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Issue 188
| September
2010 | news page |
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Polymer Industry
News | September 2010 |
Issue 187 |
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NEWS INDEX
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EUREKA – MORETTO introduces innovative approach to material drying at
K2010 in Düsseldorf
 Fast
cost benefits with PET drying systems through low energy expenditure
brings competitive advantage to moulders
MORETTO S.p.A. of Massanzago, Italy, one of the world’s leading
manufacturers of auxiliary equipment for the plastics processing industry,
will be unveiling new technologies, innovative business concepts and
state-of-the-art equipment at K 2010 in Düsseldorf in October.
Challenging economic times require new pioneering business strategies.
MORETTO offers moulders the opportunity to embark on a totally new
risk-free business model called EUREKA – involving no investment up front
– to achieve marked reductions in material treatment costs and, as a
consequence, increased profits, improved performance and better quality.
Till now no company has had the aim to realize market solutions which
allow a fast and guaranteed ROI for the customer. With the EUREKA project,
MORETTO proposes not only an efficacious and reliable system, but it
supplies also a financial tool able to guarantee a return of the
investments with a sure date. The one proposed by MORETTO is an absolutely
innovative approach because it puts the customer in a position to use a
cutting-edge technology with no financial exposition and, above all, it
guarantees a sure and proved ROI, without risk.
These are not marketing policies, but the
EUREKA project offers a series of real and tangible opportunities for the
customer, both in terms of performance and financial terms. Perceiving the
customer’s need and finding the most suitable solutions is one of the key
concepts in the MORETTO company policy that, as in the case of EUREKA,
approaches the customer with a convinced professional ethic with the aim
to solve at best the customer’s problems and strengthen the partnership.
The fully automatic high-volume modular MORETTO drying systems, combining
the new X MAX dryer and the FLOWMATIK controller with the new OTX hopper,
enable a throughput of up to 8,000 kg/h capacity, in combination with a
modular generator of 20,000 m³/h – giving total flexibility of between
three and 10 modular design dryer units and from 1 up to 32 drying
hoppers, all without requiring either compressed air or cooling water. The
result is faster, consistent and gentle drying of highly hygroscopic
polymers – such as PET – with the benefit of a significant reduction in
energy consumption. The factor separating this multi-tower system from
conventional systems is the maintenance of a consistent, i.e. uniform, dew
point throughout the process, thereby reaching high efficiency levels and
total operating flexibility, for example in the mix of preform sizes and
weights. Efficiency is never compromised – even at lower throughputs.
The innovative EUREKA project is geared to
provide moulders – treating primarily PET – with an alternative and
totally new business model to tackle the second highest cost, after raw
material cost, i.e. energy, some 30 percent of which is attributable to
drying. Offering moulders a no-risk acquisition plan, MORETTO encourages
moulders to try out, and eventually own, the new equipment. Instead of
either the outright purchase, lease of equipment or alternative finance
options, the customer is invited to negotiate the power consumption and
other operational costs of his existing equipment with the new EUREKA
system. This company is offering to install the EUREKA system without
formulating a purchasing contract and will merely charge a monthly fee
based on the amount of energy savings, calculating the differential
between the ‘old’ and the newly installed equipment. After two years, the
system will have been paid for and owned outright by the customer. This
will be achieved just through energy savings. If not satisfied, the
system(s) can be returned to MORETTO at no extra cost to the customer.
This innovative approach demonstrates the exceptional values of integrity
and trust, combined with customer satisfaction, Renato Moretto, CEO of
MORETTO, shows his customers. Several new technologies – all part of the
EUREKA project – will be shown and demonstrated at K 2010.
The basis for the new MORETTO EUREKA project – designed to reduce energy
consumption consistently and improve performance and quality – is the new
multiple unit X MAX system (X MAX dryers combined with the FLOWMATIK
controller and the state-of-the-art OTX hoppers), with its single
desiccant bed, i.e. twice the size of conventional beds. Reduced energy
consumption is achieved by the use of zeolite, a volcanic mineral, as a
molecular filter. The air flow channel of the X MAX dryer is situated in
the centre with the heater in the middle of the channel. With the heat
exchanger also at the centre, complete recovery of regenerated energy is
assured, as every Watt of energy is used in the polymer treatment.
The ‘green-factor’ labelled system with its extremely low energy
consumption accommodates increasing throughputs of, for instance, PET
preforms. This is particularly important as numbers of mould cavities are
ever increasing. All the vital factors which influence the management and
control of the drying process of numerous plastic granular materials – and
PET in particular – are taken into consideration: type of material,
granule size, bulk density, temperature, dew point, residence time,
specific airflow, initial air moisture content, final residual moisture
content in the granule, and viscosity. In a multi-dryer system, each unit,
with its stand-alone air circuit and controlled by a dew point meter, can
be set at the same temperature and air-flow rate, whilst simultaneously
staggering the different dew points. The FLOWMATIK controller manages all
relevant sequences – no simultaneous regenerating is necessary – so that
the mix of process air from the dryers maintains a constant value of
around -65° C.
figure 1
In figure 1 it is evident that a lower dew
point value improves the final result in terms of ppm, in the same time
and with the same temperature.
The integrated FLOWMATIK controller is designed and programmed to detect
each hopper’s capacity and the material’s bulk density, the desired
resident time, temperature, and the air flow rate. “Once you have control
over the process, the exact drying time needed can be established. All you
have to enter is the material type and the desired throughput rate; the
system will take care of the rest”, according to Renato Moretto. By
tailoring airflow to the throughput rate, higher savings are obvious. His
innovative ideas go even further: The FLOWMATIK Split system divides the
PET to be dried first into a larger hopper at a relatively low
temperature, then into a second, smaller hopper at the customary 180° C.
The efficient approach of EUREKA is designed to reduce airflow needs by
more than 50 percent. Research into greater efficiency and improved user
benefits utilized computerized fluid-dynamic and thermo-dynamic simulation
trials to analyze current leading hopper designs. Non-uniform flow through
the hopper, combined with temperature gradients of up to 80° C (from
centre to outside), have been identified. In addition, material can
contain twice as much moisture as the average of the hopper in its
entirety. The conclusion: given a nominal four-hour residence time in the
hopper, some material exits in as little as 2.5 hours’ time.
Another processing benefit is that one dryer can be taken off-line, whilst
a newly regenerated dryer (standard with the system) is installed as a
replacement. In order to achieve not only a considerable reduction in
energy use, more uniform heating and efficient regeneration at lower
airflow rates are possible.
The FLOWMAX system can be utilized in a number of different configurations
according to individual requirements: i.e. FLOWMAX UNI (a battery of X MAX
units), Twin and Multi with X MAX dryers creates complete Uni and
multi-hopper systems which are able to meet a wide range of needs in the
feeding and drying with very low energy consumption. FLOWMAX UNI comprises
a battery of X MAX units with a single hopper, enabling dehumidification
of large quantities of raw materials – up to 8,000 kg/h. In fact, X MAX is
a multi-tower system at constant performance. While one dryer is in
regeneration, the other units continue operation until they, too, are
submitted to regeneration – one after the other. Not only does this ensure
a steady process, but also it guarantees the rotation of the X MAX units
for regeneration which can be also in 72 hours or up to 100 between a
cycle and the following one in the same drying tower.
The redesigned state-of-the-art MORETTO OTX hopper with its new geometry
solves the problem of the non-uniform fall flows of the granules, allowing
to manage the process efficaciously. Also the air diffusion has been
optimized eliminating the temperature differences. “Unlike the
uncontrolled mixing occurring in conventional hoppers, our hopper achieves
a much more uniform moisture ppm in less time”, explains Renato Moretto.
To give an example, increased ppm control and uniformity results in a
reduction in drying time from the typical six hours to an average of four
hours and even less. In addition, drying temperatures can be reduced from
180° C to 175° C, also cutting air flow by up to 40 percent, whilst
achieving 20 ppm final moisture (Figure 2). To summarize, by using the new
MORETTO hopper, an identical throughput can accomplish a 30 percent
decrease in drying time, 40 percent reduction in air flow requirement, and
a 25 percent drop in hopper volume. Each hopper has its own heater, an
airflow valve to allow for automatic variables, and a flowmeter,
accommodating from 1000 to 10,000 litres, thus providing a flexible high
volume, highly efficient system.
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Coperion –
Integrated Degassing Solutions at K 2010
Twin
Screw Side Degassing – Higher Output, Better Quality and Lower Costs
 When
compounding and processing polymers degassing processes frequently play an
important, but often undervalued role. The ZS-EG twin screw degassing unit
presented by Coperion GmbH, Stuttgart/Germany, formerly Werner &
Pfleiderer, at K 2010 (Oct.27 to Nov. 3, 2010 in Düsseldorf, Stand B33,
Hall 14) is a representative of their comprehensive degassing solutions
for compounding and extrusion processes. This range from the degassing of
polymer melts to the manufacture of practically odour free plastic for
packaging or vehicle interiors.
ZS-EG twin screw side
degassing units have proven themselves in compounding plants over many
years as a reliable means of degassing compounding processes. Based on
this broad practical experience Coperion has made a number of improvements
to its ZS-EG side degassing units: The screw set has been optimised, the
standard models of the ZS-EG are designed for an absolute vacuum of up to
50 mbar, lower degassing pressure upon request.
Moreover the ZS-EG is
standardly equipped with a variable speed screw drive.
Compared to an open
vent dome the twin screw side degassing unit offers many advantages. It...
