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October 2013
CLEAR WINNER: POLYCARBONATE SHEET K2013: THE GREATEST SHOW ON EARTH DEVELOPING OPPORTUNITIES IN INDIA LATEST NEWS IN POLYMER RECYCLING
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contents
05 Industry news
PAGE 5
Trade bodies clash over plastic bag ban; Amcor exibles head for the Antarctic; Berry Plastics expands in exible packaging; rebranding creates Coperion K-Tron
In our nal issue before K2013, we focus on developments in polymers, additives and compounds that will be of interest to lm and sheet extruders
PAGE 13
In a nal round-up of ancillary products that can be seen at K2013, we focus on systems that boost product quality
Tool developers have been busy developing new dies that deliver everything from higher production speeds to improved coextruded lm
PAGE 37
Whether its heavily soiled agricultural lm or printed exible packaging, theres a way to clean up the plastic and make it easier to recycle. Lou Reade reports
47 Clear advantage
Polycarbonate sheet is know for its toughness, and its applications range from railway carriages to football stadiums. Lou Reade reports
Material and machinery advances help to improve the performance of BOPP, while India moves to the fore as a new player on the scene. Lou Reade reports
AMI has published a new report on the plastics market in the Indian subcontinent. Its author Alex Brownbridge provides an overview of the key trends
PAGE 59
68 Technology: Machinery 72 Extruder of the month: Berry Plastics 74 Dates for your diary
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www.lmandsheet.com October 2013 | FILM & SHEET EXTRUSION 3
news
and moving Europe towards a more sustainable economy. It supports a levy or tax on oil-based plastic shopping bags, or even banning them under certain conditions, though says that bags containing at least 50% bio-based content should be exempted. Bioplastic bags will become a symbol of a resource efcient and circular economy, said Franois de Bie, chairman of European Bioplastics. Such bags would ensure a lower carbon footprint than oil-based bags and reduce CO2
ble plastic shopping bags also offer a secondary use as biowaste bags. In its response, EuPC questioned whether bio-based shopping bags were more sustainable than their oil-derived equivalents. When considering the sustainability of a material, we need to look at resources used in their production, including land-use, water consumption and (in the case of bio-based plastics) the sustainability of biomass used, said EuPC. Any EU policy related to bioplastics needs to take account of lessons learned from the biofuels sector. Poto cnik: We will soon adopt specic proposals on lightweight plastic bags during a [recent] event on plastics waste, said EuPC. EuPC has already called for a ban on oxodegradable additives and better support for the separation of biodegradable plastics so that neither can damage the quality of recycled polymers. It says it has evidence that just 2% of oxodegradable plastics in the waste stream affects the visual quality of lm. It says such plastics have no positive environmental impact on the existing waste streams and should be forbidden in Europe. European legislators should act accordingly and the Green paper on plastics in the environment will hopefully trigger action in this direction, it concluded.
European Bioplastics proposes a ban or tax on bags with less than 50% bio-based content
It said that Europe needs to focus on better separation and collection in order to ensure the correct end-of-life solution for different plastics materials, and increase recycling towards a circular economy for all plastic products. Compostable and biodegradable plastics also need to stay out of traditional waste streams in order to avoid detrimental impacts on the quality of recycling. EuPC says it will soon publish more test results showing the negative impact of bioplastics on plastics recycling streams. Furthermore, bioplastics are not a solution to marine litter, and this has been clearly recognised by the European Commission
S www.european-bioplastics.org S www.plasticsconverters.eu
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news
www.berryplastics.com
www.kunststoffverpackungen.de
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www.willisresilience.com. www.amcor.com
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Over the last three issues, we have brought you news of innovations that will be seen at K2013. Elsewhere in this issue, you can nd details of materials, ancillaries and dies. Here, you can read about some last-minute highlights
www.ktron.com
Liquid propellants are injected directly into the twin-screw extruders processing zone and mixed homogeneously. The singlescrew extruder has a special geometry to optimise melt cooling at low drive power. KraussMaffei Berstorff has also developed two extrusion concepts for producing high-quality compounds based on recycled plastics. They are designed to handle sorted and washed plastics waste with high residual moisture levels. The single-stage option involves mechanically squeezing water from waste
plastic using the twin-screw extruder. For example, free-owing PE or PP agglomerates with 5-20% water content can be handled this way. KraussMaffei says that even before the plastic melts, most of the water is removed in the axial direction by the pressure in the compression zone. The remaining moisture is released in the downstream zones equipped with atmospheric and vacuum degassing. A double-stage recycling and compounding process is offered for non-free-owing waste material such as
agricultural lm, edge trims or bre residues. The system combines a single-screw recycling extruder with a twin-screw compounding extruder. An upstream cutter compactor breaks down the washed reclaim material before it is plasticized, homogenised and degassed by the single-screw extruder. The melt is then ltered and delivered by a melt pump to the twin-screw extruder for compounding with additives and llers, or blending with virgin material, as required.
www.kraussmaffeiberstorff.com
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Experience an extrusion line that will revolutionize your production. With extruders that provide excellent melt quality for all types of resin, and a concept that lets you move easily and reliably from one job to the next.
Discover what E-24 is at the K in Dsseldorf. Get up-to-date information about the K and our EXPO in Lengerich at www.code-e24.com or by scanning
WINDMLLER & HLSCHER KG P.O. Box 1660 49516 Lengerich Germany Telefon: +49 5481 14-0 info@wuh-group.com www.wuh-group.com
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Rebecca Utteridge Conference Coordinator rju@amiplastics.com Ph: +44 117 924 9442 Fax: +44(0)117 311 1534
News |
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S www.mas-austria.com
MAS will show its largest extruder together with its largest lter unit
Visit us at
mance technology that replaces processes normally used to improve the spreading and adhesion of coatings such as glue, paint, varnish and ink. It allows ne cleaning of the surface, coupled with chemical activation.
S www.acxys.com
www.brueckner.com
October 2013 | FILM & SHEET EXTRUSION 11
Materials |
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In our nal issue before K2013, we focus on developments in polymers, additives and compounds that will be of interest to lm and sheet extruders
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Colloids will show its Sustain bio-based masterbatches which can be used to make compostable products
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Corbion Purac will highlight the latest application of PLA bio plastics
AddWorks is about making it simple for customers. We want to provide a solution that works and ts their needs, said Ernesto Dongiovanni, head of marketing for polymer additives at Clariant. Huntsman will be showcasing its new Altiris infrared reecting pigmentsfor polymers at K 2013. These titanium dioxide based pigments preferentially reect infrared radiation from the sun. They can be mixed with coloured pigments to deliver high solar reectance in a range of colourful polymers including dark and vibrant shades. Such products can stay cooler under the suns intense heat, helping to reduce overall heat build-up which can prevent heat distortion and premature failure. This can help open up new markets for polymer products as they become less prone to warping. For example, they could be used in warmer regions of the world where they would have previously been unsuitable. Target applications include PVC proles and siding for buildings, and there has also been interest from the agricultural lm market. Imerys Talc will be highlighting the sustainable and technical advantages of its portfolio of micro-lamellar and high aspect ratio talcs derived from natural minerals. Several new developments will be on show. The companys new Mistrocell micro-lamellar talcs make ideal nucleating agents for polyolen-based foam composites, promoting uniform bubble distribution and growth. This helps to deliver consistent foam quality, reduced specic gravity and increased rigidity and strength in foamed products. 10-15% in extrusion applications. The third new grade from the company is Mistroblock which is based on very bright micro-lamellar talc. It is designed to reduce the blocking force and coefcient of friction in polyethylene lm production, while providing optimised optical lm properties such as clarity and haze. It enhances the mechanical properties of lm, such as tensile strength and dart drop resistance. Mistroblock is also effective for biopolymer lm production. Krahn Chemie will be showing an extended portfolio of pigments and additives for the plastics industry. In addition to acting as distributor for a wide range of suppliers and their products, Krahn also supplies pigments under its own Crane Color brand. Its pigment portfolio covers organic coloured pigments based on phthalocyanine, dioxazine, indanthrone and quinacridone. It also includes a broad range of pearl gloss pigments based on natural and synthetic mica and borosilicate glass. Krahn says that the pigments are high-quality alternatives to comparable products from European market leaders and are suitable for use with various polymers such as PVC, EVA and polyolens. Lanxess will be displaying a wide range of engineering resins, as well as parts of its polymer additives portfolio. An example is its Levapren, an ethylene-vinyl acetate rubber (EVM) that can be used to reduce the brittleness of PLA bioplastics. The company reports that the best results are achieved using Levapren 500 containing 50 to 60% vinyl acetate. This has been discovered through tests carried out by a team of researchers headed up by Piming Ma of the Polymer Technology Group in the Department of Chemical Engineering and Chemistry at Eindhoven University of Technology. They found that the notched impact resistance of the
BASFs Joncryl ADR chain extenders are used to improve the melt strength of recycled PET
Another recent launch is Crys-Talc, a high brightness, micro-lamellar talc that acts as a nucleating agent for homopolymer and copolymer polypropylene. Used at addition rates as low as 0.5%, the additive optimises rigidity, impact strength, heat resistance, crystallisation temperature and haze. Imerys says that Crys-Talc can increase machine output by
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The Extrusioneers
Rethinking Precision
Imagine if you could produce the best sheet ever, again and again.
