BP&R July/Aug 2018 by BP&R Magazine

British Plastics

and Rubber

bp&r july/aug 2018

WHEN DOES PLASTIC BECOME RUBBER? HEXPOL TPE KNOWS â&#x20AC;&#x201D; SEE PAGES 4&5 COOL TOOLS How hybrid additive manufacturing can speed up mould making

PIPE DREAMS How groundbreaking pilot system shortens process steps

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editor’s letter

GREEN SHOOTS OF INNOVATION

www.britishplastics.co.uk head of content: Leanne Taylor

T: +44(0)1244 952 371 E: leanne@rapidnews.com Deputy Group Editor: Rose Brooke

Amongst all the negativity surrounding plastics in the environment, they had a respect for plastics as a versatile, practical and sustainable material and had clearly considered recycling and circularity in their designs.

T: +44 (0) 1244 952 370 E: rose.brooke@rapidnews.com ASSITANT editor: GRACE NOLAN

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British Plastics & Rubber is available on free subscription to readers qualifying under the publisher’s terms of control. Those outside the criteria may subscribe at the following annual rate: UK, Europe and rest of the world £249 British Plastics & Rubber is published monthly (8 times/year) by Rapid Plastics Media Ltd, Carlton House, Sandpiper Way, Chester Business Park, CH4 9QE T: +44 (0) 1244 680222 F: +44 (0) 1244 671074 © 2018 Rapid Plastics Media Ltd 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. ISSN 0307-6164 Incorporating Polymer Age and Rubber and Plastics Age.

t’s a universal truth that innovation is the lifeblood of the plastics industry. True too, is that the industry is suffering from a skills shortage considered one of its biggest future threats. So then, a competition that combines plastics innovation and a group of talented students with irrefutable future potential is one that BP&R is proud to put its support behind. Attending the awards ceremony of the annual Design Innovation in Plastics (DIP) competition recently, I listened to presentations from six finalists, who this year had to adhere to a brief of designing for innovative garden products. All six showed true innovation, enthusiasm and passion for their designs, all of which had genuine market and commercial potential. Perhaps the most refreshing thing, however, was the appreciation of plastics as a material. With the majority studying design, some had not worked with polymers prior to the competition, and yet all those I spoke to said they would do so again. Amongst all the negativity surrounding plastics in the environment, they had a respect for plastics as a versatile, practical and sustainable material and had clearly considered recycling and circularity in their designs. The students are immensely proud of their plastic products, which, at a moment in time when others are desperate to purge plastics from their lives, is a very rare thing indeed.

You can find out more about the competition, who won and their plans for the future in our feature on pages 12 and 13. Enjoy the issue. Leanne Taylor, head of content

the big story HOW TPv combines characteristics of plastics and rubber

T THERMOPLASTIC ELASTOMERS (OR TPEs FOR SHORT) ARE SOFT AND FLEXIBLE MATERIALS WHICH COMBINE THE CHARACTERISTICS OF RUBBER WITH THE RECYCLABILITY AND PROCESSING ADVANTAGES OF PLASTICS. HEXPOL TPE EXPLAIN THE SCIENCE BEHIND THIS EVOLVING FAMILY OF MATERIALS.

TPEs offer properties found in plastics and rubber. Like rubber, TPEs are tactile, grippy and a good sealer. They are durable and flexible and available in a wide range of hardnesses. TPEs can be processed via standard thermoplastic technologies such as injection moulding and extrusion. They are also suitable for multi-component processing, combining hard and soft materials and allowing for soft-touch areas and tactile surface finishes. On the other hand, like thermoplastics, when heated and with the application of shear force, TPEs become freeflowing and when cooled regain their original structure and stability. Unlike the chemical cross-linking which occurs in thermoset rubbers, TPE involves purely physical cross-linking, which can be reversed via the further application of heat, this makes it possible to reuse production waste and end of life products can be recycled. TPE CLASSES But one TPE is not the same as another, they are in fact a diverse and expanding family of compounds, based on a number of different raw materials. Each class brings its own list of properties and each class has benefits and limitations in different environments. Here we’ll focus on Thermoplastic Vulcanisates or TPVs, which are high performance compounds designed for demanding applications where improved durability, heat or fluid resistance are required. WHAT ARE TPVs? TPVs are compounds of PP and EPDM rubber which have been dynamically vulcanised during the compounding process. The vulcanisation process changes the structure of the rubber phase making it more durable, improving its recovery to deformation and reducing the ingress of aggressive fluids such as oils and solvents.

CUSTOMISATION With increasing popularity in multiple industries and needing to fulfill a variety of different demand requirements, there is a growing need for highly customised TPV solutions. HEXPOL TPE are constantly testing new polymers, additives, stabilisers and other ingredients to create unique material combinations. They have engineered several Dryflex TPV series to suit different applications, with properties including flow characteristics, hardness, colour, specific gravity and strength resistance. COLOUR Due to the cured elastomer phase, TPV compounds can be notoriously difficult to colour. The addition of separate colour masterbatch can also have an unexpected effect on the physical properties and functionality of the compound. The Dryflex XL series of TPV compounds was developed to have a ‘clean’ appearance, which makes them easier to colour. It is also possible to supply fully colour compounded TPVs, meaning fewer production steps for the processer and a consistent colour without any loss to properties or performance. HYBRID AND SEMI-TPVs It is also possible to produce hybrid materials based on TPVs that are combined with other TPE materials such as SEBS and/or only partially cross-link the rubber phase (sometimes referred to as a Semi-TPV). The main benefits of these are to expand the possibilities of material properties and therefore also its potential applications, alter the processing characteristics (viscosity) of the material, change the surface appearance and aesthetics of the final product and in some cases to improve economics.

TYPICAL ADVANTAGES OF TPV COMPOUNDS − Improved recovery to deformation − Increased tensile strength and extensibility − Greater resistance to certain organic solvents, oils and fats − Higher thermal resistance (i.e. better performance at higher temperatures) − Improved resistance to oxidation, abrasion and tear − 100% Recyclable − Adhesion to various substrates in multi-component applications 4

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TPE CLASSES CLASS

DESCRIPTION

BASE CHEMISTRY

TPS or TPE-S

Styrenic Block Copolymers

Compounds based on SBS, SEBS or SEPS

TPO or TPE-O

Thermoplastic Polyolefin

Blends of PP and un-crosslinked EPDM rubber and polyethylene

TPV or TPE-V

Thermoplastic Vulcanisate

Blends of PP and EPDM rubber that have been dynamically vulcanised

TPU or TPE-U

Thermoplastic Polyurethane

Reaction of diisocynate and polyglycol forms rigid blocks of urethane and flexible blocks of polyethyleneglycol

TPC or TPE-E

Thermoplastic Polyesters

Crystalline Polyamides reacted with polyether diol

TPA or TPE-A

Polyether copolyamides

Carboxylic Polyamides reacted with polyether diol

TPZ

Miscellaneous material

TPZ-(NBR+PVC), …

COMPARISON OF TYPICAL PROPERTIES PROPERTY

TPS (SBS)

TPS (SEBS)

TPO

TPV

TPU

TPC

TPA

Hardness (Shore)

20A to 65D

0A to 65D

45A to 60D

35A to 50D

60A to 50D

90A to 80D

60A to 70D

Density

0.9 to 1.2

0.86 to 0.93

0.94 to 1.1

1.06 to 1.25

1.13 to 1.25

1.01 to 1.18

Service Temperature °C (unstressed)

-50 to 75

-50 to 125

-70 to 75

-50 to 135

-70 to 120

-30 to 150

Compression Set

PPP

Oil Resistance

HAPTICS AND AESTHETICS TPV compounds are shear thinning with excellent flow characteristics, helping to eliminate flow lines in complex or thin-walled parts. They are also suitable for overmoulding and co-extrusion processing, with adhesion to olefinic polymers such as PP and PE, allowing for soft-touch areas and tactile surface finishes. LONG-TERM DURABILITY TPVs are used in demanding and sensitive applications, where durability and performance are critical. To ensure product consistency and develop materials with superior performance properties, testing such as accelerated weathering is required. This simulates the damaging effects of long term outdoor exposure to the most aggressive components of weathering such as light, moisture and heat.

APPLICATIONS TPV compounds are used extensively in automotive, construction, electronics and consumer markets. They have seen strong growth in automotive seals, pipe seals, and other applications where a heat resistance of up to 135°C is required. TPVs also lend themselves to underbonnet automotive applications where improved temperature and oil resistance is required. CONCLUSION TPVs are bridging the plastics and rubber gap, offering a compound that combines characteristics of both. Their design flexibility, high-performance, recyclability and ease of processing has led to designers and specifiers increasingly turning to TPVs as their material of choice.

TPV COMPOUNDS ARE USED IN DEMANDING AND SENSITIVE APPLICATIONS, WHERE DURABILITY AND PERFORMANCE ARE CRITICAL

WWW.HEXPOLTPE.COM

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july\august 2018

on the cover

BRIDGING THE GAP: HOW TPV COMBINES CHARACTERISTICS OF PLASTICS AND RUBBER Thermoplastic Elastomers (or TPEs for short) are soft and flexible materials which combine the characteristics of rubber with the recyclability and processing advantages of plastics. Hexpol TPE explain the science behind this evolving family of materials SEE PAGES 4-5

Editor’s Letter

GREEN SHOOTS OF INNOVATION

Feature

HOOKED ON NATURE: INNOVATIVE PLASTIC PRODUCT BRINGS THE OUTDOORS CLOSER This year’s ‘Design Innovation in Plastics Award’ (DIP) tasked students from universities across the UK with the challenge of creating a new product that would better connect people with nature. BP&R spoke to the designer behind the entry that got the judges ‘hooked’.

REGULARS

HOW TO ACHIEVE A QUICK PAYBACK ON YOUR PRODUCTIVITY INVESTMENTS In the first of an exclusive two-part series, Craig Forrester of Stäubli Connectors UK talks to BP&R about the productivity and efficiency gains that can be achieved when plastic processors invest in more modest items, such as connection systems or mould handling and clamping solutions, that can often be overlooked.

09 INDUSTRY NEWS 15 MACHINERY 23 RECLaMATION AND RECYCLING 43 MATERIALS 45 POLYMERMAN 47 BUYERS’ GUIDE 49 SOFTWARE 50 NEWS FROM THE FRONTLINE

Q&A

Feature

“NO CHANGE, NO CHANCE” MACKIE’S OF SCOTLAND CHOOSES IML FOR INNOVATION IN ICE CREAM Scottish producer of ice cream, Mackie’s, switched to in-house production for its plastic tubs, opting for decoration with in-mould labels as part of both its focus on sustainability and ongoing product innovation. BP&R looks at the benefits to a company that is focused on its green credentials and keeping up with consumer demand.

40-41 Feature

PACKAGING PANEL DEBATE: FROM CONVERSATION COMES ACTION A panel debate held on World Environment Day brought together key participants from across multiple industries to discuss opportunities for radical collaboration around use – and understanding of – plastics and packaging. BP&R reports on the key highlights from the event.

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INDUSTRY | NEWS PMMDA welcomes three new members as it goes from “strength to strength”

Grants of £2,500 available for British exhibitors at Arabplast British companies are being invited to exhibit at the largest plastics and rubber exhibition in the UAE region and potentially benefit from Department for International Trade (DIT) grants of £2,500 per company. Organised by Messe Dusseldorf, Arabplast, which takes place every two years, features exhibitors from 41 countries, with the previous edition, held in 2017, having 906 exhibitors and 27,268 visitors from 119 countries. The next edition, taking place at the Dubai World Trade Centre

Borche UK Open Day a “great success” The official opening of Borche UK’s showroom and service centre has been hailed as a “great success” by organisers. On 27 and 28 June, the Chinese injection moulding machine manufacturer unveiled its first fully owned subsidiary for the company in Europe. Attended by Borche President, Mr Zhu, as well as local dignitaries and guests from the plastics industry, the day consisted of demonstrations of the company’s servo controlled injection moulding machines and associated automation. The importance placed on the UK and Irish markets has been

Arabplast will take place in Dubai in 2019

between 5-8 January 2019, will feature a British Pavilion located in Hall 6, one of the international halls that also features pavilions from Germany, Austria, Switzerland and France. Allocated on first-come, firstserved basis, the British Plastics Federation, which coordinates the British Pavilion, invites interested companies to register interest as soon as possible due to the limited number of DIT grants available. The stand booking deadline for the British Pavilion is 31st August 2018. www.BPFevents.co.uk

reflected in the investment made in the new site, which is based in Kingswinford in the West Midlands. The central warehouse is receiving machines directly from Borche’s manufacturing sites in China. Commenting on the day, Terry O’ Reilly, Sales Director for Borche UK, said: “We were delighted with the outcome of our open event, which was the ideal opportunity for us to showcase the highly successful Borche range of machines in addition to our full service capabilities. As a positive result of the showing, another new customer will shortly take delivery of his first new Borche machine from UK stock.”

The Polymer Machinery Manufacturers and Distributors Association (PMMDA) has welcomed three new member companies in 2018. The Committee has recently approved applications from STV Machinery Ltd, PL Machinery Service and Sales Ltd and Borche Machinery (UK) Co. Ltd. Commenting, Kevin Horne, Chairman of the PMMDA, said: “It’s great to see our membership going from strength to strength as we continue to support UK machinery suppliers and those involved in the plastics industry.” The new companies take the total full membership tally to 33, with an additional four supporting members. Within the organisation itself, there has been a new committee member in the form of Sepro UK’s Glen Eves. Horne said along with its internal and membership changes, it has also been working on plans to develop its activities supporting apprentices and education. “We are working on a new incentive in conjunction with the BPF to support its ‘Plastics Ambassadors’ scheme, which encourages primary school age children at to become more aware and engaged with plastics,” he continued. “With all the controversy around plastics waste, it is important that they grasp the concept and importance of plastics in their lives from an early age.” The Association held its AGM at the PDM show in Telford recently, where members said they felt “optimistic about business” with some good leads. Horne said that the upcoming RWM recycling show could provide further opportunity for business. “There appears to be a lot of major projects being looked at currently for polymer recycling in general, so watch this space,” he concluded. www.pmmda.org.uk

www.borche.co.uk WWW.BRITISHPLASTICS.CO.UK

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Repsol’s Headquarters

Largest global rubber conference held in London in 2019

Repsol awarded best European polypropylene producer 2018

Having been selected as the ‘HDPE Best Polymer Producer for Europe’ in 2017 and 2016, and bestowed with the overarching award on innovation covering all polymer types in 2016, it is the third consecutive year that Repsol has received a similar award. The company said it was “greatly satisfying” to know its clients recognise the evolution it is undertaking to put the customer at the centre of its decisions.

