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Medica Labmed Forum Presents Innovations From the World of Laboratory Medicine

Medica Labmed Forum Presents Innovations From the World of Laboratory Medicine

Presenting the newest trends in in-vitro diagnostics for discriminating stages of disease, monitoring the course of disease and therapy, and for prevention

Since 2017, the field of laboratory medicine has been represented by a scientific event of high-calibre experts at internationally leading trade fair Medica in Düsseldorf. The event takes place in the trade fair area featuring laboratory equipment and diagnostics, where several hundred exhibitors participate each year. In spite of, or maybe especially because of the Covid-19 pandemic, the Medica Labmed Forum has been enjoying growing recognition within both academia and the industry. During Medica 2022 (14 – 17 November), the newest scientific findings from across the broad spectrum of diagnostic medicine will be presented again in Hall 1. As part of the programme by the specialist forum for laboratory medicine, renowned experts will be holding highly up-to-date lectures here on stage.

After having taken place on a completely digital platform due to the pandemic in 2020, the Medica Labmed Forum returned last year as an in-person meeting-point for international guests. The two scientific organisers, Prof. Dr. med. Georg Hoffmann and Prof. Dr med. Stefan Holdenrieder, both laboratory doctors at the institute for laboratory medicine at the German Heart Centre of the Technical University of Munich, have put together a total of eight sessions for this year and created an inviting, multi-faceted programme about notable trends within in-vitro diagnostics (IVD).

The motto of the opening day will be “Regulations and quality “. The second day of the event is dedicated to short lectures and interactive stage discussions about the newest trends in laboratory medicine. On 16 November, recently discovered biomarkers take central stage. The closing day on 17 November will showcase innovative developments within the life sciences.

Day 1: Regulations and quality

The event is opened on 14 November by a session organised by Prof. Dr. Astrid Petersmann, Medicine and Health Sciences at Oldenburg University, on the current challenges posed by regulations within laboratory medicine. This day of the forum is dedicated in particular to the European In-vitro Diagnostics Medical Devices Regulation (IVDR), which aims to markedly improve the standards of quality within the area of diagnostics to increase patient safety. As of May 2022, these regulations now apply to laboratory diagnostics as well and pose enormous regulatory challenges not only to manufacturers, but also to medical laboratories using proprietary assays – for example for specialised parameters – in practical patient care. “A statement such as ‘We’ve always been doing it like this’ will be unacceptable in the future,” says Prof. Petersmann.

In the same sense, this applies to quality assurance methods which have been established for many years, but the requirements of which have so far been formulated more from a perspective of technical feasibility than from a perspective of medical necessity. This is to change in the future, and Prof. Dr. Matthias Nauck, Greifswald University Department of Medicine, will present the first steps that have been established. For example, the analytical requirements for the parameters for diagnosis and treatment of diabetes mellitus were already substantially increased for the benefit of patients. This approach will also be the foundation for further development of the guidelines issued by the German Medical Association . Other than that, information about the quality of the examinations carried out by medical laboratories must become more transparent and concrete for the attending doctors. This aspect will be discussed in the part of the event titled “Quality assurance in patient-oriented laboratory medicine”. The session leader is certain that her referents will present and discuss a number of important innovations in the auditorium.

Day 2: Trends in laboratory medicine

Referred to as liquid biopsy or liquid profiling, diagnosis through nucleic acids circulating in the blood (CNAPS) has been talked about now for years. According to Prof. Dr. Stefan Holdenrieder, who will lead the session on “New insights in circulating nucleic acid diagnostics” on 15 November, this diagnostic technique is quickly taking the leap from a scientific research method to clinical practice – from “bench to bedside”. While already standard in non-invasive pre-natal tests, there are now large studies available on its use in tumour patients, including the selection and monitoring of targeted therapies, detection of minimal residual disease and early diagnosis of multiple types of tumours. CNAPS diagnostics are also coming into focus for the detection and classification of sepsis, as well as in monitoring after a transplantation. One important reason for this progress in development, other than the availability of sensitive high-throughput technologies, is a deeper understanding of the biology, structure and function of nucleic acids in the blood. For example, epigenetic and fragmentation patterns of DNA are being increasingly used not only to detect disease, but to trace the origin of the tissue. Dr. Abel Bronkhorst from the Technical University of Munich will offer an introduction to the newest discoveries within the basic science of circulating nucleic acids, the varied uses of which for clinical diagnostics will be then presented and discussed by proven experts.

The “perpetual issue” of Covid-19 will again have its own session this year, titled “Covid-19: The challenge remains”. Current challenges include the ongoing, astounding evolution of perpetually new virus variants and the resulting necessity for adapting diagnostics, therapy and the development of vaccines accordingly. Therefore, the first presentations will focus on detecting new virus variants, on immune response assays using antibodies and t-cell tests, and on approaches to developing a universal Covid-19 vaccine. As another challenge both for individuals and for society as a whole, long-Covid syndrome is also slowly beginning to gain attention. To better understand and treat this slowly spreading “disease after the disease” which affects millions of people worldwide – including those who had a mild course of acute illness – and which can cause long-lasting physical and psychological disability, a deeper understanding of the pathophysiology, new molecular diagnostic tests and specialised treatment centres for affected patients are necessary. Prof. Dr. Uta Behrends of the Chronisches Fatigue Centrum für junge Menschen (MCFC), the centre for chronic fatigue for young people at the Technical University of Munich, already has many years of experience with fatigue syndromes following various viral diseases. She will report on her work with an interdisciplinary team of specialists caring for children and adolescents with long Covid and ME/CFS.

Day 3: Rising stars: Emerging biomarkers in laboratory medicine

The two last days of the forum will take a look at the future of laboratory medicine and the life sciences. On 16 November, Dr. Verena Haselmann from the University Hospital Mannheim and a team of young, dedicated scientists will shine a light on the “rising stars” among the new biomarkers on the scientific stage. What is new and which methods are on the way to becoming standard care – both of these questions will be the focus of lectures and discussions.

The morning will be dedicated to technologies the potential of which for medical diagnostics and therapy is still under evaluation. This includes new methods of sequencing genomes and detecting complex epigenomic changes. Another topic is the application of these methods on single cells (single-cell omics) and the examination of blood samples by magnetic resonance imaging (MRI); a method which so far has only been routinely used for diagnostic imaging. All these methods have in common that their analysis produces immense volumes of data. Their evaluation poses the real challenge here. During the morning session, Prof. Dr. Jonathan Schmid-Burgk of the Institute for Clinical Chemistry and Clinical Pharmacology of the University Hospital Bonn will provide an introduction to high-throughput sequencing and novel applications in his lecture „Next-generation sequencing – what´s new?“. There will also be a discussion on the benefits of functional genetic mapping of hotspot genes.

