European Plastic Product Manufacturer - Latest News

Derprosa presents the most complete range of bioriented polypropylene laminating films for graphic arts

Fri, 03 Feb 2012 00:00:00 GMT

February 3, 2012 Derprosa, a Spanish company with over 20 years of experience in the field of graphic support finish solutions, launches the new products that complete its range of laminating films for the graphics sector.

Continuing with its policy of always seeking to collaborate with its customers in order to improve their results, these solutions have been especially developed for high-end graphic finishes. All of them stand out for their perfect machinability, great bonding adhesion qualities and adaptability to other post-laminate finishes.

Graphic art and marketing professionals will find the following benefits in every type of bioriented polypropylene (BOPP) film we supply: Soft Touch is the first ever BOPP film with tactile properties that endows printed matter with a unique finish and sharper images than ever before. Soft Touch Metalised (part of the Soft Touch family, for which Derprosa has been granted the patent) endows printed matter with a metalised finish that provides a textured visual effect and even a holographic sensation combined with the smooth and velvety Soft Touch feel.

Its success lies in the fact that our end customers are able to differentiate their products from those of their competitors because they supply graphic supports that are pleasing to the touch and visually unique. Anti-Scratch (also BOPP) provides products with effective protection because of its excellent scuff resistance and exceptional UV ink adhesion and hot stamping properties.

Due to the special treatment it undergoes, the final result can be cold stamped and considered as a valuable alternative to matt acetate. EcoFilm is Derprosa environmentally friendly film that enables the customer to choose the Derprosa quality and guarantee while respecting the environment. All Derprosa products are available in an oxo-biodegradable version that breaks down within a period of less than 18 months due to the action of the air, temperature and ultraviolet light.

All our products include a version capable of adhering to liquid products or incorporate a thermo-lamination layer. In short, the idea behind this new range of laminating films is that Derprosa can now supply specialist graphic art companies with products that enable them to market supports that are rugged, of extremely high quality and with excellent sensorial properties. This means it will provide added value and differentiate the communication activities of the end customer, not only in packaging, but also where small and large format advertising is concerned.

Is This the ‘Greenest Ever' Refillable Bottle?

Thu, 02 Feb 2012 00:00:00 GMT

Specialist plastics packaging technology business Petainer has developed its ‘greenest ever' refillable bottle - further improving the sustainability of what is already one of the most environmentally-friendly forms of beverage packaging. The new bottle is manufactured using more than 25 per cent post-consumer ‘one-way' recycled PET but has the same performance characteristics as a refillable bottle made entirely from virgin material.

Nigel Pritchard, group chief executive of Petainer, said: "This is a very exciting development. Refillable bottles are already the beverage packing system with one of the lowest environmental footprints. This massive advance in the use of recycled material makes refillable bottles even more ‘eco-nomic'.

"They are ‘eco-friendly' because they use up to 90 per cent less virgin material per filling. This performance is improved even further by the introduction of post-consumer recyclate, which means that the bottles now require less energy and other resources to manufacture.

"They are also economic in the traditional sense because the environmental benefits translate into lower costs. As the cost of PET resins inexorably increases, the economics of refillable bottles using recycled material become even more compelling.

"We believe these new containers have a good claim to be considered one of the world's most sustainable forms of beverage packaging. This will become even more the case as commodity resources become scarcer, costs rise and environmental impacts come more to the fore."

Petainer is now working with bottled water companies, carbonated drinks producers and brewers across Europe to put its new ‘greener' refillable bottles into use.

Research has demonstrated that refillable bottles — which are returned to the retailer by the consumer once emptied, then sent to the beverage manufacturer for washing and refilling — have a lower carbon footprint than one-way bottles that are thrown away after use. This is the case even if one-way bottles are recovered for materials recycling.

Petainer, which manufactures both refillable and one-way bottles in PET, is a leader in the use of recycled materials in both types of bottle. It has demonstrated that one-way bottles can be manufactured from 100 per cent recycled material.

Petainer's latest developments in manufacturing technology allow more than 25 per cent of post-consumer waste from used PET bottles to be included in refillable bottles. The company is now working on improving the use of post-consumer recyclate even further.

The ‘greener' bottle's performance is identical to the performance of conventional refillable bottles. It gives the same number of ‘round trips', has the same top-load strength which allows it to be stacked in the same way as other refillable bottles, and provides the same level of retention of CO2 in carbonated soft drinks.

The technology can be applied both to bottles manufactured in Petainer's own plants in Sweden and the Czech Republic and also to bottles blown from Petainer-supplied preforms.

Nigel Pritchard added: "This bottle-to-bottle recycling, added to the existing environmental and economic benefits of refillable bottles, makes a strong case for fillers and brewers to consider switching to refillable bottles. We are already seeing a number of customers and countries considering the introduction of refillables."

A company using one-way bottles can spend around four to five times as much on packaging as a company that bottles the same quantity of beverage in refillable bottles, which it needs to replace only once in every 20 trips. The total PET used per filling is 90 per cent lower for the refillable container, which is improved even further with this development in the use of post-consumer recyclate.

Braj Binani Group Acquires 3B - The Fibreglass Company For €275 Million

Wed, 01 Feb 2012 00:00:00 GMT

February 1, 2012

Binani Industries Limited, the holding company of USD 1.6 billion Braj Binani Group, today announced the acquisition of 3B - The Fibreglass Company (‘3B'), a Europe-based major in fibreglass products and technologies. Binani Industries Limited is one of India's leading global diversified business houses, with interests in cement, zinc, glass fibre, composites and ready-mix concrete.

The Braj Binani Group has acquired a 100 per cent equity interest in 3B from Platinum Equity.