Repsol has been awarded the ‘PP Best Polymer Producer Award for Europe 2018’. This award is the result of an online survey carried out by the European Plastic Converters Association (EuPC) among polymer customers across Europe to rate their supplier’s performance.

www.repsol.com

Silvergate invests in new extrusion line

When installed, the technologically advanced clamshell extrusion line will increase capacity at the facility by 10 per cent. The investment also coincides with the company’s plans to further its reach across Europe, as Silvergate is actively looking for European agents and distributors who can proactively manage opportunities in mainland Europe. www.silvergate.co.uk

Silvergate Plastics has installed a new twin screw, clamshell design extrusion line at its masterbatch manufacturing facility in Wrexham, North Wales. This latest investment is part of the company’s sustainable growth strategy, responding to increasing market demands for faster processing timescales without compromising on quality.

Name change for COBA Plastics Ltd COBA Plastics Ltd has changed its name to COBA Automotive (UK) Ltd. As a Tier 1 and OEM supplier of thermoplastic extruded and moulded components to the automotive manufacturing industry, the company says its name has been changed to more aptly reflect COBA’s core business activity. Jonathan Atkinson, Chief Operating Officer, COBA Automotive (UK) Ltd, said: “The new name underlines COBA’s maturity and reputation within the industry, and reinforces our commitment as a supplier to our automotive

customers, both in the short and long-term.” As part of the company vision, COBA Automotive (UK) Ltd will continue to invest in its engineering and manufacturing facilities at its headquarters in Leicestershire.

The largest annual global conference for the rubber community will take place in London next year. Organised by the Institute of Materials, Minerals and Mining (IOM3) on behalf of the International Rubber Conference Organisation, the 2019 event will take place at the Kia Oval from 10-12 September. A call for papers has been issued for the three-day conference, which organisers say is an “excellent platform” for rubber scientists, technologists, academics, and industrialists to share knowledge and network. Original papers are invited that reflect current research and technology within the rubber industry in sectors and disciplines such as defence, civil engineering, mineral extraction, biomedical, sustainability, adhesives, sport and leisure, robotics, transportation, and oil and gas. Other topics for discussion include environmental and sustainability issues in the industry as well as innovations in polymer production, the use of fillers and other additives in compounds, and developments in vulcanisation technology. In addition, papers that can help characterise or simulation tools that can help predict a range of properties including component stiffness, dynamic performance, fracture, fatigue, and abrasion as well as chemical degradation, are invited. Alongside the technical conference, there will be technical training programmes allied to the rubber industry, a large exhibition, and taster events provided for local schools. “It is a great honour and privilege to host this event in the UK in 2019,” said Professor James Busfield, Chairman of the IRC 2019 Organising Committee. “We look forward to hearing from the best researchers from around the world about their latest innovations and showcasing the very best that the UK has to offer.” www.iom3online.org

www.cobaautomotive.co.uk

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words | Leanne taylor

hooked on nature:

innovative plastic product brings the outdoors closer

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It was evident that this product could become a marketable item, as living spaces become smaller, and more ‘Juliet’ balconies are integrated into new builds, especially in Europe

Alex Roquero with his winning design, ‘Hook’ 12

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T THIS YEAR’S ‘DESIGN INNOVATION IN PLASTICS AWARD’ (DIP) TASKED STUDENTS FROM UNIVERSITIES ACROSS THE UK WITH THE CHALLENGE OF CREATING A NEW PRODUCT THAT WOULD BETTER CONNECT PEOPLE WITH NATURE. BP&R SPOKE TO THE DESIGNER BEHIND THE ENTRY THAT GOT THE JUDGES ‘HOOKED’.

multi-use plastic shelf designed to bring nature to the smallest of spaces as well as promote mindfulness and relaxation has been awarded first place in this year’s Design Innovation in Plastics (DIP) competition. Product Design student at Brunel University, Alex Roquero, impressed judges with ‘Hook’, a portable shelf which is integrated with a flowerbox and fits to any kind of railing – ideal for people who have no garden, or reduced space, and want something which hooks onto a balcony. Thanks to its unique shape, as well as plants, it can also carry day-to-day products such as coffee mugs, wine glasses, beer bottles or even books. Produced from polypropylene and manufactured using injection moulding, judges assessed the product as having huge commercial potential, as well as meeting all the aspects of the brief relating to sustainability, uniqueness and meeting a common need. “It was evident that this product could become a marketable item, as living spaces become smaller, and more ‘Juliet’ balconies are integrated into new builds, especially in Europe,” commented Chairman of the Judges, Richard Brown. “Alex tackled a problem that he was familiar with from the environment in his home country of Spain, and took a holistic approach to provide a multi-purpose solution. We were impressed by the way he took into consideration all the elements of the brief, from initial concept, patent and IP search, manufacturability, point of sale options and sustainability. He used polypropylene, which has the mechanical properties required for this kind of product and is completely recyclable.” “A VALUABLE EXPERIENCE” Roquero said taking part in the competition had been “a real challenge” having formerly worked with predominantly metals. He explained that the process had driven him to develop expertise and gain experience in areas he had not studied before and to be especially aware of considerations such as sustainability, which had influenced even small decisions in the design and production of his balcony shelf. “Being able to produce a physical working prototype helped me realise how challenging and satisfying it is to make your designs work in real life,” he explained. “It’s a really valuable experience as a designer to explore a world of materials that I haven’t explored before. It has given me confidence to go forward with the product.” Now more familiar with both the material and manufacturing process, and buoyed by the positive feedback from the judges, Roquero said that he intends to continue to develop his product. “I don’t want to stop here, I can see this product in people’s homes,” he explained. “Now I’ve won the competition I know people believe in this product as much as I do. I’m looking forward

to talking to and working with new people to find out their feedback as professionals.” Part of this feedback will be garnered during a trip to Covestro in Germany, as well as placements with RJG Technology and PDD, the product and service design and innovation consultancy, all of which are part of the winning prize package. In addition, he will receive an invitation to the banquet given by joint competition organisers, The Worshipful Company of Horners, that is held annually at The Mansion House in the City of London. COMMERCIAL AMBITION Like many others in the competition before him, Roquero has the intention of taking his product through to commercial production. Martin Sixsmith, competition Chairman, encouraged all the finalists to take their ideas to market, highlighting several former winners that have gone on to achieve great success. One of these, Rob Law, was the winner in 1998 with his ‘Trunki’ children’s suitcase. Now synonymous with travel globally, the product has achieved great recognition. Attending the ceremony as the keynote speaker this year, some 20 years after winning, Law said the finalists’ products had “huge commercial potential”, adding “businesses are ready to be built from these products, I’m sure we’ll see them in the marketplace.” The other products making the final included ‘Bulb Garden Furniture’, designed by second place William Oughton, also from Brunel University, which comprises a set of garden accessories that fit to any type of panel, wire or post-built fences, and can be used as bird feeders, planters, bird houses or solar outdoor lights. Thirdplace Olivia Alexander, from De Montfort University, designed ‘Buzz’, a bee-friendly plastic planter that administers an anti-mite substance directly to the bees to protect them from the Varroa mite. There was also a planter for children’s development, an ergonomic garden multi-tool targeting gardeners with arthritis and a product which combines modern indoor gardening with home aquariums to enhance wellbeing. HEALTHY OUTLOOK The Design in Plastics competition, which was established in 1985, shows no sign of stopping. Bernie Rickinson, of co-organisers the Institute of Materials, Minerals and Mining (IOM3), revealed that the 2019 competition will have a theme of ‘Healthy Body, Healthy Mind,’ and will look for innovations that highlight the use of plastics in a modern world. “The competition highlights freshness and innovation by harnessing creative talent with materials science expertise,” Rickinson said. “I am quite sure next year’s competition will be no exception.” www. designinnovationplastics.org 13

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celebrating 180 years

MACHINERY | NEWS Nigel Baker appointed new Managing Director of Engel UK Nigel Baker has been named the new Managing Director of Engel’s UK subsidiary in Warwick. Baker, a familiar figure in the UK plastics industry since the 1980s, will take over the position of Managing Director in September, when current MD, Graeme Herlihy, moves on to become Regional President Europe West. Herlihy said Baker was the “ideal choice” for the role, following almost 25 years at the helm of injection moulding machine manufacturer, Netstal UK, and over five years as Managing Director at BMB Plastics Machinery. “Nigel’s appetite for

AMRC at Sheffield University takes delivery of KraussMaffei HP-RTM system The Advanced Manufacturing Research Centre (AMRC) at the University of Sheffield is using a high-pressure resin transfer moulding system from KraussMaffei to accelerate its research. The AMRC is developing new technologies and applications for fibre-reinforced lightweight construction in industries such as automotive and aerospace. It will use KraussMaffei’s RimStar Compact for the high-pressure resin transfer moulding (HP-RTM) process as it looks to drastically reduce cycle times and processes ready

Schmidhuber and Stephen Lambert (second and third left) and the AMRC Development Engineers, Davide Melis, Darren Wells and Ricky Rowett (from the left)

erlihy Graeme H Baker with Nigel

understanding his customer’s needs is exceptional. We all know him to be an unstinting and diligent Managing Director for whom customers always come ﬁrst and I am totally happy to be handing over the keys to the kingdom,” commented Herlihy. Speaking of his new appointment, Baker commented: “I am very excited by the opportunity to work with Engel UK. Graeme is leaving me a well-oiled machine comprising a team of highly professional technical engineers, sales engineers and office based staff. “The tremendous support provided by Engel Austria is known as being second to none and the two teams together will, I am sure, move forward with strength. I fully intend to build on the good work

Graeme has done and look forward to the challenge.” Although moving to his new role, which will involve a significant amount of travel, Herlihy will retain an office at Engel UK in Warwick. www.engelglobal.com

for large-scale production of fibrereinforced parts. The RimStar Compact enables use of multiple mixing heads for the first time, which KraussMaffei says provides clear advantages in precision and cost-efficiency. “The specific selection of two dosing units and the corresponding mixing heads allows for a particularly precise mixing of the resin system,” explained Sebastian Schmidhuber, Head of Development for Reaction Process Machinery at KraussMaffei. “This makes the system the first of its kind in which multiple mixing heads are used in the full scope of functions in order to enable a perfect cavity fill. Even materials that are highly reactive and fastreacting at the same time—which are increasingly in demand for the HP-RTM process—can be reliably processed.” Accroding to Darren Wells, Research Engineer at AMRC, processing such highly reactive matrix materials opens up entirely new development opportunities for composite materials and components with more intricate geometric structures. “The curing times are critical here. Using highly reactive systems, they can be reduced down to three minutes. With such short times,

they offer great opportunities for the manufacturing industry,” he explained. KraussMaffei says another advantage of its new RimStar Compact, from both a process technology and cost-effectiveness standpoint, is its compact design. Matrix material injection and curing take place in one and the same mould. This, it says, results in a consistently high quality of the components and in high process reproducibility. Stephen Lambert, RPM Business Manager at KraussMaffei UK, says that the modular design of the RimStar Compact means it can quickly meet the specific needs of its customers such as AMRC. “We provide them with a unique research and development landscape to test and verify the cycle time and cost savings advantages of the HP-RTM process live,” Lambert commented. “We are looking forward to further future collaboration and development projects at the AMRC,” he continued. “Particularly in the area of vehicle manufacturing and aviation, we see great potential. As an outcome of the collaboration, we have recently received the first series production order of a premium British automaker.” www.kraussmaffei.com

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www.kraussmaffei.com

celebrating 180 years the entatives at Arburg repres k Warwic celebration in

Sumitomo (SHI) Demag consolidates its product portfolio Sumitomo (SHI) Demag is consolidating its product portfolio to reflect market trends, with a focus on all-electric drives and toggle technology. The price difference between hydraulic and all-electric injection moulding machines is reducing every year, underlining a trend towards all-electric machines, especially in the lower clamp force range. Gerd Liebig, CEO of Sumitomo (SHI) Demag, explained: “All-electric machines like the IntElect have become so technically mature, that after considering all the criteria, more and more customers are finding it attractive.” In the past 12 months, almost half of all machines sold have been from the all-electric IntElect series. Liebig added: “In Germany, we are replacing production of small fully hydraulic machines with our superior electric drive technology. From Fakuma 2018 on, our investment in the clamp force range up to 1,200kN will shift entirely to the IntElect series.” An extensive investment programme has been launched at the company’s two German locations. At Wiehe, a global competence centre for electric injection moulding machines, new conveyor belt production lines have raised output by 30 per cent. The plant’s focus on the allelectric IntElect series is expected to increase annual manufacturing capacity to 1,000 all-electric machines. In Schwaig, capacity for platen processing will almost double by the end of 2018 due to new processing centres. In other areas of its portfolio, the focus is shifting to hybrid drive technology for packaging machines and servo-hydraulic toggle technology for medium and large machines. For fast applications, the El-Exis SP series with a clamp force range of 1,5007,500kN completes the range. For universal applications, the modular Systec Servo remains available for the clamp force range of 1,60015,000kN. Sumitomo (SHI) Demag says it will continue its commitment to refining toggle technology in all machine series. www.sumitomo-shi-demag.eu 16

Arburg UK’s global reach recognised during 25-year celebration Arburg’s subsidiary in Warwick has been recognised with “gratitude and praise” by its parent company for 25 years of service and success. During a two-day event, incorporating an evening celebration and open house with machinery demonstrations and presentations, delegates from Arburg in Lossburg recognised the work of its UK subsidiary in securing not only small and medium sized customers in the region, but also those with a global reach. Upon presentation of a sculpture to recognise the silver anniversary, Arburg Managing Partner, Juliane Hehl, said it symbolised thanks and appreciation for the success of the subsidiary and as motivation for the future. “We are uncompromisingly committed to the interests of our customers and partners worldwide, everywhere and at all times,” said Hehl. Colin Tirel, Managing Director of Arburg in the UK since 2005, told delegates that its customers represent a broad church of end-user industries producing mainly thermoplastic parts for the automotive, electronics, packaging and medical technology sectors. However, he also highlighted customer trends in recent years have led to increased sales of LSR processing and multi-component injection moulding machines. He added that the company’s extension of the clamping force range up to 6,500 kN has satisfied those customers using larger, multicavity moulds. To accommodate the needs of its customers looking to automate their production processes, the company

has an expert in the field of automation to advise and support, while the use of the Freeformer for industrial additive manufacturing will be further promoted in 2018 with several events. “We welcomed some 90 guests over the two days and were thus able to personally thank many of our customers for their excellent cooperation during the past decades as well as showcasing ideas for future projects based on the exhibits and presentations,” commented Tirel at the event. Managing Director of Sales for Arburg globally, Gerhard Böhm, also thanked customers from the UK and Ireland for their “trusting and successful cooperation over the past decades”, before looking back over the successful history of the subsidiary. This, he explained, began with the sale of the first Allrounder injection moulding machine to the UK in 1967. Initially being supported by a trading partner, the decision to found a fully-owned subsidiary was taken following growth in the overall UK plastics processing market, along with Arburg’s market share. The original manager of the UK subsidiary, Frank Davis, made a special appearance at the event, as delegates heard how the initial team of 18 he headed up has today grown to 26 and the building and facilities expanded to incorporate a showroom with Allrounders for testing customer moulds, a wellstocked spare parts warehouse and a wide range of training courses. Finally, as part of the company’s celebrations, UK staff and families visited Lossburg to experience the local area, food and culture. Tirel said the visit was an additional way of thanking staff for their commitment. www.arburg.com

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EXCLUSIVE Q&A:

how to achieve a quick payback on your productivity investments

IN THE FIRST OF AN EXCLUSIVE TWO-PART SERIES, CRAIG FORRESTER OF STÄUBLI CONNECTORS UK TALKS TO BP&R ABOUT THE PRODUCTIVITY GAINS THAT CAN BE ACHIEVED WHEN PLASTIC PROCESSORS INVEST IN MORE MODEST ITEMS THAT CAN OFTEN BE OVERLOOKED.

