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Smart Cap Gets Trade Fair in Düsseldorf Off to Impressive Start

Petra Löwer (Germany)
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Smart Cap Gets Trade Fair in Düsseldorf Off to Impressive Start

Smart Cap Gets Trade Fair in Düsseldorf Off to Impressive Start

Elmet’s innovative manufacturing cell for food cans is impressive; the caps produced are in high demand. Elmet got off to a high-profile start at the K 2022 in Düsseldorf. The Upper Austrian company was represented on two stands. Presented highlights included a manufacturing cell with four-cavity mold and Smartshot E all-electric gate valve cold runner and the new Smartmix TOP 7000 Pro dispensing system. The caps for beverage and food cans produced on the system were very popular among the visitors. The system itself impressed experts and interested parties alike – a sound basis for the successful days in Düsseldorf.

The K 2022 in Düsseldorf got off to a successful start. The world’s leading trade fair for the plastics and rubber industry also went extremely well for the Upper Austrian company, Elmet. The global player in the development and production of high-quality equipment for making silicone parts had already impressed many visitors and interested parties within the first few days.

Success on two trade fair stands

There were many interesting discussions on the company’s own stand in Hall 12. At the same time, Elmet also celebrated success on the Sumitomo partner stand in Hall 15. There, the partners presented an innovative manufacturing cell with four-cavity mold and Smartshot E all-electric gate valve cold runner and the Smartmix TOP 7000 Pro dispensing system developed in-house. “We address two different customer groups with this cell. On the one hand, we convince producers of the quality of our systems by visualizing the part weight, and on the other hand, the product produced is a real hit here at the trade fair,” says a pleased Harald Wallner, Elmet CEO. “The process accuracy visualized by the part weight shows visitors how precisely a liquid silicone mold with the Smartshot E all-electric gate valve and the Smartmix TOP 7000 Pro dispensing system can produce,” explains Wallner.

Efficiency meets sustainability

The innovative technology makes it possible to open the process window further and at the same time reduce the reject rate. In addition, the all-electric date valve cold runner reduces energy costs because production can be started more quickly thanks to the faster start-up process. The number of start-up parts that have to be disposed of as rejects is also significantly reduced. “This efficiency impressed the visitors, as we combine sustainability with precision to target the exact pain points of the industry,” says Wallner. Elmet relies on two systems developed in-house. The manufacturing cell builds on an Elmet injection mold with the fully automatic Smartshot E gate valve cold runner system. The material is supplied via Elmet’s Smartmix TOP 7000 Pro dispensing system. The Smartmix TOP 7000 Pro dispensing system is a new development from Elmet. With a footprint of only 1,150 x 790 millimeters, it is the most compact dispensing system for liquid silicone on the market.

Corporate data

Molds. Dosing technology. Part production. Jobs. Elmet inspires with Smart silicone solutions. This is Elmet’s guiding principle. The innovative company was founded in 1996. A powerful, dedicated team with a wealth of experience in moldmaking, dosing technology, and liquid-silicone injection molding has since developed into an internationally successful systems builder. Today Elmet is a global player in designing and manufacturing high-quality equipment for the production of silicone parts.

 

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Pioneer in Digitalization, Focus on System Engineering, COMPEO Now Even More Versatile

Petra Löwer (Germany)
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Pioneer in Digitalization, Focus on System Engineering, COMPEO Now Even More Versatile

Pioneer in Digitalization, Focus on System Engineering, COMPEO Now Even More Versatile

At K2022, BUSS AG will be explaining the possibilities of its digitalized machine monitoring project, which is designed to extend machine service life and ninterrupted production runs, identify maintenance needs at an early stage and avoid unforeseen downtime. BUSS will also be presenting its wide-ranging expertise as a partner in plant engineering for all aspects of compounding. Another focus will be the addition of a Laboratory version to the versatile COMPEO co-kneader series.

Making maintenance requirements plannable

Condition-based monitoring, the ongoing acquisition of parameters indicating the status of individual components and entire assemblies in a machine or plant system, is the foundation of the new SenseHub service from BUSS. Sensors for acquiring process section, vibration data or other metrics elucidate the condition of the manufacturing system at critical points on machines such as kneaders, discharge and dosing units, pelletizers, heaters and coolers. Following data analysis, the user can call up the visualized results in the SenseHub dashboard on the BUSS service portal. This BUSS service carries out monitoring, evaluation, and planning of any necessary repair work in direct consultation with the customer. Not limited to the compounding unit of the BUSS co-kneader, the SenseHub service will beextended to additional sensor data for the evaluation of the machine health, ensuring maximized production uptime.