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can be fitted at
low cost to a combi barrel segment of the ZSK twin screw extruder. By
replacing an atmospheric venting barrel with a combi barrel it can be
retro-fitted in order to make full use of the performance of ZSK
technology,
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delivers effective
degassing, even with high air or moisture content of the bulk material,
at acceptable residence times so that plant throughput can be raised by
10 to 15 %,
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improves compound
quality and consistency since no material can fall back into the
processing unit from the vent,
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lowers production
costs through reduced cleaning and maintenance times as well as
through lower wear,
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simplifies machine
control through simple operation and reduces accident risks,
particularly
during start-up.
The ZS-EG has deep
cut co-rotating twin screws that deliver its high venting capacity. Due to
the direction of rotation they keep the product within the processing
zone. The large free crosssection of the flow channel ensures low gas
velocities. With quick release connections the ZSEG is very user friendly
and can be dismantled easily for cleaning and maintenance.
ZS-EG – proven in
many applications
Typical applications
for twin screw degassing units include for example the manufacture of
glass reinforced or highly filled compounds, wood plastic compounds (WPC)
or thermoplastic elastomers (TPE).
Solvay Advanced
Polymers in the USA for instance manages higher throughput when processing
polyphthalamide (PPA) through the use of a twin screw degassing unit
because the gas flow channel is constantly open. In addition the new ZS-EG
generation increases plant output due to lower downtimes for cleaning and
maintenance.
Bayer MaterialScience
achieve high and uniform product quality in the manufacture of
polycarbonate compounds at its facility in Krefeld using a ZS-EG since
material cannot accumulate in the twin screw degassing unit and fall back
into the processing zone. Downtime for maintenance and colour changes has
dropped while the availability of the compounding plant has increased.
Moreover production costs are lower since colour changes are easier,
quicker and with time exposure for cleaning. On top of this Solvay and
Bayer have both benefited from the increased machine safety offered by the
current ZS-EG configuration.
Twin screw side
degassing has particular advantages in the manufacture of wood plastic
compounds (WPC): The moisture contained in the wood flour escapes very
quickly due to the high temperatures in the processing section. In order
to vent this gas stream safely, WPC plants from Coperion are equipped with
both an atmospheric and a vacuum side vent. Degassing takes place safely
and without dust formation achieving maximum throughput.
Website:
www.coperion.com
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 Negri
Bossi is at K2010 in Düsseldorf with numerous new technologies and designs
High technology solutions, completely renewed designs capable of
completely satisfying any and all production requirements: this is the
business card of Negri Bossi, which will use the opportunity of the K
exhibition in Düsseldorf this year, an international exhibition dedicated
to technologies for processing plastic and rubber, to showcase its latest
innovations.
This year, Negri Bossi’s newest addition will be included in its already
vast and complete offer: a full electric injection press based on a
completely new concept. The press, equipped with a highly efficient mold
for creating scoops of ice cream, is the result of Negri Bossi’s
designers’ and technicians’ years of experience. This compact and
functional press is ready to perform any type of application.
The written name of the press is “full electric,” but it should be read as
“energy saving.” Thanks to the energy recovery system, consumption rates
are extremely low, while, at the same time, high speed injection (230
mm/sec) guarantees high performance. In addition, the press components are
extremely robust, providing high productivity with low maintenance costs.
This, also thanks to easy access to all the parts.
The new NB press is smooth and steady when executing operations, thanks to
its an innovative belt transmission, while the sophisticated algorithm
calculation control system makes axis movement particularly precise. The
newest development made for this type of press is the touch screen with a
large and illuminated high resolution display, which assures the operator
ease of use.
Not to be forgotten is the sleek new style of the press, which results
from a strict collaboration between the designer and developers who had
the objective of combining aesthetics with functionality. The ideal size
of all the components in this machine permits Negri Bossi to provide a
three-year warranty to its customers.
Among the other jewels on display at K2010, Negri Bossi is presenting an
integrated molding system and finished piece work after processing, from
the burring phase to cutting and inserts. The key player of the system is
the VH 1500 press with hydraulic closing on two plates. This press is part
of the BiPower range, which consists of 1,200 to 6,000 ton presses.
The main characteristic of this press range is the two-plate hydro-block
closure with locking system on the columns and pistons used for tonnage
integrated on the mobile plate. All the presses in this range, as for the
hydraulic range, also include a connection system for the plant elements
with a field bus and electric motor on the screw rotation device, which is
fundamental for reducing energy consumption. Finally, the highlights of
the BiPower press series are the large dimensions of the surfaces and
modularity of the injection units, which guarantee a compact and reliable
system.
Negri Bossi will demonstrate at the Düsseldorf exhibition once again that
its currently developed solutions are unbeatable in terms of performance
and consumption optimization, which is increasingly more important in
today’s world. Another great advantage is the capability of Negri Bossi to
propose synergies with other technological solutions developed by the
companies in the Sacmi Group, with particular reference to systems that
automate the entire production line. This provides a considerable
advantage when the supply is not limited to machines, and foresees the
development of a complete work station.
To demonstrate an example of these synergies to visitors and potential
customers at K 2010, the VH 1500 work station will be supplemented by an
anthropomorphic SHELF robot placed on the fixed surface of the press. The
robot is developed by Gaiotto Automation; a company in the Sacmi Group
specialized in supplying glazing and robot movement systems. For this
demonstration, the work station will produce foldable boxes made in
polypropylene, while the Gaiotto robot will pick-up the product right
after it is molded and deposit it on the conveyor belt going to the
unloading and palletization areas.
Another new invention by Negri Bossi will be showcased at the K
exhibition: the VSE hydraulic injection press series. Thanks to complete
digital control, this machine performs very high precision molding
operations, which translate into frequent production repeatability to
satisfy all the end user’s needs. The VSE project developed by Negri Bossi
assures easy maintenance as well, due, once again, to the easily
accessible parts of the press, a noteworthy combination of
state-of-the-art electronics and hydraulics, capable of combining
performance of the variable cylinder pump (with closed ring control of the
pressure and delivery rate) with reduced energy cost needs. The savings
ranges between 15% and 45% respecting traditional hydraulic presses thanks
to the servo-motor that activates pump operation. The VSE is also
unbeatable in terms of performance, increased by 20% respecting
traditional models, while highly flexible use is guaranteed by the
quick-change plastification unit, which can be replaced in a few minutes.
A 180-ton VSE system with flip top cap molding and closure in the machine
will be presented at the exhibition as well. The press comes with
electronic Columbia control, just like all the other presses in the range,
and a 15-inch screen, along with an injection closing unit that is
extremely robust, following in the Negri Bossi tradition.
The top of the NB range, the JANUS series, cannot be missed at the K
exhibition in Düsseldorf. This press neatly combines all the plant
solutions developed by the company in the last few years in one. It’s a
hybrid series with energy consumption that can be compared to the electric
machines series, and, in particular, it provides a new modular concept
that allows it to be set-up in different versions to assure the customer a
personalized solution for a specific application. JANUS is not only a line
of machines; it’s a series of highly technological solutions allowing the
user to create an ideal line, thereby increasing competitiveness on the
market, thanks to high performance linked together with reduced energy
consumption, reliability and easy management and maintenance.
The 330-ton JANUS equipped with the new “Smart Energy” system will be
presented at the exhibition. This machine has the capability of saving an
amount of energy that nears the “full electric” solutions, while
guaranteeing performance levels that are nearly impossible to reach using
the standard electric presses. JANUS is also integrated with a FLASH robot
created by Negri Bossi, used for unloading and palletizing on conveyor
belts. The strongest advantage of this machine, and the entire series, is
the CANBUS management protocol, a well-known control technology provided
with all Negri Bossi’s presses.
JANUS’ goal is to complete Negri Bossi’s offer in the field of injection
machines for thermo-plastics, offering solutions that are perfectly
calibrated with the customer’s requirements. This series of hybrid
machines was developed by the company for this reason. It provides the
ideal mixture of hydraulic technology and complete electric technology.
Electric actuators are included for mold closing and screw rotating, while
hydraulic actuators are used for the injection phase to assure perfect
overlapping and high application flexibility through the possibility of
being configured in many different ways using, for example, variable
delivery rate pumps in place of the accumulators. Therefore, the
characteristics of many different presses are combined in this solution,
allowing it to perform applications in different fields and maximizing the
advantages for the final customer.
However, it doesn’t end here. The latest series of presses that will be
presented by Negri Bossi at the K exhibition is the new VECTOR series,
weighing in at 800 tons. This series represents the perfect synthesis of
“tradition and innovation,” two values that have always characterized the
company from Milan. This particular injection press range was conceived
with the idea of combining all the results reached in the past with
current needs and those of the future.
One of the innovations of this series that stands out is the closing unit,
which has been completely re-designed according to the most updated
calculation criteria, making the unit even more robust and reliable. The
press is also recognized for large rectangular spaces between the columns,
increased mobile plate and extractor strokes, as well as easier access in
terms of visibility and manual access to the parts of the mold and the
parts that operate it. Other particularly interesting elements of this new
NB solution include the injection unit equipped with a quick change system
for screws and cylinders and a plastification unit studied for controlling
all types of plastic materials. The latest addition to the VECTOR series,
which operates at high pressures and speeds, also catches the eye for its
new mechanics and a layout designed to make operator intervention easier
than ever before.