ABOUT THE expert:

Craig Forrester is the Connectors Division Manager of Stäubli UK Ltd, based in Telford. He has over 23 years’ experience in the plastics market and over 36 years in factory automation. His technical qualifications include HND in Electrical/ Electronic Engineering.

CAN TARGETED MODEST INVESTMENTS SIGNIFICANTLY RAISE INJECTION MOULDING PRODUCTIVITY WHILE ALSO PROVIDING A QUICK PAYBACK? Discussion of capital investment usually centres on new injection moulding machines or large expensive additions to the manufacturing facilities. Frequently more modest investments in items such as connection systems or mould handling and clamping solutions are overlooked and not evaluated rigorously by financial appraisals such as cost/benefit analyses and payback calculations. Detailed analysis of business processes covering a broad spectrum of company size and operating in a range of market sectors has shown that modest investment in these areas, even by the smallest companies, can significantly boost productivity often giving a payback of just a few months on equipment that will last and provide benefit over many years. HOW CAN THIS BE ACHIEVED? Injection moulds usually need to be connected to a range of circuits e.g. water, hydraulics, electrics etc. Hard piped solutions cause costly delays during connection and disconnection and often lead to further machine down-time due to necessary clean-up activities. The use of quick release connectors, either single or mounted together on a ‘one hit’ multi-connection plate, provide a fast, efficient and clean solution speeding up the mould change and eliminating potentially dangerous spillages. SO WHY IS THIS SYSTEM NOT ADOPTED BY ALL INJECTION MOULDERS? In some applications moulds are not changed frequently, if at all, making this type of investment less attractive and the benefits of speeding up the mould change not that relevant. But even in these instances the safety and security provided by quick release connectors still brings major benefits. However, most injection moulders require the flexibility

to change moulds. In such cases, dramatic improvements in productivity are achievable if the change can be quicker, cleaner and better managed. WHY ARE THE PRODUCTIVITY AND SAFETY ADVANTAGES RESULTING FROM MODEST INVESTMENT? The benefits of investment in these types of systems are sometimes recognised by operational personnel in the moulding shop. Presenting the case for investment to senior management is more challenging; the costs and benefits need to be precisely analysed and cost saving clearly defined. This can then be presented in a format that the Board and Financial Director will fully appreciate and accept. Industry experts provide experience and knowhow to facilitate a true in-depth study of the whole ‘shot-to-shot’ downtime detailing the specific areas offering the highest return on investment. Without divulging any company confidential details, financial as well as operational reassurance can be provided and the benefits of investing now firmly established and the case for investment made. WHAT SHOULD BE CONSIDERED WHEN INVESTING? The financial benefit of investing can be readily determined and the payback calculated. This analysis needs to consider the number of times a mould is changed on

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a machine, the time currently taken to change moulds and the cost incurred. Comparison can then be made with the quick connection system in place. The major benefits are reducing the costly downtime during mould changeovers thereby increasing machine availability for production and the elimination of errors. Payback times of less than a year frequently result, in some cases payback can be achieved in just a few months from modest investment in a quick connection system that precisely meets the specific production requirements of any application. CAN YOU OFFER ‘RULE OF THUMB’ SOLUTIONS THAT CAN BE APPLIED GENERALLY? As a result of the complexity and variety, it is not possible to offer ‘rule of thumb’ solutions. It is of paramount importance that each mould change is individually analysed and a corresponding report generated. The solutions are as varied as the demands of the individual application. The journey to maximising efficiency is a step-by-step process, not necessarily all undertaken at the same time. The investments should be matched to the individual needs and goals of the plastics processor. A well-defined and structured mould change analysis should provide a roadmap for any future investments. www.quick-mold-change.com 17

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PIPE AND PROFILE | NEWS Solvay launches new polymer to enhance performance of rigid and flexible pipes

Reddiplex poised for 35 per cent capacity growth

Solvay has introduced a new, high-performance polymer designed to improve the capabilities of steel pipes, flexible risers and flowlines used in oil and gas recovery. New Solef 90615/2002 polyvinlylidene fluoride (PVDF) combines high ductility, thermal stability up to 150°C and exceptional resistance to oilfield chemicals and fluids. It is also said to deliver reliable performance, despite the high temperatures and pressures required for oil transmission in onshore and offshore environments. “Solef 90615/2002 PVDF introduces a unique combination of high-performance properties that can help expand design options, improve the lifetime of oil and gas assets, and lower operating costs over the lifetime of the pipe,” said Mike O’Brien, Oil and Gas Market Manager for Solvay’s global Speciality Polymers business unit. Liners made from Solef 90615/2002 PVDF are easily inserted into steel pipes due to the material’s high ductility and elasticity. Once inserted, the PVDF liner’s high chemical resistance helps slow corrosion, while its low-stick, ultra-smooth surface supports more consistent flow rates and flow assurance over time. Solvay’s new PVDF grade also reduces the need for corrosion inhibitors, antibacterial agents and other additives. The polymer’s thermo-mechanical properties and resistance to permeation of gases, such as methane and hydrogen sulfide, further promote long-term liner integrity. The new polymer also provides ductility, offering benefits in flexible pipes as a pressure sheath material, particularly in high-pressure applications. It delivers reliable performance across temperatures ranging from 30°C to 150°C, reducing the risk of rupture during installation in colder climates and expanding options for use in newly drilled, hotter fields. The material can also resist blistering in rapid gas decompression up to 1500 bar. www.solvayspecialty polymers.com

Flooding at houses in South Lanarkshire has been averted with Weholite HDPE pipes

Weholite sewage tank boosts flood attenuation for Lanarkshire homes Regular flooding at houses in Rutherglen, South Lanarkshire, has been averted with Weholite HDPE pipes from Asset International. Scottish Water started a £3.2m project to reduce the risk of flooding by improving its waste water storage in Rutherglen, where six houses in the View Park Drive development had been flooded. Scottish Water and Asset International added Weholite pipes to the sewer network to protect the houses for flood alleviation. Asset supplied a 260m³ attenuation tank to provide additional capacity for the area’s waste water. It then made a double manifold pipe tank of seven 33.5m long 1500mm internal diameter Weholite pipes and integral 1200mm internal diameter access shafts. Lloyd Condie, Civil Engineer at Scottish Water’s delivery partners, aBV, said: “We have seen numerous benefits to using Weholite over alternatives including quicker installation, resulting in reduced disruption for members of the community, as well as cost savings and improved performance.” Chris Burke of project partners, FPP Scotland, added: “As the Scottish Water framework supplier for PE pipe systems, it is a pleasure to work with a technically competent partner such as Asset International. Our role as an innovative material supplier with technical design input is made easier by working with Asset and aBV... This is yet another example of the Scottish Water supply chain really delivering top quality products on time with technical design input just as Scottish Water intended.” www.weholite.co.uk

Manufacturer of plastic and rubber extrusions, Reddiplex, has recently invested in two high specification extruders from Boston Matthews Machinery, bringing the total number of extrusion lines to 37 and increasing capacity by 35 percent. The Worcestershire-based company says the new lines are the latest in a continuous programme of investment, allowing it to develop additional capabilities following strong growth in demand for complex extrusion across several market sectors. For example, Reddiplex now undertakes the co-extrusion of small to medium sized profiles of PP, TPE and PVC, whilst a specific line exists to produce tube and pipe up to 120mm in diameter. The rapid expansion of Reddiplex’s G2G dry joint range has also resulted in a dedicated extrusion line for this product that joins interior glass panels without the need for sealant. “The company’s commitment to investment and expansion is exemplary,” said Reddiplex’ Technical Manager, Martyn Terry. “With the latest acquisition bringing the total to 37 extrusion lines, we’re confident that we can satisfy every eventuality where extrusion is concerned.” Reddiplex says along with UK growth, it is also experiencing an upswing in exports, with 25 per cent of turnover coming from customers globally. Jude Chard, Director and General Manager, said that alongside the manufacturing investments, it has additionally invested in its people. “As our company grows, it’s not just equipment that we must invest in,” she explained. “We’re constantly developing and empowering our specialist team so that they can provide the best possible service to our customers. Whilst extrusion technology within the plastic and rubber sector has not changed dramatically, it’s the expertise of the staff operating the machines and those in the technical department selecting materials, implementing design and planning tooling that really benefit the customer.” www.reddiplex.com

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Polypipe laying the new plastic piping systems during construction of Birmingham’s new Wholesale Market

POLYPIPE PLAYS A PART IN NEW FUTURE FOR BIRMINGHAM’S WHOLESALE MARKET Polypipe has supplied a range of plastic piping systems to Birmingham’s new £50 million Wholesale Market. The new facility, which has been relocated to Witton, includes a 241,885 sq ft warehouse facility, containing nearly 80 business units selling meat, fish, poultry and horticultural goods. Polypipe has installed a broad range of its Civils and Infrastructure products at the site, including Ridgidrain and Ridgistorm-XL large diameter piping system for surface water drainage and Polystorm-R for surface water attenuation. Polysewer and EN 1401 sewer pipes have also been installed for foul water, along with a range of cable protection systems for electricity supplied to the buildings. To manage on-site surface water run-off, 18,750 Polystorm-R cells have been installed underneath the site’s proposed outdoor car park and vehicle access areas, to capture and attenuate up to 3,555m³ of stormwater. In addition, 900m of Ridgidrain surface water drainage pipe was installed along access roads and around building parameters, which then connected via manholes into 32m of 900mm Ridgistorm-XL large diameter pipe, to manage the high volume of water from the 20

site before releasing into the main sewer network. The Polypipe EN1401 sewer pipe is connected to over 1km of 150mm Polysewer pipes and fittings to help manage the flow of foul and waste water from the site buildings and business units. “This project had very tight timescales, so we were happy to recommend Polypipe’s plastic products in favour of concrete and clay materials,” explained Dave Meenaghan, project manager at EP McVilly, the Groundworker for the project. “We find their products quicker to install with excellent reliability, and it has kept this important project on track.” www.polypipe.com/civils

This project had very tight timescales, so we were happy to recommend Polypipe’s plastic products in favour of concrete and clay materials

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In the pre-qualification of new developments, we offer a service that is one-of-a-kind in the world. This is a real benefit to our customers, as lengthy and time-consuming process steps are drastically shortened.

KraussMaffei demonstrates

“groundbreaking technologies” for high-performance pipes

K KRAUSSMAFFEI BERSTORFF HAS DEMONSTRATED A NEW PILOT SYSTEM TO PRODUCE HIGH PERFORMANCE PIPES FOR THE OIL AND GAS INDUSTRY AT A GLOBAL EVENT TO CELEBRATE A MILESTONE ANNIVERSARY FOR THE GROUP. HERE, BP&R LOOKS AT THE TECHNOLOGIES DEMONSTRATED IN MORE DETAIL.

MAIN IMAGE: Three-layer PE pipes with a functional inner layer made from PA 12 and produced on the innovative KraussMaffei Berstorff tube die INSET: Fibre-reinforced PE pipe with UD tapes and protective layer for the highest stress, for example in the oil and gas industry

During a Competence Forum held to celebrate the KraussMaffei Group’s 180th anniversary, a Thermoplastic Composite Pipe (TCP) system showcased the company’s developments in fibre composite technology, demonstrating the wrapping process with fibre-reinforced UD tapes. “With our pilot line, we support our customers with their standards regarding the design of fibrereinforced pipes from a process technology standpoint,” explained Matt Sieverding, President of Extrusion Technology at the KraussMaffei Group. “In the prequalification of new developments, we offer a service that is one-ofa-kind in the world. This is a real benefit to our customers, as lengthy and time-consuming process steps are drastically shortened.” KraussMaffei Berstorff says the base pipe can either be produced on its in-house lines for manufacturing pipes, purchased on the market or provided by the customer. The tapes are then wrapped on the TCP pilot line. A reconfiguration of the line allows for subsequent sheathing with a protective layer. MAXIMUM FLEXIBILITY THANKS TO A THREE-LEVEL PROCESS “For manufacturing TCP pipes, we relied on a three-level process in our system concept. For the customer, this process ensures maximum flexibility in production. And this is combined with a minimum risk in the production process,” Sieverding continued. At the second stage of the process, the surface of the PE pipe on the winding system is heated with infrared. The tape is then attached at two successive winding stations. An infrared oven for each layer ensures the fusion of the inner pipe with the reinforcing layers, ensuring complete bonding. A corresponding guiding device ensures exact positioning and prevents potential tape overlapping. “The fibre-reinforced pipes are excellently suited for the challenging safety requirements and high pressure loads in the oil and gas industry,” Sieverding added.

