CW January 2014

ISSN 2053-7174
January 2014
PICK THE PERFECT PELLETIZER CREATING FOAMED POLYMERS NEW ADDITIVES DEVELOPMENTS COMPOUNDING WORLD FORUM
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Having led the way with high-quality digital-only magazines for the global plastics industry, AMI is now also making its titles available free-ofcharge on the iPad, iPhone and a wide range of Android-based smartphones and tablet computers. The dedicated apps for Compounding World magazine are now ready to download from Apples App Store and iTunes or from the Google Play Store. Just search for AMI Plastics. Current and past copies are available free-of-charge and new issues will be added to the apps as soon as theyre published. If you are using Apples latest iOS operating system, then the magazines will appear in your Newsstand and new editions will be added automatically if you sign up for our free subscription. The Compounding World app is sponsored by Leistritz, a leading supplier of twin-screw extruders.
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contents
05 Industry news
PAGE 13
The latest compounding industry news including international acquisitions and alliances, plus new investments and plant openings.
13 Expanding foam opportunities

Jennifer Markarian reviews new developments in foaming agents, including the latest technologies, applications and regulatory issues.
PAGE 23
23 Polyl takes a fresh approach to foaming polypropylene

Polyl is using Vistamaxx as a masterbatch carrier material to create new possibilities for foamed polypropylene sheet and thermoformed parts.
PAGE 27
27 Stay sharp! Pelletizer makers maintain their cutting edge

Peter Mapleston reports on how the manufacturers of pelletizing systems are developing their machine designs and expanding their service networks.
43 Compounding World Forum makes successful debut

PAGE 43
The rst Compounding World Forum took place in Philadelphia in December. Jennifer Markarian reports from the event.
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2013 review: all about additives

We report from Dsseldorf on a wide variety of new polymer additives that were introduced at the K 2013 exhibition.
PAGE 51
64 Compounder of the month: Sirmax 66 Dates for your diary
coming next issue

S Thermally-conductive compounds S Materials handling S Additives for polyolens
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Applied Market Information Ltd AMI House, 45-47 Stokes Croft, Bristol, BS1 3QP, United Kingdom Tel:+44 (0)117 924 9442 Fax:+44 (0)117 989 2128 www.amiplastics.com Head of business publishing: Senior editor: Contributing editor: Designer: Advertisement manager: Andy Beevers Chris Smith Jennifer Markarian Nicola Crane Claire Bishop E-mail: abe@amiplastics.com E-mail: cs@amiplastics.com E-mail: editorial@compoundingworld.com E-mail: claire@amimagazines.com Direct tel: +44 (0)20 8686 8139
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www.compoundingworld.com January 2014 | COMPOUNDING WORLD 3
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news
PCC plans further expansions

Plastics Color Corporation (PCC), the US headquartered masterbatch maker and compounder, has announced plans to signicantly expand production capacity at its Calumet City, Illinois manufacturing facility. It will add 40,000 ft2 (3,700 m2) to the building and at least one multi-function compounding line, which it expects to be operational by late 2014. PCCs corporate operations manager, Wes Woldt said that the new line will increase capacity at the site by 40%. The company plans to add seven to ten new personnel at the plant, including an operations manager. PCCs Doug Borgsdorf: Our business is growing in every area The plants management is preparing an RFQ for new extrusion equipment and says that it plans to select suppliers in late February. PCC president Doug Borgsdorf said:Weve been running three shifts at Cal City since March. Due to a rapid expansion in our black production business, weve recently gone to a seven-daya-week schedule to meet customer demand, increasing our capacity by 18% this December. The company says that its corporate strategy is to grow its black capacity in Illinois, while its facilities in North Carolina, California and China focus on liquid colours, colour concentrates and specialty solutions. The latter include new antimicrobials, ame retardants and anti-counterfeiting products. PCC recently added two new extruders at its Asheboro facility in North Carolina, and it is stepping up production in China and California as well. Additionally, new liquid colour production equipment has been ordered for the Asheboro facility. Our business is growing in every area as we continually nd ways to solve our customers challenges, said Borgsdorf. We are also exploring several opportunities in Latin America, with a partnership or acquisition in Brazil at the top of our list.
www.plasticscolor.com
Clariant reveals ColorForward 2015 colour forecasts for plastics

Clariant has launched its annual ColorForward analysis of colour trends for plastics. It is the companys ninth such guide and predicts colour trends for 2015. The analysis is designed to provide designers and Clariants new ColorForward 2015 pack predicts colour trends for next year manufacturers with a headstart in the colour selection process. In the world of plastics, colour acts as the ideal marketing driver to steer consumers purchasing choices for the future, said Judith van Vliet, designer at ColorWorks Europe/IMEA. The colour predictions are based on research of the most inuential societal trends around the world. Experts from major trend-watching organisations and diverse creative industries contribute to the process, along with Clariants own ColorWorks centres around the world. The palettes they have selected for 2015 are inspired by four societal trends that are expected to have the most inuential global impact in the near future. These palettes are entitled Tune in space out, Live2Live, Redening Eden, and Raw. For more information visit:
Epsan opens German sales ofce

Epsan, the Turkish polyamide compounder, has opened a new ofce in Dortmund, Germany to support its sales in the country. The facility will be managed by Adrian Kaminski, who has previously held management positions at Invista and Ter Hell. The new ofce shows our commitment to grow our business in the automotive Industry and Germany through direct communication, technical support and sales, said Arda Efe, Epsans global sales manager.
http://bit.ly/CCF2015
www.compoundingworld.com
www.epsan.com.tr
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January 2014 | COMPOUNDING WORLD
news
Solvay is selling PVC businesses

Solvay is selling its Benvic PVC compounding operations in Europe to OpenGate Capital. In a separate deal, Solvay has announced that it is also selling its majority stake in the South American PVC producer Solvay Indupa to Braskem. OpenGates acquisition of Benvic, which operates PVC compounding plants in France, Italy and Spain, is expected to be completed in the rst half of 2014. Benvic employs more than 200 people and has annual revenues of US$220 million. OpenGate is investing heavily in Europes PVC supply chain. It acquired Proalis, a European supplier of extruded PVC window and door proles, from the Tessenderlo Group in January 2013. Last month, OpenGate together with Alain de Krassny received approval for their joint bid to take over Kem One, the French PVC production business that was acquired from Arkema by Klesch Group in July 2012 (see page 8). In addition to the Benvic deal, Solvay is selling its 70.59% stake in Solvay Indupa, South Americas second largest PVC producer, to Braskem. Solvay Indupa operates two production sites in Argentina and Brazil and had net sales of approximately E542 million in 2012.
Schulman acquires Prime Colorants

A. Schulman has purchased Prime Colorants, a producer of colour and additive masterbatches based in Franklin, Tennessee, USA, for US$15.1 million. Prime provides pelletized colour concentrates and dry powder colour expertise to customers in the automotive and construction markets. It also provides an entry point for Schulman in the liquid colour market. The company employs around 50 people and expects 2013 revenues to be approximately US$12 million. Joseph Gingo, Schulmans chairman, president and CEO, said: This latest acquisition is part of our ongoing strategy to grow our custom colour capabilities in the United States, as well as further transform our US operations from commodity products to a business focused on niche products and services. Colour remains an area of opportunity for us in the United States, and the acquisition of Prime will enable us to serve customers better by offering colour expertise in an area of the country where we were not previously located. The deal follows Schulmans 2013 acquisitions of Perrite and Network Polymers. Our strong balance sheet and solid cash ow generation continue to position the company well to pursue its acquisition strategy, said Gingo, adding: We will remain aggressive in pursuing this strategy as well as the many opportunities we are seeing globally for bolt-on acquisitions.
www.aschulman.com
Mller to add new TPE capacity

Mller Kunststoffe is adding a new TPE production line at its plant in Lichtenfels, Germany. The 4,800 tonnes/year line is expected to come on stream in the rst quarter of 2014. The company is part of the Hexpol TPE group, which also includes the Elasto businesses in Sweden, the UK and China. Its new investment will take the groups total capacity to more than 65,000 tonnes/year. Mllers new line be used to produce Lifoex and Dryex TPE compounds. These include halogen-free ame retardant, conductive and food contact grades, as well as adhesion products for multi-component applications, plus compounds offering improved compression set performance. In addition to the new production line, Mller is constructing a new 600 m2 building to expand its technical centre at Lichtenfels. This will be used for the development of customised thermoplastic elastomers including TPS, TPO, TPU and polymer blends. Construction is expected to be completed by September 2014. Georg Ender, managing director at Mller Kunststoffe said: The production expansion and investment in technical resources is a result of our growth over recent years and will ensure continued fast and responsive customer support, as well as the development of new polymer combinations and compounds. Mller Kunststoffe is increasing TPE compounding capacity and expanding its technical centre
www.solvay.com
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www.hexpoltpe.com
COMPOUNDING WORLD | January 2014
news
Chemtura ghts changes to re safety standard

Chemtura has led a lawsuit seeking to overturn modications to Californias re safety standard. The supplier of brominated ame retardants says that the amended rules and a new smoulder-only test weaken re safety standards for upholstered furniture and represent a signicant risk to consumers Representatives said that the lawsuit is necessary to obtain a judicial review of the revised rules. The revised rules require furniture makers to pass only a cigarette smoulder test, and eliminates a vital requirement required by the law mandating the Bureau to establish re safety standards that all lling material used in upholstered furniture pass an open-ame test to replicate a candle, match or lighter ame, said Anne Noonan, senior vice president for industrial engineered products at Chemtura. For background information on the changes to the re standard, see the report in last months Compounding World (http://bit.ly/CWDec). For Chemturas full statement regarding the lawsuit, visit:
Kem One gains new owners

Kem One, the former Arkema PVC business, has been acquired jointly by OpenGate Capital and Alain de Krassny. Europes second largest producer of PVC had been placed into administration in March 2013 following its acquistion from Arkema by the Klesch Group in July 2012. Under the terms of the takeover, the OpenGate and Alain de Krassny partnership has also secured an option to acquire Kem Ones complementary downstream business, which includes Alphacan and is known as Kem One Innovative Vinyls (KOIV). This produces vinyl compounds, pipes and proles with capacities of 170,000, 35,000 and 45,000 tonnes/year respectively. Kem One (excluding KOIV) operates six production plants in France and one in Spain. It has a capacity of 900,000 tonnes/ year of PVC and 660,000 tonnes/year of caustic soda. The company employs more than 1,300 people and has annual revenues close to
http://bit.ly/FRlawsuit
Veka adds PVC recycling line

Veka Recycling has invested almost E1.2 million in a new compounding line at its UK site located at Swanscombe in Kent. The facility closes the recycling loop by taking post-industrial or post-consumer window frame material and producing high-quality recyclate suitable for a wide range of new PVC extruded products. Tony Cattini, managing director of Veka Recycling, said that the investment in UK capacity will help to meet continuing demand for recycled content in new products with associated economic and environmental benets. Veka Recycling is an accredited Recovinyl recycler and part of the Veka group, the worlds largest extruder of PVC proles for windows and doors. The group also runs PVC recycling operations in France and Germany.
E800 million.
OpenGate, the global private buyout rm, is actively investing in the European PVC supply chain (see page 6). Alain de Krassny is a veteran of the European chemicals industry and president of Donau Chemie.
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8 COMPOUNDING WORLD | January 2014
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news
Dow to close MBS plant in Scotland

Dow has announced that it is ending the production of impact modiers at Grangemouth in Scotland. It is closing the former Rohm and Haas plant that manufactures Paraloid Lincolns latest MKX features a structural interior part made from cellulose-reinforced PP methyl-methacrylate butadiene styrene (MBS) based additives for PVC and engineering plastics. Dow took control of the plant in 2009 as part of its acquisition of Rohm and Haas. It then invested in the facility in 2011, increasing its capacity by 10,000 tonnes/year and upgrading its technology. In a statement, Dow said that the planned closure is the consequence of ongoing economic uncertainty, which has resulted in a signicant deterioration of demand. It added: When coupled with increases in manufacturing costs, competition, uctuating raw material and energy prices, the facility has been operating in an increasingly challenging environment. Dow put its global Plastics Additives business up for sale in March 2013, but was reported to have shelved the planned sell-off in September after bids fell short of expectations. Dow continues to manufacture Paraloid additives at other production sites in the USA, France, Turkey and Singapore.
Ford picks natural bres

