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Italian Machinery & Equipment for Plastics & Rubber at PLAST 2012 in Milan

PLAST Milano / May, 8-12 2012Hall 13 Stand C21/D18

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Italtech is associated with

PROUD TO BE ITALTECHKL SERIES

INJECTION MOULDING MACHINES APPLICATION FIELDSViale Enrico Mattei, 16 – 25080 Mazzano (BS), Italy Tel. +39 030 2060400 – Fax +39 030 2594668

italtech@italtech.it – www.italtech.it packaging food industryautomotive general purposewww.italtechgreenproject.com

The new clamping unit of the KL Series

presents the innovative technology of the free

short tie bars, by means of locks and of jaws on

the fi xed platen. The elimination of the wearing

components, as bushings or tie-bars pads, allows

more performing machine working conditions.

HighSpeed Series Flexible Series Platform Series Cartesio Series

TOSH, with the production of its LOGICA SERIES machines, has imposed a 100% Italian quality and technological standard recognized over the world,

significantly contributing to the evolution of the pad printing process on objects as the most advantageous solution in the various decoration processes.

Offering cutting edge solutions aimed at creating concrete, appreciated advantages, especially in economic terms, is the primary target of TOSH

each and every day in order to satisfy the expectations of its clients, aware that “the success of its clients equals its own success”.

TOSH - expanding the horizons of pad printing

TOSH S.r.l. - I - 20089 Quinto Stampi - Rozzano - MI - Tel. +39 02 57566.1 - Fax +39 02 89200266 - info@tosh.it

All the news on

www.tosh.it

Machines, products and automation for pad printing

Milan, May 8 - 12Pav. 22 - Booth B25

36 ....................AMUT......................................www.amut.it20 ....................ASSOCOMAPLAST................www.assocomaplast.org33 ....................BARUFFALDI ........................www.baruffaldi.eu50 ....................BD PLAST ..............................www.bdplast.com47 ....................DEGA......................................www.dega-plastics.com55 ....................DOSS VISUAL SOLUTION ....www.doss.it11 ....................FRIGOSYSTEM......................www.frigosystem.it2 ......................FRIUL FILIERE ......................www.friulfiliere.it 58 ....................GMC........................................www.gmcprinting.com 42 ....................GRAHAM PACKAGING ........www.technespa.com15 ....................ICMA SAN GIORGIO ..............www.icmasg.it60 ....................IPM..........................................www.ipm-italy.it3 ......................ITALTECH ..............................www.italtech.it29 ....................ITIB MACHINERY ..................www.itib-machinery.com30 ....................MACCHI..................................www.macchi.it40 ....................MECCANOPLASTICA ............www.meccanoplastica.com17 ....................MORETTO..............................www.moretto.com40 ....................NEGRI BOSSI ........................www.negribossi.com19 ....................OMIPA ....................................www.omipa.it28 ....................PERSICO................................www.persico.com6 ......................PLAST 2012............................www.plastonline.org 43 ....................PRESMA ................................www.presma.it10-18-48-59 ..PROFILE DIES ......................www.profiledies.com58 ....................RODOLFO COMERIO............www.comerio.it49 ....................ROTOMACHINERY GROUP..www.rotomachinerygroup.com18 ....................SAGITTA ................................www.sagitta.it44 ....................SAIP........................................www.saipequipment.it59 ....................THERMOPLAY ......................www.thermoplay.com4 ......................TOSH......................................www.tosh.it24 ....................TRIA........................................www.triaplastics.com39 ....................UNILOY MILACRON ..............www.uniloy.com28 ....................WAMGROUP ..........................www.torex.it

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Rendezvous in Milan.................................................... page 7Machinery in the world ................................................ “ 7Better than expected.................................................... “ 8Extensive growth for WPC .......................................... “ 8Energy efficiency & productivity .................................. “ 9Electronic equipment .................................................. “ 9Polymer marketplace .................................................. “ 12Exhibitions & fairs ........................................................ “ 14Future zone in Shanghai.............................................. “ 14Meetings & congresses................................................ “ 16Composites on the lagoon .......................................... “ 17Porous polymers .......................................................... “ 17Ethical and aesthetic recycling .................................... “ 21Recycling in Italy .......................................................... “ 22Booming bioplastics .................................................... “ 23Crumb rubber for asphalt ............................................ “ 23Natural bottles.............................................................. “ 24Agricultural waste ........................................................ “ 25Recycled on the bridge ................................................ “ 25Youth Parliament ........................................................ “ 25European projects........................................................ “ 26Endless ........................................................................ “ 27Extrusion lines & equipment ........................................ “ 31Injection moulding machines........................................ “ 37Blow moulding machines ............................................ “ 38Other machinery .......................................................... “ 41Ancillary equipment & components ............................ “ 45Agriculture & polymers ................................................ “ 51Moulding temperature .................................................. “ 53Infusion for UV protection ............................................ “ 53Glass in the shell.......................................................... “ 54Inflatable car ................................................................ “ 54Ventilation system........................................................ “ 54Flying robots ................................................................ “ 55Reshapeable like glass................................................ “ 55Insect cuticle ................................................................ “ 56Acrylic towers .............................................................. “ 56Beverage holder .......................................................... “ 57Logistic revolution ........................................................ “ 57Logo plates .................................................................. “ 57

Summary

MILANO, MAY 8/12 2012 INTERNATIONAL EXHIBITION FOR PLASTICS AND RUBBER INDUSTRIES

PLAST 2012

XYLEXPO

FLUID TRANS COMPOMAC+ MECHANICAL POWERCONTROL

At FIERA MILANO,from Tuesday May 8to Saturday May 12, 2012,for the international exhibition for plastics and rubber industries.In 2012, PLAST will be the largestspecialized exhibition in Europe.As of 31 March 2012, more than 1,400 exhibitors from 46 countries have signed up for the event, but more applications have been recently submitted.Based on data from PLAST'09,when 32% of visitors came from abroad, more than60,000 visitors are expectedfrom all over the world.

Find more information, special offers for visitors,discounted rates on airfareand hotels, tourism plans in Milanand Italy generally,as well as the exhibitor listand the pre-registration formon www.plastonline.org

Organizer:Promaplast srlAssago (Milan) - Italy

This year PLAST (Milan, May 8-12) isthe largest specialized exhibition inEurope for the plastics & rubber in-

dustries, representing the entire productionchain of machinery, equipment, moulds,raw materials, recycled materials, compos-ites, and semi-finished & finished products.At the end of March, more than 1,400 ex-hibitors from 46 countries had signed up forthe triennial international event, covering anet exhibition area of 60,000 sqm approx.The previous edition of PLAST (2009)brought in a total of 1,478 exhibitors (856Italian and 622 international from 45 differ-ent countries) occupying an overall area of60,000 sqm subdivided into 7 halls. The fairalso attracted 55,175 visitors: 37,586 Italianand 17,589 from 114 foreign countries (withEurope accounting for 71% of the total). Regarding the home countries of PLAST2012 exhibitors, Italy is of course in firstplace with almost 800 companies, followedby Germany (168), China (51) and the US(41). As previously, the core of the showcomprises machinery and equipment man-ufacturers, with a wide range of technolo-gies exhibited. A section of this issue - from page 31 to48 - is dedicated to a review of new prod-ucts presented at the show by Italian ma-chinery manufacturers.

* * *With respect to previous editions, PLAST2012 has many new features underscoringthe international character of the fair andhighlighting the broad panorama of noveltechnologies and innovative applicationsthat are prominently displayed in 6 halls ofFiera Milano fairgrounds at Rho-Pero. A noteworthy feature this year is the return

of the RUBBER "satellite fair". Organizedwith the sponsorship of Assogomma (theItalian association for the rubber industry),the show draws attention to this specificsegment of synthetic materials.Another new feature of this edition is thePlastic International Award - organized bythe fair management and Poli.Design (aconsortium of Milan Polytechnics) - an in-ternational contest reserved to innovativeproposals for applicative solutions relatingto the main plastics processing technolo-gies presented by design professionals andstudents.Finally, the fair is enriched by a broad pro-gram of concurrent events (technical con-ferences, congresses, seminars etc.) onthe following topics:May 9 - Earth, water, air. Impact and sus-

tainability of PVCMay 9 - Italian research on active packag-ing, focusing especially on nanomaterialsMay 9-10 - SPE national meeting on plas-tics (I-tec)May 10 - EPS between energy and envi-ronmentMay 10 - Certification for environmentalsustainabilityMay 10-11 - Biodegradable polymer pack-aging (Biopolpack) May 11 - Thermally conductive polymernanocomposites (Thermonano Europeanproject) May 11 - Smart plastics for a high qualitysupply chain in agriculture May 11 - Innovation in plastics coating (Ver-plast)

● 7

Rendezvous in Milan

Global demand for plastics processingmachinery is projected to rise 6%annually through 2015 to 28.9 billion

dollar, a rebound from market declines ex-perienced during the recession-impacted2005-2010 period. Many nations are build-ing up their plastics manufacturing infra-structure, due to both rising domesticdemand for plastics-consuming goods andexport opportunities to developed na-tions. These and other trends are pre-sented in a new study from FreedoniaGroup.Gains in developing nations will be thedriving force behind advances in theglobal market for plastics processingequipment. China, for example, willaccount for over 40% of all additionalglobal demand through 2015, withgrowth stimulated by strong increasesin plastic manufacturing as industrial-ization efforts continue and incomelevels rise. Other nations in Asia with

smaller, less-developed economies, suchas India, Vietnam and Thailand, will alsorecord healthy market gains. In developedareas of the world, most notably the US,Western Europe and Japan, demand willrebound after a period of decline, althoughsales advances will not be as strong asthose in developing nations.Among major product types, extrusion

equipment will post the strongest gainsthrough 2015, benefiting from growth inglobal construction spending, which willfuel demand for extruded goods like pipeand siding. Injection moulding equipmentwill remain the largest product segment,accounting for 40% of demand in 2015. The construction market will post thestrongest gains through 2015, benefiting

from an acceleration in global con-struction spending. The consumer/institutional product market will alsopost solid gains, reflecting risingstandards of living. The packagingmarket will post respectable gainsdue to rising manufacturing outputand consumer demand for pack-aged products. In addition, plasticwill continue to gain market sharefrom other materials in applicationssuch as bottles.

www.freedoniagroup.com

Machinery in the world

WORLD DEMAND FOR PLASTICS PROCESSINGMACHINERY (million dollars)

2005 2010 2015

NORTH AMERICA 3,150 2,640 3,430

WESTERN EUROPE 4,040 3,830 4,560

ASIA-PACIFIC 8,130 11,510 16,150

CENTRAL & SOUTH AMERICA 580 880 1,160

EASTERN EUROPE 1,200 1,470 1,980

AFRICA & MIDEAST 960 1,270 1,620

TOTAL 18,060 21,600 28,900

Generally speaking, 2011 was agreatly satisfying year for the Italianmanufacturing industry of plastics &

rubber processing machinery, equipmentand moulds: after the deep crisis of 2009(which actually erupted in late 2008 withthe world financial crisis) and the slow re-covery in 2010, heartening figures were fi-nally witnessed again this past year.Awaiting the consolidated figures, esti-mates developed by Assocomaplast (thenational association representing theabove industry) show revenues in the sec-tor of over 4 billion euro, an increase of11% over 2010, with exports especiallyproviding encouragement at +19% forsales worth an overall 2.4 billion euro. Although we are not quite at pre-crisis lev-els (2007, the best year ever, recorded pro-

duction valued at 4.25 billionand exports at 2.75 billion),only a minimal amount ofground still remains to be re-gained. As is clear from theabove figures, production isdriven mainly by sales abroadand certainly not by the do-mestic market which, with alldue exceptions, continues tosuffer a slump that seemsendless (and the prospects for2012 are anything but rosy…). Without delving into mere statistical analy-sis, it must be said that certain foreign mar-kets (Brazil above all) seem not to have feltany impact from the difficulties in the globaleconomy. And while they have witnesseda slight slowdown, China and India con-

tinue to grow at rates that areunimaginable in a maturemarket like Europe. Russiatoo - as is well known by thecompanies that exhibited atthe Interplastica show inMoscow last January - hasresumed its pace. While notcomparable to China or India,it is nevertheless very attrac-tive to Italian manufacturers.Continuing with this briefoverview, Turkey also de-serves some mention. It is al-luring not only for its domesticmarket (in spite of the mas-sive presence of Chinesemanufacturers) but also as abridge between Europe andthe Near East.

Regarding forecasts for 2012, little can besaid with certainty except perhaps that itwill be impossible to repeat the perform-ance recor ded in 2011. There is a certainpessimism in the air among Italian busi-nesses in the sector rooted in economicconditions that are objectively anything butbright but also nurtured by negative moodsand rumours propagated in the media.Actually, as also revealed by Assoco ma -plast’s survey of its member companies,mo st of them had enough orders on thebooks at the end of 2011 to cover at leastthe first half of the current year. Of course,there is still the second half to worry about,but looking at the situation with a certainoptimism, once you’re halfway, you’re al-most there…Depending on how things develop, it is rea-sonable to expect slight oscillations in themarket - perhaps up, most likely down -with respect to 2011, without however therebeing any particularly worrisome negativedips.

www.assocomaplast.org

8 ●

Better than expected

NEGRI BOSSI

MARKET FOR ITALIAN PLASTICSAND RUBBER MACHINERY &EQUIPMENT (million euro)

2009 2010 2011

Production 3,300 3,600 4,000

Export 1,833 2,010 2,430

Import 484 570 605

Domestic market 1,951 2,160 2,180

Trade balance 1,349 1,440 1,825

With nearly 300 participants from21 countries and 30 exhibitors,the WPC Congress organised by

Nova-Institut in Cologne on December13-14 once more lived up to its reputationas a leading European event with currenttopics, developments and trends relatedto WPCs (Wood-Plastic Composites). Anextended advisory committee includingrepresentatives of manufacturers, the sci-entific community and the press selectedthe presentations to ensure adequatecoverage of topics of concern to the in-dustry. The result was a programme thatpacked 26 lectures into two days.The European market for WPCs (Wood-Plastic Composites) has been growing atan average annual rate of 35% since2005. Given the current levels of invest-ment in expanding production and grow-ing interest from both trade andconsumers, the industry is optimisticabout the future and expects continuedtwo-figure growth over the next few years.

In 2010 roughly 220,000 tons of WPCswere produced in Europe: 50,000 wereused in the automobile industry (mainlycompression moulding) and 167,000 inthe area of terrace flooring, fencing andcladding (mainly extrusion). More andmore WPC materials are being used forfurniture and office and home utensils,along with small technical parts and cas-ings. Further substantial growth is ex-pected in every sector in the comingyears. WPCs are predominantly used inapplications that emphasise productcharacteristics such as great rigidity andlow shrinkage (compared to pure plas-tics) and better durability and malleability(than pure wood products). However, asprices for plastics rise, it is only a matterof a few years before WPC pellets arecheaper than pure plastic pellets (theyare presently 20-30% more expensive)and can then conquer mass markets..The WPC sector has matured in recentyears to a point where, from a technical

perspective, there are no longer any ob-stacles to its servicing a mass market.Made up of 20-80% bio-based material,wood plastic composites represent thelargest group of new biomaterials by vol-ume, significantly outstripping bio-basedplastics. This advantage becomes evenclearer considering the international fig-ures. The US are currently in pole posi-tion with a production volume ofapproximately 1.5 million tons of WPCs. One particularly dynamic market isChina, where 700,000 tons of WPCswere produced in 2010 - and this volumeis projected to rise to 5 million tons by2015, which would make the country thelargest WPC producer in the world. En-tire houses are made from extrudedWPC panels and even the doors are fullyextruded.

www.nova-institute.eu

Extensive growth for WPC

● 9

According to a recent study of Eu-romap (Europe’s association forplastics and rubber machinery

manufacturers), there are close links be-tween energy efficiency and productivityof processing machinery. Investing forgreater productivity generally also meansinvesting in energy efficiency. The studylooks at the main plastics and rubber pro-cessing technologies, i.e. injectionmoulding, extrusion, blow moulding andthermoforming, which account for around90% of the total volume processed. The production efficiency of injectionmoulding machines has more or lessdoubled in the last 20 years. Machinesare now capable of a manufacturing out-put that would once have required twiceas many machines of similar size. Devel-opments in manufacturing technologyhave provided a significant performanceboost. The demands made on hydraulicsystems have resulted in greater effi-ciency and cut the energy consumptionof injection moulding machines by around40%. The throughput capacity of extrusion ma-chines has also doubled over the sameperiod. Machine-related energy con-sumption has been reduced by around20%. The same is true in compounding:twice the amount of material is beingprocessed with machine-related energyconsumption down by 20% at the sametime. Increasing use has been made of servo-drives in cyclic processes such asinjection moulding, blow moulding andvacuum forming technologies for a num-ber of years now. These allow the energyrequired for motion to be cut by half.Plants with a conventional, central powersource and system-related line and con-trol losses are increasingly being re-placed. Servo-engineering has long since madethe breakthrough in such high-perfor-mance areas as packaging and medicalengineering. Servo-systems now alsooffer simple solutions for energy recuper-ation. In injection moulding, for example,during rapid motion of the closing units,the drives are used as generators to pro-duce energy when braking. The sameprinciple is also used with fast-workingclosing units of blow moulding machinesand in thermoforming machines.

* * *Looking to the future, there is no doubtthat the use of energy-saving and highlydynamic components will provide a sig-nificant boost in terms of improving en-ergy efficiency further in the next tenyears. Greater use of all-electric drivesand servo-hydraulic designs instead ofconventional technology will pave theway for further efficiency gains - in some

cases as much as 50%. The most important part in improving ma-chinery is played by developments inprocess engineering: advances in screwtechnology have brought a significant in-crease in throughput rates while at thesame time improving the melt quality. This has allowed extruders and the injec-tion units of injection moulding machinesto become smaller and better while main-taining performan ce. Radiant heater sys-tems show great potential in thermofor- ming machines. There is also a great deal of potential forcombining several processes: this is ofparticular interest if residual heat fromone stage in a process can be used in the

following stage with a view to eliminatingreheating altogether.In conclusion: if increasing productivitycontinues to drive European plastics con-verters' investment decisions in the fu-ture, energy efficiency will benefit. Majorsavings can also be achieved if convert-ers fine-tune processes to minimise en-ergy consumption. Monitoring the flow of energy in ma-chines, installations and in the plant alsoproduces results. It makes the energy re-quirement transparent, which in turn con-tributes to tailoring energy consumptionto need.

www.euromap.org

Energy efficiency & productivity

AMUT

Electronic equipmentAccording to a new market report

from BCC Research, the global vol-ume for plastics in electronic com-

ponents is expected to reach 1.58 milliontons in 2012 and increase to 2 million in2017, at an annual growth rate of 4.7%.This market can be separated into twosegments: thermoplastic and thermoset.In 2012, thermoplastics are expected tototal 1.13 million tons and in 2017 the vol-ume should reach 1.4 million (+4.9% peryear). The thermoset segment is pro-jected to reach nearly 500,000 tons in2012 and 590,000 tons by 2017 (+4.3%per year).

Resin consumption in electronic compo-nents is made up of a selected group ofengineering thermoplastics led bypolyamides and thermoplastic polyestersin volume. Based on value, however,higher performance resins such as PPS,polyimides, polyketones and LCP havebecome more significant factors in themarket. Engineering thermoplastics dom-inate the moulded component segment,of which connectors are the most impor-tant.The advantages of using plastics parts forelectronic components must be weighedagainst their disadvantages. To decrease

10 ●

already small component sizes, meltsused in moulding components must pos-sess excellent flow and precise moulding,thermal endurance, and dimensional sta-bility due to tight space constraints andrelatively high operational temperatures. While mechanical performance of plas-tics can be enhanced through reinforce-ments and filler loadings, higher amounts

of these additives often impair process-ability in the molten state. A better reso-lution of this dilemma is still an ongoingissue.