In onshore use, the working pressure can attain 150 bar, says KraussMaffei. In offshore use, the pipe can be required to withstand a pressure stability of more than 500 bar. The system for live demonstration at the Competence Forum was designed for a pipe interior diameter range of 50.8 to 152.4 mm and a maximum permissible operating pressure up to 100 bar (1500 psi). It is currently intended for the use of PE pipes coated with glass-fibre reinforced PE tape. However, KraussMaffei says in future, multi-layer pipes, other fibres and engineering polymers will also be tested. ENGINEERING POLYMERS AS A FUNCTIONAL INNER LAYER In addition to the composite pipes, KraussMaffei also demonstrated the KM-3L RKW 250 F³, a newlydeveloped tube die for a three-layer pipe with an inner layer made of PA 12, which is especially suited for transporting corrosive and abrasive media. “As a complement to the composite pipes, we are taking groundbreaking steps in pipe extrusion by processing engineering polymers,” Sieverding said. “Our development team was successful in combining the various processing parameters of raw materials such as temperature or shrinkage in this innovative tube die design.” KraussMaffei says the combination of the materials was “immediately obvious”, given that PA is substantially more expensive than PE but offers very high chemical and abrasion resistance. For complete bonding, an additional bonding layer is required. The live system at the Competence Forum used the KME 75-36 B/R, KME 45-36 B/R and KME 30-25 D/C single-screw extruders and is designed for a dimensional range of 50 to 282 mm and an output of 800 kg/h for PE, 30 kg/h for the bonding agent and 180 kg/h for the functional layer. www.kraussmaffeiberstorff.com

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RECLAMATION AND RECYCLING | NEWS New £20million fund available for innovation in circular plastics production New funding worth £20million has been announced for research and innovation in changing the way the UK manufactures and uses plastics. Science Minister, Sam Gyimah, said the new ‘Plastics and Research Innovation Fund’ (PRIF) will engage Britain’s best scientists and innovators to help move the country towards more circular economic and sustainable approaches to plastics. It will be managed by UK Research and Innovation (UKRI) and delivered via the Engineering and Physical Sciences Research Council (EPSRC), Innovate UK, and the Natural Environment Research Council (NERC).

Bottle partnership proves PCR potential Borealis and Henkel have collaborated on a new postconsumer recyclate (PCR) packaging solution that they say proves the suitability of recycled plastics for demanding products. Following intensive tests, a bottle for adhesive was produced in 100 percent PCR, using polyethylene

“There’s been incredible progress in making people aware of the danger that plastic can do to our environment and our oceans,” said Gyimah. “We are announcing a £20 million fund for our best scientists and researchers through UKRI to come up with new technology and new plastics that do not harm the environment so much. This means moving from our current model of make, use and dispose to a new model where you use, you reuse and you recycle.” UKRI says it will work together with WRAP to network and connect this fund with initiatives across business, government and the research and innovation community, to encourage knowledge exchange, and to identify future research and innovation priorities to enable the move to a circular plastics economy. “It is imperative we change our use and misuse of plastic,”

commented UK Research and Innovation Chief Executive, Professor Sir Mark Walport. “This fund will help to create the range of new approaches and alternatives needed to rapidly reverse the impact that our use of plastics is having on the planet.” UKRI says the fund will seek to deliver strategic networking and research that will coordinate existing knowledge across the UK; catalysing new ideas and rapid solutions across the research and innovation landscape. It will support the polymer, packaging, retail and waste sectors as well as local government responsible for waste collection. Further information on how to apply for a share of the funding can be found on the website. www.epsrc.ukri.org

regranulate, Purpolen PE, for the bottle, and Purpolen PP polypropylene regranulate for the applicator nozzle. Günter Stephan, Head of Borealis Circular Economy Solutions said the company is “thrilled” to be using recyclates to fulfil the diverse material demands for packaging of an adhesive product. www.borealisgroup.com

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The company is “thrilled” to be using recyclates to fulfil the diverse material demands for packaging of an adhesive product

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New collaboration presents circular economy solution for black plastics Faerch Plast UK has collaborated with three major retailers — Marks and Spencer, Tesco and Sainsbury’s — as well as recycling and waste management company, Viridor, to put recycled black plastic into new food grade packaging in a project welcomed by Environment Secretary, Michael Gove. Starting in July 2018, the solution will initially see 120 tonnes of black plastic, the equivalent to eight million items, recycled each month at Viridor’s plastic recycling facility in Rochester, Kent. The volume of material will be steadily increased over the next 18 months. Gove said: “This global leading scheme has the potential to mean the UK exports less of its waste, could divert huge amounts of plastic away from landfill and prevent virgin plastic entering the market in the first place.” Viridor’s Commercial Director, Paul Ringham, explained that a project team has been working together since January on the solution, stating that the team has proven that black plastic from household mixed waste recycling can be recycled into high quality mixed coloured ‘jazz’ flakes to create food-grade packaging. From July, Viridor will start

putting this material through the new process, adding black to the coloured plastic stream already recycled. The flakes and pellets will be taken to Faerch Plast’s manufacturing facility in Ely, Cambridgeshire, where it will be used in new packaging solutions. The key to the project, says Faerch Plast, was the collaboration across the supply chain, with the retailers creating the sustained demand for the recycled material and innovative packaging being provided by industry. “The project has proved a commercial process which can be extended across the UK,” said Ringham. “The more plastic collected, the more is made available to be recycled and put back into the circular economy. In this way, we all contribute to reducing the amount of virgin plastic entering the economy.” Andrew Osborne-Smith, Regional CEO of Faerch Plast UK and Ireland, added: “It has been rewarding to see the whole supply chain collaborating on this project to demonstrate that black PET trays are recyclable. However, there is more work to do to achieve high and sustainable levels of tray recycling with further investment in commercially viable waste collection systems and sorting and recycling facilities for PET pots, tubs and trays.” www.faerchplast.com www.viridor.co.uk

oration has The collab ly d and supp seen deman m o fr te for recycla cs ti black plas

RPC bpi protec is using surplus packaging to make furniture

RPC BPI Protec turns surplus polythene packaging into furniture RPC bpi protec’s site in Worcester has established a closed-loop recycling scheme to capture surplus plastic packaging from customers and turn it into secondlife products. Unused wicketted PE bags and films are returned under the protec Reprocess Scheme, which links with its sister recycling division to create a variety of products, such as activity tables and benches, using Plaswood. Plaswood is produced using 100 per cent recycled polythene, diverting waste from landfill and providing an alternative to hardwood that itself can be fully recycled at the end of its use. RPC bpi protec’s says as an added advantage, all protec Reprocess Scheme collections are made by lorries on their return journey from making a delivery to customers, saving on fuel costs and the CO2 footprint of transportation. The company says the protec Reprocess Scheme is an important part of the service to customers that helps to deliver sustainable packaging solutions. “We have already partnered with a number of important customers on this initiative, helping to support their CSR and sustainability programmes by taking their unused packaging and turning it into Plaswood benches for the benefit of organisations local to them,” said Sue Mohan, RPC bpi protec’s Sales Director. www.bpiconsumerpackaging.com

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Volvo Cars aims for 25 per cent recycled plastics in every new car from 2025 Volvo Cars has announced its ambition that at least 25 per cent of the plastics used in every newly launched Volvo car will be made from recycled material from 2025. It also urged auto industry suppliers to work more closely with car makers to develop nextgeneration components that are “as sustainable as possible”, especially with regards to containing more recycled plastics. To demonstrate its ambition, the company unveiled a speciallybuilt version of its XC60 T8 plug-in hybrid SUV that looks identical to the existing model, but has had several of its plastic components replaced with equivalents containing recycled materials. The special XC60’s interior has a tunnel console made from renewable fibres and plastics from discarded fishing nets and maritime ropes. On the floor, the carpet contains fibres made from PET plastic bottles and a recycled cotton mix from clothing manufacturers’ offcuts. The seats also use PET fibres from plastic bottles. Used car seats from old Volvo cars were used to create the sound-absorbing material under the car bonnet. “We already work with some great, forward-thinking suppliers when it comes to sustainability,” said Martina Buchhauser, Senior Vice President of Global Procurement at Volvo Cars.

led The recyc C60 X s c ti plas

“However, we do need increased availability of recycled plastics if we are to make our ambition a reality. That is why we call on even more suppliers and new partners to join us in investing in recycled plastics and to help us realise our ambition.” The recycled-plastics XC60 was revealed at the Ocean Summit during the Gothenburg Volvo Ocean Race stopover. The race’s focus on sustainability centres on a partnership with the United Nations Environment Clean Seas campaign. “Extensive recycling and reuse of plastic is vital to our efforts to turn the tide on plastic pollution,” said Erik Solheim, Head of UN Environment. “Volvo’s move to integrate plastic waste into the design of their next fleet of cars sets a new benchmark that we hope others in the car industry will follow. This is proof that this problem can be solved by design and innovation.” Volvo Cars says its ambition represents its commitment towards reducing its impact on the environment across all operations. www.volvocars.com

We do need increased availability of recycled plastics if we are to make our ambition a reality. That is why we call on even more suppliers and new partners to join us in investing in recycled plastics and to help us realise our ambition

‘Beacon’ of hope for recycling as major funding agreement signed Funding of over £3m has been announced for four projects comprising a new plastics recycling partnership that is said to have the potential to recycle all plastics in Scotland and beyond – even those that currently can’t be recycled. The partnership, called Project Beacon, is taking place at Binn Farm in Perthshire. Designed to create a “circular world of complete plastics recycling” thanks to new technologies and an innovative integrated approach, it is backed by £1.7m in funding from Zero Waste Scotland’s Circular Economy Investment Fund (with around another £1.7m leveraged form the private sector) – supported by the Scottish Government and the European Regional Development Fund. The new recycling centre at Binn Farm brings together a group recycling firms: PI Polymer Recycling along with Recycling Technologies Ltd and Impact Recycling Ltd, with Binn Group signed on as supply chain partners. The project partners are developing a system that uses new separation systems to support mechanical recycling, fused with a chemical feedstock recycling process. This includes a patented process based on thermal cracking, which recycles end-of-life plastic waste that typically cannot be recycled using mechanical methods, such as laminated, black, hard plastics and film and contaminated plastic waste. This new process produces a range of chemical constituents that can be used to create new virgin plastics, or other chemical products. Roseanna Cunningham, Cabinet Secretary for the Environment, Climate Change and Land Reform, said: “Initiatives like Project Beacon have the potential to be potentially ground-breaking as they are finding new uses and economic potential for hard-to-recycle plastics which could make a significant contribution to reducing waste and increase recycling.” It is intended that this facility will be up and running later this year. www.zerowastescotland. org.uk

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LUXOR EM A

LUXOR EM A – probably the most efficient small dryer on the market. It was developed especially for production cells and drying small material throughputs of plastic granulate and regrind – the LUXOR EM A. It is equipped with everything that characterises excellent drying: from the fully integrated colour touch panel control to ETA plus® technology and an integrated cyclone dust filter. Conveying is also integrated. Those who do not require this can find the ideal alternative in the LUXOR E A. Both ranges are available in three sizes with drying bins of 60, 100 and 150 litres.

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IN-MOULD LABELLING | NEWS Treofan launches new, thinner IML label film Treofan has launched a new, thinner verison of its EWR film for inmould labels (IML). New EWR50 has a thickness of 50μm and is said to offer greater efficiency and larger surface yield whilst offering the same performance properties, making it attractive to brand manufactures and converters in the food and packaging industry. Treofan says the average surface yield using EW50 increases to 20.8 m2/kg, in comparison to its EWR57 film, which has a 57μm thickness and surface yield of 18.3 m2/kg. Like the EWR57, the solid white EWR50 enables the efficient production of labels with a high gloss look. EWR is specifically developed for in-mould labels for PP and PE injection moulding. With good antistatic properties, web flatness and machinability, it is suited for offset sheet-fed printing with UV curing and oxidative drying inks, as well as for gravure and UVflexo printing. Joachim Jung, Product Management and Business Development at Treofan, explained: “The new EWR50 is geared towards the increasing market demands in terms of efficiency and yield combined with excellent quality.” Commenting, Mark Taylor, UK Manager at Reflex Labels, a customer of Treofan, added: “The new EWR50 impresses with superior production performance. The moulding reject rate is significantly reduced compared to competitive IML products.” www.treofan.com

Treofan launches new IML label film EWR50 to the market: More efficiency with only 50μm film thickness

Meech supplies Enelkon with IML equipment to improve production and reduce waste Meech has supplied Enelkon with in-mould labelling equipment to improve production and reduce its waste. The Turkish automation company, which specialises in development of IML robotics, says it is benefiting from the switch to Meech’s static generation technologies, which include the 994CG Generator, 994CG Remote Setpoint Controller and 994 Hydra pinning system. First installed in 2017, Meech’s technology took the place of Enelkon’s previous IML supplier’s equipment. “Our previous provider’s equipment suffered a few difficulties, including technical failure, which had the potential to negatively affect our relationships with customers,” said Neslihan Özercan, Operations Manager at Enelkon. “We didn’t hesitate to undertake a trial with Meech’s 994 IML technology. After seeing some

impressive results, we were keen to implement the technology into our automation equipment. In fact, we also changed the design of our robots, mandrels and our static components to fully accommodate the Meech IML system.” Özzercan added: “Since our investment in the 994 IML equipment, we’ve not experienced any product failures and we’ve noticed that our overall cycle time has decreased, total production has increased and wastage has dropped dramatically due to static failures being reduced to a minimum.” www.meech.com

Partners showcase IML innovation for greener coffee capsules Bio-based coffee capsules produced and decorated using IML have been showcased recently as a sustainable, yet high-end, solution for caffeine-loving consumers. At NPE in Orlando in May, partner companies demonstrated how using biocompatible PLA for disposable capsules could provide a greener alternative to other materials, whilst giving improved packaging performance in terms of both aesthetics, mechanical and barrier properties. An exhibit running on a Netstal ELION 1200-250/55 injection machine with a mould from Fostag, an IML robot and system from Beck Automation and IML labels from Verstraete, showed a coffee capsule injected with PLA before being decorated with an in-mould label printed on a special PLA film.