Wouldnt it be perfect if polishing stacks worked with the precision of up-to-date machine tools? We think it would. With the innovative Mirex MT polishing stack you will immediately be able to adjust the polishing nip of your sheet extrusion line more precisely by a factor of 10, save setup time of at least 15 minutes, and reduce waste material by up to 75 percent. Adjustment is made fully automatically. This is how precision becomes reproducible. Find more information about us online on www.reifenhauser-csc.com You have questions? info@reifenhauser-csc.com
PLA increases by a factor of 10 or 20 by adding 10 or 20% Levapren 500 respectively. In addition, a loading of just 5% considerably increases the elongation at break, while tensile strength decreases only moderately. Milliken will focus on opportunities to save on materials and energy consumption while improving optical and physical performance using its Millad clariers for PP. The Millad NX 8000 clarier offers improved solubility compared to previous clariers, says Milliken, allowing it to produce levels of clarity matching crystal PS in some applications while processing at signicantly lower temperatures. The company says that this can lead to productivity improvements of up to 18%, energy savings of up to 13%, plus 10% reductions in carbon dioxide emissions. The clarier is said to perform particularly well with the companys ClearTint polymeric dyes. Suitable for food contact applications, the dyes have no impact on part shrinkage, which the company says can be a problem with some pigments used in polyolens. Songwon will be promoting the results of its many investments, expansions and alliances since the last K show. These include its recent introduction of hindered amine light stabilisers (HALS) which will be supplied globally in conjunction with Sabo. It has also increased its capacity for Songnox thioester antioxidants as a result of its Chinese JV with Tangshan Baifu Chemical. Wacker will be launching its new improved Vinnex binder system for bioplastics in Dsseldorf next month. It says that the vinyl-acetate-based additive enables polymers based on renewable raw materials to be processed just like conventional thermoplastics. The binder system not only enhances the physical properties of bioplastics, it also makes different materials compatible with each other. Wacker says that Vinnex improves and simplies the processing of bioplastics by injection moulding, extrusion, vacuum forming, thermoforming or calendering. It can be used in a range of bioplastics including PLA, PHA, PBS or starch-based materials, and can enhance blends of these polymers with each other and with other plastics or llers. Depending on the formulation, Vinnex can enhance impact strength, exibility or melt strength. Wacker reports that Vinnex enables the processing of PLA into extremely thin lms and it also improves the bioplastics weldability. The lms retain their transparency after the addition of the binder. Tests have shown that bioplastic blends with 10-30% Vinnex content biodegrade in less than 180 days in industrial composting conditions.
Compound interest
AF-Color, a subsidiary of polyamide specialist Akro Plastic (part of the KD Feddersen group), has developed a masterbatch for the packaging industry, which is optimised for lm applications. Lubricants and clariers for the thermoforming process have also been added to the companys portfolio. At the same time, the company has added a range of dry blends for use in various extrusion applications. Colloids has extended its standard range of coloured masterbatches to include more lead-free alternatives. The use of lead chrome-based formulations in plastics is becoming more restricted and this is due to continue in the next few years, especially in the European Union. Most lead-free replacement formulations are likely to be more expensive than lead-based versions, especially if weathering and light fastness properties are needed. However where the expected life of the plastic item is shorter, then lower cost alternatives can be achieved, says Colloids. The company now offers 16 lead-free coloured masterbatches four each for red, orange, green and yellow. All are suitable for food contact in the EU and
Lusin Lub O 32 F acts as both a lubricant and a release agent, and was developed for PET
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LEADING TECHNOLOGIES
Naturally with up to 100 % Reclaim Material and for Direct Food Contact Applications.
Messehinweise etc.
www.gneuss.com
head of global new business development for biodegradable plastics at BASF. The company will also promote a wide range of additives at K2013. For example, it will highlight its Joncryl ADR chain extenders which are used to improve the melt strength of recycled PET. BASF says that their multiple reactive sites can link polyester fragments together to form branched polymers of high molecular weight. For example, Joncryl ADR 4300 increases the tensile strength of recycled PET so that it can be used in packaging straps or high-tenacity bres. BASFs Recyclostab range of additives can also be used to improve the properties of recycled plastics, such as reclaimed LDPE lm. Recycloblend products are used for the recycling of PP/EPDM bumpers, while RecyclosNatpets new thermoforming grade of PP boasts high clarity and aesthetics have heat stabilities above 240C. Colloids has also developed a universal biopolymer masterbatch and a range of polymer specic biopolymer-based masterbatches branded as part of its new Sustain range. The range is fully recyclable and, if mixed with conventional polymers, will not affect mechanical properties. Rowa Masterbatch will demonstrate its Rowalid-LD, which is designed to make plastics cloudy while maintaining transparency. The masterbatch can be used in PMMA, PS or PC and works by diverting the light from its straight path by altering the refractive indices. Test show that Rowalid-LD gives a higher yield of light compared to a conventional light-diffusion masterbatch when used at the same loading and layer thickness. Possible applications include thin lms, injection moulded parts and LED lamps. Rowa says that its masterbatch allows more efcient use of the light, so the same light intensity can be achieved with a smaller number of LEDs. sorb is used in the recycling of HDPE from bottle crates. It increases the weatherability of polyolens, making it possible for recyclates to be used outdoors. In addition, the company has recently been exploring technologies to control the viscosity of polyolen recyclates based on its Irgatec process additive. The viscosity of polypropylene recyclates can vary greatly, and peroxides have traditionally been used to adjust the owability in reactive extrusion. However, BASF says that this presents handling difculties and that Irgatec is safer and simpler to use. Borealis will be exhibiting together with sister polyolen companies Borouge and Nova Chemicals. All are jointly owned by International Petroleum Investment Company, OMV and Abu Dhabi National Oil Company. The K show will also see the company present its newly integrated Borealis Plastomers division, formerly the Dex Plastomers joint venture between Royal Dutch Shell and ExxonMobil Chemical, which Borealis acquired earlier this year. As part of this integration, it has relaunched the Exact family of metallocene plastomers under the Queo name. Applications of the family of ethylene octene copolymers include exible packaging, stretch lm and calendared sheet. Corbion Purac is exhibiting under the theme partnering for bioplastics growth. The company is a leading supplier of lactic acid, the key ingredient for the production of PLA bioplastics. Some of Corbion Puracs PLA production partners will also be present on the stand in the distributors corner. In addition, the companys technical team will be on hand to meet compounders who are interested in learning more about PLA processing. DSM Engineering Plastics says that Akulon XS, its new grade of polyamide 6 for blown lm production, offers signicant processing advantages over previous grades. Its improved crystallisation properties give it an extended processing window, providing new opportuniwww.lmandsheet.com
Resin developments
BASF has developed a multi-layer barrier lm using its Ecovio compostable plastic. By also introducing an injection moulding grade, the company has taken the material into the packaging eld: before, it was largely aimed at waste bags and mulch lm. The two new grades of the material have been used to make compostable plastic capsules for the Swiss Coffee Company. The capsules themselves are contained within the barrier lm, which comprises three layers: an outer paper-based carrier layer; a degradable barrier layer; and an inner layer based on Ecovio. The layers are bound together using BASFs Epotal Eco compostable laminating adhesive. The packaging is designed to satisfy the demanding barrier requirements for coffee packaging with regard to moisture, oxygen and aroma, said Lars Boerger,
18 FILM & SHEET EXTRUSION | October 2013
{ we care }
www.perstorp.com
showcase its new H03TF thermoforming grade at K2013. It combines high clarity and aesthetics with a new level of dimensional stability for thermoformed cups, trays and containers, both in shallow and deep drawn parts and covering a variety of thicknesses. Using Millikens Hyperform HPN-600ei, the material allows converters to run shorter cycle times compared to conventional nucleated PP and increase the number of nished articles by minimising waste. Perstorp will be at K to introduce four new materials, of which three are relevant to lm and sheet extruders. Akestra, a high-performance co-polyester that it is developing and distributing in conjunction with Mitsubishi Gas Chemical. The polymer is pitched as an alternative to polycarbonate, polystyrene and glass, says the company. BASF has developed a multi-layer barrier lm using its Ecovio compostable plastic, moving it into the packaging eld ties to design co-extruded multi-layer as well as monolayer lm, says the company. Polyamide 6 has high barrier properties and mechanical strength, but its high crystallisation rate can limit its processing window. Akulon XS crystallises more slowly in the lm bubble than conventional PA6, matching the crystallisation rate of other material layers, to create a more stable bubble. The lm is also more stretchable, so less force is needed to achieve the same blow-up ratio (BUR). Alternatively, the same force can be used to produce a bubble with a BUR that is 7-10% higher. There are also fewer wrinkles in the at lm, says DSM. It is said to provide clarity, heat resistance and high melt strength, opening up a wide range of design opportunities particularly in the packaging market. The high melt strength of Akestra makes it particularly suitable for extrusion blow moulding as well as extrusion foaming processes. Perstorp will also display its developments in Capa caprolactones which are biodegradable polyesters. It says that they can be used in blends with PLA and starch-based bioplastics to enhance their properties, providing superior biodegradation and easier processing. And Pevalen is a general-purpose, non-phthalate plasticiser, developed for sensitive close-to-consumer applications.It is based on well-proven, reliable chemistry, says Perstorp, which also claims itsperformance is equal to or better than some currently used plasticisers. It is also efcient meaning that formulations require less plasticiser with low migration and volatility, plus high UV stability making it a good choice for applications exposed to sunlight. The company is currently seeking food-contact approval for
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Perstorps Capa caprolactones can be blended with bioplastics to improve their properties
the material. PolyOne will be showing the latest introductions from its Colormatrix division, as well as highlighting its new InVisio colour and design service. Colormatrix will launch its latest FlexCart liquid colour dosing system. Designed to be simple to use and to avoid any risk of spillage, the new version is also claimed to provide enhanced metering accuracy and product recovery of up to 99%, saving costs and wastage. FlexCart systems can be congured with dosing pumps, transfer pumps and colorant packaging to suit a wide variety of applications. The show will also present the rst opportunity for customers to explore PolyOnes recently launched InVisio colour and design service, which provides customers with advice on colour trends, consumer response and available visual effects, plus assistance on achieving the required result through colour selection and integration within the production environment. extrusion performance. Topas 7010F-600 has a glass transition temperature of 110C, putting it between Topas 8007 (80C) and 6013 (140C). It does not require pre-drying and can be run on blown lm systems with or without grooved feed extruders at process temperatures of 230C or above. It can also be processed on thin cast lm lines with low haze over a wide process temperature range. Weve added a new solution for converters and packagers that meets the needs of the market, said Wilfried Hatke, European marketing and sales manager for Topas. The material is typically used in multilayer structures with polyolens and barrier resins such as polyamide (PA) and ethylene vinyl alcohol (EVOH). It is used to produce a range of multilayer packaging lm applications including metallised lm, twist lm, hot ll, and shrink labels in thicknesses up to 100 microns. It can be processed on conventional extrusion equipment, providing transparent, defect-free lm. The material complies with US Food & Drug Administration (FDA) food contact regulations. Total will has added two metallocene-based resins to its Lumicene Supertough range of materials for multilayer lm. One is for exible packaging, while the other is aimed at industrial lm. Lumicene Supertough 32ST05 can help exible packaging converters make lms up to 25% thinner and stronger, it says. The material allows downgauging of multilayer lm structures, helping converters to create stronger lms using less material. Several multilayer applications have already used the material: compression packaging (for applications such as for heavy mattresses and lightweight diapers); deep-freeze and lamination lms; and shrink applications such as for glass bottle unitisation. Carl Van Camp, senior vice president of the polymers division, said: When the limits of downgauging are reached, Supertough 32ST05 steps in to give the necessary boost in toughness to overcome the thick-