Headquartered in Battice, Belgium, 3B is Europe's leading manufacturer of fibreglass for reinforcement of thermoplastics and thermoset polymer applications, and is a preferred supplier to global leaders in industries including automotive and wind energy.

This acquisition is part of Braj Binani Group's strategy to expand its footprint in the global fibreglass market. It further augments the Group's technological and marketing capabilities in the fibreglass business.

Mr Braj Binani, Chairman, Binani Industries Limited, said, "The acquisition, costing us € 275 million, will strengthen our group's core operations at a global level. The group is present in fast-growth business segments, of which fibreglass is one. We are among one of the few groups globally that has a robust presence in this niche segment and we are working to accelerate our fibreglass operations further over the coming years. 3B is therefore a perfect match. We look forward to leveraging its expertise, strong R&D and excellent customer network."

This acquisition gives Binani Industries full ownership of 3B's global operating capacity of 150,000 tonnes per annum (tpa). It also provides access to its established customers, world-class technologies, marketing network, vast marketing geographies and skilled manpower. 3B has an extensive portfolio of products including chopped strands, direct rovings and continuous filament mats. Goa Glass Fibre Limited, a subsidiary of Binani Industries based in Goa, India with a manufacturing capacity of 20,000 tpa, has state-of-the-art operations in similar product categories and exports its products to over 15 countries across five continents.

The acquisition allows Binani Industries to consolidate its position in the global fibreglass market by increasing its product and customer base. The company will become a prominent supplier to industries such as automotive, wind energy, electrical, electronics, marine, infrastructure and transportation, primarily in Europe, where approximately 90 per cent of 3B's customers are based. Furthermore, the manufacturing plants that Binani Industries will own in Battice (Belgium) and Birkeland (Norway) will help it serve blue-chip customers in northern and central Europe. 45 per cent of 3B's customers are in Germany followed by the Netherlands and Belgium (14 per cent each).

With regards to technology, Binani Industries will benefit from 3B's continuous product innovation and product development undertaken at its in-house R&D unit at Battice. This technology expertise will place Binani Industries in a premium position in the global fibreglass market.

Environmental Recycling Technologies plc appoint new Board member

Wed, 01 Feb 2012 00:00:00 GMT

January 31, 2012 Environmental Recycling Technologies plc. which has developed and is exploiting the patented rights to the Powder Impression Moulding ("PIM") process capable of converting mixed waste plastics into commercially viable products, announces the appointment of Lee Anthony Clayton to the Board as a Non Executive Director with effect from 1 January 2012.

From 2009 until recently Lee was a senior manager at Viridor Polymer Recycling Limited, a subsidiary of Pennon Group PLC and the UK's largest waste management company. At Viridor he oversaw the design, installation and commissioning of two very large polymer processing facilities, and the operational management of a third facility.

Between 2006 and 2009 Lee was General Manager of Intercontinental Recycling Limited ("IRL") and oversaw the sale of this business to Viridor in 2009. IRL was established in Skelmersdale to process 40,000 tonnes per annum of domestic plastic bottles, achieving profitability after 18 months of operation.

Roger Baynham, Managing Director of ERT, commented;

‘We are delighted to welcome Lee Clayton to the Board. Lee is a leading figure in the UK wastes management industry and the plastic recycling industry in particular. His unrivalled network of UK and international contacts, his technology expertise and operational experience will be of great benefit to the Group as we continue to raise awareness of our PIM technology, attract new licensees and help them quickly grow production volumes and generate royalty streams for ERT. The Board believes he will be hugely valuable as the Company continues to exploit PIM.

Lee Clayton, said:

‘ERT's PIM process has the potential to become one of the major plastic recycling technologies worldwide. I am very excited to join the ERT team and look forward to helping the Company take full advantage of the significant growth opportunities which lie ahead."

EPI launches OxoGreen - a line of Oxo-Biodegradable Plastic Products

Wed, 01 Feb 2012 00:00:00 GMT

January 27 2012 EPI Environmental Products Inc., of Vancouver British Columbia, launched its new line of OxoGreen oxo-Biodegradable Plastic Products on January 18th, 2012.

Even after more than 20 years of being in the oxo-biodegradable plastic industry, EPI felt there needed to be more 100 per cent degradable and biodegradable products available to consumers globally.

For this reason, the OxoGreen line of products was created.

This year in Canada, not only will OxoGreen produce 100 per cent degradable garbage bags but whenever possible, these bags will also be made from 100 per cent recycled materials.

OxoGreen will be establishing relationships with its current TDPA licensees to become partners in the manufacturing and distribution of the OxoGreen products initially for the North American market and thereafter will proceed to move forward on a global initiative.

EPI is the Pioneer of the Oxo-Biodegradable Plastic Additive, TDPA (Totally Degradable Plastic Additive), which when added to the manufacturing of plastic, makes them degradable.

Although the Environmental Protection Agency of Canada has been pressuring municipalities to recycle plastic bags, less than 7 per cent were being recycled due to low participation and lack of suitable facilities.

Unfortunately recycling plastic bags is not the total solution. It is too costly of a proposition as per the following example as quoted by Jared Blumenfeld, the director of the Department of Environment in San Francisco, "After 10 years, the recycling rate for plastic bags in San Francisco - which is pointed to as a model nationwide - is 1 per cent, so 99 per cent failure".

Recycling Position (San Francisco, Dept of Environment director) for 1 ton of recycled plastic bags

• Recycling and processing cost: US$4,000 / ton

• Resulting value of the recycled material: US$32 / ton

For this reason, using an OxoGreen Oxo-Biodegradable product is making the right choice. Sandy MacLean has joined the EPI team to head up our OxoGreen Division.