Ford Motor Company has specied a cellulose-reinforced polypropylene compound for interior components in its latest Lincoln MKX crossover vehicle. The natural bre composite is supplied by Weyerhaeuser and is being used in the oor console armrest substrate, a structural component located within the centre console armrest. Cellulose-reinforced polypropylene has been used on Ford prototype vehicles in the past, but its use on the Lincoln MKX is its rst commercial application. The part is being manufactured by Johnson Controls for the 2014 model. The tree-harvested natural bres are used in place of traditional glass bre reinforcements, and are claimed to reduce weight and improve sustainability. Ford says that the weight saving in the component is roughly 6%. The use of Cellulose Reinforced Polypropylene is relatively small in the current project, but has the potential to play a bigger role in the future, explained Ellen Lee, plastics research technical expert for Ford. If we transfer its use to larger parts, it could really benet the vehicle weight, which benets fuel economy, she said. Cellulose has good reinforcement, so we looked at breglass-reinforced materials for this project.
www.lincoln.com
Concentrates conference is set to attract a record audience

AMIs Thermoplastic Concentrates 2014 conference, which takes place this month in Coral Springs, Florida, USA, is set for a record attendance of senior industry experts who will meet to discuss both technical and commercial factors impacting on the industrys development. The quality of discussion is guaranteed by the fact that more than 70% of the North
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American masterbatch industry by value will be in attendance, representing more than US$2.8 billion in sales terms. The audience will also include a signicant number of large concentrate producers from Asia and Latin America. A number of leading customers for concentrates will also be in attendance, including the Rank Group, which is giving a presentation
at the conference on its current and future product needs. The company spends more than US$125 million on masterbatches each year, so this review is certain to prompt a high level of discussion and debate. The Thermoplastics Concentrates conference takes place on 28-30 January. For more details, visit:
http://bit.ly/Conc2014
www.dow.com
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Foaming agents | addivites feature
Expanding foam opportunities
Lightweighting with polymer foams offers the appeal of cost savings and enhanced sustainability, which is helping to drive growth in a variety of markets, such as food and consumer packaging and automotive applications. Microcellular foams produced using gas injection and special equipment have been advancing and gaining attention, but foamed parts made with chemical foaming agents continue to make up the majority of the market. Other additives, such as nucleating agents, also play an important role in these processes. Regulatory scrutiny is a reality for chemical foaming agents, as it is for several other polymer additives. The most commonly used chemical foaming agent, azodicarbonamide (ADCA or AZO), was listed on the European Unions Substances of Very High Concern (SVHC) candidate list under the REACH directive in December 2012. ADCA was placed on a draft list of prioritization (a preliminary step before potential authorization) in June 2013. Public comment on the draft closed in September, and some expect that ECHA will propose that ADCA be considered for authorization. An ADCA Task Force, which now includes over 50 companies, was established in 2013 by German company Tramaco and Hebron (the European afliate of Otsuka Chemical) to support ADCA under REACH. The task force worked to raise interest and advocate for ADCA during the public comment period. This was challenging because ADCA has been pushed through
Jennifer Markarian reviews new developments in foaming agents, including the latest technologies, applications and regulatory issues
the prioritization process more quickly than any other substance to date, says Cornelia Tietz, project manager and authorization expert at ReachCentrum, which manages the task force. ADCA was already restricted in food contact articles in the EU. While further restrictions on use in the EU have not yet been decided, some have been looking for replacements, but have not identied good alternatives for all applications. This situation opens doors for CFA development, suggests Ned LeMaster, technical manager at Bergen International. Take, for example cross-linked foams, he says. They are traditionally made with an AZO-type chemical foaming agent. Endothermics generally do not lend themselves to cross-linking due to their broader decomposition reactions and lower gas yields. This is an opportunity for new technology. Manufacturers of foamed products try to deemphasize foam technologies that are viewed in any way as toxic, for concerns both real and imagined, comments
January 2014 | COMPOUNDING WORLD 13
addivites feature | Foaming agents
Peter Schroeck, president and CEO of Reedy International. This includes, for example, processes that affect air quality or climate change, such as ozone-depleting blowing agents, including HCFCs. Another concern is that by-products of chemical foaming agents may belingering in nished goods, although manufacturers say that residual levels are minimal. Maximizing the use of endothermic, carbon dioxidebased foaming agents to displace AZO-foams will be a prime goal for many industries, predicts Schroeck. One particular challenge for endothermic agents has been centred around the compounding and eventual activation temperature of the CFAs within a compound. Typical AZO foaming agents achieve their full expansion a full 3040 C later than endothermic foaming agents, allowing the foaming agent to be compounded easily without prematurely activating it. Endothermic foams historically have been a little trickier because the window between compounding temperatures and foam activation temperatures was so narrow. To solve this problem, Reedy introduced Safoam HT-25, HT-45, and HT powder, which are FDA-grade endothermic foams with a decomposition curve designed to match that of AZO foams by reaching full expansion at temperatures in the range of 200210C. This will open new windows for compounders of chemical foaming agents, says Schroeck. Reedy also recently introduced the Saftec RB line that includes products to improve melt strength in PE and PP and improve chain entanglement in polyesters and nylon, which enhances the performance of foaming ColorMatrix is targeting its Excelite liquid foaming agent at PVC construction applications agents. These additives are designed for post-consumer recyclers to improve the performance of reclaimed materials, but are also useful for improving virgin PET and nylon for foaming and non-foaming applications. Bergen International has developed a new product line of exothermic foaming agents designed for foamed pipe and prole extrusions, including products for ABS
and PVC cellular-core pipe. The new additives are claimed to offer several advantages over the benchmark for this industry. They include increased line speeds, lighter proles, ner and more consistent cell structures, and lower let-down ratios. The ABS grade, for example, demonstrated 2-4% line speed improvements over the leading competitor in that application, reports LeMaster. The ABS additive was introduced in mid-2012, and the PVC additive was introduced in 2013. Bergen has also launched a line of endothermic/ exothermic blend foaming agents for foamed prole extrusion. These products have improved throughput and lower let-down ratios. One product, introduced in 2013, demonstrated reduced scrap through improved processing stability in plastic lumber applications. ColorMatrix, a subsidiary of PolyOne, has introduced new grades of its Excelite liquid foaming agent designed for PVC construction applications, such as decking, panels and partitions, proles and mouldings, and trim and siding. The liquid carriers good dispersion properties promote quicker and more consistent incorporation and foaming compared to solid foaming agents. The even distribution of active foaming agents is claimed to create a small, consistent cell structure in the vinyl sheet or prole. A ner cell structure results in mechanical property and structural integrity advantages, such as enhanced screw and nail pull properties and surface hardness. With a consistent cell structure, it is also less likely that weak spots will be formed in the sheet or prole, explains Bjoern Klaas, director of new product development and operations at ColorMatrix. He says that even at densities as low as 0.45g/cm, mechanical properties can be achieved that are comparable to, and often better than, higher density vinyl sheet foamed with
solids at similar or even higher addition rates.
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has grown in this market. Wire and cable users like the easier strippability and greater exibility that foam gives, and manufacturers like the lower weight and the fact that approximately 30% less material is used, notes Dave Seiler, Americas business manager and global advisor for uoropolymers at Arkema. At AMIs Polymer Foam 2013 conference in Hamburg, Germany, Arkema presented the use of the PVDF foam concentrate in continuous, extruded pipe applications. Arkema has also run commercial trials in lm, sheet, and rod applications.
Improvements in PLA foaming

Foamed polymers generally have a positive impact on Arkemas Kynar Foam concentrate for PVDF can be used in wire and cable applications The liquid foaming agent can be metered directly at the extruder feed throat, which allows more accurate dosing. Liquid feeding also eases changeover for PVC sheet because the dosing rate can be changed as the sheet thickness is increased or decreased over a range from 1 to 35 mm, as compared to a solid additive that would necessitate separate dry blend formulations for different sheet thicknesses. ColorMatrix offers zinc-free Excelite formulations. While the additive does contain AZO, the liquid formulation helps minimize the risk of inhalation compared to powders during handling and storage. We are following the SVHC situation closely and ColorMatrix is an active participant, working closely with trade associations and suppliers, in providing data to ECHA on its safe use, says Klaas. Our researchers and technical teams are constantly exploring new formulations. We are actively testing new formulations that meet chemical legislation criteria, but more importantly, provide the same or improved levels of performance and value to our customers. Other additives can enhance foaming. ColorMatrix offers a ready-to-use lubricant and nucleating agent formulation that is specically tailored to enhance the performance of Excelite for vinyl sheet. Next-generation, high-molecular weight process aids, when used intelligently with certain liquid foaming technologies, can potentially yield signicant consistency, performance and cost saving benets for vinyl converters by enhancing cellular structure, says Klaas. Arkemas Kynar Foam concentrate, introduced last year for foaming polyvinylidene uoride (PVDF) resins, enables the formation of consistent, closed-cell foam structures. These result in more predictable properties and better overall chemical exposure properties, says the company. The foaming system, which is added at the extrusion line in the same way as a colour concentrate, was initially targeted at wire and cable applications and it
sustainability measures because they reduce material use and reduce end-product weight, which can translate to fuel savings in transportation. Although these benets give foams a positive image, expanded polystyrene (EPS) foam used in disposable packaging and cups has been given a negative image by environmental groups who say it takes up too much space in landlls. Although EPS is not expected to disappear, companies have been evaluating alternatives. Potential candidates have been polypropylene (PP) and PET, but each has its own disadvantages, notes Bergen Internationals LeMaster. PP, for example, does not have anywhere near the thermal properties of PS, which makes it difcult to use as a replacement for disposable hot container application, he explains. Reprocessing issues and cost have been obstacles for foamed PET. Roadblocks such as these have slowed the development of a replacement for foamed PS, but it is anticipated that the efforts will continue. Biobased materials such as polylactic acid (PLA) are an obvious choice for development as an EPS replacement and are just beginning to nd commercial use here and in other foamed applications. One signicant hurdle has been the poor melt strength of PLA, which makes production of closed cell, low-density foams difcult. Chain-extending, melt-enhancing additives can be used to help stabilize foams. Although these additives increase melt strength, they also substantially increase the stiffness and viscosity of the polymer melt, bringing the undesired effects of increasing die pressure and torque on extrusion equipment, notes DrAdam Pawloski, technical director of Interfacial Solutions (IFS), which provides R&D services to the plastics industry. IFS recently demonstrated a novel reactive extrusion process that imparts hyperbranching along the backbone of compostable or biobased thermoplastics to improve melt strength as well as reduce die pressure and torque. The structures of hyperbranched polymers like PLA differ from chain-extended polymers because the
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senior product developer at Synbra. The companys polymerization process for its Synterra PLA was developed with Corbion Purac and Sulzer Chemtech, and the companys manufacturing plant started up in 2011. The grade of Synterra PLA used for foaming is optimized by varying the ratio between L- and D-lactide in the PLA to control crystallinity. If more than 10-15% D-lactide is used, the PLA will be amorphous and too heat sensitive to be used for foaming. If too little D-lactide is used, the polymer crystallizes too fast to be foamed, notes de Jong. Synbras BioFoam Expandable PLA is positioned as an alternative to EPS and is being moulded into a wide variety of products, from planting trays to surfboards. BioFoam is also used in insulation and received the Dutch Construction award in 2011 when it was introduced. At AMIs Polymer Foam 2013 conference, de Jong explained that to produce BioBeads for BioFoam, Synterra PLA is compounded and, using EPS prefoamer equipment, impregnated with a physical foaming agent, carbon dioxide (CO2). The prefoamed pearls are made Companies are looking at alternatives to EPS for disposable packaging applications branching reactions occur randomly along the backbone of the polymer andare not limited to chain ends, explains Pawloski. The high frequency of branching sites produces many random branches of different sizes generating a unique polymer structure. Effectively, the shear viscosity of hyperbranched PLA is the same as virgin, linear PLA, making it an easily processed material, but with key improvements in melt rheology. In addition, hyperbranched PLA has the ability to strain harden under elongation, which helps lock in the cellular structure of foam and therefore reduce cell collapse. Although both chain-extended polymers and hyperbranched polymers are branched, IFS found no evidence for strain hardening in the chain-extended polymers. The ability of hyperbranched polymers to strain harden is great for foaming applications, says Pawloski. Compared to using chain extended materials, a processor should make a better foam with reduced die pressure and torque on processing equipment when using hyperbranched PLA. IFS Engineered Plastic Compounds, the compounding associate of IFS, offers DeTerra biobased polymers, based on this hyperbranching chemistry, for extrusion, moulding, and foaming applications, including ame retardant grades and grades incorporating post-industrial or post-consumer recycled material. Synbra Technology offers a different solution for foaming PLA, in which foaming takes place in the solid state at temperatures less than 100C. Because the material is not molten during foaming, there are no issues with melt strength, explains Jrgen de Jong,
with densities of 15 g/litre for loose bead or 30 g/litre for further processing into moulded parts. The mechanical properties of BioFoam are currently slightly less than those of standard EPS at the same density, and the company is working on gaining a better understanding this property development. De Jong explains, Because the PLA crystallizes in the foaming process (as required to get shape stability at temperatures above the glass transition), fusion of the foamed pearls becomes critical, which is reected by the mechanical properties. In his presentation, de Jong showed that BioFoam is completely biodegradable; compared to cellulose, the degradation of BioFoam begins more slowly, but after 60 days there is no difference. BioFoam is registered as a compostable material under DIN EN 13432-2000-12. BioFoam also has Cradle to Cradle (C2C) certication, which indicates that it meets this eco-labels sustainability criteria in material health and reutilization, water and energy utilization, and social responsibility. The C2C label has been useful in selling BioFoam both inside and outside of Europe, comments de Jong. In October 2013, Synbra announced that it is collaborating on the launch of the worlds rst 100% biodegradable and 99% biobased surfboard foam. Its partner in the project is Tecniq, a California-based company focused on developing environmentally conscious products. The brandname for the new surfboard foam technology is Bim and manufacturing is scheduled to start in the Netherlands in the third quarter of 2014. There are also plans to add US production shortly afterwards.
the optimal foam expansion ratio is dictated primarily by the end-use of the foam. Expansion ratio is affected by many variables, including processing parameters and additive parameters, such as particle aspect ratio, surface area and additive dispersion. In his presentation, Altstdt compared the inuence of talc, CNT, and TRGO on radial expansion, which is the ratio of the diameter of the extruded foam to the diameter of the die. He concluded that the physical barrier force exerted by TRGO platelets on the cell walls results in a low expansion ratio. His presentation concluded that TRGO is a promising, multi-functional nanoller.
More information
The papers from the Polymer Foam 2013 conference can be purchased at http://bit.ly/Foam2013. AMIs next Polymer Foams conference takes place on 4-6 November in Cologne, Germany. For more information about attending, exhibiting or speaking at this event, Synbra and Tecniq are planning to scale up production of biobased foam blanks for surfboards
Graphite additives for foam insulation