Focus on complete systems

Where required, BUSS can supply greater complexity in the form of complete systems for various applications and is increasingly designing and implementing custom applications as a one-stop shop supplier working hand in hand with selected manufacturers. Depending on the scope of the project, such systems may include not only material dosing, kneading, discharging and pelletizing but also a variety of other components, such as filters, coolers, materials handling systems, quality control systems, clean room design and more.

Co-kneader even more versatile

The cornerstone of any system supplied by BUSS is a COMPEO series co-kneader which is designed to incorporate high levels of additives gently and thoroughly into base materials. The modular machine design is so flexible that a specially configured compounding line is avaiLable for any application at any temperature up to 400°C and for all plastics, ranging from thermally sensitive thermosets to demanding engineering thermoplastics.

The latest addition to the family of the series of five production units with throughput levels, depending on application, of 100 to over 12,000 kg/h is the new compact, user-friendly COMPEO Lab Laboratory compounder for throughputs of 50 to 100 kg/h for development, process optimization and small production campaigns. It offers all the advantages of the large COMPEO co-kneaders, including the combination of two-, three- and four-flight screw elements, and provides precise and reliable scale-up of process parameters to production conditions.

 

New COMPEO Lab compounder with detached twin-screw discharge unit BUSS

 

BUSS is an international market leader in compounding systems for demanding applications. As the originator of co-kneader technology, BUSS can offer unique compounding solutions that set the standard for heat or shear critical applications in the plastics, aluminum, chemicals and food processing industries. BUSS’s core expertise is in providing customized and application-specific solutions for advanced compounding tasks to meet stringent process technology and product quality requirements and ever greater market demand for sophisticated technology. “Swiss quality” explains why BUSS compounding systems perform so well, are a reliable investment and have made the company a leading supplier of advanced compounding technology.

 

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Hiking Gear Makes Strides With TPEs

Petra Löwer (Germany)
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Hiking Gear Makes Strides With TPEs

Hiking Gear Makes Strides With TPEs

The Thermolast K FC/LF series of compounds from Kraiburg TPE, a global thermoplastic elastomer manufacturer with a diverse range of products and custom solutions for a wide range of industries, is gaining traction in hiking equipment applications.

The healthy lifestyle trend is sweeping the globe, with more people engaging in outdoor activities, such as hiking, that can strengthen the immune system and reduce disease risks.

Hiking, without a doubt, improves overall health and reduces stress. To endure the long, strenuous walks on rocky terrains, hikers must use proper gear, clothing, and accessories that protect them from injuries, bad weather, encounters with wild animals, and other unforeseen hazards.

As with any outdoor adventure activity, packing the right gear and making sure it’s made of advanced materials such as thermoplastic elastomer (TPE) are essential for a successful hike.

Kraiburg TPE, a global thermoplastic elastomer manufacturer with a diverse range of products and custom solutions for a wide range of industries, offers multifunctional, custom-engineered TPE compounds for use in hiking goods and other outdoor activity products to achieve flexibility, scratch and abrasion resistance, and resistance to UV, temperature, and chemicals.

FC/LF series for trekking poles and wearables

It is a good idea to bring trekking poles when hiking for safety. When navigating unpredictable trails, this hiking gear aids in providing stability while out walking. Kraiburg TPE offers the Thermolast K FC/LF series for use in trekking pole handles, to assist in maintaining a steady hiking pace over longer distances. The TPE compounds provide an ergonomic design for ease of use and a perfect fit for a secure grip. This series of compounds is resistant to abrasion and scratches and accords a soft and velvety surface. It also has consistent colorability, allowing for more eye-catching equipment design.

Furthermore, the TPE series of compounds provide good adhesion to PP, thereby benefiting wearable accessories, such as sunglasses. It is used for seals and end elements on eyewear to make them more comfortable and safer for long-hour wear while still being robust enough for outdoor use.

AD1 series for shoe dial and headlamp sealing

Kraiburg TPE’s Thermolast K AD1 series of compounds is a durable and stable material solution for shoe dial and headlamp sealing applications. The series provides a soft and velvety feel and non-sticky haptics.

Sustainability successes of our TPE In addition to the material for outdoor activity equipment and gears, other recent sustainability innovations from Kraiburg TPE include a material solution specifically developed for automotive, consumer and industry applications that contains post-consumer recycled (PCR) and post-industrial recycled (PIR) content. This demonstrates how strongly Kraiburg TPE adheres to its sustainability principle. Are you looking for a sustainable TPE solution? Talk to us! Our experts are happy to answer any questions you have, as well as to offer the right solution for your application.