New marketing executive for S+S Inspection

Thu, 26 Jan 2012 00:00:00 GMT

January 26, 2012 Unlike many other companies, S+S Inspection of Fareham is increasing its marketing strength with the appointment of Rachael Payne to the new position of Marketing Executive.

Starting with a BA in Communication Design, Rachael has built a wide experience of marketing in technical markets. At S+S Inspection, she will be responsible for the management of all marketing activities, including exhibitions and web site maintenance in addition to liaising with the German parent company.

"During an economic downturn it is tempting to cut back on marketing", says managing director, Richard Lines, "but experience of past recessions has shown that increasing the marketing spend pays dividends in both the short and long term. Appointing Rachel to enhance our marketing capability is an essential part of our business strategy".

KraussMaffei Group to expand production plants in Slovakia and China

Wed, 01 Feb 2012 00:00:00 GMT

January 26, 2012 The KraussMaffei Group has decided to expand its production plants in Martin (Slovakia) and in Haiyan (China).

At both locations, the production capacities are to be doubled and the performance spectrum extended. For both sites, the start of production is planned for the beginning of 2013.

Start-up of production of injection moulding machines in China

"The KraussMaffei Group is growing. In order to strengthen our activities in core markets and in emerging markets, we have decided to expand our production plants in Martin (Slovakia) and Haiyan (China)", explains Dr. Dietmar Straub, CEO of KraussMaffei AG.

In Haiyan (China), the previous production area of 12,000 m2 will be increased to around 22,000 m2.

In addition to the expansion of existing production capacities for machines and plants for reaction and extrusion technology, Netstal and KraussMaffei injection moulding machines for PET applications and KraussMaffei injection moulding machines of the MX series will also be produced here.

In the production plant in Martin (Slovakia), which was put into operation only in autumn 2010, robots and KraussMaffei injection moulding machines of the EX series as well as machines and plants for reaction and trimming technology will in future be produced on a production surface area of around 13,000 m2 (today: 6,600 m2).

At present, KraussMaffei injection molding machines of the AX series, as well as switch cabinets and moulds are manufactured at this location.

LANXESS and South Korean Tier-One automotive supplier Hwaseung strengthen partnership

Wed, 25 Jan 2012 00:00:00 GMT

January 25, 2012 German specialty chemicals company LANXESS and South Korea's tier-one automotive supplier, Hwaseung Corporation, have further strengthened their business partnership.

Both companies have signed a long-term agreement under which LANXESS will supply Hwaseung with premium EPDM rubber. Financial details were not disclosed. Furthermore, both companies will deepen their research and development efforts on specialty rubber applications.

An agreement was signed at LANXESS' "Rubber Day Korea" in Jeju by Guenther Weymans, global head of LANXESS' Technical Rubber Products business unit, and Yoohwi Choi, Senior Vice President of Hwaseung Networks - a subsidiary of Hwaseung Corporation.

"This new agreement will further strengthen the already successful partnership between Hwaseung and LANXESS," said Weymans. "It is also another milestone in the successful integration of the recently-acquired EPDM business."

"We are delighted to be teaming up once again with LANXESS - a premium supplier of synthetic rubber, which is recognized by our customers," said Choi.

Ethylene propylene diene monomer (EPDM) synthetic rubber, sold under the brand name Keltan, is used above all in the automobile industry for door sealants. It is also used in the plastics modification, cable and wire, construction and oil additives industries. Its properties include very low density, good resistance to heat, oxidation, chemicals and weathering as well as good electrical insulation properties.

Hwaseung Corporation is a leading supplier of rubber components and other materials to global automobile producers, including the Korean manufactures Hyundai and Kia. South Korea is already one of the top five automobile producers in the world.

The Technical Rubber Products business unit, which includes the EPDM business, is part of LANXESS' Performance Polymers segment, which achieved total sales of EUR 3.8 billion in 2010.

Clariant unveils cutting-edge efficiency development in non-halogenated flame-retardants for printed circuit boards

Tue, 24 Jan 2012 00:00:00 GMT

January 24, 2012 Clariant has unveiled two pioneering, low dosage non-halogenated flame-retardants for epoxy resins to the electrical and electronics (E&E) industry.

Cutting-edge Exolit EP 150 and EP 200, developed specifically for epoxy laminates, set a new benchmark in high-efficiency halogen-free flame-retardants for printed circuit boards.   The reactive flame-retardants, which are currently available as laboratory product samples, were revealed to key players in Asia, the manufacturing hub of electronics, at Pinfa first regional workshop in Taipei, Taiwan, on November 8, 2011, entitled "Building the Future for Flame Retardants in E&E".

They will make their European debut at the Fire Resistance in Plastics conference in Cologne, Germany, on November 30, 2011.   Exult EP 150 and EP 200 have unmatched high phosphorous contents of 25% and 29% respectively which enables only a low dosage of flame retardant to be used to reach the desired fire protection effect. For example, UL 94 V0 fire ratings can be achieved at a loading of 50% less than with conventional flame-retardants.   

The Exolit EP products are easy to use, showing a broad compatibility with epoxy thermosets. Exolit EP 150 is a low viscosity liquid, which makes it suitable as a flame retardant for infiltration processes. While Exolit EP 200 is available in solid form, it will melt at usual processing temperatures to provide the same user benefit. Laminates produced with Exolit EP flame retardant fulfill the mechanical, electric and electronic properties required by IPC test specifications.

EP 150 and EP 200 are the latest additions to Clariant's highly regarded Exolit non-halogenated range, known for its total resin flame retardant integrity even under harsh conditions and in sophisticated applications.   With the non-halogenated laminate market share growing from 2% in 2004 to 13% in 2010.