Foamed materials are commonly used as insulation. Dr. Volker Altstdt, professor in the department of Polymer Engineering at the University of Bayreuth in Germany, has been examining the inuence of carbon-based additives on foamed material characteristics that affect thermal conductivity in extruded polystyrene (XPS) insulative foam materials. He presented his ndings in a presentation at AMIs Polymer Foams 2013 conference in November. One of the variables affecting thermal conductivity is infrared radiation. Various carbon-based particles, including activated carbon, carbon nanobre, and expanded graphite, are used as heterogeneous foam nucleating agents in XPS. These carbon-based particles can also act as infrared absorbers, although they have a more signicant effect at temperatures greater than
please contact Kat Langner: kl@amiplastics.com. Tel: +44 117 311 1511.
www.amiconferences.com
Click on the links for more information:
www.arkema.com www.bergeninternational.com www.biomblanks.com www.ifsengineeredplasticcompounds.com www.interfacialsolutions.com www.polymer-engineering.de (Bayreuth Uni) www.polyone.com www.purac.com www.reachcentrum.eu www.reedyintl.com www.synbra-technology.nl
A Biom biodegradable foam blank is prepared during the surfboard manufacturing process
50C. Foams nucleated with graphite-based particles improve thermal insulation because of their nucleation efciency, as well as their infrared absorption and reection capacities, Altstdt demonstrated in his presentation. Thermal conductivity of extruded foams also depends on foam density and cell size. Cell nucleators can produce low-density foams with smaller cell sizes, which results in lower thermal conductivity and therefore better insulation. Thermally reduced graphite oxide (TRGO) and carbon nanotubes (CNT) produce smaller cell sizes with greater homogeneity than talc, and TRGO seemed more effective than CNT. Particles of TRGO in the cell walls and struts exert a physical barrier force that suppresses the growth of big cells and reduces cell coalescence, said Altstdt. Another characteristic of foam is its expansion ratio;
20
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Polymer foaming | case study
Polyl takes a fresh approach to foaming polypropylene
Polyl is using Vistamaxx as a masterbatch carrier material to create new possibilities for foamed polypropylene sheet and thermoformed parts
Masterbatch producer Polyl developed its new Ecocell VM1 foaming agent to optimise the production of lightweight foamed polypropylene sheet. The patented additive concentrate is designed to create strong, light and exible parts. In addition, it can speed up production times and reduce the energy used during manufacturing. Polyl operates a compounding facility in New Jersey, USA, specialising in functional additive masterbatches. The company paid particular attention to the specication of the carrier material for its Ecocell VM1 chemical foaming agent (CFA), selecting Vistamaxx 6102 propylene-based elastomer (PBE) from ExxonMobil to give the required improvements in processing and performance. Manufacturers of thermoformed products are striving to reduce weight, while speeding up throughput and lowering production costs and energy usage. Replacing standard PP sheet with foamed PP sheet can help achieve these goals. Making foamed sheet, however, can be a complex process to get right. The level of foaming must be carefully controlled and some additives can alter the properties of the resin. For example, mechanical strength can be reduced or part rigidity increased. Vistamaxx can help overcome these issues.
Based on tests performed by Polyl, foamed PP sheets that use its Ecocell VM1 CFA with Vistamaxx can produce lighter, stronger and more exible thermoformed products compared to those made using Polyls previous foaming masterbatches based on other carrier materials. The inherent elastomeric properties of Vistamaxx PBE help the nal part to retain exibility, by reducing the tendency towards rigidity caused by additives like talc or calcium carbonate. In addition, Vistamaxx can help to decrease thermoforming temperatures, saving energy during part manufacture. Plus it can increase the retention of foam content during thermoforming, reducing part weight and raw material use. Ecocell has been well received in the marketplace, says Russ Bradley, foams market development manager at Polyl. Theres a great deal of interest in thermoforming, and using Vistamaxx PBE as a carrier resin with the foaming agent provides benets that will help open doors to that market. For example, using Ecocell in PP foamed sheeting has been found to deliver two main advantages in thermoformed microwaveable bowl applications. The incorporation of Vistamaxx PBE reduces cycle times and also decreases thermoforming oven temperatures by as
Polyl uses ExxonMobils Vistamaxx as the carrier material for its Ecocell VM1 foaming agent masterbatch
23
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Polymer foaming | case study
much as 200F (93C), leading to a 25% reduction in energy usage. Thermoforming deep-draw bowls can cause PP foamed sheet cells to open up, but using Ecocell with Vistamaxx PBE helps to prevent this because the cells are small. Usually, the thermoforming process removes around 8% of the cells from the foam. Using Vistamaxx PBE in the foaming agent not only prevents this loss, but actually boosts foam content by around 10%. The outcome is a product that can be 30% lighter and may use 25% less polymer than a foamed PP sheet that does not use Vistamaxx PBE with the foaming agent. Using Ecocell with Vistamaxx PBE for the PP foamed sheeting also improved the touch and feel of the bowls, while improving the coefcient of friction. This can be a crucial factor when handling a bowl that is lled with hot, microwaved food. We see excellent improvements when we add 1.5%-3.5% Vistamaxx PBE as a carrier resin, says Renee Lapierre, Polyls foams technology manager (the quoted percentage is the loading in the nished product). Vistamaxx PBE has been successfully integrated into processing and production. Once the process is dialled in, it is easy to replicate, he adds. In addition to offering benets to customers, Vistamaxx also improves the masterbatch production process. It can be compounded at lower temperatures than other polymer carriers, such as low density polyethylene and polyethylene copolymers. This makes it well suited to incorporating specialty additives that are shear- or heat-sensitive. Foamed PP sheet can increase throughput while reducing production costs
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Pelletizers | machinery feature
Peter Mapleston reports on how the manufacturers of pelletizing systems are developing their machine designs and expanding their service networks to meet the evolving needs of the global compounding industry
Stay sharp! Pelletizer producers maintain their cutting edge