 

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Borealis and Borouge to present fully recyclable monomaterial pouch solutions at K 2022

Petra Löwer (Germany)
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0
Borealis and Borouge to present fully recyclable monomaterial pouch solutions at K 2022

Borealis and Borouge to present fully recyclable monomaterial pouch solutions at K 2022

  • Combining optimum performance on packaging lines with excellent in-use properties, consumer appeal and circularity
  • The solutions developed with value chain partners enhance properties and recyclability
  • Partnership is embodiment of the Borealis EverMinds spirit of taking action to accelerate the move towards plastics circularity

Borealis and Borouge PLC (“Borouge” or “the Company”) (ADX symbol: BOROUGE/ ISIN: AEE01072B225), leading providers of innovative, value-creating plastics solutions, have announced the launch of three all-polyethylene (PE) pouch concepts developed in extensive collaboration with technology partners across the entire value chain to meet the most demanding challenges in flexible consumer packaging.

As many brand owners have pledged to make 100% of their packaging reusable, recyclable or compostable by 2025, there is a growing demand for more sustainable monomaterial film solutions capable of replacing incumbent, nonrecyclable multi-material structures without compromising processability and packaging performance. In line with the Global Commitment initiated by the Ellen McArthur Foundation, the vision of a circular plastics economy also requires major advances in using recycled and/or renewable feedstock to minimise fossil depletion and plastic waste.
The three designs will be on display at K 2022 in October and address the need for significant improvements in monomaterial barrier packaging, carbon footprint reduction and design for recycling (DfR). They closely align with the EverMinds approach for joint projects with committed value chain players to accelerate the transition of the plastics packaging industry from a linear to a circular economy.

New solutions with proven products 

Key challenges identified by Borealis and Borouge for a new generation of fully recyclable monomaterial pouch solutions included reliable sealability, mechanical properties, thermal stability as well as different levels of barrier performance depending on end use. Addressing the needs of various different applications, three monomaterial concepts were developed that share the same proven DfR product platform:

1. Laminated PE pouch for gas barrier packaging of oxygen sensitive products including modified atmosphere packaging, such as nuts or cheese.
2. High-barrier PE laminate pouch for packaging of moisture sensitive food products, such as crisps, biscuits and confectionary.
3. New PE pouch with 35% Ecoplast low density polyethylene (LDPE) low-gel post-consumer recycled (PCR) for non-food applications, such as detergent powder.

In all three PE monomaterial pouch solutions, BorShape and Borstar provide the required mechanical and thermal stability performances, while Anteo and AnbiqTM combined with Queo deliver outstanding sealing performances.

The full PE monomaterial approach eliminates the use of non-recyclable multimaterial solutions. At the same time, it supports the aesthetic consumer appeal (look and feel) of the pouches as well as their end-of-life mechanical recycling in existing flexible PE waste streams.

Enhanced sustainability through partner technologies

The concepts were thoroughly validated and their sustainability was further optimised together with leading industry partners. Hosokawa Alpine provided MDO (machine direction orientation) PE film extrusion line and technology, and multiple trials were run with various different pouch formats on GEA packaging equipment. Mechanical recyclability was optimised by using a solvent-free lamination adhesive from Henkel and digital watermarking technology from Digimarc. The HolyGrail 2.0 compatible digital watermark can be read using smartphones or scanners, which facilitates packaging waste sorting but does not interfere with pouch print appearance. For very sensitive goods requiring robust protection with higher moisture and gas barriers, vacuum metallisation technology from Metlux offers a cost-efficient process without compromising the mechanical recyclability of the pouches.

“We firmly believe that we can accelerate circularity only by collaborating with competent partners across the value chain to jointly re-invent essentials for sustainable living,” summarises Peter Voortmans, Global Commercial Director Consumer Products at Borealis. “The results of this major joint initiative have demonstrated the feasibility of full PE monomaterial pouch solutions for demanding packaging applications that will help our customers drive and implement their sustainability targets as they strive for carbon neutrality.”

“Borouge is committed to providing innovative solutions to advance circularity and help address global challenges. We are excited to collaborate with partners from across the value chain to develop the right solutions for our customers without compromising on the performance and productivity required for advanced packaging applications,” said Mr Youssef Taha, Senior Vice President, Marketing & Innovation, Borouge.

Physical promotional samples of the new full PE pouch concepts can be requested for evaluation, supported by full technical documentation and extensive test results of performance on various packaging lines.