The hydraulic component system has been reduced to a minimum and, thanks
to the use of variable delivery rate pumps (which guarantee complete
execution of the closed ring phases); the control plant has also been
completely renovated. As far as the touch screen control system is
concerned, its large dimensions with high resolution makes it ideal for
displaying all the information on the screen, perfectly suitable for
complex applications and particularly appropriate for any industrial
environment thanks to the front side in aluminum and a linear design. The
press will be equipped with a furniture component mold and a FLASH series
robot with a renewed design specifically for the exhibition in order to
demonstrate automated control of piece unloading and palletization to all
those who come to see it.
Website:
www.negribossi.com
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 Emerald
Polymer Additives appoints Peter Fielder as general manager of Nitrile
Latex and Rubber Chemicals Segment
Emerald Polymer
Additives, a division of Emerald Performance Materials, LLC has appointed
Peter Fielder as General Manager of its nitrile latex and rubber chemicals
segment.
In this new role, Fielder will be responsible for charting the
strategic course for the successful growth of the business and is also
responsible for sales, marketing, product line management, research and
development and all operational aspects of the business at the plants in
Akron, OH and Henry, IL, which have a long history and reputation for
quality and innovation through their predecessor organization, BFGoodrich.
“I am pleased to have Pete on board in this new role to better enable us
to take a fresh approach on a business that has been a core part of the
company for many years,” said Edward Gotch, president of Emerald Polymer
Additives. “It is especially important to continue to review and revise
our strategy at this time, since Emerald is one of the only remaining US
producers for some of the materials we manufacture. Our company is proud
of its heritage as a US producer and the strong reputation of our product
lines. Pete’s proven experience and ability to optimize the value
proposition for customers make him well suited to lead this organization
and position it for the future.”
Fielder holds a Civil Engineering degree from Ohio State University and an
MBA from Case Western Reserve. Prior to this assignment, Fielder had been
serving as the commercial vice-president of Emerald’s CVC Thermoset
Specialties division and was instrumental in the successful growth of the
reactive liquid polymers product line for the company.
Emerald’s Akron facility has been recognized by the American Chemical
Society for its efforts in developing and manufacturing synthetic rubber
technology in the US. Synthetic rubber has proven to be an effective
alternative to replace imported natural rubber sources, which were
unavailable at the time. The company continues to produce synthetic rubber
latex to this day under the Nychem® brand. In addition, the company’s
antioxidants, such as its Good-rite® Resin D product, have been an
industry benchmark for preventing degradation of tires and industrial
rubber products.
Emerald Polymer
Additives is a leading producer of antioxidants and accelerators for
rubber, plastics and lubricant applications. Key products include TMQ
(Good-rite® Resin D), Cure-rite® BBTS (TBBS), Cure-rite® OBTS (MBS),
phenolic and aminic AO’s. The division also produces Nychem™ specialty
nitrile latex emulsions, a rubber-like synthetic water based polymer. The
business markets their products globally through distribution channels
world-wide.
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Stéphane Dalimier becomes the new chairman of Federplast.be
 Brussels,
Belgian Plastics and Rubber Industry – At the board meeting of June 29th,
Henri Vliegen handed over its presidency of Federplast.be to Stéphane
Dalimier.
Stéphane Dalimier has always been very engaged in trade associations’
activities to represent the interests of the manufacturers of plastic and
rubber products. He is a board member of Federplast.be since its creation
at the end of 2006. His vision is that “Plastics and rubber are part of
daily life. Their many uses contribute to progress and to a higher quality
of life. That’s why Federplast.be has to stress continuously the many
advantages of these materials and their part in finding solutions to the
major societal challenges of our time. The trade association must also
communicate proactively on the management and control of possible risks”.
Stéphane Dalimier is Business Unit Manager DIY of NMC and Managing
Director of NMC Schäfer. The NMC group, with headquarters in the German
speaking Community of Belgium, is a world leader in innovation, production
and market development of foam plastics. Founded in 1950, NMC counts today
1200 employees in 27 companies all over the world, with a consolidated
turnover of 180 million Euros.
The sorting chairman Henri Vliegen, who continues to represent the Belgian
company Recticel NV as board member and vice-president of essenscia, is
one of the founding fathers of Federplast.be. The board expressed its
gratitude for 14 years of presidency of Federplast.be and the preceding
trade association, by granting him the title of honorary president.
The board appointed also two vice-presidents: Frédéric-Charles Bourseaux
of Kabelwerk Eupen AG and Christian Vergeylen of Renolit Belgium NV.
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Wilmington
Machinery - K2010 - Hall 13 - B91-19
 Introducing
the all-new LUMINA Pallateer Plastic Pallet Molding Systems and showcasing
the very popular Small Bottle (SB) High Speed Rotary Blowmolding Systems
Wilmington Machinery, a manufacturer of high speed rotary co-extrusion
blow moulding systems and structural foam injection moulding machinery,
will be exhibiting at K2010 in Hall 13 - B91-19.
Wilmington Machinery will introduce the all new LUMINA Pallateer Plastic
Pallet Moulding Systems. Five available models produce all types of
nestable, rackable one-way or long life pallets in medium to high volumes
(200 - 900,000 pallets/year). The systems are fully automated and are able
to process a broad range of 100% recycled plastic materials in form of
pellets or flakes.
Wilmington also produces the LUMINA General Purpose Series for multiple
mould/large part production. Models are available for shot capacity to 300
lb. (135 kg) and mould spaces to 108" x 160" (2743 x 4064 mm). Popular
applications include collapsible bins, drainage and building products
components.
Wilmington will also be showcasing their new and very popular Small Bottle
(SB) High Speed Rotary Blowmolding Systems for producing bottles size from
80 to 1000ml. Today the technology includes dual parison capability
allowing production rates up to 500-1000 bottles per minutes. The SB
technology is ideally suited to monolayer or multilayer containers for
Food, Dairy, Juice and Liquid Yogurts applications. The success of this
technology is due to the simplicity of handling the bottles at very high
speeds, and also the bottle weight reductions achieved due to the very
tight weight variation and material distribution capabilities of the blow
moulder.
Wilmington Machinery also produces a line of larger rotary blow moulders
for 1litre to 5 litre containers for liquid detergents, cooking oil, motor
oil and food applications. These systems are available with up to 30
cavities and can also be adapted to dual parison.
Wilmington Machinery is a 40 year old company specializing in the design,
manufacturing and support of high speed rotary blow moulding machinery for
packaging, high output structural foam molding machinery and proprietary
plastic processing machinery for numerous companies.
Website:
www.wilmingtonmachinery.com
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SACMI presents its latest innovations for the beverage industry at K 2010
Sacmi Group’s
newest additions will be on display at Düsseldorf
 There’s
an appointment at Düsseldorf that can’t be missed. The K 2010 exhibition,
an international trade show dedicated to technologies for processing
plastic and rubber materials, will take place from October 27 to November
3. This exceptional showcase, at which SACMI will participate with its 800
m2 exhibition stand (Hall 15 stand B06) will be used to display the
protagonists of Sacmi Group’s latest creations.
The spotlight will be pointed at the new SBF technology, which will be
previewed for the beverage sector. SBF, meaning Stretch Blow Forming, is a
machine that blow molds PET bottles with fascinating technical
innovations.
Twelve models with a number of blowing stations ranging 6 to 30, and
several new items, will be presented, starting with a dual cavity mold
capable of producing two half-liter bottles or one 1.5-2 liter bottle,
with a quick format change-over system. The stretching rod with
electro-mechanical control, allows the stretching speed to be adapted at
any time to the type of bottle being processed regardless of the machine
speed, while the brushless electric motor that supplies power to the
stretching rod permits high speed machine operation that is controlled at
the same time, blowing bottles of different formats (which can also be
complex) simply and effectively.
Thanks to the SBF, Sacmi can be considered the ideal partner for any type
of bottling line, by adapting blowing productivity to filling, while
various solutions, such as methods of inserting pre-forms into the molds
and managing compressed air for blowing, provide numerous advantages in
terms of process efficiency and consumption optimization. Among the main
“pluses” provided by Sacmi’s SBF is the possibility of being integrated
upstream with PAM (Pre-form Advanced Molding), Sacmi’s exclusive system
for producing compressed pre-forms. The bottling machines can then be
installed downstream from the SBF.
SACMI proposes the ultimate challenge in the world of compression and
closure production by offering a compression machine capable of producing
2000 pieces a minute with a cycle time of 2.4 seconds. This incredible
machine is the CCM80S, which completes the CCM (Continuous Compression
Molding) model range of machines with 12 cavities and up.
The machine provides all the advantages of compression technology: product
quality, low energy consumption and operation costs, quick powder changes,
and an optimum price/performance ratio.
One must also keep in mind that the rates of the latest generation of
bottling lines are always increasing, therefore requiring caps with
dimensions that remain the same constantly, and a level of quality that
only compression can guarantee. These characteristics are found naturally
in SACMI’s offer, making the CCM80S a product of excellence for this
sector.
The CCM80S is the production instrument with the highest levels of
performance for companies that manage high volume production lines,
providing a relatively reduced investment, thanks to its perfect balance
with the other machines already included or that may be included on the
line, especially with machines used for folding or cutting safety bands.
The CCM80S was designed to optimize energy consumption, an aspect that is
always more essential as time passes. It is equipped with new extrusion
control systems that adapt energy consumption to the speeds used (which
depends on the type and shape of the cap), resulting in an additional
reduction in individual cap cost. This can be considered a “variable
consumption system” (as best can be described) that therefore optimizes
machine use in any production situation and allows the CCM80S to fit
perfectly into the new SACMI machine range studied for increasing quality
and productivity even more, while reducing energy consumption and the
relative environmental impact.
