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in this issue
MACHINERY pages 610
REGULARS:
Latest news 67
SHOWCASE: MATERIALS HANDLING 89
SPOTLIGHT: COMPOUNDING LINES & EQUIPMENT 10
MATERIALS pages 1113
REGULARS:
Latest news 1112
SHOWCASE: PURGING COMPOUNDS 13
pages 5051 CLASSIFIEDS
K 2013: THE PREVIEW pages 1649
Your comprehensive EPPM guide to the show
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Caps and Closures
Im very fortunate in
that my job allows
me to go to Germany
quite a lot. I like
attending trade
shows in Germany,
because theyre a lot
of fun - and if you
get chance, the time
spent outside of the
show is fun too. Of
course, in part Im
referring to the excellent beer and fantastic food. But if your visit
allows you a little time to explore the surrounding area, its always
worth doing.
If youre a newcomer to Dsseldorf, youll find that many people opt to
venture into the citys Altstadt (old town). With more than 260 pubs, it
has been nicknamed the longest bar in the world. But dont just visit
for the pubs. Spend some time taking in the classic continental
architecture of the district - a good way to wind down after a day in the
heat of the halls!
The majority of this issue of EPPM is a dedicated guide to your show -
highlighting key machinery releases, new strategic partnerships and
much more, all to be announced during K. Theres even our traditional
hall plan in the centre spread, so if you have your copy on-site, it may
just help you get around.
Be prepared for the crowds - its not too late to call your top suppliers
and request meeting slots with them - theyd love to hear from you.
Keeping a relatively clear diary for ad-hoc meetings can be beneficial -
but if youre hoping to visit the major players, be warned that you may
have to wait some time to speak to specific representatives about
popular topics.
Finally, make sure you come and see EPPM, and its publisher, Rapid
Plastics Media - which is the group behind the British Plastics and
Rubber, Middle Eastern Plastics and Medical Plastics News titles, as
well as the Interplas and Mediplas trade shows. Well all be on hand in
Hall 11, Stand C03 to discuss any of those products, in addition to our
new plastics sector directory service, Plastrep.com.
As they say in Dsseldorf,
its K time!
I
n
j
e
c
t
i
o
n
M
o
u
l
d
i
n
g
John Sturgess, Director,
MG Stuma
F
i
l
m
&
S
h
e
e
t
E
x
t
r
u
s
i
o
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Graham Pickwell,
Technical Adviser,
Polymer Training &
Innovation Centre
P
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t
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u
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B
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M
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John Bunker,
Member, Worshipful
Company of
Horners
R
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c
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i
n
g
Omer Kutluoglu, CEO,
2K Manufacturing
R
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c
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c
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i
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Martin Marron, MD,
Biffa Polymers
R
e
c
y
c
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Jonathon Short, MD,
ECO Plastics Ltd.
M
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o
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i
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Barry Assheton, Sales
Director, CRDM
A
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i
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&
C
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Andy Bone, Sales
Director, Formaplex
Mark Bonifacio,
President, Bonifacio
Consulting Services
P
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i
n
g
Simon Chidgey,
Director, M&H Plastics
M
e
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Andrew Feilden,
Principle Consultant,
Smithers Rapra
M
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Graeme Diston,
Senior Injection Moulding
Engineer, Bausch + Lomb
C
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s
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i
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Andrew McArthur,
Engineering Manager, IKO
Andrew Smith, Head of
Manufacturing, Numatic
International
P
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s
f
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t
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John Ellis, Segment
Manager Polycarbonate,
Bayer MaterialScience
Nigel Brown, Founding
MD, Frontier Aerospace
W
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P
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t
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Alex Collins, Director,
Vannplastics Ltd.
W
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&
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Jon Herbert, Director,
FS Cables
B
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Dr Martin Kay,
Chief Consultant,
Pira International
B
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s
/
M
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Dr Terence A. Cooper,
CEO, ARGO Group
International
R
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i
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&
C
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Vicki Sayer, Regulatory
Manager, Colormatrix
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y
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Clive Maier,
Owner and Director,
Econology Ltd.
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I
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s
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Ken Braney, 2010-2011
President,
Society of
Plastics Engineers
E
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t
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U
K
&
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Charmaine Bowers,
Operations Manager, Polymer
Training & Innovation Centre
A
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f
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e
G
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S
p
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C
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Dr Gerd Schmaucks,
Independent
Consultant
M
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Paul Maley, Senior
Mechanical Engineer,
Selex Elsag
Our Editorial Advisory Board is comprised of a cross-section
of the plastics industry, including processors, consultants,
technicians and key industry figures.
James Goddard,
Honorary Lifetime
Member, Plastics Pipe
Institute
from the editor
Images copyright
Messe Dsseldorf.
4 WWW.EPPM.COM OCTOBER 2013
Efficiency is set to be the main theme at K 2013, and it
can now become a key part of visitors' preparation
before the event as well. Through a new microsite and
an exclusive app, ENGEL informs the international
injection moulding industry about innovations that are
on display and activities that are taking place at K.
Visitors are guided efficiently to the ENGEL exhibits
which are relevant to their sector and applications.
K 2013 has already started at www.engel-k-
online.com. On ENGEL's microsite, there is now a
preview of its stand at the fair. All 12 machine exhibits
can be seen in action in trailers, while further detailed
information makes the company's upgrades and new
developments transparent and is already offering the
public an insight into the future potential of the
innovative products, technologies and system
solutions.
In addition, the microsite provides a schedule for
machine demonstrations and an overview of ENGEL
injection moulding machines and system solutions
being presented at partner stands.
Also available to take away
The new ENGEL app for K 2013 is available free of
charge at www.engel-k-online.com for Android and
iOS. It means fair visitors can quickly access the
descriptions of the exhibits, the trailers, the
demonstration times and a plan of the company's
New ENGEL microsite and app
duo) and the first composite brake pedal produced in a
one-shot process. With the geometrically optimised
and stress-resistant plastic brake pedal ENGEL and its
partner ZF-Friedrichshafen reach a new milestone in
automotive lightweight construction at K 2013. The
concept for manufacturing a hybrid, organic sheet
brake pedal received the Composite Innovations Award
in 2011; since then it has been consistently enhanced
by ZF. ENGEL offers a first glimpse into the efficiency of
the manufacturing process from its stand. Using a
vertical ENGEL insert 1050H/200 injection moulding
machine with an ENGEL easix multi-axis industrial
robot and infrared oven, continuous fibre-reinforced
thermoplastic semi-finished products (known as
'organic sheets') will be heated, preformed in a mould
and immediately overmoulded with polyamide. The
system produces ready-to-fit components; no cutting is
necessary. Inject the future with ENGEL at K 2013.
ENGEL
www.engel-k-online.com
Well informed before
and during the trade
fair: ENGEL's new
microsite for K 2013
is now up and
running.
With the new ENGEL app for K 2013 fair visitors can quickly access the descriptions of the exhibits, the trailers, the demonstration
times and a plan of the company's stand at any time.
Always up to date efficiently informed
for 2013
stand at any time. Once installed, the app does not
need a live connection to the Internet to work.
Christian Pum, ENGEL AUSTRIA's Sales Director, says:
With the exhibits at our own stand in hall 15 and
further exhibits at the stands of our partners, our
innovation density at K 2013 will be greater than it's
ever been at a trade fair. Our new online services will
help visitors to find the innovations that are important to
their field and ensure they don't miss any highlights.
New milestone in automotive lightweight
construction
A total of 25 ENGEL exhibits open the door to new
applications, set new efficiency records and provide
answers to the big challenges of the future. The
manufacturing cells on view combine high levels of
process integration and automation, strong
performance, sustainability and process reliability. Also
on show are several new injection moulding machines
(ENGEL e-speed, ENGEL e-motion 30 TL, ENGEL v-
OCTOBER 2013 WWW.EPPM.COM 5
The vertical ENGEL insert 1050H/200 injection moulding
machine will be used to produce brake pedals.
Images: ENGEL
cover story
MACHINERY
Hydro-Gen Engineering Ltd, a specialist
in industrial water filtration in the UK
claims it has been working closely with
several customers in the plastics industry.
The initial involvement was to improve
water quality to keep the closed loop
system clean, to stop flow meters fouling
and flow control valves blocking, but as a
number of installations came on-line with
a side stream polishing system, the
group says that other benefits came to
light.
By using clean cooling water, machine
speeds improved during the trials as
curing time came back towards the
original design time, where previously,
curing time had to be extended as
cooling was becoming less effective due
to poor quality water.
To put this extension to the curing time
into perspective, the group claims that a
coating of particulate on a heat transfer
surface of only 100 micron (about the
width of a human hair) can reduce heat
transfer by 15%, so if the cooling
efficiency of a system reduces production
by just 15% this would mean that for
every 1000 hours of production, 150
hours are lost, which over a year is some
1314 hours. In a production facility with
ten machines this means one or even two
machines are being used just to cover
production lost by extended curing due
to poor water.
Another common problem is the onset of
biological growth within the system. One
solution is to routinely drain the whole
cooling system, flush it, then refill it with
fresh water. However in systems that also
contain chemicals (such as biocides and
antifreeze) these chemicals are in effect
thrown away.
Hydro-gen claims that the system best
suited to resolving these issues is a side
stream option which can polish the water
to below 1.0 micron. This is an advanced
technology which is self-cleaning and
when installed correctly can reportedly
show significant benefits within days of
installation, ensuring a clean cooling
6 WWW.EPPM.COM OCTOBER 2013
Water filtration brings new benefits to moulders
system, reducing maintenance down-time
and maintaining production levels as well
as reducing water and chemical losses.
