Lightweight PC windows
The motto of the Bayer booth was “Sharing dreams, sharing values”. Exhibits included almost every sector humans can dream of. One exhibit was the concept car Haval E from Chinese car manufacturer Great Wall Motors. All seven window components including the front windshield are made of Makrolon polycarbonate (PC). It is equipped with a large PC panorama roof to decrease the weight. This concept car is the first of its kind in China to utilise the extensive application of PC glazing to produce a lightweight vehicle. Innovative automotive glazing technology enables the use of lightweight materials in cars that reduce fuel consumption and thus increase energy efficiency.
www.materialscience.bayer.com
Dr Frank Rothbarth, External Communications/Trade press, Bayer MaterialScience next to the concept car which is equipped with seven window components for reduced fuel consumption and increased energy efficiency
High-clarity performance
Natpet, the polypropylene (PP) producer from Saudi Arabia, focused on enhancing converter productivity and end-product appeal in the rigid packaging sector by highlighting the high-clarity aesthetics, processing efficiency and performance possibilities of its advanced thermoforming and injection moulding grades. Highlights included new thermoforming grade H03TF and the injection moulding grades R25MLT and R40MLT. Four machine manufacturers produced parts from the grades at their booths. Amut and Gabler produced thermoformed drinking cups using H03T, Fanuc ran applications based on R40MLT and Dr. Boy produced insulin pen caps made from Teldene R25MLT.
www.natpetpp.com
PP grade H03TF combines high clarity and aesthetics with high dimensional stability for thermoformed cups, trays and containers. (photo: Milliken)
All-purpose silicone additive for food contact plastics
The Munich, Germany-based chemical group Wacker presented a high-performance additive for the compounding and processing of thermoplastics. Genioplast Pellet P plus is said to improve the viscosity and flow properties of the polymer compound. It is also said to ensure smooth, easy-to-clean surfaces. Genioplast Pellet P plus is an approved additive for plastics used in food contact applications and is therefore suitable for plastics in the kitchen and packaging sector.
Genioplast Pellet P plus is a highly concentrated silicone additive in pellet form. Its active ingredient is a non-crosslinked ultra-high molecular linear silicone polymer, while the carrier material for the active material is a pyrogenic silica tailored for the silicone. Since pyrogenic silica is compatible with all thermoplastics, the additive can be used to compound every type of thermoplastic.
www.wacker.com
Water flow regulator
Wittmann presented the latest model from its line of Flowcon flow regulators: the Flowcon plus with proportionally controlled stepper motor and wear-free flow meter. The solenoid valves of the previous model have been replaced, enabling proportional control of the valves, which is said to allow for an improvement in temperature control.
The valves of the Flowcon plus can be used both as simple control valves with flow monitoring and in combination with a temperature probe to regulate mould temperature. Process data such as flow and temperature values can be entered either on the touch screen of the teach box or directly on the control panel screen of the processing unit, because it is connected to the flow regulator via an interface.
The flow regulator permits continuous electronic monitoring of the preset flow and temperature values. All data are logged and can be automatically adjusted proportionally via control valves. Already proven in service many times over, the Wittmann fine regulating valve of the 301 Series performs the flow regulation function here. Wittmann says that generously dimensioned channels in the casing blocks guarantee the lowest possible pressure loss and high flow rates. The maximum equipment configuration of the Flowcon plus features 4×12 cooling circuits, which are connected to one another via a data cable.
www.wittmann-group.com
The flow regulator permits continuous electronic monitoring of the preset flow and temperature values. (photo: Wittmann)
Extrusion solutions
Coperion presented the ZSK 32 Mc18 smart, the newly developed CSpro control system, a completely redesigned die head and a new, retrofittable high-resolution torque measurement unit.
The ZSK 32 Mc18 smart features screw shafts whose axes are only 800mm above floor level. Ancillary units, such as the ZS-B and the ZS-EG can be mounted by a swivel arm on any barrel of the extruder process section and can be operated from floor level without the need for stepladders, platforms or overhead cranes. The feeders are mounted on a platform directly on the drive unit and, when required, on the swivel arm of the ZS-B twin screw side feeder. The complete redesign of the machine includes the integration of both the electrical supply system with the terminal box, and the water supply system with the manifold, into the base frame of the machine. The single-piece stainless steel cover of the process section is insulated on the inside and serves as a good dust and safety guard. The smart design version is available not only for the ZSK Mc18 series (sizes 18, 26 and 32) but also for the ZSK Megavolume Plus series (sizes 27 and 34).