K 2022 will take place from 19 to 26 October 2022 in Düsseldorf, Germany.

We invite you to “Innovate Collaborate Accelerate” together with us by visiting Borealis and Borouge in Hall 6 at Stand A43, where the new monomaterial pouch solutions will be on display.

 

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Oerlikon HRSflow Hot Runner Systems in Action: Live Molding Demo at K2022

Petra Löwer (Germany)
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Oerlikon HRSflow Hot Runner Systems in Action: Live Molding Demo at K2022

Oerlikon HRSflow Hot Runner Systems in Action: Live Molding Demo at K2022

Intricate applications of Oerlikon HRSflow hot runner systems produced in cooperation with project partners in the fields of polymer materials, mold making and machine manufacturing, will be presented at the upcoming K Show. The live molding demonstrations will be available at the partners’ booths.

Thin-walled 150ml IML Yogurt cup: the evolution towards a fully recyclable packaging

At Netstal booth (Hall 15, Booth D24), the ELIOS 4500 Injection Molding Machine will produce a thin-walled 150ml IML yogurt cup (6.4 g) from a certified renewable PP polymer by Sabic , highlighting the importance of human and environmental health. The material is based on tall oil, a waste product from paper production. The powerful and energy efficient Netstal injection molding machine compensates for the slightly thicker label in the injection molding process with a correspondingly thinner wall thickness of the cup. Wall thickness of the 5.4 g cup without label measures only 0.32 mm. This high-performance application runs with a fast 3.9 s cycle time.

The new Xp nozzle Series from Oerlikon HRSflow, specifically engineered for thin wall packaging, ensures a reliable process and an increased productivity at the lowest cost per unit. The result is a low thickness component (0.4 mm) injected with ambitious cycle times and decorated with a new generation label: the NextCycle IML™ from MCC Verstraete. The NextCycle IML labels allow that a fully decorated PP IML package can be recycled without any impact of the label on the RPP material. These labels will also feature digital watermarks from the Holy Grail 2.0 initiative. The project was developed in cooperation with Netstal, IML Solutions, MCC Verstraete, Sabic, Oerlikon HRSflow.

Eco-friendly fruit box: maximum precision combined with sustainability

Haitian (Hall 15, Booth A57) will showcase the injection molding of an eco-friendly fruit box which marks a key step in Oerlikon HRSflow’s approach to Circular Economy. The selected hot runner configuration is specifically designed to process APS PE compound with recycled Tetra Pak carton package Alu Foil. The 4 drop Flexflow servo-driven valve gate system, running on a Haitian Jupiter Series (JU4500III), ensures the production of a flawless part with the complete filling of all the ribs and walls and a high process repeatability. For an optimal gate vestige quality, Oerlikon HRSflow’s new patent pending TTC cooling bushing avoids pin’s sticking issues even with fast cycle times. Project partners are Haitian, Mundimold, Tetra Pak , APS, Oerlikon HRSflow.

Sustainable tool case: complex shapes made masterfully

Arburg will present at its stand (A13, hall 13) the injection molding of a complex tool case requiring the use of 4 hot runner systems from Oerlikon HRSflow. For the manufacturing of the two covers from a PC/ABS blend in a family mold, a 2 drops screwed-in system are used. Moreover a 3D Design Film is overmolded on the covers. Particular attention will be also given to the inner tray, the handle as well as the lateral latches made of Pet Recopound by KURZ. The result is a stable and robust end product with illimited possibilities of decorations. Project partners are Arburg, Hofmann, Leonhard Kurz, Oerlikon HRSflow.

2K Rear-Panel: futuristic smart automotive surfaces

ENGEL (Hall 15, Booth C58) will present the injection molding of a smart 2K rear panel composed by a PC+ABS frame overmolded with PMMA or alternative PC. During the first injection phase a hydraulic 2 drops system from Oerlikon HRSflow will be used while for the second one a Single nozzle from Ga Series will be employed. The part will be finally decorated with a capacitive and aesthetic film directly in the mold for an innovative result. To implement such complex requirements, exact rheological analysis calculations were necessary. Project partners: ENGEL, Schöfer, Leonhard Kurz, Röhm, Oerlikon HRSflow.

