Siemens system couples an inverter drive with a fixed displacement pump – a combination which he says has a tried-and-tested history of delivering significant energy savings.

“Increasedspares.

Bathardyears.said:

23www.interplasinsights.com injection moulding WITHMACHINESPROJECTRESULTFUTURE-PROOFINGMANUFACTURERMIDLANDS-BASEDISSETTOREAPTHEREWARDSOFINVESTMENT,ASAOFAMAJORWITH ROMIUK.DAVEGRAYCAUGHTUPNEILBATHARD,NATIONALSALESMANAGER,ROMIMACHINESUK,TOFINDOUTMORE.

The EN220T is just one of the machines that form part of the project.

This initial investment brought about over 85% energy savings for Romi’s customer, compared with the older machine it replaced.

As a result, the manufacturer has now committed to replacing all of its older machines, the first three of which will be installed today (Wednesday 3rd August). This tranche consists of two EN220T machines, and another EN300T.

AS INNO VATION k-online.com/k as innovation International Trade Shows Link Ltd. Exhibition House, 12 Hockley Court Hockley Heath, Solihull West Midlands, B94 6NW Tel: 01564 info@itsluk.com781871 kmd2202_Innovation_190x124_GB.indd 1 12.07.22 10:51 Intelligent, MeasurementConnected&Control Solutions Film | Sheet | Pipe | Tube | Hose Precisely, reliably measure: ► Film & Barrier Layer & Coating Thickness ► Basis Weight ► Haze ► Diameter & Ovality ► Wall Thickness ► Length & Speed Intelligence that transforms the world. www.ndc.com See us at K Show Hall 10/ Booth G28

background is almost 20 years’ experience in knowledge transfer for the plastics sector and building and shaping innovative projects. She has close connections with Research Councils, Defra, WRAP, DHSC amongst others where plastics sustainability is a factor. Prior to Innovate UK KTN she worked in the medical industry formulating polymeric

SPOTLIGHT

DG: WHY IS THE NETWORK ATTRACTING A HIGH PROPORTION OF WOMEN, DO YOU THINK?

environment. We connect and support innovations that will transition from the current systems, to those that are A. ones from a materials LCA perspective, and B. use systems thinking, allowing them to be revalorised at the end of their lives.

SB: In the research phase of my career it was very male dominated, although there began to be more women in research specifically as time progressed. I soon entered the medical industry and worked on formulating medical device components where it was back to all male colleagues apart from admin and a few women in assembly. Early on, I would sometimes actually get negative comments from males in the supply chain about ‘what can a girl know about manufacturing processes?’ I stress from the supply chain for the components I was specifying, not the company that employed me. But as time has gone on, more women have been visible in engineering and manufacturing roles.

SB: If we are transitioning to a more sustainable future for the industry, longer term is key. The disruption of historically well-honed business models and value chains appears to be benefiting from diversity itself. We need a breadth of skills and approaches to innovation which includes relationship building. Perhaps it is this aspect of social interaction that is appealing to women (although there are many great male networkers), and which will support us in transitioning to a different future. I certainly know I can talk for England!

Dr Sally Beken has a Ph.D. in Polymer Science and is the founder and lead of the UK Circular Plastics Network at Innovate UK KTN. She is a Senior Advisor to Systemiq and MMC Holdings, a sustainable material packaging company, and a Non Executive Director at LitterAware Ltd who have developed LitterLotto, an app designed to reward those who deal with litter responsibly.

DG: HOW DID YOU COME TO JOIN THE PLASTICS WORKFORCE?

SB: I did a degree in chemistry and then in my final year, on a polymer module, the lecturer held up a crosslinked polymer product and said theoretically this could be just one molecule. I remember the hairs standing up on the back of my neck, and, well, I was hooked! I then did a Ph.D for Dunlop and worked in further research for the Malaysian government on elastomer formulations.

SB: We have found that many of the contributors and attendees of our seminars, workshops, conferences, etc. are female and we often achieve near gender parity at our events. Sustainability as a topic of innovation seems to be attracting a particular interest from females. Whilst I have not specifically polled our network, anecdotally there seems to be a focus on the longer rather than the short-term innovations by the group as a whole.

THE UK CIRCULAR PLASTICS NETWORK AT INNOVATE UK KTN DIVERSITYABOUTAND

Her remit at Innovate UK KTN includes building collaborations and partnerships for innovative projects and has recently helped over 30 successful projects totalling £97m

HER CAREER IN THE PLASTICS INDUSTRY.

25www.interplasinsights.com

DG: WHAT IS THE ROLE OF THE UK CIRCULAR PLASTICS NETWORK?

DG: WHAT CAN THE WIDER INDUSTRY LEARN FROM THIS?

access funds from the Smart Sustainable Plastics Packaging challenge. Passionate about the responsible use of materials Sally also ran a furniture upcycling business for almost a decade and now focuses on

Sally’spolymers.professional

for the Sustainable Material Innovation Hub in Manchester, The Centre for Enzyme Innovation in Portsmouth and as a Fellow at IOM3 on both the Polymer and Elastomer Groups.

DG: WHAT WAS THE SECTOR LIKE IN 1989, AND HOW HAS IT CHANGED IN 32 YEARS?

She founded and runs the GRIPS conference, Global Sustainability in Plastics Research, which attracts around c.a. 3000 attendees annually.

FEATURE

DAVE GRAY TALKS TO DR SALLY BEKEN,ANDFOUNDERLEADOF

materials to support the Kyoto protocol enabling the protection of the Ozone layer from harmful CFC’s and has also worked for the Malaysian Government developing Shecompounds.elastomersitsontheboard

The disruption of itself.frombeappearsvaluemodelsbusinesswell-honedhistoricallyandchainstobenefitingdiversity Solutions to shape the world | www.rwc.com

SB: I set up the UK Circular Plastics Network in 2018 to work with those using plastics to ensure that they are as sustainable as possible and don’t enter the

the

you

Pentagon, pro-actively supporting from early stages of

design

The

extensively expanded HASCO cooling range in stainless steel is employed in cleanrooms or medical technology applications for the temperature control of injection moulds in reliable processes, using hot / cold water or oil. Easy - Onlinewww.hasco.comOrdering RangeCoolingSteelStainless Anz_Temp_VA_190x124_EN.indd 1 01.09.2022 08:02:48

servicesManufacturingdelivering ease of communication and a smooth supply chain

MOULDINGDEVELOPMENTDESIGN

The future of robotics and much more: 10 MUST SEESTHE MACHINERY REPORT THE MATERIALS REPORT and RubberPlasticsBritish sept 2022 bp&r ONLY IN BP&R'S OFFICIAL K2022 PREVIEW — SEE PAGES 27-42

With an expected 12,000+ attendees across the three-day event, as well as new features and an expanded floorplan, now is the time to position yourself as a company that can offer solutions, showcase innovation and offer expertise to an audience known for its quality and purchasing power.

Interplas is back in 2023, bringing with it the opportunity for you to experience the UK’s largest plastics industry exhibition showcasing the full spectrum of plastics processing machinery, materials, software, services and ancillaries in one place.

@InterplasUK #InterplasUK www.interplasuk.com +44 (0) 1244 952 519 26-28 SEPTEMBER 2023

Exhibi t w it h u s

It’s also the only plastics event in the UK where visitors can see working machinery LIVE on the show floor and where they’ll come to compare, contrast and buy.

LOVE THE PRE-K BUILD-UP. IT FEELS LIKE SO

DÜSSELDORF S y

The format (and perhaps the grandeur) has changed a little, along with the world (stalwarts of the industry will tell you of Mick Jagger and Rod Stewart being booked for the exhibitor parties – I couldn’t say, before my time!). But a lot remains the same. One thing new for 2022 however is a start-up zone. At a time where there seems to be a generational apathy towards plastic as a material, it’s refreshing to learn that young new start-ups are still seeing the unique attributes of plastic as a real problem-solving material.

For me personally, I’m really interested in how new materials are coming to the fore now. Design for recycling is set to be a big talking point at the show this year, and I think this is where material choice matters more than ever. It’s the part of the sustainability question where the plastics industry must play its part. Yes, it is fair to say that infrastructure is probably the major stumbling block in effective global recycling, but that doesn’t mean we can ignore the reality that materials for the vast majority of products will need to be fully recyclable in the future. There’s no time like now!

29www.interplasinsights.com

Linked to this, I think you’ll see a bigger turn out than ever from recycling machinery suppliers. New technologies are emerging at a rapid pace for things like collection, sorting, cleaning, filtering, mechanical. And of course, many of the major chemical names are putting investment into chemical recycling – expect to hear a lot more about that in the halls this year. The interesting thing with that is that it doesn’t work without a mechanical step as a precursor to the chemical reaction. A real ecosystem could start to form around the mechanical/chemical recycling crossover, and I look forward to seeing that.

his year the show is celebrating its 70th year – quite the milestone. In the same year that the Queen was coronated, a behemoth of a trade show was born. Of course, it was preceded by Interplas five years earlier (don’t worry, we’ve been raiding the BP&R archives for some very special 75th anniversary retrospective editorials in upcoming issues), as well as NPE in the US in ‘46. Initially, the event was designed for the domestic German market. But by 1959, it had evolved into a major international affair. The organisers of the three events agreed to synchronise their schedules to ensure that every year, visitors from around the world had a major gathering – and so it remains to this day.

Among the companies you’ll find in the new zone are Plastship from Germany, a European marketplace for recycled plastics to promote the circular economy online and oﬄine, Healix from the Netherlands, a firm which collects nets, ropes and other plastic waste based on synthetic fibres to recycle them into high-quality circular polymers for the global production supply chain, and Hage 3D from Austria: this start-up produces large format industrial 3D printers. Enlyze from Germany, a new entrant into the process control software field, will also be in the start-up zone.

In this special 16 page supplement, I hope you’ll find something that will catch your attention ahead of October’s big show. And if you haven’t yet made the decision about whether or not to visit, perhaps something in here will help tip the balance.

ITSUDDENLYSHOWS,YEARSGETSINNOVATIONMUCHSAVEDUPINTHETHREEBETWEENANDTHENIT’SALLRELEASEDTOTHEMARKET.SOMEOFISSOFUTURISTICIT’SIMPOSSIBLETOIMAGINEITINTODAY’SMANUFACTURINGSETTINGS.OTHEREXAMPLESAREFOCUSSEDONTHEPRESENTCHALLENGES.ALLAREWORTHVISITING,INORDERTOUNDERSTANDWHAT’SBEENMADEPOSSIBLEBYTHEWORLD’SLEADINGPOLYMERSCIENTISTSANDENGINEERS. I K 2022

IN THE LAST ISSUE, WE LOOKED AT SOME OF THE EARLY ANNOUNCEMENTS FOR NEW MACHINERY DEVELOPMENTS. BUT AS THINGS HEAT UP WITH THE SHOW APPROACHING EVER-NEARER, DAVE GRAY TAKES A LOOK AT THE LATEST MACHINERY LAUNCHES AND UPDATES.