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This ensured a mono component capsule which fully conforms to the EN 13432 norm regarding industrial composting. Nick Lewis, Beck Automation Americas, explained that with the small size of the capsules, the challenge lies in label inserting precision, as well as an operatorfriendly concept. “We are talking about very small labels and ultra-lightweight components with extremely high production volumes,” he explained. The IMLsystem also included a quality assurance module to perform barrier checks from IMDvista. Beck Automation says that this solution for coffee capsules has been very well received by the company’s first customers in the USA and Switzerland. These pilot customers are said to be pleased with the functionality, look and environmental performance of the capsules, which they believe suit market demands. www.beck-automation.com

Meech equipment on site at Enelkon

“No change, no chance”

Mackie’s of Scotland chooses IML for innovation in ice cream

S SCOTTISH PRODUCER OF ICE CREAM, MACKIE’S, SWITCHED TO IN-HOUSE PRODUCTION FOR ITS PLASTIC TUBS, OPTING FOR DECORATION WITH IN-MOULD LABELS AS PART OF BOTH ITS FOCUS ON SUSTAINABILITY AND ONGOING PRODUCT INNOVATION. HERE, BP&R LOOKS AT THE BENEFITS TO A COMPANY THAT IS FOCUSED ON ITS GREEN CREDENTIALS AND KEEPING UP WITH CONSUMER DEMAND.

ackie’s of Scotland, based in Aberdeenshire, has been making dairy products on its family farm since the mid-80s. The company, which puts environment and innovation at the heart of its business, has recently invested in new machinery and labelling to enable it to produce its packaging more sustainably in house and have greater control over the aesthetics and design. “Innovation is incredibly important at Mackie’s of Scotland,” explained Karin Hayhow, Marketing Director. “We are constantly looking for new ways to optimise our business and brand. In the words of our late chairman: “No change, no chance!” LOCAL PACKAGING FOR LOCAL PRODUCE The company uses as much renewable energy as possible for its production processes, generated from a mix of wind, solar and biomass to power the business and has adopted ‘green’ working practices throughout. Its packaging process is no exception to the sustainability story, with the company choosing to re-shore its production from Sweden to save on its ecological footprint. In order to do this, it invested over £1million in its own injection moulding machine to produce its one- and twolitre IML ice cream tubs. By choosing not to ship its tubs from Sweden – a journey of about 1750 miles on both sea and road –Mackie’s now sees its tubs travel just 200 meters from its moulding room, a saving of over 50,000 food miles (and a lot of CO2 emissions) per year. In addition, by choosing in mould labelling, the packaging and label is made of the same material, creating a fully recyclable tub. QUICK DESIGN CHANGEOVER USING IML The decision to use IML packaging for its tubs was also enhanced due to the ability for Mackie’s to retain control over its processes and marketing of its products, according to Hayhow. “The tubs look good – and we can use full colour to very high definition quality,” she explained. “Being in charge of our own production gives us flexibility - so we can

very easily change the label design using this decoration technique and maximise the communication opportunities on pack.” Hayhow said that this flexibility is a big plus in Mackie’s of Scotland’s book, adding: “It lets us quickly shift things whenever we want to launch a new design or new promotion. Moreover, the in mould labels are moisture-resistant and can withstand major temperature fluctuations – perfect for decorating plastic packaging for frozen and refrigerated products.” COOL RUNNINGS In order to ensure the labels used for IML decoration stand out in the retail environment, Mackie’s of Scotland chose the ‘orange peel’ look and feel option. Supplied by IML label manufacturer, Verstraete, this well-known IML technique, also called satin gloss, sees the labels created using a multilayer substrate and polypropylene foam in the centre. A part of the air in the substrate escapes due to the use of high temperatures and pressures during the IML process, creating the ‘orange peel’ effect. “These innovative packaging solutions will make our products really stand out on the shelves,” continued Hayhow. “That’s very important to Mackie’s of Scotland because we have a modest marketing budget. With the right packaging, our products will jump off the shelves, catching the consumers’ eye,” she concluded. www.verstraete-iml.com/en

Being in charge of our own production gives us flexibility - so we can very easily change the label design using this decoration technique and maximise the communication opportunities on pack

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AirWash System - the system which can convey and clean simultaneously With its two stage cleaning process it is a precise de-duster that can eliminate pelletisation and drastically reduce processing costs. The AirWash is designed to effectively evacuate material from granulators, mixers and other process equipment using its own blower, which is also used for the cleaning process. The result is a homogeneous clean regrind that can be introduced back into your product mix eliminating the cost of pelletisation. For free sample evaluation please contact us. BEFORE

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Kongskilde U.K. Ltd. Tel.: +44 1263 808 580 kuk@kongskilde-industries.com www.kongskilde-industries.com/Industry

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BLOW MOULDING | NEWS Kautex Maschinenbau demonstrates expanded capabilities at Open House Kautex Maschinenbau has demonstrated its expanded capabilities following the opening of a new assembly hall at its facility in Bonn, Germany. During an Open House event, the company showcased its latest blow moulding machines, application examples and new services for the first time since Austrian-based Plastech Beteiligungs GmbH became its major shareholder in February this year. “We are continually striving to reduce lead times for our customers. This expansion of our

Sidel outlines new shape opportunities for PET packaging At this year’s Blow Moulding Conference held in Cologne, Germany, Sidel gave insights into increased PET packaging shape opportunities and how to achieve them. The focus for Sidel was SteadyEDGE, a patented base solution for PET package design variants in the Food, Home and Personal Care (FHPC) markets that it says ensures a stable and costefficient production. Compared to standard preferential heating, Sidel says

ned how José Andre outli lp brands he n ca GE SteadyED e iat nt differe

Bonn location should improve our future capacity for on-time delivery,” explained Managing Partner of Plastech, Andreas Lichtenauer. Over the course of the two-day event, visitors had the chance to see 31 demonstration machines, including one running mould trials for E-PET bottles and two vertical training machines. In addition, presentations on issues such as energy efficiency and the Industry 4.0 smart factory were given, as well as views on automation and service, retrofitting/modernisation options and a demonstration of a test version for future services based on a current augmented reality application using smart glasses.

The Open House at Kautex Maschinenbau in Bonn

www.kautex-group.com

SteadyEDGE can reduce packaging weight from 22 grams to 20 grams, lower the blowing pressure needed to shape the package base, and increase the output speed. This way, it says brand owners, co-packers and packaging manufacturers can achieve their return on investment (ROI) in less than one year. Designed to meet the challenge of producing flat, oval and rectangular containers in PET, which require the specific preferential heating (PH) blow moulding process, SteadyEDGE allows optimum material distribution to achieve a good quality package. Sidel says the innovative base technology enlarges marketing opportunities for containers with complex shapes and large labelling surfaces. “The sharper edges on the container are used to effectively flatten and increase the ‘standing ring’ area of the base,” explained José Andre, Technical Sales Manager at Sidel. “This leads to an enhanced stability of up to 35 per cent, which in turn makes it possible to speed up the process output by up to 10 per cent. Because bottles are far less likely to fall while being conveyed between several machines, this results in

fewer costly stoppages and greatly improved uptime.” Andre said that additionally, the containers can be lightweighted by up to 10 per cent, improving the material distribution on the base while using less energy. “This is coupled with a reduction in blowing pressure, to decrease energy consumption by up to 20 per cent during production, when limitation is linked to base design,” he added. With customers looking to optimise preform and bottle design in the face of complex container shapes, whilst also increasing their production reliability, Sidel has designed a specific base for SteadyEDGE, a patented base mould system known as the Base OverStroke System (BOSS). “BOSS is a piston activated in the blowing phase to stroke the base. This mechanical element allows for the raising and lowering of the base during the bottleforming process, independent of the opening and closing of the two half-shells of the mould,” continued Andre. “BOSS provides flexible and versatile production with the option to quickly implement mould changeovers and ensure maximum production and higher bottle quality.” www.sidel.com

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WWW.MOTAN-COLORTRONIC.CO.UK |

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Boost production with Ultra Purge™ purging compounds. Our Ultra Purge™ purging compounds for thermoplastic processing decrease scrap and down time during colour changes. Watch the video and learn how to increase your performance by purging your injection moulding machine during running production at www.chemtrend.com/purging1 www.chemtrend.com/purging1.

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Amcor launches first commercial container using liquid filling technique Amcor has revealed details of the first consumer packaging application using its pioneering LiquiForm technology. Through a partnership with Greenblendz, a co-packer and developer of consumer products, PET packaging for a hand soap brand has been produced on an Amcor-built machine powered by the LiquiForm process. LiquiForm technology uses the packaged product instead of compressed air to simultaneously form and fill containers. In this case, the hand soap essentially forms its own rigid PET container using the LiquiForm process. By combining the forming and filling into one step, Amcor says the process eliminates costs associated with the equipment and energy of the traditional blow moulding process along with the handling, transport, and warehousing of empty containers. “We’re excited to be a partner in the commercial validation of such a highly sustainable manufacturing process,” said Steve Berry, Founder and COO of

Greenblendz. “LiquiForm technology delivers enormous efficiencies throughout the supply chain and improves the industry’s carbon footprint.” Amcor says the forming of bottles with its LiquiForm process also opens new pathways toward lighter, more sustainable packaging. Lighter-weight containers, achieved through improved consistency in wall thickness, combined with a reduction in the transport of empty containers, reduces environmental emissions and lowers the carbon footprint. It says the LiquiForm process also offers the potential to reconfigure supply chains and move packaging closer to the market, resulting in strong logistical benefits and further carbon footprint reductions. “LiquiForm has the potential to revolutionise the filling and packaging industries with a more flexible, efficient, and sustainable supply chain,” said Ann O’Hara, Vice President and General Manager of Amcor Rigid Plastics’ Diversified Products Division. “The development and launch of the first commercial manufacturing machine and the introduction of the first commercial product represents two major milestones for the LiquiForm technology.” www.amcor.com The first bottle produced using nology LiquiForm tech

TECHNOLOGY FOR CHALLENGES OF THE FUTURE

R&D/Leverage installs LPD Dryers from Maguire R&D/Leverage, a specialist in tooling for injection stretch blow moulding of PET bottles, has replaced desiccant dryers on seven Nissei ASB and Aoki injection stretch blow moulding lines with LPD vacuum dryers from Maguire Products. The company says the switch from desiccant dryers to vacuum dryers at its European headquarters in Sutton-in-Ashfield, Nottinghamshire, has benefitted the company by reducing energy use and decreasing start-up and changeover times. “While the desiccant dryers needed four to six hours to dry material, the LPD dryers take only one hour and 20 minutes from a cold start-up and in subsequent drying cycles this is reduced to 40 minutes,” explained Alan Tolley, Managing Director at R&D/ Leverage. Besides startups, the desiccant dryers also posed problems with job changeovers. R&D / Leverage builds single-cavity ‘pilot’ tools for making samples, plus multicavity tools for commercial-scale operation. The tools undergo trial runs on the seven injection stretch blow lines, which process at rates up to 70 kg/h. R&D / Leverage typically has five or six tool changes per week. “The LPD dryers give us much more flexibility when testing different grades of resin on one

tool,” said Mr. Tolley. “Because we are not a production-scale facility with long product runs, the desiccant dryers were always a challenge for us, posing problems with getting the material dried properly.” The LPD dryers also display improved resin filtration, which provides enhanced bottle clarity due to less contamination and more flexible throughput control for the single-cavity pilot tool versus highcavitation production tools. R&D / Leverage has also installed a central Maguire Weigh Scale Blender, delivering to the moulding process precisely controlled batches of virgin and recycled polymer, colourants and additives. Tolley added: “In the past we were forever having to change desiccant every six months because we were doing so much stopping and starting of our moulding processes. That meant added cost and added maintenance.” Paul Edmondson, Managing Director of Maguire Europe, said: “Considering that drying polymer can account for 15 per cent of the total process energy of a moulding operation, a compelling reason for using vacuum dryers is that they consume up to 80 per cent less energy than desiccant systems.”

Novodur HH-112 is an ABS material specifically designed for highest heat resistance and excellent stiffness

INEOS Styrolution’s Novodur HH-112 selected for blow moulded roof spoiler INEOS Styrolution has announced that its Novodur HH- 112 has been selected by a major European car manufacturer for a blow moulded roof spoiler. Novodur HH-112 is an ABS material specifically designed for highest heat resistance and excellent stiffness. INEOS Styrolution says its Novodur HH-112 has been selected as the material for the roof spoiler for several reasons, including heat performance, good paintability, Vicat softening temperature of 112 °C and the melt rheology required for blow moulding processing. The company added that energy and cost savings are achieved by taking advantage of the selected material solution. The material offers the advantage of painting without pre-treatment, such as surface activation, and the final application is manufactured in a single part as opposed to multiple parts that must be assembled. Eric Chambost, Key Account Manager at INEOS Styrolution, said: “Due to our long-lasting relationship with the customer and the Tier One supplying this part, an efficient technical cooperation drove to this interesting cost effective solution. With this Novodur HH112 using blow moulding technology, a high quality painted surface was achieved.”

www.maguire.com www.summitsystems.co.uk Injection Stretch Blow Moulding Lines at R&D/ Leverage

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MOULD MAKING AND TOOLING | NEWS Meusburger expands workshop equipment portfolio Meusburger has expanded its range of workshop equipment, with new assembly equipment and surface finishing products, as well as adding to its range of clamping equipment and EDM accessories. Following on from its launch of E 21311 high temperature O-ring seals in March this year, which were specifically designed for applications with water and operating temperatures up to 180°C, Meusburger has now added a matching new WZB 12112 Countersink for O-rings. This, it says, enables an easy introduction of the required O-ring groove. After the assembly, the O-ring sits closely on the outer diameter, where it can’t fall out. In addition, an optimum position is achieved under pressure from the inside, ensuring optimum tightness and high durability. Another new product in the range is the V 28100 Assembly tool set for O-rings, which consists of five tools and facilitates the assembly and disassembly of O-ring seals. Whether hitching, positioning, pushing or pulling the O-ring seal Meusburger says the new set offers “many possibilities.” For the fast detection and location of leaks in inserts and cavity plates, the company has also

Phoenix adds laser welding technology to in-house service offering Phoenix Engineering has added a suite of laser welding technology to its plant machinery portfolio, as it adds to its range of in-house service offerings. The company, part of the Pentagon Plastics Group, has invested £130,000 in a package supplied by TLM Laser, which includes an ALT 500 and AL300, a tiltable turntable, magnetic clamping capabilities and an integrated extraction and laser wire

launched a quick adapter for Ø 12 mm holes. It can be easily fixed using the cylindrical cooling holes without having to cut an additional thread. Due to the slim design, Meusburger says it is also possible to use it with minimal hole gaps. For efficient surface finishing, the company has added a powerful GESU 1300 Ultrasonic system with 100 W output, that it says is ideal for fast work on large areas. The amplitude value is adjustable and using various modes of operation and two different handpieces, the device can also be used for fine applications. In addition, a new, universal GDSW 1040 Air angle grinder with interchangeable attachments has been introduced to the range.