Hydro-Gen Engineering Ltd
Web: www.hydro-genengineering.co.uk
EMO Extrusion Molding GmbH, a
manufacturer of flat dies for plates and
film extrusion has expanded its
processing capacities in the largest
size range. Film widths up to nine
meters are now possible, says the
group. Also expanded is the range of
coatings for corrosion and wear
protection. The group will introduce
the new developments to K visitors in
Hall 2.
EMO has also developed new options
for the corrosion and wear protection
of nozzle channel and lip areas. The
group claims that operating stability
can be increased, and deposits of
degraded material in the flow channels
reduced. EMO offers a whole range of
coatings. The nozzle components are
made of steel grades 1.2311 and
1.2316, which are coated, depending
on the conditions of use, in whole or
only on the flow channel surfaces.
EMO Extrusion Molding GmbH
Web: www.emo.at
Die-maker to debut expanded
widths at K
A new generation of the
widely used contour cast
film die now incorporates an
internal deckle that enables
extrusion processors to
achieve speed and precision
without incurring downtime
for changing product width,
it was announced by
Nordson EDI, which will
introduce the die at K 2013
(Hall 2, Stand G06).
The die is said to reduce time needed
to achieve on-spec product and to
purge between product runs and
reportedly offers up to 25%
improvement in cross-directional
product uniformity, along with a
reduction in gel formation. The new-
generation Contour Die reportedly
retains 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.
While benefits from the new die will vary
with each application, in commercial-
scale trial runs by a global film
manufacturer working with Nordson EDI,
the new-generation Contour Die is said
to have achieved considerably narrower
gauge tolerances in comparison with a
coathanger die, making possible
materials saving with a calculated
annual value of US $200,000.
The Contour Die can pay for itself in
less than a year simply by virtue of the
resin savings made possible by
precision control over the gauge
profile, said Sam G. Iuliano, chief
technologist. Nor do these savings
take into account the enhanced
productivity resulting from increased
yields of saleable film and reductions in
scrap. Customers using the original
Contour Die have told us many times
that it is easier to adjust than standard
coathanger dies, starts up and settles
in more rapidly, requires less time for
purging, and speeds up product
changeovers.
The new-generation Contour Die is the
result of Nordson EDIs use of
modelling and engineering software to
generate an innovative manifoldthe
flow channel that is machined between
the upper and lower halves, or bodies,
of the die. This new manifold permits
the incorporation of a built-in internal
deckle.
In developing the original Contour Die,
the group designed a coat hanger-
shaped manifold, which produces a
streamlined melt flow. Unlike the block-
like shape of traditional coathanger
dies, however, the Contour Die has a
New extrusion die offers new possibilities for cast film
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
manifolddifferences 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 produces
a more uniform cross-directional gauge
profile and a more uniform layer
structure in coextrusion.
The new-generation Contour Die
retains all of the advantages of the
original design while making it possible
to carry out rapid changes in product
width without having to take the die
offline, said Mr. Iuliano.
Nordson EDI
Web: www.extrusiondies.com
MACHINERY ROUNDUP
Packaging group Paccor has
developed a thin-sheet technology
for form-fill-seal (FFS) applications in
dairy, along with other markets called
Neocell. The product is made using
the MuCell process, supplied by
MuCell Extrusion, LLC.
Bob Hope, Materials Technology
Manager for Paccor said: The
development of this gas injection
technology, in conjunction with
MuCell Extrusion has allowed
PACCOR to offer to the market two
new products for Form-Fill-Seal
(FFS) sheet, Neocell and Neocell+.
Neocell allows us to eliminate the
use of chemical foaming agents,
which for us leads to a cleaner
process, with much more control
over the expansion, as the quantity
of gas injected is metered very
accurately.
Paccor says that Neocell technology
has been designed for efficiency and
sustainability. According to Vincent
Duguay, Development leader for
Neocell: Neocells unique selling
point is its low density middle layer,
which forms through the use of the
MuCell process and which makes
the polystyrene sheet lighter, more
environmentally friendly and also
improves the carbon footprint.
Cell size is more homogeneous and
density can easily be adjusted to the
customers requirements. Neocell+
is an extension of Neocell. Mineral
fillers are incorporated into the
formulation, which further reinforces
the structure. This enables Neocell+
to be used in applications where
previously only solid sheet could be
used.
These two new products
demonstrate PACCOR's commitment
to the FFS market and to offering
solutions which bring real
environmental benefits, in terms of
weight reduction and carbon
footprint, said Hope.
Neocells density decrease
reportedly leads to weight reduction,
material savings and reduced CO
2
emissions. The density of the sheet
is claimed to be adjustable
according to the end users needs.
Neocell is available in a variety of
thicknesses, ranging from 0.7mm to
1.4mm, and the sheet can be
supplied in either white or bi-colour.
MuCell Extrusion, LLC
Web: www.mucellextrusion.com
OCTOBER 2013 WWW.EPPM.COM 7
Responding to demand,
mould and tool specialist
Meusburger has expanded its
range of mould products in
the grade 1.2714HH with
1,350 N/mm. As of now, the
FB sliding cores FW 50 and
FW 52 change inserts and
standard bars are available
from stock in the pre-
toughened material.
The fact that no further heat
treatment is required for this material
grade allows for shorter
manufacturing lead times. The
material also features high
temperature and impact resistance. In
MuCell chosen for thin sheet
FFS product
Pre-toughened tools available in more hardness grades
addition, it is said to be easily
machinable, despite its hardness.
Meusburger
Web: www.meusburger.com
Extrusion machinery group SML has
released a new three metre wide
machine for the production of enhanced
stretch film for performance applications.
Named SmartCast, the machine is a
modular system with four pre-configured
extrusion units at throughputs ranging
from 1,700 kg/h to 2,400 kg/h and a
choice of five or seven layers depending
on requirements.
Using an optional edge encapsulation
system, production speeds of up to 750
m/min are claimed to be achievable,
which would provide an output on the
winder of over 1,500 kg/h of 12m film.
SML has also upgraded the chill roll unit
by adding additional functions, avoiding
Extrusion line released for performance stretch film
vibrations and making operation easier.
Also new from SML is the W4000-4S
winder, which has been designed with
the following features:
Machine and jumbo rolls on 3-inch
cores
Hand rolls on 2-inch cores
Coreless and thin core technology
Reduced film tail for improved roll finish
The SmartCast line will be in operation
on the SML stand (17/C42) at K 2013 in
Dsseldorf.
SML Maschinengesellschaft GmbH
Web: www.sml.at
8 WWW.EPPM.COM OCTOBER 2013
MACHINERY
SHOWCASE
MATERIALS HANDLING
customers include Abu Dhabi Polymers,
Tetra-Pak, Indorama and Bumi Mulia.
A-Ward container loaders provide some
very attractive benefits to plastic resin
manufacturers; including the ability to fill
100% of a containers volume by loading
at 90. Full containers = optimised
freight efficiency and eliminates shifting
of material during shipping.
Another benefit that A-Wards customers
experience is the increased speed of the
container loading process by being able
to position the tilter directly below silos.
Built-in remote controls ensure that the
container loading process is a one-man
operation and the option of adding a
scale system to the machine allows the
container to be weighed during loading
which avoids over or under loading
containers.
The most common benefit that A-Ward
container unloaders reportedly provide is
the removal of the reliance on expensive
and scarce tipping trailers.
With the UO20 model, no forklift or reach
stacker is needed to transfer the
container from truck to unloader: the
trailer is simply reversed in to the
Container tilter manufacturer A-Ward has
seen a significant increase in demand
for its container tilters for loading and
unloading shipping containers with
plastic resin.
As resin manufacturers and customers
shift from shipping with many small bags
to single container liner bags, the
demand has grown for efficient container
loading and unloading solutions.
A-Ward manufactures container loading
and unloading machines, also referred
to as container tilters.
These machines are said to offer a range
of benefits for both the exporters loading
the containers with resin and the
customers unloading them.
Whilst A-Ward container tilters have been
around for many years in other
industries (such as agriculture, recycling
and mining), the company has
experienced a sudden and recent
increase in demand from some of the
worlds leading resin suppliers and
users.
A-Wards most recent container unloader
installation was at Southeastern
Container in Virginia, USA. Other recent
unloader and the unloader removes the
container directly from the trucks trailer.
Where resin importers do not
necessarily require all of the resin to be
discharged at once, the container
unloader enables companies to unload
over a longer period of time; therefore
increasing on-site storage. There is no
need for the driver to wait while the
product is discharged.
Unloading speed can also be controlled
exactly by unloading at any desired
angle and by using hydraulic container
door arms, operator safety is maximised.
A-Ward
Web: www.a-ward.com
Container loaders and unloaders finding more customers in plastics
with the difficult Kobusch regrind. The
system uses a Eureka drying system for
the virgin PET, expected to use around
40% less energy than conventional drying
systems. It also features a MOWIS
supervisory system monitoring all the
equipment feeding, blending and loading,
producing material consumption reports
and including maintenance reports.
Crawford Fleming, Project Manager at
Kobusch commented, We selected TH
Plastics as they were able to offer us a
fit-for-purpose and cost-effective solution
that was tailored to meet our specific
requirements. They were committed and
invested in the time and effort to
understand our specific needs.