3 component coffee-to-go cup: hot runner solutions for 100% recyclable parts

At Booth C06, Hall 15, Wittmann Battenfeld will show the manufacturing of a 3-component coffee-to-go cup with a lid. The rotational mold with 3 separate injection units is equipped with three different single nozzle systems by Oerlikon HRSflow optimized to process the 100% recyclable PP Bornewables™ (non-petroleum-based feedstock) from Borealis.The Bornewables™ – made of renewable raw materials derived from waste and residue streams – perfectly meet the functional requirements of the molded part without compromise in terms of quality and sustainability standards. The cup, with a thickness of 2 mm, is produced in clear optic in the first cavity and over-molded in the second cavity with an insulated shell. The insulating effect is obtained by foaming the melt through the special Cellmould technology which enables the production of lightweight, rigid parts without sink marks. Project partners are Wittmann Battenfeld, Haidlmair, Borealis and Oerlikon HRSflow.

Garden tool: 2K irrigation connector

Additionally at K show, Oerlikon HRSflow will showcase at Billion’s booth (Hall 15, Booth B24) the injection molding of a garden tool, specifically an irrigation connector. The part will be produced through a 2K tool equipped with two different hot runner systems with one nozzle. During the first phase, a face-to-face torpedo system is used to inject styrenic compounds (ASA polymer), while for the second phase, a screwed-in cylindrical valve gate system is employed to inject elastomer compounds (SEBS). During the second phase, the molded part can be easily customized thanks to the marking operations directly embedded in the tool cycle process. Among the special features the automatic and quick change of the mold version enabling the production of the three different components – in this case the coupling diameters – without disassembling the tool or stopping the manufacturing activities. Project partners are Billion, Groupe Pernoud, Actemium, Sepro Group, Resinex, Lifocolor and DeViris, Oerlikon HRSflow.

High Gloss B Pillar: accurate injection, perfect appearance

The Injection Molding Machine manufacturer Tederic (Hall 15 Booth D40) will showcase the production of a high gloss B pillar. The molded part is obtained through a 2K hot runner system developed by Oerlikon HRSflow. The hot runner solution enables the perfect appearance of the component thanks to a gentle, low-stress injection. During first phase a 2 drops conical valve gate hydraulic system combined with ICM Technology are used to inject PMMA polymer, while for the second one (ABS material) a 6 drops system is developed. The project was conceived in cooperation with Tederic, Yuyao Skymold, Piovan and Technotrans Solutions GmbH, Oerlikon HRSflow.

 

 

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Constantia Teich Celebrates 110 Years

Petra Löwer (Germany)
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Constantia Teich Celebrates 110 Years

Constantia Teich Celebrates 110 Years

2,000 guests celebrated the 110th anniversary of Constantia Teich on Saturday, October 1, 2022, in Weinburg, Pielachtal. At the open house, the company looked back on its history and gave visitors a glimpse behind the scenes of the flexible packaging manufacturer.

Where once the brothers Richard and Ernest Teich laid the foundation for today’s Constantia Flexibles Group, there was a festivity over the weekend. “It was a successful celebration with guests from the surrounding area and our employees and their families,” says Dr. Gerald Hummer, Managing Director of Constantia Teich. The production halls, where then as today foil is rolled and prepared for further processing in the industry, were open to 2,000 guests on Saturday. On the tracks of the aluminum raw material, it was possible to follow how the packaging for cat and dog food, coffee capsules, yogurt lids, chocolate, and pharmaceutical products are produced. Nearly 70,000 tons of aluminum foil are rolled yearly at the Weinburg site near St. Pölten. “You could wrap Vienna twice with that amount,” says Gerald Hummer.

Clear number 1: an employer with greatness

Constantia Teich operates the largest foil rolling mill in Austria. “We produce primary packaging, i.e., packaging that comes directly into contact with the food or pharmaceutical product,” explains Gerald Hummer and continues, “the rolling mill is used to roll one billion square meters of aluminum foil every year.” This makes the company the world’s number one in the production of yogurt lids. And within the Constantia Flexibles Group, Constantia Teich is also among the largest plant supplying materials to its sister companies. However, the company does not limit itself to rolling aluminum. ” We cover the entire value creation chain for internal production of flexible packaging materials – from the rolling and printing to final production,” summarizes Gerald Hummer. Around 1,000 employees work in production, administration, and the company’s own research and development center. Constantia Teich is one of the largest employers in the Pielach Valley. “We are a global player with a local presence. Our most valuable asset is our employees!” says Hummer proudly about the workforce. “Great loyalty of the employees towards the company, excellent training of the apprentices as well as the high level of know-how, are among our strengths and makes us a reliable producer and supplier, even in times of crisis. All this makes Constantia Teich a solid employer in the region,” continues Dr. Gerald Hummer.