* * *In another market study from BCC Re-search, the global production of plasticsin electronic enclosures is projected to be

nearly 3.35 million tons in 2012 and toreach 4.5 million in 2017, increasing at anannual growth rate of 6.1%. Electronicenclosures are cabinets designed to pro-tect electronic equipment and to preventelectrical shock to users. In addition,these enclosures are developed to be vi-sually attractive to users. The global market for plastics used inelectronic enclosures can be brokendown into two segments - stationary andmobile enclosures. The stationary seg-ment is expected to amount to 3.26 mil-lion tons in 2012, and should be at 4.3million by the end of 2017 (+5.9% peryear). The mobile segment is projected toamount to 91,000 tons in 2012 andshould reach 165,000 tons in 2017(+12.6% per year).The surge of new electronic products hasresulted in significant changes in resinselection for enclosures. Downsizing andthin walling have necessitated a re-eval-uation of resins because of more de-manding physical-property requirementsand moulding challenges. In addition, are-evaluation is also necessary for resinsused in the stationary portion of the mar-ket, which includes enclosures for desk-top computers and flat-panel displays.

www.bccresearch.com

HALL 13 - STAND C05

12 ●

World polyolefinsAn annual global market studyreleased by CMAI (ChemicalMarket Associates Inc) covershistorical developments andfuture projections for supplythe global market of polyolefins(polyethylene andpolypropylene) in the period 2006-2016. Polyolefinsrepresent almost two-thirds ofthe major commoditythermoplastics usedworldwide. Their global marketis changing dramatically inresponse to the quicklyadvancing industrializationprocess in emerging countries,as well as improvements inglobal communications and tradeliberalization. Investments in polyolefin productioncapacity are increasingly concentrated inregions with affordable supplies offeedstocks or high-demand growth areas,such as the Middle East and the Asia-Pacific region. The same trend, particularlyin Western Europe, is driving industryconsolidation, operations optimization, anda shift toward the production of higher-value, higher-performance products. InNorth America, low-cost feedstock fromshale gas is revitalizing the polyethylenebusiness, making its exports highlycompetitive globally. In response, severalproducers have announced new capitalprojects that are currently scheduled tocome on-stream in the second half of the decade. One of the most challenging issues facingthe polyolefin industry during the lastdecade has been the loss of its pricingpower. Wedged between the demands ofupstream oil and gas corporations andmajor retail chains on the downstreamside, the production chain has beencaught in the middle. While energy andraw material prices increased in responseto tighter global market conditions, pricesfor finished goods remained at the samelevel or even declined, asimports from low labour costcountries flooded the market.As a result, profits in thepolyolefin industry had all butdisappeared. Although the recession of2008-2009 only exacerbatedthe already unfavourablemarket conditions forpolyolefins, producers aremaking strategic moves toprotect against furthermargin erosion. Instead ofengaging in competition formarket shares, they havebeen controlling production

and inventories to keep the marketbalance tight. The development of “green”sources for the production of plastics isadvancing steadily and is generating thefirst tangible results.

www.cmaiglobal.com

* * *The annual market study released byEATP (European Association for TextilePolyolefins) offers an analysis of thesituation and evolution of polyolefin fibresand textiles in Europe. The main trendsand conclusions of the 2010 report aresummarized below.The leading share of polyolefins -polypropylene and polyethylene - in thetotal European textiles market has furtherrecovered from the dramatic fall in 2008and 2009 and is still increasing. In 2010they accounted for 44% of all man-madematerials used for textiles. Consumptionof polyolefin textiles was almost 2.5million tons. Spunbond & meltblownnonwovens are the largest sector productand continue to grow strongly (up by 6%in 2010), followed closely by tapes andslit film, staple fibres and filament yarn.The largest end-use market is technicaltextiles, consuming 900.000 tons ofpolyolefins, in articles such as agro & geo

textiles, strapping, packaging,construction and a wide rangeof other technical applications.Carpet markets, one of thelarge end-uses, recoveredslightly in 2010, with PP usagerising by 1.4% to 516.000tons. Hygiene and medicalapplications grew by 6.9%,reaching almost 600.000tonnes. Polyethylene usagegrew, particularly in artificialgrass, but is less than 10% ofthe total market of polyolefintextiles.Western Europe still accountsfor most production ofpolyolefin textiles production,but the combined share of

Turkey and Central Europe has risen to32%. Total production of man-madefibres in Europe reached 5,580 ktons in2010 with the following shares:polyolefins 42,8%, polyester 21,6%,acrylic 12,4%, polyamide 10,5%,cellulosic 10,3%, other 3,7%.Total consumption of PP textileintermediate products in Europe reached2.268 ktons in 2010, subdivided asfollows: spunbond & meltblown 707(31,2%), tapes & slit film 495 (21,8%),staple fibres 469 (20,7%), multifilaments433 (19,1%), strapping 105 (4,6%),monofilaments 46 (2%), others 13 (0,6%).

www.eatp.org

Rubber consumptionBased on figures through the first ninemonths of 2011, the IRSG (InternationalRubber Study Group) expects totalrubber consumption to total 25.9 milliontons in 2011, and 27.2 in 2012. Syntheticrubber (SR) demand is forecast to growby 5.5% to 14.9 million tons in 2011, andby a further 5.5% to 15.7 million this year;natural rubber (NR) demand is forecast torise by 2% to 11 million tons in 2011, andby a further 4.6% to 11.5 in 2012. GlobalNR production is forecast to rise by 4.4%

to 10.9 million tons in 2011,and this year the outputshould expand at a higherrate of 5.1% to 11.4 million.IRSG reports that totalglobal rubber consumptioncontinued to increase in thethird quarter of 2011, risingto 25.8 million tons on a MAT(moving annual total) basisin September 2011, up from25.4 million in June. The rateof expansion has continuedto decelerate, slowing downfrom 7.1 to 6%, respectively,over the same period.Global NR consumption

POLYMER MARKETPLACE

BOREALIS

● 13

totalled 10.9 million tons on aMAT basis in September 2011,continuing to grow at adecelerating rate. Global SRconsumption data were reviseddownwards in September 2011.Here, the rate of growthaccelerated in the third quarterof 2011 as compared to thesecond quarter.Global total NR exportsexpanded to 7.48 million tons inSeptember 2011, 6.5% higherthan exports at the same pointin 2010. World total SR exportscontinued to expand during thethird quarter of 2011, increasingto 8.6 million tons on a MAT basis inSeptember 2011, rising from 8.5 million inJune.On aggregate, the trend of volume ofexports of selected latex general rubbergoods from the five leading countriesappears to be continuing to decrease inthe third quarter of 2011. It is still centeredon the other gloves sector, and is drivenby the weakened state of the globaleconomy. Global NR latex consumptiondropped by 3% in September to 1.3 milliontons, and appears to be driven by NR-SRsubstitution in downstream latex industriesas well as concern over slowing global NRdemand in general rubber products.

www.rubberstudy.com

Polycarbonate demandAfter demonstrating phenomenal growthduring the 1990s due to its use in theproduction of CDs and DVDs,polycarbonate saw its demand fall in 2009and rebound in 2010, but diversification toother uses, such as electronics, droveglobal growth for the polymer by around3% in 2011, according to a new globalmarket study from IHS.Electrical and electronic applications arethe largest end-use for polycarbonates,accounting for around 20% of globaldemand at around 720,000 tons in 2011.The key driver for this market will be theincreased use of consumer electronics,such as tablet devices, flat screentelevisions, mobile phones and officeequipment, including printers. The sheetand film segment, which primarily servesthe construction industry, represents 18%as well as optical media (CD/DVD);appliances and automotive (non-windowusage) are at 12%. Other uses includeauto glazing, medical equipment andinstruments, sports, safety andrecreational equipment, and packaging. As the trend toward larger TVs continues,polycarbonate is increasingly preferredover acrylic sheet for backlight diffusers,since greater dimensional stability isrequired, which cannot be offered byacrylic sheet, especially at the hightemperatures generated in the backlightunit. These new applications for thepolymer are an important factor for an

industry that can no longer rely on opticalmedia for the long-term growth of thebusiness. Increasingly, optical mediaapplications are being superseded byother technologies, as higher internetbandwidth allows consumers to downloadmusic and movies rather than buying thephysical polycarbonate disc.According to the study, global demand forpolycarbonate is expected to grow at anaverage annual rate of around 5% duringthe next five years, reaching around 4.5million tons by the end of 2016. Thefastest growth will be in the automotiveglazing sector, albeit from a very low base.Polycarbonate has almost entirelyreplaced glass for headlights and taillightsin automobiles and is making inroads intosun and moon roof manufacture, but if theautomotive industry transitions to usingthis polymer to replace window glass, thenit would be a game-changer for thepolycarbonate industry as the demandgrowth would be phenomenal.

www.ihs.com

Raw materials in Italy In January, Federchimica (the Italianfederation for the chemical industry)published the results of its six-monthlysurvey, which analyses in depth theeconomic and market situation of thechemical industry, and issues someforecasts for the various sectors. As usual,the results of this analysis pertaining to thesector of plastic materials and syntheticresins are summarisedbelow.Also according to data fromPlastic Consult, theperformance of the plasticsmarket in Italy during thefirst 9 months of 2011 isdisappointing. Demand forpolymers on the part ofprocessors was just above4.6 million tons, that is tosay down 2% comparedwith the same period in2010, which had itself beenvery unsatisfactory. This negative trend wasdetermined chiefly bypolyolefins (-3. 4%), which

account for 56% of plasticsconsumed in Italy. Morespecifically, there was a 4.2%drop for LDPE/LLDPE,principally attributable to filmextrusion, which has felt thecontinuing crisis of stretch wrapand the collapse of shoppers (aprohibition on polyethylenebags came into force onJanuary 2011); HDPE declined5. 5% as a result of thedownturn in film and pipesectors; PP fell by 1. 8%,following the slowdown of filmand fibre, which have long beensuffering.

For what concerns the other plasticmaterials, the decline of polyamides (-2.4%) is noticeable, hurt by the crisis ofthe automotive industry, and ofpolyurethane foam(-1. 6%), whose maindestination markets, with the exception ofbedding, are in notable decline. The onlypolymers which grew, though by amodest amount, are EPS (+1. 5%),thanks to the increase in sheet thickness,followed by plasticised PVC (+0. 9%) andPET (+0. 3%). In effect, all the factors responsible fordepressing demand in last year continueto exist: stagnation in the building industry,uncertainty surrounding the recovery ofindustrial production, contraction inhousehold consumption due to lowpurchasing power, now further eroded bythe return of inflation, cuts to publicspending and to investments ininfrastructure. Added to this is thepreviously mentioned ban on PE shoppingbags, which has caused a loss ofsignificant product volumes. Based on the results posted for the firstnine months of the year, and the still-negative fourth quarter estimates(-3.6% compared to the same period of2010), the year 2011 is expected to closewith a disappointing overall trend fordemand for plastic materials. Theforecasts in fact point to a 2. 5% declinerelative to 2010.

www.federchimica.it

CALLIGARIS

14 ●

April 2-5 - NPE (Orlando, United States) April 10-13 - Plastshow (São Paulo,Brazil) April 11-13 - Plastic Japan (Tokyo,Japan) April 11-14 - Indoplas (Jakarta,Indonesia) April 17-20 - Tires & Rubber (Moscow,Russia) April 17-19 - Utech Europe (Maastricht,Netherlands) April 18-21 - Intermold (Osaka, Japan) April 18-21 - Chinaplas (Shanghai,China) May 2-3 - Plastec South (Charlotte,United States) May 8-12 - PLAST 2012 (Milano, Italy)May 10-13 - Plas Tech (Izmir, Turkey) May 14-17 - Plastivision Arabia(Sharja,Saudi Arabia) May 16-18 - Plastex Caspian(Baku, Azerbaijan) May 16-18 - Plastex Uzbekistan(Tashkent, Uzbekistan) May 16-18 - N Plas (Tokyo, Japan) May 20-22 - PPP Expo Africa(Dar Es Salaam, Tanzania) May 23-26 - Expoplast (Lima, Peru) May 29-30 - Plastics Design & Moulding (London, United Kingdom) May 29-June 1 - Plastpol (Kielce,Poland) June 5-8 - Vietnam Plas (Hanoi,Vietnam) June 18-22 - Argenplas (Buenos Aires,Argentina) June 18-21 - Rosplast (Moscow, Russia)

June 19-21 - Vietnam Plastics Fair(HoChiMinh City, Vietnam) June 21-24 - Interplas Thailand(Bangkok, Thailand) July 18-20 - High Performance FilmExpo (Shanghai, China) July 19-22 - Mʼsia-Plas (Kuala Lumpur,Malaysia) August 6-9 - PMEE - Pyongyang Machinery & Equipment Exhibition(Pyongyang, North Korea) August 10-12 - Sri Lanka Plast(Colombo, Sri Lanka) August 17-20 - Camboplas(Phnom Penh, Cambodia) August 20-24 - Euromold Brasil(Joinville, Brazil) August 20-24 - Interplast (Joinville,Brazil) September - Iranplast (Tehran, Iran) September 4-6 - Plasti&Pack Pakistan(Karachi, Pakistan) September 6-9 - Plastex (Cairo, Egypt) September 10-14 - Plastex (Brno, Czech Republic) September 12-14 - Expo Plasticos(Guadalajara, Mexico) September 13-16 - Rubber Fair(Istanbul, Turkey) September 17-19 - Kenya Plast(Kenyatta, Kenya) September 19-22 - Sistep Midest(Casablanca, Morocco) September 20-22 - China InjectionMoulding (Tianjin, China) September 21-25 - Taipeiplas (Taipei,Taiwan) September 24-27 - Plast Alger (Alger,

Algeria) September 25-26 - Mediplas(Birmingham, United Kingdom) October 1-5 - Colombiaplast (Santa Fè De Bogotà, Colombia) October 3-6 - Expoplast (Bucarest, Romania) October 5-8 - Indplas (Kolkata, India) October 10-13 - Plastics & Rubber Indonesia (Jakarta, Indonesia) October 16-20 - Fakuma(Friedrichshafen, Germany) October 16-18 - Plasto Ispack (Tel Aviv,Israel) October 23-26 - Plastics Industry Show(Moscow, Russia) October 24-27 - Vietnam Plas(HoChiMinh City, Vietnam) November 2-October 31 - PlastexUkraine (Kiev, Ukraine) November - Feiplar Composites(São Paulo, Brazil) November 7-9 - Jec Americas (Boston,United States) October 9-11 - Brityrex(Manchester, United Kingdom) November 14-15 - Expoplast (Montreal,Canada) November 14-16 - Rubbertech(Shanghai, China) November 27-30 - Euromold (Frankfurt,Germany) November 28-December 2 - Saurashtra Plast (Rajkot, India) November 29-December 2 - Plast Eurasia (Istanbul, Turkey) December 13-16 - Bakumach (Baku,Azerbaijan)

Exhibitions & fairs

Undoubtedly, industrial plastics can fitwell into the advance development ofthe automotive industry, to pursue

with the emphasis of energy saving, envi-ronmental friendliness and enhance safety.Plastics usage in the making of automotiveis under rapid growth and such trend is ex-pected to continue in the coming years.The use of plastics in this industry in de-veloped countries accounts for 7% of totalplastics consumption and is expected toreach 10-11% soon. Based on this upwardtrend, it is believed that the ideal scenarioof producing the 100% plastics-made auto-mobile will turn into reality in near future.Staging its 26th edition, Chinaplas 2012(Shanghai, April 18-21) has reached an ex-hibition area of 200,000 sqm occupying all17 exhibition halls. More than 2,600 ex-hibitors from 35 countries and regions andover 100,000 visitors from 140 countriesare getting together in this vast professionalevent. The organizer, Adsale Exhibition Services,strives to contribute to the plastics and rub-

Future zone in Shanghai

AustraliaOctober 7-10 - Cairns: “InternationalSymposium on Biopolymers”

AustriaApril 24-26 - Wien: “Stretch & Shrink Film”

BelgiumApril 19-20 - Bruxelles: “Polymer Rheology and Extrusion”May 9-10 - Bruxelles: “Food Contact Plastics”

BrazilNovember 9 - Rio de Janeiro: “Advances in Technologies for Productionof Basic Petrochemicals, Polymers andtheir Products”

GermanyApril 24-26 - Köln: “Polymers in Photovoltaics”May 14-16 - Hamburg: “Polymer Sourcing”June 19-20 - Fellbach: “Global WPC and Natural Fibre Congress”June 20-21 - Düsseldorf: “World Symposium on Performance Films”July 2-5 - Nürnberg: “German Rubber Conference (DKT)”October 8-9 - Düsseldorf: “Composite and Reinforced plastics”October 16-18 - Köln: “Multilayer Packaging Films”October 23-25 - Köln: “Polyolefin Additives”November 6-7 - Berlin: “European Bioplastics”

ItalyApril 19-20 - Parma: “Congress onBiodegradable Polymer Packaging”April 26-27 - Venezia: “European Thermoforming Conference (SPE)May 7 - Assago: “Polymer Insights”May 9 - Milano: “Earth, Water, Air. Impacts and Sustainability of PVC”May 9 - Milano: “Italian Research on

Active Packaging”May 9-10 - Milano: “SPE Italian Technical Meeting (I-tec)May 10 - Milano: “EPS between Energyand Environment”May 10 - Milano: “Quality Marks as Toolto Increase Organizations CompetitiveDevelopment”May 10-11 - Milano: “BiodegradablePolymer Packaging (Biopolpack)”May 11 - Milano: “Thermally ConductivePolymer Nanocomposites”May 11 - Milano: “Smart Plastics for aHigh Quality Supply Chain in Agriculture”May 11 - Milano: “Plastic Materials Coating Innovations (Verplast)”May 21-25 - Gargnano: “Polymer Synthesis (AIM)”May 29-31 - Torino: “Assocompositi Italian congress”June 3-7 - Gargnano: “Porous Polymer-Based Systems (Eupoc)”June 10-14 - Ischia: “Times of Polymersand Composites (TOP)”June 24-28 - Venezia: “European Conference on Composite Materials(ECCM)”July 3-6 - Ustica: “Italian Congress on Rheology”October 15-19 - Riccione: “ISO TC 45Congress - Rubber and Rubber Products”

NetherlandsApril 17-19 - Maastricht: “Urethanes Technology (Utech)”May 20-23 - Kerkrade: “Sustainability inPolymer Materials”

NorwayMay 14-16 - Oslo: “Advanced RubberTechnology for Demanding Applicationsin the Oil and Energy Industry (Rubber-Con)”

SingaporeMay 23-24 - Singapore: “World Rubber Summit”

June 26-28 - Singapore: “InnovativeComposites Summit (JEC Asia)”

South KoreaMay 21-24 - Jeju: “International Rubber Conference (IRC)”

United Arab EmiratesApril 3-5 - Dubai: “GPCA Plastics Summit”May 15-16 - Dubai: “Middle East Plastic Pipes”

United KingdomMay 29-30 - London: “Plastics Designand Moulding Summit”July 4-5 - Bristol: “Composites Innovation”October 23-25 - London: “Oilfield Engineering with Polymers”

United StatesApril 2-4 - Orlando: “SPE Annual Technical Conference (Antec)”April 18-19 - Miami: “Polymers in Cables”May 8-9 - Miami: “Bioplastics Compounding & Processing”June 19-20 - Chicago: “Thin Wall Packaging ”June 26-27 - Chicago: “Multilayer Packaging Films”August 25-26 - Minneapolis: “Durable Bioplastics”August 26-29 - Columbus: “Global Polymer Innovation”September 11-13 - Troy: “AutomotiveComposites Conference”September 24-26 - Atlanta:“Polyurethanes Technical Conference”October 9-10 - Newark: “Polymer Foams”November 6-7 - Philadelphia: “Stretch & Shrink Film”November 7-9 - Boston: “Summit on Innovative Composites (JEC Americas)”