In the afternoon, on the forum event stage in Düsseldorf, there will be an introduction of methods which are already closer to being ready for the market, but still subject to heavy discussion. This is where, for example, we will hear about detecting genetic aberrations of the embryo in the maternal blood (NIPT) or immune response assays on the cellular level, which are of importance right now when assessing the status of immunity during the Covid-19 pandemic. In his lecture “LDTs in the light of the IVDR – still an option for standard care?”, Dr. Maximilian Kittel of the Institute for Clinical Chemistry at the University Medical Centre and Medical Faculty Mannheim of Heidelberg University will ask the critical question whether and under which conditions lab-developed testing procedures will still be usable for routine diagnostics once the new IVD guidelines are wholly in place. Here one focus lies on the conflict inherent between personalised medicine and hospital performance records. The day will end with contributions to the evaluation of data through expert systems and proprietary laboratory developments (LDT = lab-developed tests), which need to pass the new IVDR regulations in order to become routine procedures.

Day 4: Innovative developments in the life sciences

On 17 November, Dr. Peter Quick, head of the Life Science Research work group at VDGH e.V., the German association of the diagnostics industry, will bring researchers and developers on stage whose work on RNA technologies, highly important for the development of vaccines, has gained widespread recognition.

Dr. Christian Dohmen, Ethris GmbH, Senior Director Formulation & Aerosol Research, will present the mRNA Therapeutics for Lung Diseases project, one of the RNA technologies discussed. The project advocates for a novel class of mRNA products to be used as therapeutics in the treatment of respiratory and infectious diseases. The Ethris technology platform will pave the way for a protein replacement therapy for rare lung diseases and for antiviral therapies.

In her lecture, Dr. Janine Altmüller, MDC for molecular medicine and head of the Genomics Core Berlin Institute of Health at the Charité, will look beyond to even more advanced, revolutionary research technologies in life sciences: single-cell and spatial omics. As all living processes in organs and organisms rely on the functions of their basic building blocks, single cells and their interactions, these methods are of immense value for research into the physiology of health and disease. Dr. Altmüller will offer a broad introduction of technological concepts for single-cell and spatial analysis, present advantages and limitations, and illustrate their effects by presenting several highly impressive case studies.

Gene therapy, genome editing and diagnostics – where does the journey lead? Toni Cathomen, professor for cell and gene therapy at Freiburg University and director of the Institute for Transfusion Medicine and Gene Therapy at the University Medical Center, will also take a look at the future. Programmable nucleases like CRISPR-Cas have hailed a new era within personalised medicine. Prof. Cathomen will explain the principles of gene therapy and genome editing, present examples of successfully applied gene therapies for diseases of the blood and the immune system, and discuss new technologies for editing the genome, which have noticeably enlarged the application spectrum of gene therapy. He will end his presentation with a closer look at diagnostic assays used to assess, and where appropriate ameliorate, the risks of genotoxicity. The audience is invited to share his vision of the future of this field.

Though the topics are complex, it is a hallmark of the four-day event that all presentations are short, precise and easy to understand, and that rewarding discussions with the audience can be held on stage. This concept has contributed significantly to the success of the Medica Labmed Forum as one of the highlights of the programme at Medica.

Medica Deep Dive: Diagnostics of infectious diseases

And for all those who would like a “warm-up” in the sense of a more in-depth preparation for their visit to Medica, the digital, English-language talk rounds “Medica Deep Dive” are ideal. They will start shortly and focus on particularly relevant trend topics in the healthcare sector. They will start on 22 September with a topic from the field of laboratory medicine: “Diagnostics of infectious diseases”, with a focus on current innovations and developments in the field of point-of-care diagnostics.

 

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Medica Health It Forum Focuses on Sustainability – The Value of Health It in Fighting Climate Change

Medica Health It Forum Focuses on Sustainability – The Value of Health It in Fighting Climate Change

Future hybrid health networking as the ideal joining of digital processes and the “human factor”

When it comes to current developments within international health IT, there is no way around the world’s leading medical trade fair at Düsseldorf and its accompanying programme, which offers further professional insights. Apart from the new products of the more than 4,200 participants from about 70 nations at Medica 2022, many of whom showcase health IT solutions, the Medica Health It Forum (in Hall 12), an integrated part of the trade fair, will from 14 to 17 November once more offer an overview of top trends in data-driven medicine, brought to you by highly acclaimed speakers hosting presentations and talks. “The focus this year is especially on how health IT can contribute to more sustainability in health care, and on optimising treatment workflows through improved interlocking of digital processes and the human factor,” says Christian Grosser, Director Health & Medical Technologies at Messe Düsseldorf, looking forward to this year’s agenda of the long established professional forum.

With the “Digital Patient Journey”, for example, an important topic is presented right at the start of Medica 2022 on Monday, 14 November, on the programme stage of the Medica Health It Forum. Moderator Prof. Felix Hoffmann, from the Apollon University for Health Care Management in Bremen, has already emphasised that processes in health care need improving. For example, a fracture of the lateral malleolus (ankle bone) usually would only need standard treatment. But if a patient arrives at the hospital late in the evening, it could happen that rather less experienced doctors have to carry out treatment, says Hoffmann. In this case, software-based check lists could render valuable support – for example those offered by Kumi Clinical. With the help of this software, clinical teams can plan, organise and synchronise treatment following a digital check list. From their arrival to check-ups in the aftermath of inpatient care, patients follow a digital treatment path, which is based on medical standards (SOPs) and can be flexibly adapted. All roles that share a part of the treatment process are integrated: doctors, care givers, service staff, hospital occupancy and discharge management, as well as medical controlling. This is to ensure that all participants are kept current at all times regarding the latest information, and the entire treatment path is followed correctly. The digital voice recognition software “voize” strives to contribute to the optimisation of these processes using digital speech assistants, and will also be represented at this forum’s symposium.

Therapy plans “powered by AI”

In a further symposium on Tuesday afternoon, 15 November, there will be a discussion of therapy plans based on artificial intelligence (AI). Alfa AI, for example, uses AI to create a therapy plan. The inherent intuitive application follows patients throughout the entire process, offers transparency as well as the prescribed training plan, including video lessons. In this way, Alfa AI brings together medical knowledge, long-term experience with sports and fitness, insights about proper nutrition and state-of-the-art technology.

There are, however, misgivings concerning “check list medicine”. According to Prof. Felix Hoffmann though, these are more a matter of the proper mindset. “How do I approach treatment?”, “When is a customised form of treatment really necessary?”, and “When can treatments be standardised and carried out following previously defined paths?” are important questions in this context. Hoffmann himself is a trauma surgeon, holds a chair at the Apollon University and is head of the staff unit for medical process development at the Klinikum Darmstadt hospital complex. For him, it is a given that digitalisation alone does not improve processes. The processes themselves also need improving. As a bad example, he cites the electronic prescription, which would in theory be unnecessary if medicines could be accessed directly, without going through a pharmacy. The pharmacists, however, probably beg to differ on this.

