OE-A at LOPEC: Printed Electronics Powers Sustainability

The “OE-A Competition 2024” shows the many possibilities of flexible, organic, and  printed electronics with inspiring products, prototypes, and fresh designs live at  LOPEC 2024, the leading international exhibition and conference for flexible, organic, and printed electronics in Munich. 

Frankfurt, February 06, 2024 – “This year’s OE-A Competition impressively demonstrates  how printed electronics is the technology to create sustainable electronics through low energy non-hazardous chemicals, additive manufacturing processes and the use of  recyclable materials.” says Dr. Klaus Hecker, Managing Director of the OE-A, an  international working group within VDMA. The OE-A (Organic and Printed Electronics  Association) is the leading international industry association for the emerging technology of  flexible, organic, and printed electronics. 

The proof will be provided at LOPEC 2024, the international platform for printed electronics,  from March 5 to 7, live at the ICM in Munich. This year, 17 projects from international  companies, research institutes and universities are participating in the “OE-A Competition  2024” to present their new products, prototypes, and concepts. The submitted projects will  be judged by a jury of representatives from renowned international companies and institutes  in three categories: “Prototypes & New Products”; “Freestyle Demonstrator”; and “Publicly  Funded Project Demonstrator”.

Henkel and OE-A foster young talents 

In addition to the established competition, Henkel AG & Co. KGaA and the OE-A Working  Group Education have for the first time launched an “Open Innovation Challenge” for  graduate and undergraduate students on the topic of Smart Living and Smart Mobility. “Together with our member Henkel, we challenged young students to develop and prototype  an innovative idea for a printed electronics application that addresses the Smart Living or Mobility markets. To bring their ideas to life, the students were provided with the Henkel Sensor Kit, which includes 5 types of printed sensors” explains Klaus Hecker. A jury  consisting of Henkel, OE-A and other industry representatives will select the winner of the  “Open Innovation Challenge”. The winning project will be showcased at the OE-A booth at LOPEC, along with all other OE-A Competition projects. 

Enabling more sustainable products 

Inspiring printed electronics projects guided by the idea of sustainability participate in this year’s OE-A competition. Here a sneak peek into three of them: 

IEE from Luxembourg competes with a multifunctional busbar connector for battery packs. This product is designed to reduce battery costs in e-mobility. The solution combines multiple functionalities in a single, flexible, and lightweight busbar “sandwich”, that enhances drivetrain electrification. With a single compound, customers have a product that performs multiple functions such as voltage monitoring, cell balancing, temperature sensing, electrical isolation, and busbar connection. The integrated bus bar connection demands less  manipulation than would be required with more components. This increases manufacturing  efficiency and reduces manufacturing costs. 

The CEA research institute in France, in collaboration with its industry partner, contributes a medical device use case with a flexible printed circuit board (PCB) within the EU-funded project ECOTRON. The first generation of the use case (GEN1) demonstrates that a conventional PCB can be replaced with a flexible printed one to create more sustainable  healthcare and wearable devices with no compromise on performance. The flexible printed circuit board is produced in an additive manufacturing process that uses less energy and chemicals. The future use case generations will include dismantling technologies (GEN2)  and bio-based/recycled materials for substrates and inks (GEN3) developed in the project.  

Another approach to a more sustainable future is offered by Fundación Tekniker of Spain  with its integrated de-icing system for wind turbine blades. In cold weather, ice build-up on  the blades reduces the efficiency of wind turbines. The de-icing system detects ice at the  initial stage of formation on the wind turbine blade and eliminates it with an integrated  heater. The ice detection sensors and the heating system are printed with conductive inks on continuous fiberglass mats, and this printed fiberglass is embedded in an epoxy/glass  composite by infusion. Wind turbine run time is maximized in icy conditions, reducing the  need to generate backup power. 

Public Choice Award  

All visitors are invited to vote for the Public Choice Award at the OE-A booth at LOPEC (this  time in the Foyer of ICM, FO.33) on March 6. The winner of the Open Innovation Challenge  and the winners of the OE-A Competition will be announced on the evening of Wednesday,  March 6, during the LOPEC Get-together & Award Show. In addition, all award winners will  present their demonstrators during a web seminar on April 25. 