Meetings & congresses

ber industries, to ride on its effective com-munication platform to promote sustainableproperties of plastics and rubber in differ-ent applications, and to cultivate, developand promote the forward-looking "green"concept. Through the collaboration be-tween students of university, experts fromthe automotive and the plastics/rubber in-dustries, a concurrent event named FutureZone is being held during the show period. The concurrent event is composed of twoparts: the first (Nurturing Our Future) com-bines plastics & rubber applications, tech-nology and innovation that lead to a brandnew design of a future car; the second(Premium Design Gallery) showcases aseries of new, unique design of variousplastic-made end products. This programis to promote cooperation between the

commercial and academic field in terms ofthree aspects: application, technology, in-novation-theory. Supporting partners and co-organizingunits for the event include East China Uni-versity of Science and Technology, Shang-hai Society of Plastics Industry, ShanghaiAutomotive Trade Association, and Asso-comaplast (the Italian plastics & rubber pro-cessing machinery and moulds manufac-turers' association). The winning entry of Future Car - which ismade as a model for display at the FutureZone of Chinaplas 2012 - is being selectedby a judging panel comprising experts inthe plastics and automotive industry, therepresentatives of university and the or-ganizer. The major selection criteria stres-ses on the degree of eco-friendliness, the

extent on improving our future living withhigh level of creativity. In addition, the Premium Design Gallery isshowcasing the stunning local and over-seas new products at the exhibition onsite.Exhibitors invited their clients to displayproducts which are brand new to the mar-ket, with major parts made of plastics/rub-ber that are environmental friendly and canbetter the quality of our living. The displayitems have to fall into categories of futuretransportation vehicle, appliances, archi-tecture and packaging, with written de-scription putting next to the product toelaborate its special features and out-standing application concept to the visitors.

www.ChinaplasOnline.com

16 ●

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tto

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Tel. +39 049 93 96 711 - Fax +39 049 93 96 710www.moretto.com

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Hall 22Stand A/B 33/34

Drying Revolution

The 15th edition of ECCM (European Conference on Com-posite Materials) - to be held in Venice (Italy) on June 24-28- is organized by the University of Padua (Department of

Management and Engineering) in cooperation with two regionaldistricts for nanotechnology (Veneto) and composite materials(Campania), respectively. The overall results of abstract submis-sion is outstanding: more than 2,000 contributions collected andmore than 2,400 registrations from 90 countries worldwide, an at-tendance that goes well beyond the European borders. The conference already shows all the conditions necessary to be-come the most important scientific event in the world history ofcomposite materials, covering all the areas related to the devel-opment of components made of these materials: from the formu-lation and production of innovative materials to the designing ofcomponents for conventional and advanced applications. Besides usual topics of the conference, such as strength and frac-ture toughness, computation methodologies and manufacturingtechnologies, special attention will be paid also to natural com-posites, “green” and recyclable, made with natural fibers andbiodegradable matrices. There is also a huge number of contri-butions in the field of nanocomposites and nanotechnology ap-plied to polymers and composites. Finally, materials for renewableenergy are another increasingly important subject.The conference is aimed at enhancing the cultural exchange andthe interaction between academic research and the industrial world,stimulating and supporting the innovation on composite materials,especially considering the difficult moment for the industry and theworld economy. In this perspective the organizing committee hasplanned more than 50 thematic sessions, organized by world ex-perts, and several roundtables on topics of industrial interest.

www.eccm15.org

Composites on the lagoon

● 17

The series of annual Europolymer Conferences (EUPOC) -organised by EPF (European Polymer federation) on topicsof recent scientific and industrial interest - is a prestigious

activity of AIM (Italian association of macromolecule science andtechnology), sponsored by the University of Milan. The 2012 edi-tion - to be held on June 3-7 in Gargnano (Brescia) - is focusedon the theme of porous polymer-based systems from design toapplication. Chairmen of the scientific committee are M.S. Sil-verstein (Technion - Israel Institute of Technology) and D. Grande(CNRS - Universitè Paris-Est), while the managing responsibilityand competence have been committed to the EPF president, G.Galli (University of Pisa). There is a recent confluence of fundamental R&D work beingconducted on porous polymeric systems by a variety of differentresearch communities. A large number of innovative routes tothese has been explored, generating new materials with wide-ranging technological applicability. As the need for porous poly-mers with more complex structures and functions has increased,so has the ability to synthesize such systems with tuneable me-chanical properties, well-defined pore sizes, pore wall function-alities, and controlled pore size distribution and interconnectivity. Moreover, such polymers can be generated with inherent mi-croporosity (subnanometer-scale pores) or with templatedmacroporosity (micrometer-scale pores). The recent advancesextend beyond the ability to synthesize novel porous polymers.These new materials challenged the capabilities of standardcharacterization methodologies. In response, innovative charac-terization methodologies were developed to provide insight intothe porous structures and their effects on material properties.

www.dcci.unipi.it/eupoc2012

Porous polymers

HALL 13 - STAND C05

18 ●

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Upcycling - or the art of giving asecond life to objects - was born indeveloping countries, where

access to consumer goods is limited andsystems for waste collection andprocessing are often non-existent, and ithas now spread to the developedcountries, which find it a major source ofinspiration. All this is evidenced andwidely documented in a serial article(which is summarized below) appeared inPlastics The Mag magazine published byPlasticsEurope.Upcycling means recycling from thebottom up. A new generation of designersare no longer content with recoveringmaterials and objects in order to givethem a second life; they are enhancingthese materials so that the result is moreattractive than the initial product: anaesthetic and ethical approach, with astrong emphasis on the notion ofcreation. Upcycling is reusing, but not just in anyold way: the object is appropriated andmodified to make it original and useful. Itis often removed completely from itsregular use and given a new purpose.Upcycling is not “turning old things intonew things,” it is avoiding throwing awaythings which could still be useful whenthey are transformed with a littleimagination. Few or no new resourcesare used in creating such an object, thusminimising the impact on theenvironment as far as possible.

In both upcycling andrecycling, an object atthe end of its life isrecovered to makeanother one. Butwhereas recyclinginvolves chemicalprocessing, upcyclingdoes not changematerials chemically. Itcan also be said that arecycled product willoften be of quality equalto that of the originalmaterial. Withupcycling, an attempt ismade to add value tothe product, often in anartistic manner. Whatever the case maybe, it can be consideredthat upcycling is a formof recycling. We shouldadd that recycling canbe carried out on alarge scale whilstupcycling remains something of a privateaffair. A little like the difference betweenindustry and crafts.From time immemorial, artists in thedeveloping countries, Africa in particular,have been skilled in giving new life to themost banal of objects. Recovering thingsthat are no longer of any use, addingvalue to handmade objects, recycling orreprocessing materials from waste. Thereare many examples of artists,associations and communities whichhave incorporated upcycling into theireveryday lives and have brought theirlocal and traditional know-how to the fore.

* * *Accra, Ghana, the streets are littered withsmall plastic bags, like everywhere inAfrica. These bags, sold in shops orpeddled in the street, are used ascontainers for drinking water. Very cheapand practical, they are thrown away assoon as they are used. An Englishentrepreneur, Stuart Gold, had the idea offounding an NGO with the view ofclearing these bags from the streets,trees and waterways and at the sametime creating jobs for the population. This was how Trashy Bags came to be,today manufacturing 350 models ofhandbags, purses, raincoats etc.,produced from the 20 million or so bagscollected. Trashy Bags encouragecitizens to bring in used bags, which arewashed, dried, flattened, cut up andfinally assembled by some sixty workersto turn them into the final product: trendy,unique and colourful fashion accessories. Florie Salnot, winner of the Coca Colasustainable design competition in 2010,

has been working for two years on apromising technique, collecting plasticbottles and using hot sand and simpletechniques with a human and socialvocation in order to produce jewels,handbags and carpets. For her project tosee the light of day, Florie set off for theAlgerian desert to make use of materialsavailable on the spot: old plastic bottlesand hot sand. There, groups of Sahrawiwomen weave fine strips of plastic, cutfrom the bottles, to produce all sorts ofgeometrical shapes. They are thenplunged into burning sand where theplastic melts and then sets. The jewel isthen virtually ready to be worn. Theobjective has been attained: creatingvalue and reviving the craft traditions of aforgotten people in an extremely arid partof the world.The Gafreh association in Burkina Fasois an eco-responsible initiative whichcombines the fine leatherwork know-howof Yves Saint Laurent with the craft skillsof the women in the association. Theyhave developed a unique techniqueallowing a textile to be produced from oldplastic bags and woven cotton. From thishappy marriage of two universes farapart, a beautiful bag has been born, theMuse Two Artisanal Recycled bag.Produced in a limited run of 60, it will onlybe available to a fortunate few.

* * *In the West, a growing environmentalawareness and the economic slowdownhave precipitated upcycling. Localinitiatives, exhibitions and happeningshave multiplied and companies such asTerracycle, Upcycle Living or Enviroglas

● 21

ETHICAL AND AESTHETIC RECYCLING

SARAH TURNER

EAKO

have rapidly developed. All over Europe,new shops have been opened.And a few companies realised, severalyears ago, that this concept had somepromising days ahead for itself. In 2006,Jean-Marc and Marie Imberton launchedReversible, which has quickly become areference in fashion bags andaccessories made of reused sheeting.For this, they have organised thecollection and recovery of, among otherthings, old PVC advertising posters putup by large companies and are trying togive a second life to these materials.They have thought up a whole series ofproducts ranging from bags to iPadcases, poufs and lamps. Today,Reversible accessories are sold all overthe world. The company’s charm lies inits joyful designs, its constant search formaterials (recently, vinyl floor coverings,i.e. lino) and also its care in recycling itsown products. Marie and Jean-MarcImberton want Reversible to be seen notonly as a brand of articles made fromrecycled materials but also as a leading-edge eco-design company. In 1993, brothers and graphic designersMarkus and Daniel Freitag were lookingfor a messenger bag. In fact, real Zurichpeople get around on bikes. And theyoften find themselves out in the rain. Fortheir designs, the Freitag brotherswanted a solid, functional and watertightbag. Inspired by the colourful stream ofheavy goods vehicles passing outsidetheir apartment and on the roads ofZurich, they cut out a messenger bagfrom an old lorry tarpaulin. For the strapthey used an old car safety belt and forthe stitching an old bicycle inner tube.Today, Freitag products are on saleworldwide, however they are still made inSwitzerland, close to the roads thatinspired them. Because they come fromoriginal sheeting materials and indifferent colours, cuts and patterns, allFreitag products are unique.In the UK, E&KO (Elvis & KresseOrganisation) is offering a new range ofaccessories in PVC (handbags, belts,schoolbags etc.) made from old firehoses salvaged from fire stations. Theinsides of the bags are lined with oldparachute silk. Each bag is handmade,unique and, of course, strong. As a markof gratitude to British firefighters, 50% ofthe profit from sales goes to a FireFighting Charity. These trusty old firehoses, enjoying a second life after 25years of loyal service saving lives andproperty, are not the only materials to bereclaimed by E&KO: pieces of sailcloth,old sunglasses, their cases, pallets etc.,are also recovered and turned into deco- and fashion accessories with verycontemporary looks. Products fired withimagination.

www.plastics-themag.com

22 ●

FREITAG

The results of the annual survey onrecycling in Italy - commissionedby FISE Unire (the Italian associ-

ation representing waste recovery con-tractors) - reveal that in 2010 plasticpackaging recycling volumes rose1.3% compared to 2009, with 711,000tons of waste - corresponding to 34.3%of the consumption volume - sent forrecycling. A total of 743,000 tons ofpackaging were consigned to energyrecovery (+7.2%), accounting for35.8% of the consumption volume.Overall, 614,000 tons of plastics werecollected, equivalent to 10.4 kg percapita, with an increase of just 4% inthe separate collection of packagingover the previous year, due to variousfactors: the financial crisis, a decline inconsumption, and failure of collectionto expand in certain regions, some ofwhich densely populated.In Italy, the material recovered from theseparate collection of municipal wasteis marketed by Corepla (the nationalconsortium for the collection, recyclingand recovery of plastic packagingwaste) primarily throughelectronic auctions, andis reserved exclusively forItalian or EU recyclerswhich undertake to carryout the recycling withinthe European Union. For this material stream,Italy is prevalently an im-porter from other Euro-pean countries, especiallyFrance, Germany, Belgiumand Austria, and an ex-porter toward the rest ofthe world. France is onceagain the top source coun-try, supplying more than53,000 tons of recoveredplastics to the Italian mar-

ket. Italian exports, meanwhile, aremainly directed towards China (165,657tons) and the US (15,476 tons).The forecasts for the three-year period2011-2013 indicate an average annualgrowth rate of around 3.5% in the vol-ume packaging waste sent for recy-cling, to reach 813,000 tons by 2013. There is an increasing diversity in theplastics used for the original productionof packaging, and in the manner inwhich they are combined and pro-cessed: packaging is becoming evermore complex and high-performingwith respect to its original function, butthis can entail greater difficulties whenit comes to recycling. It is necessary todevelop ever more sophisticated tech-nologies for processing miscellaneousplastics, possibly in combination withvirgin materials, to enable the manu-facture of ever more advanced prod-ucts with higher added value.

www.fise.org

Recycling in Italy

According to a new market report fromBCC Research, the global market forbioplastics totalled more than 850,000

tons in 2011 and is expected to increase tomore than 3.7 million in 2016, at an annualgrowth rate of 34.3%.The European region amounted to nearly307,000 tons in 2011 and is expected to in-crease at 32.1% per year to exceed 1.2 mil-lion in 2016. The Americas have nearlyidentical: in 2011 the market segment to-talled more than 307,000 tons, and in 2016that volume should approach 1.3 million(+32.9% per year). A smaller market, Asiaheld nearly 195,000 tons in 2011 and in2016 that volume should reach nearly 1.1million (+41.1%). The rest of the world to-talled more than 44,000 tons that should be-come 132,000 by 2016 (+24.5%).Global economic weakness slowed growthof bioplastics demand from 2009 to 2011,but support from powerful companies isspurring real growth of the renewablysourced plastics business. Another impor-tant factor is the Chinese government’sgrowing support for agricultural develop-ment in areas such as bioplastics as a wayto prop up the standard of living in the coun-try’s rural regions. Major indigenous pro-ducers of starch plastics and other types ofbioplastics are rapidly emerging, changingthe shape of the marketplace. Brazil andThailand also are emerging as bioplastics-producing powerhouses.

www.bccresearch.com

* * *The global bioplastics market is expected toreach revenues of more than 2.8 billion dol-lar in 2018 - corresponding to an averageannual growth rate of 17.8%, according tothe latest study published by Ceresana Re-search. With a roughly 48% share of globaldemand, Europe was the largest outlet forbioplastics in 2010, followed by North Amer-ica and Asia-Pacific.Over the next eight years, shares in demandof the individual world regions will shift sig-nificantly. Two regions will considerably in-fluence the bioplastics market: Asia-Pacificand South America. Demand trends of the individual bioplasticgrades show significant regional differences.While PLA demand in North America is pro-jected to rise by 12% per year by 2018, it willsoar by almost 17% per year in Asia-Pacific.In 2010, most demand was accounted forby starch-based plastics, followed by poly-lactic acid (PLA). Other bio-based plastics(PHA/PHB, cellulose, PBS) as well as fossil-based biodegradable plastics accounted forjust less than 17% of global demand. Ac-cordingly, biodegradable plastics are cur-rently dominating the bioplastics market witha roughly 92% share. Non-biodegradableplastics based on renewable resources areforecasted to increase their market share

from 8% in 2010 to more than 47% in 2018.

www.ceresana.com

* * *Global demand for biodegradable and bio-based plastics will more than triple from300,000 tons (2010) to over one million tonsin 2015, valued at $2.9 billion - according toanother study from Freedonia Group. Gainswill be fuelled by a number of factors but ul-timately, however, price considerations willbe the primary determinant of bioplasticmarket success. Biodegradable plastics accounted for 90%of the world bioplastics market in 2010. Ex-cellent growth is forecast for the two leadingbiodegradable materials, starch-basedresins and polylactic acid (PLA), both ofwhich will more than double in demand

through 2015. Despite the strong advances for biodegrad-ables, non-biodegradable bio-based resinswill be the primary driver of bioplastics de-mand through 2015 and beyond. Gains willbe fuelled by the availability of commercialquantities of bio-based polyethylene fromBraskem’s 200,000-tons-per-year plant inBrazil, which opened in late 2010. Two otherbio-based polyethylene plants - as well as abio-based polypropylene facility - are also inthe planning stages and are expected toopen around 2015. Additionally, industrialproduction of fully bio-based PET is forecastto become a reality by the end of thedecade. As a result, demand for non-biodegradable bioplastics will rise from30,000 tons in 2010 to 1.3 million tons in2020.

www.freedoniagroup.com

● 23

Booming bioplasticsNOVAMONT

Crumb rubber for asphaltEvery year in Italy, some 25 million

tires are discarded (in Europe thetotal is over 250 million), amounting

to some 400,000 tons in weight, of whicharound 45% are consigned to energy re-covery (in Italy and abroad), just under25% are granulated, and 30% still end upin landfills.The use of granulate, or crumb rubberfrom discarded tires, as an additive forroad surfaces, is an interesting application,also in volume terms, for the recycling oftires at end of life. The "wet" technologyhas been successfully implemented withthe development of suitable standards forthe design and laying of special asphaltcompounds, termed "gap-graded" or"open-graded", depending on their func-tional and structural characteristics. Recent studies conducted by TurinProvince and Politecnico di Torino haveexamined the use of gap-graded com-pounds as road paving materials. The goalof the project is to develop and deploy in-

novative technologies capable of extend-ing the use of crumb rubber from scraptires in road paving, with a particular em-phasis on solutions that offer an optimalbalance between satisfying technical, eco-nomic and environmental requirements. Starting in 2008, the Province administra-tion commissioned Politecnico di Torino toconduct a comprehensive R&D project,which last autumn resulted in the surfac-ing of approximately 1600 metres of theBorgaro-Venaria ring road with asphaltconcrete containing crumb rubber additivefrom scrap tires. The Tyrec4life project, which has a dura-tion of 36 months and an overall cost ofapproximately 3.5 million euro, co-fi-nanced by the European Union, proposesto validate alternative compounds with theaim of improving the performance of as-phalt mixes in terms of drainage, skid re-sistance and traffic noise reduction.