Suppliers of strand- and underwater pelletizers make a point of keeping their designs up to date with the latest trends in compound formulations. So whether you are processing really sticky high melt-ow polymers, or long bre reinforced compounds with reinforcement levels up around 80%, there is a product for you. Whatever type of pelletizer you choose, it is essential to maintain its condition, particularly with respect to its blades. Many equipment suppliers have been extending their sharpening and refurbishment services, especially in emerging markets. Read on for an update on what is happening in the world of pelletizing.
Strand pelletizers
Coperion Pelletizing Technology unveiled its new HD (Heavy Duty) Series strand pelletizers at K 2013. They are said to be ideal for processing engineering plastics with high ller and reinforcement content. The two new models have been specially developed for use with Coperions ZSK Mc18 twin-screw extruders. The SP 500 HD handles throughput rates up to 5,000 kg/hour while the SP 700 HD is designed for up to 6,300 kg/hour. Strand pelletizers for reinforced plastics are subjected to extremely high stress, since the materials are very abrasive, rigid and tough, Coperion notes. In addition, high throughput requirements demand high draw-in speed and a large number of strands. The HD pelletizers have an abrasion-resistant feed opening and feed mechanism. The rotor runs in bearings on both sides and is entirely free from play, thus ensuring constant knife clearance, says the company. Depending on the actual application, the rotor knives are made of hardened tool steel, special PM steel or
tungsten carbide. Control of the pelletizer is said to be easy to integrate into the control and visualization system of the ZSK Mc18 extruder. In view of the high draw-in speeds of between 40 and 120 m/minute and strands numbering between 125 and 150, manual feed of the strands has more or less reached its capacity limits, Coperion says. Therefore, the new pelletizers can be equipped with an automatic strand feed system that automatically guides the strands via a water slide and a conveyor belt into the pelletizers feed mechanism. Labtech Engineering of Thailand manufactures its new Sidecut pelletizers under worldwide license rights from Hoshipla of Japan. Labtech claims that they represent a new concept for the strand pelletizing of thermoplastics. The pelletizer uses a fan-shaped cutting wheel that cuts the strands sideways with a scissors action. Labtech says that the machine can be used to
Coperions HD strand pelletizers are designed to handle high loadings of llers and reinforcements
27
machinery feature | Pelletizers
Labtechs Sidecut pelletizer uses a scissor-type cutting action to handle a wide range of materials
pelletize practically any type of thermoplastic resin, even materials that cannot be pelletized using conventional machines. It cites exible PVC and thermoplastic elastomers with Shore A hardness values as low as 5. At the other end of the scale, because of the gentle shear cut action, highly-lled and brittle strands can be pelletized without causing dust and shattering of the pellets. Anything that can be cut with scissors can be cut with this pelletizer, says Daniel Gorander, export sales and marketing manager. The Sidecut can produce very long pellets of up to 50 mm lengths, which is very useful for bre reinforced engineering plastics, Gorander notes. A special version produces micropellets with diameters as low as 0.3 mm. Reduction Engineering Scheer is responding to demands from the industry for more up-time and higher production output, says product manager Tom Kernstock. This means adopting new metallurgies that provide longer-lasting
The LFT Pultrusion Pelletizer has a rotational cutting speed of 1,200 rpm, twice that of previous models, allowing for higher linear velocity. Our next-generation design was developed in response to customer demand for a faster, more productive precision cutter that also offers easy cleaning, says Kernstock. He adds that the new pelletizers are not only faster, but also deliver the strand control that is necessary for pellet accuracy and quality. Models are available in eccentric and push/pull designs. The eccentric model adjusts the rotor to the bed knife while the push/pull model adjusts the bed knife support to the rotor. The eccentric model has a redesigned ring gear adjustment which allows for precision adjustment and easier accessibility. Meanwhile, the rotor on the push/ pull version features a load isolator mechanism which reduces shear load away from the rotor bearing and allows for cooler operation. Both models are mounted on a new slide rail system. The feed rolls and the table are easily movable for simplied cleaning and maintenance. A new dust cover attachment is also available. Another key improvement is the mounting of the adjustable gap cylinder on a stainless steel cover for easy adjustability. A position-locking lift arm connects the cylinder to the upper feed roll. Both models boast a cutting gap adjustment down to 12 microns. The new pelletizer has a push distance between the nip point and the cutting point of less than 9 cm, compared to over 15 cm for previous models. The reduced distance minimizes the uncontrolled strand zone and ensures enhanced quality. Five models are available, with cutting widths ranging from 30.5 to 81 cm, and there is also a laboratory model for one or two strands. The company designed an entirely new cutter for the process, rather than basing the design on a traditional strand cutter. On compounding lines making reinforced compounds with chopped glass, speed is not a problem in pelletizer design, but LFTs, being much harder, are tougher to cut, with the result that vibrations are higher, Kernstock says. More attention has to be paid to minimizing these vibrations to prevent metal-to-metal
Reduction Engineering Scheer is targeting long-bre applications with its LFT pultrusion pelletizer
parts, and developing improved designs for ease of maintenance. The company has just launched a redesigned line of high-speed pultrusion strand pelletizers that it says incorporate an extensive range of enhancements. The system has been developed for fully wetted strand lines and it is intended to help compounders of long-bre reinforced materials handle increased line speeds while reducing maintenance requirements.
28
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Order online or by telephone, fax or email. Contact Matt Wherlock, Tel: +44 (0)117 924 9442 Fax: +44 (0)117 9892128 email: mjw@amiplastics.com All prices are correct at the time of publication but may be subject to change. Please check the Plastics Information Direct website for current prices and shipping charges.
contact, since the cutting gap is around six times less. We have to take steps to make the equipment more robust. Reduction Engineering has a history dating back to the late 80s of producing pelletizers for making LFTs. In the early days, output rates of under 10 m/minute were typical, says Kernstock. Today, for fully wetted compounds, its closer to 100. As compounders developed their processes, we followed suit, he says. Automatik Plastics Machinery has launched its largest single-side-mounted dry-cut strand pelletizer, the Primo 200E with a cutting width of 200 mm. Pellet dimensions can be quickly changed by means of an optional automatic pellet length adjuster, while a second drive motor for the feed mechanism has an integrated speed control. When processing abrasive products and at high production temperatures, the Primo 200E can be equipped with a separately driven, highly wear-resistant metal feed roll instead of the standard elastomer feed roll. The feed geometry is designed without major deections, so the plastic strands are not subjected to pre-tensioning prior to cutting. This means that even highly-lled masterbatches can be pelletized in high qualities, with hardly any longs or dust. Automatiks Primo 200E strand pelletizer has an extended cutting width of 200 mm
Underwater pelletizers
Gala says its new Eex underwater pelletizing system derives its name from its two main features: efciency and exibility. It is designed to accommodate relatively
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The EAC pelletizer comes with a mechanical seal as a standard. It is available in all of the Gala pelletizer sizes, and Gala pelletizers of any model and size can be upgraded to the EAC version. As with the previous models, a blade position indication is available as an option. Eloo says EAC pelletizers show a marked reduction of blade and die plate wear in direct comparison with other pelletizing equipment. In some applications, the blade life was more than doubled while the die plates lasted many months longer than before, even in extremely abrasive applications. Nordson BKG has introduced an innovative water ltration design for its underwater pelletizers that uses substantially less energy than previous systems and reduces the release of heat to the workplace. The new Optigon system is rated at using only 1,440 kW per year (measured at 8,000 hours), compared with 44,000 kW and 98,480 kW for the companys Optiline and Polyline Galas Eex underwater pelletizing system is optimised to handle frequent material changes small production quantities and/or frequent material changes. Gala-Europe managing director Michael Eloo says that the Eex system can be cleaned and/or prepared for the next job within minutes. Various ltration systems are available. Depending on the selected option, it will in most cases no longer be necessary to replace the process water, even in case of drastic changes of product or colour, says Eloo. This not only saves valuable resources and cleaning time but also eliminates the need to reheat the fresh process water, which again saves energy costs. Galas EAC (Electronically Adjustable Cutter) advanced pelletizer features automated blade advance, periodical blade grinding during the pellet production, and blade monitoring. Eloo says that on previous models, automation was implemented with pneumatic or hydraulic actuation controlled by valve positions and PLC controlled blade advance. While the overall function was always ensured, the complexity of the parts working hand in hand could be considered a downside, he says. While failures were rare, related troubleshooting meant that the maintenance staff had several potential paths to check. To remedy this, Gala integrated the stepper motor advance into its MAP (Manually Adjustable Pelletizer) base machine, and eliminated several components from the A5-PAC pneumatically adjusted cutter, Galas previous state-of-the-art pelletizer with full automation. This not only reduced the complexity but also signicantly improved the precision of the overall machine concept. The EAC also actively retracts the blade off the die plate surface to minimize the direct contact of these tools during the process. This results in a signicant reduction of wear on both the die face and the blades.
systems, respectively. Insulation on BKGs optional water systems helps to conserve energy and prevent its release to the environment. It also serves as touch-protection for workers. Die plate rims are provided with thermal insulation, which ensures a uniform temperature prole in the ow channels and retention of heat in the die plate. The energy saving potential in comparison with conventional die plates is said to be about 30%. Motors used in the companys pelletizing systems already achieve the IE2 classication for energy efciency (a ranking of High Efciency). Nordson BKG intends to increase energy efciency to the IE3 classication (Premium Efciency) in the near future. Italian pelletizer supplier Filtec recently appointed ADG Solutions as its exclusive distributor in North America. ADG Solutions president Sandy Guthrie says his company will supply Filtec products and parts as
Nordson BKGs Optigon water ltration system makes a major contribution to energy efciency
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well as providing technical support and engineering services. Its initial offering is the GRO water ring pelletizer, which is available in models with output capabilities from 40 to 5,000 kg/hour. In comparison with other water-ring systems, the Filtec GRO pelletizer exhibits a longer working life and entails less downtime for job changeovers and maintenance, Guthrie claims. Its one-piece design, with fully integrated cutting chamber, water system, and dryer, eliminates complications like extra piping and water overows. He adds that wear to the die face and blades is reduced thanks to a blade-holding mechanism that allows the blades to oat, accommodating surface variations in the die face. Econ developed its EUP 10 underwater pelletizing system for laboratory applications it can produce around 1-35 kg/hour of pellets. The principle is the same as for our bigger machines, there are just fewer features installed, says Magdalena Deisl in sales and marketing. When started, the melt ow is directed downwards by the polymer diverter valve. Once a constant melt ow is given, the stream is redirected and the die plate is rinsed with melt. As soon as the melt is continuously emerging from each hole, the stream is once again directed downwards. The die plate is cleaned and the pelletizer housing is xed to the pelletizing head. Afterwards, the melt is directed to the pelletizing head with the die plate installed, and the emerging melt strands are pelletized under water. The machine can be used for all thermoplastic materials. It incorporates Econs patented thermal insulation technology to prevent freezing of the die holes.
At your service
Pelletizers are by nature robust pieces of equipment, and tend to last decades. As output rates of compounding extruders have continued to rise, pelletizer makers have found it useful to design retrot packages to enable their existing installed equipment to keep pace with upstream units. Davis-Standard says that its pelletizer debottlenecking retrot technology has proven very successful, enabling substantial output increases while keeping equipment footprint unaltered. Charles Crumb,
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business group manager for extrusion pelletizing systems, says that improved model designs can increase throughput by up to 25% at low cost, enabling short payback times. A new die plate design and a conversion kit can nearly double the knife assembly life on existing pelletizers. The latest pelletizer die plate design can increase product throughput rate proportional to an increase number or size of the die plate orice holes, Crumb says. This technology also improves cutting face longevity, internal heat media distribution, and allows ease of cleaning. In addition, the design enables greater process exibility for a broad melt viscosity processing range without a die change. The technology was developed to support existing markets, de-bottlenecking projects and improved scrap recovery as well as new markets such as bio-based resins, Crumb says. Automatik makes more than 800 new cutting rotors
for strand pelletizers a year at its own factory, as well as refurbishing and sharpening almost 4,000 at its six sharpening centres in Brazil, Germany, China, Malaysia, Taiwan and the USA. The sharpening service is provided for all common rotor types on the market, including those from other manufacturers. A rotor can be sharpened as many as 15 times, depending on the degree of wear and the rotor type. The type of steel used for the rotor knife has an important inuence on cutting performance and should be selected in line with the plastic being processed, says Thomas Willemsen, director of Automatiks Aftersales BU. Available options range from martensitic chrome steel, through powder metallurgy steels and tungsten carbide steels, to a special ceramic material. The tooth prole of the rotor is a further key factor inuencing the cost-effective operation of a pelletizing system. Automatik has a range of 15 different proles, and new geom-
Soredi goes underwater with Automatik

Italian compounder Soredi has grown over the past 30 years from a small, family-run operation to a major producer with an annual capacity of over 16,000 tonnes. It produces compounds based on 15 different thermoplastics, including 23 grades of its Niplene polypropylene-based products. Soredi has traditionally used dry-cut pelletizing systems, but in the last few years it has started using underwater pelletizing, which its equipment supplier Automatik Plastics Machinery says is more effective for its particular requirements. We became familiar with the Automatik dry-cut pelletizer technology when we formed our company, and in 2009 we were introduced to the underwater cutting system, says Soredis general manager Giorgio Ghidini. After watching the Sphero 100 machine in action, we found that there was less wear to the equipment, it offered greater exibility during production when we needed to change the colour of the granules, the granules produced were of a perfect spherical size
Automatik says the Sphero 100 features a unique knife-head design and optimized water-ow conditions within the cutting chamber that combine to ensure the production of perfectly spherical pellets that are ideally suited for further processing. It can handle up to 8,600 kg/hour of material. Highlight features include optimized melt-ow channels that reduce the residence time and increase product quality; the absence of an internal adapter that results in a reduction of energy consumption; and a bolted-through diverter valve that connects directly to the valve plate, eliminating the build-up of polymer deposits We are extremely satised with the performance of the Sphero 100 cutting system and also Automatiks Duro 2000 belt dryer, says Ghidini. Automatiks Sphero pelletizer boasts a special knife-head design and optimized water-ow patterns and there was a reduction in the amount of dust that was created during the cutting process. More importantly, our clients are very satised to receive the type of granules that we are now producing, which ow very easily during their production processes.
www.soredi.it www.maag.com
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Plastic Films in Food Packaging: Materials, Technology and Applications

Ebnesajjad, 2013 185.00 or 155.00 or $245.00
Plastics Additives Handbook

Schiller, Maier & Zweifel, 2009 299.00 or 250.00 or $375.00
12
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AMIs database:
THE INJECTION MOULDING INDUSTRY IN GERMANY

