K 2013 Report Part 3


Mould Base and Hot Runner innovations

Hall 1 | Booth A23

Portfolio of moulds and hot runner innovations (photo: Hasco)

Hasco is presenting a large number of innovations from its Mould Base Division and Hot Runner Division. The Mould Base Division is focusing this year on the topics of “Guiding and Locating” and “Temperature Control”. A large number of new components will be introduced, as well as product improvements such as refined mounting tolerances for location elements. Additional to this, new connection couplings and temperature control hoses can be seen. Other functional components with DLC coating will create the potential for new applications and solutions by providing longer service life. A new, high-quality thermal insulating sheet ensures an optimum heat balance in the injection mould. 

The Hot Runner Division is focusing on needle valve technology. It is displaying a hydraulically operated Z2380/… cylinder for the displacement of needle valve assemblies, making the system easier to maintain. The cylinder can be dismantled without exposing the hydraulic drive, thus protecting the system and the environment from hydraulic oil contamination. Hasco implements the pneumatic drive for the needle valve assemblies with the Z2371/… cylinder.

Entire actuating plates for needle shut-off systems are now moved on an all-electric basis, employing a new drive and control technology. This electric activation is particularly suitable for high-cavity systems in the packaging industry and medical technology. Individually configurable travel paths and speeds help to improve product quality and process reliability during the injection moulding process. The drive programme is rounded off by a range of modular needle valves for individual pneumatic and hydraulic controls in different housing variants. In the control technology field, both a product optimisation and a central control unit will be on display.


Flat-sheet-dies up to 9m width

Hall 2 | Booth G9

Emo presents a representative overview over its deckling systems for the product width adjustment. It ranges from the manual adjustment with an outer cover blank to the internal channel-width adjustment for one or multiple sheet dies (photo: Emo)

The Austrian company Emo Extrusion Molding, manufacturer of flat dies for plates and films, has expanded its processing capacities and is now able to supply dies for a film widths of up to 9m. The company also expanded its range of coatings for corrosion and wear protection and introduces its latest developments at K. Since the integration in the Haidlmair Group in the year 2002, the Emo tool and die making capacities have been expanded, suchas the product range for 3m nozzles for single-or multi-layer films and plates, and also the top size range for construction and landfill films in the width range of 7 to 9m. The company does also supply single and multi-layer flat nozzles, and also the production of multi-layer co-extrusion adapters for up to nine layers in combination with mono nozzles. One focus of the Emo trade fair presentation is on film dies with integrated product width adjustment, the so-called “deckling systems”. As an example for that technology there will be one die with automatic thickness control and internal deckling through a customised profile slider bar in the flow channel on display.

Emo has also developed new options for the corrosion and wear protection of nozzle channel and lip areas. The basics are nozzle components made of steel qualities 1.2311 and 1.2316, which are coated, in whole or only on the flow channel surfaces, depending on the application of use. The basic level of coating is hard chrome, which provides protection against corrosion. Twice as hard and therefore a good wear protection is chromium nitride. And Tungsten carbide is said to offer an even better wear protection, a diamond like carbon (DLC) coating is said to be acid-resistant and smooth. The latter feature has an impact on the flow characteristics of the plastic melt: the common wall sticking changes to wall sliding with specific plastics, thus providing additional opportunities in the process. A high acid resistance, which is required for the processing of plastic materials with halogen-containing additives, can be achieved through the combination of chromium steel 1.2316 with a Hastelloy-coating, an almost iron-free Ni-Cr-Mo alloy.


Contour cast film die for speed and precision

Hall 2 | Booth G6

Contour die (photo: Nordson Extrusion Dies Industries)

Nordson Extrusion Dies Industries will showcase a new generation of the contour cast film die which now incorporates an internal deckle that is said to enable extrusion processors to achieve the speed and precision without incurring downtime for changing product width.

According to the company, there are two major advantages of the Contour Die over traditional dies with “coathanger” manifolds: firstly less time needed to achieve on-spec product and to purge between product runs; and secondly up to 25% improvement in cross-directional product uniformity, along with a reduction in gel formation. The new-generation Contour Die is said to retain these advantages while saving up to two days of downtime for width changes because it incorporates an internal deckle for making changes in product width.