www.provincia.torino.it

24 ●

Last December Coca-Cola announcedmulti-million dollar partnership agree-ments with three leading biotechnol-

ogy companies (Virent, Gevo andAvantium) to accelerate development ofthe first commercial solutions for next-gen-eration PlantBottle packaging made 100%from plant-based materials. This packaging is the only fully recyclablePET bottle made with up to 30% plant-based material available today. It is madeup of two components: MEG (mono-ethyl-ene glycol), which makes up 30% of thePET, and is already made from plant ma-terials, and PTA (purified terephthalicacid), which makes up the other 70%. Inthis next step, PTA will be replaced withplant-based materials, too. Since introduced in 2009, more than 10billion PlantBottle packages have been al-ready distributed in 20 countries world-wide. It is estimated the use of thispackaging in the first two years alone hashelped save the equivalent annual emis-sions of more than 100,000 tons of carbondioxide. Virent’s technology features catalyticchemistry to convert plant-based sugarsinto a full range of products identical tothose made from petroleum, including bio-based paraxylene - a key componentneeded to deliver 100% plant-based PET

packaging. PET made from bio-basedparaxylene features the same highquality and recyclability as materialsused today, with the added benefit ofbeing made from a wide range of re-newable materials. Gevo is converting existing ethanolplants into biorefineries to make re-newable building block products for thechemical and fuel industries. The company plans to convert renew-able raw materials into isobutanol andrenewable hydrocarbons that can be di-rectly integrated on a "drop in" basis intoexisting chemical and fuel products todeliver environmental and economicbenefits. Avantium has developed theYXY technology to produce 100% bio-based PEF bottles. PEF (polyethylenefuranate) can be derived from any bio-mass feedstock containing carbohy-drates, such as sugarcane, agriculturalresidues, plants and grains. Using YXYas a fast and efficient chemical-catalytictechnology, these carbohydrates can beconverted into bioplastics. Current estimates indicate that PEF will bea viable alternative to petroleum-basedPET. It is 100% biobased and when com-mercialized will be fully recyclable. Earlyin December, Avantium officially openedits pilot plant in the Netherlands, to start

up its YXY process at scale. The pilotplant, with a capacity of 40 tons per year,produces PEF material for application de-velopment. The collaboration with TheCoca-Cola Company is key to secure asmooth transition into the mass productionphase of PEF bottles

www.thecoca-colacompany.com

Natural bottles

www.triaplastics.com

Excellence in grinding since 1954

During their lifetime, plas-tic-based products suchas films, bale nets, yarns,

irrigation hoses and packagingact as versatile and highly valu-able aids to the agriculturaleconomy. Yet, at the end oftheir useful service life, theyturn into awkward waste requir-ing disposal. Into the containerand off to landfill - that is themost frequently-chosen and, atthe same time, worst route. There is a lot of good will to dothings better amongst those in-volved. But there is still a lack of sustain-able and practical disposal concepts in themajority of European countries. A recently-formed working group by EPRO (EuropeanAssociation of Plastics Recycling and Re-covery Organisations) is now working onthe development of new, forward-thinkingsolutions to address this issue. The total amount of plastics used in agri-culture is considerable. Almost half isprocessed for use in films. Approximately1.2 million tons of agricultural plastics re-quire disposal each year, yet only 22% ofthis amount is recycled. Over half, morethan 600,000 tons, ends up in landfill.Around 26% is used for energy recovery. There is enormous room for improvementin these figures. To date it is only a handfulof European countries that have efficientsystems. They are either the result of legalrequirements, such as in Ireland or Iceland,or of voluntary industrial, trade and agricul-tural initiatives (for instance in Germany,France, Norway, Sweden and Spain). In the majority of European countries - par-

ticularly in Eastern Europe - there is still nocontrolled recovery system. Pan-Europeanlegislation relating to the recovery of non-packaging plastics used in agriculture doesnot exist. At the start of March 2011, EPRO initiateda new, cross-border work group entitledAgricultural-Plastics, which currently has 14members from France, Norway, Sweden,Iceland, Germany, Ireland, Switzerland,United Kingdom, Spain, Belgium and Ro-mania. The majority of its members arerepresentatives of national, established oremerging recovery schemes. The group's overriding intentions are theexchange of information on existing dis-posal solutions, the ecological and eco-nomical enhancement of existing recoverysystems and the provision of support fornew systems in countries where, to date,no activities in this regard have been un-dertaken. A further objective is the initiationof intensive discussions with external part-ners from industry, trade and agriculture.

www.epro-plasticsrecycling.org

Agricultural waste

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The completion of Europe’s first recy-cled plastic bridge has been an-nounced last December by Axion

International. The materials for the bridgeconsist of innovative RSC (Recycled Struc-tural Composite, which is designed from100% recycled plastic. The bridge, whichwas prefabricated in the US and trans-ported to Scotland via container ship, nowspans the river Tweed near Edinburgh.

The bridge, which consists of three spans,is approximately 3.5-m wide and 27-m longand was used to replace an old steel beamand timber deck road bridge. The entireconstruction project (including dismantlingof the old bridge) was completed in undertwo weeks. Being made from plastic, thebridge will not rot, rust or corrode, and re-quires no painting or regular maintenance.In addition, it is 100% recyclable at the end

of its useful life. The remarkably fast erectiontime of only 4 days is a majorbenefit of the composite ma-terial, as it substantially re-duces the complexity and costof construction, and is goodfor the environment as well.Moreover the project was ableto save 50 tons of plasticwaste from going into landfillor being shipped to Asia.

www.axionintl.com

Recycled on the bridge

AXION

Youth ParliamentABulgarian student, Svetoslav

Kostov, has won the Europeanfinal of the third edition of Pla-

sticsEurope’s Youth Parliament De-bate which took place in Rome onMarch 16. The young winner was thebest at providing a well-rounded spe-ech on sustainability and the role ofplastics in this regard, with strong rhe-torics and robust arguments. He was elected by an internationaljury composed of politicians, expertsand journalists who judged a debatingcompetition between 50 students fromacross Europe. An Italian student,Carla Biondo, and another Bulgarian,Georgi Kotov, won the second andthird prize respectively. The Youth Parliament debate wasthrown open by Francesco Ferrante,member of Environment Commissionof the Italian Senate. He talked aboutthe positive economic and environ-mental impact of the plastics industry,as well as the responsibility of plasticsproducers in helping secure a sustai-nable future where the legacy ofNobel Prize Giulio Natta would beperpetuated. Plastics pros and conswere then introduced by Onno Gross,president of Deep Wave, and Giu-seppe Lo Faso, plant manager at Po-limeri Europa. The European final was the result ofa long process that led to 50 studentsbeing selected out of 500 participants.PlasticsEurope wanted to raise the in-terest of young people over importantissues such as climate change, theidentification of new technologies forenergy supply and the fundamentalrole of plastics in society. This pan-European debate is an effective wayto educate students to a deeper andcritical reading of these issues.Many interesting points, either for oragainst plastics, were raised duringthe event. In their arguments againstplastics, students mentioned bad litte-ring habits and poor waste manage-ment practices, as well as the needfor research on new raw materialsthat would either be easier to recycleor biodegradable. Another concernwas the risk of plastics waste enteringthe food chain.The main arguments in favor of pla-stics, on the other hand, were the ideathat consumer behaviour plays a keyrole in minimising the impact of pla-stics on the environment, as well asits crucial role for innovation and ingreen applications such as insulation,wind turbines or environment-friendlycars.

www.plasticseurope.org

Barrier whey-coating The EC-funded Wheylayerproject successfully finishedin October 2011 afterdeveloping a whey protein-coating for plastic films toreplace currently usedoxygen-barrier layers inpackaging and allow therecyclability of multilayerfilms. The coating achievedsuperior oxygen and humiditybarrier properties comparedto most other bioplastics andapproaching those ofsynthetic materials such asEVOH. In addition,Wheylayer-based laminatescomply with the requisites ofthe packaging industry interms of thermo-mechanicalproperties, food contact andprocessability. They are expected to beused mainly for the packaging ofsensitive food as well as cosmetics orpharmaceutical products.Earlier in the project, suitableformulations were developed atFraunhofer Institute (Germany) showingthat the process controls the structure ofproteins and the resulting properties ofthe coating which led to a patent filling.More recently, the lab-scale and pilotprocess was upscaled by Iris (Spain) totest in semi-industrial configuration:production speed was increased by afactor 10 and energy consumption wasreduced while still maintaining goodmaterial properties. The project mainly focused on producingfilms and derived laminates but the whey-coating is expected to be used fordifferent types of packaging. Preliminaryfeasibility tests were also done for theproduction of blisters by Serviplast(Spain), specialized in thermoforming.The research center TTZ Bremerhaven(Germany) has also recentlydemonstrated the possibility ofsubstituting standard multilayer films withlaminates including Wheylayer whilepreserving food quality and shelf life as aconclusion of storage tests of foodproducts such as cheese. In parallel the environmental impact ofthe material has been evaluated by theUniversity of Pisa (Italy) showing thesignificant advantages in terms of Humanhealth, ecosystem quality and resources.They also showed that using anenzymatic cleaning compatible withcurrent plastic recycling operations, thewhey-coating can be removed to allowrecycling multilayer packaging. The cheese maker Mlang (Germany) andthe members of the dairy cooperative Llet(Spain) are also keen in developing their

capabilities of protein isolation to supplythe whey for the coating application andto pack their cheese with a materialobtained from their by-product. Highlysuccessful industry-focuseddemonstration events were held by theconsortium (in Spain, Slovenia, Italy andHungary) at the end of the project forpresenting the new packaging materialand its process prototype. Overall, the potential for using whey-coating in packaging is high due tonumber of ecological advantages itpresents compared to barrier polymersthat are available today while keepingrequired technical performance. In termsof environmental advantages, the holistic“cradle-to-grave” approach followedthroughout the material and processdevelopment provided a new solutionwith increased sustainability to packagingproducers and consumers. Indeed as

opposed to price increasingdepleting fossil resourcescurrently used, the developed lowcarbon footprint bio-sourcedcoatings valorize a by-productfrom the agro-food industry thatcan be highly polluted due to itshigh organic content if nothandled correctly.

www.wheylayer.eu

Natural fibres for compositesIn recent years there has beenmuch interest in developingnatural fibre-reinforced polymersfor a sustainable substitution ofsynthetic materials, and also todevelop markets for the Europeannon-food crop industry sector. Asnatural fibre crops cannot beeasily separated into fibres of

consistent quality, new research wasundertaken to reduce processing costsand improve fibre quality, consistency,and efficiency. Partly funded by the EuropeanCommission under its FP7 (Framework7) programme, the UltraFibre projectbrought together 11 partners includingindustrial companies, trade associationsand research partners - coordinated byAssocomaplast (the Italian associationfor manufacturers of plastics and rubbermachinery & equipment) with the supportof Smithers Rapra. Started in December2010, the project aims to develop ahydro-acoustic radial cell decorticationprocess for the clean, continuous, highvolume production of high quality naturalfibres and an atmospheric plasmatreatment system for improved adhesionbetween polymeric materials and thenatural fibres

EUROPEAN PROJECTS

R

26 ●

WHEYLAYER

A flow through ultrasonic processor unitwas developed. The treatment removessurface contaminants: consequently itreduces fibre bundles to elemental fibreswith clean surfaces for enhancedadhesion prior to plasma treatment.Sonicating the fibres in conjunction with acaustic pre-treatment increaseselemental fibre content from 40 to 80%.This affords a greater and cleanersurface area for plasma treatment andtherefore a better adhesion to thepolymer matrix is expected, thusincreasing the mechanical properties ofthe composite.

www.ultrafibre.org

Recycling for food contact The European Commission granted afinancial contribution for research underthe Seventh Framework Programme todevelop processes and qualityprocedures for the valorisation ofrecycled plastics for food contactapplications. The 3-year SupercleanQproject, started on November 2011,consists of a 12-partner (from UnitedKingdom, Italy, Belgium, Netherlands andGermany) consortium that has securedmore than 1.9 million euro of EU fundingto develop quality assurance tools andprocedures for plastics recyclingprocesses targeted at food contactapplications. The tools will be applied to a newprocess for the recycling of coloured andlayered PET into food contactapplications that cannot be processed bycurrent PET recycling facilities. Theproject results will accelerate thedevelopment of new recycling processesfor the wider food contact materialsmarket and provide quality assurance forconverters and end-users of recycledproducts applications for food contactthereby overcoming barriers and

expanding this highvalue recycling market.The advancements overthe current state of theart are expected to be: apost-market challengetest for validation ofrecycled food contactmaterials with 100%reliability; a post-processvalidation qualityprotocol for assuring theefficacy of plasticsrecycling processes forfood contact applicationswith 100% reliability;development of aprocess to recycle the700,000 tons per year ofcurrently unrecyclablecoloured and layeredPET that cannot beprocessed by existingrecycling facilities forfood contact PET

packaging; in-line monitoring for processquality control to identify contaminantsfrom oxo-degradable additives,biodegradable plastics, bisphenol A andnon-food contact compliant levels ofchemical contamination.

www.supercleanq.eu

Rubber acceleratorsThiourea based accelerators, of whichETU is the most common, have beenused for more than 80 years in thevulcanization of polychloroprene rubberas they facilitate the rubber cure systemby speeding up the creation of molecularcrosslinks, decreasing process durationand increasing physical properties.However ETU is classed toxic toreproduction, therefore its use could beforbidden or drastically reduced at sometime in the future under the REACHregulations.Since June 2010 the SafeRubber project- funded by the European Community'sSeventh Framework Programmemanaged by REA (Research ExecutiveAgency) - has been working on a suitableand safer alternative to ETU. Theresearch consortium includes 12 partners(associations, universities, privatecompanies) from Italy, Belgium, UnitedKingdom, Spain, Latvia and Norway. The initial work concentrated on researchinto the chemical mechanism of thevulcanization of polychloroprene usingETU, a mechanism which has neverbeen fully understood or proven. Thisenabled the consortium to design andsynthesize several alternative moleculeswhich it is hoped will be safer than ETU.These molecules are now beingoptimized in polychloroprene compoundsbefore being scaled up to an industrialprocess.

www.saferubber.eu

● 27

EndlessOpened last December, the exhibi-

tion "Endless - Twelve tables forone chair", produced by Fon-

dazione Plart of Naples (Italy), featuresthe works of a collective of designers,artists and architects, as well as a writer,a photographer and a musician.Conceived as a single, spatially ex-tended work, the exhibit maps out aroute through the main hall of the foun-dation building. The arrangement of thetables geometrically - but alsometaphorically - follows the curve of ahyperbola: starting from ground level,where the first ones seem to "sink" intothe floor, with a heavy and massive ap-pearance, and finally taking flight withthe last tables, suspended in mid-air. The object evoked at the top of the hy-perbola loses weight and material sub-stance, ascending to an ideal form, thatvirtually represents all the chairs of theworld. We thus find the conventionalratio is inverted: no longer 12 chairsaround one table, as the recent Christ-mas festivities might suggest, but in-stead 12 tables for just one chair, like 12apostles or, more prosaically, 12 mencompeting for the most alluring woman.Each table leads the visitor to discoverone of the most experimental projects ofthe international contemporary designscene. Endless by Dirk Vander Koji. TheDutch designer has recovered an indus-trial robot decommissioned by a Chi-nese factory, equipping it with newsoftware and reusing it as a machine formaking interior decoration products.Paradoxically, the robot becomes a toolfor hand-crafted production, creating theEndless collection starting from a singlecontinuous band of melted recycledplastic. Meanwhile, the productionprocess itself also becomes endless:each chair or table produced in factmakes it possible to perfect the processfor making the next one, just like in theold days, one piece at a time.

www.plart.it

PLART

28 ●

IT IB MACHINERY INTERNATIONAL S.p.A. V ia Romigl ia n . 9 25050 PADERNO F.C. (BS) ITALYTEL.: +39 030 6858500 FAX: +39 030 6858559 mail: imac@itib-machinery.com - Web Site: www.itib-machinery.com

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www.itib-machinery.com

WORLDWIDE PARTNER

May 8/12 2012HALL 15 STAND B33 C32

Ultralight profilesThe international showcase of Plast2012 provides Friul Filiere (13 - C21/D18) the occasion for a livepresentation of its world-patented FFC(Foam Fiber Composite) technologythrough the display of the new OmegaEvolution extrusion line. During thedemonstrations, the new FFC ultralightcomposite is extruded as a skirtingprofile, which is the best compromisebetween the need to show the fullcharacteristics and potentials of this newmaterial and the constraints imposed byan exhibition setting. The line exhibited at the fair is equippedwith an Omega single-screw extruder,which processes a dryblend consistingof a mixture of thermoplastic materials,natural fibres and various additiveswhich is fed into the hopper andextruded directly, cutting out thepelletizing stage.The true innovative potential of FFC isthe ability to recycle not only the naturalfibre waste (jute, hemp, sugar cane, ricehusk etc.) but also, and mostimportantly, thermoset scrap, which isclassified as a special waste (rubber,urea, melamine, phenolic, MDF,coatings etc.). During the demonstrationthe skirting profile, designed in-house, isextruded using a dryblend containingrecycled coating scrap to show the highphysical, mechanical and aestheticquality of the extrudate.In recent months, there has beenspecial interest on the market in the newFFC decking profile, especially afterFriul Filiere delivered a major order to aSouth American customer, includingvarious complete lines for extruding thiskind of decking profile. Currently, WPC(Wood-Plastic Composite) deckingprofiles are widely used and theirbenefits and drawbacks are well known.This could be the reason why customersare so enthusiastic about the innovativeFFC decking profile with its improvedphysical and mechanical performancecharacteristics. Visitors to the stand find decking profilesamples toillustrating thedifferentsorts offinishes thatcan beapplied in-line: mono-material, coextrudedin FFC or PVC, embossed,printed, brushed etc. There are alsomany other samples of different types ofprofiles already made of FFC: doorframes, window profiles, wall panels,fences and more. Naturally, traditional

products are also on displaymanufactured using the company’s mostsuccessful turnkey projects: edge bandprofiles, EPS picture frames, specialcoextruded gaskets for the automotiveindustry etc.

www.friulfiliere.it

Evolution of stretch filmTo meet the demands of constant growthand development in the market forstretch film, Macchi (15 - B33/C32) hasdesigned and developed a cast line ableto produce coreless reels. This solutionallows considerable savings, includingthose resulting from the inline productionof pre-stretched film. Elimination of thecardboard core reduces the per-kilogram cost of film by 5%, while thepossibility of producing pre-stretchedfilm in-line enables higher productionspeed (over 10,000 m/min) of thinnerfilm with enhanced mechanicalproperties, without the additional costsof secondary machining processes.