Wood alternative
Simona and Resysta International have come up with an alternative to wood-based products, in the form of extruded sheets made of Resysta. The polymer contains an eco-friendly ller based on rice husks, which is made into sheets that look and feel like real wood. In contrast to comparable wood-based products, these moisture-resistant products do not swell when exposed to water. Also, they are UV-resistant and have anti-slip properties when wet. This makes the material suitable for both indoor and outdoor use. Potential areas of application include wall and facade elements, fences, outdoor furniture, interior car linings, sanitary ttings and play equipment, says Simona. Topas Advanced Polymers has developed a new lm extrusion grade of cyclic olen copolymer (COC), which claims a combination of high heat stability and robust Lumicene Supertough 32ST05 could make lms 25% thinner and stronger
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combine one layer of Supertough with the most standard of prime materials and even regrind from post consumer waste in the other layers such that the nal lm has improved performance with the benet of cost savings. Click on the links for more information:
Wackers Vinnex binder system improves the properties and processability of bioplastics
ness barrier. Totals Lumicene grades, of which Supertough 32ST05 is the newest member, boast easy processing plus high mechanical properties and a good balance between stiffness and optics. Lumicene grades cover the full range of low, medium and high densities. The second grade, Supertough 22ST05, is aimed at the industrial lm sector. Its combination of bubble stability, mechanical properties and potential to downgauge by 25% creates new opportunities for wide width lms, which are ideal for agriculture, transportation and protection applications. Its enhanced properties can help customers to improve the performance and cost of their lms. Sonia De Greef, business manager for exible packaging & personal care at Total, said: By boosting product properties, we can generate added value for customers and consumers. This innovation allows converters to
www.addivant.com www.adeka.co.jp/en www.lusin-solutions.com www.clariant.com www.huntsman.com www.imerystalc.com www.krahn.de www.lanxess.com www.milliken.com www.songwon.com www.wacker.com www.akro-plastic.com www.colloids.co.uk www.rowa-group.com www.basf.com www.borealisgroup.com www.corbion.com www.dsmep.com www.grafe.com www.natpetpp.com www.perstorp.com www.perstorp.com www.polyone.com www.simona.de www.topas.com www.total.com
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Ancillaries |
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In a nal round-up of ancillary products that can be seen at K2013, we focus on systems that boost product quality
Static control
UK-based Meech International will showcase its Hyperion static control range and Cyclean series of web cleaners at K2013. Examples include its 971IPS and 929IPS anti-static bars, which were developed in direct response to customer feedback. As a static charge is generated, products made of common plastic materials tend to mis-feed or misbehave, while the opportunity for contamination of the nal product increases dramatically, said David Rogers, director of static control at Meech. The need to control static levels is a fundamental aspect of the production environment. For example, when static is present on a roll of lm it can cause issues during the winding process, even if the charge is initially low, he says. Winding up the material leads to a battery effect, with a huge accumulated charge that can attract large amounts of contamination like dust or swarf. Separate to this, its Cyclean series helps in the production of thermoformed items and plastic bags Materials need to be free of contamination prior to the forming process, otherwise theres a risk that dust might become embedded in the nal product, said
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Adam Battrick, director of cleaning systems. This can be achieved by placing a non-contact cleaner over the web, which is capable of removing contamination to below 1 micron. The non-contact web-cleaners are also useful in the manufacture of plastic bags, as they remove waste particles after the die cutting process.
Surface inspection
Isra Vision, which provides optical in-line inspection systems, will present its latest surface inspection technologies, which nd surface defects on plastic lm. Its Smash surface inspection systems are used in all process steps. The system detects problems with substrates with or without coatings during extrusion. Plastic lms can be examined for defects such as holes, stains or weaknesses that affect their permeability. Special image-analysing algorithms work in real-time, allowing users to nd defects and irregularities on difcult material structures. By applying developed algorithms of the pattern suppression process, defects can be found on structured materials by hiding structural strips so that light and dark defect spots are found. At the same time, its Printstar tool uses a scalable
October 2013 | FILM & SHEET EXTRUSION 27
Gauge control
Addex, a supplier of blown lm equipment and components, has enhanced the capabilities of its automatic external gauge control (EGC) systems for blown lm extrusion lines. The company has spent the last two years overhauling its automatic gauge control hardware and software, using the latest electronic miniaturisation and distributed controls. New software functions deliver greater process exibility, enabling easy retrots of existing or new systems to reduce thickness variation, increase yields, and save raw materials. Weve added features that customers could only dream about until now, said Rick von Kraus, Atlas will launch an upgraded version of its Titan SR9 slitter rewinder number of cameras to ensure correct print jobs. Using the golden master principle, every repeat of the production run is inspected. This can be extended to inspect additional applications such as coatings and front and back side print inspection. president of Addex. Various functionalities have been placed directly inside each component, enabling easy retrots. All communication is handled via an industry-standard Ethernet TCP-IP Modbus connection. No matter who manufactures the rest of the extrusion line whether a new or old line we make automatic gauge control (AGC) highly exible and easy to accomplish, said von Kraus. Among the new AGC functionalities are Addex Mapper, a device that accepts most thickness proler system proles. It automatically takes into account all the twists, turns, and undulations of the bubble to create a fully mapped thickness prole with better than 1 degree accuracy. It even continues to allow proler information to be properly mapped during oscillating haul-off reversals. The company has also introduced the ALF (All Layat) capacitive sensor module, which allows for direct collapsing frame measurement of thickness to the Mapper using already available oscillating haul-off motion for highly accurate proling. Up to two ALFs can be added, one on each side of the collapsing frame for
Finding contaminants
Sikora has developed the Purity Scanner, to detect microscopic contamination in polymer pellets. Applications such as medical products demand high purity material. Detecting contaminants in the pellet or granulate ensures that they do not make it into the nal part. Purity Scanner combines X-ray and optical systems to detect impurities as small as 50 microns, whether they are on the surface of the pellet or within it. The ability to inspect non-transparent material is a key feature of the device. It is vitally important to detect impurities of 50 microns, said Siegmar Lampe, head of research and development at Sikora. Purity of raw materials is crucial. All contamination is a potential risk for the quality of intermediates and Meechs Cyclean web cleaner is particularly useful in the thermoforming process end products. Sikora says it is the rst system that can check coloured pellets for impurities, thanks to its X-ray technology. As well as having a unique method of measuring, the Purity Scanner has a novel way of transporting pellets via a vibrating ramp rather than a conveyor belt. A conveyor belt itself can create contamination, said Lampe. Furthermore, the material in the scanner does not come into contact with ambient air. During the inspection, the pellets are in a hermetically sealed channel, to guarantee purity. The device has a throughput of 500kg/h, but this can be increased by grouping devices together.
28 FILM & SHEET EXTRUSION | October 2013
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Polymer Plants
Drying Plants
Recycling Plants
Equipment
Addex has enhanced the capabilities of its external gauge control (EGC) systems for blown lm
faster response. For faster control, processors can add the Proler Module. This adds a separate proling ring, allowing all sensor technologies to be scanned automatically around the bubble. The results feed to the Mapper and then to the EGC for total system control.
heat due to the absence of infrared radiation, avoiding deformation and tolerance problems as well as the expense incurred by the cooling system needed for UV curing, says Comexi. Meanwhile, Atlas Converting Equipment will launch upgraded versions of its Atlas CW Series and Titan SR9 Series slitter rewinder technologies. It recently introduced its CW5000 Series, which is available in widths of 3600-5400mm. Last year, it introduced its CW3600 and CW1040 series. The range now covers widths of 2500-10,400mm at speeds up to 1500m/min. Benets of the new technology include greater efciency, productivity and reliability, as well as higher quality rewind reels and less noise. Atlas says that the CW Series has faster acceleration and deceleration cycles, claiming that, at 1200m/min, it has a faster rewind cycle than a conventional primary lm slitter running at 1500m/min. At the same time, its latest generation Titan SR9 Series secondary slitter rewinders have new features including reduced power consumption and faster set-up time. And nally Atlas Material Testing Technology (no connection with the previous Atlas) will show a number of its testing instruments at the show. These include the UVTest Fluorescent UV Device, which claims design features that improve test reproducibility and cut operating costs while testing various materials for their reaction to UV, temperature and moisture. Features include a touch screen supporting many languages, patented calibration safety ports, stackability, and pre-programmed tests for error-free operation. At the same time, its Ci4000 Weather-Ometer features a new user interface, plus enhancements including: WXView (WeatherView) data acquisition software; LS-200, a full-spectrum monitoring device; and E-mail notication, which advises the operator when tests are completed. Click on the links for more information:
Solventless printing
There are concerns other than quality and one of the most pressing is the need to improve environmental performance. To this end, Comexi will exhibit its solventless printing platform at K2013. In addition to inks, adhesives and laminates, it will show its Flexo F2 WB (water-based) press. It has adapted the press to use water-based inks, so that exible packaging can be printed more sustainably and efciently without losing quality or speed. It has a high-ow drying system dedicated to drying white as a rst colour background, using dehumidied air. The drying capacity between colours has been increased by a 50%. It will also showcase its Offset CI8 at the stand, demonstrating that central impression offset technology can be used with exible materials to reduce costs, time to market and high production speeds. As regards sustainability and efciency, a key feature of the system is electron beam curing. This process is applied with inks made with a liquid mix of monomers and oligomers, supplemented with pigments and other Simco-Ion will launch 10 new products for controlling static electricity additives. In contrast to UV-cured inks, EB-cured inks contain no photo-initiators, which prevents the risk of migration making the process perfectly suitable for food-grade packaging. Systems incorporating EB curing produce much less
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Tool developers have been busy developing new dies that deliver everything from higher production speeds to improved coextruded lm
Adapting the Moebius manifold, coupled with Cloerens two-stage preland, provides an optimised distribution of the polymer across the functional die width. The new version of Nordson EDIs Contour die has an internal deckle, so incurs no downtime during changes in product width
Barrier lm
Macro Engineering & Technology of Canada will introduce its latest coextrusion die, for extruding high barrier multilayer lms. The Flatpack die, for coextruding barrier lms up to 11 layers, can be used to produce structures using any barrier material including nylon, EVOH, PETG and PVdC. Its optimised design, which features round ow channels throughout, streamlines the ow of polymer to shorten residence time, which virtually eliminates interfacial instability making it more suitable for a wider range of lm structures, says Macro. The die also features shortened purging times, allowing processors to perform faster product changeovers with reduced scrap generation. Our objective is to provide more versatile extrusion dies to exible lm producers dies that allow users to manufacture a broader range of products while being more reliable and with less downtime, said Jim Stobie,
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CEO at Macro. A 9-layer Flatpack conguration cuts residence time by up to 30% and shortens purging time by 20%, says the company. It also gives processors the exibility to adjust lm structure by swapping layers, such as reconguring an ABCDE structure to ACDBE. The die boasts a short height and is available up to 760mm die diameter.