The system is monitored and gives
Kobusch a consistent overview for
monitoring schedules and altering them
for any potential issues, again minimising
potential downtime. TH Plastics included
Kobusch manufactures packaging for
protein-based products, convenience
food, dry food, consumer care and high
tech products, medical and
pharmaceutical applications. UK-based
distributor TH Plastics was selected in
early 2013 to provide a new material
handling system for Kobuschs site in
County Durham. In particular, the group
required a blender that could handle two
to three tonnes of regrind flake per hour.
TH Plastics system is a tailor-made end-
to-end materials handling system
designed to streamline production,
provide more uptime, less energy usage
and self regulation.
It features one of the largest batch
blenders sold in Europe (according to
TH Plastics), the DGM1000, capable of
blending up to five tonnes of normal
product per hour. It includes flake
loaders that are designed to work with
a three year warranty and a three year
service plan. The drying system is
demonstrating around 30% in energy
savings.
Crawford Fleming said: The systems all
work seamlessly together and weve
been able to achieve optimum levels of
over three tons of flake material per hour,
which were extremely pleased with, and
is much more than we expected. This
was a crucial project for us and we were
particularly nervous having had issues
with the last material handling system we
had implemented. TH Plastics have gone
above the beyond the call of duty and
have been really patient with us, helping
us throughout the whole process. They
have demonstrated a clear partnership
approach and much more than a
supplier customer relationship. They
have taken the time to understand what
we wanted and how we can get the best
out of our systems. For example by
looking at larger pipe work to
accommodate our needs, and looking at
the timing systems of the hopper
loaders. Theyve worked out of hours to
meet our deadlines and accommodated
all of our requests, even if it meant
departing from the initial plan. We
couldnt have asked for a better partner.
TH Plastics
Web: www.thplastics.co.uk
Kobusch takes delivery of one of the largest batch blenders sold in Europe
MACHINERY
SHOWCASE
MATERIALS HANDLING
OCTOBER 2013 WWW.EPPM.COM 9
cells, like the ResinWorks system, which
combines multiple hoppers with integral
air manifolds, ducting and wiring on a
sturdy platform for simplified shipping,
installation and operation. Each hopper
can be equipped with a Drying Monitor
probe that incorporates RTD sensors
spaced along its length. The probe
measures the temperature at up to six
different points in the bed of plastic
material so that a temperature profile
can be created to verify that conditions
for proper drying are maintained.
Up to 15 hoppers equipped with Conair
temperature controls can be linked to
the DC-T for monitoring and duplicate
control. All settings can be made,
viewed and adjusted at the dryer. Data
from individual Drying Monitor probes,
including trending graphs, can also be
displayed on the DC T monitor thanks
to the standard internet connectivity.
Controls on other Conair equipment are
The new DC-T TouchView control from
The Conair Group, which provides an
interface for monitoring and controlling
the entire polymer drying process, will
be featured in Hall 10, Booth J59 at K
2013. The new control will be part of a
central-drying cell that includes a W300
Carousel Plus desiccant dryer and a
four-hopper ResinWorks system
equipped with the patented Conair
Drying Monitor.
The DC-T TouchView dryer control has a
whole host of convenient features that
help plastics processors get more out of
their drying system. A big 8-inch-
diagonal graphical touch-screen
interface shows everything going on in
the drying system and operators can
make adjustments easily. It shows
current and historical temperature data
and includes precise dew-point control.
The DC-T also provides a gateway for
control of multi-hopper central drying
also web-enabled and will be
networked together at K
2013 so that anyone with a
computer, tablet or smart
phone with Internet access
and the right password
credentials can connect with
the controls and monitor
conditions or change
settings.
Customers have been
telling us that they want
these remote access options
to maximise productivity,
said Doug Brewster,
Conveying Product Manager.
Whether they are on the
other side of the building or on the other
side of the world, production
supervisors and management can
change settings, respond to alarms,
perform troubleshooting and other
operations just as if they were standing
Conair to present new polymer drying control at K
dispensing accuracies. Stainless steel
contact surfaces, easy-access hopper
cleaning and material drains are key
features of the new design.
The blender is suitable for the blown film,
cast film, lamination coating, cable coating
and fibre extrusion sectors.
The next generation Batch Blender
combines TSMs patented reverse auger
technology with, responsive throughput
measurements for real-time control. The
mechanical design delivers a small
footprint, making it ideal for either new or
retro-fit installations. A combination of both
batch and continuous technologies are
deployed in a single unit that reportedly
provides improved performance over the
traditional batch blender.
The hardware and mechanical design is
Specialist supplier of gravimetric systems
TSM Controls has introduced two new
products to its range at K 2013 which
have reportedly been designed to deliver
improved cost-performance for plastics
manufacturers.
The new Loss-In-Weight blender
minimises scrap during start-up and
product changeovers, reducing end
product manufacturing costs for those in
the extrusion sector while offering
improved product quality and
consistency, claims TSM. The unit can
dose up to seven materials at a time and
features optional cascade mixing
chambers and multiple augers for varying
feed rates. A new control algorithm,
developed in conjunction with a leading
UK university improves weighing and
New blending technology improves cost performance
in front of the operator interface on the
plant floor. Its a tremendous time-
saver.
Conair
Web: www.conairgroup.com
now delivered with a control strategy that
is said to offer faster and more accurate
control.
The introduction of these new products
is a direct result of listening to our
customers and developing products that
make a real difference to the bottom line.
Achieving true bottom line results needs
not onl, great technology but also great
people who understand your business
with the in-depth skills and strong track
record in delivering results, said Declan
Byrne, TSM Director of Sales.
The new blenders are on display during
the K Show at the TSM stand in Hall 10,
J54.
TSM Controls
Web: www.tsmcontrols.com
smooth transport of materials. Bucket
elevators are used for conveying at
heights and under high performance
conditions, an area where RUD claims to
have an extensive product range.
BULKOS central chain type bucket
elevators are mainly used to provide
conveying capacities in extreme
conditions and to meet high speed
conveying requirements. RUD says it
has a robust and durable design for a
long operating life.
BULKOS round steel chain type bucket
elevators reportedly enable handling of
materials operating under the toughest
of conditions such as high temperatures
or bulk flow rates. The RUD multiple link
bucket attachments are robust, durable
and help guarantee a high degree of
safety during transport.
RUD states that it retains a high level of
technical experience in conveyor and
conveyor systems for the handling of
The transportation of bulk materials is a
major challenge, to ensure the
availability of building materials when
they are needed. System availability and
reliability are often overlooked and quick
solutions are used which sometimes
only secures limited success.
Thats according to RUD, a manufacturer
and supplier of chain systems and
components to the bulk materials
industry supplying; complete bucket
elevators and spare parts, complete
conveyor systems and drive systems for
bulk materials handling.
The groups BULKOS range provides
conveyors and systems for a wide range
of bulk material applications. BULKOS
complete bucket elevators are suitable
for vertical conveying applications for
powdery, granular, lumpy and high
temperature bulk materials.
BULKOS belt type bucket elevators are
reinforced with textile or steel inlays for
Bucket elevators allow reliable conveying of bulk materials
bulk materials. Supplying standard and
specialised solutions across all
conveyors, drive and elevator
applications.
RUD Chaines
Web: www.rud.co.uk
10 WWW.EPPM.COM OCTOBER 2013
eppm COMPOUNDING LINES & EQUIPMENT
A hydraulic
power unit
with two
pumps
effectively
overcomes
resistance
during slide
plate or diverter
valve operation
without need for a
pressurised hydraulic oil accumulator,
it has been announced by Nordson
Kreyenborg GmbH, which will
introduce the system at K 2013 (Hall
9, Stand A44-48).
The new system reportedly eliminates
the costs associated with maintaining
pressurised accumulators, as well as
the additional costs and
complications caused by the safety
inspections required for such
accumulators. Inspections must be
carried out every one to two years in
Belgium, for example, and every five
years in Luxembourg and Germany.
In addition, the two pumps in the new
Nordson Kreyenborg system are
supplied from a single oil reservoir
and are driven by a single motor,
simplifying the design and reducing
the initial investment.
In a conventional hydraulic system for
slide plate screen changers, a
MACHINERY SPOTLIGHT
POWER UNIT
ELIMINATES
NEED FOR A
PRESSURISED
OIL
ACCUMULATOR
Austrian group
Econ, a
manufacturer
of extrusion
peripherals,
especially
underwater
pelletizing
systems, pellet
dryers, screen
changers and pyrolysis
furnaces will launch a new laboratory
version of the underwater pelletizing
system at K 2013.
Named EUP 10, it is designed for
throughputs of 1-15 kg per hour,
depending on density and granule
size. The nozzle platen can be fitted
with one to five nozzles of individual
diameters.
Also launching (or re-launching) will be
the groups screen changer, which
has been re-designed. The main
difference is a patent-pending sealing
technology, which is said to be
advantageous when processing very
low-viscosity plastic melts (e.g. PA,
PET).
The unit features a free-flow area on
the screen, in which 75% is
permanently open for the melt stream,
while 25% of the stream is
backwashed. This is due to the new
screen assembly. The two meshes are
located next to one another in each of
the two displacement piston units,
allowing for a more direct flow in the
melt channels. This reduces the back
pressure in the melt flow and the
associated energy consumption.
Also on display will be the S+L pellet
dryer. The dryer is available in four
standard sizes for
throughput rates from
500 to 10,000 kg/h
(based on a bulk
density of 0.7 kg/m).