OE-A booth at LOPEC  

At the OE-A booth at LOPEC 2024, LOPEC visitors will gain a comprehensive insight into  printed electronics applications. A visit to the OE-A booth is also worthwhile to learn about  the latest results of the new business climate survey and the activities of the numerous  international working groups. “Stop by the OE-A stand in the foyer of the ICM, I promise  there will be a lot to discover. We are proud to present all projects of the OE-A Competition  and the winning student project of the Open Innovation Challenge. And last but not least, the  Public Choice Award needs your voice, so please cast your vote for your favorite  demonstrator,” concludes Klaus Hecker.

www.oe-a.org 

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MEAF Supplies First Food Grade R-Pet Sheet Production Line To Lithuania

By mating its energy efficient sheet extrusion lines with Kreyenborg’s IR-CLEAN Super-Clean process for post-consumer recycled PET, MEAF Machines can now offer its customers a cost effective alternative for the production of FDA/EFSA approved single layer PET food grade sheet. A first R-PET extrusion line combining the two, has recently been installed at Pack Klaipėda UAB in Klaipėda, Lithuania, for the production of meat packaging. The line is also suited for the production of PP trays without alterations, providing the customer with even more flexibility.

Founded some 12 years ago, Pack Klaipėda UAB initially focused on expanded PS containers for take-away food. However, three years ago the company decided to move into other food packaging, notably for meat and poultry. “We looked at several potential suppliers, but found MEAF to have the same output at a much smaller footprint than competitors’ offerings,” says Darius Kontrimas, CTO at  Pack Klaipėda. “Because of rising energy costs, energy efficiency was high on our list and MEAF’s machines are probably best in class when it comes to that. Once we made our decision, we were pleasantly surprised by the level of support we received. Being new in the sheet extrusion business, we had tons of questions. MEAF answered all of them and provided us with all the info we needed and more,” he concludes.

 “This new line perfectly fits the current global trend to produce ever more with 100% Post Consumer Recycled (PCR) material such as bottle-flakes and works also with other thermoforming regrind,” says Roald de Bruijne, Sales Manager at MEAF. “However, the process needs to ensure that the cleaning and decontamination is properly done in order to adhere to the strict FDA/EFSA regulations. This requires processors to invest substantially in dedicated equipment to upgrade their sheet production. At MEAF we believe our affordable, energy-efficient and flexible solution allows our customers to make the transition to recycled material more easily.”

Kreyenborg’s IR-CLEAN is specifically designed as a cost-effective solution for the direct reprocessing of post-consumer PET flakes for food packaging, combining crystallization and drying in a single process. The  system operates without vacuum technology and can be retrofitted on existing extrusion lines. The efficiency of the cleaning process has been verified by a Letter of Non-Objection from the US Food and Drug Administration (FDA), while tests have shown compliance with the European Food Safety Authority (EFSA) criteria for the use of recycled materials for direct food contact packaging.

Roald continues: “At MEAF we already have a good reputation for energy efficient, affordable and flexible extrusion machines. When it comes to the use of R-PET for packaging, bottle-to-bottle is relatively easy as the mechanical properties of the regrind are pretty stable. However, the tray-to-tray recycling process is a lot harder. We are therefore now working hard on the development of a compact unit for IV level increase that can be fully integrated in new and existing extrusion lines. This will further support customers in their transition toward true circularity.“

www.meaf.com/

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Digitization Of Packaging – A Great Opportunity At Drupa!

At last. drupa is back, with less than a year to go the anticipation is building. Trying to work out what the theme of the show will be tricky, after eight years and the impact of COVID.

The drivers of sustainability, automation and workflow as the world continues to digitise dominate most print and packaging operations. Recruiting and retaining skilled staff is increasingly difficult for many businesses as baby boomers retire and the younger digital native generations demand a different approach to their working life.
Digital print developments will be centre stage across all graphics, industrial and packaging and there will be further announcements this year at drupa. Digital packaging offers many opportunities for commercial printers looking to move into new sectors as many traditional print applications continue to decline. The same dynamic is encouraging more equipment suppliers to offer digital printing systems for labels, corrugated, cartons, flexible packaging, rigid plastics, glass and metal packaging.

The figures show how the suppliers of digital print equipment for labels and packaging has developed since this technology map was first produced in 2019. There has been a steady stream of new entrants, from established analogue print equipment suppliers and new providers leveraging their digital print expertise.