Outlook on the future

“An anniversary like this is not something you celebrate every day. Our employees are primarily responsible for our success. Without them, Constantia Teich would not be what it is today: an important international company. A big thank you and congratulations on the anniversary to the entire team,” honors Pim Vervaat, CEO of Constantia Flexibles the valuable work of the workforce. To ensure the company remains successful, investments are being made. 34 million euros will be invested in a new coating and laminating machine, including an extension, as individual markets, such as the coffee market, are growing strongly.

 

 

 

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Solvay Launches Solvalite Surfacing Film for Automotive Body Panels at CAMX 2022

Petra Löwer (Germany)
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Solvay Launches Solvalite Surfacing Film for Automotive Body Panels at CAMX 2022

Solvay Launches Solvalite Surfacing Film for Automotive Body Panels at CAMX 2022

Fast cure and impeccable flatness for large Class A painted surfaces,compatible with advanced prepregs for high-volume applications

Solvay has announced the launch of SolvaLite SF200 surfacing film, a light tack film for ‘Class A’ paintable body panels. The new product will officially be introduced to the market at the Composite and Advanced Materials Expo (CAMX) in Anaheim, California, where Solvay will be exhibiting its comprehensive composites offering from October 17 through 20, 2022, at Booth W56. “With a curing time of less than 10 minutes at 150 °C, our new SolvaLite

SF200 Surfacing Film lends prepreg layups for high-class automotive body panels a very smooth cured surface where impeccable flatness is an indispensable prerequisite for painting,” says Dan Eskelsen, Head of Product and Asset Management Adhesives at Solvay’s Composites business unit. “The product is based on our latest fast-cure technology and compatible with autoclave curing. It combines a longer outlife than previous surface films with good adhesion to automotive paints and primers, and minimizes the required rework prior to painting.” Moreover, SolvaLite

SF200 provides a one-stop solution for OEMs and tier suppliers who wish to receive a perfectly matched prepreg and surface film package from a single source. The new surfacing film is targeted at large body panels used on premium sports and other luxury class vehicles. It complements Solvay’s new series of SolvaLite 714 Prepregs available in a wide range of unidirectional carbon fiber reinforced and woven-fabric formats for automotive and other high-volume press-cure applications.

 

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SML’s Presents Its PowerCast XL Stretch Film Line With a Patented, Brand-New Triple Turret Winder on K 2022

Petra Löwer (Germany)
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SML’s Presents Its PowerCast XL Stretch Film Line With a Patented, Brand-New Triple Turret Winder on K 2022

SML’s Presents Its PowerCast XL Stretch Film Line With a Patented, Brand-New Triple Turret Winder on K 2022

SML comes with a world debut in stretch film manufacturing to K2022: A patented triple turret winder for the PowerCast XL stretch film line. The W4000-4S-3T is the first winder in the market for manufacturing 2” stretch film hand rolls on a 4.5 m wide line. SML’s new “three-turrets-in-one-frame” concept enables significantly higher production speeds for maximum output quantities – especially at the lighter 2” rolls.

“The PowerCast XL with the new turret winder W4000-4S-3T has yet to meet its match. The possibility to manufacture also 2” rolls on that 4.5 m wide increases the product diversity and productivity of our PowerCast stretch film line significantly,” says SML Product Manager Thomas Rauscher. Until now, it was only possible to
run 2” hand rolls on lines up to 3 m width, thus the new development boosts the output of hand rolls by about 50 %. As before, 3” hand rolls, machine rolls and jumbo rolls an also be manufactured, with ease, with this new solution.

Brand-new and patented winding technology

“The trigger to develop a new winding system for 2” hand rolls for our 4.5 m wide PowerCast XL line came right from our customers. As a starting-point for our development works we took the proven double turret winder W4000-4S”, Thomas Rauscher explains. The technical basis of the new winder W4000-4S-3T is the patented
‘three turrets-in-one-frame concept’. Compared to other winders for wider lines, the three winding shafts with 1.5 m each are relatively short. This guarantees very stable production processes and allows significantly higher production speeds, especially at hand rolls.

Resource-saving winding technology

The new turret winder W4000-4S-3T can be equipped with a range of cutting-edge winding technologies for stretch film production:

Thin Core Technology: This well-proven concept allows to run thinner and therefore lighter paper cores on specific winding shafts. A reduction of the core weight of approx. 50 % minimises the raw-material consumption in the core production – and with it the CO2 emissions in the same way.

Coreless Winding: Even better than winding on thinner paper cores, is to use no cores at all. SML’s Coreless Technology was developed for the coreless production of hand and machine rolls. Beside considerable sustainability effects, this winding method has also a significant impact on production costs.