They can be used as
stand-alone devices as
well as in combination
with Econs granulation
units.
Econ GmbH
Web: www.econ.eu
LAB-SCALE
UNDERWATER
PELLETIZER TO
ENTER
MARKET
pressurised
accumulator is
required to overcome
the resistance caused
by residual degraded
or baked-on polymer,
which can
otherwise
impede the
movement of
slide plates in
a screen
changer or of
the bypass, start-up,
and switch-over valves used in various
polymer processing applications. The
Nordson Kreyenborg system makes
rapid action possible in these devices
while avoiding the maintenance,
costs, and safety issues of a
pressurised accumulator.
The new system utilises two hydraulic
pumps that are capable of operating
simultaneously. One, called the
volume flow pump, draws on a larger
volume of oil to provide fast
movement when the level of
resistances is low. The second, called
the high-pressure pump, uses less oil
but generates a pressure buildup that
overcomes high levels of resistance.
Kreyenborg
Web: www.kreyenborg.com
OCTOBER 2013 WWW.EPPM.COM 11
MATERIALS
An analysis of the global market for
expandable polystyrene (EPS) has been
released.
Market research firm Ceresana carried
out the study, which revealed that global
demand for EPS in the construction and
packaging industries will slow down, but
continues.
It also goes on to highlight factors like
the recovery of the construction sector
after the financial and economic crisis in
2008/09, state-funded programs to
improve energy efficiency, and
increasing wealth and population in
emerging countries.
Average growth rates of 4.8% p.a. that
have been generated in the previous
eight years are unlikely to be reached
again, but Ceresana nevertheless
expects consumption to increase at an
AAGR of 3.8% in the next eight years.
An expected market volume of more
than US$15 billion in 2020 shows that
the market for EPS is well worth a closer
examination.
Asia-Pacific already is the most
important consumer of EPS worldwide,
accounting for about 54% of global
demand, followed by Western and
Eastern Europe. Market analysts at
Ceresana forecast Asian-Pacific
countries to continue to gain shares of
the global EPS market, mostly at the
expense of saturated industrialised
countries in Western Europe and North
America.
Developing and emerging countries, on
the other hand, can capitalise on an
increasing per capita consumption of
packaging materials and other EPS-
based products. The most important
growth trend on the international market
is China.
One of the major application areas is the
construction sector that accounted for
more than 61% of total demand in 2012.
European countries in particular record a
widespread use of EPS in the
construction sector, as a range of state-
funded programs target at improving
energy efficiency.
All around the world, EPS-based
products are used in the construction of
new residential building and in the
EPS market analysis now available
refurbishment of
old buildings.
Even on saturated
markets, this can
create growth
impulses because
EPS consumption
in the construction
sector is expected
to increase by
4.1% per year.
Packaging made
from EPS that is,
for example, used
to transport fresh
fish or electronic
goods, account
for more than a third of global demand.
Especially in Asia-Pacific and South
America EPS products are accounting
for a significant share of total demand.
Other EPS-based products include
recreational goods such as helmets,
cores for surf boards, life jackets or foam
cups for hot beverages. A particularly
large consumption volume in this
segment is recorded in North America,
not least due to a comparatively high
consumption of foam cups. EPS is also
used in child safety seats, casting
moulds, and horticultural applications.
Taken together, all these applications
accounted for about 4% of global
demand.
Ceresana
Web: www.ceresana.com
The first of two new products from UK-
based Detectamet is a fully detectable
large straight clip that is designed to re-
seal large bags or sacks used in the food
industry to contain ingredients. It is easy
to close and open and is coloured dark
blue. It has a sealing length of 320mm.
Modern food processing companies now
use detection systems to carry out final
checks on their finished product. Pieces
of plastic can be detected by these
machines and the contaminated
cupcakes can be detected and sent into
the reject bin.
The plastic meets the requirement of EU
and US regulations for food contact, and
it will continue to do its job at
temperatures as low as -50C / -58F. This
means that the clips can be used to seal
sacks or large bags of product or partly
used ingredients that are to be stored in
the deepest of deep freeze stores as well
as at ambient temperatures.
For companies that dispense their dry
goods by the scoop rather than by the
part sackful, Detectamet has also
launched a new range of food scoops.
They are made from the companys
Metal detectable scoops and bag clips reduce contamination risks
detectable high impact polypropylene
and are available in three sizes of 250ml,
500ml and 1000ml.
The scoops have inner graduation
marking for easy measurements when
dispensing ingredients such as flour and
sugar. The handle offers a sturdy,
comfortable grip and with a hole for
hanging and easy storage.
Each scoop has its size stamped on the
handle for instant recognition and the flat
bottoms allow them to safely sit flat on
counter tops and tables and can be
stacked when not in use.
The small scoop is marked in 50ml and
in 2oz increments, the medium is marked
in 100ml and in 3oz increments and the
large scoop measures in 200ml and in
5oz increments.
The onepiece manufacture means that
the scoops offer due diligence solutions
to cleaning risks and the detectability
reduces the risk of product
contamination when post production
detection systems are installed.
Detectamet
Web: www.detectamet.co.uk
Following two years of steady decline in
the European price of 12 micron bi-
oriented polyester (BOPET) film, it would
appear that the trend has finally
stabilised, according to PCI Films
Consulting. BOPET film prices have
remained unchanged for three months
running.
Whilst some modest reductions in price
are likely for Q3, 2013, PCI believes that
future price movements in either direction
are not expected to be significant due to:
Already squeezed film producer
margins
Excess film extrusion capacity
Stable raw material costs
European film producer margins have
been weakened in 2013 due to the
absorption of higher input costs, mainly
because they have been unable to pass
these increased costs onto customers.
In addition film producers have been
chasing volume to improve capacity
utilisation at a time when European
BOPET film demand remains at best
stable. Both factors are putting BOPET
film producers under significant financial
strain.
Speaking of the problems facing the
West European BOPET film extrusion
industry, PCI Managing Director, Mr
Simon King said: European producers
of 12 micron BOPET films will be glad to
see prices finally stabilise but they still
face strong competition from Turkish,
Middle Eastern and Asian producers.
European buyers of BOPET film now
source the majority of their commodity
EU BOPET film prices finally stabilise says consultancy
films from lower-cost suppliers outside of
Europe so if the European industry is to
survive, successful strategies to develop
and supply added-value products will be
critical.
In the latest edition of, European
Monthly BOPET Film Pricing Series, PCI
reports on industry average prices
obtained from interviews with buyers and
sellers of 12 micron BOPET film across
Europe.
PCI Films Consulting
Tel: +44 1604 749001
Email: info@pcifilms.com
Web: www.pcifilms.com
12 WWW.EPPM.COM OCTOBER 2013
MATERIALS ROUNDUP
Hugo Jnsson, the founder of Swedish
compounder Polykemi, has passed
away at the age of 83.
Hugo is said to have visited the office on
a daily basis, even in his final days. His
role recently was as Senior Advisor to
the current management.
Hugo Jnsson was born in the village of
Ingelstorp east of Ystad. He began his
career at Persner, at the time largest
company in Ystad. There he advanced
to Deputy Manager of the textile
recycling department. In his book, My
Own Story, which he wrote after his
retirement, he recounts how he
suggested to the management of
Persner to close the textile department
and grow into the field of plastics; a
suggestion which was apparently
rejected.
Obituary: Hugo Jnsson, a life in plastics
Hugo continued to pursue the industry,
borrowed money and founded Polykemi
in 1968. A few years later the company
was expanding outside the borders of
Ystad and Sweden. Today Polykemi has
approximately 250 employees with
foreign subsidiaries in the Czech
Republic, Denmark, Germany and China
and agents/distributors in seven
countries. The subsidiaries Rondo Plast
(recycling) and Scanfill (packaging
compounds) are both located in Ystad.
The plant in China was opened in 2007
and Hugo Jnsson was instrumental in
the process for establishing Polykemi in
the Chinese market, as it was his
conviction that it was necessary for
Polykemi to be present there.
Despite a huge fire in 1975, Hugos
business continued to grow, venturing
into mineral reinforced PP in 1979, which
turned out to be more complicated and
expensive than calculated, almost
causing the company go under. The
development of Polyfill in 1982/1983
gave the company long term financial
stability. In the mid-eighties, Jnsson
invested in an R&D department for
Polykemi.
In 1997 he retired as Managing Director
and handed responsibility of daily
operations to his sons Ola and Lars,
naming himself Chairman of the Board
at Polykemi now the largest private
employer in Ystad and in the southeast
of Scania.
Outside of work at Polykemi Hugo also
involved himself in local politics and was
Chairman of the Ystad Harbour for three
years, where he managed to convince
the Polish ferry
line operating
the Polonia to
choose Ystad as
its Swedish
harbor.
Hugo Jnsson
was fond of non-
profit sports, in
particular Ystad
IF team
handball.
Jnsson
transformed YIF
into the major club it is today, and is said
to have been behind the clubs first
Swedish Championship in 1976.
Polykemi
Web: www.polykemi.se
DSM, along with automotive component
specialist KACO, has developed a
lightweight crankshaft cover that uses
EcoPaXX, DSMs bio-based polyamide
410, for the latest line of diesel engines
developed by the Volkswagen Group.
The cover incorporates integral seals in
PTFE and liquid silicone rubber (LSR),
as well as various metal inserts. It will be
used on Volkswagens new MDB
modular diesel engine platform,
implemented across its Audi, Seat,
koda and VW brands.
