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ALPLA and PTT Global Chemical Realise Thailand’s Largest Plastics Recycling Plant Equipped With State-of-the-art Technology

Petra Löwer (Germany)
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ALPLA and PTT Global Chemical Realise Thailand’s Largest Plastics Recycling Plant Equipped With State-of-the-art Technology

ALPLA and PTT Global Chemical Realise Thailand’s Largest Plastics Recycling Plant Equipped With State-of-the-art Technology

Start of production at the Envicco joint venture in Rayong province

Following 18 months of construction and installation, the ALPLA Group and PTT Global Chemical are opening the state-of-the-art Envicco recycling plant in Thailand. With an annual production capacity of 45,000 tonnes of recycled Pet and HDPE, it is one of the largest recycling plants for these plastics in Asia. With this plant, the two companies will strengthen the region’s circular economy and supply the growing markets with high-quality recycled material.

Thirty thousand tonnes of recycled, food-grade Pet and 15,000 tonnes of recycled HDPE – the packaging and recycling specialist ALPLA and the chemical company PTT Global Chemical (GC) have realised Thailand’s largest plastics recycling plant of its kind. After around 18 months of construction, production is set to start at the Envicco joint venture. Located in an economic zone on the coast of the south-eastern province of Rayong, the plant is equipped with the latest recycling technology and production lines to manufacture high-quality plastic recyclates with approval from the USFDA.

‘Built in record time thanks to the excellent collaboration with GC, this highly modern plant is an important part of our recycling activities in Asia,’ said ALPLA Chairman Günther Lehner during the grand opening on 13 September. The opening was also attended, among others, by Kongkrapan Intarajang (Chief Executive Officer and President, GC), Dietmar Marin (ALPLA Managing Director Recycling) and Bernd Wachter (ALPLA Corporate Director Circular Economy & Recycling Asia).

‘Demand for recycled, sustainable packaging materials is rising sharply in Southeast Asia, and high-quality plastics have a key role to play here. With this new plant, we are now applying our many years of expertise in the treatment and processing of packaging made from post-consumer recycled resins in Thailand,’ explains Bernd Wachter. ‘This joint venture is a truly circular, eco-friendly project creating a comprehensive value chain for plastics in Thailand and is an excellent example of the worldwide use of Austrian green tech know-how,’ adds Georg Weingartner, the Austrian Commercial Counsellor in Bangkok.

Successful partnership
ALPLA contributes more than 25 years of recycling experience to the joint venture. It will supply its production facilities in Asia with recycled material and is also fostering the circular economy at the local level. With the plant, majority shareholder GC supports sustainable development in the region, moving it towards resource-conserving business and lifestyles.

‘Today, GC is proud to reveal that Envicco is ready for commercial operation. Used plastics within the Kingdom of Thailand will make up 100% of the raw materials processed by Envicco’s cutting-edge production technologies to transform used plastics into valuable products,’ says Kongkrapan Intarajang. ‘The Envicco production plant is part of our long-term circular economy strategy to fully realize GC’s value chain. It also has the added benefit of creating jobs within the community while simultaneously aligning with the Thai government’s Bio-Circular-Green Economy Model.’ The Envicco team will comprise approximately 180 employees at the start of production.

Significant expansion potential
The 30,000-square-metre plant is on a plot of land measuring a good 90,000 square metres at the Map Ta Phut Industrial Estate. There is, therefore, also space for future capacity expansions. ‘We have long-term plans to promote the bottle-to-bottle cycle not only here in Thailand, but across Asia and other regions around the world. Carbon emissions and waste can be reduced through optimised resource consumption,’ emphasises Dietmar Marin.

Global expansion of recycling activities
In early 2021, the ALPLA Group announced that it would invest an average of 50 million euros a year until 2025 in the ongoing expansion of its recycling activities. In particular, it plans to globalise its activities in the area of high-quality recyclates to close the materials cycle in as many regions as possible. In total, the annual production capacity of ALPLA’s recycling companies and cooperations around the world amounts to approximately 203,000 tonnes of rPet (recycled Pet) and 74,000 tonnes of rHDPE (recycled HDPE).