advantages while saving up to two days of downtime for width changes because it incorporates an internal deckle for making changes in product width. The Contour die can pay for itself in less than a year by virtue of the resin savings made possible by precision control over the gauge prole, said Sam Iuliano, chief technologist at Nordson EDI. Nor do these savings take into account the enhanced productivity resulting from increased yields of saleable lm and reductions in scrap. Meanwhile, Hosokawa Alpine will show its Alpine X die heads, which can be used to make ve-layer lm that is 5-10% thinner than conventional three-layer lm. During K2013, it will demonstrate the production of a variety of ve-layer structures. It will also demonstrate its Trio thickness control system for oriented blown lm. The system corrects for the fact that, during the orientation process, lm is constricted in the transverse direction and its width is reduced. This means that the thickness of the oriented lm increases gradually from the centre towards both edges. Trio reduces the thickness variation on the edges of the lm and balances the thickness prole of the reel to improve atness. At K2013, it will run a live demonstration of the system. Click on the links for more information:
New generation
Nordson Extrusion Dies Industries has developed a new generation of its Contour cast lm die. The new design incorporates an internal deckle, allowing extruders to balance speed and precision without incurring downtime for changing product width. The company claims two major advantages of the Contour die over traditional dies with coathanger manifolds: less time is needed to achieve on-spec product and to purge between product runs; and there is up to 25% improvement in cross-directional product uniformity, as well as a reduction in gel formation. The latest version retains these
15 October 2013: Cologne, Germany 30 October 2013: Philadelphia, USA 9 December 2013: Dubai, UAE
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Whether its heavily soiled agricultural lm or printed exible packaging, theres a way to clean up the plastic and make it easier to recycle. Lou Reade reports
of coarse debris, a belt conveyor feeds the material into the Power Universo 2800 a slow-running, single-shaft shredder with a throughput capacity of 3-8 tonnes/hour depending on the type of lm being processed. The machines point blade rotor, around 2,800mm long, is driven by two 132kW electric motors. At a stepless variable operating speed of around 100rpm, the rotor carrying 86 knives draws in the lm pieces effectively, uniformly and with low dust release. Interchangeable screens with 50 to 100mm hole diameters adapt the shredder to each specic lm
October 2013 | FILM & SHEET EXTRUSION 37
Amuts DLB de-labeller system removes shrink sleeve labels from postconsumer PET bottles
Our standard portfolio ranges from LDPE through LLDPE to customer-specic blends, said Sciascia. This makes us the only recycler capable of offering high-quality LLDPE from washed agricultural stretch lms for lm blowing applications.
Re-engineered lm
A recycling line designed by ADG Solutions has helped the engineered lms division of Raven Industries to recover polymer and re-pelletise it for immediate use. Sandy Guthrie, president of ADG Solutions, specied a Polycycle cascade reclaim system and Epic III process control system from Davis-Standard. ADG supplied the shredding/conveying system, automatic screen changer, and pellet handling system. This line achieves a closed-loop recycling stream for our facility by reclaiming excess production material A Lindner Power Universo 2800 pre-shredder forms the rst part of Soreplastics lm recycling line charge. At the end of the pre-shredding step, shreds measuring 50-100 mm are obtained. Harald Hoffmann, managing director of Lindner Resource, said: The system uses a belt-type power transmission. Its countershaft drive carries a large safety clutch (slip clutch) which limits the maximum torque input and makes the shredder insensitive to coarse foreign matter. This is important because the lms processed by Soreplastic may contain metal parts, which will nd their way into the shredder. The inspection and maintenance hatch can be hydraulically opened inwards, giving spacious access to the rotor area. This allows convenient turning or replacing of the knives each of which has four cutting edges, or any of the eight counter-knife segments. Foreign debris is easily removed this way. The screen basket can be opened hydraulically in order to clean or change screen modules quickly. All this means short downtimes in day-to-day operation, says the company. The shredded lm passes through a washing system followed by wet grinding and drying, reducing it to 20-30mm in size. It is then ready to enter the Erema 1716 TVEplus recycling extrusion line which, thanks to special degassing technology, can provide optimum melting, ltration and homogenisation of the washed stock despite its high initial moisture. Ultimately, the material is pelletised by an Erema HG 244 D type die-face pelletising unit featuring a special cutting geometry and automatic air-pressurisation of the pelletising knife for maximum longevity. The overall system delivers an output capacity of around 1,400kg/hr at a typical batch size of 2,500kg. The plant has run since November 2011. It gives Soreplastic the capacity to recycle around 20,000 tonnes of input material per year.
38 FILM & SHEET EXTRUSION | October 2013
in a process that is fully controlled from start to nish, said Anthony Schmidt, vice president and general manager for Ravens engineered lms division. It is a critical step in implementing our sustainability initiatives by reducing product waste and municipal landll consumption. Until now, Ravens multi-layer PE lm which is used for agricultural, construction, environmental, and other heavy-duty uses has been too difcult for the company to reclaim because of the polyester bre reinforcement built into the product to enhance strength and wind resistance. The excess internal material from start-ups, job changes, or edge trim was either sent to a reclaim specialist (for a fee) or went to landll. The new system allows Raven to reprocess up to 15 million lbs (6,800 tonnes) per year, says the company. At the start of the line, shredded scrap is fed into a Davis-Standard ram stuffer extruder, which compensates for bulk density variations. Then, the contaminated polymer passes through a self-cleaning screenchanger from Italian rm Fimic SAS which is designed to lter out contaminant without causing extruder downtime or requiring operator intervention. As molten polymer enters the screenchanger, contaminant accumulates on the screen plate until back pressure reaches a preset level. At this point, a rotating blade sweeps the screen and purges the contaminant through a central discharge port. After this, a melt pump delivers the ltered material through transfer piping into a showerhead die, which produces thick strands that drop into the feed throat of a Davis-Standard hot melt extruder with devolatilising chamber. (Feed additives can be added to the material at this stage.) Finally, after passing through a hydraulic screenchanger, the molten polymer enters an underwater pelletiser. The material is cooled from 160-180F
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different types of plastic ake. The sorting process consists in collecting the akes at different heights. In one step the process eliminates contaminants, such as wood or foam, and we get separate streams for polypropylene, polyethylene, PET, and polystyrene, at a cost below E100 per tonne, said Peter Rem, a researcher in resources and recycling at the Technical University of Delft in the Netherlands, and a member of the project. He says the technique is precise enough to separate plastics whose densities differ by 0.1%. Project partner Redox Recycling Technology in the Netherlands is operating a prototype magnetic separator that can handle 200kg of plastic waste per hour. Dutch recycling company Van Vliet Utrecht has also completed an experimental magnetic density sorter for heavy polymers with a capacity of 400kg/hour of plastic waste. Material in the Raven Industries line starts with the red shredder (far right), moves through a Davis-Standard ram stuffer extruder (centre) and onto pellet loading (left) to 80-85F, moisture is removed, nes are ltered out, and pellets are classied by size to ensure no over- or under-sizing. The end product is pellets that are fully conditioned, said Guthrie. They can be conveyed into gaylords or supersacks for immediate use, or sent for storage in silos. Rem says there are reasons why such a new technology is not guaranteed wide adoption: polymer manufacturers are not involved in the recycling of their products unlike in the steel industry and view recycling as conicting with their own interests, said Rem. As a consequence, he added, technical information about them is lacking. The manufacturers also engineer the polymers in such a way that they cant be easily recycled, said Rem. The wide variety of plastics creates another obstacle to recycling. A polymer that has to be extruded is entirely different from a polymer used for blow-moulding bottles, he said. It is difcult to separate these different types of plastic from waste, so that they can be recycled easily into a new product. Jean-Marc Saiter, a researcher in dense matter and materials at the University of Rouen, in France, wonders whether the cost of recycling technology can be justied for polyolens. They are not toxic, so why would we recycle them? he said. The recycling process itself is not green, and
Magnetic attraction
Researchers in a pan-European project, called W2Plastics, have developed a way to separate different types of plastic by their specic weight, or density in a single step. The technique, called magnetic density sorting, consists of passing plastic waste through a tank with a suspension of nanometre-scale iron oxide particles, placed on top of a magnet. By attracting the iron oxide particles, the magnet articially increases the density of
the liquid so it is highest at the bottom of the container, and lowest at the top. As the plastic, mixed in the iron oxide suspension, ows through the tank, it separates into different layers that match the densities of the
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TRENDSETTERS
5 layer polyolefin-dedicated (POD) technology was introduced by Macchi in 2001 to foster film production economies and quality enhancement by expanding the product design option. Today that break-through concept is still well alive. Together with the synergistic developments made possible by the new resins offering unprecedented possibilities of downgauging, output rates and product performances for new business opportunities across the flexible packaging value chain.
17C20 Hall 17
MACCHI SPA Via Papa Paolo VI, 5 - Venegono Inferiore - Va - Italy Tel +39 0331 827717 - macchi@macchi.it www.macchi.it
The panEuropean W2Plastics project separates different plastics using magnetic density sorting
recycling uses energy and transport, making it expensive. But he believes that the magnetic separation technique is worth developing, especially for potential applications in the future. What is expensive today can be economic tomorrow, he said.