feed system. The Pentagon Group says laser welding has been a major sub-contracting expense for its companies for many years, and through investment into the right machinery, it believes the benefits will be far more than the initial costs, with reduced lead times for tooling work, improved control of work-flow and the offering of a new business service in-house. “For Phoenix, most our tooling is for the caps and closure sector, ranging from four to 64 impressions. Expediting servicing and repairs are key to keeping the tool downtime to a minimum,” said

Meusburger innovations in workshop equipment. Credit: Meusburger

Finally, Meusburger’s clamping equipment and EDM accessories range has been expanded with the indroduction of futher electrode holders, HER 1442 and HER 1642. These were, until now, available with groove widths 10, 15 and 20 mm - with the new widths expanding the offering to include 25 and 30 mm. Threading electrodes from copper and tungsten copper are also now available in numerous new thread sizes, and there are also new sizes for the rod electrodes from copper. www.meusburger.com

John Horspool, Tooling Manager. “Many of the elements require laser welding to re-instate shutoffs etc., therefore the weld needs to be very exact and repeatable, driving the business need for a high spec machine, with a rotary axis, self-feed wire and programmable movement in all axes.” The group business will have three fully trained operatives available for laser welding projects ensuring that the required skill set is available daily to accommodate the throughput of internal and subcontract support work. www.phoenix-engineering.co.uk

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How hybrid additive manufacturing

can speed up mould making

I INJECTION MOULD TOOLS, TRADITIONALLY MANUFACTURED IN THE FAR EAST, CAN NOW BE CREATED IN THE UK IN HALF THE TIME REQUIRED FOR CONVENTIONAL TOOLMAKING, SAYS MARCEL GOWERS OF PLASTIC INJECTION MOULDING SPECIALIST, OGM. IN THE FOLLOWING ARTICLE FOR BP&R, HE OUTLINES HOW. ABOUT THE author:

Marcel Gowers is Additive Applications Engineering Manager at OGM, with over 25 years of mechanical engineering experience. This includes 15 years at Smiths Group plc within a high technology environment.

peed and quality maintenance are the holy grail of any industrial manufacturing process and nowhere is this truer than in the production of injection-moulded components. Traditionally, manufacturers have been looking to the Far East to cut the time it takes to get a design from concept to production. However, even in the Far East, the manufacture of mould tools suitable for the high-volume production of complex parts is a time-intensive process; with lead times of up to four months between design sign-off and delivery of first part production in the UK. And the performance of a tool - especially its ability to cool parts effectively prior to ejection determines the cycle time, quality and overall productivity of the moulding process. INNOVATION CUTS MOULD MAKING TIMES Additive manufacturing is finding its way into toolmaking and a new technology - hybrid metal additive manufacturing and machining – is enabling moulds to be made quicker and more cost-effectively than ever before. The first of its kind to be installed in the UK at OGM, this new technology is creating waves in the injection moulding sector and is ushering in major change in the manufacture of plastic parts in the UK and beyond. TWO TECHNOLOGIES, ONE MACHINE Hybrid metal additive manufacturing and machining is proving particularly popular with customers looking to achieve complex moulds quickly and cost-effectively. At the heart of the solution is the combination of hybrid metal additive manufacturing - using direct metal laser sintering – with conventional CNC machining. They have been combined into an integrated build process, with stunning results. The system builds mould features from powder material layer-by-layer using a laser. After each layer is added, an

CAD being used for the design of complex moulds

automated secondary machining process rapidly removes excess material to generate the finished geometry of the tool. The result is high dimensional accuracy and a fine surface finish that allows core and cavity details to be manufactured automatically in one go. The material surface finish produced is also hard, often avoiding the subsequent need for heat treatment to produce production tooling. If required, a full range of textured or polished surface finishes can be applied in secondary processes. RAPID PRODUCTION TOOLMAKING TECHNIQUE COMPRESSES LEAD TIMES BY UP TO 50 PER CENT To make the most efficient use of this hybrid metal additive manufacturing technology, OGM’s Rapid Production Toolmaking technique is also used to combine the process with conventional high-speed machining. The basic shape and simpler features of a core or cavity are machined first from a solid block of tool steel and this becomes the base structure onto which the more complex features are added. This approach compresses lead times by up to 50 per cent, with just a few weeks from order to first production parts, and produces mould tool inserts with good levels of surface finish and precision, to within 50 microns.

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BETTER QUALITY AND FASTER CYCLE TIME WITH IMPROVED CONFORMAL COOLING The hybrid metal additive manufacturing approach enables the production of mould features that would be extremely difficult to manufacture with any alternative technology. Notably, the production of conformal cooling channels in moulds with complex geometry. In many components, cooling channels compete for space within the tool with other features, such as ejector pins or moving inserts. Although injection mould toolmakers have developed solutions to this problem they inevitably add to the time, complexity and cost of producing each mould tool or mould tool insert. The hybrid approach, by contrast, allows tools incorporating conformal cooling channels to be manufactured automatically in one hit, with no need for separate finishing activities. As a result, typical lead-times can be reduced from more than 12 weeks to less than six weeks. With time being of the essence on any production job, being able to guarantee quality, whilst reducing lead times and improving cost efficiencies is good news for customers. www.ogm.uk.com

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Finalist in 3 categories at 2017 Plastics Industry Awards Specialist in complex tooling solutions 5-Axis Mikron high-speed graphite and hard metal machining centre Agie Charmilles spark erosion Consistent track record in on-time tooling delivery Product design consultation service Design for Manufacture principles 2018 SolidWorks and SolidCAM multiple licences 35 years’ experience ISO9001 certification 3D printing, prototyping and testing

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DTL Machinery UK deals in used plastic injection moulding machinery and related ancillary equipment since 2003. We buy all makes, age and sizes of machines for our stock and also redundant / very old machines (1980 onwards) for our overseas customers for refurbishment.

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PACKAGING | NEWS Netstal expands ELIOS series for thinwalled packaging Netstal, the Swiss injection moulding machine manufacturer, is expanding the lower end of its ELIOS series with versions featuring clamping forces of 4500 kN and 5500 kN. The ELIOS 4500 has a stroke of 574 mm and a dry cycle time of 1.5 seconds according to the Euromap norm and the ELIOS 5500 has a dry cycle of 1.7 seconds at a stroke of 644 mm. Renzo Davatz, Netstal CEO, said: “Manufacturers of thin-walled packaging know that the shortest cycle times coupled with top availability and quality are the keys to an effective reduction of unit

costs. That has been our guiding principle during the development of the entire series.” A five-point dual toggle lever, which is moved via a central crosshead with drive elements that act simultaneously, sits at the heart of the machine and a dual toothedrack drive with a highly dynamic, water-cooled servo motor is used for the purely electrical movements. Two synchronous cylinders, which feature a parallel alignment, assist with building up the full clamping force. “This concept offers many advantages, because the small mass moment of inertia of the motor allows high acceleration values and dynamic movements of the clamping plate,” Davatz continued. “At the same time, the plate is

moved very harmoniously while the mould position is controlled with great precision and in a way that is gentle on the mould.” Thanks to the optimised toggle lever geometry, Davatz says the clamping unit of the ELIOS is particularly energy efficient and offers ideal conditions for the recovery of the movement energy. The kinetic energy generated during braking processes flows into the electric motor of the main drive where it is converted into hydraulic energy and stored. That is why, compared to conventional designs, an ELIOS is said to require approximately 50 per cent less energy.

Tesco to remove all non-recyclable packaging materials by 2019

loop system,” said Jason Tarry, Chief Product Officer. “We will work with our suppliers to redesign and reduce all packaging materials and, after consultation with our leading suppliers earlier this year, we will remove all packaging that is hard to recycle from our business by 2019.” He added: “To complete the journey to a closed loop approach, we stand ready to work with Government to reform the current approach to recycling in the UK.” As a part of its plan, Tesco says it will also work to develop ‘easy to understand’ packaging recycling communication and the amount of recycled materials it buys to help shoppers who want to reduce their packaging impact. The announcements tie in with Tesco’s ‘Little Helps Plan’, which it originally unveiled in October last year.

www.netstal.com

The new ELIOS series machines are designed for top packaging application productivity

unced Tesco has anno its r new plans fo by 2019 grocery packaging

Tesco has announced new plans to remove hard to recycle and nonrecyclable materials used for its grocery packaging by 2019. The UK’s biggest supermarket chain said its ambitions for a ‘closed-loop system’ across its UK operations extended to removing, reducing and redesigning the way it uses packaging. For this closed loop to become a reality, Tesco called on the Government to establish a consistent recycling infrastructure across the UK, where it said variations in current levels of actual recycling “are extreme”. “We are committed to reducing the total amount of packaging used across our business. Ideally we would like to move to a closed

www.tescoplc.com

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Packaging panel debate:

From conversation comes action

A PANEL DEBATE HELD ON WORLD ENVIRONMENT DAY BROUGHT TOGETHER KEY PARTICIPANTS FROM ACROSS MULTIPLE INDUSTRIES TO DISCUSS OPPORTUNITIES FOR RADICAL COLLABORATION AROUND USE – AND UNDERSTANDING OF – PLASTICS AND PACKAGING. BRITISH PLASTICS AND RUBBER REPORTS ON THE KEY HIGHLIGHTS FROM THE EVENT.

the call was for society to recognise the value of plastic as a resource and one to be used in the right way for the right purpose, so retaining thriving market potential for responsible provision.

aced with calls to address the use of plastics within the micro-city for which it is responsible, the Canary Wharf Group has recently launched a 12-month programme where it will pilot new technologies and processes for its tenants and residents. However, keen to address and facilitate discussions for wider collaboration and change that could apply nationwide, it brought together key stakeholders on June 5 to lead the debate. Panellists leading the discussion included Lubna Edwards, Global Sustainability Director at Klöckner Pentaplast; Tor Harris, Head of Sustainability and Responsible Sourcing at Waitrose; Ian Schofield, Own Label and Packaging Manager for Iceland; and Jim Brisby, Group Commercial Director for Cranswick Group. Alongside them, stakeholders from multiple industries including packaging, retail and recycling, attended as delegates, where they discussed the overall themes with the panellists in small breakout groups to produce action points for coherent direction for increased recycling, consumer responsibility and less waste plastic ending up in the environment. ONE VISION As a stated aim for the day, collaboration was not surprisingly referenced throughout the debate – championed not only in the sense of multiple stakeholders actively working together in practice, but also achieving a strategic and coherent shared vision for plastics, in policy and principle. Facilitating this collaboration, it was agreed, demands clarity and consistency in communication. Accordingly, two other recurring themes concerned the need for education and the drive for simplification. For event outputs to prove more than just rhetoric, there was a determination amongst participants that commitments should necessarily address a fourth, underlying theme, too: the issue of cost. EDUCATION It was agreed that society in general lacks the necessary understanding around plastics at present – not just in terms of appreciating the impact of waste disposal, but also the positive benefits of plastic and packaging plus the bigger social, environmental and economic picture. The public struggles and frequently fails to know the right thing to do. “We follow the mantra of avoid, reduce, reuse and recycle when it comes to plastics packaging,” said Lubna Edwards, Global Sustainability Director at Klöckner Pentaplast. “However, plastics should not be demonised. They are much misunderstood. There are good, sustainable plastics. We need to increase collections and work on our national collection and sorting infrastructure.” Acceptance of personal responsibility remains an issue and it was argued that significant portions of society do not care about recycling or plastic waste and are unlikely to alter their

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ways unless faced with consequences for noncompliance and especially littering. To overcome some of these barriers, pledges were made across the spectrum of participants, to help inform both industry and in-house, up and down the supply chain, as well as working with consumers, local communities, schools and colleges. As well as myth-busting around such issues as benefits of compostable and biodegradable materials, plus waste-stream contamination, commitments were made to lend vocal support to campaigns to build consumer responsibility, calling for zero-tolerance of littering and enforcement measures. SIMPLIFICATION It was found that the common barriers to changing the way that customers think about plastics came down to customers needing simple answers – is it recyclable, yes, or no? At present, however, lack of alignment amongst local authorities’ collection criteria makes household recycling unnecessarily complicated. The current picture is one of confusion. “Consumer confusion is a minefield,” commented Jim Brisby, Group Commercial Director for Cranswick Group. “Labelling on packaging doesn’t help. The more we can simplify the better.” The waste industry itself is also wrestling with both the confused disposal behaviours of consumers and vagaries of local collection regimes. It is crying out for a coordinated, standardised approach. Suggestions were to simplify by format (such as meat trays), by colour (such as black), as well as by lobbying producers to split polymers. The argument was made that it is effectively ‘game over’ for mixed polymers, as the sector moves away from mechanical to chemical recycling. Participants championed the need for clear on-pack calls to action, a simpler set of logos that removed the ambiguity and confusion for consumers, plus potential use of colour coding, or embossed symbols. In short, they felt on-pack messaging must drive positive decision making. COLLABORATION The participants agreed that they could all achieve more through collaboration, and, if consumers hear the same message consistently from several different sources. However, there is often a disconnect (perceived or real) between government targets, business goals and consumer aspirations. Whilst simplification is desirable, however, over-simplification is not. The law of unintended consequences applies to the potential for rising food waste, because of packaging cuts, for instance. Collaboration around consistent quality of material not just quantity, is also needed to develop domestic revenue streams for recyclables, negating the need for imported material.

Whilst simplification is desirable, over-simplification is not. The law of unintended consequences applies to the potential for rising food waste, because of packaging cuts, for instance. There were pledges and recommendations to co-ordinate on innovation, plus support for engagement with WRAP on the ‘UK Plastics Pact’ initiative to help drive change throughout the entire value chain. Such collaboration could help address big-picture issues, such as Government leadership, infrastructure development, policy and legislative frameworks. COST Getting waste collection right starts with balancing the cost-benefit equation, it was found. This is not only about what costs might be, but who is going to pay them - with consumers not keen to pick up the tab. Commercialising solutions also calls for some security in terms of the longer-term economics of the problem, with fiscal instruments from Government such as deposit-return schemes and a plastic bag tax in the mix, alongside incentives for investment and lending institutions to offer favourable terms. There was support for exploring opportunities to leverage the tax system to drive change, as well as endorsements for investment in infrastructure for collection facilities at point-ofuse. As well as removing avoidable plastic from packaging, producers, suppliers and retailers should look for opportunities to reduce plastic usage, including through right-sizing packaging. The caveat is though, that parties should sense-check all such decisions for unintended consequences. “There is absolutely a place for plastics,” said Tor Harris, Head of Sustainability and Responsible Sourcing at Waitrose. “We are looking to turn our use of plastics down, not turn it off altogether. We are increasingly looking at options for re-use.” There was also support for a reformed Packaging Recovery Notes scheme – with funds ring-fenced and cash funnelled back into education and recycling to continue driving growth in the market. CONCLUSION In conclusion, the call was for society to recognise the value of plastic as a resource and one to be used in the right way for the right purpose, so retaining thriving market potential for responsible provision. The full report from the day can be downloaded from the Canary Wharf Group.