The SK 58 and SK 70 extruder die heads feature a completely redesigned heating system. The temperature control is said to ensure a homogeneous temperature across the entire die plate, even when the throughput rates – as in the case of the ZSK Mc18 series – are high.
The new CSpro control system is based on state-of-the-art control components. It is available in two versions: the CSpro basic version covers all standard functions, for instance, for the production of masterbatch or powder coatings, and is equipped with a 15-inch touch panel PC. It provides additional features, such as order/batch and formulation management. The CSpro medium version is equipped with a high-performance industrial PC with 19-inch touch panel.
www.coperion.com
The new SK 70 extruder die head for homogeneity of the extruded strands across the entire width of the die plate (photo: Coperion)
High performance friction and wear polymeric materials
Gharda Plastics, the high performance engineering polymers business of Gharda Chemicals, has launched a speciality lubricating solution for industrial and business appliances, incorporating various reinforcements in G-PAEK and Gazole grades; this collaborative development with other industrial partners is aimed at applications that require high wear resistance. The G-PAEK product family is based on polyetherketone (PEK) and Gazole represents newly commercialised thermoplastic alloys of PEK and polybenzimidazole (PBI). The two featured wear grades, G-PAEK 1230FCT and Gazole 6430FCT are easy flow for injection moulding of intricate multi-cavity parts. The heat deflection temperature of 350°C to 360°C makes them suitable for demanding high heat resistance applications.
www.ghardaplastics.com
The high fatigue strength and wear resistance make FCT grades suitable for automotive/transportation segment for gears, bearings and bushes. (photo: Gharda)
Pelletiser with large cutting width
Primo 200E is Automatik Plastics Machinery’s new single-side mounted dry-cut strand pelletiser with an extra-large cutting width of 200mm. The short unguided length between the feed rolls and the cut is said to enable good straight cutting of both hard and very soft plastic strands. The Primo 200E is particularly suitable for compounding thermoplastics, for functional and additive masterbatch production and for the production of colour concentrates up to a line throughput rate of 1.5t/h.
Highlights of the pelletiser are its cutting tool sets for hard, abrasive and soft, flexible plastics. The pellet dimensions can be quickly changed by means of an optional automatic pellet length adjuster. This is done using a second drive motor for the feed mechanism with an integrated speed control.
When processing abrasive products and at high production temperatures, the Primo 200E can optionally also be equipped with a separately driven, highly wear-resistant metal feed roll instead of the standard elastomer feed roll.
Another feature of the machine is that the feed geometry is designed without major deflections, so the plastic strands are not subjected to pre-tensioning prior to cutting. This means that even highly fragile polymers such as polystyrene or highly filled masterbatches can be pelletised in high qualities, virtually dust free.
www.psgdover.com
Cutting chamber (photo: Automatik Plastics Machinery)
Counter Current system
In its 30th anniversary year Erema is all set to launch Intarema, a plant system with new core technology and technical innovations. The patented Counter Current system, the central core technology of the new Intarema plant, shows innovation in the interface area of the cutter/compactor and extruder. To date the worldwide technical standard has been a system in which the material in the cutter/compactor moved in the direction of the extruder. The difference with the Counter Current system is that the material spout in the cutter/compactor is now reversed and thus moves against the direction of the extruder. The result of this inverse-tangential configuration is increased process stability and, at the same time, higher throughput, says Erema.
www.erema.at
The patented Counter Current system is the central core technology of the new Intarema plant and shows innovation in the interface area of the cutter/compactor and extruder. (photo: Erema)
Multi-touch roll stack
In October 2013, 400 visitors to Battenfeld-Cincinnati’s Open House event at the Kempen plant saw the live demonstrations of a polypropylene (PP) sheet extrusion line, a coextrusion line producing a fibreglass reinforced four-layer PP-R pipe and a co-extrusion line manufacturing a three-layer polyvinyl chloride (PVC) pipe.
One highlight of the event was the multi-touch roll stack. The Packaging Division gave a demonstration of how high-speed extrusion and efficiency can go perfectly hand in hand. For this purpose, the extrusion line for producing PP sheet with thicknesses ranging from 200 to 2,500µm was equipped with a high-speed BC-75-40 DV T4 extruder and the new, unique multi-touch roll stack incorporated in the line. It operates with only two large chill rolls instead of the conventional stack of three rolls, but with the addition of five post-cooling rolls. In this way, even cooling and calibration of the sheet is achieved on both sides. The outcome is a virtually tension-free sheet with narrow thickness tolerances.