Ink removal
Spanish researchers have developed a process to remove printed ink from used exible packaging. This new technology, developed and patented by the Waste, Pyrolysis and Combustion Research Group at the University of Alicante, uses a physical-chemical treatment to remove the ink to leave clean plastic lm which increases its recycled value. The pigments can be separated and used for other applications. Printing ink often prevents exible packaging from being recycled, as it decreases the viscosity of the plastic which creates problems when the recovered material needs to be re-extruded. The most important advantages of removing ink are: increasing the value of engineered plastic to match the quality of the new plastic with a virgin one; and increasing the selling price of recycled plastic compared to virgin plastic, said Andrs Fullana Font, a lecturer of the universitys department of chemical engineering, and a member of the research group. During the process, no organic solvents are used to remove the ink. The cleaning solution can also be re-used, making it more economic and sustainable. We obtain a higher quality recycled material than print materials made up from production losses, Fullana added. There is currently no industrial method to dispose of printed ink for these wastes: usually, they are recycled without any treatment and used in applications with low added value. The technology has been tested in a pilot plant on different printed forms of polyethylene, polypropylene, polyester and polyamide, and has been proved effective for both solvent-based and water-based inks. It can also be used in sectors such as plastic recycling, graphic printing and packaging.
Label removal
Amut has developed its DLB de-labeller system, to remove shrink sleeve labels from post-consumer PET bottles. The sleeves, which are usually made from PVC or PETG, cover the whole bottle and are liable to pollute the PET recycling stream if bottles are simply shredded with the labels intact. The DLB system is a continuous process that aims to overcome this problem. Amut says that the shape of the elements that generate the tearing force to remove the labels helps to ensure a fast process. It claims an 80% removal efciency, and removes the labels dry. According to Amut, other delabellers on the market remove labels very quickly, using a rotor running at very high speed. However, this can lead to broken bottlenecks which are then removed along with the waste material. The high speed rotor also leads to excessive wear on components, and hence more maintenance. Amuts DLB overcomes this by using easy-to-replace
42
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It takes sophisticated technology to make plastics recycling sustainable and more efficient and to continuously improve pellet quality. And it takes commitment to really be successful. SIMPLY ONE STEP AHEAD
Visit us! K2013, Dsseldorf, Oct. 16 23, 2013 Hall 9, Booth D05
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NCF supertangential granulators from Conair have a smaller footprint than comparable granulators
on the larger models is 400rpm, although 260, 400 or 840rpm can be specied on any of the granulators to increase capacity, improve regrind quality and minimise energy consumption. A tilt-back hopper and drop-down screen cradle provide easy access to the cutting chamber for maintenance and cleaning. These contribute to increased productivity and reduced downtime. An optional sound attenuation package makes the NCF series quieter than other small granulators, says Conair. The super-tangential chamber design ensures that the rotor grips bulky scrap on the downward stroke, drawing it into the knives and preventing it from bouncing on the rotor. Standard tangential and straightdrop in-feed congurations are also available. The rotor itself can be open with three rows of double-angled knives for a clean scissors cut with minimum heat generation. For tougher materials, a solid rotor can be equipped with three rows of up to ve cassette knives in a staggered array. Cassette knives allow for quick and easy knife changes and reduce downtime for service and maintenance. The knives require no adjusting to maintain a consistent knife gap for improved quality. cutting elements that are bolted in place, rather than being welded. The special design of the cutting elements also allows blades to be used on four sides prior to sharpening, says the company. At the end of the process, labels are collected from a hopper underneath the machine, then extracted by conveyor belt to a compacting press. Amut offers three sizes of delabeller. DLB 60 and DLB 30, for high ow rates, are suitable for treating bottles from the very start of the washing line; DLB 10 works downstream and is suitable for treating rejected bottles from the main sorter. Starlinger is to launch a system to recycle highly contaminated post-consumer and post-industrial plastic waste such as agricultural lm and heavily printed material. The technology, which will be seen at K2013, also features excellent compounding capability for upgrading the nal product. During the exhibition, a Recostar Universal 65 Vac will process highly printed PE lm, to show the melt degassing and cleansing capability. The company will also premiere its new Decon reactor. A Viscostar reactor will be set up in hall 16, where a video wall will also show the recently launched Viscosheet PET sheet line, which can process up to 100% recycled PET, virgin PET, and post-industrial regrind at guaranteed IV levels, meeting FDA/EFSA levels for food-grade applications. Click on the links for more information:
Small footprint
Conair says that its NCF super-tangential granulators have a footprint at least 30% smaller than many other granulators with similar capabilities. The cutting chamber conguration is ideal for handling lightweight bulky parts, but also produces clean uniform granulate from smaller parts. Different hopper designs and rotor/ knife choices are available to maximise performance with a wide variety of scrap types. Four different models feature 8in (203mm) diameter rotors, in widths of 10, 14, 19 and 24in (240, 360, 480 and 600mm), and deliver standard maximum throughputs of 150-450lb (68-205kg). The smallest unit is powered by a 5hp motor and the three larger sizes have 7.5hp motors with options to 15hp. Standard rotor speed for the NCF 810 is 260rpm and standard speed
44 FILM & SHEET EXTRUSION | October 2013
S www.lindner-resource.com S www.erema.at S www.adgs.net S www.ravenind.com S www.davis-standard.com S www.innovationseeds.eu S www.ruvid.org S www.amut.it S www.conairgroup.com S www.starlinger.com S www.plasticsconverters.eu
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AMIs Directory
New 2013
AMIs Directory
Injection moulders
3E SP. Z O.O.
Type: Custom, Proprietary Products Polymers processed: PS, ABS, LDPE, HDPE, PP, PMMA, PC, ASA. Polymer throughput: Less than 50 tonnes Markets served: Automotive, Electrical, Alarm Cases. Services offered: Pad Printing, Silk Screen Printing Number of machines: 4 Minimum lock: 120 Maximum lock: 268 Minimum shot: 5 Maximum shot: 600
ACE LUXE
Type: Custom, Proprietary Products Polymers processed: ABS, PC, Elastomers. Polymer throughput: Between 1001 - 1500 tonnes Markets served: Telectron Services offered: Assembly Number of machines: 13 Minimum lock: 270 Maximum lock: 850 Maximum shot: 2500
3E SP. Z O.O.
ul. Okr na 1B 19-300 E k Tel: 087 620 1630 Fax: 087 620 1630 E-mail: a.sznelinska@3E.net.pl Website: www.3E.net.pl Contact: Mr. Z. Ho dyk, Plant Manager Parent company: Privately Owned Processes operated: Injection moulding
Type: Custom Polymers processed: PS, LDPE, PP Polymer throughput: Less than 50 tonnes Markets served: Household, Clothes Hangers. Services offered: Hot Foil Stamping Number of machines: 10 Maximum lock: 20 Minimum shot: 30 Maximum shot: 200
Type: Custom, Proprietary Products Polymers processed: PS, ABS, PP, PA, PC, PET Polymer throughput: Between 101 - 250 tonnes Markets served: Electrical, Electrical Connectors Services offered: Assembly Number of machines: 11 Minimum lock: 60 Maximum lock: 160 Maximum shot: 200
197
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Over the past decade polymer consumption has grown on average by 4% per year in Poland Make sure you know all about this dynamic industry
Companies included: Injection moulders Blow moulders Rotational moulders PE lm extruders Sheet extruders Cable extruders Pipe extruders Prole extruders Tube and hose extruders Compounders and masterbatch producers
6th edition
AMIs Directory
For more information contact us on sales@amiplastics.com or Tel: +44 (0) 117 9249442
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The production of rigid lm and sheet is a business worth 12 billion with 65% of it in the hands of just 50 groups. A new report from AMI reveals the business strategy of these fty leading players along with an overview of the thermoplastic sheet market in Europe.
7.2%
Location
Benelux 7.7%
Country
Piesendorf
Other W Europe 9.4%
Austria
In 1999 Senoplast Klepsch & Co. GmbH opened a plant in Queretaro, Mexico, producing ABS, PS, ABS/PMMA sheets. This location a quicker and more efficient service Spain and Italy have also seen a large number ofand plant closures since 2008 because of allows the customers in the NAFTA area. into the growing economic downturn. As the major food for companies and retailers expand markets of Central and Eastern Europe, so the leading European players are often required to follow these customers, setting up greenfield sites or taking over existing operators. As a Product offering result the Central European markets are of growing importance. Several of the leading companies now operate within Central Europe, some moving into Russia. The with senosan also range of specialised sheets are coextruded PS/PS, ABS/PC, ABS/ABS,
ABS/PMMA and ABS/ASA for a variety of industrial applications including automotive industry, refrigerators manufacturing, displays, ID cards, sanitary applications and furniture. The company also produces PS sheets for vehicles, sports equipment, playgrounds and other applications as well as PS and foils. The sheet sector has several major players using over 100,000 tonnes of PC resin/year. The largest is Klckner Pentaplast, a leading supplier of rigid PVC films. Klckner manufactures for a range of markets, although packaging applications food and non-food, remain its Other activities in both plastics major outlet. The group were bought by the private equity firm The Blackstone Group in 2007 and since then there has been some Senoplast restructuring and modernisation Klepsch & Co. GmbHof isits a companies, member of the Klepsch Group. Together with the with a more expansion strategy since 2010 with moulding the acquisition of MAG Group's injection company Seletec PlasticNovopac Products GmbH & Co. KG, Zell-Metall GmbH which extrudes plastic stock shapes under the trade name zellamid and the PVC and PVC/PE sheet business in France, the PP andengineering PS mono- and multi-layer rigid film Senova Group, a distribution company, the companies activities of AMB in Italy and the unprinted PET monoand multi-layer rigid films business of offer an overall competence in plastic their 2012, customers worldwide. Bemis Packaging Deutschland GmbH. Into June the group was acquired by a group of
investors led by Strategic Value Partners LLC. Bilcare Solutions, part of the Indian-based Bilcare Group, is the other leading PVC rigid film and sheet producer in Europe. The former Ineos Films business was acquired by Bilcare in 2010. The deal included Ineos' film operations in North America, Europe and Asia (PVC, PVC/PE and PET). Paccor International GmbH (owned by Sun Capital Partners, Inc, USA) is now Europes leading manufacturer of thermoformed polystyrene packaging. It was created by the acquisition and full-scale integration of Huhtamaki's consumer packaging goods, Veriplast Rigid and Pannunion in 2011 and although only recently formed, the individual units have
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Clear advantage
Polycarbonate sheet is know for its toughness, and its applications range from railway carriages to football stadiums. Lou Reade reports
The combination of toughness and high clarity makes polycarbonate a unique material, helping it to corner the market in applications like glazing. In addition, its high ame retardancy means it can be used in challenging applications like rail interiors. UK-based Brett Martin will launch a number of new sheet products at K2013, including several that help to improve climate control. Its Marlon CS Opal Diffuser is a corrugated polycarbonate (PC) sheet that offers advanced solar control and enhances UV resilience in hotter climates. It is the latest addition to the companys Marlon CS range. At the same time its Marlon ST Blue a transparent, multi-wall PC sheet contains Cool Light technology, which blocks near-infrared solar energy to reduce heat build-up by as much as 7C. This new product joins a range that already includes thicknesses of 4-55mm in a range of structures and special options. Other PC-based offerings in the Marlon range include: Marlon FS, which is designed with safety and impact resistance in mind; and Marlon Clickx, a complete architectural glazing system providing quality natural light, insulation and UV protection. In addition to PC, the company will showcase its latest PETG product: Marpet-g FS claims to offer ease of workability in print and display applications. The lightweight, durable, clear substrate with high optical clarity and light transmission properties, is currently available in thicknesses of 2-6mm. It also offers two types of PVC either foamed or unfoamed. Its foamed sheet, Foamalux, is commonly used in sign, display and print applications. The
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company recently extended its Foamalux Colour range to 15 options with the addition of Neon Pink, Neon Green, Raspberry and Black Sparkle. Meanwhile, its Marvec PVC is a weather-resistant, durable material for roong, glazing and cladding that is available in corrugated, at sheet and roll formats. Visitors to K2013 will see a number of options: Marvec CS, a roong grade with UV, chemical and re resistance; Marvec CS agri, a chemically resistant and durable covering for agricultural buildings; Marvec FS, a at sheet in clear and white options, suitable for glazing, cladding and DIY; and Marvec FS bio, a hygienic cladding that helps to stop bacterial growth, and kills bacteria. Laurence Martin, managing director of Brett Martin, said: Our product range provides design exibility in applications like glazing, roong and cladding, right through to secondary fabrication and quality graphics solutions for the print and display sector.