Modified Edges: ME is a patented SML technology to reinforce the edges of stretch film, making them nearly indestructible. The whole process is very efficient as it completely takes place in-line. Higher residual stretchability and puncture resistance are the key-characteristics of stretch film with modified edges.

Designed for SML PowerCast XL

The 4.5 m wide PowerCast XL in combination with the winder W4000-4S-3T is the latest step forward in SML’s PowerCast series, successfully uniting maximum output volumes of up to 3.400 kg/h net with highest flexibility in production. Like all stretch film lines from SML, the PowerCast XL is able to process up to 80 percent post-consumer recyclate, i.e. from LLDPE/LPDE.

Observing machine values at K 2022

Moreover, the machine features BitWise, SML’s in-house developed user-friendly data monitoring and analysing solution, that is open to the OPC-UA standard. Visitors who have downloaded the Umati web app and scanned the QR code displayed on the machine, have the opportunity to observe some real-time production values of
the PowerCast XL.

 

Technical features of PowerCast XL + W4000-4S3T:

  • Output up to 3,400 kg/h net
  • Compact design – 240 m² floor space
  • Ø 1,600 mm chill roll – the biggest in this sector
  • 7 or 67 layers
  • Ready to manufacture PIR and PCR
  • Maximum flexibility: 2” hand rolls 3” hand rolls, machine rolls and jumbo rolls
  • ThinCore technology
  • Coreless technology
  • Modified Edges

 

 

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New LSR Grades for Alternative Drive Concepts and Low Curing Temperatures

Petra Löwer (Germany)
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New LSR Grades for Alternative Drive Concepts and Low Curing Temperatures

New LSR Grades for Alternative Drive Concepts and Low Curing Temperatures

At K 2022 Momentive Performance Materials will present the newly developed product family of Nevsil LSR and HCR silicone rubbers, which is geared towards the requirements of modern mobility concepts, i. e. New Energy Vehicles. The new generation of LTC-LSRs from Momentive, which cure at particularly low temperatures, is especially suitable for thick-walled parts and combinations with temperature-sensitive materials.

Nevsil for alternative vehicle drive systems

Momentive’s new LSR and HCR-based Nevsil product family is suitable for a wide range of sealing applications in vehicles powered by alternative energies, including e-mobility, hybrid concepts and fuel cell technology. In addition to a generally low compression set, their wide range of grades includes high temperature resistance as well as flame retardancy, self-lubricating, low viscosity, low stiffness, fast curing, increased crack and ageing resistance, good colourability, and thermal conductivity.

The flame retardant Nevsil FR LSR and HCR grades with Shore A hardnesses ranging from 35 to 70 meet the requirements according to UL94 V-0 for 1 mm thickness with balanced mechanical properties and very good heat resistance. Typical applications include connectors and heat ageing resistant moulded components such as gaskets, O-rings, etc.

Included in the Nevsil FR portfolio are two Nevsil SLFR grades, offering both UL94 V-0 flame retardant properties (1mm) coupled with self-lubricating functionality. Both grades are peroxide cured HCR grades offering balanced physical properties in addition to high heat and temperature resistant characteristics.

Resistance to high heat is the outstanding property of the Nevsil HTHR HCR compounds, with Shore A hardnesses ranging from 30 to 80. Properly catalysed, these products qualified to the demanding SAE/USCAR-2 temperature classification T5 (-40 °C to +175 °C at 1008 h) are suitable for demanding environments with long-term exposure to temperatures up to 300 °C. They combine very good mechanical properties with good miscibility, creating a series which is easily blendable to achieve varied hardness levels. Typical applications are O-rings, seals, gaskets, and other moulded parts for high temperature applications.

 

Sealing of bipolar plates in fuel cells is the typical application of the new LSR Nevsil FC140.

 

In addition, the Nevsil portfolio offers thermally conductive silicone technologies in both LSR and HCR offerings. Nevsil TC LSR grades provide hardnesses in both 30 and 60 Shore A, while the HCR version provides a thermally conductive solution in a 60 Shore A durometer. Additional capabilities include Momentive’s ability to custom tailor the thermal conductivity to meet demanding application needs while optimizing the thermal management properties. All grades are easy to process with high reactivity and exhibit low compression set even at low temperatures. Typical applications here are heat dissipating pads and gaskets as well as battery seals.