30 www.interplasinsights.com WWW.QUICK-MOULD-CHANGE.COM | QUICK MOULD CHANGE SOLUTIONS

The electric Allrounder 370 A

Three further machines on the main Arburg stand will also be running with the company’s recyclate package, including an electric Allrounder 470 A, produces PP handles from postconsumer recyclate (PCR), a hydraulic Allrounder 270 S compact using glass-fibre-reinforced PPS recyclate to make tweezers, and an Allrounder 375 V with a six-axis robot and Arburg Turnkey Control Module (ATCM) producing a bicycle tool from recycled PA66/6 (GF50). Also looking green and clean will be Engel, which will also keep a strong focus on recycling as part of the injection moulding process. Its latest innovation, which it will debut at K, makes it possible to process plastic waste as flakes in injection moulding directly after grinding – eliminating compounding and pelletising steps.

behind the V-LINE technology is to separate the injection and plasticization processes in one unit, resulting in accurate, rapid, and repeatable resin injection; suppressing outgassing, reducing fibre fracture, and preventing backflow.

Rıdvan Inan, General Manager at Inpak Makina, a specialist in 24/7, fully automatic air pressure thermoforming machines, told me the firm is planning to “set a new trend” with its TS-1000, which it will run alongside a robot stacker on stand E30 in Hall 3.

The new process will be shown on an ENGEL duo 12060H/80Z/900

THERMOFORMING

et’s start with, Sodick Europe. Well-known for its EDM machines, the firm also deals in IMMs. At this year’s show the group will be demonstrating the 30-tonne hydraulic hybrid GL30 injection moulding machine, as a means to showing the group’s ‘V-Line’ technology for small, complex, parts in the medical and electronic sectors. The application running will be 28-pin 0.35mm pitch micro

Sodick says this helps to protect the melt condition of the resin, and brings stability to the density of weighed resin and thirdly in the true fill Arburg,volume.in its green livery, is planning to emphasis that green is not just a branding choice, by including a dedicated ‘green’ pavilion for its own sustainability efforts – staffed largely by the next generation of Arburg employees currently in training. An electric Allrounder 370 A, fitted with the company’s recyclate package and Multilift robotic system will produce the ‘Greenline’ wall plugs from Fischer. The sprue will be shown being deposited directly into a mill. It is then returned straight back into the process as regrind and reused. 2022: machinery report

Engel says its team spent time enhancing the new degassing unit – work which has resulted in the ability to produce high quality finished parts from contaminated waste in fewer steps.

MOULD DESIGN

For product designers, it’s worth taking a look at a new section on the Meusburger stand, which is dedicated to the company’s digital services. As well as displaying an array of hot runner systems, the company will use the new space to demonstrate its online tools for configuring mould bases, which and calculating the corresponding components and export the CAD data.

IT'S HOT, IT'S LOUD AND IT SMELLS LIKE MELTED PLASTIC... WE MUST BE IN A MACHINERY HALL

At K, dolly pallets will be moulded on an ENGEL duo 12060H/80Z/900 using a blend of polyolefins from post-industrial waste.

Netstal will premiere the newest edition of the ELIOS which now uses all-electric mould closing, allowing the dry cycle to be accelerated by 0.1 seconds. The machine is also 450mm shorter in length. The ELIOS 4500 will produce thin-walled 150ml IML yogurt cups from a certified renewable PP from SABIC. The material is based on tall oil, a waste product from paper production. It has identical processing properties to conventional polypropylene (PP) and can be returned to the resource cycle.

Theconnectors.concept

Plastic flake is melted in a conventional plasticising screw, and then transferred to a second screw for injection into the cavity.

V-Line technology is to separate the injection and plasticization processes

Depending on the material and application, a melt filter and a degassing unit can be integrated into the process between the plasticising and injection units. This is really an opportunity for

a significant carbon footprint reduction in the recycling and moulding processes – about 30 percent less energy than using compounding as an additional step, according to Engel.

EFFICIENTappliedCORE

E 21000 also available with sealant already

TEMPERATURE REGULATION E 21010 E 21000 EXCLUSIVELY AT MEUSBURGER Discover more at www.meusburger.com

Comparison of cross sections (left: stainless steel, right: brass)

COOLING WITH THE DEFLECTION BAFFLES FROM MEUSBURGER

Head connection adapts to the conditions of the cooling hole

HOW YOU BENEFIT

With the new E 21010 stainless steel baffles you can create up to 26% more flow than brass baffles.

Stainless steel ensures high durability

Visit us at KBoothHall202215C58

We don‘t just look at the injection moulding machine, but the entire system. The combination of temperature control, intelligent device communication and smart process control leads to maximum e ciency. Up to 67% energy can be saved compared to a hydraulic injection moulding machine with a constant pump and conventional temperature control.

67%

Energy prices are exploding and electricity suppliers are adjusting their tari s upwards. But you as a company cannot raise your prices from one day to the next. Under these circumstances, your calculations could be ruined.

The solution from ENGEL:

all-electric machine + temperature control + intelligent assistance = energy savings

Read more: engelglobal.com/be-e cient Be the first. Be efficient.

Your situation:

NDC will also be displaying the FilmPro infrared gauge for the film, sheet and coating industries, and the HazePro gauge, which allows manufacturers to adjust the film and sheet extrusion process to tightly maintain appearance of optical films, solar panel films, anti-glare films, agricultural films, packaging films and other applications.

33www.interplasinsights.com

MADE TO MEASURE

First up is the new Series 9 online measurement gauge for the converting and extrusion industries. While it has been available for other industries since 2020, interest from the plastics sector has led NDC to develop the Series 9 Converting gauge.“The Series 9 Converting gauge is the sum of what we’ve learned over the past years to meet the manufacturing challenges faced by the converting and extrusion industries,” said Mark Rainville, product manager for NDC’s film extrusion and converting businesses. “We’re excited to deliver the best-in-class, best-invalue measurement system on the market today. This product is equipped with a unique set of capabilities for

Inan said “rethink, reuse, recycle and renew” is a core principle in the firm’s machine development, with the group’s technology keeping pace with recent developments in more sustainable materials, as well as energy efficiency requirements.

WWW.QUICK-MOULD-CHANGE.COMunparalleled

Among the products on the stand will be the CM-36dG colour and

The equipment from the firm ranges from simple pass/fail instruments up to colour matching, formulation, dosing, and QC throughout global supply chains.

| QUICK MOULD CHANGE SOLUTIONS measurement performance across a wide range of converting Whenapplications.”integrated with NDC’s highperformance single-beam scanners, such as the new SlimTrak II, and Pro.Net TDi web gauging controller, users can perform ultra-accurate measurements of moisture, coat weight, degree of cure and film/ layer thickness across a wide range of converting applications such as extrusion, coating and lamination, according to NDC.

Devices on the stand will be connected to the group’s Colibri Platform, showcasing how digital colour data can help producers formulate colours, effectively optimise and correct formulations, share colour data with sites and suppliers through a single software and secured database.

Digital colour data helps stakeholders in a given supply chain to. collaborate on colour design, approval and QC, removing subjectivity. This is really useful, especially for those in the packaging supply chain, looking to integrate recycled polymers or reuse waste whilst maintaining colour accuracy. The platform contains several features developed to simplify the process of seamlessly and cost effectively integrating recyclates.

Meanwhile, Konica Minolta Sensing Europe (hall 11, stand F68) will be demonstrating a range of instruments and software for digital colour data management for masterbatch producers.

Thierry Rottiers, Manager Corporate Sales, Konica Minolta Sensing Europe, said: “K represents a fantastic opportunity to access a huge breadth of experience from across Konica Minolta. Our Application Engineers are working every day to set up, optimise and train digital colour data systems all throughout EMEA regions so I am confident that visitors to the stand can get practical help and advice.”

The TS-1000 from Inpak Makina

NDC Technologies (hall 10, stand G28) is debuting several new products at this year’s show.

The CM-36dG colour and gloss benchtop spectrophotometer and the CM-26dG colour and gloss portable spectrophotometer. 2022: machinery report

gloss benchtop spectrophotometer and the CM-26dG colour and gloss portable spectrophotometer.

The firm also promises long-term stability from the Series 9, with “no need” for recalibration, systematic monitoring or correction for drift Also new is the firm’s DataFusion software for real-time visualization of quality measurements. “This powerful software platform lets you harness measurement data from film extrusion, coating and lamination lines and transform it into actionable intelligence”, said a statement from the company. It works by collecting quality measurements of thickness, weight, moisture and coat weight from film extrusion, coating and lamination lines and pipes it to an SQL database. Measurements can be either fixed point or scanning.

The aim with the TS-1000 has been to achieve increased production output with less overall costs.The company operates in a production area of 6000 m2 with a production capacity of 50 machines per year, and continues to grow to meet increasing demand. Inpak has exports in 46 countries across 6 continents.“Happycustomers are our priority. From our customer feedback we are able to monitor our position in the thermoforming industry and we see this by the increase in order volume and repeat orders from our existing customers from around the world”, said Inan.

The Series 9 Converting gauge.

njection moulders today face more serious challenges to success than ever in recent memory. There is heightened pressure to ramp up production levels to meet rising demand even as the resources to do so are limited. The shortage of even non-skilled workers, not to mention those with technical knowledge and experience, became especially acute during the Covid-19 pandemic, and has not improved much since. Supply-chain issues have made it difficult and/or expensive for moulders to increase production capacity even as plant-floor space constraints limit their potential to expand. All this, while profitability concerns place a premium on increased quality and efficiency.

Think about the current labour issues. For moulders having difficulty finding skilled operators, process engineers, or maintenance technicians, automation can almost certainly help increase productivity, efficiency and quality. Automation almost always works faster and occupies less floor space than a manual operation. Robotic systems also can operate 24/7 and can offer a consistency that manual operation cannot. The

ABOVE: One solution to the automation challenge facing moulders today could be production cells like this one, but they will require a highly integrated control system.

OF ROBOTIC AUTOMATION OF INJECTION MOULDING Expl ring the future

was coined by Ford Motor Company in 1948, will be a major theme when K 2022 opens its doors in Dusseldorf in October. For injection moulders, the industrial robot, the icon of automation, will be front and centre. They won’t look much different than they did at the global plastics trade show three years ago, or even ten years ago, but what they can do and how they can interface with moulding machines and peripheral equipment of all kinds will be wonderful to behold.

WORDS | Charles de Forges, CEO, Sepro Group

Robotic automation is also important in the production of parts that have delicate surface features, are comprised of softer materials, and/or have critical dimensions that must be maintained during the moulding process. Any uncontrolled interaction with humans can damage a part or decrease its quality. Many medical or high-end electronic parts are particularly susceptible to contamination through human interaction, so automation is essential.

added consistency in cycle time not only improves product quality, but also can help more accurately identify operating costs and forecast production output. Automation can help moulders become more competitive in almost any market.

automation at k

WHY IS ROBOTIC AUTOMATION SO IMPORTANT TODAY?