In developing the original Contour Die, Nordson Edi designed a coathanger-shaped manifold, which produces a streamlined melt flow. Unlike the block-like shape of traditional coathanger dies, the Contour Die has a “sculpted” configuration that is smaller and tapered at the ends. This unique shape offsets the differences in die-body deflection across the width of the die that are caused by the great pressure of the molten polymer that the extruder continuously charges into the manifold – differences that in traditional coathanger dies cause gauge variations and the product deformation known as “clamshelling.”

Because it exhibits uniform die-body deflection, the original Contour Die can be adjusted to achieve on-specification film more quickly than the traditional coathanger die while still yielding a streamlined flow. In addition, it is claimed to produce a more uniform cross-directional gauge profile and a more uniform layer structure in coextrusion.


Stacking systems increase productivity

Hall 3 | Booth C92

Pressure forming machine KMD64 Speed (photo: Kiefel)

Kiefel focuses on efficient stacking in the packaging area. The company presents two stacking systems which can help to save time and increase productivity. At the fair, the company will demonstrate how to produce highly transparent polypropylene (PP) cups using the cup forming machine KTR 5 Speed combined with the stacking system Best. Special feature of this stacking system is that the cups are stacked vertically which is said to create optimal conditions for the next automated steps such as sleeving and packaging. The stacking station Best has been developed particularly for the food industry. This system does not include any wear parts and therefore guarantees a high product safety. Combined with this stacking station, the KTR 5 Speed cup former reaches almost the same cycle times when processing PP as when processing polyethylene terephthalate (PET).

The other stacking system is integrated in the pressure forming machine KMD 78 Speed. A 16-up tool will produce biscuit trays made of PP. This stacking system already comprises the formation of horizontal stacks for efficiency. A conveyor belt with an ergonomic height transports the stacks out of the machine.

It is noteworthy to mention that both the KTR 5 Speed and the KMD 78 Speed are flexible regarding the material processing. Not only PP and PET can be processed, but also bioplastics like polylactides (PLA).


IMD and IML on the same machine

Hall 5 | Booth A19

Automotive air vent covers decorated by means of the 3DHS process (photo: Leonhard Kurz)

Leonhard Kurz Stiftung will be giving a live demonstration of a process for decorating 3D geometries under technically demanding conditions. A special highlight of the display will be the combined application of inmould decoration (IMD) and inmould labelling (IML) on the same injection moulding machine. This machine will be used to produce a curved automotive centre console panel, which will be both decorated and equipped with special functions during the injection moulding process.

The patented 3DHS finishing process, which, in contrast to conventional hot stamping, is capable of decorating three-dimensional components, will also be demonstrated. Kurz developed the 3DHS process as a cost-effective decoration option for slight to moderate 3D geometries. Visitors to the trade fair booth will be able to see a vertical stamping machine developed by the Kurz subsidiary Baier being used to apply a true chrome finish to an automotive air vent cover.

Besides these live demonstrations, numerous new foil design ranges and trends for a variety of industries, such as consumer electronics, home appliances, automotive and cosmetics, will be presented. These include metallic and wood designs with tactile structures for automotive interiors, brushed designs with novel patterns for home appliance products, as well as trendy colours with shimmering effects for mobile devices.


Flame retardant additive masterbatches

Hall 5 | Booth B48

A typical area of application of the new flame-retardant masterbatch for thin-walled PE applications. (photo: Gabriel-Chemie)

Gabriel-Chemie has developed three new product groups of halogen-free, flame retardant additive masterbatches for various areas of application and processing: one of them is Maxithen PP7A9850FR for thick-walled polypropylene (PP) applications. Frequently, only halogen-free compounds that meet the high flame retardance requirements in accordance with UL 94 V0 are offered for thick-walled PP applications. However, these lead to compromises in terms of the mechanical properties. On the other hand, this flame retardance classification and thus the high quantity of flame retardant are not necessary at all for many areas of use. The fully halogen-free flame-retardant masterbatch Maxithen PP7A9850FR fulfils the frequently requested flame retardance classifications in Europe in conjunction with advantages in mechanical strength. These include, for example, DIN 4102 B1, UL 94 V2 and also various flame retardance tests with a vertical test as in the case of cable conduits. The recommended addition rates range from 8 to 15%.