Clariant is expecting a lot of interest from potential customers in the efficiency-boosting Exolit EP grades. It has already begun the up-scaling process for commercial production.   "Clariant's Exolit EP grades meet the market preference for liquid flame retardants. But most importantly they outperform conventional flame retardants in terms of efficiency and, as such, offer exciting potential to printed circuit board manufacturers looking to switch to non-halogenated flame retardants and to be more efficient," comments Adrian Beard, head of flame retardants marketing, Clariant.

"The full-house at our presentation in Taipei reinforces the high level of interest in non-halogenated flame retardants. We are looking forward to sampling the new grades with customers and hearing feedback based on their expertise and requirements."

Husky announces sale of Injectoplast to Alpla

Wed, 25 Jan 2012 00:00:00 GMT

January 24, 2012

Husky Injection Molding Systems today announced that it has signed an agreement to sell Injectoplast, the former closure injection molding operation of KTW, to Alpla Holding GmbH (A-6971 Hard, Austria).

Injectoplast was a division of KTW, a closure mold maker that Husky acquired in early 2011. At the time of the KTW acquisition Husky announced that it would be divesting Injectoplast due to potential conflicts with its existing injection molding customers. After completing a thorough process, a deal has been signed with Alpla Holding GmbH. The deal is anticipated to close before the end of the first quarter of 2012.

Wind blade composites market grows as offshore wind energy advances

Tue, 24 Jan 2012 00:00:00 GMT

January 24, 2012 Many nations have set challenging targets for renewable energy production and it was in this setting that AMI held the latest global conference on Wind Turbine Blade Manufacture in December 2011 in Dusseldorf, Germany. The UK Minister for the Environment had announced potential plans for another 29,000 wind turbines mainly offshore, and Siemens Energy had unveiled its latest 6MW turbine with rotor diameters of 120 and 154 metres. In the same month the American Wind Energy Association (AWEA) announced that more than 1200MW were installed in the US in the third quarter of 2011, which is better than any quarter since 2008: the US wind energy market has been boosted by the federal Production Tax Credit.

Frank Virenfeldt Neilsen, the Chief Technology Officer of LM Windpower, from the earliest windmills dating back to 4000BC, reviewed the advances in the wind industry. The first windmill to produce electricity was built by Poul La Cour in 1891. The global wind energy market took off in the late 1970s as oil prices rose and many governments commissioned research, for example NASA and Tvind both had a 2MW project. LM Windpower has been involved in marine composites for 55 years and in wind blade manufacture for several decades. The company is developing longer offshore blades of 73.5m in length weighing in at 26 tons, using experience from current installations, such as Alpha Ventus in Germany, Vattenfall in the UK, Thornton Bank in Belgium and Vindeby in Denmark. The latter installation was set up in 1991 and used 33 blades: inspection over the next 20 years showed only minor leading edge erosion, which was restored. In 2000, 60 more blades were installed at Middelgrunden, Copenhagen and inspection 10 years later revealed only limited surface damage to gel coats, 9 blades with laminate cracks and 2 with lightning damage. Routine inspection and maintenance of blades can keep operating costs to a minimum and LM has extended its services beyond manufacture to support wind farm operators. The limiting factor in blade scale up has been weight, and the solutions lie in new technology coming from studies of aerodynamics, load control and integrated design. Managing loads on blades can maximise the windswept area and increase energy production. A prototype glass fibre-polyester blade takes around 9 months to develop and testing takes a further 6-12 months. LM has set up blade production in many areas of the world, with around 36% in China and 32% in Europe, and relies on suppliers to provide consistent, cost-effective supplies.

The cost breakdown of an onshore wind turbine shows that the drivetrain, hub and nacelle absorbs 25%; the tower, electrical systems and civil work each take up about 13%; and the rotor blades make up 11% of the total expense. Blade development can affect the load and cost of other components and this is being studied extensively by Christian Bak at Riso Danish Technical University (DTU) looking at drivers such as high aerodynamic efficiency (high power), blade-tower clearance, loads, transportation and moulding. The virtual 5MW turbine of the EC Upwind project was used as the model in this investigation, which took into account the structural dynamics of the whole turbine. In the new slender blade design, the blade chord length was reduced by 16.7%, and the slender blades reduced the extreme loads on components by up to 24% and fatigue loads by up to16%.

Design is the key issue in blade scale up. Dassault Systemes Deutschland supplies composite simulation software to the wind industry covering aerodynamics, structural analysis, and design and manufacturing planning. Quality control can offer big opportunities for cost savings, in one aerospace project with EADS Composites Atlantic the scrap rate was reduced from 13% to zero.

Vestas has 30 years of experience in wind turbine development and has 44,000 installed in 66 countries on 6 continents. The company's V112 3MW turbine is established for operating in low and medium onshore winds. The company manufactures blades at 8 sites worldwide: Windsor and Brighton in Colorado, USA; Lem, Denmark; Daimiel, Spain; Taranto, Italy; Lauchhammer, Germany; and Hohhot and Tianjin, China. Vestas blades were initially manufactured as polyester shells and spars: this changed in 1991 to an epoxy spar and in 2002 the company used a carbon fibre-reinforced spar for load bearing. This allowed it to add 5 metres to the length of the blade without increasing the weight. Frank Weise, the Vice President of Vestas Blades Deutschland, described the slender V112 blades including the wider root diameter to reduce blade bearing wear, integrated lightning receptors and grounding cable, and profile design for low noise level. The planned lifespan is 20 years. Weise's manufacturing background began in Japan and he is studying the whole production process and introducing standard operating methods with controls at each step to ensure consistent, high blade quality. This is a key precursor to instigating automation, which is still proving difficult in the wind composites industry.