Brett Martins Marlon ST Blue is a transparent, multi-wall PC sheet that blocks nearinfrared solar energy to reduce heat build-up
Track record
Visitors to the recent American Public Transportation Association (Apta) annual meeting in the US saw details of how polycarbonate sheet has been used to improve safety and comfort on the railway. Bayblend MTR (mass transit rail) and Makrolon TG polycarbonate sheet from Bayer MaterialScience were both developed specically to meet performance and cost challenges in the passenger rail car industry. The company showcased a prole section of a passenger rail car made from Bayblend MTR. The material complies with the latest recommended levels for low ame, smoke and toxicity (FST), for
October 2013 | FILM & SHEET EXTRUSION 47
POLYMER F O A M 2013
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example. These regulations include US Federal Railroad Administration (FRA) DOT: 49 CFR 238, Appendix B ammability and smoke emissions requirements. The materials also satisfy Bombardier Transportation Standard SMP 800-C for Toxic Gas Generation, says the company. The Bayblend MTR product line, available in a range of colours and textures, has high rigidity, strength and impact resistance. It claims to be up to 30% lighter than traditional products and can be easily fabricated. When Makrolon TG polycarbonate sheet is used in rail glazing, it meets stringent FRA requirements for impact and ballistic performance. It is abrasion, chemical and UV resistant, half the weight of glass, and can be manufactured in clear and custom tints. Celeste Dunn, transportation segment manager at Bayer MaterialScience, said: Bayblend MTR can yield substantial energy savings in use, compared with other products. It weighs signicantly less than PVC-based, low FST sheet and bre-reinforced polycarbonate. Its high strength, compared with PVC-based products, allows for designs with thinner parts without compromising durability. Bayblend MTR polycarbonate thermoforms easily on tooling that is often used with other sheet materials to form passenger car interior components. It draws easily into corners, and maintains retention of design detail, adding to the materials cost effectiveness. The BBVA Compass stadium in Houston, Texas is the rst in the US to use Thermoclick sheet from Sabic
Orange revolution
A new football stadium in Houston, Texas makes use of Lexan Thermoclick polycarbonate sheet from Sabic. The BBVA Compass stadium, home of Houston
Plastics Packaging Producers - 4th edition Amongst the leading groups included:
Amcor Alpla-Werke Sealed Air Aptar Group LINPAC RPC Constantia Klckner Pentaplast and more...
4th Edition
A N
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A M I
Europe
All plastics packaging plants operated in Europe, including their polymer throughput Financial results in plastics packaging
This report provides very useful benchmark information for your own business to allow you to see how you compare with Europes best.
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Applied Market Information publishes over 50 different reports and databases covering thermoplastics markets globally. The range of publications aim to provide complete listings of plants carrying out particular plastics processing operations and to give an analysis of the leading groups. AMI also produces authoritative industry reports which provide cost effective statistical data and analysis on polymer trends. For more information go to our website or contact Rgine Futter or Elizabeth Carroll on sales@amiplastics.com or Tel: +44 (0) 117 9249442.
Dynamo, is the rst US stadium to use Thermoclick sheet for its enclosed entrance faade which was supplied in vibrant orange to match the teams colours. The materials nine-wall conguration helps to boost thermal insulation, while the 1,000mm width twice that of traditional panels reduced installation time and labour costs. This latest expansion in Lexan sheet has been chosen to create large and dramatic architectural glazing, roong and faades in stadiums and arenas around the world, said Sandeep Dhawan, general manager in the Americas for the speciality lm and sheet at Sabic Innovative Plastics. Lightweight, versatile Lexan Thermoclick sheets perform beautifully in a range of climates and conditions, to improve energy conservation in large structures like stadiums. The 50mm thick sheet provides high impact resistance, ultraviolet (UV) protection on the outer surface (for weatherability) and good light transmission. It has a U-value of 0.176Btu/ht2 Fahrenheit (1.0W/m2K) for thermal insulation, leading to energy savings by reducing energy consumption by up to 17% in comparison with traditional double glazing, says Sabic.
Sheet acquisition
Rowmark, a US-based manufacturer of extruded plastic sheet for engraving and speciality applications, has been bought by private equity company Bertram Capital. Rowmark has two product divisions: Engraving Products and Premier Material Concepts (PMC). The Engraving Products division produces engravable sheet, which is sold through an international network of distributors in more than 80 countries. PMC provides engineered custom extruded sheet and roll stock for speciality thermoforming applications for a number of end markets. We believe Rowmark is uniquely positioned for signicant growth opportunities, through both organic initiatives and add-on acquisitions, said Jeff Drazan, managing partner of Bertram Capital. Rowmark, founded in 1987, is based in Findlay, Ohio. Click on the links for more information:
www.kreyenborg-bkg.com
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Material and machinery advances help to improve the performance of BOPP, while India moves to the fore as a new player on the scene. Lou Reade reports
machines as monoweb and in laminates. The lms can be used in most areas of food packaging, including dry products like biscuits and nuts, and as lidding and ow wrap for meat, poultry and cheese. They are ideally suited for secondary packaging in medical applications.
BOPP producer Treofan has called off its takeover of Max Speciality Films
Pilot line
On the machine side, Brckner has developed a pilot line to improve barrier properties for both simultaneous and sequentially produced BOPP ultra-high barrier (UHB) lms. The added value chain for exible food packaging is
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permanently striving to improve its packaging materials in many different aspects such as functionality, sustainability, convenience and very important gas barrier properties against moisture and oxygen, said Martin Wolf, laboratory manager at Brckner Maschinenbau, in a recent paper. A typical ve-layer UHB-barrier lm comprises: a high surface energy (HSE) polymer; an adhesive layer; a PP core layer or PP blends; a further PP/PP blend layer; and a PP co-polymer. There is also a metallised/ glass surface, if this is a metallised lm. Metallised simultaneous UHB BOPP barrier lms can be used as a possible aluminium foil replacement. Typical barrier values for the simultaneous stretching mode with high surface energy polymer 1 (HSE 1) and a PP-copolymer based tie-layer material are an oxygen transmission rate (OTR) of 0.080cm/m d bar and water vapour transmission rate (WVTR) of 0.075g/m d. By choosing a modied HSE polymer and a PPhomopolymer based tie-layer material, sequential UHB BOPP barrier lms can also be produced on the pilot line. Reasonable MDO stretching ratios of up to 4.5 have been obtained. Typical barrier values of metallised
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sequential UHB BOPP barrier lms are an OTR of 0.071cm/m d bar and WVTR of 0.280g/m d. The simultaneous metallised lm shows a far superior WVTR barrier, due presumably to different raw materials and processing conditions, says Wolf. But this can be improved further by adding low molecular weight PO additives (LMW-PO). While it has little effect on OTR, the WVTR can be improved to 0.043g/m d. For transparent UHB BOPP lms, SiOx vacuum coatings were applied to simultaneously oriented HSE base lm, giving barrier values similar to the metallised UHB lms. (OTR was 0.2cm/m d bar and WVTR was 0.3g/m d.) We also tested transparent AlOx vacuum glass coatings, applied with different new systems and treatments, on simultaneously produced HSE base lms, said Wolf. Although the barrier performance was generally lower, the AlOx processes are interesting due to high coating speeds which are comparable to standard metallisation processes at much lower production costs in comparison to SiOx coatings. Click on the links for more information:
ANDRITZ Biax supplies complete sequential and simultaneous stretching lines, also on turnkey base, for the production of all types of biaxially oriented films. Whether your goal is highspeed commodity film production, or the production of high-value technical films, we have proven solutions. Visit our ANDRITZ Biax experts at K 2013, hall 3, booth C17.