The lower concentration of flame retardant gives rise to the following advantages: improvement of the mechanical properties, easier processability and higher flexibility in the colouring, the use of other additives and the selection of polymers.

The second masterbatch is Maxithen PP7AA1940UVFR for thin-walled PP applications. The masterbatch is a combination of flame retardant and UV stabiliser. It can also be used with a wall thickness of over 150µm without loss of quality. The recommended added amounts lie between 7% and 15%. Higher LOI values are also achieved with these dosage recommendations. Fibres, tapes and films made of PP are typical applications.

Flame retardance standards such as DIN 4102 B2/B1, UL94 VTM 0/2 and FMVSS302/DIN75200 are fulfilled with the halogen-free flame-retardant Maxithen HP7AA1460FR masterbatch for thin-walled PE applications (LDPE, LLDPE or HDPE). It contains effective flame-retardant additives that do not impair the transparency of the final article. Maxithen HP7AA1460FR is said to exhibit good effectiveness even with wall thicknesses of up to 500µm. Depending on the wall thickness and the melt-flow index of the polymer, added amounts of 3.5 to 8% are recommended in order to achieve flame retardance class DIN 4102 B2, while 9 to 13% are usually sufficient for DIN 4102 B1. Higher LOI values are also achieved with these dosage recommendations. Films and tapes can be named as typical areas of application.


Additive creates lasting bonds

Hall 5 | Booth E17

Byk Additives & Instruments will be presenting its latest additive developments from its worldwide Byk laboratories. Applications for plastics modifiers of the Scona brand are this year’s main focus at Byk.

• New additives for improving scratch resistance in polypropylene (PP) compounds

• Modifiers for wood plastic composites (WPCs), glass-fibre reinforced PP and polyamide (PA) compounds

• Modifiers for improving the adhesion of TPE-S overmoulding compounds on hard substrates

• Wetting and dispersing additives for masterbatch production

• Process additives for highly filled compounds

• Additives for PVC plastisols

• Additives for glass-fibre reinforced plastics


PLA partnerships for new bioplastic applications

Hall5 | Booth B22

PLA in packaging application (photo: Corbion Purac)

To highlight the most recent developments in polylactic acid (PLA), Corbion Purac will be exhibiting a number of biobased applications resulting from numerous strategic partnerships. The company has teamed up with partners in a number of industries, including packaging, automotive, home interiors and sporting goods. PLA is an adaptable material that can often be processed on existing equipment, with commercially acceptable cycle times, states Corbion Purac. They welcome converters and compounders who are interested in learning more about PLA processing. The technical team will be on hand at the fair to discuss and exchange PLA processing experience, from sheet extrusion and thermoforming, to injection moulding and foaming.


PA Insulating profiles for aluminium windows

Hall 6 | Booth B11    Hall 6.1 | Booth N4

EcoPaXX in insulating profiles for aluminium windows (photo: DSM Engineering)

DSM says producers of aluminium window systems can make more sustainable products by using insulating profiles made from its EcoPaXX polyamide (PA) 410, a polymer with a biobased content of 70%. The material is said to answer the increasing need for the use of sustainable raw materials in buildings. Approximately 70% of the polymers building blocks are derived from the castor plant (Ricinus Communis), a renewable resource. EcoPaXX has been proven to be carbon neutral from cradle to gate, says DSM, meaning that the carbon dioxide (CO2) generated in producing the polymer is completely compensated by the CO2 absorbed during plant growth.

Its high melting point of 250°C is said to enable it to pass through the powder coating process in a fully assembled aluminium frame, facilitating the assembly process. EcoPaXX is said to offer good hydrolysis and chemical resistance and lower moisture absorption than PA66. Window profiles incorporating EcoPaXX can be designed to conform to requirements laid down in EN14024 standard, which sets requirements for mechanical performance of metal profiles with thermal barrier.