These results were obtained thanks totechnology involving the use of aspecific winder (for which Macchi holdsexclusive European rights), developedin collaboration with NoEl, that enablesthe creation of coreless reels for manualor automatic use. Film in thickness from7 to 23 microns can thus be produced toprovide practical responses to a widerange of issues, from a need forlightweight film for pallets to reducedcosts for transport, storage, andcardboard disposal.Macchi cast technology enablesproduction of all these films withoutchanging system configuration.Moreover it is possible to reduce filmthickness without affecting machineproductivity: the film exits the chill rollwith a thickness of 23 microns and isthen further reduced to 12 microns byincreasing the line speed without fullypre-stretching the film.The new line was presented at a recentopen house in a demo version based on5 extruders (65-100-100-100-65 mm)

and a 2600-mm extrusionhead. It permits the productionof film in thickness from 12 to50 microns at a speed of 600m/min with an output of 1,000kg/h (23-micron film). Thecooling unit is composed of amain chill roll (diameter 1350mm) and two stabilization chillrolls, one of which featuresadjustable positioning. During Plast 2012, Macchi isshowing a 9-layer blown filmcoextrusion line in operation.The configuration againcomprises three integrated

● 31

EXTRUSION LINES & EQUIPMENT

MACCHI

FRIUL FILIERE

platforms equipped with Plastex Barrier55 extruders and Siemens Torquemotorization feeding a COEXflex IBChead with all melt conveyi ng channels atthe same level. The inner design isbased on the dual distribution concept,first at binary partition and then withconventional spirals, to feed a 500-mmdie with automatic profile control.Multiple layers bring various benefits,from a better barrier effect for the sametotal thickness of PA and EVOH layers toimproved physical-mechanicalproperties, including thermofomability.

www.macchi.it

Thirty-year partnership for compoundingThree new compounding lines for theproduction of engineering plastics,supplied by Icma San Giorgio (13 - C29/D26), will add 30,000 tons tothe total annual production capacity ofthe Softer Group. The lines are intendedfor installation in the Forli and Ferrara(Italy) and Silao (Mexico) plants and willenable the Italian group to strengthen itspresence in the automotive andhousehold appliance sectors and also toconsolidate its role as a global supplier.The machines are three co-rotating twin-screw extruders capable ofprocessing different materials, such aspolypropylene and polyamide filled orreinforced up to 50% with glass fibre, athigh flow rates. The extruder is made ofwear-resistant steel alloys and featuresa modular design which makes itpossible to optimize maintenance costs.The significant results achieved bySofter, one of the largest independentcompounders globally, were madepossible partially thanks to its 30-yearpartnership with Icma, which over theyears has supplied high performancemachines backed by world classcustomer service. Moreover, therelaunch of the Ferrara plant (former P-Group), acquired in 2011, allows themachinery maker to participate as a

supplier in a verypositive initiative that

helps keep a centre oftechnologicalexcellence in Italy.In addition tocontributing to therecovery plan of theFerrara technologicalcentre, the newinvestment confirms theintention of Softer tomaintain Italy as aprivileged productionplatform for theEuropean markets.On the other hand,with its strategiclocation and efficientlogistic structures, Mexico is becomingthe basis for expansion towards theNAFTA countries: it will be easy tosupply companies located in the US orCanada from there as well as tocollaborate with corporations that haverelocated their production to Mexico andare looking for local partners boastingEuropean technological and quality.The range of Softer products includesthermoplastic elastomers, thermoplasticvulcanizates and engineering plastics.Thanks to its technological know-how,the group can offer innovative solutionswith a strong specialization in theautomotive, appliance, electrical-electronic, construction, footwear andsports sectors. The group has twomanufacturing plants in Italy, two furtherunits in Latin America (Mexico, Brazil)and a sales subsidiary in Germany.

www.icmasg.it

Giant corrugatorThe increasing demand for double-wallPP corrugated pipes as an alternative toconcrete or PVC pipes for seweragenetworks or drainage of rainwater hasprompted Itib Machinery (13 - C25) toinvest greater resources in developingsuitable production technology. Afterproducing the F700SH9 shuttlecorrugator, of which an exemplarwas recently put into operation atthe facilities of the Slovak

processor Plastika, the company isdeveloping its successor, F1200SH10,for pipes with inner and outer diameter,respectively, up to 1,000 and 1,200 mm,depending on applicable standards.The corrugator is composed of 10 pairsof mould halves, 6 of which are in theforming position while 1 pair is in theclosing phase, 1 pair is in the openingphase, and 2 pairs are on the returnpath. In this model, as in the previoussmaller one, the mould halves are notmoved using chain conveyors butinstead by means of a shuttletechnology, i.e., a sliding mould-holdertrolley. This solution is more suitable fora machine of such large size, reducingthe necessary number of pairs of mouldhalves, the machine footprint andinvestment costs.Each mould half is equipped with acircuit for cooling water, which is appliedunder pressure from an independentinlet-outlet point. Pipe forming is carriedout under vacuum assisted by a low-pressure blown air. In emergencysituations or in the event of a power cut-off, the F1200SH10 corrugators can bemoved backwards in order to allow freeaccess to the head, extrusion die, andthe cooling mandrel of the inner layer ofthe pipe thereby allowing any residual

material to be removed.The corrugator can achieve hourlyoutputs up to 1000 kg. Moulds ofdifferent sizes can be fitted by liftingor lowering the upper structurewhere part of the cooling andsuction systems is installed therebyaffording easy access for mouldassembly.

www.itib-machinery.com

Extrusion & thermoformingFor thermoforming applications,Amut (13 - B39/C38) introduces

the evolution of the FFG high-speedautomatic machines with steel rule diecutting: the FFG820 ADV model is inoperation with air pressure and/orvacuum forming. The toggle system forplaten stroke, with planetary rollerscrews, ensures resistance and durationof cutting efficiency for the toughest

32 ●

ICMA

ITIB

● 33

materials at high speeds, both in theforming and in the cutting stations, withan installed force of 60 tons. Greatattention has been given to flexibility anduser-friendliness, as seen in the quickmould change system in all the stations,direct connections to the utilities on themould-holding platens of the formingstation, and the electric hoist.A machine from this range has recentlybeen installed on a complete line forextrusion-thermoforming of PP sheet forhigh speed production of pots (depth 200mm) for the flower-nursery market. Onthis occasion an additional hole-punchingstation was included to make holes in thebottom of the flowerpots, while thefinished items are automatically stackedby a 3-axis handling robot. Also on display is a BA 130 twin-screwextruder for the production of WPCprofiles. The Easy Wood systemdeveloped for this application is providedas complete lines (from 300 to over 1,000kg/h) for direct extrusion, without pre-mixing of materials and additives, with upto 80% vegetable fibres in a polyolefinbase (HDPE-PP) and around 50% for PVC.The extrusion line is equipped with asingle-screw extruder and a counter-rotating twin screw extruder. The latter isconsidered the ideal machine forprocessing highly viscous compounds,such as WPC, with high percentages of

vegetable fibres.Thanks to the lowrevolution speedsand high torque ofthe screws, it ispossible to extrudeat high pressureand reduced shearkeeping the melttemperature lowso as to preventthe degradation ofvegetablecomponents. Another machineon display is an EA75 single-screwextruder for theproduction of smallpipes in special

materials for medical and automotiveapplications. Depending on screwgeometry and barrel configuration, hourlyoutputs up to 750 kg can be achieved.The pipes produced on these lines mustcomply with very strict dimensional andovalization parameters. For this reason,the lines are equipped with very accuratemeasuring and control systems fordiameter and thickness, which ensureconstant, oscillation-free production.

www.amut.it

Irrigation pipesSpecialized in the construction ofextrusion lines for the production of dripirrigation pipes, Profile Dies (13 - C05)has recently developed a new fastextrusion line for pipes with flat drippershaving the following technicalspecifications: minimum pipe thickness0.15 mm, mechanical line speed 150m/min, production speed up to 130m/min, insertion of 800 drippers perminute.The line is composed of the followingcomponents: automatic inserting unit fordrippers, gravimetric dosing units,extruder with 65- or 80-mm screw,coextruder with 20-mm screw, specialhead-die, calibration and cooling tanks,haul-offs, mechanical drilling unit,automatic winder, control panel with

high-quality components and softwarefully developed and manufactured by thecompany. The line also includes a hotrunner injection mould for drippers (up to96 cavities).Production of this new line has enabledthe company to achieve very high outputand quality standards. Another line wasdeveloped at the same time for irrigationpipes with round drippers having thefollowing technical specifications: pipediameter 16 and 20 mm, insertioncapability of up to 400 drippers perminute, production speed 80-100 m/min.

www.profiledies.com

Socketing & packaging Precisely on the occasion of Plast 2012,IPM (13 - C37/D34) celebrates its 25th

year of activity, previewing the innovativeBA 200 PP belling machine forpolypropylene pipes, operating inconnection with a fully automatedpackaging system for pipes up to 500-mm long. Considering the highproduction capacity of these belling

PROFILE DIES

AMUT

machines (up to 924 sockets per hour for50-mm diameter x 1.8 mm), end-of-linemanagement (collection, automaticpackaging and conveyance to storage ofa huge amount of pipes) is increasinglynecessary. Moreover, an automatedquality control (checking the correctposition of the automatically insertedgasket) and socket tightness checksystem is also displayed, demonstratingthat only the pipes that pass inspectionare conveyed to the automatic packagingunit. The company offers its Europeancustomers customized automatedsolutions for pipe packaging involving theuse of robots for pipe handling andpackaging into suitable supports, withautomatic forming of pallets pre-arrangedto be picked up by forklifts and stocked, orfor packing shorter pipes into cardboardboxes provided for the purpose. Thereare many requests from other regions forautomatic packaging systems for pipebundles by means of multiple straps andoptional packing into sacks (or wrappingup by film) as well as subsequentpalletization of the produced bundles inspecial cases. These are fully automatic systemsoperating in-line with extrusion(sometimes consisting of more than oneof the above-mentioned technologiescombined together) which are able topack up to 1,500 pipes per hour withlength of 150 to 3,000 mm. Furthermore,it is also possible to handle, sort and packseparately (with socketed ends havingopposite position) pipes having differentlengths but manufactured in sequence bythe same extrusion line. Another piece of equipment on displayduring the fair is the new version of the BA200 RS (Rieber System) socketingmachine, which can attain very highoutput rates thanks to the use of ovensequipped with short-wave lamps. Inaddition to their very high efficiency andexcellent energy performance, theseovens ensure better penetration as wellas direct and dynamic temperaturecontrol of the material undergoingprocessing. The direct effect is areduction of heating times and thereforeof power consumption, particularly when

the machine is not working at maximumpotential. Moreover, these ovens do notneed to be brought to temperature beforethe extrusion line is started, because theyare instantly operative. Lastly, on May 5, the eve of Plast 2012,IPM is organizing an open house at itsheadquarters to celebrate its 25 years inthe business as well as to introduce thenew (patented) INJ range for belling ofdouble-wall PP and PE corrugated pipes.The model being demonstrated (BA 1200INJ) is the largest of the range and cannotbe displayed at the fair due to its size.Together with the cutting unit, thismachine completes an extrusion linemade by Unicor and having its finaldestination in the Arabian countries. It isbe able to socket pipes in-line havingouter diameter from 315 to 1,200 mm,ensuring the dimensional stability of thesocket, even if exposed to highly variableenvironmental temperatures

www.ipm-italy.it

Optical qualityWith more than 45 years of experience,development, and in-house productionand over 95% of its products exported,

Omipa (13 - C30) is a leader in theconstruction of complete extrusion linesfor various thermoplastic materials. Thecompany is already an establishedpresence in the market for extrusion linesfor high optical quality sheets and foils inPMMA-PC-PS-MS with thickness from0.3 to 10 mm. These products aredestined for the continually growingmarket of LCD, LED and 3D screens, andalso for touch-screen technology andadvertising applications. For theautomotive industry, sanitaryapplications, food packaging, andappliances the company offers highperformance lines for the production ofsheets in PE-PP-ABS-PET withcoextrusion in up to 7 layers. In recent years, Omipa has been workingwith its clients to design and develophollow polycarbonate profiles withincreasingly innovative architecturalgeometries for application in public andprivate construction, major projects suchas stadium roofing for Olympic and othersports events, stations, shopping malls,and greenhouses.High line speed is the main feature ofextrusion lines for hollow PP profiles inthickness varying from 1.8 to 20 mm foruse in industrial and agriculturalpackaging applications (e.g., fruit boxes,containers, folders etc.) withdevelopments also in the fields of heavy-duty packaging and advertising. In hollow polypropylene profile segment,the company is developing the newFoam System, which makes it possible toreduce final product weight withoutaltering mechanical resistanceproperties. Fluctuating raw materialsprices and the need to improve existingapplications have led the company todevelop a production system for hollowPP-foam profiles, especially designed formedium-high weights, which makes itpossible to reduce raw material

34 ●

OMIPA

IPM

consumption by 20-30%, producingeconomic savings and environmentalbenefits without compromising thephysical and mechanical characteristicsof the finished product. An absolute novelty for the market is thenew range of machines, presently in thedevelopment and testing phase, for theproduction of low shrinkage EVA forencapsulation of silicon cells forphotovoltaic panels. The idea is to buildand deliver a turn-key plant, includingblend formulation. Lastly, Omipa hassuccessfully carried out tests for theproduction of hollow profiles in ABS, amaterial which has not previously beenused for these applications. Besidesmaking it possible to replace theproducts commonly used for heavypackaging, it guarantees excellentperformance even when subjected tovery low ambient temperatures.

www.omipa.it

High speed for roller shuttersSpecialized in the development ofadvanced technology for high-outputextrusion tooling of roller shutters, inwhich it boasts world leadership withspeeds of up to 12 m/min in doubleoutlet, Baruffaldi PlasticTechnology (13 - B43) is introducing a newgeneration of Combiroll andCombipack, in-line and off-lineautomatic and semi-automatic machines forassembling and packagingroller shutter profiles of allsorts and sizes up to 12 m,in single or dual outlet.These machines stand outfor sturdiness, highproduction rates, versatilityand ease of use.When it comes to punchingprofiles, even the largestand thickest ones, aninnovative punching and striking systemhas been designed to reach speeds ofup to 15 m/min with no detrimentaleffects (such as burrs, swarf or dust) on

the quality ofthe finished

products while keepingnoise levels and environmental

impact to a minimum. The new rotarypunching machine, which can handle allsorts of technical profiles includingangular ones, can run at 30 m/min, isextremely versatile and can be used in-line and off-line. Simple to operate, itcomes with height adjustment and quickchangeover tooling.The patented horizontal guillotine cuttingsystems, available with either hot or cold

blade, give a high quality cutwith no deformation of theprofile while reducingenergy consumption andmaintaining operator

comfort through noiseand dust reduction.These cutting unitsare highly versatileand customizableand can be supplied

as stand-alonemachines orintegrated intoexisting cuttingsystems. What makesthem unique is theircompact size, thespeed with which theoperator can change

the blade and thequality of theirmaterials and

components.

Moreover, thecompany has recentlyextended its productrange to covermachines forprocessing PVC andpolypropylene pipesby acquiring thePrimac brand andtechnology.

www.baruffaldi.eu

Advanced screenchangersThe capability of a company to expressits philosophy through R&D of innovativeproducts represents a fundamentalfactor in its growth and development.Finding new market opportunitiesthrough expertise gained over decadesof effort requires readiness andflexibility. Following this idea, BD Plast(15 - B23) has continuously improved itsrange of screenchangers, addressinggrowing demand in a very challengingmarket and introducing new lines ofproducts strictly embodying itstraditions. For many years the need for melt pipes,elbows and adapters for extrusion hasfound response in the company’sportfolio of products supplied to OEMsand end users. The company has understood thegrowing need to introduce a completerange of downstream equipment forextrusion lines offering services that gobeyond the engineering andconstruction of a single component. Thereference market in this regard areOEMs which can concentrate on theircore business while leaving theengineering and construction of ancillaryequipment between extruder and die inthe hands of a reliable and qualifiedpartner. Through the flexibility that hasalways distinguished it, BD Plast hasonce again demonstrated the ability towork closely with clients, producingproducts based on client’s designs orthrough their own in-house engineeringcapabilities. Participation in Plast 2012is the best opportunity to display theresults of these efforts. These include acomplete frame fitted with a 5-layer castmelt pipe group complete with heaters,wiring, and 5 different screenchangers,ranging from simple manual to hydraulictypes. In addition, a large filtration areasingle plate hydraulic screenchanger ison display together with a continuous

flow double platescreenchangerwith a newsealing systemsand protectiveguard layout.

www.bdplast.com

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BD PLAST

BARUFFALDI

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INJECTION MOULDING MACHINESLow tonnage with 2 platensThe introduction of the innovative EOSrange represents for Negri Bossi (24 - C64/D62) not just an occasion toshowcase a new low-tonnage injectionmachine range - which completelyrevolutionizes customary approachesto design, providing customers with anew concept in presses of this size -but also an opportunity to offer asolution that combines efficiency,cleanliness, energy savings andenormous versatility at a decidedlyattractive quality-price ratio. Theimpressive features of this innovativeseries - silent operation, precision, andenergy consumption levelscomparable to those achieved onelectric machines - are all on display tothe benefit of visitors.The new range is proposed with a 2-platen solution clamping unit and extremelywide tiebar spacing while also offering thelowest floor space requirements in itscategory. The need to meet the challengesof the low-tonnage press segment in aninnovative fashion has led the company tofocus strongly on product engineering andcontainment of overall dimensions withoutcompromising ergonomics, performance,efficiency, and moulding quality.EOS presses are equipped with a newcompact twin-cylinder injection unitfeaturing a practical and fast plasticizing-unit changeover system that provides easyand comprehensive access for tooling andmaintenance tasks. The clamping unitadopts a 2-platen solution with the movingplaten sliding on prismatic guides whilehydraulic oil is circulated through channelsin the fixed platen. In addition tostreamlining plant engineering, this solutionalso allows clamping and release to takeplace at high pressure using a reducedamount of fluid, thereby reducing energyconsumption. Fast low pressure movement duringopening and clamping is achieved by twopiston-corepullers with reduced cross-section, which ensure outstandingsensitivity during the mould securingphase, thereby minimising mould damageand wear. This new design, together withthe decision to support and guide themoving platen on prismatic guides, makesthis range ideal for the medical or foodsector, or for the production of any itemswhere it is important to ensure that nolubricating oils enter the mould area.The most important achievement, however,has been made in energy consumption.After years of experimentation andpractical application with servo-motors,inverters, vector inverters, andregenerative systems (for all-electric andhybrid presses), the engineers decided totake development of the inverter-controlled

variable displacement pump even further.This involved studying and mappingvariable-displacement pump efficiencycurves and actuator curves to develop apress software that ensures the bestcombination of motor rotation speed andpump capacity for each phase of themoulding cycle.

www.negribossi.com

Non-standard technologyA leading manufacturer of special injectionmoulding machines, Presma (22 - B09) isdisplaying two new machines, bothupholding the “non-standard technology”slogan. One of them provides a particularlyclear expression of the company’s aim toattract visitor attention to the new range offully Italian-made presses for rubber andsilicone elastomers. In this application segment the spotlight ison the PRO 400/100, a 400-ton horizontalpress with 4-tiebar direct-piston clampingunit. Its main features are the heated steelmould-holding platens (700 x 700 mm),

with a tiebar clearance of600 x 600 mm, as wellas the movable platenequipped withsynchronized centraland side ejectors with a100-mm and 350-mmstroke, respectively. Themould approachingstroke is 600 mm andthe maximum distancebetween the platens is750 mm. The injection unit of thetwin-screw cylindermodel with stationarycarriage unit andelectrically-driven screwrevolution by motor-gearbox and frequencyinverter is a 1,000-cm³

FIFO system, with 2,000-bar specificpressure. The unit is also equipped withdouble thermo-regulated circuit for theplasticizing barrel and for the injectionbarrel + nozzle, with the possibility toremove the injection punch for cleaning.Injection stroke control involves the use ofa linear transducer. The machine is set upfor the assembly of feeding systems forrolled rubber bands and silicone blocks.Tool cleaning is accomplished by anadjustable electrically driven brush. The second machine on display isPresmall, a 6-ton all-electric mini-presswith electric coaxial drive for clamping andejection and three independent drives forthe injection unit. The machine, equippedwith touch-screen interface and dedicatedsoftware, offers quick cycle time, highprecision and very low energyconsumption. This model is particularlysuitable for micro-moulding even in cleanrooms and can be equipped with a feedingunit for rubber or both solid and liquidsilicone.

www.presma.it

NEGRI BOSSI

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BLOW MOULDING MACHINESZero energy After the success achievedwith the presentation of theall-electric UMA 12 SeCoEZ blow moulding machinein sequential coextrusionfor technical parts, UniloyMilacron (22 - A11/B14)continues the developmentof new models to enrich itsEnergia Zero (Zero Energy)range, the brand thatdistinguishes all thecompany’s technologieswithout hydraulic drives.The UMS 200 shuttleextrusion-blow mouldingmachine on display duringthe fair follows thisdirection: it is anintermediate model with200-kN closing force andhorizontal 710-mm carriagestroke that has already gained a highlevel of acceptance among customers. Fit to accommodate up to 12-cavitymoulds with 55-mm centre distance, themachine is already prearranged forcoextrusion configurations of up to 7layers. Engineered to easily install theIML system on both sides of the bottle(also available for double-stationversion), it finds its ideal application in thefood, detergent, and personal carepackaging industries. The application ofthe most advanced electrical andelectronic technologies, the use of latest-generation servomotors and multipledrives with energy recovery during thedeceleration phase of all movements (asit happens in Formula 1 or on hybrid cars)provide exceptionally low powerconsumption. The absolute precision of all electricmovements of UMS 200 EnergiaZero,not depending on the processingtemperature, makes it possible tomaintain a constant level of quality of theblow moulded product within narrowtolerances. The possibility of using theinnovative parison cutting device withdirect electric movement in multi-cavityproductions - typical of the food industry -makes greater precision in the cuttingphase possible than can be achievedwith traditional systems and thereforegreater process stability with productionscrap reduction. In addition to the particularly silentoperation, the absence of the hydraulicpump and the hydraulic circuit eliminatesthe risk of fluid spillage caused byleakage or breakages, while the absenceof ball screws and bearings for linearmovements removes the risk ofcontamination from lubricants and theneed for periodic maintenance, making

the machine suitable for production inclean rooms. Like other Uniloy Milacron’s machines,UMS 200 EnergiaZero is equipped with aspecial bottle take-out system (two-axismovement, fully electric servomotordriven). Bottles are dropped on a linearconveyor system and then released toone side of the machine also in thedouble-carriage version. The eliminationof the traditional bottle conveyors allowsa dramatic reduction of footprint andbetter accessibility to the machine for aquick mould change.

www.uniloy.com

All-electric blowThe absolute innovation introduced byMeccanoplastica (22 - A19/B22) isMipet-1P, an all-electric single-cavitymachine for in-line 2-step stretch-blowmoulding of PETpreforms.