Amongst SACMI’s other inventions displayed will be the CBF12 (Compression
Blow Forming), a state-of-the-art machine that performs the plastic
transformation process based on continuous resin extrusion, combined with
the compression and blowing process, which allows plastic granules to pass
to the container in a single cycle regardless of the type of resin used.
This solution adds together all the advantages of a single-stage process
with the advantages of the compression molding technology developed by
SACMI.
A machine that inspects caps, the CHS series, will also be on display at
the exhibition. This machine was made for installation on compression and
injection lines downstream from the new linear system for orientating ORCS
160 caps. The CHS represents the ideal solution for complete cap
inspection (inside and outside), thanks to its modular structure that
permits the machine to be set-up according to the customer’s specific
quality control needs. The success of the CHS machine line, launched at
the end of 2009, exceeded expectations from the start with over 40 units
sold all over the world.
The new linear system for orientating ORCS 160 caps can be found upstream
from the CHS at the exhibition. Highlights of this system include an
updated machine layout that optimizes space, a particular cap orientation
process that, after being picked up by an innovative and silent brush
lifter, slides the caps down onto the counter-rotation belt until they
reach the pick-up zone, where they are turned over by a cylinder-shaped
horizontal axis brush and moved in a continuous line through a transport
channel.
Some of the main advantages offered by the ORCS system are efficiency,
reduced consumption, silence and flexibility.
Mechanical parts move the caps to be orientated, completely eliminating
compressed air, while the format change is simply handled by only 2
adjustment screws. Another special characteristic of the machine is the
capability of orientating caps in only one movement, reducing friction to
a minimum, and therefore dust production as well.
As far as the plastic sector is concerned, Negri Bossi will present the
latest technologies for plastic molding and injection systems, as well as
for production line automation.
Website:
www.sacmi.com
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Plasticizing Screws – made for resistivity and longevity
 Durable
and sturdy plasticizing screws are among the special features Groche
Technik GmbH of Kalletal in Germany will be presenting at K 2010 in Hall
13, Stand D 60. These feedscrews do not reveal at the first glance that
they have a lifespan of some three to four times and higher resilience of
that available from conventional plasticizing screws. Because of the
special tungsten-carbide coat-ing, essential for the processing of
aggressive plastics compounds in the injec-tion moulding, MIM, extrusion
and thermoset industries, the investment is justi-fied in each and every
case – despite the increase in initial cost.
A wide range of applications
As Armin Groche, CEO
of Groche Technik, explains, the screws and cylinders made in Kalletal,
Germany, by this specialist company are suitable for all established raw
mate-rials processed in the plastics industry. “We not only supply screws
for standard ther-moplastic materials, but also feedscrews and cylinders
for the processing of rubber and silicon. In addition, our offer includes
plasticizing screws for thermoset materials. Here, durability is
essential; that is why we apply special coatings. ”For the coating of the
com-plex steel screws, Groche relies on 88 percent tungsten-carbide and 12
percent cobalt with a thickness of between 0.125 and 0.25 mm for plastics
with a high percentage of fi-ber glass and low corrosion impact. With
plastics of higher corrosion impact, the same coating is offered, but
based on nickel. “For plastics causing extremely high corrosion, such as
PFA, PMMA, PC or fluoric polymers, we offer our special coating GT4000 –
based on nickel and chrome”, continues Armin Groche. Due to the new HVOF
process – where screws are improved and refined – Groche Technik can
guarantee twice the life span of the screws, with almost all applications.
 Complex
geometry
Coating and
post-grinding are difficult processes with such a problematic screw geome-try.
Therefore, Groche has entrusted a partner specializing with these tasks.
The com-plete machining of screws with diameters of between 22 mm and 150
mm is completed at Groche. After that, coating and post-grinding takes
place at the partner company, us-ing diamond tools and processes developed
in-house. According to Groche, coating of the cylinders is carried out by
other companies in the region. The cylinders gain lasting wear and tear
protection from a process where a tungsten-carbide layer based on nickel
is attached to them at extremely high speed. “Only then does the cylinder
last with such a hard screw”, continues Groche.
Less wear and tear and improved cleaning
The special Groche
coating ensures that wear and tear is reduced and anti-adhesion improved.
For example, in the processing of PMMA and PC significantly better
cleaning cycles are achieved: “Due to its hardness, the surface of the
screw remains totally smooth. The uniform cycle time is reached because
the screw remains as good as new after cleaning,” according to Armin
Groche. An additional advantage is the extremely high temperature
constancy, up to 600° C for the processing of high temperature plas-tics.
Groche guarantees twice the life span of a screw. “But it could equally be
three or four times better“, emphasizes Groche. However, the specially
coated Groche screws are more expensive. It pays for users because of the
at least doubling of the life span and the much reduced cleaning times.
The Groche screws are equally suitable for proc-essers in the automotive,
electrical and engineering industries.
Groche is close to its customers
To be close to
customers is an essential principle for the company based in Germany’s
North Rhine-Westphalia. The entire breadth of plasticizing technology for
thermoplastic materials will be shown at K 2010. The company offers screws
with diameters of be-tween 12 and 160 mm. At K 2010, Armin Groche is
planning to focus on his regular cus-tomers and existing relationships are
to be strengthened further. Of course, new cus-tomers play an important
part too. Groche customers are, above all, based in Germany, then in
Scandinavia, Austria, Switzerland, France and Eastern Europe.
Website:
www.gt-plast.de
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Instron at K 2010:
Testing Technology from Thermoplastic Materials to Components
Instron will underline its position as a versatile partner for a full
range of polymer testing services at K 2010, October 27th to November 3rd
in Düsseldorf, on Stand J18 in Hall 10.
 The
company will present its comprehensive portfolio of newly-developed and
enhanced testing devices, ranging from high-precision melt flow testers
for the quality control and research of thermoplastic materials, to impact
test systems and devices for the measurement of static and dynamic
material properties, as well as application-specific systems for the
evaluation of plastic parts. A new high performance data acquisition
system, and the equally new, highly-flexible Instron® Bluehill® 3 testing
software, help facilitate both the routine execution of standardized tasks
and the time saving set-up and execution of customer and
application-specific tests.
Instron’s new multi-weight high-precision melt flow tester CEAST MMF 7028
complies with the greater demands of the forthcoming test standard ISO/DIS
1133, T.2. Its unique mechanical concept includes a tilting oven support.
The System can test up to 5 weights in any sequence, automatically
managing fully customizable pre-installed masses. The new melt flow tester
is equipped with a touch-screen control panel, designed to facilitate full
test programming and to display all test results.
Instron will also
present its CEAST 9340 compact instrument for falling weight impact tests
as well as its advanced pendulum machine CEAST 9050 for instrumented and
uninstrumented impact testing, featuring a solid monolithic metal
structure, which carries the accessories to be used for testing.
Another first is the
DAS 64K data acquisition system, which is perfectly suited to work with
the CEAST pendulum and falling weight systems. With its four data
acquisition channels, and a storage capacity of 64,000 sampling points,
the DAS 64 K is capable of producing an impressively high resolution
representation of transient motion sequences.
Instron® 5969 belongs
to the new, uniquely ergonomic and variably adaptable series 5900 tensile
testing machines. The dual column tabletop system for mid-range testing
loads provides a maximum tensile force of 50 kN, a crosshead travel of
1140 mm and a maximum crosshead speed of 600 mm/min, thereby covering the
majority of standard tests in the polymer industry. At K 2010 the device
will be equipped with Instron’s equally new pneumatic grips, featuring
jawface shields which are easily adjustable to different sample geometries
and can be changed quickly and without the use of tools.
Bluehill® 3,
Instron’s new testing software is adapted to low speed tasks such as
bending or tension tests. Compared to its predecessors, it is even easier
to use because a multitude of standard testing tasks and reports have been
pre-configured. Customer-specific test runs can easily be added.
Substantial time savings are made possible by eight task specific
application modules, adapted to the requirements of testing glues,
elastomers, polymers etc., each covering the areas of test control,
analysis and reporting.
Instron’s new
automatic carousel system is dedicated to standard tests on series 5900
table top tension machines, where numerous comparable test runs can be
carried out at a remarkably high level of reproducibility. It is designed
to significantly reduce the time and workload required to carry out these
tests and to minimize human influence on the results.
The carousel can be
adapted to numerous specimen types and geometries, including films or
textiles, standard test bars, pipes, and elastomers. Once loaded with a
specific number of specimens according to the application, the testing
sequence, as well as the subsequent evaluation of its results, can be
started at the press of a button using the Bluehill® 3 testing software. A
pincer then picks up a specimen and aligns it precisely between the clamp.
After finishing the test run, the remaining specimen parts are released
from the clamp and the pincer immediately commences with the positioning
of the next sample. In the meantime, the operator can prepare the next
carousel or carry on with other activities.
Website:
www.instron.de
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Brückner Maschinenbau at the
K 2010
50
Years Brückner - World Market Leadership Strengthened
 Brückner
is celebrating the company’s 50th anniversary in 2010. Over decades, not
only was Brückner able to secure, but also to strengthen their position as
world market leader for film stretching lines – within the entire BO
market as well as in the BOPP segment. As to BOPET, Brückner has been able
to gain a significant market share in recent years.