One of the certification bodies for wind blade manufacturing sites is Germanischer Lloyd (GL) and some wind farm authorities and insurers expect this standard from suppliers. The standard covers facilities, materials, processes, and personnel qualifications. For example, the workshop is expected to keep temperature and humidity within limits and the laminating resin is specified as having good wetting and impregnation, resistance to ageing, cure between 16C and 30C with a maximum of 12% filler by weight. At the Wind Turbine Blade Manufacture 2011 conference questions were asked about the compatibility with IEC guidelines and the rationale for the GL requirements.

The Fraunhofer IWES conducts rotor blade testing, which can take a year for fatigue tests. It is developing facilities for up to 80 metre blades. At the end of 2010 biaxial testing was implemented, for example with vertical loading in blade eigenfrequency plus horizontal quasi-static loading. Movement of the blade was monitored at different radii and the tip at different load levels. The Materials Engineering Research Laboratory (MERL) has looked at the causes and modes of delamination in composites in order to predict fatigue life. This can then be factored into the design process.

Euros Entwicklungsgesellschaft Fuer Windkraftanlagen designs blades in Germany and has two manufacturing sites in Poland at Ustron and at Zory-Warszowice. The company carries out its own testing programme, for example on coupons to determine material properties, on samples to see the performance of complex structures and on full scale blades to exclude size effects on smaller samples. Mass content measurements can be misleading if the stitching yarn and the sizing covering the glass fibre are not taken into account as these will decompose during calcination of a specimen and this may affect the calculation of void content.

There are a variety of techniques in use for non-destructive testing of wind turbine blades. The University of Stuttgart has used an ultrasonic-echo method to examine the bond between the shell and the spar by taking measurements of a pulse sent through the outer shell and reflected as the material changes. It was also possible to look at bonding on the trailing edge despite the sound damping effect of the foam component, using a through transmission method. Local resonance spectroscopy on the blade shell detected delamination and air inclusions. Force Technology has applied the pulse echo ultrasound technique to whole blades in an automated inspection procedure. This can be used to verify prototype blades before commencing production. The AMS-46 cart scanner crawls along the blade surface and is used to detect laminar defects, dry areas in a girder spar, to indicate waviness and wrinkles, and to check adhesive bond quality.

During use wind Igus ITS, now Bosch Rexroth Monitoring Systems can continuously monitor blades using a system such as that developed. Accelerometers are placed in the blade to measure vibrations, which are then transmitted, converted to a frequency spectrum and analysed. As one example, in hull damage with multiple trailing edge crackings, the spectrum is affected between 150 and 300 Hz. In the case of severe lightning damage, the turbine can be switched off in a few seconds and limit the effects. In the case of ice formation on blades, the system is said to detect 5-10kg on a 2MW turbine blade, which may not always be visible from the ground, but formed as a surface layer in icy rain.

Research in Bremerhaven has indicated that around 2020 there will be about 26,000 tons of waste blades in Germany. Disposal of end-of-life blades has been reviewed by Holcim (Deutschland) looking at processes like pyrolysis, incineration and landfill. The option that Holcim chose to implement involved cutting the blades in the field to ease transportation, size reduction in a closed system and separation of materials like metals for recycling, then homogenization of the shredded blade to provide fuel and raw material in a cement plant. The blade ash forms part of the clinker matrix.

At the end of 2011 Suzlon completed its purchase of REpower Systems. Offshore is an expanding market for the company and the 5MW/6MW manufacturing facilities are located at Bremerhaven. In 2011, 30 5MW turbines were installed at Ormonde, and in 2012-13 a further 290MW are scheduled for installation at Nordsee Ost and Thornton Bank. Design of the new blades is complex involving over 800 load cases, and the effects of the environment like rain, ice and salt and temperature cycling. The scale up of blade size leads to far greater demands in manufacturing, for example the 40m blade weighs 7 tons and has a surface area of 180 square metres and the 61.5m blade weighs 22 tons and has a surface area of 470 square metres. Automation is an obvious solution to improve efficiency and quality, and due to the large size of the new blades, manual labour is almost impossible to use for some tasks. Aerospace has implemented some solutions, but these would be too slow for blade making. The biggest manual job is hand laydown of glass fibre and the difficulties of automating this are that the fabric is limp and difficult to handle, the automated process is currently too slow, the complexity of the task and the huge size of the task, not to mention the high investment cost.

IDP Sistemas y Aplicaciones has robotic systems for finishing wind blades, which the companies claims can cut the time take for a 40m blade from 100h to 10h. There are a variety of coating systems for wind blades. Re-Turn AS focuses on development and has a background in marine coatings including the use of carbon nanotubes. The claim is that the new Advanced Marine Coatings (AMC) gelcoats lower friction and thus allow boats to travel faster, and Re-Turn is looking to take this technology to the wind industry. Coatings can assist in many areas such as UV stability, fouling and erosion.

Zoltek has been examining when it is cost-effective to use carbon composites in wind blades. The industry uses heavy-tow carbon, most commonly as pre-impregnated unidirectional tapes. These materials are used in spar caps and sometimes in the trailing edge girder, and allow blades to be made longer without increasing weight. The cost-effectiveness increases with blade size, and in one example of a 57m blade, use of carbon led to a 27% weight reduction alongside a 14% cost increase compared to glass fibre only designs: at 90m the cost comparisons are predicted to be about the same. Other aspects such as labour and load on other turbine components can also contribute to the cost-effectiveness of carbon fibre usage.