How medical networking can help save energy

Improving processes in health care could also help fight climate change – for example through beneficial use of information technology. “How can Healthcare become more sustainable with digital help? ” is a question that Armin de Greiff, technical director at the university hospital in Essen will ask during the expert panel at the Medica Health It Forum on Wednesday, 16 November, which is wholly dedicated to the issue of “Green Health & Sustainability”. “You cannot quite align furthering modern data-driven medicine with saving energy”, says de Greiff. However, he emphasises that using medical networking does save energy, for example by helping to avoid repeat examinations. Images and findings should not be printed, faxed, sent by post and above all not be transported by taxi. Rather, it should be possible to access them anywhere, at any time.

Armin de Greiff further describes the use of artificial intelligence (AI) for the generation of “virtual contrasts”. With appropriate training, networks are said to be able to predict different contrasts from simple data sets and thus save on time intensive examinations. AI could also help to reduce or eliminate the need for contrast agents during CT examinations. Saving on examination time while reducing radiation and contrast agents could be viewed from a sustainable perspective. On the other hand, this also means, according to de Greiff, that the persistent wish for the newest end user devices runs counter to sustainability. He goes on to explain in this context that the ever shortening product cycles serve to improve performance more than to reduce energy consumption. At the same time, he warns: “We are facing a paradigm shift.” With this, de Greiff calls attention to the fact that a higher energy consumption in data centres is not necessarily the same as overall higher consumption of energy. Virtualisation of the work place, e.g. through mobile working and by outsourcing applications with high processing demands to servers at a data centre, leads to a concentration of consumption, but not necessarily to raised levels of consumption overall.

Hospitals have room to improve when protecting the climate

Dr. Anna Levsen from the Deutsches Krankenhaus Institut, the German hospital association, also strives to improve processes. Her tech talk centres on “Circularity in the Healthcare Industry” on Wednesday, 16 November at 12:00 noon. Expanding on her presentation at the forum, Levsen calls attention to the strict limitations that hospitals face in their actions for sustainability and protection of the climate. However, she insists: “There is a big lever we can use here.” Levsen, too, sees the more sustainable use of, for example, large equipment as a chance. Outdated technical equipment is rather wholly renewed than repaired and kept in the system, as a circular economy would do. One solution could be a service contract with a manufacturer for medical technology, who could maintain the device in good working order. “Hospitals then would not own a device which they would have to throw away in the end, but they would own a contract according to which the company would provide the device, which would be kept usable as a high-quality product”, Dr. Levsen describes this approach. In this approach, manufacturers of medical technology would retain control over their devices.

The view must stretch to the entire energy and resource cycle

Auch There is also room to improve for many hospitals when it comes to food, reducing the number of surplus meals and avoiding waste. From a clinical perspective, technologies used in telemedicine within radiology for example, also offer options to reduce the need for resources. If patients must be taken care of at home while receiving telemedical treatment, they also need the appropriate devices and need training in how to use them – and this is often difficult to achieve as Dr. Levsen summarises: “A lot of things aren’t thought through.” Circular economy means that all processes from beginning to end would have to be thought through, and even single-use products could offer a more sustainable solution than expected, especially where hygiene is an issue.

We talk a lot about reducing carbon emissions, but we also have to talk about keeping resources in the system”, Dr. Levsen emphasises. For her, it is clear: “There is a need for action.” The main hindrance from the perspective of the hospital association are a lack of funds for urgently needed investments to protect the climate, which could also help to make the entire energy and resource cycle more efficient. Considering the current gas crisis, Levsen hopes that this will now set things into motion. Another challenge is to get hospital staff “on board”. As a rule of thumb, about ten percent of energy consumption can be saved by the users. Even taking the stairs instead of the lift or bringing your own coffee cup to work could help save resources.

On the final day, 17 November 2022, the forum will focus on general developments and their possible relevance with regard to health IT. Some of the topics in the programme are “Gender-sensitive medicine” and “New work & occupational health” as well as new developments in the area of artificial intelligence.

 

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Borealis Fibremod Used to Produce First and Largest-ever All-Thermoplastic Tailgate for the New Volkswagen Multivan

Borealis Fibremod Used to Produce First and Largest-ever All-Thermoplastic Tailgate for the New Volkswagen Multivan

  • Collaboration between Borealis and Magna yields largest, lighter-weight tailgate for Volkswagen with high design freedom
  • Innovative Fibremod portfolio helps industry reduce vehicle weight for lower carbon footprint
  • Borealis and Borouge, leading providers of advanced and circular polyolefin solutions, will showcase successful collaborations with industry partners at the K-Fair 2022 from 19 to 26 October

Borealis Fibremod is used to produce first and largest-ever all-thermoplastic tailgate for the new Volkswagen Multivan. The revolutionary tailgate of the new Volkswagen Multivan demonstrates how customer-centric innovation and collaboration can produce high-performance parts which can lower the overall carbon footprint of vehicles. The Fibremod portfolio of lighter-weight polypropylene (PP) compounds is giving Tier One suppliers and OEMs the freedom to design and manufacture more sustainable and lightweight solutions for leading automotive brands and their increasingly electric fleets.

Reduced weight thanks to innovative Fibremod compounds
Fibremod PP fibre reinforced compounds have a proven track record when it comes to lightweighting for interior, exterior, and under-the-bonnet automotive parts. The proprietary Fibremod long glass fibre reinforced polypropylene (PP-LGF) technology offers excellent fibre impregnation, flexibility in the use of various PP matrices, and the production of grades in customised colours. Fibremod compounds are cost-effective alternatives to conventional metals and engineering plastics-based solutions, as they are highly suitable for injection moulding processes. Moreover, Fibremod LGF compounds boast excellent flowability for smooth processing and low warpage.

The most recent new addition to the Fibremod portfolio has already demonstrated its value as a lightweight design solution and lower-density replacement for conventional engineering polymers. Fibremod GB416LF was specifically tailored for use in tailgate carriers and visible structural parts. As a high-flow, 40% fibre-reinforced material, it fulfils stringent emission and mechanical performance requirements. It also offers excellent surface aesthetics. Using Fibremod GB416LF can eliminate the need for additional surface finishing steps such as painting, making it an even more sustainable alternative.

Fibremod GB416LF used to make the largest-ever PP-LGF tailgate for the new Volkswagen Multivan
The new Volkswagen Multivan is a model with many “firsts”: the first VW bus based on the brand’s MQB modular design construction platform; the first completely redesigned VW Transporter in nearly 20 years; the first Transporter variant available as a plug-in hybrid (in Europe); and the largest-ever visible interior tailgate structure made using PP-LGF.

Leading Tier One supplier Magna used Fibremod GB416LF to ensure that a range of challenging demands on this part could be met. The tailgate consists of several components; the outer frame and the inner part made of Borealis Fibremod GB416LF, glued together to meet the design and load requirements. Painted exterior parts are glued to the tailgate structure as well. As a loadbearing part, the tailgate must be extremely robust in order to withstand static and dynamic loads. Part of the tailgate also lies in the vehicle’s interior, meaning compliance must be assured for emissions, fogging, and odour. Finally, to achieve overall weight reduction for the new Multivan – which weighs around 200 kg less than its immediate predecessor – the tailgate itself must also be lighter. Using Fibremod GB416LF enabled Magna to meet these challenges head-on.