UV resistant PA6 compound

Hall 6 | Booth D15

Bursa, Turkey based Epsan has introduced “Eplamid 6 GFR 30 UV” and “Eplamid 6 GFR 50 UV”, high ultraviolet resistant grades designed for exterior automotive applications. The company claims that both materials have been approved by one of the Scandinavian Truck manufacturers and has already been consumed in rear view mirror application by one of the French Truck and passenger car manufacturers. According to Epsan, both grades have passed the tests by Deutsches Kunststoff-Institut, an independent lab in Germany prior to commercialise. Eplamid 6 GFR 30 UV has also been tested by a German passenger car manufacturer in their Chinese factory for about duration of four months. And it is recently approved for side mirror application. With this product development, the firm aimed to meet the requirements of good original surface quality under microscopic picture and good mechanical properties.

In addition, Epsan is planning to announce new product developments in addition to high ultraviolet resistance grades at K.


Antistatic plastics in vehicle interiors

Hall 6 | Booth E75

In order to prevent plastic parts from attracting dust particles through their electrostatic charges, for example, in vehicle interiors, Grafe Group have been developing new antistatic materials with improved properties. Further development in the field of migrating antistatic agents has mainly been aimed at prolonging their effect. To this end, the Grafe Group have introduced a new product for polyolefins: the high performance antistatic agent (HPAS), which, in long-term tests with PP components, is said to have shown to be effective for more than four years.

In the development of permanently effective non-migrating systems, the focus lies on improving their efficiency. New permanently antistatic agents have been developed and tested for application in PP and in PC/ASA. These products are characterised in particular by lower concentration levels. In addition, combination products have been developed for application in PP and in PC/ASA where the material is coloured and endowed with permanently antistatic properties in just one step.


Intelligent additive solutions

Hall 6 | Booth A23

Recycling circle (photo: Struktol)

Struktol Company of America has developed several new additives designed to provide greater processing and performance capabilities for compounders, processors and end users.

Struktol RP 11 provides a combination of viscosity reduction and mould release characteristics for polypropylene-based resins and compounds. Loading levels as low as 0.2% result in increased melt flow and allow for improvements in mould filling and release. Processors using Struktol RP 11 will benefit from the versatility provided; allowing greater use of regrind or recycled content without sacrificing certain properties or performance. Struktol RP 11 is a suitable replacement for peroxide modifiers and internal or external mould releases.

Struktol RP 17, a combination lubricant and odor neutralising mask, was originally designed for reducing/eliminating compounding and end-product odors in wood-filled plastic compounds. The product has been modified for use in a variety of polymer resins and compounds that require the multi-functionality of lubrication, mould release, and odour reduction. RP 17 can be used in recycled applications as well as automotive interior compounds where neutral odour may be a requirement.

Struktol TR 451 is a combination product designed to improve the incorporation of fillers into polyolefin compounds. This additive also provides viscosity reduction, mould release and consistent processing. Studies are said to show that adding Struktol TR 451 to highly filled calcium carbonate-polypropylene compounds allow for higher filler loadings without sacrificing processability or performance. Alternatively, compounders using treated fillers may be able to substitute untreated fillers in combination with Struktol TR 451. Struktol will exhibit with its European distributor, Velox.


Expanded range of PA compounds

Hall 6 | Booth C54-3

Teknor Apex Company will rebrand its entire range of polyamide (PA) compounds under the Chemlon name and has expanded its product portfolio in Europe by adding dozens of proven PA formulations originally developed by the company in the US.

Teknor Apex supplies European customers from its plant in Oldbury, UK, where it now produces Chemlon PA compounds developed in the UK and in the US. Prior to its acquisition by Teknor Apex, this facility was well known to customers in Europe under the name Chem Polymer. It will continue to manufacture PBT, PET and PP compounds under the Beetle brand name, though this will no long be used for PAs. The company supplies PA compounds to many markets, some examples of which are:

? Automotive: many of the Chemlon products developed in the US have a long history of use in powertrain, chassis, exterior, and interior components, with approvals from Chrysler, Ford, and General Motors.

? Consumer, Industrial, Electrical: Chemlon MD82 is a halogen- and phosphorus-free flame retardant moulding grade of PA6 that is used extensively across Europe; it has a UL flame rating of V-0.

? Merchandising and Packaging: Chemlon R106, a 50% glass fibre reinforced PA6 that is said to offer good mechanical performance and surface finish, has a long history in supermarket transportation and other packaging designs.