34 www.interplasinsights.com

Automation,impediment.awordthat

If there is a bright side to this situation, it is almost certainly this: not since the Industrial Revolution – the so-called Industry 3.0 – has technology brought to bear such a large arsenal of weapons to overcome these challenges. The automation weapons of today (Industry 4.0) are digital and they allow moulders an unprecedented level of control over their equipment, their process and their operational efficiency. Best of all, this same technology is getting much easier to implement, meaning that the lack of skilled technicians need not be an

BELOW: Sepro Group is developing controls that not only govern the operation of multiple robots, but also drive peripheral equipment like the fixturing and packagingshowndeviceshere.

Processcell.

• Simplifying operations;

• Maximising overall equipment effectiveness.

For injection moulders, the industrial robot, the icon of automation, will be front and centre. They won’t look much different than they did at the global plastics trade show three years ago, or even ten years ago, but what they can do and how they can interface with moulding machines and peripheral equipment of all kinds will be wonderful to behold.

The human-machine interface will be getting simpler too, borrowing from smartphones, videogame controllers and other devices that the current generation of operators and technicians are already familiar and comfortable with.

Today, Sepro engineers are working toward what they call “no-code” programming, with the robot controller using artificial intelligence (AI) to recognise process details and help fill in the blanks to complete a final operational sequence. The controller will be able to communicate with all the equipment in a production cell including the IMM, robot(s) and peripherals that perform secondary functions like assembly, marking, packaging, and so on.

CONNECTIVITY SUPPORTS EFFICIENCY Sepro began connecting its controls with other systems more than ten years ago, when it started partnering with major injection-machine makers to allow virtually seamless integration of the robot and IMM. This connectivity has been improved and extended so that, today, Sepro Visual controls readily communicate with moulding machines and also manage the operation of all the other peripheral equipment (mentioned above) that comprise a truly integrated moulding

WHERE IS ROBOTIC TECHNOLOGY HEADED?

Sepro Group, a leader in injection moulding automation for over 40 years, is again breaking new ground in the area of robot and automation control. Its work in recent years and vision for the future of robotics focus, in particular, on two areas that have the potential to help moulders meet their current challenges. They are:

A robot (or more than one) makes it possible to do more value-additive operations right at the moulding machine, placing inserts before moulding, enabling efficient overmoulding and retaining control of parts through post-mould operations and even into final packaging. With everything done in one manufacturing cell, there is no need to ship parts to and from warehouses for secondary processing. Automation limits processing variables and decreases errors and defects too.

data gathered through these connections can be used to support the machine learning that is necessary for simplified no-code programming discussed previously. But there’s more to it than that. The control gathers huge amounts of process and performance data from all components in the cell – including IMMs – regardless of the type of device or its manufacturer. This makes it possible to recognise patterns and predict equipment and process events and outcomes. Eventually, this will enable robots to actually adjust themselves and optimise process behavior and outcomes automatically. These kinds of capabilities will prove essential as moulders work to maximise equipment and plant effectiveness, leading to increased productivity and profitability.

WINNING THE ROBOT AUTOMATION CHALLENGE

35www.interplasinsights.com

For all of the benefits that robotic automation offers injection moulders – including, but not limited to, those delineated above -- there have been some impediments that have limited more widespread implementation. Chief among these is the fact that programming and operating a robot can be technically complicated. Some 20 years ago, Sepro pioneered easier robot programming with its Visual controller, which includes a Simple Pick & Place feature. Even a relatively new employee with limited training could use this system to set up a basic mould-release cycle.

The Sepro stand (Hall 12, stand A36) at Messe Düsseldorf will feature two operating moulding machines, five robots and a range of other peripheral equipment, all operating in cells that highlight advances that injection moulders can use to overcome today’s toughest challenges. The moulding cells will employ a new modular software architecture that enables the control of multiple pieces of robotic and auxiliary equipment via a single central control system. They will be interactive and visitors will be encouraged to take control of Sepro robots and see for themselves how easy-to-use these systems can be. At the same time, Sepro engineers will be watching carefully to see how people respond and react to these technical novelties so that this feedback can be used to help focus development efforts as they continue in the years to come.

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RAFTER-SCRAPING BLOWN FILM MACHINERY

You may be used to the warm smell of the sheet extrusion process, but those of us who sit in offices most of the time don’t get to experience it so often. When we do, it never fails to make an impact – as does the sight (and the height) of the machinery, as well as the logistics and the engineering that goes into transporting and reconstructing such immense technology. Don’t miss Hall 17 and exhibitions from Windmöller & Hölscher and Reifenhäuser if you want to be blown away!

IT’S

FUTURE LAB

THE MARCH OF THE ROBOTS

THE CIRCULAR ECONOMY FORUM

DuPont, a household name well-known for its innovative material developments, will present Future Lab from Hall 6, Booth C43 all day on day one (19 October). DuPont’s materials experts will guide visitors through the up-and-running projects shaping the future.

Italy-based plastic pipe processing machinery specialist SICA S.p.A is celebrating 60 years of growth throughout 2022, culminating in an on-site event in Hall 16, Booth F18.

RECYCLING GETS SMART

K 2022 TOP 10 10. 4. 8.9.I 7.

Escape the noisy, dusty halls and head outside for the Circular Economy Forum, where some of Europe’s big names in injection moulding and recycling machinery will exhibit in co-operation with materials handling specialists to showcase the best of recycling partnerships. Watch out for Austrian start-up plasticpreneur – part of the Erema Group – which handcrafts portable equipment to enable small-scale recycling in remote locations.

Recycling and the circular economy may have played bit parts in previous iterations of the K show. This year –thanks to digitalisation and Industry 4.0 – visitors can get excited about the progress made since 2019. As an example, don’t forget to drop in to Hall 11, Booth C39 to witness Hellweg Maschinenbau’s Smart Control system for its granulator range, and its digital central lubrication unit with Bluetooth data transmission.

K-OUNTDOWN

With Industry 4.0 continuing to make progress in advancing manufacturing precision and efficiency, the latest in robotic technology will be abundant throughout the event. Make sure to find time to venture into Hall 12 where the robotics machinery specialists will be located, including leading names such as Sepro, Beck Automation, Campatella, TecnoMatic, Wittmann Technology, and IML Solutions.

BIG NAMES – BIG BOOTHS

Who doesn’t love a large and well-designed trade fair booth? If K 2019 is anything to go by, look out for those operated by Reifenhäuser, Sepro, Lyondellbasell, BASF, Covestro, ENGEL, Arburg, SABIC and LANXESS – to name just a few – but don’t overlook the smaller, equally eye-catching booths.

The BPF, in co-operation with the UK Department for International Trade (DIT), has reserved a unique space for UK exhibitors to gather – whether a start-up or multinational company, British attendees can share values, experience and ideas. DG Philip Law says: “The DIT British Visitors Networking Area is part of the British Pavilion this year and we encourage British visitors to make use of this space for their meetings with potential future business partners.” The space will open with a drinks reception on 19 October in Hall 5, Booth A28.

THE BRITISH VISITORS NETWORKING AREA

60 YEARS OF SICA S.P.A

3.2.1.

The K Show is a festival of plastics and machinery, and what festival would be worth going to if not for a good old-fashioned boat party or two. Interplas – K’s British cousin – will be on the Rhein as the UK’s biggest plastics and rubber trade event prepares to celebrate 75 years of business and innovation. Visit interplasuk.com to book your ticket. Old enough to be someone’s granddad, but still able to kick it big time on a boat.

37www.interplasinsights.com

What better environment for the leaders of the European Supply Chain’s big hitters to come together and discuss the state of the plastics industry. With the authoritative publication Plastics – The Facts adorning the shelves of manufacturers everywhere, expect speeches from Virginia Janssens, Marco ten Bruggencate, and Lucrèce Foufopoulos-De Ridder.

VectorExtensometer THE FUTURE OF EXTENSOMETRY Easy to use More efficient R +/-obust100mm tolerance Fantastic roi www.tiniusolsen.com Your global plastics test and inspection partner Whether you are a resin supplier, recycler, manufacturer or laboratory, our range of polymer testing equipment will cover all your sample preparation and mechanical testing needs. Try the range • Density testing • Impact testing • Melt flow testing • Sample testing • Strength testing info@industrialphysics.comindustrialphysics.com theShowcasing NEW fromImpactFallingInstrumentedWeightTesterRay-Ran Find us at hall 10, booth G31

K 2022: materials report

electronics, automotive, textile, and transportation markets, and is developing new products for these systems. During the last two years, Tolsa has completed extensive testing with PA matrices using a range of ADINS products, and K 2022 comes at the perfect time to showcase these developments to the world. Following a period of extensive stay-at-home preferences for many, these developments could not only increase the safety of electrical products, but the hygiene of plastics-based surfaces on furniture and toys, for example.

Oneothers.of

Modern Dispersions

Exhibitors have been encouraged to showcase their sustainability credentials during K this year, and Zotefoams (well-known for its packaging materials solutions) will take up the call by introducing the first selection of materials in its Ecozote Sustainability foams range. These are designed to meet the need for plastic products that improve circularity or reduce reliance on fossil-based materials.

t’s obvious that the majority of material innovations will have been developed with the circular economy for plastics in mind – whether in mono-material packaging applications or the ability to reuse flexible packaging, exhibitors will be keen to promote their recycling and recyclable solutions. So, why not start at home with Suffolk-based Chase Plastics’ Recothene solution that enables the reuse of polyethylene film packaging used in the shrinkwrapped transported goods sector?

certain property enhancement features including electrical and thermal conductivity, increased tensile strength, and improved barrier properties for fibres and films applications.

ROB COKER HIGHLIGHTS SOME OF THE EXCITING MATERIAL-BASED INNOVATIONS WORTH EARMARKING FOR A CLOSER LOOK – OR TOUCH – WHILST VISITING K 2022.

the developmental grades contains graphene oxide, which is undergoing testing to assess Spain-based Tolsa S.A. has improved the safety of flameretardant materials by incorporating its specialised ADINS range of additives for PP, PVC, rubber and silicones – and now for PA Tolsamatrices.has translated its ADINS FR technology to nylon (PA) matrices for applications in electrical/

Chase Plastics CEO Johnstone Smith is keen to clean up this material from the numerous industrial estates across the UK: “The world has woken up to the urgent need to rethink how transit packaging is handled at the end of its life,” he said. “Many businesses can support the transition to a circular economy through ensuring their used polythene is sent for recycling.”