In the first half-year 2010, Brückner Maschinenbau received further
increasing order volumes, by the end of the year it should be around 300
million Euro. With almost 50 % of all incoming orders, China still remains
customer country number one, other orders came from USA, Peru, Thailand,
Taiwan, Indonesia, India and Korea. Whereas in 2009 mainly BOPP and BOPET
lines were sold, the product range in 2010 was significantly
differentiated.
For Brückner Maschinenbau, China has by far been the most important market
for many years. Although a downturn is presently being observed for lines
for standard packaging film in China, this shall, above all, be
compensated by the demand for production lines for technical film (e.g.
BOPET thick film)
The demand from other markets, such as India, Middle East, Eastern Europe
and Commonwealth of Independent States (CIS) weakened slightly in the the
past two years in view of the global economic crisis. At present, however,
there is clear indication of revival of trade. In these regions, the
production of standard packaging film comes first and foremost, hence, the
demand for larger lines with higher output, maximum efficiency and lowest
energy consumption per produced film ton.
In Western Europe, USA, Japan, Taiwan and Korea, only a few large lines
are being ordered to meet the slightly increased demand for standard film.
There is a tendency that film manufacturers are more and more turning
their attention to specialty films. Particulary smaller, flexible special
lines for the production of first class and high price films are in
demand.
In order to fulfil the diverse customer requirements, Brückner offers a
wide range of lines. At K 2010 the company presents new line concepts
Website:
www.brueckner.com
New
Line Designs:
More efficiency and sustainability in film production / manufacture of
trend-setting specialty films
Apart from issues on productivity
and efficiency, energy consumption and sustainability have increasingly
gained importance - particularly in the last ten years. At an early stage,
Brückner has given great thought to such issues and has come up with
relevant concepts in order to meet the ever-increasing demand for modern,
highly efficient and environmentally-friendly film production lines.
Productivity and Efficiency
At the K 2010, Brückner shall exclusively present four new types of
high-performance lines. Such capacities have never been reached before,
namely:
-
BOPP Lines: 8.7 m,
525 m/min, 47,000 tpa
-
BOPP Lines: 10.4 m,
525 m/min, 56,000 tpa
-
BOPET Lines: 8.7 m,
525 m/min, 32,000 tpa
-
CPP Lines: 6.2 m,
300 m/min, 16,000 tpa
High-speed lines
offer many advantages: On the one hand, specific investment costs are
reduced by each kilogramme output, on the other hand, considerable savings
are involved in factory building, personnel costs as well as costs for
periphery equipment ( auxiliary supply, slitters, roll handling etc.).
Furthermore, operation expenses are reduced as - in terms of percentage -
less material is recycled and - all in all - less energy is consumed.
 Brückner’s
experience in the design of larger and higher performance lines has over
the years consistently been implemented in the development of new high
output lines - also in the field of non-oriented packaging films.
Energy Saving
On all line designs - irrespective of whether production lines for the
manufacture of first-class mono- and biaxially stretched films or for
extruded flat film sheets - Brückner optimises the potential for energy
saving and - compared with 1990 - has achieved a 30 % reduction in energy
consumption required for the production of film.
At the K 2010, Brückner shall furthermore present the brand new optimised
cast film temperature control. Compared to the customary set cooling zone,
where - after the chill roll - the cast film runs through the water bath,
the cooling zone is now variable. Depending on the film thickness and line
speed, it is controlled in such a manner that the cast film over the
entire thickness is merely cooled down as little as necessary and from
this temperature level with reduced heating energy, is again heated up and
oriented in the MDO (Machine Direction Orienter).
Highlight of this year’s K in the field of energy saving will be
Brückner`s specially designed „Energy Monitoring Tool“. Brückner
recognised that besides the implementation of the technical limit, energy
saving is highly dependent on how line operation is performed. In
principle, the energy monitoring tool can be visualised like a vehicle
computer, the one displays how much energy one consumes with the actual
driving style.
The line operator is able to ascertain the energy consumption in several
steps. The device displays how much energy per component is being consumed
for the actual film production. On the basis of energy monitoring, semi-
and fully automatic processes are offered which bring the line to the
required operation mode whilst saving energy and resources.
With this new technology, Brückner has responded to the specific
challenges in connection with a conscious energy awareness and the CO2
emission related to that – not only for the production of certain film
types but also for the defined production time periods.
Sustainability
Apart from the reduction of energy consumption, the issue of
sustainability in film production refers to the use of renewable raw
materials as well as the overall reduction of the raw material charge.
Thin Films
To date, packaging films are made of products based on crude oil. In times
of limited resources and ever increasing oil prices, the clear objective
of film manufacturers is to produce thinner films – with unchanged or even
improved properties – in order to reduce raw material consumption. On
account of the implementation of „High-End System Components“ and improved
process technologies, Brückner is able to offer film manufacturers optimum
line efficiency for the production of thin films:
• Smooth guiding and stretching of ultra-thin films: controlled drives on
all feeding film rolls over the entire line ensure a gentle handling of
the film without damage to surface
• Further development of the highly flexible multi-gap technology
• Gas heated transverse direction orienter (TDO) with constant air
distribution over the entire film width
• Further development of the web tension control in pull roll and winder
• Highly accurate thickness control with fast-acting profile control
The simultaneous orientation process offers a well defined advantage in
terms of thickness reduction. Brückner has taken a pioneer position with
their unique LISIM® technology. Brückner`s LISIM® pilot line has already
produced 7 µm BOPET film with excellent film properties - absolutely
comparable to those for 12 µm thick BOPET film.
Multi-Layer Film
The reduction of certain process steps (e.g. lamination, coating) up to
end packaging is also a distinguishable trend. This is exactly where
multi-layer films are applied. By means of so-called function layers,
whether EVOH, PA or PE, film properties can be attained - in particular
for barrier requirements - which normally can only be attained by means of
a subsequently manufactured composite film. In their own technology center,
Brückner has developed several new promising multi-layer film types and
has implemented this know-how in their film stretching line technology,
namely:
• Adjustment of the extrusion and filter system in order to attain thinner
function layers (1 - 4µm)
• Special die for the corresponding exact layer arrangement (rearrangement
of the layers must not occur)
• Process control to ensure the smooth implementation of the required
stretching tension without damage to the thin layers.
Biodegradable film
As an alternative to raw material based on crude oil, renewable materials
are increasingly being applied for the manufacture of biaxially stretching
packaging films – above all PLA. These films convince in view of their
sustainability which meanwhile is increasingly in the limelight. Also
here, Brückner is able to offers concepts for new lines or the
modification of existing lines:
• Special raw material handling systems for the hygroscopic material PLA
• A specially adapted extruder screw design for PLA ensuring gentle
plastification
• Special adaption of all melt leading components ensuring gentle handling
of the acidic PLA
• A temperature control system specially adapted and aligned for PLA for
machine and transverse stretching of the material given the fact that PLA
must be stretched with considerable lower temperatures than other polymers
• Units for film surface treatment adapted to the material
Films for tomorrow
Solar Panels and LCD Displays
The growth of stretched films is expected to continue at an even higher
pace - not only in the packaging industry. Also for the growth market for
photovoltaic applications (PET films in the thickness range of up to
approx. 250 µm) and optical applications such as for example for LCD
display (PET-films in the thickness range of up to approx. 400 µm),
Brückner has focussed on the development of adequate line. The newly
designed lines have responded to the specific demands for such films:
• Proven profiling of the melt ensuring that the required optical
properties are attained
• Smooth and gentle film handling during orientation and winding in order
to avoid mechanical surface faults and to ensure the required form
stability for subsequent application
• Recycling systems not only allowing the fluff recycling of edge trim of
finished film but also of the considerably thicker end film after the
casting roll
Electric powered mobility
For the future market concerning electric powered mobility, Brückner is
presently carrying out R & D for battery separator films which not only
can be applied for batteries for electric vehicles, but also for all kinds
of transportable devices. Based on their long term experience within the
field of capacitor film, Brückner is engaged in the topic concerning the
requirements for such films and relevant technology and line design. One
can compare their involvement with that of over 10 years ago, when
Brückner made trials with the scarcely known PLA.
Website:
www.brueckner.com
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Trexel to
Show K-2010 Attendees How "Thinking in MuCell"
will
Improve Part Quality, Reduce Production Costs and Minimize CO2 Emissions
at the Same Time
 Trexel
will display at this year's K 2010 a broad variety of leading-edge
applications across many industries, all molded using Trexel's MuCell®
microcellular foam molding process. The theme of this year's Trexel
exhibit is, "Thinking in MuCell". The Trexel exhibit is located in Hall
13, A48.
"Today, a fast-growing number of companies located around the world are
taking advantage of the design flexibility offered by the MuCell® process
to produce high quality, high performance applications, that are much
lighter in weight along with a dramatically reduced carbon footprint,"
said Steve Braig, president & CEO of Trexel Inc.
"Thinking in MuCell means true design for function, having material only
where it's needed for strength. As a consequence, many MuCell® process
users are saving 20% or more in weight over conventional solid injection
molded designs" said Braig.
Trexel officials and technical experts from around the globe will be
present at the K exhibition to demonstrate and discuss many of the latest
innovative applications that are now in production. "Thinking in MuCell
offers our customers a true competitive advantage in today's global
marketplace," said Braig.
Website:
www.trexel.com
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Waldorf Technik – K 2010 – Hall 7A, Stand B02
We don’t sell
equipment, we provide safety
Waldorf Technik GmbH & Co. KG, Engen, Germany, is a specialized
provider of auto-mation for injection moulding productions.