Germany is without a doubt the powerhouse of the European injection moulding industry. In depth knowledge of this industry can be yours with AMIs new comprehensive guides and database.
VERARBEITETE POLYMERE
3D-PLASTIC HANS KINTRA GmbH Einruhrstr. 92 41199 Mnchengladbach Contact: Herr H. Kintra, Geschftsfhrer A & T KUNSTSTOFF GmbH Wittenburger Str. 1 19209 Renzow Contact: Herr G. Augustin, Kaufm. Geschftsfhrer A-FORM AG Gewerbegebiet Nord 7 09456 Mildenau Contact: Herr P. Parczyk, Vorstand A-Z AUSRSTUNG UND ZUBEHR GmbH & Co. KG Ruhrall 1/3 45525 Hattingen Contact: Herr O. Venschott, Geschftsfhrer A. FOLLMANN GmbH Lindenstr. 14 54518 Niersbach-Greverath Contact: Herr A. Follmann, Geschftsfhrer A. KAYSER AUTOMOTIVE SYSTEMS GmbH Hullerser Landstr. 43 37574 Einbeck Contact: Herr H. Borth, Geschftsfhrer A. RSLER GmbH Wiesenauel 40 51491 Overath Contact: Herr G. Rsler, Inhaber A. U. K. MLLER GmbH & Co. KG Dresdner Strasse 162 40595 Dsseldorf Contact: Prof. Dr. D. Riedel, Geschftsfhrer ABEL GmbH & Co. KG Gewerbegebiet Ihne 7 58540 Meinerzhagen Contact: Herr R. Abel, Geschftsfhrer ACCUMA DEUTSCHLAND GmbH Drausendorfer Str. 1 02763 Zittau Contact: Herr A. Rberg, Verkauf
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ACLA-WERKE GmbH Frankfurter Str. 142-190 51065 Kln Contact: Herr G. Kiefer, Geschftsleiter
Learn all about... 2280 injection moulders which process over 2 million tonnes of polymers and operate over 55,000 machines.
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3D-PLASTIC HANS KINTRA GmbH Tel: 02166 43033 - Fax: 02166 41051 Email: info@3d-plastic.de Website: www.3d-plastic.de A & T KUNSTSTOFF GmbH Tel: 038874 23434 - Fax: 038874 23323 Email: info@at-kunststoff.de Website: www.at-kunststoff.de A-FORM AG Tel: 03733 55 09 0 - Fax: 03733 55 09 20 Email: info@a-form.de Website: www.a-form.de A-Z AUSRSTUNG UND ZUBEHR GmbH & Co. KG Tel: 02324 92020 - Fax: 02324 920299 Email: info@az-hattingen.de Website: www.az-hattingen.de A. FOLLMANN GmbH Tel: 06508 476 - Fax: 06508 596 Email: kontakt@afo-online.de Website: www.afo-online.de A. KAYSER AUTOMOTIVE SYSTEMS GmbH Tel: 05561 7902 0 - Fax: 05561 7902 2090 Email: info@kayser-automotive.com Website: www.kayser-automotive.com A. RSLER GmbH Tel: 02206 2369 - Fax: 02206 4023 Email: info@a-roesler.de - Website: www.a-roesler.de A. U. K. MLLER GmbH & Co. KG Tel: 0211 7391 0 - Fax: 0211 7391 281 Email: info@akmueller.de Website: www.akmueller.de ABEL GmbH & Co. KG Tel: 02358 315 - Fax: 02358 8541 Email: info@abel-pllastic.de Website: www.abel-plastic.de ACCUMA DEUTSCHLAND GmbH Tel: 03583 5166 0 - Fax: 03583 5166 22 Email: info@accuma.de Website: www.accuma.de ACLA-WERKE GmbH Tel: 0221 69998 0 - Fax: 0221 697121 Email: info@acla-werke.de Website: www.acla-werke.de
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AMIs Verzeichnis DIE DEUTSCHE SPRITZGUSSINDUSTRIE Band 1: Norddeutschland
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email: sales@amiplastics.com www.amiplastics.com
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AMIs Guide to the Injection Moulding Industry in Germany Volume 1: North Germany
AMIs Verzeichnis DIE DEUTSCHE SPRITZGUSSINDUSTRIE Band 2: Sddeutschland
edition
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Applied Market Information Ltd. 6 Pritchard Street Bristol, BS2 8RH United Kingdom Tel: +44 (0) 117 924 9442 Fax: +44 (0) 117 989 2128 email: sales@amiplastics.com www.amiplastics.com
edition
AMIs Guide to the Injection Moulding Industry in Germany Volume 2: South Germany
Book format: The data is available in two seperate books, Volume 1 North Germany & Volume 2 South Germany
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CD database functions include: Search and select records by name, country, polymer, market, number of machines, etc. Export addresses and contacts to an excel spreadsheet
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content in a compound from 1% to as much as 8%. Following consultations with Automatik, the compounder installed a new rotor and cutting blade tailored to the new formulation. This enabled the service life of the rotor to be quadrupled, delivering a substantial reduction in production costs. Another customer was helped to signicantly improve pellet quality in the processing of a TPU with a Shore A hardness below 75 by replacing the rotor and installing a new cutting blade tailored specially to its material. Originally, the pelletizer was producing more than 30% skewed cuts and approximately 5% overlong pellets. After the upgrade, skewed cuts were down to just 2 or 3% and overlong pellets were occurring only sporadically. etries have been developed specially for softer plastics. The importance of specifying the right cutting components is highlighted in case studies provided by Willemsen. For example, one compounder was unhappy with the durability of a rotor after it changed the TiO2 Producers of strand pelletizers are challenged with the task of designing machinery that is versatile enough to handle materials ranging from extremely high melt ow resins through to 70-80% lled long glass bre reinforced pultruded products, says Jim Forgash, vice
Econs EUP 10 makes its underwater pelletizing technology available for lab-scale operations
Underwater pelletizing systems.
Moscow, 28.01.-31.01.2014 Hall Forum, stand FA49
www.bkg.de | +49.251.26501.0
a variety of specialized products. Reduction Engineering Scheer recently announced a signicant expansion of its sales and service operations in the Far East. The company has doubled the size of its China operation in Shanghai and established a new sales and service centre in Tainan, Taiwan, to support its customer base in Thailand, Malaysia, Singapore, Indonesia, and Vietnam. It has constructed a new 600 m2 production area and renovated 200 m2 of an existing facility for ofce space. The expansion comes in response to strong demand for pelletizing machines in the region, according to Paul Merich, Asia-Pacic sales director for Reduction Engineering Scheer. The company produces replacement pelletizer blades for its own equipment and for other OEMs. It has grinding operations in the US, Germany, in China, as well as in Taiwan. Half of the companys sharpening business is for third party equipment in fact, its origins were in sharpening, before buying pelletizing equipment businesses, rst from Conair, and later from Scheer. Davis-Standard offers retrot die plate designs that boost throughputs and reduce knife wear president sales at Bay Plastics Machinery. He says that the company has traditionally focused on markets in North and South America, but more recently it has added a new emphasis on supporting markets throughout Asia. Ongoing sales growth has led to recent facility expansions, with BPM nearly doubling its manufacturing oor space. This increased capacity and in-house engineering has led to a signicant growth in the support of spare parts for any and all brands of pelletizers throughout the world, says Forgash. He also puts growth down to a surge in demand from markets such as recycling, pultrusion and micro-pelletizing for which BPM offers Click on the links for more information:
S www.coperion.com S www.labtechengineering.com S www.reductionengineering.com S www.maag.com (Automatik) S www.gala-industries.com S www.bkg.de S www.ltec.it S www.adgs.net S www.econ.eu S www.davis-standard.com S www.bayplasticsmachinery.com
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AMIs Directory
PLASTICS PROCESSORS IN HUNGARY

4th edition
4th edition
LOCATION & PRODUCTION DETAILS OF 440 PLASTICS PROCESSING PLANTS
AMIs Directory
AMIs Directory of Plastics Processors in Hungary Blow moulders

LOCATION & PRODUCTION DETAILS OF PLASTICS PROCESSING PLANTS Address Listing
GYURIK MANYAG KFT.
Egres u. 11. 2624 Szokolya Tel: 27 585 010 Fax: 27 375 038 E-mail: info@gyurik.hu Website: www.gyurik.hu Contact: Mr. Gy. Gyurik, Managing Director Parent company: Privately Owned ISO registration: ISO 9002. Processes operated: Injection moulding.
Type: Custom Polymers processed: LDPE, HDPE, PP, PVC, PET Markets served: Food/Drink, House Chemicals, Medical/Pharma, Bottles for Automotive Industry AMIs Directory of Plastics Processors in Hungary (For Fuel). Size: Under 1 litre, 1 to 5 litres, 5 to 25 litres. Services offered: Tool Design, Tool Manufacture, Assembly, Filling, Pad Printing, Silk Screen Printing Polymer throughput: Less than 500 tonnes per annum
MEDICAL PRODUCT SZVETKEZET
Polymers, products & machinery

NEW-MKER MANYAGFELDOLGOZ KFT.
Type: Custom Polymers processed: LDPE, HDPE, PP Markets served: Food/Drink, House Chemicals, Horticulture/Agriculture. Size: Under 1 litre, 1 to 5 litres. Polymer throughput: Less than 500 tonnes per annum
PACCOR HUNGARY ALMAND KFT.
HD - ROTATECH KFT.
Ipari Park Bnki Dont t 7528/5 HRSZ 2373 Dabas Tel: 52 514 010 Fax: 52 514 011 E-mail: hd-rotatech@hd-rotatech.hu Website: www.hd-rotatech.hu Parent company: Privately Owned Processes operated: Rotational moulding.
MEPLA MANYAG S FMIPARI KFT.
Type: Custom Polymers processed: LDPE, HDPE, PP, PET Markets served: Food/Drink, House Chemicals, Bottles; Washing Liquid Bottles. Milk Bottles; Water Bottles Size: Under 1 litre, 1 to 5 litres. Services offered: Assembly, Pad Printing Numbers of colours: 1 Polymer throughput: Less than 500 tonnes per annum
Type: Custom Polymers processed: LDPE, HDPE, PP, PET, PETG Markets served: Cosmetics/Toiletries, Food/Drink, House Chemicals, Industrial Chemicals(including IBCs and Big Drums), Medical/Pharma Size: Under 1 litre, 1 to 5 litres. Services offered: Product Development Polymer throughput: Between 1001 and 2500 tonnes per annum
PACCOR HUNGARY EFFEKT KFT.
HAJR KFT.
Tarnyi J. u. 14. 4030 Debrecen Tel: 052 471 874 Fax: 052 471 874 E-mail: hajrakft@freemail.hu Website: www.hajraKFT.hu Contact: Mr. J. Szab, Managing Director Parent company: Privately Owned Processes operated: PE film extrusion.
HEMBACH KFT.
Szabadsg t 41. 8154 Polgrdi Tel: 022 366 261 Fax: 022 576 025 E-mail: hembach@t-online.hu Website: www.hembach.hu Contact: Mrs. Z. Hembach, Managing Director Parent company: Privately Owned. ISO registration: ISO 9001; 14001. Processes operated: PE film extrusion.
METALCAR KFT.
Type: Custom, In House Polymers processed: LDPE, HDPE Markets served: Toys Size: Under 1 litre, 1 to 5 litres. Services offered: Pad Printing Polymer throughput: Less than 500 tonnes per annum
MIKROPAKK KFT. -BUDAPEST-
HA-NO PLASZT KFT.

Orion u. 14. 1214 Budapest Tel: 12 761 911 Fax: 12 761 911 E-mail: hanoplast@mail.datanet.hu Contact: Mr. Z. Hamvas, Managing Director Parent company: Privately Owned Processes operated: Injection moulding, Blow moulding, Tube and Hose extrusion.
Addresses & contacts

HENKEL MAGYARORSZG KFT.
Vsrtr 2. 5516 Krsladny Tel: 066 474 666 Fax: 066 474 996 E-mail: name.surname@henkel.com Website: www.henkel.hu Contact: Mrs. A. Ujhelyin Mojzsis, Managing Director Parent company: Henkel Group, Germany ISO registration: ISO 9001. Processes operated: Blow moulding.
Type: Custom Polymers processed: LDPE, HDPE Markets served: Cosmetics/Toiletries, Medical/Pharma, Non-Packaging Technical Parts Automotive Parts) (excluding Auto Size: Under 1 litre. Services offered: Tool Design, Tool Manufacture, Product Development, Assembly, Silk Screen Printing, Design Polymer throughput: Less than 500 tonnes per annum
Type: Custom Polymers processed: HDPE, PP Markets served: Auto Fuel Tanks, Food/Drink, Industrial Chemicals(including IBCs and Big Drums), Non-Packaging Technical Parts (excluding Automotive Parts), Jerrycans; Flasks; Hospital Waste Containers; Barrels. Size: 1 to 5 litres, 5 to 25 litres, 25 to 220 litres. Services offered: Assembly, Labeling Polymer throughput: Between 2501 and 5000 tonnes per annum
PET HUNGARY KFT.
Type: Custom Polymers processed: PET, APET Markets served: Food/Drink, House Chemicals, Medical/Pharma, Body Builder Drink Bottles. Size: Under 1 litre, 1 to 5 litres. Polymer throughput: No polymer consumption available
PET STAR KFT.
MOTOPLAST KFT.
HRSHEGYI LSZL
Which information is shown: Full addresses and numbers of all manufacturing plants Managerial contacts Polymers processed Markets served/products manufactured Machinery information
Parent company: Privately Owned Processes operated: Blow moulding.
Apponyi t 16. 7084 Pincehely Tel: 074 406 005 Fax: 074 406 005 E-mail: harshegyila@citromail.hu Contact: Mr. L. Hrshegyi, Owner
HE-PA HUNGARY PLAST KFT.