On top of these there are digital overprint systems and sophisticated bespoke integrations, some operating as a part of manufacturing and filling lines. While there has been consolidation in the supply side it is striking that there have been few exits from the sector, the high number of players now competing in the wide range of packaging applications, offering new capabilities and functionalities, with steadily increasing productivity and lower costs.

Well, the good news for us print techies is this diagram will get even more crowded this year. Smithers tracks the developments in this sector, publishing reports and running conferences on digitally printed packaging. The European, American and Asian events bring together hundreds of brands, retailers, packer/fillers, converters, agencies and designers together with equipment, substrate and ink/toner suppliers, with workflow and logistics companies also involved. These are excellent forums and over the years the discussion moved from technology issues into tangible benefits and improved business processes from adopting digital printing, and increasingly digital finishing.

Today quality, reliability and productivity are no longer issues for inkjet and electrophotography packaging presses. At drupa there will be sheetfed inkjet machines offering the equivalent of process colour sheetfed litho at speeds of 11,000 B1 sheets per hour, while web presses offer speeds in excess of 400m per minute up to 2.8m wide. These are mainstream alternatives to litho, flexo and gravure alternatives.

The printhead and press manufacturers are developing methods to eliminate inkjet artefacts, compensating for nozzle outs and deviations in real time that extend the life of the heads and machine uptime. Inkjet will be the real winner, with faster machines being shown, particularly in flexible packaging. Ink technology is improving, with UV and water-based inks being employed for specific applications. There will be more highly pigmented formulations helping reduce the inkfilm thickness while lowering the total cost of ownership further boosting the share of digital print.

It is not just printing. Some vendors will show single pass, highly automated systems to print and finish corrugated boxes, cartons and flexibles in a single pass. The enabler is the combination of digital print with digital finishing. These will feature automated control systems that drive the press, measure and check the print then track through finishing which may be coating, laminating, cutting, creasing, folding and gluing, together with a wide variety of embellishments. The digital front end controllers are becoming increasingly powerful, automating and driving the digital print unit while at the same time measuring and controlling quality and then to set and drive the finishing technology. This approach helps replaces the traditional skills of press minders and finishing journeymen operators – important as skilled labour resources become scarcer.

While new digital presses are the shiny and sexy headline grabbers, even more important is the enabling workflow software. The only way of making money from a digital press is to produce saleable output and powerful workflow is vital to prepare the artwork files and keep the print queue well stocked. This can be a barrier for packaging converters entering the sector as many do not have the necessary prepress and data handling skills. drupa will see many companies providing solutions, integrating with management information systems to automate the administration needed to handle many short run jobs. Workflow will become increasingly collaborative, with new designs produced and approved, then loaded into job queues for automated colour management and imposition with no manual involvement at the converter. The MIS is linked, ordering substrates and planning the production on printer and finishing to meet the customer requirements and optimise capacity at the converter.

Digital workflow can be daunting for packaging converters used to handle a few large jobs but it is the way of the world. Companies can explore solutions at drupa to simplify supply chains that will be key to future success supplying packaging and labels. The market leaders offer a broad variety of creative software. They will show new methods to automate the repetitive processes involved with packaging design, approvals and prepress taking time and cost out of the process. Other players will offer specific solutions for integration and to optimise colour management, imposition and providing variable data capability.

All these packaging developments are ultimately driven by end customer expectations, or rather demands. In the increasingly connected world these demands and expectations are changing, with more engagement and interaction to improve the consumer experience of the brand. Digital printing allows brands to make content decisions later in the supply chain, closer to the consumer that helps packaging offer additional valuable functions. These additional functions move packaging beyond the traditional containment and protection functions, with information and promotion. A unique digital print can be connected to the cyber world, opening new opportunities of logistical efficiency and greater consumer engagement.

drupa is the most important print show, because the exhibitors (and all the important ones will be there) show what they have, while using the event to showcase what they are working on to gain feedback. And digital packaging print (plus finishing) will very much be on the agenda. There will be more machines for labels; corrugated – post and preprint, replacements for litholam; for folding cartons; for flexible packaging; for metal and there will be direct-to-shape machines doing interesting things on cans, aerosols, plastic and glass. Established players will show improvements to quality, speed and formats, with new inks and toners broadening the types of packaging they can produce.