ANDRITZ (China) LTD. Foshan, Guangdong, P.R. China Phone: +86 (757) 8296 9222
ANDRITZ Biax S.A.S. Le Bourget du Lac, France Phone: +33 (479) 268 560
biax@andritz.com www.andritz.com
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AMI has just published a new report on the plastic market in the Indian subcontinent. Its author Alex Brownbridge provides an overview of key trends
Reduction of regulation
It has only been in the last decade or so that Indian polymer demand has begun to ourish, albeit from a low base. Polymer consumption in 2013 will be over 80% larger than it was in 2007. Whilst the economy has been a signicant driver in such growth, polymer demand has been growing at 2% per year faster than GDP as thermoplastics increased penetration in many applications. The development of the plastics industry has been underpinned by a process of deregulation and the abolition of numerous quota and production licences and the gradual removal of most plastics products from the items reserved for Small Scale Industries (SSI), which previously limited the scope of foreign investment. SSI had only served to hold back the development and growth of plastics processing and created a very fragmented and unsophisticated plastics processing industry. Its relaxation has improved both productivity and competition. The reduction in Indias import tariff on polymers to 5% in 2007 also helped to stimulate demand. So too did the build-up in capacity for key commodity polymers such as polypropylene. There are a number of other Indian policy alterations which are likely to increase the rate of polymer growth within the economy including the relaxaOctober 2013 | FILM & SHEET EXTRUSION 59
PS
PVC
PP
the respective plants are due to be commissioned between 2013 and 2016. Indian Oil is the second largest producer and owns tion of the Jute Packaging Act, the Micro Irrigation Scheme and improving foreign direct investment (FDI) conditions in the countrys Special Economic Zones. In 2013 it was announced the Indian government is to construct six plastic parks in Punjab, Haryana, Rajasthan, Uttar Pradesh, Odisha and Andhra Pradesh. The plastic park scheme is to encourage clusters of small- and medium-sized plastic processing companies, as well as recycling organisations, to set up in India. The recent legal relaxation of foreign retailers investing in Indias multi-brand retailers has the potential to westernise the packaging industry. At present only 5% of food is packaged and only 10% of retail is organised. Since 2012, India has allowed foreign retailers to take a 51% stake in multi-brand retailers, provided that investments are larger than US$100 million and retailers source 30% of produce from local small enterprises. There is also regulation that now allows 100% FDI in food processing companies. The Indian automotive industry is already attracting investments from foreign producers that have located production plants in the country to benet from low labour costs over 10% of Indian production, although it only produces PE and PP grades. Financially challenged Haldia owns a further 10% of resin capacity, while the remaining 30% of polymer production is split between 14 substantially smaller producers. In contrast to resin supply, the polymer processing industry is for more fragmented with 75% of Indias processors classied as small-scale operations and commanding just 30% of polymer consumption. These processors are typically very small family-run companies with limited technical capability and nancial resources. Protectionist tendencies of national and regional governments continue to pose a threat to the development of the plastics processing industry. In 2012, for example, India proposed to ban the import of secondhand machinery that was more than ve-years-old in order to protect its indigenous capital goods industry. While on the one hand such a move may encourage investment in newer equipment, the move was generally opposed by organisations such as the Chamber of Industrial and Commercial Undertakings (CICU) as likely to particularly impact on the ability of micro-, small- and medium-sized enterprises (MSMEs) to expand and grow their business as such companies often rely on low-cost second-hand equipment.
and a closer proximity to emerging Asian markets. Foreign producers include Ford and Hyundai whilst domestic manufacturers are Mahindra and Tata Group. Foreign investment and increased production has aided penetration of polymers in various automotive applications. For example, in 2011 Maruti Suzuki introduced a new fuel efcient model that incorporated a plastic fuel tank. HDPE fuel tanks are standardised in western
PHOTO: PA WANJI SP IC
60
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140mm Berstorff ZE130A 40D corotating twin screw compounding line,300rpm screws,500Kw motor W&P UG200 face cutter,centrifugal dryer & pumps.
1040mm wide Welex sheet extrusion line: 90mm Welex extruder with gear pump, die head, 1040mm wide Welex 3 roll polishing stack, haul off and winder.
100mm Union single screw extruder. 35D vented with fan cooled barrel. Vacuum vent. 110kw dc motor and drive. Temperature panel 1987
60mm Cincinnati Alpha60 extruder with inverter drive powering a 37 kW motor , electrically heated barrel with fan cooling.
Sheet Equipment
1900mm Egan/Omam Sheet line 1700mm Line for ABS and PMMA 1500mm Bandera 3 roll stack 1350mm Welex/union sheet line. 1300mm Battenfeld sheet line 1040mm Welex Coex sheet line. 1040mm Welex 3 roll stack 890mm Welex PET Shet line 1000mm Esde 3 roll Stack 1000mm OMV co ex sheet line
Extruders
50mm Welex single screw coextruder 60mm Betol BC60. 25:1 l/d 80mm Cincinnati twin screw extruder 90mm Egan extruder 30Dv, 150hp 90mm Kaufmann STMP single screw extruder 90mm Welex single screw extruder 4.5" (115) Welex single screw extruder 140mm Berstorff Twin screw extruder 150mm Egan extruder
1900mm Welex/Omam sheet extrusion line. 115mm extruder. 1700mm die. 1900mm three roll stack, masking unit. Inline saw, travelling saw.
250ltr Motan Luxor 80 Dryer With Twin Desiccant Beds Which Provide Consistently Low Dew-point Air To Process, While Reducing Energy Consumption.
Thermoforming
Profile Lines
Granulators
Mixers
TRANSXL INTERNATIONAL LIMITED . THORNHILL . SOUTH MARSTON . SWINDON . SN3 4TA . ENGLAND
ONLINE AUCTION
due to cessation of the laminating activities in Tilburg of
ONLINE AUCTION
of machinery and equipment from KIMFA SpA Bankruptcy (Italy)
with 2 SUB COAT AND PRINTING STATIONS (refurbished 2009) design speed 500 m/min, rollers width 1700 mm, working width 1500-1600 mm, with autom. turret reel unwinder, butt-splicing machine with tape-setting device, 2 accumulators, cap. 90 m, 7 corona treaters Pillar Technologies, back printing station with gravure printing system Rotomec, ink dryer, 2 web position controllers, laminating sections rear and top side, ozon generator / dosing system Shermann PBS 0-500, high reliability scanner Measurex 2002, working width 3500 mm, inline colour scanner Zeiss, sub coating station with gravure system and bar coater system; various rolls incl. chill / nip / expander / treater rolls, etc.; cap. 1000 kg output and 2.5 screw; 4 extruder dies with lip heating, lip clearence 0.8 1.2 mm / 0.6 1.3 mm; die-calibrator with dust suction / filter unit;
incl. 2x 3-layer: Windmller & Hlscher Varex / Filmatic-K, 1x single layer Ghioldi (03); 2 film slitter rewinders Schiavi;
8 S/S SILOS incl. Hosokawa Micron, Zeppelin, vol. 110 m3, height 17.500 mm; 14 vacuum pumps incl. Busch RC 0630B, 630-218 and Rietschle SMV 300, 20 Mbar; sieve unit Smog Hog, 3.5 x 11 m; drum exchange lipsuction unit; 3 overhead travelling cranes Demag, cap. 3200 kg x 5.000 mm; filter units, (s/s) drying/weight/mixing/storage tanks, vacuum hoppers, vibrating conveyors, pumps, actuators, exhausters, piping;
machine Windmller & Hlscher Astraflex and roto gravure printing machine Schiavi Pulsar; printing cylinders; plate mounter & proofer Bieffebi; corrosive roll cleaner; COMPLETE 18-HEADS INK MIX STATION INKMAKER (04); ink / solvent treatment installation D.W. Renzmann;
4 WICKETING BAG PRODUCTION LINES: 3x Lemo Intermat S1100 TU.ST, Intermat S 600 ST-N400LT (03), Intermat L600STN400R, Hudson Sharp 1067WLH620 (01); foil recycling machine; cyclone silos; cool condensors; after burning unit; stock of polyethylene, foil, ink; packaging, etc.;
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Indias GDP is expected to outperform most international economies, growing at over 6% per year up to 2017
pipe, automotive and electronic applications, driven by a mix of government spending on infrastructure projects, private investment and rising consumer demand. As the Indian economy develops and becomes westernised, huge opportunities will arise in the plastics processing sector. For example, now that multi-brand organised retail has been opened up to foreign investment, supermarkets will require a reliable local supply of plastics packaging to extend shelf-lives and improve transportability of their produce. Ultimately, initiatives like this will modernise the plastics industry as demand for transit and retail packaging develops from an embryonic base. In addition, consolidation will occur as OEMs prefer to liaise with large processors capable of supplying across the country instead of several smaller regional businesses. Such alterations in market dynamics will provide improved prospects and organic growth to Indian companies, as well as opportunities for multinational processors to enter the market to drive their own growth targets. G Thirdly, whilst these countries tend to have a strong entrepreneurial ethic, this has led to a proliferation of small processing companies, running old and inefcient equipment, which lack the access to capital to invest and really develop an internationally competitive, modern manufacturing industry. The plastics processing industry in India needs to rationalise and consolidate to reduce costs and improve performance. G Fourthly, national and regional government policies are often counter-productive and discourage private investment (eg high tariffs, and the blocking of FDI). Despite the industrys rapid growth in recent years, plastics processing remains underdeveloped with enormous potential for further penetration in packaging, agriculture and building, as well as developing a more consistent manufacturing base. Traditional materials, such as paper and metals, are frequently still preferred due to availability and cost in many end-use applications. Per capita consumption of polymer remains below 9kg compared to a world average of 28kg. Although per capita consumption has already increased rapidly, substantial potential still
Demand Capacity
Market challenge
However, the plastics processing industry in India still faces a number of challenges which need to be addressed. G First of all there is the infrastructure, which does not just relate to transport links but to a whole range issues from energy to the banking system, the limitations of which all serve to hold back business. G Secondly, India remains desperately poor, particularly in rural areas, and governments have struggled to introduce policies to extend the economic growth from the urban centres to the rural areas.
20000
remains and demand for polymers is expected to continue growing substantially over the next ve years. In its report AMI forecasts a 9% per year average increase, which will push demand in India close to 16 million tonnes by 2017. Ultimately, investment opportunities and growth will
15000
10000
be dependent on the success of regulation reform, incentives for FDI and how quickly the economys structure develops more consolidated and efcient operations.
5000
More information
Alex Brownbridge is a market analyst with AMI. His
0
2012 2013 2014 2015 2016 2017
Indian Subcontinent Plastics Industry Report is now available in book and PDF formats from AMI Publishing. Full details can be found at: http://bit.ly/IndiaAMI. S www.amiplastics.com
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62
What are the challenges faced by the plastics industry in the Indian sub-continent?
LL/LDPE
Gilan
2013 EDITION
rapidly and consistently through the period 2007 to 2012, averaging growth of nearly 10% every year. Slower years were between 2010 and 2013 where the global recession, extended monsoon season and the eurozone crisis slightly curtailed growth. Generally, growth for LL/LDPE has been growing at 1.4 times that of the subcontinents GDP growth. 84% of the subcontinents demand is accounted for by India. LDPE is produced in dedicated plants whereas LLDPE can be produced in swing plants capable of producing both high density as well as linear grades. Swing plants in the region have tended to favour LLDPE grades however the ability to swing between grades makes calculating capacity problematic. All subcontinent LL/LDPE production comes from India. Production has been consistently lower than local demand and hence the region has become increasingly dependent on imports. In 2011 Indian imports were 625,000 tonnes but this increased to over 785,000 tonnes in 2012 (50% of demand). To cope with fast growth in demand there will be a number of new Indian plants coming on stream in 2013-2015. BCPL, % change Reliance, GAIL and OPaL will be investing in HD/LLDPE swing plants whilst Reliance Industries also plans a 400,000 tonnes/year LDPE plant as part of its USD12 billion capacity 2011-2012 2012-2013 investment programme. While capacity is expected to exceed regional demand by 2015 overall the subcontinent will continue to rely on imports although India is expected to become 10.0% 8.4% a net exporter before 2016.