Dedicated to sealing bipolar plates (BPP) and membrane electrode assemblies (MEA) in fuel cells is Momentive’s new translucent LSR grade Nevsil FC140. Its low viscosity enables a lower injection pressure, critical when overmolding sensitive substrates. In combination with the company’s XP81-A6361 primer technology, the material offers good adhesion properties to both stainless steel and graphite. With its fast cure and low compression set properties without post curing, Nevsil FC140 offers significant advantages over RTV products used in similar applications.

LTC-LSR: Halved curing time at low curing temperature

Momentive’s LTC-LSR (Low Temperature Cure) grades cure at particularly low temperatures, enabling shorter curing times for thicker-walled articles, for example for applications in e-mobility and general high-voltage technology. At the same time, the lower processing temperature allows energy savings in mould heating. For two-component parts, LTC-LSR can also be used to produce material combinations that would not be economical to manufacture with conventional curing LSR due to the low temperature resistance of the material to be overmoulded.

By optimising the reactivity, Momentive was able to realise these diverse advantages with curing times that are acceptable in practice and was already able to demonstrate this at Fakuma 2021 with the LTC type LSR 5650. An even further, productivity-increasing reduction in curing times at low curing temperatures has now been achieved with the development of the LTC generation LSR-K2022. Thanks to further increased reactivity at temperatures between 90 °C and 130 °C, this cures 30% to 50% faster than the previous version. The pot life is more than a week, whereas for conventional curing systems with similarly high reactivity it is less than 24 hours. This means that the efficiency of processing into high-quality moulded parts is significantly higher, not only due to the higher reactivity, but also due to a lower curing in the conveyor system.

 

At a cross-linking temperature of 90 °C, the LTC-LSR grade from Momentive presented at K 2022 achieves a curing density of 60 % after only half the time required by the predecessor LTC grade LSR 5650.

 

 

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Archroma Launches Appretan NTR Barrier Solutions for Food Packaging Based on a Renewable Natural Ingredient Component

Petra Löwer (Germany)
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0
Archroma Launches Appretan NTR Barrier Solutions for Food Packaging Based on a Renewable Natural Ingredient Component

Archroma Launches Appretan NTR Barrier Solutions for Food Packaging Based on a Renewable Natural Ingredient Component

Archroma, a global leader in specialty chemicals towards sustainable solutions, today announced that its ground-breaking Appretan NTR range based on 30% renewable raw material can now be applied to impart barrier properties to selected types of food packaging.

Consumers are increasingly frowning upon being served their favorite street foods or fast foods in polystyrene or plastic based boxes and wrappings. Paper-based packaging can offer a much more sustainable alternative if they are not lined with a plastic film which can make them unsuitable for recycling and composting. The solution is to carefully select paper coatings and barriers solutions which are fit for purpose and that are designed to make food packaging both safe for food contact and more recyclable.

Archroma is well known for its innovations and sustainable solution systems aimed at helping packaging & paper manufacturers to optimize productivity and/or create value in their markets. Just a few months ago the company launched Cartaseal VWAF, a PFC-free and ammonia-free barrier for odorless paper-based food packaging, as well as in 2019, a ground-breaking binder, Appretan NTR, made with 30% active content based on natural, renewable raw materials, designed for use in nonwoven articles such as tea bags and coffee filters.

In line with the principles of “The Archroma Way to a Sustainable World: Safe, efficient, enhanced, it’s our nature”, the paper & packaging R&D experts of Archroma decided to explore the properties of Appretan NTR for paper-based packaging applications.

They investigated a new specific application aimed at providing a more sustainable barrier option for general food packaging used with a short contact time, such as burger or sandwich paper wraps.

The Appretan NTR range is made with over 30% renewable raw material component, allowing the reduced use of fossil fuel based resources without compromising on the needed performance of water, oil and grease resistance. It is a more sustainably responsible option for packaging manufacturers and food retailers willing to help tackle the impacts of our food consumption habits.

The Appretan NTR range is therefore at the core of Nature Bites, a barrier system just launched by Archroma. In this new system, Appretan NTR can be combined with Cartacoat primers suitable for food contact that will seal the paper surface for further increased performance.

“Consumers are increasingly questioning how products are made, and expecting them to be harmless for themselves and their loved ones, and the planet”, comments Andy Bell, Head of Competence Center Paper Chemicals, who adds: “That is why it is critical that major food and beverage brands and retailers have a close look at their packaging supplier, and ensure that they work only with leaders in sustainable innovations such as Archroma. Appretan NTR and the Nature Bites system illustrate once again the commitment of Archroma to drive sustainable innovation in everything we do. Because it’s our nature.”

 

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