I am really looking forward to seeing the newcomers who have already announced developments that they will be showing off and I know of several potential developments sadly under NDA that I am not allowed to mention, which is the bane of a technology correspondent. That will change when drupa opens.

https://www.drupa.com/

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THERMPROCESS China 2024 – High Potential For The Global Thermal Process Industry On The Chinese Sales Market

International companies benefit from exhibiting in the German Pavilion in Shanghai from 25 to 28 September 2024.

From 25 to 28 September 2024 the international thermal process industry will meet at THERMPROCESS China presenting numerous technological innovations and a line-up of high-calibre side events in parallel with the world-leading Düsseldorf trade fairs for wire, cable and tube and pipes, wire and Tube China, at the Shanghai New International Expo Center (SNIEC). In 2020, the total output value of China’s heat treatment industry was approximately USD17 billion, of which approximately USD 14 billion were accounted for by the sale of heat treatment processes and about USD 3 billion by the sale of heat treatment equipment and process materials (including USD 2 billion for heat treatment equipment and USD 1 billion for process materials).

In recent years, the number of companies and the market size of China’s heat treatment industry has grown steadily, and the demand for high-quality heat treatment equipment, instruments and application software has increased year by year. As a result of China’s “Dual Carbon” strategy, the Chinese heat treatment industry will vigorously promote the upgrading of equipment and technical research in the fields of energy conservation and eco-friendly manufacturing.

This trade fair for the Chinese market has formed part of the “Bright World of Metals” since 2020, thereby complementing the international THERMPROCESS portfolio in Düsseldorf. It is held every two years. With this trade fair, the organisers Messe Düsseldorf (Shanghai) Co., Ltd. and MC-CCPIT will again offer the international thermal process technology sector a comprehensive business platform for showcasing the latest products, technologies, solutions and services. The complete spectrum of thermal process technology will be on show: industrial furnaces, industrial heat treatment plants, plant construction, drive technology, firing technology, power and heat engineering, heat treatment and technology, heating systems, heat pumps and other accessories.

Companies can apply for participation in the German Pavilion with the Federal Ministry of Economy and Climate Protection as of now

Due to the good reputation THERMPROCESS China enjoys in the industry and the growing market interest numerous international exhibitors have already voiced their willingness to repeat participation in THERMPROCESS China 2024. German enterprises from the thermal process technology industry receive official funding for their trade fair participation and attractive special conditions from the Federal Ministry of Economics and Climate Protection (BMWK). Interested companies can register online with the BMWK and secure their exhibition area at the German Pavilion: https://registration.german-pavilion.com

 Red-hot side events come care of the Heat Treatment Technology Seminar

At the Heat Treatment Technology Seminar held during the trade fair, the Shanghai Heat Treatment Association will provide an overview of current developments and innovative approaches in heat treatment technologies. The agenda lists renowned speakers from the industry as well as lectures on the heat treatment of automotive parts and pipe-casting dies. The seminar offers industry experts an opportunity to exchange knowledge and network.

The latest THERMPROCESS China registered 332 companies participating from 14 countries. This means a 30% increase over the first event in 2020. More than 22,000 trade visitors from 53 countries travelled to Shanghai (figures include the concurrently held wire and Tube China). These included numerous buyers from the automotive industry, the chemical industry, the oil and gas industry, the energy sector, aviation and aerospace, and other user industries.

www.thermprocess.de/de/Overview

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Alio Industries Promotes Monolithic Design To Ensure Ultra-Precise Motion Control Solutions

ALIO Industries’ adoption of monolithic design in its motion control systems is a strategic decision to ensure unparalleled precision and reliability in its products. The monolithic design promotes stiffness, and integrates all essential components into a single, compact unit, which eliminates the mechanical complexities and alignment challenges associated with modular designs. This integration is crucial for applications where even the slightest discrepancy can lead to significant errors, making the precision and stability provided by monolithic design essential for the success of ultra-precise operations.

Bill Hennessey, President of ALIO says, “The monolithic design choice is particularly beneficial in sectors where precision is non-negotiable, such as metrology, ultra-fast laser processing, digital pathology, and semiconductor processing. For example, in digital pathology, ALIO’s monolithic, low-profile, open-center X, Y, Z electromagnetic driven stages are critical for achieving the high-speed, high-throughput, and low-friction motion needed for precise sample analysis. The integrated design allows for better pre-scan images by maintaining consistent motion with sub-micron variation, which is essential for capturing all data points in one pass.”