New amine cure systems are being developed by Huntsman Performance Products after requests from the wind composites industry for longer pot life and faster cure for big blades. The National Technical University of Athens is developing process monitoring during resin infusion using sensors to detect factors such as resin ageing, viscosity changes and the end of cure. Intelligent automation in composites production is the subject of the iREMO project.

Epoxy adhesives have played a critical role in blade assembly and bonding for several decades and 3M has produced a new high performance type. It has been compared with standard epoxy for a range of properties including the cure exotherm where it releases 240J/g compared to 290J/g for standard epoxy, thus limiting the bond line temperature, and linear shrinkage during cure is 0.33%. There was no reduction in bond strength after 1,000 hours of immersion in a variety of solvents, high humidity and high temperature. The cure speed is significantly faster and there is a longer pot life.

Core materials are used to reinforce the shell structure of blades, as they are lightweight with high bending stiffness. CTC Engineering BV based in the Netherlands has reviewed the different core materials in the wind market. The most common are balsa and PVC, but due to demand the price has increased. The newer alternatives are cork and foams from other polymers like polyethylene terephthalate (PET), styrene acrylonitrile (SAN), polystyrene (XPS), polymethacrylimide (PMI) and glass reinforced polyurethane (PUR/PIR). CTC Engineering looked at a set of properties for each material namely, density, compression modulus, shear modulus, peel strength, temperature stability and resin consumption. The comparisons are not always simple, for example PET foam is 10-15% cheaper than PVC by volume, but has higher density and resin consumption. The SAN foam has better properties than PVC and is comparable in price; however there is currently only one supplier, which could cause issues in manufacturing.

The next networking event for the industry, Wind Turbine Blade Manufacture 2012 will take place from 27-29th November 2012 at the Maritim Hotel, Dusseldorf, Germany and the call for papers is open until 25th May 2012: offers of papers should be sent to Dr Sally Humphreys, sh@amiplastics.com before that date.

SPE names Willem De Vos as its new chief executive officer

Fri, 20 Jan 2012 00:00:00 GMT

January 20, 2012 The Society of Plastics Engineers (SPE) has appointed Willem (Wim) De Vos as its new Chief Executive Officer. He succeeds Susan Oderwald, who left SPE in December.

"In our worldwide search for a new chief executive officer, we were delighted to find in Wim a 20-year veteran of the plastics industry who is already active in and understands our Society, has a truly global perspective, and brings outstanding management experience at a time when SPE is focused on growth," said Russell Broome, SPE's 2011-2012 president.

"His expertise in extending business activities into emerging markets and his global network in the plastics industry will be of enormous value in carrying out SPE's mission of strategic growth."

Willem De Vos comes to SPE after serving as CEO of the Vitalo Group, a global supplier of plastic packaging and thermoformed products. Previously he managed compounding and processing units of Recticel, an international producer of polyurethane automotive components. He entered the industry in 1991 with technical and sales positions at Eurocompound, a supplier to the textile and automotive industries.

As head of the Vitalo Group, Mr. De Vos oversaw an enterprise with worldwide factories and sales offices, including locations in Europe, the USA, Mexico, India, Thailand, China, Japan, and the Philippines. At Recticel, he first supervised plants in Belgium and Detroit, Michigan; then, as a director of Recticel Interior Solutions, based in Germany, he was responsible for several European and Asian car brands. In addition to his responsibilities in Europe, he set up Recticel's first plant in China, and was a board member of a Japanese joint venture.

A member of SPE, Mr. De Vos most recently served as chair-elect of the European Thermoforming Division. His speaks Dutch, English, French, German, and some Italian.

Mr. De Vos holds an engineering degree in polymer chemistry from Industrirle Hogeschool CTL in Gent, Belgium, and an executive MBA from the Vlerick Leuven Gent Management School.

KraussMaffei and its partners promoting lightweight construction processes for structural components

Thu, 19 Jan 2012 00:00:00 GMT

January 19, 2012 Over 100 people came to Munich to find out about the latest development status of lightweight structural components in the SpriForm Cooperative Project at KrausMaffei. Pioneering findings for lightweight construction using plastics.

'Lightweight structural components' formed the electromobility-specific topic presented by the cooperative partners - Audi AG, Bond-Laminates, the Institute for Composite Materials (IVW), the Jacob Plastics Group, Lanxess and KraussMaffei - during the closing event in the SpriForm Project.

In the framework concept "Research for future production", which was financially supported by the German Federal Ministry of Education and Research (BMBF), KraussMaffei and other industrial and scientific partners jointly developed a production process during the SpriForm Project. This production process combines the advantages of thermoplastic injection moulding with the advantages of thermoforming of continuous fiber-reinforced, semi-finished products, so-called organic sheets, for applications in structural lightweight components.

"We were delighted with the large number of persons attending the closing event", said Nicolas Beyl, director technology at KraussMaffei.

"The high attendance proved that we had found precisely the right topic." In addition to process development with material handling technology for the organic sheets and trim optimisation for geometrically complex components, the focal point was calculation of the all-plastic hybrid components. Georg Kaufmann Formenbau AG was responsible for constructing the moulds.

Extensive know-how in lightweight construction technologies using fiber composites

Fiber composite technology is very important in lightweight automotive construction and the proportion of plastics, as an automotive material will continue to increase. The costs and unit numbers of each component must therefore be evaluated in regard to lightweight construction potential in order to select the most suitable options from the large number of materials and production solutions.

"Due to our extensive experience in numerous production processes for lightweight fiber-reinforced components, we are a recognised partner along the entire process chain", said Beyl. "From the feasibility study through to post-mould processing and subsequent processing, manufacturers and suppliers appreciate our know-how and are increasingly asking us about interdisciplinary services." What's unique is the extensive portfolio of processes for manufacturing composites made of thermoplastic and duromer materials containing reinforcement fibers made of glass, carbon or plastics.