Compared with covers made of
aluminium, system costs for the
EcoPaXX cover are said to be
considerably lower, thanks in part to the
use of an integrated, fully automated
production cell for the component at
KACO. Weight has been reduced
considerably too, since the EcoPaXX
grade is 45% less dense than
aluminium.
DSM says that 70% of its EcoPaXX
polyamide 410 is derived from
renewable resources, and the polymer
is certified 100% carbon neutral from
cradle to gate. In the production stage,
KACO moulds the crankshaft cover,
and integrates two separate seals: the
first, made of PTFE, is placed into the
mould by a robot, and EcoPaXX is
over-moulded onto it; the second,
made of LSR, is then moulded directly
into the part using a 2K process.
Thermoplastic crankshaft covers are
still uncommon, with polyamide 6 or 66
being the favoured material.
Andreas Genesius, Head of Project
Management at KACO said: The part
comes out of the injection moulding
cell ready to be assembled onto the
engine block. No trimming is
necessary at all. By taking a holistic
approach to automotive part design
and production, we are contributing to
sustainable technological progress
without any compromise on part
performance or competitiveness.
Fibre orientation, the number and
position of gating points, and the
design and integration of the various
inserts have been optimised to
minimise warpage and ensure tight
Volkswagen cranks up lightweighting in new diesel engines
seals between the cover and the
engine block and oil sump, says DSM.
The cover is also resistant to the
tightening of bolts fixing it to the
engine block and the sump (each of
which are built to different tolerances),
as well as from tools used to fix the
position of the FEAD (Front End
Accessory Drive) belt.
DSM
Web: www.dsm.com/automotive
Celebrity UK hairdresser Richard Ward
has released a plastic hairbrush that
uses antimicrobial additives. Named
Tangle Angel, the brush uses Biomaster
antimicrobials to make it more hygienic
and safe to use.
Biomaster antimicrobials are blended
specifically for the end application and
are said to reduce the growth of
harmful bacteria including MRSA, E.coli
and salmonella.
The active ingredient in Biomaster is
silver, a natural antimicrobial that has
been used for centuries to prevent the
growth of bacteria. Added during
processing, the properties do not leak
out or wash off through use.
Tangle Angel, which also has heat
resistant and anti-static properties built
in, has reportedly seen a strong growth
in sales through hair salons and directly
through hairdresser Richard Wards
website.
Ward said: Brushes can collect hair,
dead skin and residues of hair products
which can become sticky and attract
dirt. I wanted to create a brush that not
only detangles and looks beautiful, but
has an added benefit through the
added antibacterial
agent, which acts as a great defence.
We are so pleased with how customers
have responded to the brush and are
looking to develop further products with
Biomaster.
Paul Morris, Managing Director at
Biomaster said: Its been said that the
average hairbrush holds more bacteria
than a sink plughole or dog bowl. Were
pleased to be partnering with Richard
Ward on a product that can make a
difference to peoples everyday lives.
Biomaster
Web: www.biomastertechnology.com
Applications: the health and safety hairbrush
Rhein Chemie has officially
opened its first Russian
production facility in
Lipetsk where the
company is to produce
Rhenogran (pre-dispersed,
polymer-bound additives)
for the rubber processing
industry.
The product range
includes accelerators,
sulfur donors, antioxidants,
and crosslinking activators
for the manufacture of tyres and
technical rubber products such as
extruded profiles, hoses, and seals for
the automotive industry.
Rhein Chemie says Rhenogran helps
rubber processors by making production
more safe and cost-effective as well as
significantly increasing the quality of
rubber components and improving their
long-term functionality and durability.
The product is dust-free, thus
significantly reducing the need for
occupational safety and cleaning
measures.
Rhenogran is said to be renowned for its
optimal miscibility in the processing of
Production facility for polymer-bound rubber additives opens
rubber additives in the mixture. It
spreads quickly and completely in the
rubber matrix, thus enabling active
crosslinking substances to unleash their
full effect. This reduces dosing amounts
and prevents chemicals from blooming,
says Rhein Chemie.
Compared to powder, Rhenogran is said
to generally reduce mixing time by 30 to
50 percent. Optimal dispersion of
chemicals makes it possible to meet the
highly exacting quality requirements
demanded today, especially by OEMs.
Rhein Chemie
Web: www.rheinchemie.com
OCTOBER 2013 WWW.EPPM.COM 13
MATERIALS
SHOWCASE
PURGING COMPOUNDS
Routsis, President of Routsis Training.
On November 8, 2013 at 11 AM EST, the
third webinar will be presented by the
Doctor of Scientific Molding, John
Bozzelli. Mr. Bozzelli spent 20 years at
Dow, has written well over 100 industry
papers and is one of the most respected
experts in the injection moulding
industry. His webinar titled Proper
Planning in Screw/Barrel Design Will
Improve Profits: How to avoid the most
common injection moulding problems
before they start will focus specifically
on how to eliminate common problems,
such as degradation and lengthy color
changes, before they occur.
The series concludes with a fourth
webinar on December 4, 2013 at 2 PM
EST presented by Nancy Mitchell, the
Technical Product Manager at Dyna-
Purge.
Those interested in registering or
obtaining additional information on each
of the four webinars should visit:
www.dynapurge.com/resources/webinar
s.aspx
Dyna-Purge
Web: www.dynapurge.com
The Dyna-Purge Division of Shuman
Plastics, Inc., Buffalo, NY, has
announced a four-part webinar series
titled From the Boardroom to the
Shop Floor: Answers to your top
questions. Dyna-Purge recently asked
its customers to identify their biggest
business challenges. The majority of
responses, as stated by Tim Cutler, Vice
President of Dyna-Purge, led to four
common themes hiring and retaining
the right people; developing talented
technicians; avoiding injection moulding
problems; and solving common
problems with purging.
The series has already kicked off with Dr.
Russ Riendeau conducting a live
presentation to a large audience at
UBMs Plastec Midwest show in
Chicago, IL. Dr. Riendeau, co-author of
The CEO's Guide to Talent Acquisition,
shared his first-hand knowledge about
what it takes to hire and retain the very
best talent. Dr. Riendeaus live
presentation was then uploaded onto
the UL IDES website, where it is now
available on demand at no charge to
viewers.
The series continues with a webinar
scheduled for October 2, 2013 from 2
PM EST to 3 PM EST titled Making
Permanent Sustainable Change Through
Training: A better way to develop
talented techs, presented by Andy
Purging compound supplier offers informative webinars
Purging compound an effective choice for blow moulder
dies for
cleaning
and the
knock-on
effects of
frequent
disassembly
and
reassembly.
It can be
used while
the machine
is cooling
and left in the tooling even for
extended periods until the next start-
up, when it is itself purged by standard
material.
Flexible PVC processors used to
experience more problems than those
working with rigid PVC compounds. This
was because cleaning flexible PVC from
extrusion and moulding machines
requires specifically formulated purging
materials that match the material within
the machine.
Dugdale Ltd
Web: www.dugdalepvc.com
UK and European PVC extruders and
injection moulders can now gain access
to a wide range of REACH-compliant,
lead-free purging compounds and a
pool of specialist knowledge according
to UK-based Dugdale PLC. Reformulated
purging compounds that meet current
European chemicals regulations are part
of the Dugdale range, which also
includes a selection of rigid and flexible
PVC compounds for UK and European
customers.
The compounds are formulated to work
in tandem with the groups customised
extrusion and injection moulding
compounds.
In addition to being a lead and tin-free
formulation, the compounds feature new
stabiliser technology which gives
Ducafreeze elevated temperature
resistance, making it suitable for use as
a freeze or purge compound for rigid
and flexible PVC production across a
wide range of applications. It is
especially suited to high-end rigid PVC
applications with processing
temperatures over 200C. Ducafreeze is
said to eliminate the need for stripping
PVC compound range expanded to facilitate purging
Purging compound developer
Aquapurge has been partnering the RPC
Group at its Llantrisant, Wales, site in the
latters ongoing continuous improvement
operational efficiency work.
Aquapurge says its new Poly Clear
HMEX compound has been used during
blow moulding production at RPC and
says the product requires just a fraction
of the time previously taken to clean out
previous production runs.
Aquapurge Technical Director, John
Steadman, commented: We worked on
white bottle production issues on start
up after the weekend. Black speccing
issues were at the time disrupting
production and requiring manpower
intensive inspection, sometimes for a
two hour period. Our solution was to trial
some 10kg of Poly Clear HMEX on a
twin head machine making 2 x 380ml
containers. Within 18 minutes we
achieved clear production with no further
need for remedial work.
RPCs Chris Walstow led the project
from the client end. We made great
strides with Aquapurge on the machine
purging front, he said. All of this
production work contributes to our
companys Overall Equipment
Effectiveness (OEE) and our plant
efficiency generally. We are now
confident in the performance of Poly
Clear HMEX in helping us achieve some
of our production goals.
Aquapurge is marketing its Poly Clear
HMEX as the most universal and most
effective purging compound that the
company has developed for both
continuous and accumulator blow
moulding of polyolefins. Aquapurge is
targeting sales on the global blow
moulding sector and says UK blow
moulders have been first to take
advantage.
The company says plastic blow-moulded
container applications, typically from 0.5l
upwards are set to see immediate
benefits, especially in saving downtime;
material cost and colour contamination.
The accumulator blow moulding
process is sensitive to inherent hold-up
points in all head designs and, over
time, can contribute to black specking
and loosened or degraded polymer or
masterbatch. At Aquapurge we question
the practice of taking a risk with all these
factors and Poly Clear HMEX is our
solution, concluded Steadman.