www.battenfeld-cincinnati.com
Multi-touch roll stack operates with only two large chill rolls instead of the conventional stack of three rolls, but with the addition of five post-cooling rolls. (photo: Battenfeld-Cincinnati)
Printing, coating and converting flexibles
In addition to Bobst’s presentations in Düsseldorf, the company had invited existing and prospective customers to Open House events at their Technology Centres in Bielefeld, Germany, Manchester, UK and San Giorgio Monferrato, Italy. The focus at all these locations was entirely on solutions for printing, coating and converting flexible materials. All in all, several hundred companies from more than 50 countries visited Bobst, including a substantial number from emerging countries such as India and from the Middle East. A good 60% of the visitors were new customers. Contracts for numerous projects were finalised. While activities on the Bobst exhibition stand at K 2013 revolved around technology demonstrations, the Bobst Technology Centres focused on offering hands-on sessions addressing the subjects of flexo printing and laminating, vacuum metallising and gravure printing and laminating.
www.bobst.com
Open House event at the Technology Centre in Bielefeld, Germany (photo: Bobst)
Caps in only 1.44s
Sacmi showcased the latest machines and complete plants for caps, preforms and large “one-step” items. Also on display were presses designed to combine the best of hydraulic and full electric technologies.
Visitors saw the devices on the new CCM 48 S, specially optimised to e fitted with the Cool+ mould, resulting in a high-output combi capable of manufacturing 29mm mineral water caps with the shortest cycle times ever achieved in the industry (1.44s).
Negri Bossi, the Sacmi Group company that is one of Europe’s leading designer-manufacturers of thermoplastic injection moulding presses, showed a range of presses which offer the ability to produce large one-step items of complex design. These presses are said to offer good reliability and short cycle times. All machines are equipped with Smart Energy devices to reduce energy
www.sacmi.com
16 live demonstrations of IML systems
Verstraete in-mould labels partnered with 34 companies at the K, running 16 live IML systems showing solutions for Oxygen and Light Barrier IML, MockUp IML, DoubleSided IML, Metallic IML and Peelable IML.
Roboplas produced a 200ml rectangular container with Metallic IML, based on the combination of Arburg’s injection moulding machine and Erkoc’s IML mould. The use of Metallic IML preserves a metallic look, even when a producer moves from metal packaging to plastics, and gives the product a high-end quality look.
Automation producer Well-Lih demonstrated the production of a 200ml yoghurt cup, using Pass Card’s mould and an Arburg injection moulding machine. Wittmann produced three IML products: a 300ml cup and a 13l container, both with Verstraete’s Metallic IML as well as a hockey stick. Italian automation producer Campetella produced a 5l container with Metallic IML labels in close collaboration with BMB and Top Grade Molds. Swiss mould producer Müller showed a rectangular lid with metallic IML, resulting from its collaboration with Ferromatik.
Wetec’s automation capabilities were seen at four different partners’ booths. There was a 2.5l pail with a cycle time of only 6s, produced on a Stork injection moulding machine. Wetec was also producing a 700ml container with lid, using Metallic IML on a combination of Jon Wai Machinery and Nypro Tool. A 200ml yoghurt container with IML labels from Verstraete was produced at Victor Taichung’s booth, using a Mo Chyi mould and Wetec’s automation. Equally impressive was machine producer Yizumi’s 250ml oval container with a cycle time of just 5.5s.
BMB was partnering with Star Automation and Collomb, showcasing a 5l container with a Wrap Around IML label. Machine producer Tederic produced a 1l pail in collaboration with Campetella and Tecnopool.
Stork and Brink, both from the Netherlands, teamed up to demonstrate two IML products together: a 150ml container with a three-sided IML label and a 2.5l paint container. Automation producer Polymac presented a 4l container in collaboration with Stork. Interestingly, the container was produced with Peelable DoubleSided IML labels. These labels are printed on both sides, offering space for extra information, such as suggestions on how to use the product, an incentive to participate in a competition, or legally required labelling information, and more.
Verstraete’s Peelable IML label is easy to peel from the packaging. With the label removed, the consumer is left with a neutral packaging item, ready for re-use. A Peelable IML label is also an elegant solution for campaigns involving discount vouchers. It is easily combined with DoubleSided IML, offering packaging with a peelable label that contains product information on the back.
www.verstraete-iml.com
Containers from live demonstrations on IML systems (photo: Verstraete)
Better drinking water
Borealis has recently introduced two new BorSafe products exhibiting higher resistance to chlorinated disinfectants. According to the company, pipes based on BorSafe ME3440-D and BorSafe HE3490-DS-H have shown in trials to last at least three times longer than conventional polyethylene (PE) pipes. The extended lifetimes of pipes based on these new product materials is thus said to enhance the quality of drinking water in the long term in demanding chlorinated disinfection conditions. The BorSafe family of PE pressure grades for infrastructure and pipe systems is based on Borealis’ proprietary Borstar bimodal technology and each grade meets or exceeds stringent international standards for drinking water applications. Thanks to their bimodal design, the new grades also feature good mechanical properties which enable installation in difficult laying conditions. Finally, with one medium density (MD) PE80, more adapted to small diameters, and one PE100, the new BorSafe products cover the full range of pipe diameters and offer fully versatile solutions across all pipe sizes.