"Fruit-Pops"- Pure and Simple

Wed, 18 Jan 2012 00:00:00 GMT

January 18, 2012 Baltimore Innovations is adding to its portfolio of specialty packaging with the launch of the Fresh-R-Pax "Fruit-Pop" pouch. It will make its European debut at the Fresh Conex show in Berlin on the 8th February. Fresh Conex is the World's leading Fresh Produce trade show and runs alongside Fruit Logistica, attracting the movers and shakers from the world of fresh produce to Berlin each year.

The "Fruit Pop" Pouches are made with food-safe absorbent technology, which allows processors to pack ripe and sweet tasting fruit. The new packs are easy to open, tamper evident, and are ideal for packing slices of fresh-cut pineapple and melon. Most importantly, it offers extended shelf life relative to other alternative in the market.

"Customers have been asking us to develop a way of packing fresh cut fruit into single-serve portions, with extended shelf life. At the same time they've asked us to keep the solution economically attractive. We've been working on this new Fruit-Pop pack for a few years, and we're now happy that it ticks all three boxes" said Matthew Valentine, managing director, Baltimore Innovations.

The new "Fruit Pop" Pouches are ideal for target markets such as; kid's snacks, school lunches and convenience stores.

Baltimore has been working as the European distributor of Fresh-R-Pax for over a decade, on behalf of Maxwell Chase Technologies, a US company based in Atlanta. Maxwell Chase, is a leader in extended shelf life technology, manufactures a range of absorbent packaging including; pads, trays, retail containers, pouches. In addition to these consumables, it also produces specialist fruit slicing and packing machines.

More plastics recycling a key 2012 focus, predicts Axion Consulting

Wed, 18 Jan 2012 00:00:00 GMT

January 18, 2012 Increasing UK plastics recycling tonnages will be a key focus for 2012 as the sector continues to extend pioneering work done on PET and HDPE bottles recycling, predicts Keith Freegard, director of Axion Consulting, one of the UK's leading resource and recovery specialists.

With UK plastic bottle recycling rates nudging 50 per cent for drink and dairy bottles, Keith believes that further investment in technology and equipment to extract a wider range of materials from mixed plastic collections offers major potential for improvement.

"To get even higher bottle recycling rates, UK Plc has to find viable technologies to deal with mixed rigid plastics, films and the inevitable residuals," asserts Keith.

"Kerbside collection data points to a huge untapped source of rigid, non-bottle packaging items becoming available as local authorities offer collections of more household plastics, as well as an often-ignored, high volume of post-consumer films."

While full mixed plastics collections are very popular with local authorities, they can only realistically be initiated when processing infrastructure is in place, otherwise recovery of the materials that are currently targeted will actually decrease.

Greater emphasis on rigid post-consumer plastic packaging and films could also lead to more ‘co-ordinated' approaches in overcoming challenges presented by these more difficult-to-recycle waste streams.

"Today's primary sorting Material Recovery Facilities (MRFs) and bottle-sorting Plastic Recovery Facilities (PRFs) were developed in response to PET and HDPE recyclate demand," continues Keith.

"Next-generation infrastructure must be capable of extracting value from other rigid plastics and films if we are to achieve higher overall plastic packaging recycling targets."

New investments must complement continued growth in annual bottle recovery and be capacity-matched to the inevitable rise in other rigid and flexible plastics generated from existing plastic recycling infrastructure.

"People are realising we need to tackle more difficult waste streams. One solution would be to build more integrated ‘resource parks' where varied and mixed waste streams can be processed in complementary ways," explains Keith. "For example, residual materials from sorting commingled waste streams can be used as an energy source to provide local heat and power for adjacent washing and reprocessing units."

However, such novel ways of dealing with plastic and other waste streams would require fundamental changes to how Materials Recovery Facilities (MRFs) assess and handle their infeed and output waste streams.

Keith adds: "2012 will see increasing importance placed on MRF optimisation, including the use of sophisticated modelling, sampling and analysis services like those provided by Axion. Accurate and representative measurement of inputs and outputs is vital to highlight where plant control responses are needed to optimise operational efficiency, maximise profits and ultimately recover the valuable resources that would otherwise be discarded."

Hubertus Schulte: the new CTO of ENGEL

Tue, 17 Jan 2012 00:00:00 GMT

January 17, 2012 With effect from 1st January, Dr. Hubertus Schulte (50) took over the responsibility for technology and production within the management team of ENGEL AUSTRIA.

Hubertus Schulte brings more than 20 years of international experience in plastics processing machines to the role. In his previous post, he was the CEO for a leading German supplier of extrusion systems; a role in which he was responsible for both engineering and global sales and distribution.

Dr. Schulte, a native of Westphalia, completed an apprenticeship as a toolmaker before reading for a degree in machine technology (plastics engineering and process technology) at the University of Paderborn/Germany. He went on to achieve a doctorate in the field of injection moulding plasticising units at the same institution.

"The appointment of Dr. Schulte will give the company another boost", said Dr. Peter Neumann, CEO of ENGEL (who himself assumed this role during the time of crisis).

"We are delighted to have Hubertus Schulte, an expert with international experience, in such a key position. His highly innovation-oriented and client-focused approach to his work will be invaluable in helping us pursue our strategic goals and enhance customer proximity."

Fasti-Koch- State-of-the-art material drying: It's what's inside that counts!

Mon, 16 Jan 2012 00:00:00 GMT

January 16, 2012 Fasti-Koch is enhancing its compressed air dryers for small throughputs of hygroscopic material and equipping them with technology fit for the future.