 The
company concentrates on safe solu-tions which are highly appreciated by
customers in the medical-technical branch. The specialized engineering
company has qualified again for the renowned German award “Top 100 – the
most innovative middle-class companies”. During K 2010, Waldorf Technik is
represented on the Netstal stand D24 in hall 15 and on the Sumitomo De-mag
stand D22 in, hall 15, and maintains an information stand at B02 in hall
7A. The Netstal exhibit displays the largest medical-technical plant –
with regard to numbers of cavities – ever shown during a K exhibition.
Plastics above all
We provide innovative
solutions for the medical-technical branch as well as for the packaging
industry, “says Wolfgang Czizegg, CEO of Waldorf Technik. For the
medical-technical branch, the company de-signs automation equipment
downstream of injection moulding machines producing consumer articles such
as contact lenses, laboratory items such as pipettes or receptacles,
insulin injection pens or Petri dishes – almost any plastics part which is
required in large quantities. “In the packaging industry we have opened
new markets, by substituting glass and tin with plastics”, says W. Czizegg.
Record breaker
During K 2010,
Waldorf Technik will be represented on three stands, clearly concentrating
on medical-technical applications. Netstal stand D24 in hall 15 highlights
a record breaking machine with 96 cavi-ties: “This is the largest
injection moulding line of its kind ever shown on a K exhibition,”
emphasizes Wolfgang Czizegg. The system produces – at very high output –
components for a medical-technical product. “The components are subject to
highly stable production requirements. This is why no cavity must be shut
off or plugged when a problem arises during the injection moulding
process”, explains W. Czizegg. All 96 grippers for demoulding the parts
are controlled separately to allow flexible reactions in case of problems.
Mr. Czizegg says: “After all, if a single cavity is shut-off in the
continuous quality control and surveillance procedure, the entire
production cell continues its operation to ensure that the mould flow
balance is maintained. The robot simply separates out those components
which are even-tually blocked.” In fact, the 96 perfect components are not
deposited in a single common chute, but they are located in groups in 16
containers. “All perfect components are used, and in the case of a de-fect
at a later point in time the affected batches can easily be identified and
separated.“ The supplier is always ready for delivery,” reports W. Czizegg.
Consistent readiness to supply is a highly important criterion. A diabetes
patient, for instance, must be assured that the insulin-pen he or she is
used to will always be available. And product quality must be safeguarded
permanently. “Validation and readiness to supply are essential to be
commercially successful. We take care of this and show on the Netstal
stand how safety works in the supply chain,” says W. Czizegg. On the
Sumitomo Demag stand D22 in hall 15, visitors will find a modular plant
producing pipette tips in a 32-cavity mould. The automation unit can be
adapted to 64-cavity production. Demoulding and cavity-oriented deposition
of the parts is demonstrated. A camera unit safeguards complete control in
this rather open system – and 100% product quality including pipette
geometry is high-end priority: “The principle is a fully modular design.
No matter which additional functions are required – such as filter
attachments, various further quality surveillance checks or the formation
of packaging units – these functions can be added or supple-mented
according to individual customer specifications,” explains W. Czizegg. In
addition to these two exhibits on the Netstal and Sumitomo Demag stands,
Waldorf Technik maintains an information stand within the WVIB community
in hall 7A, stand B02.
Safety first
“Competitive pressure
in the packaging industry is higher than in the medical branch. The
companies have to adapt to the filling lines of their customers which
often they do not have their own products. And the price pressure is much
higher, too,” summarizes W. Czizegg. Waldorf Technik reacts upon the
growing demand for even safer, faster and more productive manufacturing
processes with innova-tive engineering power. Says Czizegg: “We compete
through a high degree of engineering intelligence and strength. We look at
the customer’s market in the centre of the project and then we develop ex-actly
the plant for the solution of the problem. In most cases, the robots are
of modular design and can easily be adapted to the new products. The
market is not very innovative and generally chases noth-ing but cycle
times. However, it is more important to recognize what customers really
need to be suc-cessful, and to react fast upon those demands.” Wolfgang
Czizegg emphasizes that suppliers to the medical-technical branch want to
buy process safety: “In cooperation with the customer, experts in the
medical environment elaborate process and risk analyses and develop a
project from there. The risk is assessed, followed by a detailed statement
of the individual safety strategy. This is the unique selling proposition
for our customers. We simulate risks and ‘sabotage’ production processes
in the test field to learn all imponderabilities and consequently to be
able to offer the highest possible level of safety.” This is W. Czizegg’s
recipe of success: “We don’t sell equipment, we provide safety.”
Three major methods for barrier packagings
Wolfgang Czizegg
recognizes a growing trend where plastics solutions substitute glass and
tin con-tainers. Actually, three production methods are represented in the
market which are trend-setting and where Waldorf Technik is one of the
pioneers: “Firstly, it concerns the cup production involving
in-mould-labelling where containers are produced in a single injection
moulding operation using multi-cavity moulds. “The barrier function is
thus contained in the label,” explains W. Czizegg. The second method
utilizes the barrier material as a central layer, injecting Polypropylene
and EVOH which has gas barrier properties. Czizegg: “No water vapour or
oxygen can migrate in or out of the packaging. EVOH has rarely been used
in injection moulding due to lack of traceability or test methods.”
Mean-while, a special test installation is utilized in the new ‘Check’n
Pack’ automation module which visual-ized EVOH. The savings in production
and logistics cost of this method are about 40% compared with those of
tin-plate ware. The third method involves conventionally injection moulded
plastic cups which are coated with a barrier layer. The extremely thin
layer which covers the cup has a similar hermetic property as glass does
and offers the potential to substitute traditional packing solutions such
as glass and tin-plate ware or aluminium cups. In all three methods,
Waldorf Technik has meanwhile reached a high degree of specialization and
a leading position worldwide.
Success despite the crisis
For years, Waldorf
Technik’s development is characterized by growth. Meanwhile, the company
em-ploys a staff of 96 specialists and has recently established a
subsidiary in the USA. Main markets are central Europe and Scandinavia
with remarkable business growth rates in Ireland, the UK, Middle East, and
America. New agents were established in England and France. The Engen,
Germany, mother company has doubled its production area. The team of
experts, predominantly in design, engi-neering and sales, will be
reinforced and a new IT system will be installed. In 2008, the company was
able to raise its turnover by 30%, and by 16% in the year of the crisis.
Looking at 2010, Wolfgang Czizegg is optimistic: “Last year’s development
may continue this way. We find ourselves in a fast de-velopment phase, but
with a constant view on the long-term stability of our company – equally
impor-tant to our customers and our staff.” One expression of the upward
trend is the present (and second) qualification for the ‘Top 100’
companies’ award. The award competition across all branches thor-oughly
focuses the innovation management of middle-class companies. The most
ingenious and as-similation-friendly firms in Germany are identified,
distinguished and honoured this way.
Website:
www.waldorf-technik.com
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Everyone Is Talking about Energy Saving
HERBOLD has the appropriate granulator design
Granulators by nature are high energy consumers based on the level of
work and tough cutting applications they are placed in. As part of any
recycling plant they almost always become the machine with the highest
installed drive capacity.
As energy savings is a hot topic in the news media and concern for
consumers it seems quite logical to focus on these machines to improve
their efficiency. HERBOLD has published several success stories with our
forced feeding granulators, the SB series with increased efficiencies and
power savings that a patent in the USA has been applied for based on their
unique design. Two years after their commercial launch, as many as 80
machines of this series have been sold and the customer’s feedback was
unanimous: energy savings between 30 and 50% have been achieved. This
means reduced operating costs and money savings in the amount of 15 to 25
thousand Euros per year with a 75 kW granulator operated in three shifts.
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SML SB 60/100 |
Schematic
diagram Herbold granulators of the SB series |
Why is there such a high energy saving with these machines? Energy is not
wasted tossing the material around in the feed hopper instead the material
is directly forwarded to the grinding chamber by the crammer feeders. The
operation is more efficient, the feed stream is consistent reducing
current spikes and in addition eliminates the annoying fly back associated
with conventional granulators. The benefits of this feed design also
improve the number of cuts per minute as the feed material is kept in the
cutting path reducing the amount of fines and heat generation of the
ground material due to a reduced dwell time in the grinding chamber
And there are more advantages:
- There is an intermediate buffer above the screws, thus increasing the
utilisation ratio especially if there is a shredder with an oscillating
hydraulic ram just before the granulator. The hydraulic ram pulsates as
the material is discharged and the buffer in front of the granulator
ensures that even with no-load operations the granulator is used to
capacity.
- Increased efficiency and output means a smaller machine can achieve
rates that would have required a much larger machine in the past. Smaller
means less overall equipment cost, reduced foot print, reduced labor costs
and substantial savings on wear items.
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Efficiency comparison between a
conventional granulator and the Herbold SB series (blue bar) with a
rotor diameter of 600 mm and a rotor width of 1000 mm. |
The force feed concept is particularly efficient for size-reducing of
beverage bottles. with the addition of water to the size reduction step
and the friction – a by product of size reduction provides a washing
action that removes contamination during the size-reduction step. Reducing
blade, screen and internal wear of the granulator at the same time,
basically a win, win.
There are 5 different sizes of the SB series from 1 to 12 t/h throughput
(with a 12-mm- screen) and with drives from 45 to 315 kW.