Aquapurge
Web: www.aquapurge.com
ABS
LUCOFIN
PVC
SAN
HIPS
GPPS
PPCO
PPHO
LDPE
HDPE
MBATCH
POM
PC
PMMA
PBT
TPE
PA6
PA66
SMMA
EVA
TPU
PC/ABS
IffhhIfAL SuPP0kI
Material Indentification
Processing Advice
Product Development
THfkH0PLASTIC
fLASI0HfkS
Range includes SEBS, EPDM
and TPO based compounds
Wide range of hardness from
Shore A90 to A0
Small lots available from stock
0YhA-Puk6f
We Buy
We Sell
CONTACT: CHRIS ISAAC
1o|: +44 [0J 1724 Bbb14 Mob||o +44 [0J 7740 32907
Visit our new tablet/mobile friendly website: www.angloplastics.com
Email: info@angloplastics.com,
Krauss Maffei KMD2-90-2
Pipe screws
Technoplast TDE 6000
Profile line
2 x Weber DS 7.22
Twin Screw Extruders.
2000/2002. Also available DS8.22
Krauss Maffei KMD110
Twin screw pipe extruder
pipe screws (2 years old)
Battenfeld BEX2-90-22V
Twin screw extruder profile screws
Krauss Maffei KMD110
Twin screw extruder, profile screws
16 WWW.EPPM.COM OCTOBER 2013
K 2013: THE PREVIEW
Reproducible, fast results and an easy to
use measuring instrument are of highest
priority in the area of quality control of
polymers according to Netzsch, which
says it has incorporated these into the
development of the new Netzsch DSC
214 Polyma. The result is an instrument
said to be optimised for the polymer field,
also ideal for sample preparation and
incorporating flexible software.
The core of the newly developed DSC
214 Polyma is comprised of the new
Arena furnace for fast heating and
cooling rates, the new Corona sensor
and the Concavus pan. These form a trio
of elements combined for achieving fast
and reproducible measurements.
Measurement preparation has been
simplified by means of the new
SampleCutter, which is available
exclusively from Netzsch, and the brand-
new 3in1 Box containing 96 pre-sorted,
securely packed Concavus pans.
Time savings are reported to be achieved
by the new SmartMode of the
measuring software. Pre-defined methods
and automatic calibration allow for the
measurement to be started at the push of
Reproducible DSC results now faster and easier
a button, claims Netzsch.
The introduction of the AutoEvaluation
function allows more effective evaluation
of measurement results. Netzsch claims
that with AutoEvaluation it is now possible
to determine thermal effects in the
measuring curve automatically.
Another new piece of software
development is Identify. This algorithm
can be used to identify unknown
polymers. In addition, Identify can
compare results from routine quality
control checks with the saved standard
condition for the raw material, thus
allowing a quick insight into the quality of
delivered goods.
Additional information on the new 360
approach of the new DSC 214 Polyma
can be found at www.netzsch.com/20650,
or on the Netzsh stand at K.
Netzsch
Web: www.netzsch.com/20650
Stubli to demonstrate quick
mould change and new robot
for IMM
At this
years K
Show,
Stublis
Connectors
and
Robotics
Divisions will
jointly present a
range of products
specifically designed for the plastics
industry to improve productivity and
production flexibility.
Stubli Connectors has devised a
quick mould change (QMC) demo
application to be shown at K, which it
says illustrates how easily, quickly and
reliably even the heaviest tools can be
changed on a modern injection
moulding machine.
Also on display will be the divisions
complete range, presented
interactively, including a new multi-
coupling plate (MCI209) that provides
centralised non-spill connections for all
mould temperature control circuits;
preventing pollution and reducing the
consumption of heat transfer fluid.
Jointly exhibiting is Stublis Robotics
division, which has a range of four-
and six-axis robots specifically
designed for automation applications
in the plastics market. These, it says,
combine high precision and ultra-short
cycle times with straightforward
programming and easy communication
with the IMM.
Being unveiled at the show is Stublis
new TX340 SH 6-axis shelf robot
designed in response to customer
demand for a robot that can be
mounted on top of the IMM, giving
exceptional reach to both sides of the
machine with excellent payload
capability; increasing production
flexibility within a smaller footprint than
conventional gantry robots. The group
will be in Hall 11, Stand 11.
Stubli
Web: www.staubli.com/en
OCTOBER 2013 WWW.EPPM.COM 19
The ability to reduce cost, increase
production efficiency and minimise
waste when adding colour and additives
to thermoplastic processes is
imperative. Additives often represent a
significant percentage of the materials
mix so choosing the correct solution is
vital to ensuring that aesthetic,
functional and processing requirements
are met.
PolyOne is a leading supplier of colorant
and additive materials for plastics and
the Companys specialty solid and liquid
additive solutions, design and technical
expertise and colour matching and
development capability are helping
customers around the world improve
their manufacturing processes.
There are a number of different ways
that additives can be introduced into the
production line and the decision to use
liquid or solid solutions depends on a
multitude of factors specific to individual
application requirements.
Where liquid solutions are specified,
advanced metering systems and
technical support are an integral
component of the additive solution.
PolyOnes ColorMatrix business
adopts a full service approach
whereby advanced volumetric
metering systems and technical
support are provided to
maximise the value of using
ColorMatrix liquid colorant and
additive technologies. The
FlexCart family of next-
generation, flexible metering
systems offer clean and
controllable colorant and
additive incorporation for a
wide range of thermoplastic
applications.
The flagship FlexCart,
launched earlier this year,
features a modular base unit
that accommodates a wide
range of global packaging and
pump variations. The system
eliminates the need for
additional dosing equipment
and provides standardized
metering for processors with
multiple production sites.
Three new additions to the
FlexCart range will be on
display at the K 2013:
FlexCart Mini - Offers excellent
flexibility, mobility and ease of use but
with reduced complexity and a smaller
footprint, making it suitable for
processors with limited production floor
space.
FlexCart Micro - Easily transferred
between machines or set up as free-
standing, this model offers a more basic
metering setup without compromising
control or accuracy.
FlexCart Nano - Designed for low
quantity, accurate metering and can be
positioned on any flat surface in the
production environment.
When used in conjunction with
ColorMatrixs preferred packaging,
FlexCart systems deliver product
recovery rates of up to 99%, reducing
material waste and improving
sustainability for a maximum return on
materials cost.
Global technical support
ColorMatrix has a team of experienced
Technical Service Engineers that provide
comprehensive on-site support to
customers around the world. Their
services include production process
reviews, on-site support for new start-
ups and guidance and training on
equipment selection to ensure accurate
metering, shot to shot consistency and
minimal waste.
PolyOne ColorMatrix will be hosting a
special equipment showcase and
technical clinic at K2013. The new
FlexCart range of liquid metering
systems will be on display in Hall 6,
Room B1. Experienced Technical
Services Engineers will be on hand to
demonstrate the benefits of these
advanced volumetric systems.
Furthermore, ColorMatrix is inviting
visitors to challenge their technical team
with any processing issues they may
have. Feel free to bring along parts that
may illustrate the problem.
K 2013: THE PREVIEW ADVERTORIAL
Maximise Value
Advanced metering systems and technical expertise
See the new FlexCart range
of liquid additive metering
systems or challenge the
technical team to solve your
processing issue: Hall 6,
Room B1.
For more details and to
register, visit
www.colormatrix.com/K2013
The flagship
FlexCart
liquid metering
system provides
flexibility and
accuracy.
Metering control is a key benefit of FlexCart metering systems. Pumps can be interchanged between systems and according to
processing requirement.
20 WWW.EPPM.COM OCTOBER 2013
w
w
w
.
a
r
b
u
r
g
.
c
o
.
u
k
ARBURG Ltd.
Tachbrook Park Drive
Warwick CV34 6RH
Tel.: +44 (0) 1926 457 000
Fax: +44 (0) 1926 457 020
e-mail: uk@arburg.com
Freedom
has to be experienced!
1
3
A
1
3
2013
D
sseldorf
G
erm
any
16.10.-23.10.2013
22 WWW.EPPM.COM OCTOBER 2013
K 2013: THE PREVIEW
This is an important year for you, not
just because of K, but because it's a
big anniversary. What has been key to
the successful growth of Mold Masters
over the last 50 years?
Over the last 50 years our company
always recognised the importance of
innovation. Of course product design has
been key and there are numerous
examples of products being released
that became solution standards and
technology leaders in the fields. A great
example is the release of our Melt-Disk,
the first high performance edge gating
solution. This was huge for the medical
market and has fueled various design
releases by many hot runner companies
since then. Even in our new products like
Accu-Valve MX and our line of auxiliary
injection units, E-Multi these products
are all leading the way in their fields.
However, in addition to product
innovation, we have been innovative in
the way we have expanded. A great
example is China. As we continued to
monitor the growth in hot runners in Asia
in the mid 2000s and saw how quickly
cold runner applications were being
converted to hot runner designs, we
realised that a strong presence in China
was key as well. Since 2007, our China
facility has become our largest, most
impressive manufacturing center, serving
the Asia needs with fast delivery, high
performance hot runners. This innovative
foresight allowed us to firmly position
ourselves in this key market. In fact if you
consider our total global foot print, the
company has been well positioned
through various growth initiatives to best
serve our customer base very effectively.