Visiting Düsseldorf from Massachussets, USA, Modern Dispersion Inc., a thermoplastics compounder and masterbatch producer, will be exhibiting its latest developments in nanocarbon technology, which has been designed to boost the performance of masterbatch in compound solutions for use in automotive and construction applications, amongst

Technology Director Dr Karl Hewson said: “The challenge for Zotefoams is the sheer diversity of the markets we serve: In product protection, and notably single use packaging applications, the hierarchy of waste (reduce, reuse, recycle) is the key driver for sustainability, while in commercial aviation, reducing fuel consumption through lightweighting is imperative to meet 2050 targets for carbon reduction. Ecozote has been conceived to help customers address these diverse interpretations. LDR18 and LDR27 with 30 per cent recycled content are part of the first Ecozote product line driving plastics circularity, with more to follow.”

39www.interplasinsights.com Your Sustainable Solutions Provider from Design to Production

when it was introduced, and is still the most used hightemperature polyamide today. Its high-temperature mechanics and distinguished wear and friction resistance make it suitable for high-temperature applications in automotive, electronics and consumer goods industries.

Always among my favourite booths at any trade event is specialty chemicals company LANXESS. Its smart, stylish booths are not only eye-catching but filled with the

40 www.interplasinsights.com Your Sustainable Solutions Provider from Design to Production

New Tepex composites based on recyclates or bio-based raw materials will be exhibited, TepexandwhichTepex dynalite Scopeblue 813,inlcudingisproducedfromflaxfibresPLA.AlsoonshowwillbeadynalitewithaPA6matrix

The High Performance Materials business unit will be on site to discuss sustainable material and lightweight solutions, component concepts for consistent lightweight construction in the future market of electromobility, and lightweight structural components based on the continuous fibre-reinforced composites of its Tepex brand.

that consists of more than 80 per cent sustainable raw materials.

Roeland Polet, President DSM Engineering Materials, said: “The launch of Stanyl B-MB is an important step forward for our industry. With the same specifications and performance but with a 50 per cent lower carbon footprint, this new portfolio will enable our customers to fulfil their sustainability goals and contribute to a planet-positive future.”

K 2022: materials report

With a similar focus on sustainability – and with an equal claim to the ‘favourite booth’ accolade – Covestro’s always colourful presence will exhibit material solutions fit for the ever-growing demand for sustainable industries such as emobility and renewable energy. ‘Plastics will play a central role in all these in the future,’ Covestro predicts.

Stanylsustainability.B-MBredefined polyamides

Does that not sound like an invitation to the Zotefoams booth where visitors can get touchtight to some lightweight and recyclable material options? Alongside Ecozote, Zotefoams will also present its range of technical block foams, spanning its AZOTE polyolefin foams range – which includes ZOTEK high-performance foams produced from engineering polymers and the long-serving Plastazote PE foam.

DSM Engineering Materials will launch a new, more sustainable version of its flagship product Stanyl: Stanyl B-MB (Bio-based Mass Balanced) at K 2022. An industry-first launch of a 100 per cent bio-based high-temperature polyamide underlines the business’s ongoing commitment to

wonder of plastics for engineering purposes. K 2022 will be no different as this year, and under the motto ‘Quality Works’, LANXESS will be focusing on sustainable material solutions for the emobility sector.

inpakmakina.com.tr Rethink – Reuse – Recycle – Renew RELIABILITY IN QUALITY PERFORMANCE&FORSUSTAINABLEPACKAGINGPRODUCTIONINPAKTHERMOFORMINGMACHINES 3E30 TSR-800 (In-mould cutting) TS-1000TS-850TS-800 800 mm x 580 mm 800 mm x 580 mm 850 mm x 650 mm 1000 mm x 750 mm MAX. MOULD DIMENSIONS

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Potting throughshock,electroniccommonencapsulationandaremethodsusedtoprotectandLEDassembliesfromvibration,andtheenvironment.Inapplicationswhereitisimportanttobeabletoseethematerial,manufacturerstypicallyspecifyanopticallyclearproduct.

Once the design engineer has established the level of protection needed and what testing will be required to assess for it, they can begin to narrow down appropriate chemistries that achieve the desired hardness, clarity, resistance to yellowing, and process benefits.

Kevin Brownsill, Learning Intertronics,curingequipment,DevelopmentandManageratadhesives,dispensingandspecialistexplorestheconsiderationswhenspecifyinganopticallyclearcompound.

electricals & electronics

SPECIFYING AN OPTICAL ADHESIVE

There are multiple chemistries of optically clear encapsulant and potting compound available including UV acrylics, silicones, epoxies, and polyurethanes (PUs). It is important to note that there is no perfect adhesive, all materials come with advantages and disadvantages that must be weighed up. However, polyurethanes are typically recommended as the first chemistry to test, as they are versatile, reasonably priced and have good UV resistance i.e. they can be formulated to be nonyellowing and colour stable. Cured, they can be quite resilient or very hard. Our most popular polyurethane products are the Opti-tec 4000 and 4200 range.

such as lighting for war ships, may need to consider Mil-SPEC testing of physical characteristics relating to operational durability, ruggedness, and reliability. If the optical adhesive is being designed into a medical device, the designer will need to consider meeting ISO 10993.

ometimes, the circuitry can’t remain hidden. The biggest application for optical potting compounds these days is when the circuitry contains LEDs for illumination, which can be in anything from traffic lights to torches. Another reason for using an optical potting compound is when the electronics contains indicator lights or displays, and these need to be seen. Sometimes, light needs to get in, for a sensor. If these circuits require protection from the elements, then there are two main choices – seal them into an enclosure with a clear window, or pot them with a clear resin.

ENVIRONMENTAL PROTECTION

Manufacturers may need to protect electronic assemblies from dust, debris, moisture, pressure, impact, vibration, and chemicals. The level of protection required from potting or encapsulation depends on the final environment in which the product will function. Underwater swimming pool lights, for example, will need to be fully waterproof to IP68, as well as resistant to chlorine and other chemicals, whereas indoor lighting will require a lower level of water resistance. Potting compounds may require to be hard or scratch resistant of they might be walked on or subject to potential vandalism, forAsexample.wellas assessing the environment, the design engineer can consider the sector the product will be supplied into. Companies that supply into military assemblies,

43www.interplasinsights.comwww.interplasinsights.com

One drawback of PUs is that they are sensitive to moisture before cure, so must be kept dry during storage and application. Polyurethanes are hygroscopic and POT FOR THE CURE

Pisces, a sophisticated kit of ten LED lights that fits onto fishing gear to enable more precise fishing

Silicones offer good clarity, are suitable for potting large areas, and are relatively soft when cured, which can be advantageous for products in environments that are subject to extremes of shock or temperature. They are available in gel formulations, where they retain a jelly-like consistency even post cure. They are UV resistant and tend not to discolour, while offering good temperature resistance of up to 200˚C.

BUILDING A PROCESS

For small area and shallow encapsulation, UV cured acrylics may be a good candidate to trial. They are single part, easy to handle, fast curing, and, compared with room temperature alternatives, reduce work in progress (WIP). One option is Dymax 9000 Series Encapsulants, which have high ionic purity, excellent adhesion, and resistance to humidity and thermal shock to effectively protect components. For applications where shadow areas are a concern, the Dymax 9100 Series offers a secondary moisture cure.

PU, silicone, and epoxy potting compounds are predominantly two part materials, which means you will need to ensure the materials are mixed correctly and dispensed accurately. An experienced adhesives provider can talk you through setting up a repeatable process.Available process options range from manually mixing and dispensing from a twinpack, dispensing from a cartridge through a static mixing nozzle, right through to metering, mixing and dispensing equipment, fed from bulk containers. For applications where the highest accuracy is required, a preeflow eco-DUO precision metering, mixing and dispensing system offers accuracy of ±1%, >99% of the time.

Epoxies are a cost-effective option, which offer high temperature and chemical resistance and perform well in salt water or mineral/oil-based environments. However, they tend to yellow with exposure to UV/ energy, and so are typically selected for applications where yellowing is not as important as other properties. Epoxies are often used for smaller applications, as their exotherm during cure in larger volumes can lead to a loss in clarity. In one recent example, a customer was experiencing yellowing when using 2 ml of epoxy for potting during the assembly of lighting for emergency vehicles. We recommended they switch to a PU, which resolved the problem.

When specifying an optical adhesive, considering the packaging your material will be supplied in can impact your process as well as your costs. For smaller runs, cartridges or twinpack sachets are a more suitable option, whereas for high volume applications, bulk containers might be more efficient.

readily absorb moisture from the air, which reacts to form a gas. Consequently, they are packaged in airtight containers and/or with desiccants. Taking care in han dling the materials in accordance with the manufactur er’s recommendations can prevent problems later. PCB assemblies to be protected with PU compounds may need to be baked-out to ensure they are dry. Best prac tice would suggest cleaning of contaminants, drying, and allowing parts to acclimatise before processing, as well as ambient temperature control during processing.

A DEEP SEA FISHING APPLICATION

44 www.interplasinsights.com

Intertronics recently assisted a sustainable fishing start up, SNTech, with the development of Pisces, a sophisticated kit of ten LED lights that fits onto fishing gear to enable more precise fishing. Pisces was rated to 20 to 30 bar pressure (around 250 metres), and SNTech’s team was developing a new model for use at 1,000Themetres.device works by exploiting a natural behavioural response of fish — different colours of light will attract some species of fish, while scaring others away. The correct wavelength of light is essential to how the product functions, making optical clarity important for material selection. Because the potted resin would form part of the outer surface of the device, the material needed to be scratch resistant, UV resistant, capable of withstanding thermal shock, salt water, and more. Following testing, the material that best met SNTech’s criteria was the optically clear Opti-tec 4210, a two-part, high hardness, room temperature curing polyurethane resin. Opti-tec 4210 has Shore D80 surface hardness, and boasts excellent long-term UV stability for outdoor use due to the incorporation of UV stabilisers and antioxidants. The resin has high mechanical strength, and its low viscosity makes it easy to mix and process. Based on both the commercial and technical conversations with Intertronics, the team at SNTech chose to incorporate both Opti-tec 4210 and IRS 3071, a black polyurethane potting compound, into itsSpecifyingdesign. an optical encapsulant or potting compound is a complex process, based on the environment, sector, and application your product will be supplied for. Considering your choice of optical encapsulant or potting compound early in the process, rather than later, can help increase the chances of the product passing the environmental testing and qualification phases. An experienced supplier can guide you through this process, helping you develop a reliable and repeatable process.

The correct wavelength of light is essential to how the product functions, making optical clarity important for material selection. is important to note that there is no perfect adhesive, all materials come with advantages and disadvantages that must be weighed up.

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And it’s not just moulders, toolmakers are reaping the benefits too. Make UK reports that 42% of manufacturers surveyed in 2022 has increased its suppliers in Great Britain. It’s been said that the ‘just in time’ model is a thing of the past. Quality moulds, and quality moulding services, with reliable supply chains, are able to offer ‘just in case’ scenarios that simply can’t be matched by companies on the other side of the world.