Manufactured at theSpanish branch inBarcelona, during theexhibition the machine isequipped with a mould toproduce 750-ml bottlesstarting from model 28/410preforms (weight 38 g).Designed for using bothstandard and specialpreforms to produce PETbottles of up to 2.5 litres, themachine can reach atightness strength (at 10bar) of 450 kg with a 140-mm max openingstroke. Its peculiar innovativefeature is the high speed ofthe production cycle, thanksto the prompt responses ofthe all-electric drive.Another all-electricmachine is HL 350 for 2-

station continuous extrusion-blowmoulding, designed to producecontainers having a volume of up to 3litres. The machine can reach 6 tons ofmould clamping force with a carriagestroke in the two versions of 350 and 400mm, respectively. Its innovative feature isthe hydrostatic-pneumatic system usedfor the clamping phase, actuated by abrushless electric motor. During the fairthe machine is running equipped withtriple-parison extrusion head (120-mmcentre distance) to produce 350-mlHDPE oval-shaped cosmetic bottles(weight 30 g).Finally, JET55/L, an all-electric 3-stationinjection-blow moulding machine, hasbeen designed to produce smallcontainers up to a 250-ml volume and

can achieve 55 tons oftotal clamping force

(50 for injectionand 5 for

blowing). During

UNILOY

MECCANOPLASTICA

theexhibitionthe machine isequipped with aset of 18-cavitymoulds to produce 10-mlHDPE bottles (weight 5 g).This is currently the only all-electric injection-blowmoulding machine inoperation anywhere in theworld. The absence ofpollutant or noise emissionsmakes it particularly suitablefor pharmaceuticalapplications, where there is acritical need for clean roomwork with very stricttolerances.

www.meccanoplastica.com

Advanced generationIn the new Advancegeneration of extrusion-blowmoulding machines,developed by Techne(Graham PackagingCompany Italia), the “fully-electric” concept has beenpushed beyond normal limitsthanks to innovative featuressuch as kinetic energyrecovery during machineslowdown cycles. During eachstep of the production cycle,kinetic energy is stored andthen fed back into the networkin the subsequent step,producing energy savings.The final result offers a rangeof machines with an overallenergy consumption of 0.31kWh per 1 kg of extrudedmaterial, with a 37% saving inreal terms if compared toconventional machines.The flexibility concept wasthen developed, bearing inmind that nowadays themarket requires machinescapable of handling differentkinds of productionprocesses. In order tomanage this important issue,the mould clamping systemaccommodates a range ofcontainers starting from smallsingle-serving capacity up to20-litre industrial tanks. Thesame concept has been

applied to the handling devicefor calibration nozzles, withthe aim to precisely andconstantly cut large diameternecks, and conventional onesfrom multi-cavity moulds.The project is completed bythe energy saving extrusionsection with high quality rawmaterial plasticizing, heatingand stabilization time, and fineadjustment of parisonthickness. The extrusionplatform includes a widerange of models and sizes inorder to cover the mostsuitable production choice interms of both hourly outputand extruded material. Ofcourse the multilayer andmulti-cavity platforms (up to 6layers and 80 cavities throughthe neck-to-neck technology)are available as well as theoption for production ofaseptic containers. Modularity is a unique specialfeature of the Advance range:machines are built withconfiguration capacity of up to4 shuttles, with high outputvolumes in limited floor-space,making use of conventionalunits. For limited productionoutput, machines can run with2 shuttles only or bereconfigured with differentcavity platforms.The production cycle hasbeen drastically reducedthanks to solutions which offer15% increases in productivityfor small containers, and over25% for industrial tanks. Thepicture is completed by theIML feature, with just one labelapplication robot serving twoshuttles, which allows quickapplication time and high-precision label placement.

www.technespa.com

TECHNE (GRAHAM PACKAGING)

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OTHER MACHINERYThirty years of pad printingPrecisely in concurrence withPlast 2012, Tosh (22 - B25)celebrates thirty years of activity inthe field of pad printing. This is aunique opportunity to thankcustomers, suppliers,representatives and all those whohave believed in the company andits products. In addition, theexhibition provides an occasion tolearn more about possible goalsfor the future, thanks to thecompany’s expertise andprofessionalism.Founded in May 1982, thecompany quickly established aleadership role in pad printing notonly in Italy but also in theinternational marketplace.Passion, solution-basedmotivation, and design ingenuitymade the name Tosh well knownamong the most satisfied andsuccessful users of pad printingtechnology worldwide. Gainingleverage from the economic boomof the Eighties, the Logica Serieswas designed and developed.This line of pad printing machinesintroduced the clearly innovativetechnological component of an all-electric operating cycle with digitalcontrol of all axes of motion. Thechoice not to design the systemsaround the traditional pneumatic driveproved to be a winning one. This isattested by thousands of machines sold todate in a dynamic and expanding market.Parallel to the advancements in the areaof machine design, the company workedto develop a complete line ofconsumables specifically developed forpad printing. Here, a second winningchoice was made with the decision toproduce, in addition to pads of any shapeand hardness, printing inks, clichés andaccessories, thus acquiring the capabilityto provide customers with products thattruly meet their requirements.Continuing along the same path andencouraged by satisfied customers, theNineties saw the company expand outsideof Italy and Europe to other countriesaround the world. New countries broughtnew opportunities, leading to thedevelopment of more sophisticated,application-specific, highly automated padprinting machines. These years were alsocharacterized by the proliferation ofhermetically sealed systems that have allbut eliminated the old open inkwellsystems of the past making pad printingincreasingly production-friendly.The first decade of the new millenniumreaffirmed pad printing as an essentialtechnique for decoration of a seemingly

infinite number of products. Niche marketsdeveloped as companies sought todifferentiate their products. At the turn ofthe century, Tosh was routinely providingcustomers with solutions that wereinconceivable only a few years earlier.During this decade the companyrecognized the need to divide its Logicarange into two distinct lines - High Speedand Flexible - to meet the specific needsof those customers seeking to make

investments in technology thatensures concrete advantages inan increasingly challengingeconomic environment.In these last two years the range ofmachines has continued to growvia the advent of Logica Platformand Logica Cartesio. Both of thesesolutions come “sized to fit” andwill serve the customers well asthey continue to expand thehorizons of the pad printingprocess. Last but not least, incontrast to most competitors, whenTosh says “made in Italy”, it meansusing 100% Italian design andcomponents, in the full Italian style.

www.tosh.it

Alternative rotomouldingSome materials currently availableon the market have not yet foundtheir best use in rotationalmoulding because of a lack ofadequate automation and processcontrol in the conventionalprocess. Recent experimentscarried out by Persico (22 - A23)have been focused precisely in thisdirection.One of these experiments regardsthe production of PA6 componentsstarting from caprolactam chipswhich are polymerized through

anionic addition. The company hasdesigned a material preparation plant forthis application in which the raw materials(caprolactam+activator, andcaprolactam+catalyst) are melted in twoseparate tanks where specially designedstirrers uniformly blend the additives. Thematerial in liquid state is mixed in anantechamber and pumped into rotatingmoulds heated at the proper temperature

TOSH

PERSICO

● 41

for polymerization. Material solidificationoccurs through a chemical reaction andnot by cooling inside the mould. This being a chemical process, it is vital tocontrol and monitor the processingtemperature inside the mould. OnLeonardo, the first fully-automatedrotomoulding machine, the heatingelements consist of a series of resistorsapplied directly to the mould surface. Thisfeature allows for uniform heattransmission and precise, instantaneouscontrol of process temperature, which isrequired for effective completion of thechemical reaction inside the mould. The second experiment was focused ontransparent polycarbonate processing, inwhich a newly developed version of theLeonardo machine with electric heatinguses a vacuum technique. This processalso requires precise mould temperaturecontrol in addition to rotation speedshigher than in conventional rotomoulding.As is well known, one of the problems ofpolycarbonate moulding is the presence oftiny air bubbles trapped on the outside andinside surface of the moulded part duringsintering. If the bubbles are not eliminated,they negatively affect the mechanicalproperties of the material as well as itsaesthetic appearance. The classicapproach to removing the bubbles is toprocess the material at a much highertemperature and for a longer time than istheoretically necessary to melt thepolymer. The higher temperatureincreases melt fluidity and, by keeping thematerial in this state for a sufficiently longtime, the bubbles can be “reabsorbed” bythe polymer. To overcome this technological limitation,Persico carried out some tests comparingthe results of different samples mouldedunder the same processing conditions butwith a different internal mould pressure.Thanks to the Leonardo machine, besidescontrolling the mould temperature directlyand precisely, it is easy to monitor internaltemperature and even pressurize anddepressurize the cavity of the rotatingmould. Testing revealed that a vacuum techniqueleads to the complete removal of thebubbles both on the outside surface and

inside the wall. In addition, the mouldsurface was subjected to a specialtreatment, and some adjustments indesign and construction have produced asignificant improvement in moulded partquality.

www.persico.com

Wood-imitation embossing in registerThe market shows great interest inlaminated materials and coverings forproduction of wood-grain flooring,composed of a substrate encapsulatingseveral PVC film layers filled with highpercentages of calcium carbonate andpossibly reinforced with glass fibre,laminated to a printed film, which can bereinforced or non-reinforced (extensible)and perfectly imitates wood.Progress in printing techniques, includingdigital printing, makes it possible to obtainvery high quality imitations of any kind ofnatural material. For example, prints canbe produced that perfectly reproducecolours, shades, and grains of any kind ofwood. But this is not sufficient to give anacceptable appearance to the product, asits surface is glossy and smooth to thetouch, which is absolutely unnatural andfar from the real appearance of a naturalmaterial.

Currently, this problem is addressed bysubjecting the material, after the baselayer and printed sheet have beenlaminated together, to an embossingprocess that imprints relief into thesurface, creating tactile irregularities thatmake the product more similar to itsnatural counterpart. However, suchtechniques do not provide satisfactoryresults since the engraved roll createsrelief that does not correspond to theprinted pattern. Thus, grain, knots, andother printed features of the wood have nocorresponding features in the embossedrelief.This drawback can only be overcome byperforming embossing in registerdiscontinuously, thus making it a slowprocess. Furthermore, the embossingpress, working offline, is expensive andcumbersome. Since laminates are, bynature, economical products, the processneeds to be simplified and as cheap aspossible. It is thus necessary to carry outembossing in a continuous process, i.e.,directly on laminated film instead of onpre-cut panels, something hithertoconsidered infeasible. Specific patent-pending systems havebeen invented and are presented at thefair by Rodolfo Comerio (11 - C42). Theaim is to offer an effective, fast, and

RODOLFO COMERIO

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economical technology forembossing in register (orsynchronized embossing) ofsingle-layer or laminated sheetcomposed as describedabove.

www.comerio.it

Insulating panelsEarly in 2011, Saip (11 - A73)and Dow Chemicalestablished a new company inSpain, CeDePa (Centro deDesarrollo del Panel enContinuo), located in Tudela(Navarre). It is a new, one-of-a-kind, state-of-the-artindustrial-scale developmentcentre for thermal insulationpolyure6thane panelsproduced with continuouslamination process. Dedicatedtechnical resources and acomplete network of experts inequipment, chemical systems,process engineering, andapplications assist teams fromdifferent companies toconfidentially develop,prototype, and test innovativeand most effective solutions. CeDePa builds on years ofexperience in this industry ofthe two partners, who havedecided to jointly invest in thisinitiative as they both believethat the combination of theirrespective expertise inchemical and mechanicalproduction processes andtechnology is a decisive factorfor rapid innovation and theenduring success forcustomers and the industry asa whole. The new company isalso open to external R&D andtechnology centres,universities, qualitycertification organizations, andother external playersinterested in innovation andsustainability in this industry.A state-of-the-art industrial-scale line has been installed at

CeDePa and is fully devotedto testing and prototyping. Ithas been conceived to allowSaip and Dow customers, andthe construction industry as awhole, to accelerate thedevelopment of novelsolutions for themanufacturing of polyurethanepanels for thermal insulationand to accelerate thediscovery and availabilityacross the industry of novelsolutions to help increaseenergy efficiency throughenhanced thermal insulation ofbuildings while also simplifyingand accelerating theirconstruction, durability andsafety including fireperformance, and final usercomfort.The line, with a length of 135m, includes the whole range ofproduction equipment from thesteel uncoiling section to thewrapping section: roll formingsection for corrugated and flatsteel facing profiles with aquick profile changeoversystem; primer equipment forsteel facing treatment; flexiblefacing, EPS and mineral woolprocessing equipment; multi-stream, high-pressurefoam dispensing machine (9components); double pressconveyor with operatingtemperature up to 70°C (panelthickness processing range upto 240 mm); handling sectioncomplete with coolingequipment, stacking and panelbundle wrapping; state-of-the-art line process control andsupervision system (over 100parameters constantlymonitored); up to 16 camerasmonitoring and recording theproduction and trial process.

SAIP

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www.saipequipment.it

Shuttle rotomouldingAs a supplier of solutionsfor all rotational mouldingneeds, RotomachineryGroup (22 - C10) isintroducing a new shuttlemachine with 3 stations,where each carriageenters the ovenindependently. The clientdemanded maximumflexibility for the productionof huge tanks (capacity upto 40,000 litres) requiringlong cycle times forhandling the moulds andmoulded parts. Thepresence of the additionalcarriage has brilliantlyresolved these problems, allowingoptimization of resource use (operatorsand equipment): each arm (with a mouldor group of moulds) can be put intooperation totally independent of theothers, either sporadically or continuously.The insulation system for the walls of thecooking chamber allows high efficiencyeven with low production volumes. Thesynergy between Rotomachinery Group’sItalian and Canadian research teams hasled to noticeable progress in the efficiencyof hot air circulation inside the mouldingchamber. And the results can be appliedto any type of plant in the range(independent arm machines, shuttlemachines, and rock-and-rollmachines).Tests carried out on a new typeof hot air blower and a betterperforming directional airhandling system have proven asignificant reduction in cycletimes and lower energyconsumption thanks toincreased heat exchange in theoven. The goal of reducedconsumption is constantlypursued with tests of newinsulating materials and auto-adaptive cycle managementthanks to software thatautomatically determinesoptimal cooking and coolingtimes and verifies the best

combination of the moulds based on thespecific programmed recipe.

www.rotomachinerygroup.com

Digital decorationIn 2012 GMC is introducing the innovativeD-HDT system for direct printing of digitalimages on plastic containers. The specialfeature of the system is the ability to printdigital images using dry thermoplastictoner, applying them subsequently to themoulding process. The system permits thedecoration of plastic pails or jars withdifferent geometries: truncated-cones,cylinders, and objects with oval, round or

square bases with orwithout handles. The new system wasdeveloped in response tospecific demand in theprinting market forreduced production timeswith respect to thetraditional thermaltransfer. This is achievedthanks to the immediatedecoration of the objectand simultaneous checkof the final result, reducinglabour costs because theentire process can bemanaged by a singleoperator.Based on mechanical and

software innovation, D-HDT makes itpossible to set up a single line to printdigital images and apply them tocontainers, simplifying processmanagement, improving cycle time (warm-up time 5 min; print launch time 30sec) and increasing productivity. Rolls ofvariable length (from 1,600 up to 7,000 m)can be used to decorate as many as 450seventeen-litre pails or 650 three-litre pailsper hour. Thanks to the innovativetechnology of the print controller andprocess electronics, the printing processoffers excellent performance in terms ofconsistently accurate colour reproduction,simplicity of use, and operational economy.

The new system conserves allthe characteristics of thetraditional system, such asmaximum printing area (1,200 x300 mm), resolution (1,800 x 600dpi equivalent) with pantonecolour calibration, a commercialprint engine model that is widelydistributed and serviced all overthe world to ensure clients fullfreedom and autonomy inacquiring and managingconsumables. The new systemis characterized by a quick sizechangeover, absence ofmandrels, reduced maintenance,and easy management.

www.gmcprinting.com

SAIP surl- via Bressanella, 13 - 22044 Romanò d’Inverigo - Como - Italy - tel. +39 031.605762 - fax +39 031.606934 - www.saipequipment.it - infosaip@saipequipment.it

EQUIPMENT AND TECHNOLOGY WITH VALUE ADDED SOLUTIONS

FOR POLYURETHANE FOAMS PROCESSINGVisit us at STAND A73 - HALL 11

IMPIANTI E TECNOLOGIE

PER LA LAVORAZIONE

DI POLIURETANI ESPANSI

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FROM THE FILE TO THE CONTAINER (GMC)

44 ●

ANCILLARY EQUIPMENT & COMPONENTSInnovative approach to dryingThe Eureka project has been developedby Moretto (22 - A33/B34) to significantlyreduce energy consumption and improveperformance in drying systems. Itincludes three exclusive technologies:the new X MAX modular dryers, theFlowmatik control device and the OTXhoppers.The modularity of X MAX dryers makes itpossible to create large drying systemswith capacity of up to 20,000 m3/h. Theunits can be configured from aminimum of 3 to a maximum of10 with up to 32 dryinghoppers, with no need forair pressure or coolingwater. The result is afaster, consistent andgentle dehumidification ofhygroscopic materials,ensuring a significantreduction in energyconsumption. The main feature ofthis multi-bed systemis the capability ofmaintaining a consistent anduniform dew point during the process.High efficiency levels can thus beachieved with total operating flexibility.The individual units are rotated forregeneration: while one dryer is beingregenerated, the other units are inoperation, guaranteeing constantperformance. The variable airflow adjustsautomatically depending on processrequirements, thus preventing thermalstresses and viscosity variations in thepolymer.Flowmatic is an automatic integratedsystem for process air distribution inmulti-hopper systems. It supplies thecorrect quantity of air needed by thehoppers. This technology manages thesystem by adjusting the individualhoppers and process variables. Themachine uses only the process airneeded, which is calculated on the basisof the quantity and type of polymer to behandled. This produces excellent resultsin terms of minimizing consumption.The proprietary OTX hopper has aninnovative geometry which resolves theproblem of non-uniform material fallingflows and results in more efficientmanagement of the drying phase,keeping the process inside the hopperunder control. The particular hopperconfiguration provides homogeneousairflow and temperature, thus ensuringoptimal treatment of the granule with aconsiderable reduction in energy costs incomparison with conventional hoppers.The high impact Spyro finish, besidesproviding this new hopper with itsdistinctive look, also makes it more

resistant than those using standardlinings.

www.moretto.com

Cooling & thermoregulationThe new range of Raca Plus Energychillers is now complete with theinnovations to be introduced byFrigosystem (15 - B30, 24 - D40) duringthe fair. This series boasts successfulworldwide installations: many customershave already attained the benefits of theecological R410 gas, saving an average of35% energy compared to the traditionalR407. These chillers are also appreciatedfor their highly reliable technology and theflexibility of application.

However, the company continues toenlarge and enrich its range of

products to better address theneeds of its customers. Inits quest to stay ahead ofcompetitors, the newseries will include modelsfrom 50 to 1,200 kW ofnominal cooling power, allwith multi-circuit and multi-compressor systems. Themax ambient temperaturerange will move from 43 to45°C without options. Thefree-cooling system,integrated or not, has beenoptimized too, and willconsequently reduce theenergy consumption in themost favourable climaticconditions. i-Remote is thename of the newlyintroduced control system,a local and remotesupervision system,applicable also to the mostcomplex cooling plants.