On top of all this, our people are what
kept us strong over all these years. We
have a tremendous amount of
employees that are experts in our fields
with well over 20 years of experience.
This vast knowledge base has acted as a
foundation of support for our company
over 50 years, advancing our
organisation and keeping us in front of
the market.
The recent acquisition by Milacron hit
the headlines. How will this affect
business going forward, and what is
the strategy for the future?
The Milacron transaction has allowed us
to expand even further into markets all
over the world. Although each Milacron
brand operates as a very unique identity,
we can take advantage of each others
service foot print, sales and service
centers, internal process to allow for
work flow optimisation, creating one
common goal to offer our customers
the best support and the most advanced
technical solutions.
And now to the technology on display
at K. Were particularly interested in
the IRIS co-injection technology. Can
you elaborate on how the system
works? And what are the benefits to
moulders using the technology?
Iris is fully based on Mold-Masters Core
Technologies. Its a compact co-injection
system that integrates with a standard
injection moulding machine and
standard mould, allowing customers to
take advantage of their existing capital
equipment. This is key. The technology
utilises specially designed nozzles and
iFLOW manifold technology that
combines melt streams and provides
balanced fill. Valve gate control of the
opening and closing movements of the
servo-actuated valve gate pins is done
with the E-Drive to achieve fast cycle
times and precise cavity fill, allowing for
full control of the placement and
thickness of the barrier. The co-injection
results are obtained by precise
integrated control of dosing, flow, and
pressure of the two melt streams.
Balanced filling of 3-5% barrier-layer
material into all parts equally is achieved
using proprietary iFLOW manifold
technology, precise control of the E-Multi
unit, and the positioning of the valve pins
using the E-Drive actuation system. The
single integrated IRIS control system
controls the E-Drive pin positioning, hot
runner heaters, and the barrier injection
flow to ensure that the elements of the
system work together in harmony. The
IRIS co-injection technology is currently
available for 64 cavity tools and possible
applications are continually evolving.
One of the recent developments is a new
E-Drive controller that allows for
simultaneous control of up to four E-
Drive systems. This drastically reduces
the space requirements and technical
resources that are required for actuation
synchronisation.
This entire concept is key wherever
barrier layers are required to prevent
permeation of oxygen and migration of
CO
2
or against moisture for medicine or
food containers, the IRIS system
provides a comprehensive solution for
process optimisation and cost reduction.
The complete system consists of the
Mold-Masters IRIS co-injection hot
runner, an E-Multi injection unit, and a
servo-electric E-Drive valve gate
actuation system.
It has a single, integrated Control System
for all co-injection movements; the
associated control unit is fully integrated
and is located in a single, space-saving
housing. The high-precision controller is
measuring flow and pressure for both
melt streams, controls the absolute
EPPM talks new products, new trends and K Show
with Mold-Masters.
accurate movement of the servo-
actuated pins and also incorporates
temperature control.
It offers an attractive alternative for the
food packaging industry suitable for the
production of food packaging, such as
diced fruit, pet-food, coffee pods,
sauces, soups, beer, and baby food. IRIS
also provides an attractive alternative to
glass, metal, multilayer thermoforming or
multi-piece assemblies to achieve a
functional barrier. The system produces a
net-shape part with no waste or
additional processes.
The IRIS system benefits closure
moulders, because the new co-injection
technology allows for caps to have a
directly co-injected EVOH barrier, which
merely constitutes a proportion of 3-6%
of the total cap. The co-injection process
simplifies the production of the closure
where a barrier layer is required and
eliminates previously required multi piece
assemblies. The result is a simple but
100% sealed cap, which can be used
directly in the packaging process.
Which markets would you say you are
looking to engage most with during
the show?
Looking at our Iris system, this is clearly
Closures, Thinwall Packaging and
Medical Packaging Applications. With
our partners we showcase solutions from
all segments live at this K show and we
are highly confident that therell be many
inquiries for similar applications as well
as new ones that will use Iris for i.e.
challenging product design or shelve life
extensions. Iris is a real game changer
and this K show is where we go out
widely and showcase our capabilities.
We look forward to customers
approaching us with their challenges to
create the most benefit for them from our
unique technology. In addition, within our
booth we are launching key new
products specifically for the medical,
automotive and high speed packaging
markets as well, which are also key
market focuses for our company.
Also new for the K crowds are the
latest additions the E-Multi portfolio
(pictured) for multi-material/multi-
coloured applications. What do these
products bring to the range?
At K 2013 we showcase the most
complete E-Multi product
range ever. With a total of
12 models the E-Multi line
now covers really all
needs of multi-material
injection moulding on
single material machines.
No matter if the
application is for small or
large shot weight, theres
an E-Multi for it. With the
latest addition EM4-550
we provide shot weights
up to 500 cm. The new
radial-mount E-Multi (first
introduced at K show)
offers flexible positioning
and options for almost
any type of application. Since the release
of our E-Multi product line in 2009, we
wanted to ensure that the product could
be used by any of our customers, in any
market. We now have the product range
to do this!
You also have a strong presence at the
show on the stands of your partner
companies. What do you look for in
partner companies, and, likewise, why
do they select you to work with?
Mold-Masters covers almost all industries
and therefore we also partner with a
larger number of companies to show our
broad portfolio. With Mold-Masters now
being part of Milacron it is obvious to
partner with other Milacron companies,
so customers will see our Sprint system
for Beverage Closures running on the
Ferromatik booth in Hall 15, Booth C06.
We also showcase medical solutions and
our temperature controllers live at
Ferromatik and the DME booth in Hall 01
Booth C10. Apart from our group of
companies we also see the value in
partnering with key companies in the
industry that are focused on high
performing, technical solutions. We are
working with Schttli to show another
high speed, Sprint closure system
running at Netstal in Hall 15, Booth D24.
Our unique IRIS technology will be
running live on our booth (Hall 1, Booth
A39) as well as at Stork in Hall 13, Booth
D72. A full list of partners and systems
running will be on display on our booth
as well as ready for takeaway from there
to take a full Mold-Masters tour a K
show. Mold-Masters also follows a very
customer-focused development
approach so all of these partner
showcases are based on cooperative
development and thats a clear
strength of Mold-Masters globally. We
are proud to be known as taking on the
most challenging projects and creating
the most valuable solutions to our
customers. The partner projects we
showcase at K2013 are excellent
examples of what we deliver every day.
Finally, what are your predictions for
the hot runners market going into the
next year?
Mold-Masters anticipates a continuous
growth, based on overall economy and
also based on the innovative solutions
we bring to the market and that are
making the difference for our customers.
The plastic market is continuously fueled
by trends such as light weighting
(packaging), new single-use technology
(medical), increase in plastic part usage
(automotive), model proliferation
(electronics), all important key trends that
drive the need for new and advanced hot
runner products. We are very confident
that our showcase at K show will support
our current initiatives and look forward to
a growing 2014. This will be another
successful year in Mold-Masters bright
history as we just celebrate our 50th
corporate anniversary here at K and we
look forward to at least another 50 years
of innovation.
EXECUTIVE Q&A: MOLD-MASTERS
24 WWW.EPPM.COM OCTOBER 2013
K 2013: THE PREVIEW
Proflex manufactures a range of multi-layer plastic
enclosures for bulk liquid packaging of non-hazardous
and food grade liquids. These large enclosures can
withstand temperatures of up to 60C and consist of
layers of polyethylene for flexibility and woven
polypropylene for tensile strength along with a number
of injection moulded components. Ensuring that they
produce a quality product is the responsibility of
Andrew Sangster who is the Global Quality and
Technical Director for Proflex.
Increasingly companies are using this type of
technology to ship their products around the world
said Sangster, the product lowers shipping costs and
products can often by shipped in concentrate form
and reconstituted and bottled at the other end.
During a recent QA / QC audit Sangster recognised
several areas that could be improved and add towards
product confidence and reliability. Specifically, it was
identified that there was too much reliance on simple
mechanical testing of the final enclosure and a need
for audit consistency further back in the supply chain.
Sangster sought out new methods and procedures
and whilst working with one of their contract testing
laboratories, Edwards Analytical, was introduced to the
identiPol system from Lacerta Technology. The
identiPol is a simple system for the testing and
comparison of incoming plastic material, in either thin
film/pellet form or a sample cut from a component. A
simple 15 minute test is all that is needed in order to
generate a go / no go indication of the product
quality and consistency. This greatly appealed to us
said Sangster, along with not needing an expert
scientist to run the unit. The only qualification
required is a degree of care and attention.
Following trials and evaluations an identiPol system
was purchased and since then several changes have
been implemented at Proflexs manufacturing facility.
The identiPol is routinely used to check incoming film
as well as moulded components and also a sample
of the plastic granules used by Proflexs supplier for
testing. This allows us to test what our supplier
provides as a product, as well as what was supplied
to them as a raw material. It enables us to test the
quality of our suppliers manufacturing process and
also look at potential issues regarding cross
contamination that may arise during manufacturing,
something that was not easily picked up by
mechanical testing alone said Sangster.
The identiPol gives us more than DSC, gives us
more than DMA and we use it in preference to these
techniques that are more at home in the R&D
laboratory. Specifically the determination of the end-
point where the plastic has fully melted is a very
useful number for us.