ALIO’s commitment to ultra-precision is also evident in its focus on nanometer-level accuracy and repeatability, which surpasses the commonly found micron-level precision in the industry. By prioritizing nanometer precision, ALIO’s monolithic designs cater to advanced applications that require the utmost accuracy, thus differentiating its products and positioning the company years ahead of its competition​​​​.

Moreover, ALIO’s innovative approach extends to incorporating novel materials into their monolithic designs, leveraging properties such as high stiffness and low thermal expansion. These materials contribute to the stability and precision of the motion control systems by minimizing thermal fluctuations and vibrations, which are critical factors in maintaining accuracy over time and under various environmental conditions​​. 

Hennessey continues, “ALIO ensures that its monolithic motion control solutions are future-proof, designed not just for current needs but with the foresight to adapt to evolving application requirements. Our product configurator tool exemplifies this approach, enabling customers to specify solutions that are tailored for both present and prospective challenges, thereby offering a smart investment for long-term operational efficiency​​. This forward-thinking strategy underscores ALIO’s dedication to providing customers with motion control solutions that deliver persistent ultra-precision performance in a rapidly advancing technological landscape.”

ALIO’s relentless pursuit of ultra-precision is further reinforced by its internal standards and practices. The company’s in-house metrology department and advanced machine shop underline its commitment to quality and precision. ALIO’s standards have been recognized by the adoption of their Point Precision approach into the ASME B5.64 standard “Methods for the Performance Evaluation of Single Axis Linear Positioning Systems”. This point repeatability method accounts for 6D spatial errors, providing a true representation of nanometer-precision performance​​.

Hennessey concludes, “The use of monolithic designs underpins ALIO’s strategy to deliver ultra-precise motion control solutions. By integrating components into a single unit, leveraging innovative materials, focusing on future-ready solutions, and adhering to stringent internal standards, ALIO provides its customers with a competitive edge in an array of high-precision industries.”

www.alioindustries.com

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SABIC’S New LNP LUBRILOY Compounds Extend Portfolio of non-PTFE Lubricated Materials

SABIC, a global leader in the chemical industry, today announced here at MD&M West 2024 (Booth #3287) a significant expansion of its LNP LUBRILOY portfolio of internally lubricated specialty compounds. The new LNP LUBRILOY products can meet customer demands for high-performance alternatives to materials lubricated with polytetrafluoroethylene (PTFE), which is a per- and polyfluoroalkyl substance (PFAS). These new grades extend SABIC’s LUBRILOY technology to additional base resins and feature a novel, patented lubrication technology enabling OEMs to help avoid health and regulatory issues associated with materials containing intentionally added PFAS.

“In the face of proposed European and individual U.S. state regulations severely restricting or banning the use of PFAS, customers in the healthcare industry and other markets are seeking self-lubricated solutions that don’t incorporate these chemicals,” noted Ralph R. Buoniconti, SABIC senior specialist, Regulatory. “SABIC has taken the lead in developing multiple new specialty compounds that can serve as alternatives to polymers lubricated with traditional PTFE. By expanding and enhancing our LNP LUBRILOY portfolio, SABIC aims to help customers successfully navigate the changing regulatory landscape for PFAS.”

Materials Deliver High Performance without PTFE

Internally lubricated thermoplastics have been used for years because of their advantages over externally applied greases or oils, which add processing time and costs and can transfer to and contaminate other surfaces. As an internal lubricant, PTFE is known for imparting very low friction and enhancing wear resistance. However, global concerns about PFAS have prompted customers in a wide range of industries to consider more-sustainable lubricants to replace PTFE.

“SABIC continues to add value to LNP specialty compounds in multiple ways – from expanded choice to improved regulatory compliance,” said Ed Williams, senior product manager, LNP Compounds, SABIC’s Specialties business. “Deep knowledge of polymer chemistry enabled our experts to achieve a milestone by developing a novel lubricant technology and incorporating it into multiple new base resins. Our new-generation LUBRILOY compounds offer customers the opportunity to achieve excellent wear and friction performance while easing concerns about anticipated restrictions on PFAS.”

New Base Resins Offer Broader Choice

The new grades, which include unreinforced and reinforced products with up to 30 percent glass fiber, complement SABIC’s other grades for medical devices. The company’s diverse healthcare materials address a range of performance needs, including withstanding multiple sterilizations, resisting aggressive disinfectants, and improving wear and slip-stick performance in applications like drug delivery pens, gears and bearings.

