Resource-optimised production of plastic components such as packaging is becoming increasingly important. Cost savings can be made right from the production stage. Grafe has introduced an additive masterbatch flow improver which is said to permit faster processing at lower temperatures.
Packaging is often an integral part of a product. But changing environmental conditions are presenting producers and product developers with new challenges. Plastics packaging manufacturers are striving to meet the latest functional, design, cost and sustainability requirements through innovative material developments. At the request of this customer group, Grafe Advanced Polymers, based in Blankenhain, Germany, has developed an additive masterbatch flow improver to help achieve resource-optimised production of plastics packaging.
Sample board showing the different effect of a newly developed additive masterbatch with adapted machine parameters (photo: Grafe)
How it works
The flow improver has a significant influence on the processing properties of the polymer, says Dipl.-Betriebswirt Markus Benzler, Key Account Manager, Grafe. He continues that this is due to two complementary action mechanisms. Through the positive effect on crystallisation properties, temperatures and cycle times are said to be substantially reduced.
According to Grafe, advantages are, in the first place, a reduction in machine temperature of around 30% which cuts direct energy costs. In addition, less waste heat is produced, which improves working conditions around the machine. The machine can also be restarted more quickly after stoppages or set-up, says the company and the accelerated crystallisation is said to ensure faster cooling of the component and so permits cycle time to be optimised.
The additive masterbatch can be used on all current machines and is suitable for injection moulding, extrusion and blow moulding. The flow improver is added during the process, generally at a rate of about 3 to 5%. It can also be combined with dyes in a masterbatch.
Benefits
This masterbatch, tailored to the end product, claims to offer processors new technical and commercial options. Lower energy consumption and faster cycles have a direct influence on the cost structure and contribution margin for the packaging. The resulting unit cost optimisation allows producers to adjust their price policy individually to the requirements of the market and so creates the opportunity for a competitive advantage.
Assuming that the value of the contents, for instance, in the case of convenience goods, determines the value of the packaging, then the increased efficiency achieved with the flow improver opens the way for attractive cost-saving options, for example, in food packaging, explains Benzler. The cost ratio between the contents and packaging changes.
Overall, it may be concluded that resource-optimised production of packaging has a far greater effect on product cost structure than simple cost optimisation. The ecobalance of the end product is also improved, providing added value in terms of carbon footprint and sustainability, which can be realised through variable marketing concepts and additional marketing potentials.
www.grafe.com