Proflex have been successfully using the identiPol at
their UK manufacturing unit and have plans to roll out
the system to their other manufacturing sites, such as
China. They rightly take great pride in the resilience
of their quality assurance systems and procedures
and these are starting to turn the heads of their global
blue chip customers who have been impressed with
their set-up. Weve detected batches drifting out of
specification and the identiPol has allowed us to
catch them in time and reject these batches
Sangster concluded IdentiPol is now a fundamental
part of our quality strategy, if an organisation may be
considering shipping or using a different grade of
material, so that they can improve their margin, we will
find them out. Most importantly that material will not
enter our supply chain.
Lacerta Technology will exhibit in Hall 5, Stand B30
at K.
Lacerta Technology
Web: www.lacerta-technology.com
Molecor, a specialist group in PVC-O technology for
pipe extruders will display its integrated Seal System
(ISS+) as well as PVC-O pipes up to 800mm.
The group has developed air-based molecular
orientation technology for water transport pipelines.
Now, the company has grown into two business units:
Molecor Canalizaciones (manufacturing and
commercializing PVC-O pipes) and Molecor Tech,
which has developed a technology to manufacture
PVC-O pipes up to DN 800 mm and 365 psi.
The first PVC-O pipe manufactured with Molecors
patented technology was produced in 2007, just in time
to be shown at K 2007. This first tube was a DN
200mm.
In 2008 the range increased to DN400mm, which
Molecor claims was the unofficial limit for PVC-O
pipes at the time.
Oriented PVC pipe breaks new diameter records
By 2010 the group was able to manufacture tubes with
diameters of 450-500mm. The group marketed this at K
2010 as the biggest PVC-O pipe in the world.
Now, in 2013, the group claims that its technology is
ready to reach the DN 800mm mark for PVC-O pipes.
The manufacturing concept uses an air-based
technology in which no water is involved, which
reportedly makes for a safer, cleaner, more efficient and
profitable process. It is a flexible system able to work
continuously with an extrusion line, or it can operate in
batches.
The new integrated seal system (ISS+) is one of the
more recent technological developments.
This system, patent pending, is designed to
manufacture socketed oriented pipes with automated
integration of the gasket, retaining the orientation
degree in the critical areas of the pipe.
Breyer is a specialist in manufacturing high-quality and
efficient extrusion lines for plastic processing. The group
is currently working on gap impregnation technology to
open up new markets for the company in the field of
composites. The process allows the automated
production of a vehicle bonnet, made of CFK integral
construction in only 15 minutes. Sandwich building
elements can be manufactured in one single step. Using
a fibre composite design, the weight of the bonnet has
been reduced by 60%. Its weight is about 5kg.
The machine concept is essentially built of six modules: a
basic machine with mould carriers, a tool kit with both
mould sets and the central part, an injection system,
vacuum device, temperature control and handling system.
The tool comprises a tool frame and two mould halves.
The maximum clamping surface size is 1.2 x 1.7m.
The tools surface topography has been optimised to
allow direct painting of components. The sandwich
construction structure supports connecting elements for
mounting in order to avoid subsequent installations of
additional elements on the formed part.
For the set-up of the machine no elaborate foundation is
necessary, as it is used (for example) for presses. Both
process and machine are designed for low pressures
(<10 bar), hence the whole construction is less extensive
than high pressure machines. This is also beneficial for
the movement dynamics. Fast open-close movements
Breyer to present gap impregnation technology
Molecor
Tel: +34 902 566 577
Email: info@molecor.com
Web: www.molecor.com
can be carried out by saving energy with linear units.
For a fully automated production the machine is supplied
with handling systems that can be integrated into the
machine concept.
The current version of the machine is set up for form
sizes up to 1.2 x 1.7 m. The group will exhibit in Hall 16,
Stand 16C18.
Breyer GmbH
Web: www.breyer-extr.com
Proflex uses identiPol system to improve product quality CASE STUDY:
Laura Wight loading another sample into
Proflexs identiPol system
26 WWW.EPPM.COM OCTOBER 2013
7a
8a
8b
NORTH
ENTRANCE
Arena
7
5
6
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7.1
7.2
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K 2013 FLOORPLAN
HALL 5
HALL 7
HALL 9 HALL 8
Hall 9, Stand E19
Hall 9, Stand A44
Hall 9, Stand B65
Hall 8A, Stand J10
Hall 7, Level 2 Stand A20
Hall 5, Stand B48
Hall 5, Stand A45
Hall 8B, Stand A61
Hall 9, Stand D21
Hall 5, Stand E20
Hall 7.1, Stand B35
OCTOBER 2013 WWW.EPPM.COM 27
1
2
9
10
SOUTH
ENTRANCE
EAST
ENTRANCE
11
12
13
14
15
16
17
4
3
HALL 11
HALL 10
16-23 October 2013
Dsseldorf, Germany
Hall 11, Stand B58
Hall 10, Stand B40
Hall 15, Stand D24
Hall 10, Stand J54
Hall 10, Stand A59
Hall 10, Stand J18
Hall 15, Stand C24/27
Hall 10, Stand A21
Hall 12, Stand D35
Hall 10, Stand C04
Hall 10, Stand A41
HALL 15
Hall 11, Stand B40
Hall 12, Stand F56
HALL 12
OCTOBER 2013 WWW.EPPM.COM 29
K 2013: THE PREVIEW
battenfeld-
cincinnati is
planning its
appearance at K
2013 around the
theme of high
performance and
energy efficiency in
extrusion
technology.
The company says
its three divisions,
namely
construction,
infrastructure and
packaging, will
present extrusion solutions that operate
energy-efficiently and save material
whilst maintaining high standards of
quality.
In response to the trend towards
increasing use of recycled materials in
profiles, the construction division of the
group will showcase a newly designed
extruder combination - the conEX 63 P
conical extruder mounted in a
piggyback configuration on a twinEX
78-34P. The two counter-rotating twin-
screw extruders combined are said to
achieve an output of about 500 kg/h.
The infrastructure division is rolling out a
new, gearless single-screw extruder
series for K 2013. The solEX GL series
includes four models with screw
diameters of 45, 60, 75 and 90 mm and
battenfeld-cincinnati says the new
machines achieve high standards of
quality achieved with low melt
temperatures, low energy input and an
battenfeld-cincinnati to focus on energy and cost reductions
optimal capital/output ratio.
The packaging division is also focusing
on efficiency. New initiatives on display
will include the Multi-Touch roll stack,
which is said to produce stress-free film
at high line speeds, as well as a new
anti-wear concept for planetary roller
extruders, which are being used for
applications such as calender feeding
and pelletising.
For the PET industry, battenfeld-
cincinnati says it will showcase its
specialised single-screw extruder with an
integrated compounding section for
outputs between 500 and 1,000 kg/h.
With this extruder, battenfeld-cincinnati
says up to 16 percent of energy costs
can reportedly be saved by processing
undried PET, eliminating the need for
preliminary material drying.
battenfeld-cincinnati
Web: www.battenfeld-cincinnati.com
On the heels of the Graham Groups
acquisition of majority interest in
American Kuhne (AK) in October 2012
and Graham Engineering Corporations
(GEC) acquisition of Welex in June
2013, GEC has announced that the
three companies will exhibit together at
K 2013 in Hall 14, Stand 14A54.
Together, GEC, AK and Welex create a
convergence of leading technologies,
people and capabilities in extrusion. We
are excited about the multiple points of
synergy for the markets we serve and
look forward to adding further
technologies, businesses and talent to
our platform, said founder, Donald
Graham.
True to our motto Innovation Taking
Shape, we have already leveraged
patented GEC die-centering technology
to create precise, full closed-loop
control of concentricity for the benefit of
AK medical tubing customers and are
actively working on additional
innovations, said GEC Chairman Bill
Kerlin.
At K 2013, GEC will exhibit innovation in
Graham Wheel clamp technology that
introduces flexibility and configurability
to enable a range of package shapes
and sizes on a single platform. AK will
be demonstrating extruder technologies
for energy savings, quick changeover,
and configurability. In addition, Welex
will highlight the new Welex Converge
CTS Sheet Line, conical twin screw
technology for dryerless PET and PLA
sheet production.
Graham Engineering Corporation, American Kuhne and Welex
to co-exhibit
GEC is a supplier of extrusion blow
moulding equipment and offers a
complete range of monolayer and
multilayer blow moulding equipment
and technology upgrades including:
rotary wheel blow moulders for bottle
sizes from 85 ml up to 5 gallon
packaging applications, shuttle
machines for up to 10 litre capacity,
reciprocating screw and shot pot
machinery for lightweight HDPE
containers, and single and dual head
accumulator head industrial machines
for up to 75lb shot capacities.
AK is a global supplier of standard and
customised single screw extruders, feed
screws, and also controls to multiple
end-use applications, as well as
complete extrusion systems for medical
tubing, pipe, and profile.
Welex is a global supplier of high
performance sheet extrusion solutions.
The group has equipment installed in
more than 3,000 customer locations in
69 countries. Welex products include
co-extrusion and multi-layer methods as
well as dozens of barrier lines installed
globally.
Graham Engineering Corporation
Web: www.grahamengineering.com
American Kuhne
Web: www.americankuhne.com
Welex
Web: www.welex.com
K 2013: THE PREVIEW
As a market leader in high quality
Laboratory consumables,
SciLabware have an unrivalled
reputation for product quality and
customer service.
We are ISO 9001: 2008 accredited
and work to the most rigorous
international standards. Product
excellence is achieved by the
enforcement of strict quality
standards and meticulous quality
control, supported by the
specialist skills of some of the
worlds most experienced polymer
technicians.
The result is a quality conscious
culture committed to total
customer satisfaction.
For more than half a century, the
Azlon
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