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MATERIALS | NEWS IKEA collaborates with Neste in a bid to make all products from renewable materials by 2030 IKEA is working to change all plastic used in its products to plastic based on recycled or renewable materials by 2030. Initiated in 2016, IKEA has collaborated with Neste in an ongoing project to eliminate virgin fossil-based raw materials in its plastic products. This collaboration has allowed IKEA and Neste to turn waste and residue raw materials, such as used cooking oil and sustainable vegetable oils into polypropylene (PP) and polyethylene (PE) plastic. The production of bio-based plastics will be based on Neste’s 100 percent renewable hydrocarbons and the pilot, commercial-scale production will start in autumn this year. The production of the plastics will be based on Neste’s 100 percent renewable hydrocarbons. IKEA will use the new plastic in products that are part of the current product range, such as plastic storage boxes, starting with

IKEA hopes to have all plastic products based on recycled or renewable materials by 2030

a limited number of products and as capacities improve, more products will follow. Erik Ljungblad, Category Manager Plastic Products at IKEA of Sweden, said: “This new material represents a significant step towards a fossil free future. No one has ever before been able to produce PP plastic from a fossil-free raw material other than on a laboratory scale. Together with Neste, we are ensuring that there is an opportunity to scale up the production of this material.” www.neste.com

This new material represents a significant step towards a fossil free future. No one has ever before been able to produce PP plastic from a fossil-free raw material other than on a laboratory scale

BIESTERFELD ANNOUNCES EXCLUSIVE ELASTOLLAN TPU DISTRIBUTION DEAL WITH BASF Biesterfeld Plastic has announced it has secured exclusive distribution rights for BASF’s ‘Elastollan’ thermoplastic polyurethane elastomer (TPU). The company will supply the material in central, western and southern Europe and says it is “the perfect addition” to its product portfolio, which includes Ester and Ether TPUs, light-resistant aliphatic types and products with various hardnesses from Shore A 35 to D 83. “We’re delighted to be able to strengthen our strategic partnership with BASF,” said Claus Berger, Product Manager, Biesterfeld Plastic. “Elastollan is an important component of our portfolio of higher-grade technical TPEs.” “The product can also be processed in various ways with other polymers from our portfolio, so we offer our customers comprehensive solutions from a single source,” added Dietmar Zinkand, Business Manager Engineering Thermoplastics, Biesterfeld Plastic. Elastollan TPUs are suited to use in gear knobs, door handles, and liner mats in the automotive industry. It is also processed in the sports and leisure industry, such as in ski boots and sports shoes, the electrical industry, where it is used in connectors, cables, and sleeves and it also has applications in machine construction as a raw material for gears and transport systems. It benefits from a high resistance to wear, abrasion and tearing, and, as well as excellent tensile strength, it is said to possess outstanding mechanical properties. “With Biesterfeld at our side as a strong pan-European distribution partner, we have the best possible starting point to optimally position Elastollan on the European market,” commented Carsten Buschmann, Head of Product Management TPU at BASF. www.biesterfeld-

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What is the value of prime polymers which contain a recycled content?

IN HIS COLUMN THIS MONTH, MIKE BOSWELL ASKS WHETHER NEUTRALITY IN PRICING IS THE BEST WAY FORWARD FOR THE INCREASING NUMBER OF ‘CIRCULAR POLYMERS’.

istorically, recycled polymers have traded at a significant discount below the prime virgin polymers from which they were derived. The diminution in value is associated with a variety of factors including: change in physical properties due to thermal degradation during processing; contamination through the prior use of colourants and/or other additives; restricted scope of application including approval for use in food contact products; variability in processing properties; and strong odour affecting finished products. In the case of high performance steel, the reduction in performance resulting from the presence of contaminants is often referred to as ‘down-cycling’. However, the term ‘recycling’ has now been widely adopted in the plastics, paper, wood and other sectors and, with that, the acceptance that the recycled materials are not the same as the materials from which they come. Today there is a new generation of prime polymers with recycled content, which offer some or all the properties of prime polymers, but with ecological credentials that move these polymer grades in the direction of the circular economy. In many cases, prime polymer producers including Total, Sabic, Borealis and Lyondell Basell are now actively involved with the production of these polymers through partnerships, joint ventures and subsidiaries. In these cases, the prime polymer producers bring their polymer engineering expertise, which enables the properties of the materials with recycled content to be

If these ‘Circular Polymers’ have very similar properties to the prime polymers from which they are derived, why should they not have the same value? maintained or enhanced through the use of appropriate stabilisers (to prevent thermal degradation at processing temperatures), or property modifiers (to ensure good processing and end application characteristics). Moreover, these grades are typically presented with a manufacturer’s data sheet providing key property data, with some materials even being certified for use in food contact applications. So then to the question of value. If these ‘Circular Polymers’ have very similar properties to the prime polymers from which they are derived, why should they not have the same value? Not only does this neutral approach have logic, it neither provides a cost penalty to the producer, nor a cost advantage to the processor or downstream user. Of course, what is vital, (and somewhat what surprisingly the major polymer producers fully support) is that use of these materials is embraced by processors, brand owners and consumers so that we can move beyond the current produce, use, dispose towards a more circular approach in which more use is made of existing resources.

PART OF A SPECIFICATION SHEET FOR A ‘CIRCULAR POLYMER’

Who is ‘Polymerman’?

Mike Boswell is Managing Director of UK materials distributor, Plastribution, as well as the Chairman of the British Plastic Federation’s Polymer Compounders and Distributors Group and its ‘BREXIT Committee’. ‘Polymerman’ is the title used for announcements made via his Twitter account. This column is compiled using data from PIE (Plastics Information Europe) www.plastribution. co.uk | www.pieweb.com

PART OF A SPECIFICATION SHEET SHOWING A TYPICAL ‘PRIME VIRGIN POLYMER’

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Colour Tone granted new patent for the market’s only PVCu colour system Colour Tone has been granted a new patent for formulation improvements made to the market’s only PVCu polymer specific colouring system, Vynacol. Supporting both granular and prill format favoured by dry-blend processors, the patent covers the refinements made to the formulation technology for this masterbatch. Originally developed to solve compatibility and processing problems found when adding colour concentrates to PVCu, the Vynacol colouring system employs innovative technology. Suitable for injection moulding, extrusion and blow moulding, processors can benefit from reduced stock of coloured compounds, reduced cost and greater production flexibility by selfcolouring. patent Colortone has been granted a for its PVCu colour system

Vynacol can be formulated to meet international standards for food, toy, packaging, automotive and electrical products. Prior to Vynacol, colour was added to PVCu by using liquid colours, wax dispersions, universal and flexible PVC based masterbatches, these systems often presented processing difficulties that could lead to application failures. “Since Vynacol’s launch in 2000, advances have been made in raw materials and demand for smaller granules also emerged. In response, we developed the prill format that meant changes to our formulation technology to support the different processing required,” said Tony Gaukroger, Director at Colour Tone. “This improved masterbatch is available in both formats for ease of mixing and homogenisation. It also offers significantly improved melt rheology control for consistent processing of more highly loaded formulations, which together ensures a high quality PVCu product.”

World Cup may be over but Stadium set to last The World Cup is over for 2018 but the Luzhniki Stadium in Moskow, which hosted the all-important final, is set to last thanks to materials science from Covestro. Fully renovated ahead of the tournament, the stand roofing consists of transparent, robust and lightweight Makrolon polycarbonate sheets. The X-structure of the multiwall sheet ensures high stability in all kinds of weather and withstands high snow loads. Thanks to new additives and a special UV coating, the polycarbonate sheets are guaranteed to be protected from weathering for 25 years.

www.colourtonemasterbatch.co.uk

www.covestro.com

Chem-Trend’s new agent removes adhesion promoters with ease Chem-Trend has developed a new product for instant cleaning of assembly and clamping jigs in the production of rubber-metal parts. New Chem-Trend PM-J5525W ensures rapid and easy removal of adhesion promoter residues that can often remain following manufacture. Chem-Trend PM-J5525W is applied to the pre-heated, clean jig

before starting production and then burnt into the jig at a temperature of 130 degrees celsius. Once the jig cools down, the product process can begin and the jig can then be removed for cleaning, here adhesion promoter residue can be easily detached. The jig is placed back into the machine once cleaning is complete and coated with the Chem-Trend PM-J5525W release agent again before the new production cycle starts. Chem-Trend says the efficiency of the release agent results in

savings on manufacturing costs while also reducing workload and downtimes. www.chemtrend.com

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New Chem-Trend PM-J5525W

BUYER’S GUIDE MATERIALS

pulse staking

MOULD RELEASE

MASTERBATCH

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Specialists in supplying Plastic Joining, Bonding and Assembly Solutions

Technologies:

-Pulse Staking -Pulse Fusion -Ultrasonic Welding and Metal Insertion -High Frequency Induction Heating -Hot Air Staking

BLACK & WHITE MASTERBATCH Compounding

Recycling

Moulding

Film

Pipe

Conduit

Whitelands Mill, Whitelands Road Ashton-under-Lyne, OL6 6UG, UK Tel: +44 (0)161 308 2550 Fax: +44 (0)161 343 2026 E-mail: aml@abbeymb.com Eclipse Guide_Layout Web: Buyers www.abbeymb.com

Tel UK: +44 7467 959240 Tel IRL: +353 1 8013261 Email: info@hte.ie

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ultrasonic welding

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colour masterbatch

HOT RUNNER SYSTEMS hot runner controllers

CONTROL SYSTEMS AND EQUIPMENT quality monitoring control Kistler Instruments Ltd

T: 01256 741550 F: 01256 741551 E: sales.uk@kistler.com W: www.kistler.com Pressure transducers and associated monitoring/control equipment for new and existing injection moulding applications.

DRYERS Motan Colortronic Ltd

Matilda House, Carrwood Road, Chesterﬁeld Trading Estate, Chesterﬁeld S41 9QB T: 01246 260222 F: 01246 455420 E: sales@motan-colortronic.co.uk W: www.motan-colortronic.co.uk

Units 3E + 3F, Hillam Road Industrial Estate, Bradford, West Yorkshire, BD2 1QN T: 01274 731552 F: 01274 738118 E: sales@eclipsecolours.com W: www.eclipsecolours.com Polymer Specific and Universal Colour and Additive Masterbatches. Fastmatch colour matching service. 1 mm Easysperse MicroPellets to 4 mm MaxiPellets. Standards second to none.

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cleaning materials

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JOINING

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Find your perfect joining method.

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MATERIALS HANDLING AND STORAGE gravimetric/ volumetric blending

New & Used

For Sale &

Wanted

Motan Colortronic Ltd

Matilda House, Carrwood Road, Chesterﬁeld Trading Estate, Chesterﬁeld S41 9QB T: 01246 260222 F: 01246 455420 E: sales@motan-colortronic.co.uk W: www.motan-colortronic.co.uk

Branson - Mecasonic - Telsonic Sonotrodes (Horns) all Frequencies Fixtures, Repairs, Service, Parts Sub-Contract Welding, Hire & Consultancy

Tel; 01258 459257 Tel; 07730 413197

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InControl Ultrasonics Ltd (FFR Ultrasonics Ltd)

PO Box 10380, Sileby, LE12 7ZX T: 01509 621992 E: enquiries@ffr-ultrasonics. co.uk W: www.ffr-ultrasonics.co.uk W: www.incontrolultrasonics.co.uk

DEHUMIDIFIERS Motan Colortronic Ltd

Matilda House, Carrwood Road, Chesterﬁeld Trading Estate, Chesterﬁeld S41 9QB T: 01246 260222 F: 01246 455420 E: sales@motan-colortronic.co.uk W: www.motan-colortronic.co.uk

HEATING EQUIPMENT

Telsonic UK Ltd

Unit 3 Vitrage Technical Park 27 Witney Road , Nufﬁeld Industrial Estate, Poole, Dorset BH17 0GL T: 01202 697340 F: 01202 693674 W: www.telsonic.com Blog: telsoniccuk.wordpress.com

Branson Ultrasonics

Matilda House, Carrwood Road, Chesterﬁeld Trading Estate, Chesterﬁeld S41 9QB T: 01246 260222 F: 01246 455420 E: sales@motan-colortronic.co.uk W: www.motan-colortronic.co.uk

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hopper loaders

158 Edinburgh Avenue, Slough, Berkshire SL1 4UE T: 01753 756675 F: 01753 551270 E: bucuk.sales@emerson.com W: www.bransoneurope.eu

Motan Colortronic Ltd

Suction Blowers pipework cyclones New and Used recycling Equipment Kongskilde Spares, Parts and Pipework Suppliers industrial BLOWERS FLAKE/REGRIND Friendly Expert advice Les 01568 611338 Hereford W: WWW.GRAINBLOWERS.CO.UK

MATERIALS HANDLING AND STORAGE

vibration welding

CHILLERS/ TEMPERATURE CONTROLLERS

AM&LT PUGH KONGSKILDE MAIN DEALER

induction heating for platens and tools MF Induction Heating

Unit 5, Martindale, Hawks Green, Cannock, Staffs, WS11 7XN Replacement Coils New platens T: 01543 570642 E: sales@mﬁnduction.com W: www.mﬁnduction.com

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BUYER’S GUIDE MACHINERY & EQUIPMENT MIXING, FEEDING AND DOSING Motan Colortronic Ltd

Matilda House, Carrwood Road, Chesterﬁeld Trading Estate, Chesterﬁeld S41 9QB T: 01246 260222 F: 01246 455420 E: sales@motan-colortronic.co.uk W: www.motan-colortronic.co.uk

METAL DETECTION AND SEPARATION EQUIPMENT Motan Colortronic Ltd

Matilda House, Carrwood Road, Chesterﬁeld Trading Estate, Chesterﬁeld S41 9QB T: 01246 260222 F: 01246 455420 E: sales@motan-colortronic.co.uk W: www.motan-colortronic.co.uk

TO ADVERTISE IN THis SPACE CONTACT mandy o’brien 01244 952373 Magnetics Separators Metal Detectors Eddy Current Separators