Jzsef Attila u. 80. 8284 Nemesgulcs Tel: 87 433 322 Fax: 87 433 389 Website: www.hepahungary.hu Contact: Mr. A. Rehberg, Managing Director Parent company: Privately Owned ISO registration: ISO 9001. Processes operated: Injection moulding.
Type: Proprietary Products Polymers processed: HDPE Markets served: Toys, Ride on Three Wheels Motorcycles (The Wheels). Services offered: Tool Design, Tool Manufacture, Product Development, Assembly, Silk Screen Printing, Design Numbers of colours: 11 Polymer throughput: Less than 500 tonnes per annum
Type: Custom Polymers processed: PET, CPET Markets served: Cosmetics/Toiletries, House Chemicals Size: Under 1 litre, 1 to 5 litres. Polymer throughput: No polymer consumption available
PET-EXPRESSZ KFT.
Type: Custom Polymers processed: PET Markets served: Food/Drink, House Chemicals Size: Under 1 litre, 1 to 5 litres. Polymer throughput: No polymer consumption available
Available as a fully searchable database

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By the end of 2013, total polymer demand in Hungary is set to reach 784,000, seeing an increase of 6.7% on the previous year and Hungarys highest demand to date.
Companies included: Injection moulders Blow moulders Rotational moulders PE lm extruders Sheet extruders Cable extruders Pipe extruders Prole extruders Tube and hose extruders Compounders and masterbatch producers
4th edition
AMIs Directory

LOCATION & PRODUCTION DETAILS OF PLASTICS PROCESSING PLANTS
Book: 205/245/$320
Gold database: 460/ 550/$715
For more information contact us on sales@amiplastics.com or Tel: +44 (0) 117 9249442
Compounding World Forum | event review
Compounding World Forum makes successful debut

More than 220 key players from throughout the thermoplastics compounding industry gathered in Philadelphia, PA, USA last month for the rst Compounding World Forum. Organised by AMI and Compounding World magazine, the conference and exhibition attracted attendees from across America and from further aeld, including representatives from Europe, Asia, The Middle East and Africa. They heard expert presentations about the latest trends and developments in market demand, business strategies, materials technology and process optimisation. Andy Beevers, publisher and editor of Compounding World, chaired the conference and gave the opening presentation. He highlighted the critical role that compounders play in bridging the gap between the relatively small number of resin, additive and pigment producers a few hundred major players around the world and the huge number of plastics processors. There are more than 200,000, of the latter, each with their own requirements. Compounders help to tailor materials to meet these needs, and also act as educators who teach how plastics can provide value to an application. biobased compounds, for example, PolyOne recognized a market shift to long-lasting, biobased materials and identied the need for durable, ame-retardant biobased compounds. He also discussed 3D printing as another emerging opportunity for compounders. Medical compounding is an established and growing opportunity for compounders willing to invest in this highly regulated industry. Minimally invasive surgery devices, such as catheters, are one high-growth area in which materials and additives play an important functional role. Larry Acquarulo, founder and CEO of Foster Corporation, described llers that provide x-ray visibility, surface modiers to optimize the critical coefcient of friction, and nanoclays that can reinforce thin-wall catheter tubes. To operate in this medical market, clean compounding must be performed under good-manufacturing practice (GMP) standards. The entire manufacturing space must use only materials that comply with regulations to avoid cross contamination, explained Paul Burke, vice-president of manufacturing at Teknor
January 2014 | COMPOUNDING WORLD 43
The rst Compounding World Forum took place in Philadelphia in December. Jennifer Markarian reports from the event
The Conference World Forum attracted an international audience of more than 220 industry professionals
Opportunities
Compounders must understand the changing forces in technology, regulations, the environment and the marketplace and then must balance materials expertise, design services and processing skill to serve the market, explained Roger Avakian, vice-president of scientic development at PolyOne. In commercializing
event review | Compounding World Forum
Although the US industry is not anxious to have additional regulations, centralized regulations at the federal level would be preferable to inconsistent regulations that differ by state, noted Keithline, who called on industry members to stay active in regulatory discussions.
Additive technologies
A primary function of compounding is adding value to plastics using additives to meet specic property requirements. Anti-counterfeiting additive technology, for example, includes a range of pigments and molecular tracers that must be increasingly sophisticated to thwart counterfeiters, explained Stuart Swain, director of sales and marketing at Chroma. Antimicrobial additives have an important role to Paul Burke of Teknor Apex discussed the implementation of clean compounding at its Vermont plant (above) Apex, which operates a clean compounding plant in Vermont. A company must make an all-or-nothing choice to create a clean-compounding facility, which might mean saying no to a product with, for example, heavy metals or ame retardants, he noted. Although metals have been a long-time target for plastic part suppliers, metal substitution still offers low-hanging fruit opportunities for compounders in areas such as appliances and automotive, explained Jeffrey McCoy, manager of marketing and business development at A. Schulman. He emphasized that using plastics is not about making a one-to-one replacement for metal, but developing a proposal for an alternative material that can provide value through lightweighting, manufacturing simplicity and reduced system cost. OEM engineers are not always educated about plastics, and materials suppliers need to go to them to provide technical education to the engineering community, said McCoy. In addition to being teachers, compounders need to be diligent students of changing regulations. Jeffery Keithline, an expert in food and drug law with Keller and Heckman, described a host of regulations affecting plastic compounds. These include the US Toxic Substance Control Act (TSCA) reform efforts, EU REACH requirements, and US and EU food contact controls. Stuart Swain of Chroma discussed how to combat counterfeit products such as this unsafe cable (left) play in helping address increasing concerns about antibiotic resistance and the ongoing, high levels of healthcare-associated infections. Cost is a signicant factor, and applications that have a functional need for antimicrobials will have the most success, predicted Lise Moloney, director of healthcare business development at Sciessent. Producing compounds with electrical conductivity requires excellent dispersion and depends on many variables, such as carbon black loading and type, the polymer, and other additives in the formulation, explained Christine Van Bellingen, product manager for carbon black & graphite for polymers at Timcal. She also demonstrated how graphite is used to make compounds thermally conductive, and pointed out that conductivity can differ strongly depending on whether it is measured in-plane or through-plane. Hexagonal boron nitrides are a cost-effective additive for thermal conductivity, added Armin Kayser, director of business development at ESK Ceramics, a 3M company. He described a new product with a larger particle size that offers a more isotropic conductivity. Martin Klatt, senior manager for ame retardancy research at BASF, explained the different modes of action by which ame retardants can act. Combinations of phosphorous compounds and melamine salts broaden the application of non-halogenated solutions and will continue to be a development focus, he noted. Jim Harper, applications development manager at Imerys, reminded delegates that mica is a valuable mineral for reinforcing polypropylene compounds. Although it has been in the compounders toolbox for some time, its advantages are not always well understood. Mica is a platy, high aspect-ratio mineral that is easily dispersible. Even at high loadings it has a low effect on melt ow because the plates orient in the ow direction, and it can be used in class-A surfaces. Suppliers combine expertise in materials and
44 COMPOUNDING WORLD | January 2014 www.compoundingworld.com
AMIS 2013 EUROPEAN PLASTICS INDUSTRY REPORT

The most comprehensive statistical market survey from Europes leading plastics industry consultants
This report brings to your desk a wealth of information with key gures, tables, graphs and statistical analysis of capacities and demand for thermoplastics in Europe.
Covers all commodity and engineering thermoplastics Analyses trends from 2007 to 2013 Gives forecast through to 2017 Analysis by processing sectors Statistical data of country demand by polymer for all EU 27
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This report gives a unique insight into the use of materials by plastics processing activity and end use segments.
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APPLIED MARKET INFORMATION LTD.
Applied Market Information publishes over 50 different reports and databases covering thermoplastics markets globally. The range of publications aim to provide complete listings of plants carrying out particular plastics processing operations and to give an analysis of the leading groups. AMI also produces authoritative industry reports which provide cost effective statistical data and analysis on polymer trends. For more information go to our website or contact Rgine Futter or Elizabeth Carroll on sales@amiplastics.com or Tel: +44 (0) 117 9249442.
PLASTIC CLOSURE INNOVATIONS 2014

Trends and technical developments in the international closures industry
28-30 April 2014

Hotel Concorde, Berlin, Germany
* + 19% German VAT
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I M D vista
More than a Vision System
Rocio Martinez Conference Organiser rmm@amiplastics.com Ph: +44 117 924 9442 Fax: +44(0)117 311 1534
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Compounding World Forum | event review
processing with an understanding of design. Styron, for example, worked closely with Renault to co-develop and engineer a fully thermoplastic, mono-material lift-gate for the French car makers new Clio, noted Anis Tebib, marketing manager for Styron Automotive. Part design, tool design, and optimal processing, all aided by process simulation, were crucial for the success of long-glass bre reinforced polypropylene in the part. Designers must understand how bre content, the bre-matrix interface, and bre orientation in the moulded part affect properties. In one composite part, for example, designers needed to gate in an unusual location to allow the bres to orient in line with the stress and remove a vent that hindered the desired ow, explained Raj Mathur, vice-president of technology and business development at Plasticomp. medium, and high rpm and throughput, suggested Bert Elliott, engineering manager at Leistritz. Optimizing screw conguration is another way to improve productivity. On the average line, there are theoretically about 500 trillion permutations of potential congurations, and a few of these will produce better output and/or better properties, noted Adam Dreiblatt, director of process technology at CPM Century Extrusion. Simulation software is a good tool, especially for comparison studies that can show relative changes The sold-out exhibition at Compounding World Forum featured more than 30 suppliers
Optimizing the process

The Forum featured experts on extrusion technology to share best practices in running a compounding process. Finding the optimal degree of ll is one of the keys to success. This optimum can be found by running a simple experiment design with combinations of low,
>>The next step toward your success: Coperion and K-Tron share a passion for successful
partnerships with our customers. From now on, we will be combining our know-how and experience in all stages of plastics manufacturing, compounding and plastics processing to offer you a perfectly aligned portfolio of products and extensive services. Together, we are opening doors to new possibilities. Experience what it means when a global company unites engineering excellence with partnership on a whole new level. Join us on the journey. >>www.coperion.com/next-level
event review | Compounding World Forum
bre from Sonae Industria, is easier to process than other natural bres; it is surface-treated similarly to sized glass bre, explained Christophe Chambonnet, global manager for Woodforce. Extrusion trials have been carried out by ICMA San Giorgio using Woodforce with the goal of increasing extrusion rates without degrading the bres. Silvano Zattra, ICMAs export sales director, explained that extrusion processing simulation helped predict optimal conditions, such as melt temperature to avoid burning the bres. The development of the groundbreaking thermoplastics tailgate for the Renault Clio was discussed in detail in properties such as mixing quality. Successfully feeding difcult materials, such as high levels of low bulk-density powders, combines optimal ll and screw conguration with proper feeder-system layout and design. Having a short drop from the feeder to the extruder is crucial, noted Paul Andersen, director of process technology for Coperion. Having effective venting and ensuring that powders are fed into the screw are also important. Turn-key compounding lines can integrate the extruder, upstream dosing, and downstream functions, Woodforce and ICMA San Giorgio discussed the compounding of wood bres or the package can include everything but the building shell. Such lines can be built in modules, which minimizes onsite work, can be quickly installed and provide the potential for easy relocation of the equipment, explained Matt Sieverding, general manager of Krauss Maffei Berstorffs North American extrusion division. Turn-key systems are advantageous for greeneld sites in the developing world, but are also used in North America, he noted. Among all the complex, technical discussions, Kimberly Williamson, corporate process manager for Techmer PM, brought a fresh look at how using lean manufacturing principles allowed the compounder to improve sustainability in its facilities and save costs at the same time. Bringing about behavioural changes in the way employees functioned was key to signicantly reducing water and electricity consumption and the amount of waste going to landll. Employees shared in the monetary savings from the new, sustainable prac-
Steps to sustainability
Biobased polymers and natural bres add an extra challenge to the compounding process because of temperature and moisture limitations and shear sensitivity. Variable kneading blocks can be used to provide a combination of dispersive and distributive mixing, and bres can be added downstream so that they experience only distributive mixing, noted Dean Elliott, lab manager for Entek Extruders. Woodforce, a high-aspect ratio engineered wood The use of hexagonal boron nitride in conductive compounds was discussed by Armin Kayser of ESK tices, with the result that the entire company is engaged in the commitment to reduce, reuse, and recycle.
More information
The complete proceedings for the Compounding World Forum 2013 are now on sale. For details, go to http://bit.ly/CWF13D. The next Compounding World Forum will be held on 9-10 December in Philadelphia. The venue has been switched to the Loews Hotel which provides extra space for more exhibitors and more attendees. For details on attending, exhibiting, sponsoring or presenting at the Compounding World Forum 2014, please contact Kelly Cressman, the conference coordinator: kc@amiplastics-na.com, Tel: +1 610 478 0800. Book your place by 9 May and save $500 on the full delegate fee. For details of this special offer and lists of compounders and exhibitors who took part in 2013, visit: http://bit.ly/CWF2014.
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Additives |
show review
We report from Dsseldorf on new polymer additives that were introduced at the K 2013 show
K 2013 review: all about additives