A BEGINNER’S GUIDE TO RESHORING YOUR PLASTIC INJECTION MOULDING…

We hope to publish a more full, comprehensive guide in the new year – reach out to me on david. gray@rapidnews.com if you’d like your services to be included. If you’re reading as a brand owner considering bringing parts of your supply chain to the UK, I hope you find this useful. Similarly, if you’re at the start of your product development journey, you’re bound to find reliable partners in the pages within.

contract injection moulding & reshoring

WHILE

As Neil Bathard at Romi Machines UK told me recently, “We have seen a renewed interest in the domestic market for our new machines, due to reshoring and increased taxes brought about by Brexit. Companies are fuelling the growth of British manufacturing. The high-quality products the UK market is capable of producing gives investors peace of mind, not to mention control over their supply chains, and, of course, over their cashflow.

ccording to an article in SHD Logistics, BNP Paribas reviewed units of 100,000 sq ft and above. The data showed that the first half of 2022 saw take-up of industrial manufacturing floorspace from manufacturing occupiers increase by 53% versus the same period in 2021. In fact it was the strongest first half since 2017 (which was a period of uptake following the EU referendum). So if the Brexit effect was already accounted for in 2017, it doesn’t take a genius to work out what’s causing this demand for space: it can only be supply chain-related reshoring. While Brexit still remains a factor in the trend, clearly the remarkable events of the period 2019-2022 are rapidly turning the wheel in favour of domestic Inmanufacturing.recentmonths,

OFFICE SPACES REPORTSOFACROSSREQUIREMENTLANGUISHING,THEACROSSUKARESURPLUSTOTHEUKINTHEAFTERMATHTHEPANDEMIC,BNPPARIBASREALESTATETHATTHEINDUSTRIALANDLOGISTICSLEASINGMARKETISBOOMINGHERE. Quality moulds, and quality moulding services, with reliable supply chains, are able to offer ‘just in case’ scenarios that simply can’t be matched by companies on the other side of the world.

46 www.interplasinsights.com

I’ve heard horror stories recently of tools being sent back from overseas partners, to be re-made here. On delivery and inspection, the tools are coming back faulty, damaged, even unusable. At a time when the industry is having to pass so much cost along to customers to account for rising energy prices, not to mention new taxes and levies, it can’t be sustainable to deliver a sub-standard product, and so bringing tools and manufacturing home is the best and most logical option. For me, it’s not about an excessive display of ‘British is best’ either, rather, it’s just what common sense dictates right now. And, one hopes, the increasing demand for skilled manufacturing here will create an even bigger jobs market, leading, in time, to a renewed push from the Department for Education and Skills towards uptake of engineering apprenticeships. But that’s another story…

For now, we’ve put together a brief guide to just some of the UK’s contract injection moulders and injection mould toolmakers. I’d like to thank the team at the BPF, who publish an excellent, wider list of all plastic manufacturing service providers in their member’s directory – a lot of the information over the next few pages was sourced from there.

our sister publication, InterplasInsights.com, has published multiple case studies from moulders investing in new equipment to try and keep pace with demand. While the situation isn’t all sunshine and roses (the energy crisis looms ever larger), there is no doubt that we’re in the middle of a strong period of regrowth for UK manufacturing.

CAPABILITIES

Thermoset

“ Faulkner Moulds are a rare breed in this field. Excellent quality, on time, every time, no exceptions. I have nothing but praise for this automotiveinDirector,Salestoolmaker.professional”andMarketingmanufacturerleisureandindustry» 25 years of specialising in complex tooling solutions » Design for Manufacture principles » Specialists in high production multi-cavity tooling with fast cycling » Medical, packaging, automotive, electronics and other sectors » Continual investment in technology and skills » Sodick spark erosion » 5-Axis Mikron high-speed graphite and hard metal machining centre » Fanuc wire erosion » Product design consultation service » Current SolidWorks and SolidCAM multiple licences » ISO9001: 2015 certification 01422 info@faulknermoulds.net371072faulknermoulds.net Three Times UK Toolmaker of the Year COMPANY NAME Taylor Engineering and Plastics Limited INDUSTRIES SERVED Niche Automotive, Public Transport, Medical, Vending, Amusement, EV Charging, Construction, Agricultural, Building and Material Handling SPECIALISMS Compact engineeredinjection,structural foam (110 – 2700 Tonne) and DCPD with part weights of over 44 kgs, cosmetic finishing. CONTACT O1706 www.tep.co.uksales@tep.co.uk714700

region: north west

are used in niche automotive, public transport, medical, vending, amusement, charging, construction, agricultural, building and material handling. To which we offer full technical and design support to ensure that the most cost-effective processes are utilised.

Since 1977 have provided a full solution in the provision of technical mouldings to domestic and international markets, from initial processes are thermoplastic compact injection and engineered structural foam (110 – 2700 Tonne machine range), plus DCPD with part weights of over 44 kgs. These are supported by our cosmetic finishing skills which includes high gloss paint and EMI/RFI coatings via robotic and manual paint lines in 4 of our manufacturing sites. Finished mouldings, where required, are converted into complex high-level assemblies for

ourOurclients.services

concept through to production.Ourmoulding

COMPANY NAME Faulkner Moulds Limited INDUSTRIES SERVED Medical, industrial,automotive,packaging,electronics,consumer. SPECIALISMS Plastic injection mould toolmaking, designed for manufacture. CONTACT 01422 www.faulknermoulds.netinfo@faulknermoulds.net371072 CAPABILITIES Three-times Plastics Industry Awards UK ‘Toolmaker of the Year’. Superb quality injection mould toolmaking. Over 25 years’ experience. Serving medical, packaging, electronics, industrial and consumer sectors. Specialists in complex tooling solutions and high production, multi-cavity tooling with fast cycle times. Caps and closures, twin-shot, overmoulds, unscrewing cores, collapsible cores. 1 million tool shot guarantee. Product development. Continual wireSodickhardMikronCapacityaccuracy.prototypingandlicences.SolidWorksandBespokeandfollowingISO9001:2015investment.certification,stringentqualitytestingmeasurementprotocols.projectmanagementcustomerservice.CurrentandSolidCAMmultipleToolmaintenance,repairmodification.3Dprinting,andtesting.MicronsHighlyinnovative.includesnew5-Axishigh-speedgraphiteandmetalmachiningcentre,sparkerosionandFanucerosion. region: yorkshire & the humber

48 www.interplasinsights.com contract injection moulding & reshoring Region/Name North East Injection Moulding Toolmaking Labone Castleside Ltd ✓ via 3rd parties www.labonecastleside.com North West Injection Moulding Toolmaking Champion Mouldings Ltd. ✓ www.championmouldings.co.uk Sanko Gosei UK Ltd. ✓ ✓ www.sanko-gosei.co.uk HT Tooling Solutions. ✓ www.httoolingsolutions.com Kavia Tooling ✓ www.kaviatooling.com Taylor Engineering and Plastics Ltd. ✓ ✓ www.tep.co.uk Yorkshire & The Humber Injection Moulding Toolmaking Advanced Plastics ✓ ✓ www.advanced-plastics.co.uk Faulkner Moulds Ltd. ✓ www.faulknermoulds.net Forteq UK Ltd ✓ ✓ www.forteq.co.uk PolyGlobal ✓ ✓ www.polyglobal.co.uk Malton Plastics (UK) Ltd. ✓ ✓ www.maltonplastics.com Rosti ✓ via 3rd parties www.rosti.com Midlands Injection Moulding Toolmaking Agentdraw Ltd ✓ ✓ www.agentdraw.co.uk Fenton Precision Engineering Ltd ✓ ✓ www.fentonprecision.co.uk Norton Plastics Ltd ✓ www.nortonplasticsltd.co.uk Petford Tools Ltd ✓ ✓ www.petfordgroup.co.uk Rutland Plastics ✓ ✓ www.rutlandplastics.co.uk CJ Tools and Mouldings Ltd ✓ ✓ www.cjtoolandmouldings.co.uk Fern Plastic Products Ltd ✓ ✓ www.fern-plastics.co.uk Goodfish Ltd ✓ ✓ www.goodfishltd.com Counterplas ✓ www.counterplas.co.uk Tekniplaz ✓ www.tekniplaz.com KA Tooling ✓ www.katooling.co.uk S&S Plastics ✓ ✓ www.ssplastics.co.uk Amies Plastic Moulders ✓ via 3rd parties www.amiesplastics.co.uk WHS Plastics ✓ ✓ www.whs-plastics.com MJ Toolmakers ✓ www.mjtoolmakers.co.uk

custom injection moulding services for over 75

invest in fromcompetitivematerialsWecleanLSR,IMD,specialistandgoals,technologies.cutting-edgeWhateveryourwehavetheexpertiseequipmenttodeliver.OurcapabilitiesincludeIML,multi-kinjectionmoulding,injectionblowmoulding,roomproductionandmore.cancost-effectivelysourceandmanagetooling,andtailoredsolutions,concepttoreality.

region: yorkshire & the humber

global plastic injection moulding company and contract manufacturer Get in touch: www.rosti.comsales@rosti.com Rosti Group CMYCYMYCMYMCK ROSTI AD 31st.pdf 1 30/08/2022 11:48 TEL: 01905 www.chessplastics.co.uk794405SpecialistsinLargePlasticInjectionMoulding COMPANY NAME Rosti Group INDUSTRIES SERVED Life science, consumer, energy, filtration, technical, business machines and packaging SPECIALISMS In-mould decoration, inmould labelling, injection blow moulding, clean room production, overmoulding, multi-K injection moulding CONTACT www.rosti.comsales@rosti.com

High precision injection moulding is at our core, delivering injection moulding and contract manufacturing in the consumer appliances, life science, business machines, smart home, energy and technical markets. We have