A modern touch panel-based control offers intelligently adapted granulate drying with maximum convenience for the operator. The new control system regulates energy and compressed air consumption to the levels actually required. An integrated database for materials and operating data helps the user save, change and always have access to process parameters.

The previous generations of Fasti-Koch compressed air dryers have all used the same impressive, modular basic concept. The control module, also known as the pilot module, and drying containers of various sizes can be quickly disconnected and put together again.

This pilot module now features a modern touch panel-based control, the first of its kind to ever be used in compressed air dryers. The touch-sensitive display makes for easier operation and clarity. The user can call up all relevant data in a clear form and change it with just the pressure of his or her finger. This might include drying temperatures, drying time monitoring, holding times, an interval or weekly timer program, the integrated control for air-jet conveyance, the option of dew point recording or the new feature of a material database.

Data such as temperatures, lowering times and regulation of air volumes for the dried materials are stored in this database for subsequent access. The intelligent control system automatically adapts to the material volume throughflow. This means that if the material throughput increases, the energy and compressed air consumption values are changed by a proportional amount. If the material throughput falls or no material is being removed, energy and compressed air are automatically reduced. The energy and compressed air consumption values are therefore minimised.

"We took the idea of touch panel-based control from the compressed air dryer's big brothers - the dehumified air dryers from Koch-Technik," says Werner Koch, managing director of Fasti-Koch.

"This form of control proved a success in these products and went down well with customers so we are now using it in Fasti-Koch compressed air dryers too."

The control components in the touch panel module are perfectly matched to the gentle drying of all plastic materials currently used (such as ABS, PA and PP). Dew point measurement and recording can be integrated in the new compressed air dryer control system. The user can also use ports such as Ethernet and USB to exchange data. Combining all the control components in the compact touch panel module has greatly reduced the weight of the pilot module, simplifying changes on the processing machine.

From 2012, the new control system will be standard in all Fasti-Koch ERD dryer models, ranging from the ERD Micro dryer for very small volumes to the ERD Xpert dryer for small volumes, which is available with V2A stainless steel drying containers of between 7 l and 62 l.

A beverage holder that elegantly ‘holds its own'

Fri, 13 Jan 2012 00:00:00 GMT

January 13, 2012 The beverage holder ‘Stick-iT' made of Terblend N plastic receives innovation award in Geneva.

‘Stick-iT', a portable beverage holder made by the Belgian company CP Multi Trading BVBA, received the golden innovation award at the 2011 International Exhibition of Inventions in Geneva, Switzerland.

This piece, which serves as a holder for plates, glasses, bottles or cans, is made of the plastic Terblend N NG-02 EF, an ABS+PA blend produced by Styrolution. In spite of its fiberglass content, this plastic can be used without being coated. The granules, which are pre-dyed by the manufacturer, come in a wide range of colours, thus saving time and cutting costs.

This Terblend N grade has been specially designed for aesthetically pleasing applications. It has relatively low fiberglass content at eight percent and provides an excellent balance between enhanced stiffness and durability. Moreover, this plastic stands out for its high surface quality and pleasant surface feel. In addition, mould textures can be replicated very precisely, giving the plastic a matt surface that is easy to grip during use.

Another advantage of Terblend N is that it is easy to process. In particular, the EF (excellent-flow) grades are especially free flowing, allowing the creation of geometrically complex injection moulded parts, such as the filigree details of the beverage holder.

This plastic also offers the requisite dimensional stability under heat as well as chemical and UV resistance, making the beverage holder very stabile and robust. It can easily withstand exposure to sun, rain and other liquids, thus lending itself well to outdoor use in the backyard, at the campground or on the beach.

Flexible extruders for thermoforming sheet lines on the advance

Fri, 13 Jan 2012 00:00:00 GMT

January 12, 2012 Reifenh�ser Extrusion is recording a remarkable increase in incoming orders for thermoforming sheet extrusion lines featuring production capacities between 700 and 1500 kgs/h.

Ten lines of this type used for the production of drinking cups and deli containers of polypropylene (PP) and cups of polystyrene (PS) for the dairy industry have been sold since the K 2010 show. And there are further prospective projects on hand.

The great interest in these lines is mainly based on the flexibility required by the market. Soaring raw material costs, smaller orders from customers, and a strong pressure on end user prices, which has even been increased as a result of the global financial crisis are forcing producers to rapidly adapt themselves to new market situations.

This is only possible to a limited extent using high-performance, single-purpose extruders that are optimised for processing a specific raw material recipe. Product changes require costly and time-consuming machine resetting's which can frequently only be realised installing a new screw - if available.

Michael Beckhoff, sales manager at Reifenh�ser Extrusion says: "Single-purpose extruders were discussed as upcoming trend before the financial crisis. Now it seems that a more differentiated view on this subject is being taken since there is an increased demand for flexible solutions instead of high performance for a single product.

"Our order books clearly reflect this development because Reifenh�ser lines provide the requested flexibility: Our customers are not bound to the production of a certain product or large quantities, but, if necessary, they can rapidly change to other raw materials without any problem.

"In addition, they are flexible in reacting to new market requirements and can handle small orders efficiently."

Reifenh�ser thermoforming sheet lines are designed for a medium speed range which allows to process a large spectrum of raw materials such as Polypropylene (PP), Polystyrene (PS), Polyethylene terephthalate (PET) und Polylactide (PLA), with one and the same screw.

Thanks to the modular concept, the line can be tailored to the specific requirements of the customers without compromising flexibility. For the production of finished cups, an automatic in-line vacuum former can be integrated in the system.