These new compounds are versatile, with possible use in applications across multiple industries. Besides medical devices, they offer the potential for mobility, industrial and infrastructure applications such as automotive under-hood components and interior parts, water meters, conveyor belt guides and tensioners, and other moving parts.

The new LNP LUBRILOY grades and example applications are on display at the SABIC booth (#3287) at MD&M West in Anaheim, Calif., from February 6-8, 2024. Also, Ed Williams, senior product manager, LNP Compounds, will give a presentation on these materials on Tuesday, February 6, at 12:30pm in the MD&M West Design Alley, The topic is “Solving thermoplastic wear and friction problems in medical devices without intentionally added PFAS.”

https://www.sabic.com/en

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REIN4CED and DIEFFENBACHER form strategic partnership Collaboration to accelerate large-scale production of thermoplastic carbon bicycle frames

A shared vision for using thermoplastic manufacturing to produce more durable and sustainable carbon bicycle frames has led DIEFFENBACHER, the Germany-based manufacturer of turnkey composite systems, and REIN4CED, the Belgian developer of a new, patented impact-resistant composite material, to announce a strategic partnership. Traditional carbon used in high-end bicycle frames is light, strong and stiff, but highly impact-sensitive. REIN4CED resolved brittle fracture issues by adding small amounts of steel fibers to specific locations inside the carbon material.

“The partnership with our longtime supplier DIEFFENBACHER seeks to make thermoplastic manufacturing the go-to method for producing unbreakable carbon bicycle frames,” says REIN4CED CEO Johan Miermans. “Together, we’ll accelerate and enhance process efficiency, robustness and flexibility to move toward our shared vision,” states CTO Michaël Callens.

DIEFFENBACHER is a leading manufacturer of press systems and complete production plants for the forming industry. The company helps manufacturers produce complex and robust composite components used in the automotive, aerospace, e-mobility and lightweight construction industries. The sports and leisure industry, which includes bicycle frame manufacturers, is another growing market for the composites components produced using DIEFFENBACHER technology.  

“Long-term, trusting partnerships with our customers are one of our core values and the basis of our entrepreneurial success,” says DIEFFENBACHER CEO Christian Dieffenbacher. Georg Obermaier, who leads DIEFFENBACHER’s forming business, explains that partnerships like the one with REIN4CED help DIEFFENBACHER advance technology innovation across their customer base. “The bicycle frame project is an ideal example of a cooperation that benefits both parties but can also help move the forming industry ahead,” he says.

REIN4CED’s ongoing cooperation with DIEFFENBACHER resulted in the world’s first serial production line for thermoplastic bicycle frames based on DIEFFENBACHER’s Tailored Blank Line, which consists of the Fiberforge tape-laying system and the Fibercon consolidation system.

DIEFFENBACHER Fiberforge is the fastest UD tape-laying system in the world. The Fibercon system consolidates the continuous fiber-reinforced tape layups into near-net-shape laminates with excellent quality. Fiberforge and Fibercon can be used to manufacture structural composite components or to provide local reinforcements. This provides components with excellent deflection behavior, strength and impact resistance, all essential properties of bicycle frames.

“REIN4CED’s feedback provides valuable insights into how our technology is used and its potential for further development,” Obermaier concludes. “In the form of further product developments and process improvements, this will ultimately benefit all our partners and customers.”

https://dieffenbacher.com/de/

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Stadler And Krones Close The Plastics Circular Economy Loop At The Las Vegas Polymer Center – The First Of Its Kind In North America

STADLER Anlagenbau GmbH, in collaboration with Krones, has designed and installed the new Republic Services Polymer Center in Las Vegas, Nevada, which processes plastic bottles, jugs and containers to produce plastic materials ready for use in new packaging. The first of its kind in North America, this facility closes the circular economy to meet the rising demand for high-quality and food-grade recycled plastic. 

Republic Services, a leader in the U.S. environmental services industry, has opened North America’s first vertically integrated plastics recycling facility, producing recycled resins for use in sustainable packaging. Krones, acting as general contractor in the project for the new Polymer Center in Las Vegas, worked hand in hand with STADLER, which was responsible for mechanical sorting on the PET and PO lines. The new plant will produce more than 100 million pounds per year of recovered resin products that are returned to the circular economy. 