Innovations are also announcedon Kite air and water chillers, purpose-built and engineered for blown filmextrusion and already valued by German,Italian and North American customers.The technical focus remains on energysavings, R410 efficiency and flowvariations, with constant and precisecontrol of process temperature. The rangenow offers units with 1-2-3 cold air outletsand heat regulated water connections forextruder utilities.On the temperature controllers, thecompany is presenting the new i-Heatingunits, with a new-generation controlsystem. In 2011 Frigosystem was namednumber one Italian manufacturer oftemperature control units, with more than150 models in its catalogue and 2,800produced units: water or diathermic oil,

simple solutions or sophisticatedtechnologies, but always

and totally “made inItaly” with an excellentquality-price ratio.

www.frigosystem.it

Band granulatorsBand granulators fromSagitta (11 - C06) aresuitable for dicing nonvulcanized rubbercompounds of anytype, natural or

synthetic, as well asthermoplastics, linoleum,

cellulose, and silicone.Feeding extruders and moulding

machines with granules instead ofFRIGOSYSTEM

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MORETTO

strips offers severaladvantages, such as theability to blend differentcompounds thus obtainingbetter product quality, lesspulsation in extruder screws,energy savings, andautomatic operation.Many solvent manufacturerstake advantage of bandgranulators because thedissolving times can bereduced considerably bymeans of granules (5x5 or3x3 mm). The use of the GR450 S2 model isrecommended forprocessors who often havechanges of compounds orcolours. On this machine thecutting unit moves forward for easycleaning.Sagitta delivers machines with workingwidth of 135-235-430-620-830 mm forgranules of 3x3, 5x5, 8x8, 10x10 and15x15 mm. Toothed feeding disc-cylinders are available for very hardmaterials in order to prevent slippage.Hardened metal knives can be suppliedfor granulating very abrasive compounds.The hourly output capacity ranges from300 to 10,000 kg according to themachine model and granule size.Machines with or without automaticpowdering equipment are available.Furthermore, the delivery programincludes pneumatic conveyance ofgranules and de-powdering systems aswell as de-packing powder feedingequipment.Sagitta also produces other rubberprocessing machines: horizontal splittingmachine to divide elastomer sheets (maxwidth 550 mm, max thickness 60 mm,minimum thickness 0.2 mm); automaticmachine for trimming and cuttingelastomer gaskets placed on rotatingspindle and trimmed with extremeprecision by lance tooling; automaticmachine to cut elastomer sleeves onrotating spindles into rings by means ofspecial knives; automatic machine to cutextruded elastomer profiles and hoses byelectronically-controlled revolving circularknives.

www.sagitta.it

In-line recoveryAmong the innovative proposalsintroduced by Tria (15 - C26, 24 -C55/D50), a special emphasis is put onthe evolution of JM grinders, devoted toin-line recovery of injection mouldingscrap. Following sales of more than4,000 units, the company decided to sumup in these machines the Blue Linedesign philosophy that it has developedin recent years. This vision has led to thoroughgoingresearch into performance whilemaintaining flexibility of use, compliance

with standards and legislation, advancedergonomic solutions, and managementeconomy combined with constructivequality to ensure a medium-term returnon investment.The aims which have served asguidelines in renewing the JM range maybe summarized as follows: low noiselevel (below 80 dBA) for in-line grinding;low energy consumption (max 700 W)with motor power reduced by 20% whileensuring the same performance;ergonomic design and reliability withsimplified access to the hopper andfunnel, and a 27% reduction in footprint.Similar design standards and solutionshave also been applied to other widelyused machine ranges, Series 30 and 42,

which are proposed in updatedversions.As for large-sized machines, arevamped version of the Series80 (rotor diameter 620 mm) ison display for grinding in-line(thermoforming and film scrap)and off-line (extrusion andrecycle). A new counter-knife securing systemhas been designed for thewatertight grinding chamber;moreover it is possible to fitstationary or rotary discs andthree different shafts, includinga forged one for wet grinding orextrusion spurges.A further innovation on displayis the CR K high speed forcedloader for film fluff, designed in

cooperation with major manufacturers ofcast film lines. Equipped with visualwarnings and video cam for internalmonitoring, its special design allows it tointegrate with any type of extruder.

www.triaplastics.com

Sprue-pickers & driersThe sprue-picker manipulators in the AVPrange, suitable for on-board use withinjection moulding machines, have beendesigned by Dega (24 - D14) to pick-upsprues or parts (with grip device andvacuum generator) from the mould area.Amortized pneumatic cylinders and largesolenoid valves permit a considerablereduction of the extraction cycle times. Thanks to the programming softwaredesigned by the sister company DegaAutomation, the manual control allowsconstant and accurate monitoring of allcycle times, with visualization of eachmovement on the display. The selectionof standard programs is easy and fast:there are 4 pre-set programs in thememory which can be called up andmodified at any time. Moreover, it ispossible to create new programs andstore them in memory. The operatingfunctions, such as vacuum circuit, partgrip verification, and part pick-up from themoveable and fixed platen, are easilyselected by a key on the hand-heldcontrol.For small batch dehumidification with astable process quality, Dega isintroducing the latest version of its DD60-R, a small dehumidifier with a 60-m3/h rotor which is positioned in acontainer that rotates, divided into 3different compartments, each specializedin a different function: processing,regeneration and cooling. With thissystem, the processed air exits the rotoralways at the highest level of dew point,eliminating the rippling effect observed inconventional systems.When it is dried, industrial compressedair (6-15 bar) has a dew point of 3-5°C.When it expands to atmosphericpressure, the dew point falls naturally

SAGITTA

46 ●

TRIA

to -20 or -28°C. With the Series AC micro-dehumidifier it is possible to reachan average and constant dew point ofeven -18°C. Hence, for small batches itbecomes convenient to adopt thissolution because similar results areachieved, per unit of energy consumed,as with traditional dehumidifiers, with theadvantages of small space requirements,temperature control managed by specificsoftware, micrometric control of the airflow at low pressure, insulated hopperwith rolling cover, and air diffuserpositioned in the socket adapter.

www.dega-plastics.com

Quality firstThe latest innovative solutions introducedby Doss Visual Solutions (11 - A31) inthe field of artificial vision systems andindustrial automation include Migl II,which makes it possible to sort complexand irregular parts with length up to 600mm and width up to 200 mm. Linearcameras and laser measurementsystems collect all the data necessary forrepeatable quality control. The point-to-point laser acquires the real partthickness and the cameras carry out bothsurface (on two sides) and dimensionalchecks. The machine can be equipped withloading and unloading robots. A turnoversystem has been developed specificallyfor 180° flipping of any type of part ormaterial. All sorting data are saved to adatabase that can easily be accessed bythe operator and statistics can bearranged in tables that can be exportedwhenever needed.Designed for the sorting of large gasketsup to 200-400 mm (in two versions), theDuet machine is composed of a firstrobot, guided by a camera, which picksup the parts directly from a bin: 2 differentcameras frame the scene from twodifferent viewpoints and send back to thePC all the information about the XYZposition of the part to be picked up. Therobot then places the part on aback-lit plate fordimensionalcheck; asecondrobot rotatesthe part andpasses it infront of acamera forinspection ofthe entireexternalsurface. Thesoftwaredetects

stains, rings, scratches, tears, flash ormissing material. Depending on theoutcome, the robotized arm places thepart into the bin for good parts or thescrap bin.

www.doss.it

Nozzles & controllersInnovations introduced by Thermoplay(24 - D34) for injection systems include anew nozzle for multi-cavity moulds usedfor manufacturing tubular-shaped parts,which contributes to the elimination oftraditional “tunnel” sprues normally used inthese applications. Injection is direct in theannular cavity wall. The nozzle structureallows easy machining of the injectionsystem housing in the mould. In addition the nozzle is provided with adouble sealing ring preventing materialleakage. The thermal profile of the nozzlebody and the isolation of the tip from theforming matrix make it possible to useprocess parameters aligned with thosesuggested by plastics manufacturers. Theextraction operation helps create a defect-free injection point thanks to the lateralinjection. Another innovative injection systemenvisages that the nozzle, with or withoutthe shut-off group, can be mounted atdifferent inclinations and assembled to themanifold ensuring perfect perpendicularityto the injection platen. An innovativesystem of joints that distributes expansioninside the manifold enables the use ofnozzles without minimum lengthconstraints depending on distance fromthe centring element. The system issupplied prewired in variousconfigurations based on specific needsand equipped with conditioning andelectrical circuit, and pneumatic/hydraulicsystem, simplifying handling andinstallation of the system in the mould.Thermoplay also introduces a newsequential controller designed to optimizethe molding process in criticalapplications. Each shut-off valve isdetected and controlled by the

system, so the end product isfree of welding lines,

DEGA s.p.a.Largo del Lavoro 4 - 6 - 8

25040 CLUSANE SUL LAGO (BS)Tel. +39 030 989595 - Fax +39 030 989596

Email: info@dega-plastics.comwww.dega-plastics.com

www.pubblicitab

elotti.it

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DOSS

thus meeting the most strict qualitystandards. Technical characteristicsinclude: sequential control of pneumaticand hydraulic shut-off valve systems,automatic and manual test operation forfunction testing of each valve, maximumconfiguration 16 valves, mobile high-resolution touch-screen unit andshockproof case, temperature control ofconditioning circuits.

www.thermoplay.com

Strategic maintenanceToday more than ever,maintenance is recognized as astrategic asset for anycompany. An accuratemaintenance strategy,together with the use ofsystem components thatenable reduction in overalloperating costs, is fundamentalin optimizing machine functionand plant operation in theplastics processing industry.Even though service processesoften play a secondary role inthe production system,Wamgroup (11 - B92) offersnew specializedcomponents aiming atoptimizing processes,improving performance, andensuring high safety standardsfor both personnel andequipment.The new VHS pressure reliefvalve, manufactured from engineeringpolymers, relieves any excess pressureoccurring during silos filling or generatedby physical or chemical reactions that maytake place inside containers. The valveconveys dust emissions to a collectionspoint to ensure constant safety in the workarea. Reliability in operation coupled witheasy maintenance make the VHS valve aone-of-a-kind component fully compliant

with environmental protectionregulations.

Reduction in maintenancetime and costs also plays

a key role for Torex,another Wamgroupcompany, which hasdeveloped VAR, a

drum-type diverter valvefor pneumatic conveyingsystems. This valve, withstandard inflatableseals, has beenspecifically designed to

minimize maintenanceand considerably extend

the product life cycle.Distinctive features ofdiverter valves are

specific anti-abrasivecoatings designed for theplastics industry and aparticularly maintenance-friendly design.

Finally, the GT pipe couplings,developed to join plain pipe ends ofpneumatic conveying lines in a safe,quick and rigid way, help reduceinstallation costs as compared to weldedjunctions, at the same time ensuringgreater flexibility of use, work safety andno pressure drop along the pneumaticline.

www.wamgroup.com

HALL 13 - STAND C05

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WAMGROUP

AGRICULTURE & POLYMERSHigh performance filmsThe increasing importance of plastics in thearea of agriculture and horticulture hasbeen highlighted by AMI (Applied MarketInformation) with a new report onagricultural films in Europe, a 2-billion euromarket which accounts for over 500,000tons of polymer-based films every year.The latest trends of this market were alsothe focus of an international conferencethat was organised last November by AMIin Barcelona, bringing together agriculturaland horticultural cover specifiers,researchers, manufacturers and the supplychain to the industry. Plastic films for silage, mulch andgreenhouse applications have made asubstantial contribution to the developmentof agriculture over the past 60 years. Theiruse has been notable in the horticulturalindustry, as well as the beef and dairysector, contributing to continuouslyincreasing yields. These films have alsoenabled the extension of cultivation interms of the growing season and thelocation for a variety of plants through theiruse in protective mulching andgreenhouses.While plastic films can undoubtedlycontribute to improved efficiency andoutput, growing concerns about their wasteand disposal is leading to growing interestin the use of biodegradable materials.Reductions in dairy herds may lead to adecline in silage films in one area; growthin biomass crops may create opportunitiesin another. Climate change may extend theopportunity for plastic greenhouses furthernorth, while at the same time existing userswill want more durable, longer lasting filmsto cut costs. Currently the overall impact of thesevarious trends is a market which in volumeterms is showing very little growth butwhich will still present opportunities for filmproducers to develop better performingfilms in areas such as barrier performance,thermal, visual and photo-selective properties. The market is mainly in theMediterranean region withItaly and Spain taking thelead particularly inconsumption of greenhouseand mulch films. In the longterm, however, demand foragricultural films is expectedto grow more strongly incountries in Northern Europewhere climate change willcontribute to morefavourable conditions foragriculture and ongoingpush for higher yields willdrive demand for agriculturalfilms.Silage film is the largest

segment accounting for almost a half of theEuropean market, split fairly evenlybetween clamp silage and stretch silagewith a small share accounted for by silobags/tubes. Consumption of greenhousefilm represents around 30% of the marketconsisting of film for classic greenhousestructures, macro tunnels/walking tunnelsand low tunnels and floating/direct covers.Mulch film represents the remaining 25% ofthe agricultural film demand in Europe andis expected to show a small overall declinemainly due to replacement bybiodegradable types and where feasiblefurther downgauging. The ten largest agricultural film producersaccount for more than a half of the filmsproduced in Europe. While theMediterranean producers account for themajority of the greenhouse film output, theNordic and North-West Europeanproducers offer primarily silage film and toa lesser extent mulch film.

www.amiplastics.com

Drip irrigationFresh water usage for irrigation, fromsurface or underground sources, accountsfor approximately 70% of the totalworldwide. Also at a global level,

approximately 60% of water drawn forirrigation is lost in the transport networksand during delivery to the crop. Thechallenge we face, at the start of the thirdmillennium, is to protect the fundamentalrole of water in supporting the ecosystem,by encouraging sustainable use of thisresource and water conservation duringirrigation. Management of irrigation water is still farfrom matching the ever escalatingdemands of crop production, howeverthere have been some new technologiesdeveloped able to significantly reducewater waste. The most well-known andefficient of these, adopted in developingcountries, is micro-irrigation or dripirrigation, which by delivering smallamounts of water directly to the roots ofplants, is able to reduce water consumptionby around 60% and improves the qualityand yields of agricultural crops. In low-pressure localised irrigation, theefficiency of water delivery is generally highbecause evaporation losses are negligible,as also are losses due to surface runoff. Inorder to achieve good uniformity ofdelivery, the system needs to be sizedtaking care to select the diameter of thetubes as a function of their length, as wellas of the flow rate and the spacing between

emitters.The introduction of plasticshas made possible countlessadvances in this sector, andpolyethylene is the preferredmaterial for its processabilityand mechanical properties.Suitably formulated, it isemployed for the productionof tubes, hoses and drippers.For this application, PolimeriEuropa offers a vast range ofproducts that can be usedeither alone, or in blends.The product traditionallyemployed for this applicationis Eraclene FB506, whosesuccess is due to key factorssuch as versatility, ease ofextrusion at low thicknessCONSUMPTION OF AGRICULTURAL FILM IN EUROPE (AMI)

Spain 20%

Other WE 11%

Poland 3% Other CEE 5% France 9%

Germany 11%

Italy 21%

UK 7%

Benelux 6%

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Nordicterritories 7%

52 ●

andability to

dispersepigments

(carbon black).The growing

demands of thishighly technological

application, where thekey goals to pursue are

increasing the hourly flowrate and gradually reducing

the wall thickness of the tubes,have prompted to the

development of a specific product,Eraclene DB 506, characterised by

an optimal balance between meltflowability and toughness, which make

it the ideal choice for producing flat driplaterals, i.e. ultra-thin walled (120-200micron) tubes, 12-25 mm in diameter,inside which a drip tape running the entirelength of the tubing is inserted during theextrusion phase.This product is used in dripper line systemsfor irrigating annual crops, and is madeentirely from a single resin. Thischaracteristic allows it to be completelyrecycled at end of life, making this anecologically sustainable application interms of both water resource managementand the safeguard and protection of theenvironment.

www.polimerieuropa.com

Barrier for silageGlobal consumption of plastics inagriculture has grown significantly in recentyears, to reach nearly 3 million tons, ofwhich 20% is used in Europe and isemployed chiefly for three applications:40% for greenhouse covers, 20% formulching fruit and vegetable crops, and40% for covering silage in livestock farms. The use of plastics for ensilage involvestwo different technologies: wrapping roundbales using 25-micron thick stretch film,and covering silage in trenches or stacksusing 110-200-micron thick film. Thetechnique of preserving livestock feed bymeans of ensilage relies on lacticfermentation in an anaerobic environment.Therefore the quality of the wrap, and itsability to completely isolate the silage fromoxygen, are crucial to the success of thismethod. Historically, film for ensilage was madefrom polyethylene. In 1985, a techniquewas developed for preserving ensilagedforage by wrapping round bales, madepossible by the first commercial balewrapping machine and the availability of

stretch polyethylene film. In the Nineties,the idea arose of improving the oxygenbarrier of silage sheets, in a manner similarto the controlled-atmosphere packaging ofagrifood products, but it was not until 2005that a commercial application wasdeveloped. The technological development of film andof new polymers with high oxygen barriercame out of a collaboration between theUniversity of Turin, IPM (Industria PlasticaMonregalese) and Nippon Gohsei Europe.Thanks to the far-sightedness of thisJapanese company, which believes thatdevelopment of high oxygen barrier film willbe the future of ensilage, in 2007 a newgrade of EVOH was developed for thisapplication (SoarnoL SG611). This polymer retains the extremely highoxygen barrier typical of EVOH, coupledwith mechanical properties essential forthis type of application, such as elasticityand resistance to puncture and tearing,which make it suitable for producing stretchwrap for round bales. During the Agricultural Films internationalconference, held in Barcelona lastNovember, Giorgio Borreani (University ofTurin) presented the first experimentalresults of the application of these films toensilage on a farm scale. The findings show a marked improvementin the efficiency of silage storage quality,with a reduction in the losses of ensilagedproduct and improved healthfulness of theresultant fodder. Improving the quality ofsilage for livestockfarming is one of themost ambitious goalswhich the scientific andinternationalcommunity has setitself for the nearfuture, becausemodern livestock farmsrely on silage for over50% of their animals’feed. Availability ofhealthful and high-quality silage istherefore of theessence, and the newfilms developed for thisapplication open up

very promising future prospects for thispreservation method.

www.unito.itOlive harvestingRecently the Italian moulder Saroplastwas tasked with the design of newgears for a tool designed for thecommercial harvesting of fruit, mainlyolives. The original tool had both

ergonomic and practical problems. Itwas heavy and therefore tiring for the

user who has to carry it normally all daylong. The weight also had a negative effecton mechanical functioning, with the devicekept in constant operation for hours at atime.So the company evaluated the possibility ofreplacing some metal components withpolymers, in order to achieve a morelightweight and easy to handle tool, whileenhancing the lifetime of the device. Thedesigners focused on the toothed gearwheel that drives the tool via a connectingrod. The first tests were carried out with a PPS-based material, which failed after only3 minutes because of excessive wear. Anynew material would have to be able tosurvive heavy use. It had to be lightweightand offer excellent resistance to wear,fatigue and high operating temperatures. Itwould also need to support manufacturingto tight tolerances. A modification was made to a metal ring,also adding a roller bearing that controlsthe movement of the rod. The key was touse the PEEK 450CA30 grade from VictrexPolymer Solutions, in the first instance tooverprint the component, in the second tomould it directly.The design was tested successfully. PEEKprovides a lightweight solution that enablesease of use throughout an entire day. Thehigh thermal resistance of the polymerallows the tool to operate continuouslywithout incurring excessive wear. The newtool also runs more quietly and reducesenergy consumption significantly. The newdesign weighs 10 times less than theoriginal model, improves the acoustic indexand reduces power consumption.

www.victrex.com

POLI

MER

I EUR

OPA

VICTREX

Moulding temperatureThermoplastic polymers are injection

moulded at temperature and pressureconditions that depend, obviously on

the type of mould and its geometry (dimen-sions, gate location and conditioning aresome of the factors to consider), but alsoon the type of material used.With respect to this last-mentioned aspect,the essential consideration which deter-mines the choice of moulding conditions isthat the polymer must be able to very rap-idly fill the mould. This to prevent the meltfrom cooling inside the mould before it hasbeen entirely filled, which would result in anincomplete part. It follows that moulding of thermoplasticpolymers requires sufficient flowability, bothto fulfil the above requirement, and also toensure a faster moulding cycle, and sohigher throughputs. Given these premises, it is important to re-member that the moulding temperature isdetermined differently for the two maintypes of thermoplastics, i.e. semi-crystal lineand amorphous polymers.Moreover, we have to consider that semi-crystalline polymers (which include poly -propylene, polyethylene, polyamides,ace tal resins and polyesters) have a par-tially ordered arrangement of macromole-cules within the polymer matrix, whereasamorphous polymers (such as polystyrene,polycarbonate, PMMA and ABS) have acompletely random and disordered arran -gement of macromolecules (generally de-scribed as a tangle of chains).Due to these structural differences, themanner in which amorphous and semi-crystalline polymers pass from the solid tothe fluid state differ, as do the temperaturesat which these transitions take place: forsemi-crystalline polymers, this change ofphase occurs at the melting temperature,and for amorphous polymers at the glasstransition temperature.