www.borealisgroup.com
Borealis has responded to the need for improved resistance to aggressive chlorinated disinfectants in hot and cold water pipes through innovation in grades BorSafe ME3440-D and BorSafe HE3490-DS-H. (photo: Borealis)
Flexible and rigid packaging solutions
Sabic showcased the latest advances in both flexible and rigid packaging such as Sabic LDPE nExCoat 5 for extrusion coating and its new multi modal high density polyethylene (HDPE) portfolio for blow moulded packaging applications. Sabic LDPE nExCoat5 is produced by Sabic’s CTR tubular process with additional proprietary technology. According to the company it supports the footprint reduction objectives of customers and helps them save money by delivering a one-grade solution, creating opportunities for them to reduce their inventory and transportation costs.
The company’s new blow moulding grade for the production of milk and juice bottles, Sabic HDPE B5260ULS, features good organoleptic properties, which are important when using in-bottle sterilisation, where the packaging, as well as the product, is subjected to tough thermal and mechanical conditions. Additionally, the new grade has high stiffness, impact resistance and environmental stress crack resistance (ESCR), which helps to prevent breakage and potential contamination.
Sabic announced the launch of an additional new range of multimodal grades which can be used in applications varying from small bottles to standard and UN approved jerry cans and 220l drums (tight and open head). The new grades have good low die swell characteristics that meet the packaging industry’s most stringent demands, for example, the (UN) packaging of dangerous goods requirements.
www.sabic.com
Sabic LDPE nExCoat 5 for extrusion coating shows a low carbon footprint. (photo: Sabic)
Security additive masterbatch
The Maxithen ProTec4 additive masterbatch is equipped with security pigments – inert, inorganic and highly temperature-resistant substances that are integrated homogeneously into the plastic matrix to provide the end products with an unmistakable code. Clear proof of the origin can be ascertained using the measuring technology provided. By using different codes even different product lots are said to be clearly identifiable.
The additive masterbatch is said to offer various solutions for a large number of applications, such as quality control during the production process excludes possible false dosages; security against forgery because original and counterfeit are clearly distinguishable; product liability risk for functionally relevant components is verifiable and unjustified claims for damages can thus be ruled out or function control – by means of transmitted signals different actions or reactions can be triggered on the prefabricated part.
www.gabriel-chemie.com
Premiere of the new twin screw extruder series
One highlight at the Feddem trade show stand was the new FED 43 MTS with a 43mm screw diameter. This parallel twin screw extruder is suited for the production of small to mid-sized batches – engineering plastics, high-performance polymers, masterbatches and the like. As with all other Feddem MTS models, a wide selection of equipment options and accessories are available. Depending on the job at hand, the screw units and housings are available in various grades of steel – from nitrided steel to special hot isostatic pressing (HIP) alloys. In addition to the gentle compounding process the company focused also on the flexibility of their turnkey lines. With minimal effort, these machines can be configured to meet a wide range of customer requirements (such as elongation for process unit, individually tailored side-feeding/side-degassing solutions and more).
www.feddem.com
The Feddem trade show stand with the new FED 43 twin screw extruder, which celebrated its premiere at the trade show. (photo: Feddem)
Carbon fibre recycling through special impregnation
Cannon presented their complete range of innovations, with a special emphasis on the energy efficiency contribution provided by the products made with their different types of technologies. The company also celebrated the 30th anniversary of Cannon Deutschland operations in Germany with a party held in the booth with colleagues, customers and visitors.
At this event composites played an important role for Cannon: lightweight carbon fibre reinforced parts made with both epoxy and polyurethane formulations were on show, especially during the public presentation of the Cresim project (Carbon fibre REcycling through Special IMpregnation) aiming at commercialising the use of recycled carbon fibres obtained from numerous industrial processes. A 130cm diameter modular, portable satellite dish for defence and civilian telecommunications was unveiled, as one of the first results generated by a Life-EU sponsored project currently run by Cannon.
www.cannon.com
The modular satellite dish for defence and civilian telecommunications (in the background) built with seven triangular composite parts (in the foreground) moulded with recycled carbon fibre using Cannon’s Cresim technology on show (photo: Cannon)