Bangladesh
Units: 000 Tonnes LL/LDPE HDPE PP PVC GP-HI PS EPS PET Sub-total commodity ABS/ SAN PBT PA PC Acetals PMMA Sub-total engineering TOTAL POLYMER DEMAND
1
3.5% 9.1% 4.4% 5.3% 1.9% 15.6% 8.3% 12.8% 22.2% 15.1% 7.1% 10.0% 7.1% 10.9% 8.4%
Table 2.1 SUPPLY/ DEMAND FOR LL/ LDPE IN THE INDIAN SUBCONTINENT 2007-2013 9.2%
Units: 000 Tonnes 3.9% Capacity Production 2007 595 479 1,203 2008 620 501 1,356 12.8% 2009 635 534 1,491 9.9% 2010 910 750 1,628 9.2% 2011 1,020 878 1,752 7.6% 2012 1,020 856 1,908 8.9% 20131 1,130 915 2,078 8.9%
3.2%
6.3%
3.6% Demand
% demand change 12.2%
1
Forecast
7.5%
31
Forecast
Vital strategic market intelligence giving you the edge over your competitors.
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Shu-Lan Cheng, research analyst: areas of expertise include BOPP lms and the plastics markets in China and Asia. Vitas Sabaliauskas, research analyst: areas of expertise include ame retardant additives, pipe coating, insulation and Russian markets. Carole Kluth, senior project manager: areas of expertise include BOPP lms, exible packaging and polymer markets in Europe.
REGULAR CONTRIBUTORS
In addition to our UK-based magazine team we have a number of regular contributors to our magazines. These highly experienced writers and industry experts are based in Europe and the USA.
Jennifer Markarian: Based in the USA, Jennifer Markarian is a chemical engineering graduate and a highly experienced technical writer covering the plastics, pharmaceuticals and chemicals sectors. She also has industry experience, working for seven years with Mobil Chemicals polyethylene group as a development and technical service engineer. Peter Mapleston: Based in Italy, Peter Mapleston is a very experienced plastics industry journalist and editor. He has a degree in polymer science and technology from the University of Manchester in the UK. Peter spent 17 years with Modern Plastics magazine, becoming its senior editor covering the full range of materials and processing technologies. John Goff: Based in the UK, John Goff is a well respected expert and author on injection moulding technology with more than 35 years of industry experience. He was a senior lecturer at the University of London, and process engineering manager at Demag. He is now managing director of G&A Moulding Technology, a global consultancy. Pat Toensmeier: Based in the USA, Pat Toensmeier is a highly experienced plastics industry writer and editor. He was with Modern Plastics magazine for 17 years, including eight years as its editor-in-chief. He has also written for Plastics Technology, Plastics Engineering, Defense Technology International and Modern Mold and Tooling magazines.
waterproof membranes
2013
World waterproong conference covering market economics, technical innovation, performance and manufacturing
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Materials | technology
CoNSTRUCTIoN
addITIVES
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PET FILm
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October 2013 | FILM & SHEET EXTRUSION 67
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technology | Machinery
PVC cling lm production line now runs 20% faster thanks to technology upgrade
Macro Engineering & Technology of Canada has upgraded its high-speed cast line for producing PVC cling lm, boosting output by more than 20%. The new 2m wide line has an extrusion output of 300kg/h (up from 230kg/h in the previous design). It produces strong lm from 8-16 microns thickness that can be used in both handwrap and machine-wrap applications. A key feature of the redesigned line is the winder, which operates up to 280m/min. It is a specially designed two-spindle contact version that creates high contact forces to generate rolls that are transparent and with uniform geometry. The cutover sequence on the new winder has also been improved to minimise scrap during roll indexing. When fully equipped, the line is supplied with auxiliary roll edge cutter, resin blend preparation system and a recycling system.
cAST FILM
www.macroeng.com
SHEET EXTRUSION
moved mechanically so that a spray coating can be applied to either the top or bottom of the sheet. In this case, a spray of solution can be applied through sparger tubes on the top or the bottom of the sheet. If coating is needed on both sides, the web is simply dipped into the anti-static reservoir. This system can coat the top side, bottom side or both sides of the sheet, depending on customer needs. These anti-static coating units are primarily used on packaging sheet applications for both roll stock production and in-line systems. The roll stand is a key feature of the G Series of sheet extrusion systems, and is also sold separately.
www.ptiextruders.com
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Available to buy on the AMI stand at K 2013: Hall 7.0 Stand 70C11
This 20-page brochure from Bandera covers innovative sheet extrusion lines for A-PET, C-PET, PET-G, foamed PET, PP, PS and PLA. The lines feature co-rotating twin-screw technology for improved efciency, performance and exibility.
Colines: stretch lm
This brochure from Colines promotes the companys HANDrollEX, HANDrollEX Triple, JUMBOrollEX, HANDrollEX Combi and Unicast systems for producing stretch lm for manual, auto and jumbo wrapping applications.
www.ngr.at
01 | 12, E
This brochure describes NGRs broad range of recycling systems including machinery for the inline recovery of edge trim, plus systems for recycling lms, rafa, biodegradable plastics and post-consumer waste.
If you would like your brochure to be included on this page, please contact Claire Bishop. claire@amimagazines.com. Tel: +44 (0)20 8686 8139
Polymer Foam
POLYMER F O A M 2013
International conference on blowing agents and foaming technology for polymer materials
AMI is running the eighth international Fire Resistance in Plastics conference on 12-14 November in Cologne, Germany. The high-level programme covers the latest technology developments, market trends and regulatory changes.
AMI is holding the Polymer Foam 2013 conference in Hamburg, Germany, on 19-21 November. Download this brochure to see the line-up of speakers who will cover developments in blowing agents and foaming technology for polymers.
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2013
International conference and exhibition on wind blade composites design, manufacturing and markets
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Thermoplastic Concentrates
THER MOPLASTIC Template CONCENTRATES 2014
The international marketing, business, and technical conference for the thermoplastic concentrate industry
The international conference on business strategies and new technologies for compounders
AMIs Thermoplastic Concentrates 2014 conference is being held in Coral Springs, Florida, USA on 28-30 June. Check out the top quality programme with its strong focus on product design and end-use markets.
Ft. Lauderdale Marriott Coral Springs Golf Resort, Coral Springs, Florida, USA
SPECIAL OFFER: Save $200 if you register before December 13, 2013
Organized by: Applied Market Information LLC Sponsored by: Media supporter:
To see our full line-up of more than 25 plastics industry events over the next 12 months, please visit www.amiconferences.com
Berry Plastics
Head ofce: Date founded: CEO: Turnover: Ownership: Prole: Evansville, Indiana, USA 1967 (as Imperial Plastics) Jon Rich $4.76bn (Flexible packaging division: $737m) Public (listed on NYSE) Although Berry Plastics is predominantly a producer of injection moulded plastic products, it has a exible packaging division (which it recently expanded through acquisition). At the same time, it produces medical lm, agricultural lm, thermoformed cups, rubbish bags and stretch lm. Berry Plastics produces a wide range of lm-based products: in agriculture, it offers high clarity greenhouse lm, as well as silage wrap; building products include roof and window ashing tapes; and, in food packaging, products include bag-in-box barrier lm, frozen and microwavable lm, lidding lm and stand-up pouches. Its Optym medical device packaging lms are used to protect products such as syringes. The company has worldwide production capability. As well as having a network of facilities across the USA, it has operations in countries including Canada, Mexico, Brazil, Germany, The Netherlands, Belgium, India, Malaysia and Australia. The company recently expanded by acquiring the exible plastics and lms division of Graphic Packaging, which made $100m in sales this year. This adds three US manufacturing facilities and 270 employees to the company.
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Forthcoming features
The next issues of Film and Sheet Extrusion magazine will have special reports on the following topics:
November/December 2013 Screenchangers/melt ltration Converting & bag making equipment Masterbatch developments K2013 review
January/February 2014 Materials recycling/granulators Developments in bioplastics Mineral llers for lm Polyolen for lm & sheet
Editorial submissions should be sent to Lou Reade: lou@lmandsheet.com For information on advertising in these issues, please contact Claire Bishop: claire@amimagazines.com Tel: +44 (0)20 8686 8139
Compounding World Oct The biggest ever issue of Compounding World is lled with features on the latest reinforcing bres, developments in titanium dioxide and opportunities in Indias plastics market. It also has an 18-page guide to the highlights of the K 2013 exhibition. Click here to view
Compounding World September Compounding Worlds September issue includes special features on selecting pigments, testing melt properties and boosting bioplastics. Plus it has a preview of new materials being launched at K 2013. Click here to view
Pipe and Prole October The October edition of Pipe and Prole Extrusion looks at the latest innovations in optical bre ducting, trenchless pipe technologies and downstream automation. Plus, a preview of the materials and equipment on show for extrusion processors at K 2013. Click here to view
Injection World Oct The biggest ever edition of Injection World is packed full of features on electronic applications, conformal cooling, 3D printing, hot runners, PET performs and thermoplastic composites. Plus theres a huge guide to K 2013 for moulders. Click here to view
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E 13 U 20 LOG TA CA
Formats Most of the data is available electronically either as a PDF or as a database, typically supplied on CD. The Gold database is a superior product with extra information.
EUROPE
Table of contents
AMIs 2013 European Plastics Industry Report is considered by the industry as the most comprehensive and best value market report on the plastics industry. It provides a wealth of information with key gures and graphs on polymer capacity and demand.
AMI also provides statistical analysis of plastics markets for other regions of the world, please contact us for more details.
APPENDIX ......................................................................................................................... 257 Data coverage ...................................................................................................................... 257 Country coverage ................................................................................................................. 257 The plastics industry in France ............................................................................................ 258 The plastics industry in Germany ............................................................................................... The plastics industry in Italy ....................................................................................................... The plastics industry in the United Kingdom .............................................................................. The plastics industry in Belgium ................................................................................................