Europe, Asia

CAPABILITIES provided years. With decades of have the knowledge, moulding project. Rosti, an international company, has sites in and North America. Rosti has continued to develop and

skills, and tools to take on any injection

COMPANY NAME Chess Plastics Limited INDUSTRIES SERVED Automotive, industrial plant, leisure and construction industries SPECIALISMS Larger manufacturecomponent CONTACT 07837 www.chessplastics.co.uk395886 CAPABILITIES Chess Plastics Ltd is an IATF 16949 & ISO9001 certified plastic injection moulder, operating 21 modern machines from their 53,000sq ft site in the West Midlands. Established in 1968 the company operates machines from 500t up to 1400t all with 6 axis Abb robots ,with a maximum shot weight of 12kgs and tool sizes up to 1600 mm with weights of 20t. Our production facility operates 24 hours a day and can provide a full service from product design, tooling manufacture through to a selection of secondary operations and final assembly to customer specifications. region: midlands

industry experience and state-of-the-art facility moulding machines, we

50 www.interplasinsights.com contract injection moulding & reshoring Region/Name Midlands Injection Moulding Toolmaking Burnetts Manufacturing Limited ✓ via 3rd parties www.burnettsmfg.com Advanced Plastic Technology ✓ www.apt123.co.uk Aztec Tooling & Moulding Co Ltd ✓ via 3rd parties www.aztecmouldings.co.uk Peak Plastics Ltd ✓ via 3rd parties www.peakplastics.co.uk Andel Plastics Ltd ✓ ✓ www.andelplastics.co.uk Talisman Plastics ✓ ✓ www.talismanplastics.co.uk South East Injection Moulding Toolmaking Lettergold Plastics Ltd ✓ via 3rd parties www.lettergold.co.uk RGE Group ✓ ✓ www.rgegroup.com South East Injection Moulding Toolmaking BEC Group ✓ ✓ www.becgroup.com Boddingtons ✓ ✓ www.boddingtons.co.uk Velocetec ✓ www.velocetec.com Broanmain Plastics ✓ ✓ www.broanmain.co.uk White Horse Plastics ✓ via 3rd parties www.whitehorseplastics.co.uk Pentagon Plastics ✓ ✓ www.pentagonplastics.co.uk Data Plastics Ltd ✓ via 3rd parties www.dataplastics.co.uk South West Injection Moulding Toolmaking Merriott Plastics Ltd. ✓ via 3rd parties www.merriott.com ND Precision Products ✓ www.ndprecisionproducts.co.uk Tex Plastics Products Ltd ✓ via 3rd parties www.tex-plastics.co.uk Plastic Engineering Solutions Ltd ✓ ✓ www.plasticengineeringsolutions.co.uk Avalon Plastics ✓ ✓ www.avalonplastics.co.uk Scotland Injection Moulding Toolmaking Agentdraw Ltd ✓ ✓ www.agentdraw.co.uk Wales Injection Moulding Toolmaking Norton Plastics Ltd ✓ www.nortonplasticsltd.co.uk Petford Tools Ltd ✓ ✓ www.petfordgroup.co.uk Northern Ireland Injection Moulding Toolmaking CJ Tools and Mouldings Ltd ✓ ✓ www.cjtoolandmouldings.co.uk Fern Plastic Products Ltd ✓ ✓ www.fern-plastics.co.uk

THE NEXT GENERATION UK MANUFACTURER THERMOFORMING,OFPRESSURE FORMING BLISTER AND SKIN PACKAGING MACHINERY Email: info@ridat.com MACHINERY info@ridat.com674www.ridat.comFinchleyRoadLondon NW11 7NP England Tel: +44 (0)20 8458 6485 - OVER 60 YEARS OF EXPERIENCE IN THE DESIGN MACHINERYTHERMOFORMINGMANUFACTUREANDOF - OVER 70 MODELS IN THE RANGE - TO UNDERTAKEREADILY AND PROVIDE SOLUTIONSBESPOKE - RESPONSIVE AFTER SALES AND SPARE PARTS BACK-UP - UP TO 5 WARRANTYYEARS 80637 ridat advert 190x124.indd 1 01/09/2022 17:15

MIKE BOSWELL LOOKS AT THE REALITY OF SHORTAGESGAS

Mike Boswell is Managing Director of UK materials distributor, Plastribution, as well as the Chairman of the British Plastic Federation’s Europe)compiledused‘Polymerman’itsDistributorsCompoundersPolymerandGroupand‘BREXITCommittee’.isthetitleforannouncementsmadeviahisTwitteraccount.ThiscolumnisusingdatafromPIE(PlasticsInformationwww.plastribution.co.uk|www.pieweb.com

he constraints on Russian natural gas supply to continental Europe is a cause for serious concern; not only in terms of how the highly restricted supply via the Nord Stream gas pipeline to mainline Europe is impacting price, but also on the availability to consumers who are highly dependent on gas as a primary source of energy. In particular, it is the lack of interchangeability between natural gas and other energy sources at a time when European demand for gas escalates as the demand from homes depending on gas for heating increases, with further uncertainty coming from the severity of winter that will arise. If gas supply becomes critical and it comes down to a choice between gas for heating versus gas to supply industry, then there is little doubt that authorities will prioritise supply for domestic and civil users and restrict the supply of gas to energy intensive applications deemed not to be critical.

ACROSS EUROPE ON RESIN SUPPLY.

Once again it appears that the European plastics sector faces another period of uncertainty, within which the consequences are largely unknown, but as we have seen over the past few years the UK plastics processing sector is robust, adaptable and capable of meeting changing demand needs.

Who ‘Polymerman’?is

GAS SUPPLY SHORTAGE IMPACT POLYMER SUPPLY AND DEMAND?

52 HOWwww.interplasinsights.comCOULDAEUROPEAN

Restricted gas supply to industry is likely to impact the petrochemicals sector in Europe, where sites such as Ludwigshafen are amongst the biggest consumers in the region. Whilst supply of standard polymers such as PE, PP, PS, PET and PVC is international in nature and therefore any production shortfall could be met through increases in imports from other regions of the world, it is the more specialist materials that are likely to be impacted if European production is shuttered. This restriction in supply could push the supply/demand balance towards shortage with the inevitable consequence of price inflation.

A less obvious implication of restricted gas supply is the potential for increased plastics usage if the output from gas-dependent, energy-intensive manufacturing process such as glass, aluminium and steel become restricted, either through supply constraints and/or economics. Not only does plastics have an advantage in terms of lower energy intensity in the conversion stage, but plastics processing is mainly dependent on electricity which is not going to face the same availability constraints as gas. If this situation does arise then demand for bottles, containers, and pouches for FMCG applications could increase significantly as manufacturers look for alternate packaging for their products.

Herbold

www.frimo.com FRIMO. HIGH TECH AND HIGH PASSION. We love forming customized production solutions. Our technologies offer innovative options to make decorative surface production more efficient and user-friendly. THERMOFORMINGThe FRIMO Augmented Reality App –exciting 3D views of our technologies! PERFECTVARIETY.Visitus!K2022Düsseldorf,Germany19th–26thOctober2022|Hall13/C602022

Meckesheim GmbH Your partner for plastics recycling www.herbold.com Size Reduction See our innovative full-sized machinery at our Booth B34 in Hall 9 at K 2022 which are part of our modular system solutions for customized plastics recycling Agglomerationplants. Drying We have a long lasting expertise in separation, size reduction, washing, drying and agglomeration - to recycle new, used, mixed or contaminatedVisitplastics.us at K 2022 in Hall 9, Booth B34

There is both a hidden and a visible impact of plastic pollution. The visible impact is the clogging of water bodies and hygienic issues caused by litter in the streets. The invisible impact is far larger – fisheries that contribute to around one per cent of the GDP and employ around 14 million people is in danger as the water bodies become clogged with plastic, killing the aqua and marine life. Climate changes fuelled directly and indirectly by the plastic pollution threatens the farming community which employs – directly and indirectly – around 50 per cent of the population. Tourism is another area that is being severely impacted. Tourism, which contributes around five per cent of the country’s GDP and employs around 15 per cent of the people, could be seriously impacted by plastic pollution.

HOW IMPORTANT IS THE PLASTICS RECYCLING SECTOR TO INDIA’S ECONOMY, AS WELL AS ITS NATURAL ENVIRONMENT?

Plastic has now taken such a centre-stage for the government to combat at such a large scale, we are hoping that it would help us in spreading awareness about the plant, the process and the product.

IS YOUR FEEDSTOCK SOURCED FROM THE JAIPUR REGION ALONE OR NATIONWIDE?

The PET bottles are recycled and converted into fibres which are further used to create yarns and are sold to markets in India and around 70 countries worldwide. These yarns work as starting

ROB COKER SPOKE TO CHIEFDIRECTORMANAGING JHUNJHUNWALARIJU TO FIND OUT HOW.

This is just the tip of the iceberg. The real impact could be worse as more and more industries are connected to each other in today’s connected world.

According to The Central Pollution Control Board (CPCB), India, the plastic waste generated is around 3.5 million tonnes per year. Out of this roughly around 12 per cent is incinerated and 78 per cent goes to landfills. Plastic waste is blocking the drainage systems, threatening marine life and generating health risks for residents. It is a big menace for the nation and costing the country billions of dollars every year in terms of lost opportunities in ecotourism, increasing the potential for climate changes and thereby unleashing the wrath of nature, resulting in droughts and floods. Therefore one of the biggest challenges faced by India is to recycle its plastic before it pollutes its water bodies and causes irrevocable damage to the naturally endowed tourism destinations in the country. India has recently passed a resolution banning single use

are able to convert this threat into an opportunity. Opportunity to create value out of waste and generate employment – not just in textiles, but also in ancillary industries like waste collection and transportation. It’s a very tiny beginning but with greater acceptance and awareness, this could become a global phenomenon supported by India. And then it could be a big boost to the national economy overall.

54 www.interplasinsights.com

The quantity of PET bottle that we consume is quite large. Therefore, it is not possible for dealers from the Jaipur region alone to meet our requirements. We collaborate with national suppliers and tap into national networks to meet our demands.

INTOLTDRECYCLERINDIA-BASEDPETBOTTLERSWMTRANSFORMSWASTEBOTTLESTEXTILESATANASTONISHINGRATE.

plastic to arrest the degradation caused by plastic We,pollution.however,

HOW BIG A PROBLEM IS PLASTICS POLLUTION CURRENTLY IN INDIA?

WHAT IS THE RECOVERED PET BOTTLE RECYCLED INTO EXACTLY AND IN WHICH MARKETS ARE THE PRODUCTS SOLD?

The Indian company converting 125MT of PET bottles into yarn

country focus: india

www.interplasinsights.com/bpr

BRITISH PLASTICS & RUBBER

Connecting the industry

For over 45 years bp&r has acted as a central connection between the industry, those working in it, those supplying to it and those buying from it.

The essential publication for UK plastics and rubber processors.

TODAY

WE ARE IN Hall 15, Stand B24

Give your machine some this Christmas... With a scrap free start up 01656 644907 www.cjpsales.co.uk

The awareness will drive consumption and consumption will drive more recycling, which can motivate more and more companies to get in this segment and thereby more and more PET bottles can be recycled around the world and thus making the environment a safer place. It could be one of the biggest contributions we can make towards saving the environment. At RSWM we remove approximately 800,000 tonnes of CO2 annually from the environment.

materials for clothing, bed linens, curtains and other forms of finished materials. We are working with some of the leading brands around the world who source from us.

THERE MUST HAVE BEEN SOME GOVERNMENT ASSISTANCE TO ESTABLISH A FULLY AUTOMATED PLANT OF THAT SIZE AND CAPACITY IN JUST SEVEN YEARS?

process and the product. Also, help in making people aware that the garments they are wearing are manufactured from recycled PET bottles. Seeing our contribution to the economy and employment generation, the government should look into offering tax benefits or other rebates to manufacturers like us.