* * *In practical terms, these two different poly-mer structures entail a difference in be-haviour, due to the fact that, immediatelyafter completing the phase transition, asemi-crystalline material is significantlymore fluid than an amorphous one. Evi-dently, this in turn influences the choice ofmoulding temperature for a polymer, giventhat, as noted above, it must achieve a cer-tain degree of flowability, and the fluidity ofa material in the molten state increaseswith increasing temperature.This means that for semi-crystalline poly-mers, which as we have seen alreadyhave a higher flowability to start with, therequisite temperature for moulding isreached at only slight above (a few tens ofdegrees) the melting temperature.In the case of amorphous polymers, in-stead, since even after exceeding theglass transition temperature, and therefore

passing to the molten state, they never-theless continue to be highly viscous,achieving the fluidity needed for mouldingrequires increasing the temperature by amuch greater amount, at least 100°Cabove the glass transition temperature.To illustrate the above points, let us com-pare the behaviour of a semi-crystallinepolymer (PA 6) and an amorphous polymer(PC) as they change state. Polyamide hasa melting point of 220°C, while PC has aglass transition temperature of 150°C. Yet,even though PA 6 melts at a much highertemperature than that at which PC beginsto soften, it is in practice moulded at alower temperature than PC (240-250°C forPA 6, approximately 300°C for PC).

In fact, PA 6 is already so fluid at its melt-ing point that only a slight increase in tem-perature (20-30°C) is needed to achievethe requisite flowability for moulding,whereas polycarbonate, after reaching itsglass transition temperature, is still far fromfluid enough, and requires its temperatureto be raised by a further 150°C approxi-mately.

* * *This article was contributed by the expertsof Cesap, the Italian centre for training andapplication support to processors andusers of plastic materials.

www.cesap.com

GIANAZZAHITECH

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As UV light attacks polycarbonate atthe surface, UV protection is mosteffective when concentrated there.

Yet, with traditional compounding of ad-ditives it is not possible to concentrateprotection at the surface. This limits UVabsorber effectiveness in outdoor appli-cations, such as lenses and covers forlighting fixtures, where protection fromsunlight is essential to durability and clar-ity.A cost-effective and environmentally re-sponsible way to improve the UV protec-tion of injection moulded or extrudedpolycarbonate parts is offered by Aura in-fusion technology, developed by BayerMaterialScience and licensed exclusivelyto Radco Infusion Technologies for world-wide use. The infusion of UV additivesutilizes the same process used to addcustom colorants. In this new twist, fin-ished plastic parts are immersed in amostly aqueous solution containing UVadditives. The parts are removed fromthe solution after a short period of time,rinsed with water to remove excess solu-

tion from the surface and then dried toproduce a market-ready product. The infusion process allows for the use ofheat-sensitive additives that break down atextrusion/moulding temperatures, but re-main viable at the lower temperatures as-sociated with infusion technology. Aura technology works in a water-basedmedium with a minimum of organic addi-tives. The liquid, constantly recycled and reu -sed, does not add to the waste stream.Processing solvents are reclaimed andreused within the system, and theprocess produces no hazardous waste.This technology is opening a way to thefundamental redesign of LED light en-gines and fixtures for outdoor applica-tions. The heat-resistive properties ofpolycarbonate combined with long-termUV protection through Aura makes pos-sible simple, elegant and cost-effectiveLED solutions.

www.materialscience.bayer.com

Infusion for UV protection

Inflatable carAmong the many new products previewed at

the 2011 Motor Show - held last Decemberin Bologna (Italy) - there was the revolution-

ary BlowCar, a micro-car developed by former Fiatdesigner Dario Di Camillo, which draws its inspi-ration from the technology of the pneumatic struc-tures of airplane evacuation slides and the largeairbags for space probes. Parts of the external bodywork and the rigid plas-tic interiors of the car are replaced with inflatablerubber components, in order to make the vehiclemore lightweight and thereby also reduce its fuelconsumption compa red to an equivalent vehiclewith traditional bodywork. The two-ply panels, in-flated to 2 atm (like normal tyres) and made froman aerospace-inspired fire-resistant compound ofrubber and textile, allow the overall structure toweigh just 350 kg. Developed starting in 2008, between Pescara andTurin, the project is now in the full implementationstage, so that as early as next December it should be possibleto purchase - for a price close to 12,000 euro - this micro-carjust 3 m in length, capable of carrying up to 4 people, equippedwith an electric, hybrid or diesel engine, that will be produced bythe newly created company likewise named Blow Car.In addition to better safety in case of impact, and all the ad-vantages connected with a lower overall vehicle weight, it is

also possible to envisage in future an entirely customisable car,with colours and lines that are no longer pre-established, butopen to the inventiveness of clients, who will be able to renewthe appearance of their vehicle whenever they like. Car makerswill be able to offer vehicles that are always stylish, while at thesame time cutting down production costs.

www.concept-inn.eu

CONCEPT-INN

Glass in the shellThe successful overmoulding of a

glass perfume bottle using Surlynionomer resin is the result of collabo-

ration between Bormioli Luigi, DuPont andthe Italian injection moulding specialist Pibi-plast. This was made possible thanks to anew glass formulation as well as to Surlyn3D technology. The bottle concept hasbeen designed by French luxury designspecialist QSLD. The twisted shape of the glass inner bottleis accentuated in perfect transparency bythe thick walls of the resin cube that en-cases it. Further emphasis on the contrasts

shapes is madepossible by theovermouldingtechnology in

its choice of colours. The charcoal grey forthe outer resin layer is an obvious optionfor the mood and type of design, and goldis the best colour to enhance this smoky ef-fect. One of the amazing possibilities ofSurlyn 3D technology is the ability to cre-ate two contrasting shapes, each of themdecorated differently. The spectacular endresult is a bottle that is almost limitless interms of the colours and shapes adopted

for both materials andalso the finish of boththe internal and exter-nal surfaces.Bormioli's patented

Sparkx glass formu-lation provides highresi stance to che -micals and alcoholand a luxurioussense of weight,whilst the resinshell can be usedto magnify, enhan -ce and durablyprotect the visualeffect of the bottle,as well as render-ing it far less sus-

cep tible to breakageor da mage.

At the same time, thematerial's favou ra ble tactile

properties make the bottle both smoothand pleasant to the touch.

www.dupont.com

DUPONT

54 ●

Zeus ventilation system has beendesigned by NDA (Nuove Dimen-sioni Ambientali, Italy) to provide

thermal insulation and sound absorptionin building air vents. The inside is linedthroughout with light gray Basotect G,the open-cell melamine resin foam fromBasf which is used in a thickness of 20mm for this application. The foam en-sures that the 54-dB rated system meetsthe strict noise control requirements thatapply to residential buildings in Italy, witha minimum requirement of 40 dB. The ventilation system (45 x 34 x 18 cm)has a 15-cm wide air inlet, it is easy tointegrate into the façade and is compat-ible with all standard mortars and rough-casts. This type of system is specifiedfor Italian kitchens for safety reasons, asgas is the primary cooking fuel. As wellas sound absorption, such ventilatingsystems also place a lot of emphasis onthermal insulation, as they create ther-mal bridges in the wall. In addition to offering very good soundabsorbing and thermal properties, thefoam fits the contours of the ventilatingsystem precisely, so that it can be cut tosize and glued in place. The material isvery flexible and can easily be adaptedto various shapes. It is also free of min-eral fibers.

www.basf.com

Ventilation system

Replacing metals bylighter but just as effi-cient materials is a ne-

cessity for numerous indu -stries. Due to their exceptionalmechanical strength and ther-mal and chemical resistance,composite materials based onthermosets are currently themost suitable. However, suchresins must be cured in situ,using from the outset the de-finitive shape of the part to beproduced. In fact, once theseresins have hardened, weldingand repair become impossible.In addition, even when hot, it isimpossible to reshape parts inthe manner of a blacksmith orglassmaker. This is because glass, onceheated, changes from a solid to

a liquid state in a very progres-sive manner (glass transition),which means it can be shapedas required without usingmoulds. Conceiving highly re-sistant materials that can be re-paired and are infinitely mal- leable, like glass, is a real chal-lenge both in economic andecological terms. It requires amaterial that is capable of flow-ing when hot, while being insol-uble and neither as brittle noras “heavy” as glass. From ingredients that are cur-rently available and used in in-dustry (epoxy resins, harde-ners, catalysts, etc.), resear-chers from the LaboratoireMatière Molle et Chimie(CNRS/ESPCI ParisTech), sup-ported by Arkema, developed a

Reshapeable like glass

From December 2through Febru-ary 19 the FRAC

centre in Orléans,France hosted for thefirst time a very spe-cial exhibition, FlightAssembled Architec-ture, which was builtentirely by flying ro-bots. It is a tower(height 6 m, diameter3.5 m) made up of1,500 prefabricatedEPS modules whichhas been developedby Swiss architectGramazio & Kohlerand Italian robot de-signer Raffaello D'An-drea, to inspire newmethods of thinkingabout architecture asa "physical process ofdynamic formation”.The installation in-volved a fleet ofquadrocopters thatwere programmed tointeract, lift, transportand assemble thefinal tower, all thetime receiving com-mands wirelessly from a local control room. The tower was con-structed within a 10 x 10 x 10-m airspace, in which up to 50vehicles could be tracked simultaneously at a rate of 370 framesper second. Each quadrocopter was fitted with custom electron-ics and onboard sensors to allow for precision vehicle control,whilst also providing the opportunity for pre-programmed flightpaths, avoiding possible collisions by taking over when the flyingrobots get too close to each other.

Flying robots

FRAC

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novel organic material made of amolecular network with originalproperties: under the action ofheat, this network is capable ofreorganizing itself without alter-ing the number of cross-links be-tween its atoms. This novelmaterial goes from the liquid tothe solid state or vice versa, justlike glass. Until now, only silicaand some inorganic compoundswere known to show this type ofbehaviour. The material thus acts like purelyorganic silica. It is insoluble even

when heated above its glasstransition temperature. Remark-ably, at room temperature, it re-sembles either hard or softelastic solids, depending on thechosen composition. In bothcases, it has the same charac-teristics as thermosetting resinsand rubbers currently used in in-dustry, namely lightness, resist-ance and insolubility. Mostimportantly, it is reshapeable atwill and can be repaired and re-cycled under the action of heat.

www.cnrs.fr

Acrylic towersLast June, one week before the open-

ing of the 54th Biennale exhibition,the “unsurfaced roads” of Venice

posed a logistical challenge, when a boatmoored at the quay of Arsenale Novis-simo carrying two cylinders (height 7.8 m,diameter 3 m, weight 3 tons) made ofPlexiglas PMMA from Evonik that Russ-ian artist Alexander Ponomarev wantedto use for his Formula installation.For this challenge Ponomarev placed histrust in the German company Heinz Fritz,which used a special thermoformingprocess to turn 4 PMMA blocks into four6-mm thick half-tubes, then into two cylin-ders without visible joints. The acrylic ma-terial is particularly suitable for thispurpose because it is easy to form. Thatwould be impossible with glass.

Once the base plates had been bondedwith adhesive, the sanded and polishedcylinders were sent off on their journey tothe world’s oldest art festival, firstly bysemi-trailer, then by pontoon boat oncethey reached Venice. Upon their arrival,two cranes installed the tubes at the his-torical hall. This called for precision work,because the tubes that were later toserve as water pillars had to stand ab-solutely straight. Steel foundations weremade for this purpose, since the originalclay floor would not have borne theweight of 3 tons of PMMA plus 15 tons ofwater. When the exhibition opened, the hightransparency and light transmission ofPlexiglas made it barely visible. To view-ers, it looked as if two pillars of water

were standing in the historical shipyard.Inside them are submersibles that appearfrom nowhere and break through the roofof the former shipyard building. They riseand fall, setting the pace for a phase tran-sition, a state that expresses creativity bymeans of the antique concept of “techne”,making no distinction between art andtechnology.

www.evonik.com

EVONIK

CNRS

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Researchers at the Wyss Institute forBiologically Inspired Engineering atHarvard University have developed

a new material that replicates the excep-tional strength, toughness, and versatilityof one of nature's more extraordinary sub-stances - insect cuticle. The latter isuniquely suited to the challenge of pro-viding protection without adding weight orbulk. As such, it can deflect externalchemical and physical strains withoutdamaging the insect's internal compo-nents, while providing structure for themuscles and wings. It is so light that itdoes not inhibit flight and so thin that it al-lows flexibility. Also remarkable is its abil-ity to vary its properties, from rigid alongthe body segments and wings to elasticalong its limb joints.Insect cuticle is a composite material con-sisting of layers of chitin, a polysaccha-ride polymer, and protein organized in alaminar, plywood-like structure. By study-ing the complex mechanical and chemi-cal interactions between these materialsand recreating this unique chemistry andlaminar design in the lab, the researchers

were able to engineer a thin, clear filmthat has the same composition and struc-ture as insect cuticle. The material is called Shrilk because it iscomposed of fibroin protein from silk andfrom chitin, which is commonly extractedfrom discarded shrimp shells. It is similarin strength and toughness to an alu-minium alloy, but it is only half the weight.It is biodegradable and can be producedat a very low cost, since chitin is readilyavailable as a shrimp waste product. It isalso easily moulded into complex shapes,such as tubes. By controlling the water content in the fab-rication process, the researchers wereeven able to reproduce the wide varia-tions in stiffness, from elasticity to rigidity.The material could be used to make trashbags, packaging, and diapers that de-grade quickly. As an exceptionally strong,biocompatible material, it could be usedto suture wounds that bear high loads,such as in hernia repair, or as a scaffoldfor tissue regeneration.

www.wyss.harvard.edu

Insect cuticle

Aportable holder for plates, glasses,bottles or cans, made by CP MultiTrading (Belgium), received the

golden innovation award at the 2011 In-ternational Exhibition of Inventions inGeneva, Switzerland. Identified as Stick-iT, this piece is made of a grade of

Terblend N, an ABS+PA blend producedby Styrolution. In spite of its glass fibrecontent, this material can be used with-out being coated. The pre-dried granulescome in a wide range of colours, thussaving time and cutting costs. Designed especially for aesthetically

pleasing applications, thisTerblend N grade has relativelylow glass fibre content (8%)and provides an excellent bal-ance between enhanced stiff-ness and durability. Moreover,the material stands out for itshigh surface quality and pleas-ant surface feel. In addition,mould textures can be repli-cated very precisely, giving amatt surface that is easy to gripduring use. The excellent flow of the blendallows the creation of geometri-cally complex injection-mouldedparts, such as the filigree de-tails of the beverage holder. Italso offers the requisite dimen-sional stability under heat aswell as chemical and UV resist-ance, making the holder verystabile and robust. It can easilywithstand exposure to sun, rainand other liquids, thus lendingitself well to outdoor use in thebackyard, at the campground oron the beach.

www.styrolution.com

Beverage holder

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Plans to phase out the use of woodenpallets across global operations andto transition instead to alternative

plastic pallets have been announced byIkea. Though the change required a com-plete overhaul of supply chain operationsand routines, the company still found thatit was the best business decision, basedon the overwhelming advantages associ-ated with plastic pallets. Designed andproduced by OptiLedge, a new US com-pany totally controlled by the Swedishgroup, the new pallets will be suppliedalso to other interested customers. Pro-duced by injection moulding from strongpolypropylene copolymer, the less than500-g shipping pallet is extremely durable,100% recyclable, helps keep the air cleanby reducing overall wood consumptionand reduces overall fuel emissions.The OptiLedge platform presents the op-portunity for dramatic savings to othersupply chains, as well, by decreasing thecosts associated with labour, fuel, pack-aging and product damage. It has manyadvantages over paper platforms as well.

For instance, it is less susceptible to mois-ture, maintains stiffness with flexible loadsand is more durable.

www.optiledge.com

Logistic revolutionSTYROLUTION

OPTILEDGE

The logo plate is virtually the “figure-head“ on the engine block. It carriesthe brand of the car manufacturer

and should be clearly and permanently vis-ible. TPE-bearings on the logo plate areimportant for being able to put it on the en-gine cover and remove it again. In cooper-ation with Kraiburg TPE, Mues Products &Moulds has developed a method to pro-duce the logo plate including the TPE-com-ponent in just one manufacturing processand to improve the properties of this part atthe same time. This was made possiblethrough the application of the high-perfor-mance Hipex compounds, which are ex-tremely temperature and media resistantas well as suitable for thermoplastic pro-cessing, but which still retain their elasticproperties with a hardness of 70 Shore A.A special challenge during the develop-ment of the logo plate is the construction ofthe anchorage of TPE on the hard compo-nent (polyamide), in which a ring has beenprovided with slots and tooth which arecompletely overmoulded and penetratedby the TPE compounds. Thereby the TPEbecome anchored with the hard compo-nent mechanically and furthermore theyare formed by means of an elaborate un-dercut construction. The cavity has beendesigned more voluminous in the lowerarea and therefore the rubber bearingbuilds a narrower part in the upper area,which allows to put on the logo plate on theengine cover similar to a press stud.De-spite the undercut, demoulding does notcause difficulties thanks to the firm me-chanical anchoring of the TPE-componentand the high flexibility of the material.Up to now, rubber bearings have been fit-ted on the hard component manually in asecond work step, which required muchmore time and held the risk of failure.

www.kraiburg-tpe.com

Logo plates

58 ●

HALL 13 - STAND C05

Sideinjection nozzle

2 or 4 dropsMedical parts moulding

with special shapesDirect injection in the circular cavity wall

Double plastic sealing on the nozzle Uniform wall thickness

Process parameters optimizationNozzle tip insulation from the matrix

Very small injection pointEasy maintenance on machine board

Milan, Italyfrom 8 to May 12

Hall 24 Booth D34

Hot Runner Special

Solutions

THERMOPLAY S.p.A.Tel. +39 0125 800311

thermoplay@thermoplay.com www.thermoplay.com

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Giving shape to ideas, discovering new horizons, marking out new in-

novative routes with the usual quality and reliability, are our entrepre-

neurial challenges. Twenty-fi ve years of steady growth, thousands of

machines produced and sold all over the world are the tangible evidences of the

passion, diligence and serenity with which we want to face the future… together.

Together, the challenge goes on...

Lugo (RA) Italy · tel. +39 0545 23342 · info@ipm-italy.it · www.ipm-italy.it

HALL 13 / STAND C37-D34