Following on from our extensive previews and reviews of the K 2013 exhibition, which took place in October in Dsseldorf, Germany, we bring you our nal report on the big show, focusing on new additives that were launched at the event. Over the following pages we look at the latest developments in compatibilizers, impact modiers, PVC plasticizers, stabilizers, pigments, cross-linking agents, anti-counterfeiting technologies, masterbatches, antimicrobials, processing aids, thermal management products, antistatic additives, ame retardants and laser-marking materials. You can nd links to our previous coverage of the K 2013 exhibition, including machinery, materials and business news, at the end of this story.
Arkema showed a wide variety of its latest polymers

and additives in Dsseldorf. For example, the French company has extended its ethylene acrylate copolymer range with the addition of a Lotryl grade with a modied molecular structure that gives it excellent compatibility with both polar and non-polar matrices. It can be used in masterbatches for the improved dispersion of llers. It can also be used as an impact modier or an adhesion promoter in exible packaging. Another recent development from Arkema is its Lotader IM ethylene acrylate terpolymer for improving the impact resistance of polyamides, including PA 6 and PA 6,6. The new IM grade is said to retain the same processability as existing Lotader products, while offering further improvements in impact resistance. Another new impact modier for engineering plastics is Clearstrength E950, a high-performance MBS core-shell product specically designed for polycarbonate applications, including glass-reinforced grades and PC/polyester blends. For applications in PC/ ABS blends, Durastrength 480 is a new acrylic impact modier that is effective at low temperatures. It also maintains melt viscosity to facilitate injection moulding. Arkema was also highlighting the use of Orevac
The K show is still the best hunting ground for discovering innovations in polymers and additives
AkzoNobel introduced a new easy-to-use concentrate version of its vegetable-based Armostat antistatic additive. Armostat 1800-XP75 is supplied as free-owing granules containing a 75% loading of the additive in a PP carrier resin. The product is designed as an alternative to the animal-based antistatic additives for PP lm and rigid packaging applications.
S www.akzonobel.com/polymeradditives
51
show review | Additives
resistance for PVC prole applications. New processing aids for PVC include Plastistrength 564 and 559 (meth)acrylic additives for helping to control fusion and melt elasticity. The former is for window sills, wall panels and siding, while 559 is for sheets and proles that include CaZn stabilizers. Other additions include Plastistrength 560 and 566 for controlling PVC foam processes 560 is for sheets, while 566 is for pipes and proles.
S www.arkema.com
Brggemann Chemical introduced two new

Bruggolen colour-stable copper-based stabilizers that are designed to enhance the performance of polyamides in electrical and electronics applications. Bruggolen H3376 and H3386 achieve comparative tracking index (CTI) values of 600 V and 575 V respectively polyamides The heat ageing performance at 150C of PA 6,6 stabilized with 0.3 % by weight with a new Bruggolen copper stabilizer from Brggemann (A), compared with 0.6 % of an arylamine-based stabilizer package (B), 0.4 % of a stabilizer package based on sterically hindered phenols with synergists (C), and unstabilized PA 6,6 (D) 18340 as a coupling agent for cross-linked halogen-free ame-retardant (HFFR) wire and cable compounds. The new grade is said to provide optimised reactivity and uidity to enable excellent processability of the HFFR compounds, particularly for applications requiring good mechanical properties plus chemical and abrasion resistance at high temperatures. For PVC applications, Arkema was promoting its Durastrength impact modiers, including two new products: D362 is a cost-efcient composite acrylic modier for proles and siding, while 382 is a highperformance grade that delivers very high impact resistance, high surface gloss and strong plate-out Eckart showed Energysafe solar reective additives for a wide range of coloured plastics used in electrical and electronic (E&E) components should have a CTI of at least 550 V to prevent short circuiting and component defects caused by tracking. The new stabilizers are also claimed to offer considerably greater long-term protection against thermal and oxidative degradation compared to antioxidants based on amine, phenol or phosphorus derivatives. It has long been known that polyamides can be stabilized against thermal and oxidative degradation by the addition of a mixture of copper salts (in particular copper iodide) and halides (usually potassium bromide or potassium iodide). However, this kind of stabilization can have serious drawbacks, which is why it has rarely been used for E&E products. For instance, polyamides absorb approximately 3 % water when in service, which results in stabilizers based on copper salts being extracted due to their water solubility. Once extracted, they reach the surface of the component and form a lm resulting in defects
52
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Additives |
show review
and blemishes or serious discolouration. This not only makes polyamide articles unattractive, but the components tracking resistance also drops signicantly. The new Bruggolen copper stabilizers do not contain any water-soluble salts and thus do not bloom or cause any blemishes or defects on the surface of the article. In addition, polyamides can be stabilized with smaller quantities of the new stabilizers while offering improved performance. This includes elevated protection against thermo-oxidative degradation, even at temperatures in excess of 150C. Both of the new Bruggolen stabilizers are colourstable and, unlike conventional salt-based copper stabilizers, do not discolour after conditioning. They are therefore particularly suitable for products which are natural coloured or in light colour shades. Available in powder and pellet form, the new copper stabilizers are ideally suited to compounding polyamides. Applications for polyamides in electrical engineering include insulating elements and housings for circuit-breakers, contactors, transformers, electric motors and printed circuit boards.
Colorant Chromatics, a subsidiary of PolyOne,

introduced a new range of colour masterbatches for high-performance applications in polysulfone (PSU), polyethersulfone (PES) and polyphenylsulfone (PPSU). The range includes 10 standard colours and provides resistance to heat, re and oxidation. Target markets include the aerospace, automotive, telecommunications and healthcare sectors. These colour concentrates are formulated without
Grafe has developed an antistatic compound for the production of coloured safety helmets
S www.brueggemann.com
C.A.PICARD INTERNATIONAL
PLATE TECHNOLOGY
INDUSTRIAL SERVICES
EXTRUDER TECHNOLOGY
What we produce
Original C.A.PICARD screw elements, barrels, liners and shafts for almost each twin screw extruder from diameter 12 - 380 mm. C.A.PICARD process parts and services for your twin screw extruders. Our additional performances Rework- and wear-measurement-service for barrels and liners Time- and cost-saving dismantling-service for all screw elements up to 120 mm diameter
Headquarters Carl Aug. Picard GmbH, 42857 Remscheid, Germany, Phone: +49 2191 893-0, E-Mail: info@capicard.de USA C.A. Picard Inc., Elyria, Ohio 44035, Phone: +1 440 366-5400, E-Mail: info@capicard.com Hong Kong C.A. Picard Far East Ltd., Tai Po N.T., Phone: +852 2665-7868, E-Mail: sales@capicard.com.hk Japan C.A. Picard Japan Co., Ltd., Kawaguchi-City, Phone: +81 48 263-5017, E-Mail: sales@capicard.co.jp
www.capicard.com
Grafes Blue Wet masterbatch creates a water effect in plastics
heavy metals and use state-of-the-art pigment dispersion techniques to promote consistent colouring and improve homogenization for more efcient processing and reduced waste.
www.colorant-chromatics.com
Dow Elastomers used the Dsseldorf show to

announce its new Intune polypropylene-based olen block copolymers. It describes these as compatibilizers that enable the combination of non-polar and polar polymers with PP. For example, they can be used to combine PP with PE, EVOH, PA or polyolen elastomers, providing benets from each material while minimizing trade-offs in properties. The company says that the new technology can be used to produce unique blends and multi-layer structures. It is targeting a wide range of markets, including packaging, consumer durables, transportation, construction, hygiene and wire and cable. Samples are already available and commercial production is scheduled for early 2014. together with Entira EP in a twin-screw extruder provides recyclates in pellet form with excellent mechanical and processing properties, even when there are high degrees of contamination. It also claims that the re-compounding process is more economical, because using Entira EP signicantly reduces the need for melt lter cleaning operations.
www.dow.com
www.dupont.com
DuPont introduced its Entira EP compatibilizers for

the high-value recycling of mixed polymers. The rst grades are ethylene-copolymers that are optimized for recycling mixtures of PE and PP. In particular, the compatibilizers are said to signicantly improve low-temperature toughness, even when used at low concentrations of around 4%. Huntsman is testing its Altiris infrared reecting pigment in greenhouse applications The company is currently developing further formulations of compatibilizers for other mixed materials. These include PE together with PA or EVOH, which are typically used as barrier resins in polyolen based packaging products. Another area of interest is PE-PET mixtures with PE as the dominant matrix. DuPont says that compounding mixed polymers
Eckart showed a range of new effect pigments at K

2013. These included new Energysafe products for the production of solar reective plastics. They are designed to lower the heat build-up in plastics products exposed to the sun, and therefore reduce surface temperatures. The pigments can be used in polyolens, PVC, styrenics and a range of engineering plastics. One example is Energysafe Graphite Black which enables the production of solar reective plastics in very dark shades. The resulting plastics can reect up to 33% of the incident solar energy; by comparison plastics pigmented with carbon black reect less than 5%. Target applications include outdoor products, such as garden furniture, and automotive components, such as dashboards. Eckart has also developed Energysafe Lignum Brown for applications in wood-plastics composites (WPCs), where Total Solar Reectance (TSR) values of 20% can be achieved. Other products in the range include: Energysafe White for adjusting the brightness of light shades; Energysafe Granite for high levels of nearinfrared reectance; Energysafe Argentum for plastics with a metallic look; Energysafe Henna for reddish shades; and Energysafe Aurum Solar which exhibits a golden yellow in full shade. The company also showed Platalux, its new generation of effect pigments that use silver-coated pigments based on glass. These combine an inherent sparkle with a champagne coloured shade that creates pronounced
56
POLYMERS
in
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parts, something that can be limited by other antimicrobial technologies. The German masterbatch maker and compounder has also been focusing on developing new antistatic and conductive materials, and it presented a range of such applications. For example, it has developed a permanently antistatic compound for coloured safety helmets. Another antistatic product is its High Performance Antistatic Agent (HPAS) which is designed for automotive interior parts made from PP or PC/ASA. It helps to prevent components from attracting dust and has been shown to be effective for more than four years. Grafe has also been working on a new ow-improver for medical products. This is designed to overcome streaking problems that can occur when moulded Perstorps Pevalen plasticizer can be used in toys and provides outdoor durability glitter effects in pure colours or in combination with transparent colour pigments and dyes. plastic parts are over-moulded at the same temperature. The company says that its Flow-Improver can reduce the processing temperature of the over-moulding plastic by 40C to help overcome the issue. In the colour masterbatch eld, Grafe says that blue and unusual effects will be taking centre stage in 2014. Its Blue Wet product is designed to create the effect of a plastic lled with water, while Starry Blue is said to capture the appeal of the sky at night.
www.eckart.net
Evonik was promoting its new Elatur phthalate-free