Website:
www.herbold.com
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Arburg as strong partner
for the future
K 2010: World premieres for unique Selogica features and large
high-performance hybrid machine / Efficient moulded part production with
complex production cells, applications and mould technology
Arburg's traditional address at the international K trade fair has always
been stand number A 13 in Hall 13. However, except for the stand location,
almost everything else in Arburg’s appearance at the “K” is, as always,
new. One of the highlights presented by the company in Düsseldorf is the
world premiere of the unique and versatile Selogica control system with
completely new operator guidance features. The second debut awaiting
visitors is a high-performance hybrid technology in the form of the new,
large Allrounder 920 H, which has a newly designed servo-electric toggle
clamping unit with a clamping force of 5,000 kN. Arburg’s presence at the
K 2010 is rounded off by project systems for cost-effective part
production and real treats in mould and application technology.
 Managing
Partner and Spokesperson for the Arburg Management Team, Michael Hehl,
describes the company’s focus at the K 2010 as follows: “Our aim is to
open up opportunities for an even more efficient production environment to
the practitioners in injection moulding who make up our customer base. Our
partnership goes far beyond the modular Allrounder machine level. All of
our injection moulding solutions are in line with our company maxim, which
defines Arburg as a partner for efficient injection moulding. We are
demonstrating this at the K 2010, both with the new features in the area
of machines and control systems and with our various high-tech exhibits.
This is complemented by customer-specific consulting and support, which
enable us to develop the best possible solutions with our customers in
mind.
With the absolute highlight of the trade fair, the Selogica Assistant, we
are once again treading a new path as pioneers in injection moulding
technology, that will guarantee us a unique selling point in the
industry.”
Selogica Assistant: the quick and easy way to program machine
sequences
By creating a
special, separate area on the exhibition stand, Arburg aims to underline
the international pioneering position of its Selogica control system
philosophy, which now enables not just machine sequences, but also entire
production systems, the associated peripherals and six-axis robotic
systems to be programmed and centrally controlled.
The new “Selogica Assistant” launched at the K marks Arburg’s next
milestone on the road to effective, simplified injection moulding
management. As a unique and very simple interface between man and machine,
the Selogica Assistant now offers menu-guided, supervised set-up, or
“teaching”, functions for the entire mould sequence. Machine operators are
actively supported during set-up and are literally “led by the hand”: It
takes just five logical steps to create an entire cycle sequence. The
Selogica Assistant thus permits the Allrounder to be set up quickly,
simply and reliably without requiring the operator to be familiar with
every detail of the control system.
Hidrive expanded: new Allrounder 920 H underlines Arburg’s focus on
hybrid technology
Following the
addition of the large hydraulic Allrounders 920 S and Golden Edition to
its large machine range, Arburg is now following up with a hybrid
high-performance machine with a clamping force of 5,000 kN, starting from
the K 2010. The expansion of the upper end of the successful Hidrive
machine series underlines Arburg’s aim of providing all customers with a
sophisticated, powerful, as well as cost and energy-efficient machine
concept for fast operating cycles, even at higher clamping forces.
The new, large and powerful servo-electric toggle clamping unit with a
clamping force of 5,000 kN for fast, high-precision movements, makes the
Allrounder 920 H particularly impressive. The exhibit is combined with a
size 4600 hydraulic injection unit and adaptive hydraulic accumulator
technology. The large Hidrive machine will demonstrate a technical
application from the packaging sector with sophisticated mould features,
such as collapsing cores and multiple slide demoulding.
Projects and applications: individually tailored to the tasks in
hand
With a total of ten
exhibits, including numerous complex production cells, Arburg will present
its broad spectrum of application-based, energy-efficient injection
moulding solutions. Accordingly, the trade fair stand is dominated by
hybrid and electric machines from the Hidrive and Alldrive series, all of
which bear the Arburg energy-efficiency label. These exhibits are used to
present high-speed packaging applications from the fields of in-mould
labelling, multi-component injection moulding, including liquid silicon
and thermo plastics, the production of a medical technology part and
micro-injection moulding with the new micro-injection module from Arburg,
which combines an 8 mm injection screw with a second screw for melting the
material.
Complex made
simple with Selogica
Special production
cells in which all processes are managed centrally via the Selogica
control system are a further demonstration of perfect communication
between man and machine. Highly complex work tasks can be programmed and
implemented with ease by following the appropriate control system
philosophy.
One example of this is the flexible, fully-automatic encapsulation of
cables on a vertical Allrounder 375 V and a Kuka six-axis robotic system
with Selogica user interface. Advantages: the injection moulder can
program the robotic sequences himself, set-up and training efforts are
greatly reduced and cycle times are effectively shortened. The other
advantage of this application is that there is no need for the manual
preparation and insertion of the cables. As a flexible component, the
cable is inserted into several cavities at freely-selectable positions.
The length of the cable loops can be determined without limits.
The majority of production cells produce multi-component products and
parts using innovative mould technology - further proof that the
integration of functions, texture and design is gaining increasing
importance in cost-efficient production sequences.
Sophisticated assembly injection moulding
The application
technology highlight is the production of a rotation angle encoder as
three-component part with inserted magnetic sensors on an Allrounder 370 S
with a clamping force of 700 and three size 70, 70 and 30 injection units.
The part-design was developed by Oechsler in cooperation with the
institute of polmer technology of the University of Erlangen. The
injection mould, designed and built by Oechsler, demonstrates assembly
injection moulding in action. A Multilift V robotic system with a
longitudinal configuration is used to feed the magnetic sensors into the
mould, remove the parts and perform an integral function check. The
magnetisation of the injection moulded magnet in the mould is another very
interesting technical feature of this application.
The assembly injection moulding process, which is so important for the
fast and efficient production of complex parts made from multiple
components, can only work to optimum effect if the mould, machine and
robotic technology operate in perfect harmony. As you would expect, the
central Selogica machine control system also works hand-in-hand with the
operator in this example, to ensure that this complex injection moulding
and handling process is programmed with utmost efficiency. All three
injection units, as well as the robotic system, are united in a single
process. This ensures smooth production involving a clear and intuitive
dialogue between man and machine that is quite unique.
Paternoster guarantees high-quality parts
Two large
two-component machines are used to demonstrate some really special
mould-related features.
An electric Allrounder 720 A with a clamping force of 3,200 kN and size
800 and 290 injection units is fitted with a twelve-cavity mould from
Zahoransky. This is employed in the production of the cores and handles
for toothbrushes using so-called SCPS, or paternoster technology. The
mould inserts are rolled through the mould vertically. The benefits here
are the absolutely central application of force, which has a positive
effect on the quality of the parts and the cycle time and the compact
mould design achieved using this technology. Furthermore, the mould
impresses through its flexibility, as parts can be inserted and finished
articles can be removed without having to open the mould. This helps to
achieve significant advantages in terms of cycle time.
On a hydraulic Allrounder 630 S with a clamping force of 2,500 kN and size
1300 and 400 injection units, caps will be produced for five-gallon water
bottles. The pressure closure with original seal will be produced on an
eight-cavity cube mould from Foboha. The pre-moulded part is produced in
the first station and cooled in the second station. The second component
is injected in the third station, while the fourth station is reserved for
demoulding from the closed mould.
Both exhibits once again demonstrate the performance and flexibility of
the Selogica machine control system, which can be used to program and
monitor the entire mould technology.
Greater individuality for more flexibility and cost efficiency
Our presence at the K
2010 fair demonstrates one thing clearly: as a strong partner for all
areas and branches of injection moulding, Arburg offers its customers
individual, efficient production solutions that are perfectly suited to
their complex injection moulding tasks in terms of performance, equipment,
support and service. This requires expertise in modular series production
and main contractor qualities. Arburg meets both requirements in its
machine and equipment program. This is perfectly demonstrated at the “K”
in Düsseldorf with Allrounders and systems that offer exemplary evidence
of how greater individuality can permit greater flexibility in the
application, thereby facilitating more cost-effective part production.
However, individuality can only succeed if the technical resources are
available. Closer ties between man and machine are necessary here. At the
K 2010, Arburg provides a clear demonstration of how this will work in the
future: the new and established control features of the Selogica will
enable effective dialogue between the operator and machine technology,
promoting a lasting partnership between man and machine. Even complex
production processes are made intuitive, enabling the responsible
personnel to retain secure and problem-free control of all sequences. This
is how injection moulding technology should work: simply, quickly and
effectively - hand-in-hand with the operator.
Website:
www.arburg.com
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MANN+HUMMEL ProTec at K 2010
Innovations in material handling increase flexibility, efficiency and ease
of use
 At
this year’s K-exhibition, MANN+HUMMEL ProTec is presenting the new
generation of energy-efficient SOMOS® D dry air dryers, a new dryer for
small loads, new conveyer equipment and a high-precision dosing system for
small amounts, especially designed for extrusion.
MANN+HUMMEL Pro Tec
introduces further developments and expansions of its innovative systems
for drying, conveying and dosing of free flowing plastics in hall 9, stand
D60 in Düsseldorf. Single workplace solutions and solutions for complete
factories offer great operating comfort and flexibility for stable,
efficient and economic process management in extrusion, injection
moulding, calendering or blow moulding.
Module dryer
update – small load dryer for engineering plastics
The new generation of
stationary material drying systems is presented at the K with the example
of a SOMOS® D200 dry air dryer (air flow 200 m³/h) and a module hopper
system with drying hoppers from 50 to 300 l. The technical innovations in
design, process control and control engineering that are utilised here
combine great operating comfort with a further improvement in energy
efficiency. This results amongst other things in the new process control
of the rotary desiccant container of the D dryer taking a much shorter
time for regeneration of the drying agent, which means that the energy
required for this can be used more effectively. At the same time all
module hoppers have their own control system structured on a universal
concept. This independent mode of operation makes things like the
expansion
of the module system through the adding on of one or several drying
hoppers considerably easier. The tried and tested ALAV and Super-SOMOS®
control mechanisms used in SOMOS® dryers continue to provide high energy
efficiency adapted to the respective current material throughput.