The new Polymer Center processes presorted plastics collected by Republic Services across the Western United States to recover PET, which is converted into recycled PET (rPET) flakes ready to be turned into new bottles, and Polyolefins (PO) ready for use in the production of new bottles, jugs and containers. 

“The Polymer Center is the first facility of its kind in North America,” says Pete Keller, Vice President, Recycling and Sustainability at Republic Services. “It’s the first time a single U.S. company has managed the entire plastics recycling stream, from curbside collection to production of high-quality recycled resins ready for use in sustainable packaging.” 

This was an important project for Republic Services that required careful planning and research to select the best partners: “We started to think about the Polymer Center business model in 2019,” explains Pete Keller. “We chose STADLER and Krones because we think we’re going to produce the highest-quality and highest-value product in the marketplace. We had familiarity with STADLER’s equipment and people, and we knew we were going to get a solid design. We consistently heard that the Krones wash line produced the highest-quality rPET flake in the marketplace. These systems give us the ability to produce both food-grade and color-sorted materials in a way that hasn’t been available to the market in the past, enabling greater material circularity.”

Dual Line plant closes the loop with high-quality, food-grade recycled plastic

The Polymer Center in Las Vegas sorts and processes the materials, which are delivered in bales, on two lines: one for PET and one for mixed plastics, each with a capacity of 5t/h. “This is the largest Dual Line plastics recycling plant in the USA,” comments Mat Everhart CEO, Stadler America LLC (a subsidiary of STADLER Anlagenbau GmbH). It is expected to put 100 million pounds of plastics a year back into the circular economy by producing high-quality, food-grade recycled material ready for use in packaging. 

The materials fed into the PET line undergo mechanical separation and the singulated material is cleaned of ferrous particles. A STADLER STT2000 ballistic separator sorts the material into rolling (3D), flat (2D) and fines fractions. 

The fractions go through sensor-based sorting with Near-Infrared (NIR) sorters. Caps, rings, and the 2D fraction go to compactors. The 3D fractions are directed to a STADLER Label Remover to remove the labels. The clear PET, caps and rings are directed to the Krones washing line, which granulates and cleans the material, while the color PET is compacted into bales. 

On the Mixed Plastics treatment line, mechanical separation sorts the infeed into fines and sieve overflow – the latter further separated into light and heavy fractions. The heavy mixed plastics fraction is sorted into four Polyethylene (PE) products – Natural, White, Red/Orange/Yellow, Other/Color – and two Polypropylene (PP) products – Natural/White and Other/Color.

PET is sorted out of the remaining material and sent to the PET line. The products of the Mixed Plastics line are conveyed to storage bunkers where a semi-automatic feeding program allows for materials to be discharged by grade to be fed into the baler.

A successful collaboration to achieve a true plastics circular economy 

The Polymer Center in Las Vegas is part of Republic Services’ plans for a nationwide network to help customers achieve a true plastics circular economy: “Republic Services is committed to challenging every truckload we collect from customers and advancing circularity for key materials,” explains Pete Keller. “The Polymer Center will help enable true bottle-to-bottle and package-to-package circularity for plastics, helping customers achieve their own sustainability goals. Our integrated regional hub-and-spoke model will ensure nationwide coverage. We’ve received an overwhelming response from the industry and potential customers, which has accelerated the development timeline for our second and third Polymer Centers.”

The company plans to build three more Polymer Centers to address the gap between supply and the fast-rising demand for recycled plastics driven by regulations and a shift in consumer preferences for sustainable packaging. A report by the Recycling Partnership estimates that the gap between the current US supply of rPET for use in bottles and the projected demand in 2025 is close to 500,000 tons.

Following the positive experience working with STADLER on the Las Vegas Polymer Center project, Republic Services has decided to extend this collaboration: “Our strong partnership with STADLER and Krones, the design and quality of equipment, and successful implementation in Las Vegas has given us the confidence to purchase systems 2 and 3 for our centers under development,” concludes Pete Keller.

http://www.w-stadler.de/en/index.php

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GRC Welcomes TotalEnergies Fluids Dc Cooling Biolife To Its  Electrosafe Fluid Partner Program

GRC (Green Revolution Cooling), the  global leader in immersion cooling for data centers, announced today that the Special Fluids  division of global multi-energy company TotalEnergies has joined GRC’s ElectroSafe Fluid  Partner Program, a platform for collaboration to advance the performance and environmental  footprint of single-phase immersion cooling fluids. 