Borealis mobility experts, some of whom are based at Borealis Innovation Headquarters in Linz, Austria, worked closely with Magna during the serial validation process of the PP-LGF tailgate. Borealis uses its sophisticated application testing methods and standards in tandem with its own modelling and simulation methodologies to offer comprehensive support to customers like Magna when developing and implementing new applications based on Fibremod. This can speed up the process by minimising the need for lengthy prototyping and physical testing.

“At Borealis, we use innovation and customer collaboration to accelerate the pace at which mobility becomes more sustainable. Our aim is to work with our industry partners to supply high-performance, polyolefin-based solutions that enable lightweighting and ultimately a lower carbon footprint for vehicles,” says Franck Lagoutte, Borealis Global Commercial Director Mobility. “We are pleased and proud that Fibremod is enhancing the sustainability of the iconic new Volkswagen Multivan.”

Accelerating sustainability in the Automotive Industry
When it comes to accelerating action towards greater sustainability in the automotive industry, the Fibremod portfolio is augmented by other Borealis and Borouge efforts in the circular economy sphere. For example, Borcycle grades with post-consumer recycled (PCR) plastics content are helping meet growing industry and end-user demand for high-quality materials that make better use of natural resources. Borealis was recently commissioned to supply Borcycle M GD3600SY-9502, a 30% short glass fibre reinforced PP with high post-consumer recycled (PCR) plastic content, for use in the centre console carriers in a leading OEM’s 2023 models.

Borcycle M is an ever-advancing technology for mechanical recycling that can transform plastic waste into materials fit for demanding applications. Borcycle C denotes material solutions based on chemical recycling; these are virgin-grade materials suitable for the most demanding applications when it comes to performance and safety. The grades in the Bornewables portfolio of circular polyolefin products are manufactured with renewable feedstock. These premium polyolefins offer the same material performance as virgin polyolefins yet are decoupled from fossil fuel-based feedstock.

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 Mobility solutions will be on display.

 

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3-Component Allrounder Cube: Compact and Efficient Cube-Mould Technology

3-Component Allrounder Cube: Compact and Efficient Cube-Mould Technology

At the K 2022 trade fair, a particularly innovative application in terms of cube-mould technology can be seen at Arburg stand 13A13, where an automated three-component Allrounder Cube 1800 will be producing a functional component from PP, TPE and POM using an 8+8+8-cavity cube mould from partner Foboha. The finished moulded part is produced directly in the mould thanks to assembly injection moulding. Mould filling, cooling, part removal by a six-axis robot and other assembly steps including capping in the gripper take place synchronously.

The K exhibit is a current customer project and a successful example of how maximum output can be achieved in a minimal footprint.

Compact cube, new turning technology
The compact Allrounder Cube 1800 three-component cube machine with a clamping force of 1,800 kN is particularly well suited to smaller cavity numbers. The exhibit works with three injection units in sizes 70, 170 and 70. At its heart is a compact cube from partner company Foboha, which is easily accessible from above. The 8+8+8-cavity tool with two index platens on each side of the cube features the new CITI technology. CITI stands for „Cube with Integrated Turning Inserts“, an index technology patented by Foboha.

Eight functional components can each be produced with the 8+8+8 cavity cube mould in a cycle time of around 9.5 seconds. First, a frame made of PP is injected on the moving nozzle side. The cube rotates 90 degrees, then the pre-moulded parts are turned 180 degrees by the CITI technology and, after another 90-degree cube rotation, a TPE seal is applied on both sides and a functional element made of POM is moulded on.

Final assembly directly in the gripper
A six-axis robot integrated in the control system removes all eight parts from the mould at the same time. Final assembly takes place directly in a gripper from Arburg’s partner Kiki in a five-step process that takes just four seconds, with no effect on the cycle time. The ready-to-use products are finally deposited on a conveyor belt.

Innovative cube-mould technology from Arburg
Depending on the circumstances, one Allrounder Cube can replace several conventional injection moulding machines and reduce the overall footprint by up to 75%. Innovative cube-mould technology significantly reduces cycle time. In addition to efficient high-volume production in the packaging and medical technology industries, compact cube machines such as the Allrounder Cube 1800 are also increasingly being used for the production of technical parts and smaller quantities.

 

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Photopolymer Film for Next-Generation AR Displays

Photopolymer Film for Next-Generation AR Displays

Bayfol HX is used in Sony’s prototype 360-degree holographic display

The Bayfol HX photopolymer film of Covestro helps the R&D of Sony Group Corporation to realize the prototype of a transparent display. This display delivers novel and fascinating visual experiences, as the images holographically generated within it appear to float freely in a transparent cylindrical column. Viewers can walk around the 360-degree display and look at the displayed image from all angles. Since the holographically evoked image is very bright – but the display is transparent at the same time – the image and background merge almost seamlessly. In the spirit of an augmented reality (AR) system, this transparent 360° holographic display expands reality. Because whatever is displayed in it seems to actually be there for the observer. Covestro is presenting this application of Bayfol HX at the K 2022 plastics trade fair, which will be held in Düsseldorf from October 19 to 26.

Bayfol HX consists of a transparent film as a substrate and a photoreactive layer that is optimized for the specific customer requirements. Bayfol HX gives designers the greatest possible design freedom. For example, it is flexible enough to be bent – as in the Sony application – so that it can completely enclose a cylinder. It has tailor-made optical properties to produce high-quality holographic images. Both the very high transparency of the photopolymer film and the image brightness it enables were key factors in Sony’s decision to use Bayfol HX for its development project.

“We spent a long time looking for the right material to realize our idea,” said Sony’s Yutaka Imai. The R&D General manager continues, “The project showed that Bayfol HX has excellent performance for AR applications.” It is imaginable that the prototype display technology will be used, for example, in museum showrooms and corporate presentation rooms – or in the home, for example, to accompany music with 360-degree videos.

“We are pleased that digital image information can now be presented floating in space rather than just presented in a frame, as it were, thanks to Bayfol HX and Sony’s innovative screen concept. In addition to automotive head-up displays (HUD) and head-mounted displays (HMD), this is another extremely promising AR application for our holographic films,” says Yuen-Ling Lok, Head of Commercial Operations Holographic Lightguiding at Covestro.

 

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“CMF Has an Opportunity to Really Understand All Those Different Consumers.”

“CMF Has an Opportunity to Really Understand All Those Different Consumers.”

Interview with Falza Khanani, Global Director of Color, Material and Finish design and Incubations, Dell

Chris Lefteri: Hello Falza. Thanks for joining me. So, a simple question to get us started. Tell me about your current role and what you do?

Falza Khanani: Sure, I’m the global director of color, material and finish design and incubations at Dell. The CMF team works across the entire portfolio of products at Dell, developing strategies, applying CMF design , and innovating new materials for the future. it’s tip-to-tail in terms of anything to do with a material’s surface. My job is the CMF portion of any product design at Dell.