? Wire Coating: Chemlon MD21 is a medium viscosity grade of PA that has been optimised to ensure adhesion between the wire and the PA at high extrusion line speeds.


Binder system for bioplastics

Hall 6 | Booth A10

Binder system for easy processing of biopolymer blends, which can be used to manufacture biodegradable bioplastics for food packaging and containers. (photo: Wacker)

Wacker is launching an improved binder for the next generation of bioplastics. The Vinnex binder system is said to enable polymers based on renewable raw materials to be processed just like conventional thermoplastics. According to the company, the system enhances the physical properties of bioplastics and makes different materials compatible with each other.

The Munich-based company states that this vinyl-acetate-based polymer binder system enables manufacturers to develop high-performance blends of bioplastics. These can be processed with conventional equipment without need for modification, says Wacker. Vinnex is said to make injection moulding, extrusion, vacuum forming, thermoforming and calendering much easier.

The binder is said to be compatible with many biopolymers. Different Vinnex grades can be combined with one or more biopolyesters and fillers in a modular system. Depending on the application, polylactic acid (PLA), polyhydroxyalkanoates (PHA), polybutylene succinate (PBS) and starch, for example, can be used to create various polymer blends. This is said to improve the physical properties of biopolymers, which are difficult to process otherwise.

Vinnex opens up an expanding range of applications for biopolymers. For example, the new blends can be processed into food packaging materials, brochures, parts for electronic appliances or self-degradable gardening and agricultural containers. Under industrial composting conditions, the tested Vinnex polymer blends – with typical binder contents of 10 to 30% – biodegrade in less than 180 days. Experts estimate that bioplastics could replace up to 90% of all conventional plastics in the future.


Effective recycling of composites

Hall 7 | Booth B5

A new process enables the efficient recycling of metal-plastic composites, EPS and PLA. (photo: Fraunhofer IVV)

The Fraunhofer Institute for Process Engineering and Packaging IVV will present new ways of recycling composite plastic materials. Three variants of the solvent-based CreaSolv process will be introduced, permitting efficient recycling of metal-plastic composites, expanded polystyrene (EPS) and polylactide (PLA).

The CreaSolv process allows the complete separation of the composite into its constituents and can be used to efficiently recycle both the metallic and polymeric components of composites.

Expanded polystyrene (EPS) is at present mainly treated thermally to recover heat. This because contaminated EPS waste, mainly originating from the construction and packaging industries and sometimes containing fire retardants, cannot be effectively recycled due to the poor purification and recycling efficiency of processes developed hitherto. The new process developed at Fraunhofer IVV offers efficient purification and is able to produce virgin-quality re-expandable polystyrene from EPS waste. Simultaneously, a new logistical plan for collecting EPS waste at low cost is being set up.

PLA is becoming an ever more important industrial plastic. Fraunhofer IVV has shown that combustion and composting, the two standard recycling methods used to date, are not the only options for recycling plastic packaging made of renewable raw materials. Due to the growing amount of PLA waste, Fraunhofer IVV is evaluating the effective recycling of composite materials using the CreaSolv process whole process chain for PLA recycling, including possible effects of PLA on the recycling of other plastics. The envisaged Fraunhofer IVV process will allow pure PLA, PLA-containing fractions, PLA composites, and blends to be separated from packaging waste and processed into high-quality PLA recyclates. These recyclates can then be used for manufacturing high-quality packaging for non-food applications and for consumer goods.


Portfolio of cyclic olefin copolymers

Hall 7 | Booth A5

Topas Advanced Polymers will showcase its line of cyclic olefin copolymers (COCs). Topas’ manufacturing technologies are said to enable the development of new COC grades with a range of useful performance capabilities. These include elastomeric materials, advanced compounds, and resins with HDT nearing 200°C. The resins are finding increased use in optics and electronics. The clarity and heat resistance of COC is driving use in touch screen and light distribution components of modern mobile devices, while its fluoropolymer-like electrical properties are suitable for complex, easy-to-mould antennas in the same devices.

Most recently, Topas is focused on the development of elastomers which deliver high barrier and purity. ey application areas an

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