and bio-based plasticizers for PVC. Production of these new 1,2-cyclohexane dicarboxylic acid diisononyl additives (a similar chemistry to BASFs Hexamoll DINCH) started in June 2013 at the Marl Chemical Park in Germany. The company was highlighting its Elatur CH grade, a phthalate-free plasticizer that is particularly suitable for sensitive PVC applications such as articles that come into direct contact with the skin. It is currently developing new grades including bio-based versions Evonik also used K 2013 to introduce two new additives for the cross-linking of polyethylene using the Monosil process in the production of high-performance cables. Dynasylan Siln 201 and 202 are its rst products of this type that contain tin-free catalysts. The standard catalyst for the Monosil process is the tin-organic compound dibutyltin dilaurate (DBTDL). However, there are health and environmental concerns regarding tin, so Evonik decided to develop alternatives.
www.grafe.com
Huntsman presented a new application for its Altiris

infrared reecting pigment. As previously covered in
Compounding World magazine, this new TiO2 based additive was initially aimed at PVC building applications, such as siding and proles. However, it is now being tested in polyethylene greenhouse lms to provide improved growing conditions. Recent lab and eld testing in Turkey has shown that 50 micron greenhouse lm containing 1% Altiris pigment successfully reects infrared energy, resulting in reduced temperatures inside the greenhouse. This helps to keep relative humidity levels high and reduces the loss of moisture from plants.
www.evonik.com
www.huntsman.com
Grafe used K 2013 to promote a wide range of its

latest additive and colour masterbatch products. For example, it showed a new counterfeit protection masterbatch for synthetic yarns and bres. The patent-pending technology uses a new combination of chemical substances that can be detected by X-ray uorescence analysis. The company also showed its latest development in antimicrobial masterbatches which is based on additive technology from Amistec in Austria. This protects against pathogens such as MRSA, VRE and ESBL, but allows the production of brightly coloured plastics
Merck used K 2013 to highlight its special effect

pigments for plastics used outdoors and exposed to the sun. For example, its silver-white pigment Iriodin 119 WAT product was developed for such applications. It is thermally stable up to 800C and extremely resistant to yellowing. Target applications include outdoor furniture, architectural products and automotive interiors. The company was also showing its latest Iriotec pigments. For example, Iriotec 9000 reects heat and is designed for outdoor applications such as blinds and canopies. Aimed at laser-marking applications, Iriotec 8000 enables precise labelling of products, regardless
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Songwon has developed its new Songxtend range of stabilization packages for polyolens
of the type of polymer and colour being used.
www.merck-pm.com
Perstorp was showing Pevalen, a non-phthalate PVC

plasticizer for sensitive applications. The polyolester additive is claimed to be efcient and easy-to-process, as well as exhibiting excellent UV stability for outdoor durability. It also has low volatility, cutting out VOCs and providing consistent properties. Pre-marketing of the product has shown that it is suitable for sensitive close-to-consumer applications. Target markets include vinyl ooring in hospitals, schools and public buildings, plus automotive interiors, toys, moulded parts and coated fabrics. Perstorp is investing in scaling up Pevalen production it says that by 2015 it will be commercially competitive with other high-volume plasticizers. It is also planning to increase the bio-based content of the additive.
Sukano introduced new antimicrobial masterbatches

for long-lasting freshness control in polyester and polyamide bres. They are designed to bring permanent protection against unpleasant odours in sportswear. The products combine Sukanos functional masterbatch experience with patented Pure technology from the Swiss performance textiles company HeiQ. The silver-based concentrates enable bre manufacturers to spin pre-dyed bres with a permanent antimicrobial effect that withstands wash cycles. Sukano says that the antimicrobial masterbatch is effective in low concentrations and provides the good dispersion required for the production of low denier microlament bres.
www.perstorp.com
Songwon used K 2013 as the launchpad for its new

Songxtend range of stabilization packages for polyolens. Songxtend 1101 and 1102 are general purpose products for polypropylene, protecting properties and avoiding discolouration during high temperature processing. The Songxtend 2121, 2122 and 2123 packages are specically aimed at automotive applications and are tailored to address fogging and odour issues in car interiors. The different grades have different sulphur levels: 212 reduces sulphur by 60% while still maintaining high thermal stability; 2122 offers an optimised cost/performance balance by reducing sulphur by 30%; and 2123 is 100% sulphur free to minimise odours while still retaining stabilisation performance.
www.sukano.com
Tosaf launched a new range of ame retardant

masterbatches for corrugated pipes that are used as conduits for electrical cables in construction applications. Such conduits need to meet the European ame retardant standard IEC 61386-1. The company says that efcient and low-cost chlorinated parafns have traditionally been the additives of choice for such applications. However, these chemicals have come under pressure from the REACH regulation, which has restricted the use of short-chain chloroparafns as they have been classied as Substances of Very High Concern (SVHC). At the same time, increasing numbers of pipe producers are trying to make their products comply with the Low Smoke Zero Halogen regulation (LS0H; IEC 607541). In response to these issues, Tosaf has developed the new masterbatch which uses no chlorinated additives and meets the LS0H norm for standard pipes. In addition, the company says that the high-efciency products reduce dosing requirements and present no additional costs for the pipe producer.
www.songwon.com
The complete K story

This materials review is the nal instalment in our extensive coverage of the K 2013 exhibition, which has focused on the product launches and news stories that are most relevant to the compounding industry. For the complete picture, click on the links to see our previous reports. Materials preview part 1: http://bit.ly/Kmats Materials preview part 2: http://bit.ly/Kmats2 Machinery preview: http://bit.ly/KMach Compounders views on K: http://bit.ly/Kviews Industry news from K 2013: http://bit.ly/K13news Machinery review: http://bit.ly/KMach2 Other K 2013 product launches have been included in our recent features on topics such as ame retardants, carbon black, mixers and lab-scale compounders. The next K show will be on 12-26 October 2016.
www.tosaf.com
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RE Scheer: Bullet pelletizer

This brochure from Reduction Engineering Scheer has full details of its Bullet range of strand pelletizers. These are designed to be easy and fast to clean and service, making them ideal for rapid changeovers.
Bullet Series Strand Pelletizer Granulador de Hebra Serie Bullet
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compounder of the month
Sirmax
Head ofce location: Date founded: CEO: Ownership: Number of employees: Sales 2012: Plant locations: Production 2012: Prole: Cittadella, Padua, Italy 1999 Massimo Pavin Privately owned 170 142 million Cittadella and Tombolo in Italy; Kutno in Poland; and Jundia in Brazil 85,000 tonnes Sirmax was formed by the merger of Maxplast and Sirte in 1999 and it has grown to become one of Europes leading technical compounders. It operates two plants in Italy and opened a facility in Kutno, Poland in 2006. This has been gradually expanded, most recently with the installation of an 8,000 tonnes/year Coperion twin-screw extruder in October 2013, taking its total capacity to 40,000 tonnes/year. The company also opened a plant in Brazil last year and a second compounding line is expected to be installed during 2014. PP compounds account for around 85% of Sirmaxs output, with the remainder including PA6/66, ABS, PC/ABS, POM, PBT and PPO materials. Sirmax is one of the leading independent suppliers to the large appliance market, which accounts for almost 75% of its output. The remaining volume is sold to the automotive, electrical and small appliance industries, including applications such as power washers and coffee makers. Innovation, exibility and logistics.
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dates for your diary
Global exhibition guide

21-23 January 28-31 January 29 Jan - 1 Feb 11-13 February 17-20 February 4-6 March 11-13 March 7-10 April 23-26 April 8-14 May 27-30 May 16-19 June 18-19 June 3-6 September 29 Sept - 3 Oct 30 Sept - 3 Oct 14-18 October Swiss Plastics, Lucerne, Switzerland Interplastica, Moscow, Russia Samuplast, Pordenone, Italy Plastec West, Anaheim, CA, USA Saudi Plastics & Petrochem, Riyadh Plastics & Rubber Vietnam, Ho Chi Minh JEC Europe, Paris, France Plastivision Arabia, Sharjah, UAE Chinaplas, Shanghai, China Interpack, Dsseldorf, Germany Plastpol, Kielce, Poland Argenplas, Buenos Aires, Argentina PDM & PRE, Telford, UK Indoplas, Jakarta, Indonesia Plastex, Brno, Czech Republic Equiplast, Barcelona, Spain Fakuma, Friedrichshafen, Germany www.swissplastics.ch www.interplastica.de www.samuplast.it www.plastecwest.com www.saudipp.com www.plasticsvietnam.com www.jeccomposites.com www.plastivision.ae www.chinaplasonline.com www.interpack.com www.targikielce.pl www.argenplas.com.ar www.pdmevent.com www.indoplas.com www.bvv.cz/plastex-gb www.equiplast.com www.fakuma-messe.de
AMI conferences
28-30 January 18-20 February 24-26 February 11-13 March 18-20 March 18-20 March 12-14 May 13-14 May 16-18 June 17-18 June 24-26 June 28-30 October Thermoplastic Concentrates, Coral Springs, FL, USA Grass Yarn & Tufters Forum, Barcelona, Spain PVC Formulation, Dsseldorf, Germany Cables, Cologne, Germany Green Polymer Chemistry, Cologne, Germany Masterbatch Asia, Bangkok, Thailand Polymer Sourcing & Distribution, Hamburg, Germany Fire Retardants in Plastics, Denver, CO, USA End Of Life Plastics, Dsseldorf, Germany Polymers in Cables, Philadelphia, PA, USA Masterbatch, Berlin, Germany Polyolen Additives, Cologne, Germany
For information on all these events and other conferences on lm, sheet, pipe and packaging applications, see
www.amiplastics.com
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CW January 2014

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ISSN 2053-7174

ANDROID VERSIONS NOW AVAILABLE

13 Expanding foam opportunities

23 Polyl takes a fresh approach to foaming polypropylene

27 Stay sharp! Pelletizer makers maintain their cutting edge

43 Compounding World Forum makes successful debut

2013 review: all about additives

64 Compounder of the month: Sirmax 66 Dates for your diary

coming next issue

quan tec 85 G3 -14 C

Economical PVC compounding redefined BUSS Kneader series quantec G3

Buss AG Hohenrainstrasse 10 4133 Pratteln Switzerland

Phone +41 61 825 66 00 Fax +41 61 825 68 58 info@busscorp.com www.busscorp.com

PCC plans further expansions

Clariant reveals ColorForward 2015 colour forecasts for plastics

Epsan opens German sales ofce

January 2014 | COMPOUNDING WORLD

Solvay is selling PVC businesses

Schulman acquires Prime Colorants

Mller to add new TPE capacity

COMPOUNDING WORLD | January 2014

Chemtura ghts changes to re safety standard

Kem One gains new owners

Veka adds PVC recycling line

The Maguire Gravimetric Blenders

NUMBERS NUMBERS NUMBERS

Dow to close MBS plant in Scotland

Ford picks natural bres

Concentrates conference is set to attract a record audience

COMPOUNDING WORLD | January 2014

THER M O P L A S T I C Template CONCENTRATES 2014

January 28-30, 2014

FINAL REMINDER BOOK NOW

Foaming agents | addivites feature

Expanding foam opportunities

addivites feature | Foaming agents

solids at similar or even higher addition rates.

COMPOUNDING WORLD | January 2014

addivites feature | Foaming agents

Improvements in PLA foaming

TURNKEY EXTRUSION SYSTEMS

ENGINEERED TO PERFORM, BUILT TO LAST

addivites feature | Foaming agents

addivites feature | Foaming agents

Graphite additives for foam insulation

COMPOUNDING WORLD | January 2014

18-20 March 2014

Polymer foaming | case study

Polyl takes a fresh approach to foaming polypropylene

January 2014 | COMPOUNDING WORLD

11-13 March 2014

Polymer foaming | case study

THE LATEST INNOVATION FROM THE WORLD LEADER IN CARBON BLACK

Unbeatable deals for 2014

Pelletizers | machinery feature

Stay sharp! Pelletizer producers maintain their cutting edge

January 2014 | COMPOUNDING WORLD

machinery feature | Pelletizers

COMPOUNDING WORLD | January 2014

BROUGHT TO YOU BY Plastics Information Direct Online Bookshop

PLASTICS ADDITIVES AND TESTING

POLYOLEFIN ADDITIVES 2013 - CONFERENCE PROCEEDINGS

COMPOUNDING WORLD | January 2014

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