Chris Lefteri: And what was your background before?

Falza Khanani: I’m originally an industrial designer. I worked in the footwear industry for many years, first as a designer, then focusing on material and color direction, and then I started to be curious about CMF and other product industries. I’ve worked in mobile phones, the trucking industry (where I developed CMF for interiors and exteriors), footwear, apparel.

Chris Lefteri: That’s quite a range of different industries you’ve worked for! What do you feel is the connection between them all, and how that applies to Dell and its products?

Falza Khanani.

Falza Khanani: I moved around because of CMF. My curiosity just kept growing because CMF is so integrated into design, but also the process of collaboration is different across industries. I don’t think consumers or users or people that buy things think about CMF separate from the actual product. Yet it’s the one thing that people interact with: it’s a visual interaction, a tactile interaction, it’s how you’re intersecting with the actual product in very tangible ways. And so if you step back a bit and think about human perception, and emotions, and what causes desire, CMF has an opportunity to really understand all those different people, different consumers, different desires and either bring them to a new place with a new experience, or build on what they love and keep delivering that.

Dell has so many different types of products with different materials in their portfolio. It’s an interesting design challenge: you can start to design these CMF interactions, or build on the Dell customer base so that the customers are getting to know Dell for the subtleties that cause emotional reactions, like how the product feels, or the technical aspects which might not even be visible – like making products more carbon neutral because of the materials being chosen on the inside.

There’s so much to build on in terms of human connection with the actual tech products and it goes beyond just the performance and quality they deliver. So it’s the ability to think about humans, and their interaction with the product, whether it’s through technology, or surface, or how a color inspires or makes you feel. It’s an interesting design problem to keep approaching in different ways, yes.

Chris Lefteri: And it’s different for each of your product categories? Different values?

Falza Khanani: Exactly. We have different brands so they have different qualities that consumers connect to. Even thinking about products that are supposed to be very affordable and accessible, or others that should enable productivity. I think that’s where CMF design often gets overlooked: you can always do a lot with very little, and there’s also things you don’t notice that have been intentionally considered. There is always a different design and innovation problem to solve. Instead of “Oh, I can’t use this material or color”, it’s like: “How can I make the minimal choices to make just as interesting an experience?” Choices the designers make significantly change the perception and experience of the final design.

Chris Lefteri: And can you give me an example of some of those experiences or qualities?

Falza Khanani: For example, we have the new XPS 13 series of notebooks; they are a high performance, minimal design product, mostly made of low carbon aluminium, meaning the material are produced using hydro power. This means it has a different story in terms of being a material that appeals to people when they’re buying a top tier device: it’s like an additional kind of value. There’s an emotional value that connects to a rational purpose of sustainability. On the same topic of materials and sustainability, we have some products that are exclusively moulded plastic, with a high amount of recycled content; that product has a different experience and accessibility, yet the details of tactility and materials is equally thoughtful.

Chris Lefteri: What do you mean by ‘exclusively moulded plastic’?

Falza Khanani: We have the education focused 3000 series, that’s made exclusively of plastic. So in the past, if you had a plastic object of any product category you usually wanted to cover it. Plastic seemed really undesirable and cheap, it didn’t have any kind of value. You tried to paint it with metallic paint or you put a film on it that made it look like something else. We’re now actually choosing to explore and talk about the honesty of this material. We’re thinking things like: what else can we do to the surface so that this is an elevated material experience, both for the consumer and for manufacturing?

So the XPS and the 3000 series are wildly different in terms of pricing, as well as from a functioning perspective – we’re talking opposite ends of the product spectrum – but they can still both be equally thoughtfully designed. You need to consider the end user experience and then integrate that with the material choices. A low-end product or a lower price doesn’t necessarily mean it’s a lower-end experience on the surface.

Dell.

Chris Lefteri: Is there a particular product and a detail on that product that you want to highlight?

Falza Khanani: We have the Latitude 3000. The Latitude is our commercial portfolio and then the 3000 model is generally used in a pretty high-volume way across the globe for things like education. So just because it’s going to be used by students and banged around and reused again and again, and made in the millions, that doesn’t mean it needs to be basic and unconsidered. So with the Latitude 3000 we added a little speckle to the resin, we got rid of paint, we developed a micro texture to give the surface a better quality, so it doesn’t look so flat, it has a bit more dimension, it has tactility – a tiny bit of expression. And then the material itself has a pretty high PCR content (and uses a bio-based TPU) so at the same time we’re building some sustainability into it as well. So that’s a pretty thoughtful product that would have been considered “low end, high volume” in the past. I just think those names and categories aren’t relevant anymore. It’s more about the different experience that a consumer is using the product for, and therefore we’re designing a different CMF experience and function.

Chris Lefteri: You talked about experience of plastics. How do you think the experience, and perception, of plastics has changed from when you were first working in a different industry to where it is now? Your perception, I mean.

Falza Khanani: When I first started working in design, I was in the footwear industry and I was sourcing a lot of materials. The best materials were always from Europe. They were always something like a leather, or a natural fibre, or linen, or silk. Then plastics, or synthetic materials, started to find their way, their own place. They got their own stereotype, like being “an athletic material”, for example, for footwear, or “it’s very cheap and basic” (when you think about those plastic cups and dishes). Basically, it was a throwaway material that had durability. And then there was always the perception that plastics came from Asian manufacturing, and maybe back then it wasn’t so much about original ideas, they were really just about “copying” materials. Making a fake version of soap, for example. I think plastic was always known as the “fake material”, right?

If you come to the present moment in time, and I think plastics are being used in so many different product applications, there are so many different types of plastics. You can build a plastic completely from recycled material, you can weave textiles, make recycled bottles or fibre. So there’s now the “reuse” case. There’s also changing the perception from “fake material” to a material that has its own authentic honesty of texture, or whether it’s a gloss… And then there’s color, of course. When plastic first came out, before I was born, probably before you were born!, when it was like “fantastic plastic”, it was basically Bakelite products that were all about color and shape and moulding things into anything, as opposed to the handmade product. So it started out as an amazing, cool material, for high-end jewellery and dishware. But then it became so prolific and simplified – and affordable! – so it lost its value.

There’s now so much innovation around, plastic is just a whole different thing, you can’t even say one material is plastic. There are so many performance functionalities, so many different activities, the ability to incorporate color or visual noise in the actual resin (versus adding something topical to cover it). I’m thinking about different moulding processes, in terms of improving the surface, or how you can create a blended look using different colors: I’m thinking about, for example, a marble effect, how you design your injection moulding tool or add biobased materials for a textural or visual story.

So plastic has really just moved into a whole different space of sub-categories, with its own really high-end tier too.