Bunting Magnetics Europe Ltd European Design & Manufacturing Facility

Northbridge Road Berkhamsted Hertfordshire HP4 1EH, UK Tel: +44 (0) 1442 875081 Email: sales@buntingeurope.com www.buntingeurope.com www.magneticseparation.co

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Contact: Carlton Hicks

Refurbished machines with fault and leak free guarantee. COMPOUNDS

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HOPPER LOADERS

SCREEN CHANGERS

Motan Colortronic Ltd

Industrial Plastics Ltd

Matilda House, Carrwood Road, Chesterﬁeld Trading Estate, Chesterﬁeld S41 9QB T: 01246 260222 F: 01246 455420 E: sales@motan-colortronic.co.uk W: www.motan-colortronic.co.uk

Unit 13 Canterbury Industrial Park, 297 Ilderton Road, London, SE15 1NP T: 020 7252 9600 F: 020 7252 9601 E: sales@ipl-london.co.uk W: www.ipl-london.co.uk

SCREWS & BARRELS

www.magog.co.uk Design, Manufacture, and Refurbishment of Screws & Barrels for the Plastics and Rubber Industries. • Screw design • New manufactured Screws, Barrels, Feed Sections & Liners • Proven wear resistant specifications for screws • Nitrided and Bimetallic barrels • Refurbishment and repairs • Condition monitoring and wear checks Contact us to find out how we can help you Magog Industries Ltd, 10 Crane Mead, Ware, Hertfordshire, SG12 9PY T: +44(0)1920 465201 E: enquiries@magog.co.uk

TO ADVERTISE IN THis SPACE CONTACT MANDY O’BRIEN 01244 952373

SECONDHAND AND RECONDITIONED ANGLO PLASTICS LTD

Buy/Sell Used Plastics Machinery Rutland Road, Scunthorpe, DN16 1HX T: +44 (0) 1276 470910 T: +44 (0) 7740 632907 E: information@ angloplastics.com W: www.angloplastics.com

Cooper Plastics Machinery

8 Lyall Court, Flitwick, Bedfordshire MK45 1UX T: 01525 719850 E: Cooperplastics@gmail.com W: www.cooperplastics.co.uk Extruders, water baths, haul-offs, ﬂy knife cutters, conveyors/tip tables, in-line punches, coilers etc. New and used. Repairs, servicing or rebuilds. UK agent for Lyons Electronics.

POLYMERS MOULD CHANGE

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BUSINESS FOR SALE

Buying, Selling, Merging? Whatever your business needs, Richmond Capital Partners are the industry experts with a proven track record of guiding acquirers or sellers through the process of buying, selling and merging. Contact Paul Holohan in complete confidence on 07798 530684

FOR SALE Manchester Plastics

PVC / CABLE REGRIND / WASHED, SCREENED & DRIED / SUPPLIED IN ONE TONNE BULK BAGS @ £80.00 per tonne + VAT ex.works Available now from sales@macnchesterplastics.com Or call us on 01260 224010

TESTING EQUIPMENT hardness - IRHD and shore MAPRA Technik Co — BAREISS For Bareiss of Germany IRHD & SHORE hardness testers, Abrasion & Rebound testers. T: 020 8508 4207 F: 020 8502 5107 E: info@mapra.co.uk W: www.mapra.co.uk

inspection & measurement MAPRA Technik Co – DOSS – MARCEL AUBERT – KAFER

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For DOSS visual solution of Italy – Inspection & sorting machines for O’rings, Seals, Gaskets. T: 020 8508 4207 F: 020 8502 5107 E: info@mapra.co.uk W: www.mapra.co.uk

THERMOCOUPLES

DM Machinery Ltd

Used Injection Moulding Machine Stockists 40 Thorne Lane, Wakeﬁeld West Yorkshire, WF1 5RR T: 01924 290206 E: sales@dmmachinery.co.uk W: www.dmmachinery.co.uk

Tel: 01952 671918 Fax: 01952 608579 Email: connectors.uk@staubli.com

www.quick-mould-change.com

DTL Machinery UK

NOZZLES AND NOZZLE TIPS Engineers to the Plastics & Rubber industries, specialising in the following: Screw & Barrel Manufacture Screw & Barrel Refurbishment Tie Bar Repair & Manufacture Screw Tip Assemblies Feed Liners, Plain & Grooved 100 Tonne Screw & Barrel Press Bimetallic Barrel Blanks up to 50 mm In Stock Please e-mail or phone Karl for more info. E. info@tws-mail.co.uk T. 01706 655402 W. www.tws-ltd.com Technical Welding Services (Rochdale) Ltd

- We buy / sell all makes / age / sizes of Plastic Injection Moulding Machinery & Ancillaries equipment. - We also buy redundant, nonrunners & faulty machinery. - Machinery repair and maintenance services available. T: 01925 596170 M: 07838138342 E: info@dtlmachinery.co.uk E: douglastrading@gmail.com

TransXL International Ltd

Plastics Processing Machinery Bought & Sold, Thornhill, South Marston, Wiltshire SN3 4TA T: 01793 827666 F: 01793 823826 E: sales@transxl.co.uk W: www.transxl.co.uk

SECOND HAND AND RE-CONDITIONED TRAINING

‘USED INJECTION MOULDING MACHINERY DEALERS’

Single Machines to whole plants purchased Tel: David 07540 633552 info@plasticinvestments.co.uk www.plasticinvestments.co.uk

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BUYER’S GUIDE 3D PRINTING

3D Printing

in Plastic & Rubber

TO ADVERTISE IN THis SPACE CONTACT mandy o’brien 01244 952373 PRINTERS

printers of plastic mouldings Total Print Ltd

Tel: 01420 88645 www.cdg.uk.com

TESTING/ CONSULTANCY

Specialist Pad Printers Station Road, Gedney Hill, Lincolnshire PE12 0NP T: 01406 330122 F: 01406 330123 E: info@totalprintltd.com W: www.totalprintltd.com Sub-Contract Pad Printers to the Plastics Industry

COMPONENT PRINTERS TAMPO.SCREEN.FOIL

Contour Marking Co Ltd Albert house, Gledrid Industrial Park, Chirk ,Wrexham, LL14 5DG T: 01691 770093 F: 01691 770023 Sub Contract Tampo, Screen & Foil Printing to the plastic moulding industry E: sales@contourmarking.com W: www.contourmarking.com

Gammadot Rheology Testing & Consultancy Services

SERVICES CONSULTANCY

CONSULTANCY

Unit 5C, Leaton Industrial Estate, Bomere Heath, Shrewsbury, Shropshire, SY4 3AP T: 01939 291677 E: enquiries@gammadot.com W: www.gammadot.com Providing independant testing solutions to all your quality control, failure analysis & ﬂow simulation data needs

SOFTWARE

TROUBLESHOOTING MOLDFLOW ANALYSIS PRECISION PROTOTYPE PLASTIC PARTS TRAINING

Mould Tool Design CAD CAM software

INJECTION MOULDING 3D LASER SCANNING

01743 213 007 sales@plastic-it.co.uk

MOULDFLOW ANALYSIS

plastic-it.co.uk

Tel: 01420 88645 www.cdg.uk.com

SOFTWARE DIRECTORY A listing in the Software Directory costs £160 per programme per year. Call Lisa on 01244 680222 for details. REAL TIME PRODUCTION MONITORING, SCHEDULING AND PROCESS MONITORING Epicor Mattec Real-time MES (Microsoft Windows™ PC Servers & “Web Based”) Epicor Software (UK) Ltd T: +44 (0)1344 468 468 E: info.uk@epicor.com

Modules: Production Monitoring, Process Monitoring, “Drag and Drop” Scheduling/Planning, “Family Moulding”, Preventative Maintenance, Bar Coding/Parts’ Trace-ability, Operator Visual Aids, Process Parameter Profiling, E-mail/ Public Address System Alerts, Standalone “Drag and Drop” Scheduler, Stand-alone SPC “Machine Analyzer”, Machine Energy Monitoring, KPI Dashboards, Visual Manufacturing (Large LED Displays), Automatic Data Import/Export Functions (For Integration with Epicor ERP & Other Manufacturing Systems/Software Packages). PlantMaster BMS Vision Ltd T: 01254 662244, E: sales.bla@visionbms.com Website: www.visionbms.com/ plastics. Affordable and flexible MES system for the plastics/rubber industry. Realtime production monitoring features wireless data units and OPC Ethernet machine connections. “Drag & drop” job scheduling supports frame/insert level family tooling plus KAN BAN. ERP system integration, SPC/SQC, Touch Screen Data Units, Machine Maintenance, Operator Tracking, Traceability, DNC, Energy Monitoring, Bar Coding, Pager Alerts. Easy to use systems from a €600m company with over 30 years experience. intouch T: 01604 537100 E: enquiries@ intouchmonitoring.com Website: www.intouchmonitoring.com Real-time production monitoring systems. Designed to be easy to use and providing affordable solutions to all sizes of businesses. Production monitoring, scheduling, reporting, data import/export, databases for parts, tools and operators, integration with other software packages. ProHelp EPM (for Microsoft Windows™ PC Servers) Mattec Ltd T: 01909 561544 F: 01909 560675 E: a.jewell@mattec.com Real-time Modules: Production Monitoring, ‘Drag and Drop’

WWW.BRITISHPLASTICS.CO.UK

Scheduling/Planning, Preventative Maintenance, Bar Coding/Parts Traceability, Operator Visual Aids, Process Parameter Profiling, Pager/ Tannoy Alerts, Stand-alone ‘Drag and Drop’ Scheduler, Stand-alone SPC Machine Analyzer, Automatic Data Import/Export Functions (for integration to Manufacturing Systems and other software packages).

ENTERPRISE RESOURCE PLANNING

Epicor ERP Manufacturing Software (For Plastics’/Rubber Processors) Epicor Software (UK) Ltd T: +44 (0)1344 468 468 E: info.uk@epicor.com Epicor ERP software for the polymer converting industry covers the full range of back office operations from on-line and off-line sales and quotations to production planning, inventory management and finance through to logistics, warehousing and distribution. Available on-site, hosted & SaaS it seamlessly integrates with Epicor Mattec Real-time MES to provide a single system that offers a complete quote-to-cash solution for the plastics’/rubber industries.

PROCESS OPTIMISATION SOFTWARE RJG Technologies Ltd Moulding Technology T: +44 (0)1733 232211 E info@rjginc.co.uk

Zero Defect Moulding – What’s your target? • Cycle time reduction • Reduced scrap rates • Improved process capability • Higher yield and OEE PRO-OP™ software provides a stepby-step procedure for optimising the injection moulding process to deliver optimum quality products at the most favourable cycle time. PRO-OP™ is a server based application which, by setting an optimum moulding process, highlights weaknesses and problems in relation to part design, mould design, mould construction, moulding equipment efficiency, moulding equipment specification and material selection. The moulding process is documented with explanations for each key process parameter setting demonstrating the processing conditions and equipment contributions to the final result. PRO-OP™ is aimed at companies whose focus is quality and consistent part manufacture. PRO-OP™ supports companies by providing a documented and structured validation protocol which is recognised in the in the pharmaceutical and medical sectors. 49

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NEWS FROM THE FRONTLINE

IN IN HIS EXCLUSIVE COLUMN, PHILIP LAW, DIRECTORGENERAL OF THE BRITISH PLASTICS FEDERATION, GIVES A ROUNDUP OF A BUSY MONTH FILLED WITH MEETINGS, ROUND TABLE DISCUSSIONS AND ACTIVE RESPONSES TO CONSULTATIONS AS THE POLITICAL SPOTLIGHT INTENSIFIES ON PLASTICS.

Yet the mists swirling around the government are still obscuring how all these initiatives, both UK and EU, will be interpreted and synthesised into government action. It is pretty certain that the Budget in November will provide the conclusion.

hilst the negative press coverage of plastics has substantially abated, partly because of press exhaustion with the subject and the lack of anything new to say, the political situation has intensified. Plastics waste is but one of many issues on the government agenda and the attention of Ministers is very much preoccupied by Brexit and the occupancy of leadership positions in the government, indeed the leadership itself. Protagonists in the waste issue, such as Michael Gove, are acting as government firemen, despatched to resolve issues way outside of their formal brief. A new dimension has been introduced with the government’s commitment to fund the NHS to a much higher level. This has highlighted that the government is clearly strapped for cash. The temptation to target the plastics using sector for a smashand-grab raid must be high – and this is something the BPF is working to avert.

bp&r

We also want companies in the industry to engage with their MP. There’s a lot of helpful material on the BPF website. So, what do you say when you are in front of an MP? Tell him/her that we share the objective of eliminating plastics waste; that we are recycling a lot already, we are extraordinarily innovative, constantly changing to provide society with what it wants as it evolves; that we are a huge economic asset to the UK which needs protecting to provide the high-tech industrial base of the future. Indeed, that government attention should focus on the reform of the PRN system and that monies should remain in the system to help develop collection, sorting and recycling infrastructure and new technologies; how a smash-and-grab raid would send out negative signals internationally at a time when we need to be establishing the UK as a global trading partner. Finally, that the competitiveness of the plastics industry must be protected domestically and internationally. Help us to help you. www.bpf.co.uk

ASSOCIATED ORGANISATIONS

We are diligently responding to any number of individual government consultations on ‘single-use plastics’ etc. We have attended round table meetings with Michael Gove, we have had a one-on-one meeting with the Treasury Minister, Robert Jenrick, and we have had further round table meetings with him. We have arranged for Treasury civil servants to visit member firms to better understand the financial dynamics of the industry.

We are working intensively to influence MPs and we have had lengthy meetings with three this week. I had a meeting with Theresa May’s Political Director at No 10. Downing Street on 10th July and Industry Minister Richard Harrington on the 12th July. We have a meeting planned later in the month with the Policy Director of the Conservative Party.

WWW.BRITISHPLASTICS.CO.UK

www.kraussmaffeiberstorff.com

Efﬁcient machines and complex system solutions for technical proﬁles – Single-screw extruders and complete systems for diverse customer requirements – Flexible in the processing of technical plastics – Optimum monitoring and closed-loop control with modern C6 control system

Engineering Value

We’ll get you connected Stäubli’s technology and unique expertise in the plastics industry ensures safe, reliable and quick connection solutions – reducing downtime – optimising mould change – increasing productivity. Quick connection of thermal regulation and hydraulic circuits: Reliability. Efficiency. Safety. Stäubli. www.quick-mould-change.com

Stäubli (UK) Ltd - mail : connectors.uk@staubli.com - Phone: +44 1952 671918