The new SOMOS® TP 8
compressed air dryer extends the series of small load dryers specially
designed for multi-component injection moulding in the processing of
engineering plastics. With an insulated drying hopper of eight litres
capacity and a freely selectable drying temperature from 60 to 180°C it is
suitable for throughputs of up to approx. 2 kg/h. The dryer works on the
principle of air expansion and can be fitted with conveyer equipment that
is operated directly from the dryer control unit.
Communicating
conveyer equipment – high-precision, gravimetric dosing of small amounts
The current SOMOS® FG
series of suction conveying equipment differs from existing models
particularly in its range of features: the devices are fitted with control
units which can communicate with each other. There are also cost
advantages with this further feature, as up to 16 conveyer units can now
be flexibly linked together to a composite without the requirement of a
central control.
Another innovation at
the K is a fully weighing dosing system for small amounts which can be
used in the SOMOS® Gramix S9 or Gramix E gravimetric dosing and mixing
systems for the production of multi-component mixtures for extrusion
processes.
Designed for
throughputs of approx. 2 kg/h down to 200 g/h, a dosing precision of ± 1 %
is achieved. In a throughput of 200 g/h the target weight of approx. 3.3
g/min thus varies on average by a mere ± 33 mg. This high dosing precision
has clear advantages in the increasingly used practice of dosing very
small amounts of highly concentrated masterbatches into the main flow of
material.
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ILLIG
at K 2010 - Thermoforming Pushed to High-Performance
 State-of-the-art
technologies and benefits provided by system solutions for thermoforming
of plastic packs in any shape or size in large quantities are core
elements of ILLIG's trade fair appearance at this year's K trade fair,
Düsseldorf, Hall 3, Stand A52.
Two
roll-fed thermoforming lines will be demonstrated under production
conditions with machines and tooling of current 3rd Generation RDK and RDM-K
series. RDK automatic pressure forming machines for combined
forming-punching operation are employed to produce products from hinged
packs and menu trays through to closing lids. Machines of the RDM-K series
are predominantly used for thermoforming of cups in any shape or size
using multi-cavity tools. Compared to the previous standard, current
systems achieve increases in cycle speeds at clearly double-digit rates
featuring improved product quality and considerably lower energy
consumption at the same time. This also applies to socalled sheet
processing machines of the UA series. ILLIG will also demonstrate the
efficiency of this series at K fair.
On
the RDK 90 production line, which is the largest version of these
automatic pressure forming machines, featuring up to 900 mm processable
material width and 700 mm index length, trays are produced just like those
sold millions of times as sales and keep-fresh packages for food articles,
by processing APET on a 18-up tool at a speed of 55 cycles/min.
Yogurt cups are produced on RDM 70K automatic forming machine, forming
area 680 x 300 mm², using a 27-up tool and also APET material. Downstream
equipment ensures reliable handling of these large numbers of products –
50 000 trays and almost 70 000 yogurt cups. For this purpose the RDK 90
line is equipped with double-handling system for product removal and
stacking device. The stacking device of the RDM-K line is equipped with a
new turning head system that can be swiveled by 180 degrees. Designed for
a speed of up to 45 cycles/min, the demolded cups can cool down further
for one cycle to ensure gentle stacking.
Consistent use of servo motor drives and new
control concept
 Consistent
use of servo motor drives for all motion sequencing is one of the
pre-requisites to achieve high cycle speeds in thermoformers. They work in
an energy-saving manner, as well as fast and precisely and thanks to high
positioning and repetition accuracy maximum overlapping of working steps
can be realized which saves process time. The very high dynamics involved
in forming pressure build-up and reduction is a further decisive element
for the clearly improved productivity compared to the previous generation.
In the RDM-K series 3rd Generation tools are the decisive factor. They
operate with up to 75 % less forming
air volume per cavity and in this way increases in cycle speed of at least
30 % and sometime even considerably higher are possible. In thermoforming
with multi-cavity tools, also with respect to product quality, uniformity
of all cup geometries is achieved which was not possible before. Based on
this, weight reduction and thus material saving of up to 10 percent can
even be realized, without having to accept impairment of dimensional
accuracy or cup stability.
Developed for the first time for the large-size RDK 90, roll-fed
thermoformers – like RDM 70K that will be demonstrated for cup production
at K fair – can be consistently equipped with the new "ILLIG
ThermoLineControl" concept. All additional devices and lines required for
the completion of a production line, from material roll stand through to
additional cooling devices, can now be centrally managed and operated via
the thermoformer's control. Besides providing an increase in operator
convenience, e.g. by central process optimization, data management or
process visualization, even the non-productive secondary times needed for
format or tool changes are considerably reduced. Moreover, error diagnosis
and trouble shooting can be carried out much easier and faster. In this
way the new ThermoLineControl
combined with the high cycle speeds of today's machine generation
contributes to a considerable increase in creation of value.
Energy efficiency significantly increased in
thermoforming
Servo
motor drives used for all movements of the thermoformers not only
contribute to an increase in productivity, they have an equally positive
effect on the energy balance. The supply units employed are equipped with
energy recovery systems. The available generative energy from the system,
e.g. braking energy from one or several drives, is used for other drives
or other loads, among others also tor the infrared heater. Subject to
machine type and drive this saving amounts up to approx. 20 % of the drive
energy.
The
energy efficiency topic, however, is much more complex for thermoforming
since the machine drives require maximally approx. 10 to 15 % (subject to
machine type) of the whole energy requirement in the thermoforming
process. Among others, the following are also influential elements: Type
and use of infrared heater elements for material heating, energy
requirement of temperature control and cooling devices and – for automatic
roll-fed machines working predominantly with pressure air a very important
"energy factor" – energy requirement for generation of forming air.
In
their K trade fair booth ILLIG will illustrate these interrelationships
based on practical examples. They will show how high productivity in
thermoforming (high cycle speeds) can be combined at the same time with
efficient energy consumption that saves operation costs. Comparative
measurements conducted on ILLIG machines of previous generations revealed
that today's 3rd Generation thermoformers which are considerably more
efficient feature up to 50 % less energy consumption.
Website:
www.illig.de
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Amcor Expands Material/Process Capabilities with Acquisition of Ball
Plastics Packaging Americas
Deal Boosts Presence in High-Growth
Diversified Products Packaging and Complements Beverage Business
Amcor Rigid Plastics' acquisition of Ball Plastics Packaging Americas on
Aug. 2 complements the company's PET beverage packaging business and
expands its role in the high-growth diversified products packaging
category which includes health care/pharmaceutical, home care, personal
care, food, and distilled spirits, says William Long, president of Amcor
Rigid Plastics. The deal brings expanded material and process
capabilities, including multilayer, retort, and barrier technologies,
along with know-how to manufacture HDPE and PP extrusion-blow molded
containers.
"This acquisition makes us a larger and more diverse company positioned to
offer a broader range of innovative and technology-based solutions to our
customers," said Long. "We've again stepped outside of PET and we expect
to take advantage of the growth opportunities presented by our new
material and processing expertise." Amcor has long been recognized as a
global leader in the design and production of PET hot-fill packaging for
the beverage, food, and non-food industries and recently expanded from
that with the acquisition of the Alcan Pharma Rigid Plastics business.
The acquisition of Ball Plastics Packaging Americas for $280 million comes
on the heels of Amcor's February 2010 purchase of Alcan's Pharmaceutical
Plastics packaging business, which produces PP, PE, and PET rigid
containers for over-the-counter drugs, vitamins, and other pharmaceutical
needs. That deal moved Amcor into new applications, materials, and
processes, and provided a valuable entry into the pharmaceutical market.
With the Ball acquisition, Amcor remains committed to the North American
carbonated soft drink (CSD) and water segments, where Amcor's focus on
manufacturing excellence is well known and longstanding. However, the
company sees strong opportunities in diversified products such as
multilayer food packages and retortable containers for food and beverages,
including coffee drinks, nutraceutical beverages, and other dairy-based
beverages. Ball's proprietary barrier technology includes Gamma-Clear
multilayer OPP containers for barrier food applications and Gamma PP
retort bottles that withstand retort sterilization temperatures up to 250
F. Ball also offers other barrier solutions including Plasmax SiOx
internal barrier coating.
The Ball acquisition also opens up new market areas including wine,
retorted food, and non-PET food and beverage packaging. While Ball's
historic business has been based in North America, these new technologies
and product categories will be transferable to Amcor's growing businesses
in Mexico and Latin America. The acquisition of Ball Plastics Packaging
Americas includes five plants in North America and sales of approximately
$600 million. The company employed approximately 950 co-workers and
maintains manufacturing capacity for more than 5 billion units of PET,
HDPE, and PP containers per year.
Website:
www.amcor.com
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PEplus
Due to the ongoing
economic crisis (don't let any government spin doctors try and convince
you that it is all over), we have taken stock of the state of the UK and
European polymer industries. We have spoken to many companies and
organisations. We have listened to what you want and need. Together we
have put together a new structure for PEplus, so that we can provide the
industry with a free trade publication, with added services.
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From now on PEplus
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