Chris Lefteri: Let’s talk briefly about sustainability without going into too much depth here. Dell has a record of doing some really important projects around reclaimed ocean waste, packaging and recycled carbon fibre. How do you even begin to break that discussion down into a manageable chunk when you’re looking at the hardware? Do you say, “this time we really want to focus on circular materials, circular plastics”, or “this time we want to focus on longevity”? Do you break it down in those terms?

Falza Khanani: The way I approach sustainability – and we do have a sustainability team of engineers in the design team – is that it depends on the body of work or the project: you have to consider the most important thing about that particular product and then choose its path of sustainability. The key question is: is this going to be lowering the carbon footprint or this is about creating something with recycled materials? So, our Concept Luna, for example, was about longevity, service, disassembly. You can’t really put just one sustainable parameter across so many different products and product experiences. You have to think: what’s the biggest impact you can make with each product or product category? If it’s all moulded plastic, for example, then looking at your PCR content is really important if the product is super heavy. You start to look at the material and design choices: can we make this lighter so that when you ship it, it really lowers the carbon footprint (weight being such a big factor in terms of increasing carbon footprint when you ship things)?

We all have different approaches to sustainability. So it’s really about looking holistically at the different ways you’re creating the product, right? The consumer desire, the business case, the function, the volume, is it a big thing?, is it a small thing? It’s a whole different opportunity of thinking about design very differently.

Take power usage, that’s a really big thing. If we create servers, the fact is servers are mostly made of steel and most steel is already recycled throughout the globe. So it’s really about energy usage. Because a large datacenter full of servers is obviously going to use a lot of energy, and it’s going to be there for a really long time, so the materials have to endure longevity. But it’s also going to use a lot of power. So that would be a different approach. We approach it differently each time.

Chris Lefteri: I’d like to finish on a simple question: do you have a plastic product you most admire? It could be something you worked on personally, or it could be something that you think was just a fantastic piece of design in plastic.

Falza Khanani: I actually collect vintage Bakelite bracelets and brooches. I’m probably paying way too much for them when I find them online! You never think “Oh, I’m gonna wear plastic” but it’s really interesting what they were using this material to design with. Some are like intricate insect bugs that are brooches, others are trying to mimic things like wood and tortoiseshell, with a rough design. I also love stretchy clothes – and of course vintage ’50s stuff – when everything was plastic: it was polyester and vibrant colors, the playful future of everything synthetic!

Chris Lefteri: It was very celebratory, right? It’s interesting, you talk about the jewellery, I take from what you said that it was about replicating something else – i.e. plastic trying to look like wood or another natural material. And then in the ’60s, it became much more of a celebration of its own material?

Falza Khanani: Yeah, I mean the Bakelite dishes. They’re really beautiful because you have different wall thicknesses, and then there are some very geometric shapes. In the past, in the way the products were manufactured, there were limitations to form and shape and edge and radius, and I think that’s what you see in a lot of that early “fantastic plastic” design. You had mid-century design, which was interesting, right?, with these modern new shapes of things, and I think those were influenced a lot by what you could do with manufacturing, particularly plastic.

 

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Machine Communication: OPC UA as The Linguistic Basis

Machine Communication: OPC UA as The Linguistic Basis

Interview with Thorsten Kühmann, Managing Director Plastics and Rubber Machinery, VDMA e.V.

Communication is key, and this also applies to machines, since the ability of machines to communicate has economic advantages. However, this first requires a common linguistic basis, because then the machines can be used particularly efficiently. Thorsten Kühmann from the German Engineering Federation VDMA explains in an interview what OPC UA means in the context of M2M communication and why it is the future of production.

Mr. Kühmann, what is OPC UA?

Thorsten Kühmann.
Thorsten Kühmann.

Thorsten Kühmann: OPC UA (Open Platform Communications Unified Architecture) is the global language of production. Simply put, it is about machines being able to communicate with each other in the same language. Only this enables machine-to-machine communication across manufacturers and internationally.

Why is OPC UA indispensable for the plastics industry in the future?

Kühmann: It is indispensable because the production language creates a decisive prerequisite for being able to offer intelligent machine systems. Intelligence is created by algorithms that can be generated from a large amount of data. The basic prerequisite for this is that data is collected reliably along the process chain. This requires a reliable, standardized data flow, and that is exactly what the OPC UA-based production language is designed to deliver.

What can the technology already do today? Where does the industry still want to take it?

Kühmann: OPC UA provides the technical framework for the new language; it is, so to speak, the grammar of a new language. Within the industry, we are working internationally on the definition of interfaces for the respective application, the so-called specifications. This is then comparable to the words of a language. In the area of injection molding, extrusion and peripherals, we have already made good progress.

To what extent will this topic also be present at K 2022?

Kühmann: It will be present through a variety of use cases. Visitors will be sent on the OPC UA journey with their smartphones and will be able to read out defined data from around 70 machines exhibited at K. In the VDMA Dome, we will also install a control panel with which visitors can reach all connected machines. This will give them an impression of cross-manufacturer machine-to-machine communication.

Are there exhibitors who are already successfully using OPC UA?

VDMA e.V.

Kühmann: At K alone, there are more than 40 exhibiting companies from Europe, Japan, China and Canada showing the applications on site!

What experience reports do you get from these users?

Kühmann: Experience shows that customers are increasingly interested because networking on the store floor offers direct benefits: Production becomes transparent from day 1 and thus can be controlled incorruptibly and reliably. Especially in the current climate, with high energy and material costs, processes must be optimized along the entire chain. For example, it simply makes no sense to preheat material continuously when it is perfectly sufficient to do so on demand. In addition, there are requirements for the use of recyclates and the CO2 balance. The processes can only be precisely controlled and made transparent through digitization.

What is missing for OPC UA to be fully functional?

Kühmann: The data flow itself works with OPC UA; now many specifications still have to be created to connect all machine systems!

The next crucial step will then be data collection and processing beyond the store floor. So it’s all about interoperability between companies. This is necessary to create intelligent and self-controlling machine systems. In addition to the technical prerequisites, the trust of customers plays a decisive role here. Only when they are willing to supply data on a large scale, smart services can be created via algorithms. This can then lead to self-learning and self-operating machines. In times of a shortage of skilled workers and high costs for energy and materials, these are exactly the right answers. Initial considerations are moving in the direction of a federal structure for data collection with governance created by the industry. At this point, the VDMA is in exchange with the federal government under the keyword Manufacturing-X!

 

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Coperion Presents Complete Plastics Recycling Solutions at K 2022 Making the Plastics Economy Even More Circular

Coperion Presents Complete Plastics Recycling Solutions at K 2022 Making the Plastics Economy Even More Circular

Complete systems for industrial-scale plastics recycling from a single source – the recently completed merger between Coperion and machine manufacturer Herbold Meckesheim makes it possible. Coperion, technology leader in extrusion and compounding, bulk material handling and feeding systems, brings its own expertise in the field of recycling together with that of Herbold Meckesheim, specialist in the mechanical recycling of plastic and plastic waste, forming a new Recycling Business Unit. This new Business Unit makes innovative process solutions possible that represent a new benchmark in the efforts towards a circular economy in the plastics industry. Coperion is providing a first look at its integrated recycling solutions at K 2022 (19-26 October 2022, Dusseldorf) at its booth 14/B19, at its Recycling Pavilion in the open-air fairgrounds (CE09), and at Herbold Meckesheim’s booth 9/B34.