HOW MUCH RECYCLED PET (IN WEIGHT) IS RSWM LTD ABLE TO RECYCLE PER DAY/PER YEAR?

WHICH COMPANIES SUPPLY THE HIGH-TECH PROCESSING MACHINERY?

The plant is recycling 122 million tonnes of PET Bottles every day. It is operational every day of the year, which makes it a catalyst in recycling a fairly large amount of plastic waste. In numbers, we recycle close to 183 Crores (1,830,000,000) of PET bottles.

country focus: india

57www.interplasinsights.com

The plant was initially conceptualised to make RSWM Ltd. self-reliant. It was started at a time when we wanted to produce our own polyester fibre as we wanted to stop depending on external vendors for supplying the material. At that time, plastic was not viewed as a national problem as it is now. Therefore, we have not received any direct aid from the government. However, since plastic has now taken such a centrestage for the government to combat at such a large scale, we are hoping that it would help us in spreading awareness about the plant, the

IN WHAT WAYS CAN RSWM LTD PARTNER WITH AND LEARN FROM EUROPEAN COUNTERPARTS AND HOW DOES IT INTEND TO ACHIEVE THIS?

There are lots of companies who are supplying these machines. Some are from India while some are from around the world. The notable ones are from China’s Boretek, Shaoyong (CTMTC) and Shanghai Pacific companies. We also have some machines from Torsion Balance (Hungary) and Keisokki (Japan).

We are already working with a lot of global companies. Some of them are European as well. We are trying to promote the concept of yarns manufactured from PET bottles. We need to work on the awareness around the world for which we need platforms and exhibitions such as yours, government support so that there is a positive shift towards using yarns from recycled PET bottles, and consumers, who are consciously looking for these when they buy products.

The energy and carbon savings are made possible through reduced polymer melt temperatures, which results in lower heating and cooling energy requirements, plus cycle time savings from faster cooling. It enables embodied carbon to be reduced in moulded parts, while also becoming more productive with existing moulding machines.

Crucially, physical testing of parts moulded with and without Soniplas flow enhancement validates no change in moulded part physical properties. Similarly, before and after MFI testing also validates no changes to the moulded material properties.

USESONIPLASMANAGER,COMMERCIALMATRIXMOULDINGSYSTEMSLTD.,INTRODUCESTHESYSTEM,ANULTRASONICTECHNOLOGYDESIGNEDTOREDUCEENERGYFORINJECTIONMOULDERS.

operating conditions, enabling the system to ‘ring’, just like a tuning fork.

The flow enhancement reduces the injection pressure required, making the part easier to mould around complex tooling features. In addition, with injection pressure defining the clamp force requirement for a given mould, Soniplas can be used to reduce the clamp force requirement for a given tool.For those designing new parts and tooling, the technology provides an additional design freedom, enabling a downgauging of wall thickness, helping to satisfy those driven by the lightweighting or material saving agenda.

The low-power ultrasonic energy is only used to vibrate the molten polymer, with all material heating coming from the barrel heaters.

Systems are configured to give optimum performance for a range of different settings.

This scheme is preparing to announce its successful Phase three applicants and accepting applications for Phase Four now.

Each sonotrode and booster system is acoustically modelled to ensure resonance at the correct

The polymer melt is vibrated using transducers mounted within the melt stream, between the nozzle and the tool cavity.

The Soniplas system, a retro-fit system using ultrasonic energy to enhance molten polymer flow, was recognised with a BPF special commendation (Horners) award and Plastics Industry Award for Best Technology Application in 2021.

ANDY WATTS,

58 www.interplasinsights.com sustainability

For existing, difficult to mould parts with a high scrap rate, the system may be used to improve part quality and reduce scrap.

new technology with the potential to transform injection moulding has completed its pilot phase and is now on the market with promising results, including cutting energy use by up to a Thethird.Soniplas technology, created by Matrix Moulding Systems (a spin-out of The Technology Research Centre), was first demonstrated by Barkley Plastics over six months in 2021. During this time, it was found to cut energy use by 34 per cent and cycle time by up to 27 per cent, transforming both the profitability and productivity of injection moulding.Thesereductions are important from a sustainability and carbon savings perspective, but increasingly important for regulatory and commercial social responsibility. With spiralling energy costs at the forefront of moulders’ minds, energy reductions are another hugely important benefit.

It applies ultrasonic energy to excite the molten polymer, providing a temporary reduction in viscosity, which enhances the flow as it is injected.

Soniplas systems can be supplied in a range of formats to suit the application. Traditional cold runner tools are serviced through a fixed platen mounted system – a range of bolster sizes are available and can be specified by the customer. This format can also be used to run heated sprue bush tooling.Users may be able to integrate Soniplas into their hot runner systems, although this is likely to be more attractive for new build “Soniplas ready” tooling – something which Barkley Plastics is keen to offer other moulders from their in-house toolmaking facility.Thefirst pilot of Soniplas at industrial scale was supported by the Industrial Energy Efficiency Accelerator (IEEA), funded by the UK Government’s Department for Business, Energy and Industrial Strategy.Thisprovided funding and support for the technology to be installed at Barkley Plastics’ Birmingham site then to report on findings.

The energy and carbon savings are made possible through reduced polymer melt temperatures, which results in lower heating and cooling energy requirements, plus cycle time savings from faster cooling.

The low energy vibration of the polymer melt enables Soniplas to unlock the thixotropic (shear thinning) properties of polymer materials, and with ultrasonic energy being transferred into the melt with transducer amplitudes of just a few microns, the acoustic modelling of each transducer is a critical part of each system build.

THE FUTURE ULTRASONICIS

59www.interplasinsights.com WWW.KRAUSSMAFFEI.COM | PIONEERING PLASTICS

New milestones in latest Tetra Pak sustainability report

• Commercial validation of a andaluminiumbarrierpolymer-basedtoreplaceincartons;

I will continue to work for and with the members to ensure the survival and growth of the industry.

Incoming Chairman Dave Raine will be looking after this column and here’s what he has to say..As my first contribution to this article, I have to agree that 4 years

• Partnering to reduce food waste, change.”thenecessarypartnershipsandnewaction,industry.changeaheadtheOrivecarbonconsumptionwaterandfootprint.added:“IrecogniselongjourneyandthestepneededbytheCollectiveinnovation,operatingmodelsunconventionalwillbetoacceleratecurrentpaceof

• A land initiativerestorationthataims to restore up to 7,000 hectares of land by 2030 for changecapturerecovery,biodiversitycarbonandclimatemitigation;

INDUSTRY | NEWS

• Global school feeding programmes;

highlights the company’s achievements and ongoing initiatives – to protect food, people and the planet. These •include:Reduced operational GHG emissions, with 80% of energy coming from sources;renewable

COMMENT

The word from Hird

ow 4 years of the “Word from Hird” where did that go?

viewed retrospectively seems to have gone in a flash – however, the next 4 years looks like a very long time from this vantage point, and my hope is that I can do the role the justice it deserves and also follow in the footsteps of the past Chairmen, who have done a fantastic job for both the association and the industry as a whole.

• Investment in collection and recycling;

• Plant-based solutions;

RICHARD HIRD, CHAIRMAN OF THE BUYERSANDMANUFACTURERSMACHINERYPOLYMERDISTRIBUTORSASSOCIATION(PMMDA)ONTHETOPPRIORITIESOFTHEDAYFORSUPPLIERSANDOFPLASTICSMACHINERY.

As they say, all good things must come to an end and it is time to say, “good night from me, and good morning from him”, as I will pass the baton to the new Chair of the PMMDA at our September 2022 AGM.

Echoing everyonelookandofI’mgrowthensurewithcontinueholderswouldgenerations.quicklytoandiscreatedandtheanotherbattered,emergedandthroughandchallengeshascomments,Richard’stheindustrybeenbesetwithandissues,havingbattledborderchangespandemics,we’vebruisedandonlytofindchallengeinEastEuropeanissuetheenergycrisisit’s–Iguessthisthemodernworld,thingsaregoingchangemuchmorethaninpreviousFornow,mymessagebethat,likepastoftherole,Iwilltoworkforandthememberstothesurvivalandoftheindustrysoproudtobepart–it’sbothachallengeaprivilege,andIforwardtomeetinginpersonsoon.

As part of my role as Chair of the PMMDA I have had the enjoyable task of reflecting on the current state of affairs that the members of PMMDA and the plastics industry have experienced during this time.On reflection, I have to say that we are a very resilient and adaptable bunch, especially the way the industry coped (is coping) with Brexit and rose to the challenge that the pandemic presents, but most importantly the way that the Plastics Industry came together to celebrate achievementsourat Interplas and the PIA awards.

Tetra Pak has published its annual Sustainability Report highlighting the company’s achievements and progress in the last year and detailing the actions to help realise resilient and sustainable food Sustainabilitybetterandwhichtodependstomorrow.worldsustainabilityTheownpartnersourworkingthehaveinitiativesourtransformationtosaid:androlepackagematerialstransportation,andFromimpactwhilewaynewthechallengesThesystems.sustainabilityunderscoreneedforaradicalapproachtothetheworldisfedminimisingtheontheplanet.source,productionprocessing,totheusedtofood,andtheofcollaboration.AdolfoOrive,PresidentCEOatTetraPak,“Ourambitionisleadsustainabilitywithinindustryandourinthisregardcontinuedoverlast12months,togetherwithcustomersandtosupporttheireffortsaswell.costofinactionontodayisawewon’trecogniseOurprogressonbeingableembraceamindsetdrivesbothgrowthsustainabilityforafuture.”TetraPak’s23rdReport

given automation task in an injection moulding operation.TheViper 4 is designed tasks,parttoclampingmachinesonswiveldownstreamofmanipulationforweightsthreekilogramsoftheaxisandforuseinjectionmouldingwithaforceofup2200kN.InsimplepickingandplacingtheViper4achievesadrycycletimeof5.5seconds,withapickingtimeoflessthanasecond.

KraussMaffei to demonstrate maximum cleanroom efficiency

demands with a complete OMNI Recycling Machine featuring a new 3C Rotary Feeder, an MRSjump 70 extruder, a fully automatic melt fi ltration system RSFgenius 90, and an online viscometer VIS for the processing of 200kg/h (450lbs/h) of undried and uncrystallised polyester (PET) thermoform reclaim.

Eddy Current Separator will handle up to two tph of 0-15mm shredded plastic perfume bottle caps. Both the recovered aluminium and plastic will have purities exceeding 98 per cent.

Gneuss is ready to meet newrecyclingdemandstheofwithmachinery

At K 2022, KraussMaffei will be demonstrating how purity and quality are key to the production of sensitive products in medical technology, and how efficiency and cost-efficiency are also increasingly critical.Themachinery manufacturer will aim to demonstrate how its all-electric PX 200-1400 in a cleanroom design can achieve all four. Caps for insulin pens will be manufactured with maximum precision under cleanroom conditions, in short cycle times and with minimum use of resources such as energy and materials.AttheKraussMaffei booth (Hall 15, Booth C24-D24), each shot will yield 96 caps for polypropylene in a cycle time of six seconds and a shot weight of 105g. The PX 200 is part of KraussMaffei’s circular economy circuit at K 2022.

exhibiting at K 2022from Hall 10, Booth B01.