GRC’s ElectroSafe range of liquid coolants is available globally and deployed with GRC  immersion cooling systems in twenty-two countries. The range provides a broad spectrum of  high-performance, earth-friendly, synthetic coolants that have undergone a thorough testing  process. Under the ElectroSafe Fluid Partner Program, TotalEnergies Fluids and GRC will  jointly evaluate and gather fluid test data through a proprietary protocol to optimize material  compatibility, safety, and thermal performance. This will provide GRC’s customers around the  world with an expanded range of trusted fluids for their unique data center requirements. 

“TotalEnergies Fluids is proud to join GRC’s ElectroSafe Fluid Partner Program and expand  its presence in the data center immersion cooling space,” said Dominique Vincent, VP  Special Fluids. “Our DC Cooling BioLife is the first biosourced, biodegradable, and high performance dielectric fluid specifically designed for immersion cooling. It exhibits one of the  lowest viscosities in the market and fully contributes to our ambition of commercializing 30%  low carbon solvents by 2030.” 

As a member of the ElectroSafe Fluid Partner Program, TotalEnergies Fluids will provide its  sustainability focused BioLife Immersion Cooling Fluids. BioLife coolants are manufactured  from 100% traceable feedstocks coming from the circular economy and certified by ISCC  PLUS. Biosourced fluids deliver incomparable environmental benefits, with a significantly lower  carbon footprint than fluids from fossil or synthetic hydrocarbons and no compromise on  efficiency. They deliver excellent thermal management performance, with very low viscosity,  high fluid stability for enhanced safety, and strong electrical component compatibility. 

“TotalEnergies Fluids provides an excellent addition to our family of ElectroSafe coolants,” said  Ben Smith, Chief Product Officer at GRC. “BioLife’s focus on environmental friendliness  enables our most sustainability-focused customers to obtain the advanced data center  performance they require without compromising on their commitment to reducing drastically  the carbon footprint of their data center operations.”  

https://totalenergies.com/ 

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UFlex to Showcase Advanced Machine Technology at PlastFocus 2024

India’s largest multinational flexible packaging and solutions company, is participating in PlastFocus 2024, and will feature its advanced machine technology at Booth No. A 51, Hall 1, at Yashobhoomi (IICC), Dwarka, New Delhi from February 1-5, 2024. Recognized as an ideal platform for the plastics and packaging sector, PlastFocus 2024 will feature UFlex’s state-of-the-art machine technology, primed to redefine industry standards.

At the event, UFlex will highlight the technological prowess and capabilities of two of its groundbreaking machines:

CI flexo Machine: UFlex presents its CI flexo Machines, including the first-ever made-in-India gearless central  impression  flexo  printing  machine, introduced in 2017. Building on this legacy, UFlex has ventured into manufacturing a central impression, up to 10 colours, 800-1600mm web width CI flexo printing press. This collaborative endeavor with Italy-based Comiflex has resulted in a machine that offers unparalleled performance. With a printing speed of up to 400 meters/minute, this system is equipped with modem connectivity to UFlex’s service team for remote monitoring, diagnostics, and troubleshooting, ensuring real- time assistance to clients.

Combi Lamination Machine: UFlex’s Combi Lamination Machine features a digital AC vector drive and AC vector grade motor technology. This versatile model facilitates the lamination of two different substrates seamlessly using any of the two modes at a given time. The machine includes unwind and rewind features, a solvent-less coating unit, a gravure coating unit, a lamination unit, and a drying tunnel. With a speed of up to 300 meters/minute for solvent- based operations and 450 meters/minute for solvent- less operations, this machine sets new benchmarks in efficiency and performance.

UFlex invites industry enthusiasts and stakeholders interested in these pioneering technologies to experience live demonstrations of these machines at its Noida manufacturing facility. These exclusive plant visits will provide a first-hand experience of UFlex’s avant-garde manufacturing processes and technological advancements. Moreover, during the visit, engage in discussions about the upcoming launch of the ELS (Electronic Line Shaft) Rotogravure Printing machine models G-24/G- 25, set to be rolled out in the near future.

Join the UFlex team at Booth No. A 51, Hall 1, Yashobhoomi (IICC), Dwarka, New Delhi, to delve into the future of printing technology for converters. The team will be available for discussions, showcasing how these machines can enhance packaging processes, taking efficiency and sustainability to new heights.

corpcomm@uflexltd.com