The newly created Recycling Business Unit is able to offer modular system and plant solutions that combine the complementary technologies of Coperion and Herbold Meckesheim to benefit customers. From mechanical processing – shredding, washing, separating, drying and agglomerating of plastics – to bulk material handling as well as feeding and extrusion all the way to compounding and pelletizing, the systems that both companies have developed together cover the entire process chain for reclaiming plastics. Moreover, the plastics industry will profit from this cumulative expertise thanks to their combined global sales and service network.

Experience PET Recycling Live

PET recycling is one example that illustrates how Coperion will be able to implement a complete system for plastics recycling in the future. As the plastics industry makes advances towards a circular economy, PET plays an ever more important role due to its increasing use in disposable and reusable bottles and its recovery through deposit systems, along with other factors. This material possesses outstanding recycling properties, regardless of whether it is to be recycled in bottle-to-bottle, bottle-to-film/sheet, or bottle-to-fiber processes, or whether it comes from other product streams.

Complete PET recycling solutions from Coperion offer throughput performance of up to ten tons per hour. The quality of PET recyclate manufactured using Coperion recycling technology and decontaminated in an SSP (Solid State Polycondensation) reactor is so high that it is approved by the U.S. Food and Drug Administration (FDA) for direct contact with food.

One unique feature is that virgin material and various recyclates – such as regrind, agglomerates, or flakes – can be processed together, even if they exhibit different IV (Intrinsic Viscosity) values. Compared to conventional PET recycling procedures, Coperion’s solutions save on operation and energy costs and create less logistic efforts. Visitors to K can see and experience key components of this process at the Recycling Pavilion CE09/open-air fairgrounds and at Herbold Meckesheim’s booth 9/B34.

SML 60/100 SB 2 Granulator

This is a granulator used for crushing PET bottles and is suitable for wet operation. One unique feature that it offers is horizontal force feeding using screw feeders. The granulator allows for space-saving installation and easy material feeding. Up to two tons of polyolefins or more than one ton of film per hour is processed.

T 2016 PA Mechanical Dryer

This mechanical dryer is suitable for various materials such as film, regrind, and mixed and rigid plastics. Thanks to its optimized design and the position of the exchangeable, wear-resistant paddles, it achieves up to 50% higher drying performance than its

HV 70 Plastcompactor

The high-performance HV 70 Plastcompactor from Herbold Meckesheim processes material in continuous operation between one rotating and one fixed compactor disk,
each equipped with screwed-on and easily replaceable kneading bars. Since the material leaves the compactor zone within a fraction of a section, the thermal impact
upon the plastic is very low. The process is regulated using two parameters – the screw speed and the distance between the disks.

FLUIDLIFT Ecodry

The FLUIDLIFT ecodry process dries the regrind while it is being conveyed to the extruder. A flash dryer specially modified for recycling regrind removes the moisture remaining after the washing process. Moisture content is significantly reduced which optimizes the energy consumption of the downstream process and leads to improved end product quality.

Smart Weigh Belt (SWB) Feeder

For feeding flakes and fiber, a Smart Weigh Belt (SWB) feeder is used. This low-headroom gravimetric feeder can feed large quantities of bulk material into the extrusion process at high accuracy, even at low and variable bulk densities.

ZSK Twin Screw Extruder

Coperion ZSK twin screw extruders are the heart of the plastics recycling process. With their high-performance processing properties and high devolatilization performance, ZSK twin screw extruders are suited to energy-efficient recovery of plastics of all sorts. The ZSK extruder features high end product quality with gentle product handling, short residence time, intensive devolatilization, and outstanding dispersion with concurrently high throughput performance. In the Recycling Pavilion CE09/ open-air fairgrounds, Coperion is showing a ZSK 58 Mc 18 twin screw extruder with a 58 mm screw diameter together with a melt pump, screen pack changer, and an underwater pelletizer.

Product Discharge

Diverters, melt pumps, and screen pack changers follow the extrusion step. Depending upon whether pellets, fiber or film are to be manufactured from the PET, Coperion
provides water baths and underwater pelletizers, fiber spinning pumps or film stretching lines as part of their complete solutions.

New Recycling Innovation Center

The start of construction on the state-of-the-art Recycling Innovation Center in June of this year demonstrates the importance of the topic of plastics recycling for the market leader in extrusion and compounding technology. This new test center for recycling applications is located in immediate proximity to Coperion’s existing test center for bulk material handling at its Niederbiegen/Weingarten production facility in Germany. In the future, every major step of the plastics recycling process can be tested under production conditions and results can be examined by customers down to the smallest detail prior to making an investment.

 

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Kisuma Gets Set to Tell the World About Landmark Sustainability and Product Innovation Progress at K 2022

Kisuma Gets Set to Tell the World About Landmark Sustainability and Product Innovation Progress at K 2022

Kisuma, the world’s largest producer of synthetic hydrotalcite, is gearing up to showcase an enormous array of sustainability progress and product diversification at the upcoming K 2022 show in Düsseldorf upstairs in Hall 7/A28.

The week-long event, starting on October 19, is the world’s leading business platform for the plastics and rubber industry. Stakeholders from around the world will converge to discuss key innovations, trends and challenges, as well as take the opportunity to forge new relationships and set out their visions for the future.

“Our organization has been historically low-profile about our contributions to customers, industries and most importantly to the global communities in which we service. Walking the walk is embedded in our culture. It’s our duty. We do it every day, pragmatically and proudly,” comments Marlus Ferretti, Chief Operating Officer at Kisuma Americas.

“The K 2022 has a particular significance to Kisuma, where many novel technologies and innovative solutions in polymer processing will be revealed. As per our legacy, we are not stepping out of character in big PR announcements. For that, we invite you to visit our booth at Hall 7 – level 1 – A28. Your time will be well spent.”

Kisuma’s K Show booth A28 in Hall 7.

This year marks the first time that Kisuma will have a booth at the K forum. It promises to be a bustling and busy week, the company arriving in Germany with many stories of progress to tell, as well as one or two hints at what lies ahead in the pipeline.

Making sustainable gains
One such story centers around decarbonizing heavy industry through carbon capture.
Since 2010, Kisuma has been heavily involved in a project led by a TNO-backed platform to develop Sorption Enhanced Water Gas Shift (SEWGS) technology – a solution which can be used for reactive separation of H2 and CO2 from syngas sources.

The company has been developing and producing the sorbent used in SEWGS, which is being successfully demonstrated on an industrial scale at Swedish Steel company SSAB. Its initial pilot project named STEPWISE, has been operating at a cyclic capacity of capturing 14 tons of CO2 per day, with plans to expand this by a multiple of five by 2024.