At K 2022, Gneuss will aim to reiterate how its Multi Rotation Section (MRS) Extrusion Technology is a proven alternative for the reprocessing of plasticcontaminatedmaterials. In combination with the Gneuss Rotary Filtration Systems (RSF) and vacuum formachinerydisplaylinestailor-madetechnology,recyclingcanbeengineered.Gneusswillalsoitslatestinnovationstoday’srecycling

Conducting tests at our Customer Experience Centre enabled us to understand the material and ensure that we could meet the separation expectations.

ENGEL demonstratewill how lowvoltage drive technology significantly boosts energy Availableefficiency.ineight sizes for nominal loadbearing belinear120kg,betweencapacitiesthreeandENGEL’srobotscanadaptedtothe

In combination with the Gneuss Rotary Filtration System and vacuum technology, tailormade recycling lines can be engineered.

Higginbottom, Bunting’s Sales “ConductingEngineer.the tests at our Customer Experience Centre enabled us to understand the material and ensure that we could meet the expectations.”separationBuntingEuropewill be

WWW.KRAUSSMAFFEI.COM | PIONEERING PLASTICS

ENGEL will use its exhibition booth to show how to save space and energy

RecyclingpassSeparatorsMagneticBuntingtheHMLtest

HML has installed two Bunting OverbandPermanentMagnets in their cable recycling process, and a Metal ModuleSeparationonanew wideInseparationtoCentreCustomercontrolgranulator.cableamagneticremovesmetals.separationtoentrappedthevibratoryisperfumefor recycling plasticslinebottlecaps.OneOverbandMagnetpositionedacrossafeeder,wherevibrationliberatesmaterialenabletocleanerofmagneticThesecondsteelandothermetalsfromshreddedcoppermixtoprotectaBuntingconductedtestsatitsExperienceinRedditch,UK,confirmcapacitiesandcapabilities.operation,the750mmDrumMagnetand

MACHINERY | NEWS

ENGEL extends its series of linear robots for K 2022 with the new viper 4. What is currently the smallest Viper model sees the Austrian injection moulding machine manufacturer and automation expert explore a new approach.

“The HML Recycling installation is another exciting project for Bunting,” said Tom

60 www.interplasinsights.com

People. Think. Plastics. Sustainable Products For a sustainable future K.D. Feddersen UK Ltd. Member of the Feddersen www.peoplethinkplastics.comGroup Your contact: Roberta Leech roberta.leech@kdfeddersen.com Andrew Pilling andrew.pilling@kdfeddersen.com Phone +44 1785 413389 OmniTest materials testers and VectorPro MT materials testing software Discover more mecmesin.com/omnitestat Powered by VectorPro MT Software +44 (0)1403 799979 info@mecmesin.com www.mecmesin.com • Intuitive drag and drop GUI for fast test creation • Touchscreen enabled • Extensive suite of calculations for materials testing • 5 models available: 5, 7.5, 10, 25 and 50 kN • Optional extensometry and full range of test ﬁxtures

Richard Sederman, Strategy and M&A Director said: “Reaching a 50/50 ratio is an incredible achievement not only for our team but for the wider plastics industry. We’ve demonstrated that the reliance on virgin plastics as a primary component is now an outdated

Essentra Components is now consistently achieving a 50/50 balance of virgin and post-consumer recycled plastics within its LDPE product range.

concept. Provided the wider supply chain can maintain consistent supply of high performing recycled content plastic recyclate, we can continue innovating and increasing these ratios, in turn improving the carbon footprint of both our customers.”processesmanufacturingandthatofour

Lily Wang, global head of the Engineering Plastics segment, added: “We offer a drop-in solution that can quickly and easily integrate into existing production processes without requiring any technical changes. The products show the same good quality as their Ascounterparts.”fossil-basedpartoftheCQfamily

The achievement means almost all LDPE products leaving Essentra’s facility at Kidlington in Oxford, will consist of 50 per cent recycled content. The milestone represents a step in making industrial plastics more environmentally sustainable by reducing the amount of virgin resin needed to produce products.

62 www.interplasinsights.com WWW.PLASTRIBUTION.CO.UK | EXPERTS IN THERMOPLASTICS

As part of its drive to reduce carbon emissions, Essentra Components has also experimented with higher percentages, and as the sourcing of recyclate continues to improve, will introduce them into its production lines in due course.

Covestro will now be supplied with the two mass-balanced raw materials phenol and acetone from INEOS’ INVIRIDIS product range. Covestro uses these to signifirawbalancedswitchingofCommercialapplications.andmedicallightforpartsItpolycarbonatehigh-performancemanufactureplasticforuseinautomotiveandhousingselectronicdevices,guidesandlenses,devices,otherhigh-endSuchetaGovil,ChiefOfficerCovestro,said:“Bytomass-renewablematerials,weaimtocantlyreduceour

Technical supplier CJP Sales, the stocking distributor for Lucobit EBA in the United Kingdom, says Lucofin, Lucobit’s ethylene butyl acrylate copolymer, can be used as an impact modifier and compatibiliser when used in polypropylene and polyethylene recycled compounds.Lucofin1400 MN is a polar can30%,the5%10%.ratesmouldingcompound,candensity.withethyleneandLucofiitslowandconsistingcopolymerofethylenebutylacrylatewithcrystallinity.Duetochemicalstructure,n1400MNissoftermoreflexiblethanhomopolymers,comparableLucofin1400MNbeaddedtotheoratthemachine,atbetween5%andThefirmclaimsaadditioncanimproveimpactstrengthbywhilea10%additionimprovetheimpact

CJP says Lucofin does not adversely affect the clarity at this level addition, but can show a slight weight advantage with a Density of 0.89%.

Lucofin improving impact properties in recycled compounds by 97% in injection moulded applications

strength by 97%.

MATERIALS | NEWS

With this achievement, Essentra Components has demonstrated the viability of recycled plastics within high-performance component parts.

Due to its polarity and wide 90-95flaextrusion,meltfoamcoatingcompounding,blownmarketacrossLucofitemperatureprocessingrange,ncanbeusedarangeofsectorsincludingandcastfilm,cableextrusions,production,hotadhesives,profileand,usedaspolymer,itgivesasoftexiblefeelintheshoreAhardnessrange.

Essentra Components achieves 50/50 ratio of recycled content and virgin plastics in LDPE range

indirect emissions in the supply chain and offer products with a reduced carbon footprint. In doing so, we’re helping our customers to meet their climate goals and advance the transition to a circular economy.”

of circular intelligent solutions, Covestro offers them under the names Makrolon RE, Bayblend RE, Makroblend RE, and ApecINVIRIDISRE. brand phenol and acetone are produced from bioattributed cumene at INEOS’ Gladbeck and Antwerp sites – without competing with the food supply. Both sites are certified according to the products.thanlowerrawRSBPLUSrecognisedinternationallyISCCaswellasthestandard.Thematerialshaveacarbonfootprintpetroleum-based

INEOS supplies Covestro with mass-balanced raw materials for polycarbonates

Notched charpy impact testing was carried out using an instrumented impact tester according to BS2782 Method 359 Appendix A, using a 2J hammer at 23°C and 50% RH. Results are an average of 10 specimens of each sample tested.

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We don’t want to be needlessly alarmist but if this situation continues unabated what could be looming is a situation as serious as the energy related travails of the late seventies and early eighties, although the circumstances surrounding both situations are not exactly comparable.

he issue which has well and truly planted itself centre stage is the price of energy. This has become the leading topic in the BPF’s casebook, particularly as companies are coming to the end of existing contracts. The UK plastics industry is much more dependent on electricity than gas but companies in the sector are facing threefold increases in the price of energy. This is unsustainable and it is amazing that little has been said about the plight of manufacturers in the face of these increases, as if it was just a consumer problem.

PHILIP LAW, THETHEGENERALDIRECTOR-OFBPF,GIVESTHEBPF’SPOSITIONONWORSENINGENERGYCRISIS.

PHILIP LAW, BPF

State for Business, Energy and Industrial Strategy, explaining the situation, my case resting on the results of the latest Business Conditions Survey we carried out in the summer. 59% of respondents cited energy costs as a major challenge to profitability, with very many companies saying they cannot pass the cost increases onwards. In my second missive I detailed the plight of one particular member company as a graphic case study to illustrate the overall condition of the Fundamentallyindustry.weare looking to government to facilitate urgently some form of financial aid to enable companies to survive until the energy market reconfigures. This is to be delivered either directly by the government, through the banking system or through energy suppliers. We are also looking for a modification to the scheme allowing ‘Energy Intensive Industries’ to claim a waiver on the renewables charge on the energy bill. The ground rules for the ‘business test’ certainly need to change to enable very many more companies to claimBPFrelief.iscurrently carrying out a survey of energy usage in the industry and its impacts on company performance. The analysis of the results will provide us with the additional substance to develop the lobby further through the political and energy communities. In this we will draw strength from our subsidiary company, BPF Energy, which is one of the largest Climate Change Agreements with over 550 plastics manufacturing sites in membership. This has also provided us with considerable technical expertise and experience in the energy field.

It is amazing that little has been said about the plight of manufacturers in the face of these [energy price] increases, as if it was just a consumer problem.

COLUMN

On a related theme, BPF has recently published a uniquely comprehensive book called ‘Sustainability Management in Plastics Processing’ written by noted expert Dr Robin Kent. A complimentary copy has been sent to all BPF member firms but copies can be bought www.bpf.co.uk/sustainabilitymanagementon https://

It doesn’t help of course that we have this current impasse in government with the arrival of a new Prime Minister, plus the fact that UK government normally goes into a lower gear due to the Parliamentary summer recess, all rather amateurish in my opinion.Something needs to be done and the ‘someone’ who should do it is the UK government by making a strong intervention. I have written formally twice this month to Kwasi Kwarteng, Secretary of

Sadly this is reflected in government policy responses which have been all about relieving the consumer of the impending burden, ignoring the fate of business, particularly manufacturing. There’s a need to get back to basics. Who employs the consumers and where do they get their money from? Well, the UK plastics industry employs over 160,000 directly, without including employees in onward supply chains. If you apply a reasonable multiplier to direct employment, say one direct employee has two dependents, you have about 480,000 potential economic casualties from this industry alone.

KraussMaffei helps you gain the purest recyclates in a „like new“ quality that seemed unimaginable a few years ago. We imple ment your formulations in a way that costs little in terms of money, energy and CO2 emissions. Our groundbreaking technology in compounding and recycling gives you the critical edge in the competition for sustainability – for your company‘s figures and our children‘s future.

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