SEWGS will allow industries to eliminate hard-to-abate CO2 emissions and produce blue hydrogen at lower costs than previously possible. So far, we have demonstrated a 30% cost saving versus the next best carbon capture alternative, the highest purity of carbon capture (97.5%) and successful production of blue hydrogen at 400°C.

“Subject to further demonstrations at technology readiness level 8 across 2026 and 2027, we anticipate being ready to scale up to full commercialization by 2028,” added Tim Hauck, General Manager of Sales and Marketing at Kisuma. “We remain open to connecting with new partners on this project and welcome any conversations and enquiries at K 2022.”

In other developments, Kisuma is fulfilling a growing demand for tin stabilizer replacements with ALCAMIZER, an effective non-toxic acid scavenger for PVC that delivers numerous benefits such as reduced exposure to harmful substances, improved weathering and improved recyclability at end of service life.

Meanwhile, the company continues to make impressive energy efficiency strides across its production processes. Since beginning full operations in 1999, Kisuma has reduced CO2 emissions per ton of product by 55% – a period in which it has also doubled plant capacity.

Non-stop innovation
Additionally, the company has laid the foundations for future waves of innovation. It has just invested in a new, state-of-the-art R&D lab which will support the diversification of product portfolios based on market insights.

In June 2022, Kisuma opened a new facility dedicated to running pilot projects. Designed to bridge the gap between small laboratory testing and bringing products through to commercialization, it will be able to process small and medium batch sizes to validate and optimize product quality as production volumes scale.

On the product development side, DHT-4 is the trusted acid scavenger designed to replace conventional (often heavy metal based) scavengers in BOPE films.

“This is the strongest acid scavenger available on the market,” said Mathijs Preenen, Business Development Manager at Kisuma. “It irreversibly scavenges acidic catalyst residues through an innovative interlayer capturing process. “Replacing the traditional acid scavenger with DHT-4C allows converters and brand owners to achieve superior surface properties of their BOPE layer, leading to stronger metallization of the film and enhanced surface printing capability.”

Unveiling their newly upgraded R&D laboratory.

Crucially, DHT-4 also represents a fully recyclable solution, enabling customers to enhance their sustainability credentials by introducing completely circular BOPE film products to the market.

Looking ahead to a bright future
Kisuma will not be able to reveal everything at K 2022, however.

Some initiatives remain in development, including the company’s ongoing partnership building with academia and hospital networks to see how its products can be used in potential cancer treatments. Meanwhile, the company is lining up sizable investments into more plastic recycling solutions. Hauck commented: “We invite visitors to K 2022 to come and see us upstairs in Hall 7/A28 to learn more about our plans in these areas.

Kisuma’s K Show booth A28 in Hall 7.

“Whether it’s progress already made or exciting innovations and developments in the pipeline, Kisuma sees a lot of opportunities for the future. We will continue to serve our customers with reliable products that have stood the test of time, and we will also work on the next potentially game-changing solutions for worldwide problems. “We are in a solid position to move forward by investing in our brand, which includes finding the exceptional talent and resources we need to keep moving.”

 

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Safely Packaged: Recyclable Reusable Transport Box Protects the Environment and Sensitive Goods

Safely Packaged: Recyclable Reusable Transport Box Protects the Environment and Sensitive Goods

Interview with Prof. Rudolf Pfaendner, Head of the Plastics Research Department at the Fraunhofer Institute for Structural Durability and System Reliability LBF

Packaging materials are often not very sustainable. This is partly because they are only designed for single-use transport. Researchers in the Fraunhofer LBF’s Plastics department have taken this fact as an opportunity to develop an alternative. With their recyclable reusable transport solution for sensitive goods, the climate, the environment and resources can be protected.

Prof. Rudolf Pfaendner, Head of the Plastics Research Department at the Fraunhofer Institute for Structural Durability and System Reliability LBF.

Prof. Pfaendner, congratulations: together with the Darmstadt-based start-up Berges GbR, you and your colleagues have developed a fully recyclable reusable transport box. How did that come about?

Prof. Rudolf Pfaendner: Sustainability is one of our core topics at the Institute, namely sustainability in the entire development – from the design of the material to the design of the application to high-quality material recycling. The latter means developing a product whose first application is followed by a second, third and so on. The latter means developing a product whose first application is followed by a second, third, etc. application and which can be completely recycled at the end of its life cycle. The fact that it has become a transport box came about through an internal discussion about ordering goods on the internet. People who order on the internet still usually produce a lot of waste – for the yellow bin through cushioning material such as polystyrene flakes and bubble wrap, for the waste paper bin through the cardboard box and corrugated cardboard. This has to be better in view of the CO2 footprint, the need to save energy and the scarcity of raw materials, we thought to ourselves and started to develop a sustainable transport box with equally sustainable padding material.

How did you get there?

Pfaendner: For one thing, we were able to draw on our extensive experience with the entire range of plastics that exist today. On the other hand, there are properties that our product multiple transport box must necessarily achieve or have: mechanical properties, high durability and more. For example, we tested the durability of the outer shell of the box in the laboratory by accelerated ageing, the weather resistance by UV light tests. The air cushion, in turn, had to have a certain stability and also withstand stretching over several hundred percent. Many laboratory tests were necessary until we found the material of choice.

The innovative transport box with inflatable air cushion can be customised and fully recycled. Copyright: Fraunhofer LBF, Raapke

The development has been successful. What makes it stand out?

Pfaendner: Certainly above all that the transport box and the cushioning material inside are made of the same material. This is an ideal mono-material for recycling and the box can be recycled in one step. The material is HDPE – High Density Polyethylene, the commercially available standard material. However, the box and cushioning material could also be produced from PLA – the renewable raw material polylactic acid. But the industry is still closer to PE.

What was the biggest challenge?

The new transport box with inflatable inner cushion. Copyright: Fraunhofer LBF, Raapke

Pfaendner: The challenge was certainly to develop cushioning material in a sustainable form. We succeeded with the airbag. It is a re-inflatable air cushion that can be inflated to different degrees via a valve, for example with a compressed air gun, and then wraps itself protectively around the packaged goods. In this way, a wide variety of objects can be safely packed – from sensitive machine parts to works of art. Up to now, the latter have often been transported in boxes produced especially for one-time transport, which are also foamed. Not very environmentally friendly.

What is the next step in your development?

Pfaendner: The box already has utility model protection and a patent application. We have shown its technical possibilities and proved that it works. Now we are looking for a partner who will produce it in larger numbers and test it in practice. Logistics and shipping companies that pack things in different quantities and dimensions would be suitable. But what would probably be closest is someone who has to continuously move machine parts between company location A and company location B, for example.

And when the “end of life” of the transport boxes is approaching and they are no longer functional, do they then go into the yellow bin?

Pfaendner: Oh no, they are far too good for that! Ideally, their owners collect them until a few have been gathered, have them shredded as recyclate stream and make new boxes out of them. Properties such as durability may then have to be improved with additives. We know these and they can easily be added.

 

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