 

 

 

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Dow and Mura Technology Plan to Locate Europe’s Largest Advanced Recycling Facility at Dow’s Site in Böhlen, Germany

Petra Löwer (Germany)
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Dow and Mura Technology Plan to Locate Europe’s Largest Advanced Recycling Facility at Dow’s Site in Böhlen, Germany

Dow and Mura Technology Plan to Locate Europe’s Largest Advanced Recycling Facility at Dow’s Site in Böhlen, Germany

  • Facility expected to be the largest of its kind to date in Europe, and the first of its kind in Germany
  • Part of a goal for multiple planned units across Europe and U.S. to add as much as 600 KTA of advanced recycling capacity by 2030, enabling greater supply of recycled plastic content to major brands across the globe
  • Mura’s Hydro PRS advanced recycling process is unique, as it uses supercritical steam to convert most forms of plastics, which have previously been deemed ‘unrecyclable’
  • Represents a key contribution to Dow’s climate and circularity target to enable 1 million metric tons of plastic to be collected, reused or recycled by 2030
  • Dow’s support of Mura Technology enables Mura to build on its multi-year pipeline of planned projects, the first of which will be sited in Teesside, U.K. and is on track to be fully operational in 2023

Dow (NYSE: Dow), the world’s leading materials science company, and Mura Technology, the global pioneer of an advanced plastic recycling solution, today announce the next step in their ongoing collaboration to help solve the global plastics waste issue and advance circularity. Mura plans to construct a new facility at Dow’s Böhlen site in Germany – the latest in a series of planned facilities across the U.S. and Europe to rapidly scale advanced recycling of plastics – and the first expected to be based at a Dow site. This project is targeted for a final investment decision by the end of 2023.

Mura’s new Böhlen facility in Germany, which is expected to be operational by 2025, would deliver approximately 120 kilotons per annum (KTA) of advanced recycling capacity at full run-rate. This and the other planned units expected to be constructed across Europe and the U.S. would collectively add as much as 600KTA of advanced recycling capacity by 2030 – and position Dow to become the largest consumer of circular feedstock for polyethylene production globally.

“The continuation and growth of Dow and Mura’s collaboration is another example of how Dow is working strategically to expand and build momentum around securing circular feedstocks and supporting breakthrough advanced recycling technologies,” said Isam Shomaly, Dow business vice president for Feedstocks and Commodities.

“We continue to increase Dow’s capacity to use recycled content as feedstock, and continue to invest in the most effective technology available to enable our circular business model for plastics,” said Diego Donoso, president of Dow Packaging & Specialty Plastics. “The diversification of our feedstock slate and decarbonization of our assets will enable the achievement of Dow’s goal of a sustainable, low-carbon future, and meet strong and growing customer demand for circular polymers. This will be a significant step forward to decrease our dependency on virgin fossil-based feedstocks.”

The planned facility builds on Dow’s ongoing collaboration with Mura, first announced in 2021, with an initial project to construct the world’s first plant using Mura’s Hydro PRS process, located in Teesside, UK, which is expected be operational in 2023 with an initial 20KTA production line. The Böhlen, Germany, site, expected to be co-located with Dow’s manufacturing facilities, would enable a significantly larger capacity for plastic waste and considerably increase the supply of fully circular feedstock to the industry. This circular feed, derived from plastic waste currently destined for incineration or landfill, would reduce reliance on virgin fossil-based feedstocks and would enable Dow to produce a recycled plastic which is in high demand from global brands, particularly for high-end sensitive markets like food and medical applications.

Dow aims to take advantage of co-location benefits, which could significantly reduce the cost of scaling advance recycling facilities. In addition, co-location of Mura’s facilities at Dow locations would be expected to reduce carbon emissions by minimizing transportation of the offtake and as gas output from the advanced recycling process can be converted back to plastics, thereby ensuring no by-products go to waste.

Steve Mahon, chief executive officer at Mura Technology, said, “Combating the global plastics crisis requires innovative solutions which can drive a circular economy. Mura’s collaboration with Dow has led to the largest commitment across the industry to date, showcasing the urgency from industry leaders to adopt scalable solutions such as Hydro PRS that will transform the plastics industry worldwide. Dow’s continued support for Mura Technology has led to a highly financeable commercial arrangement and the deepening collaboration will allow both companies to achieve their stated ambitions in the advanced recycling space.

“Dow’s commitments to accelerating a global circular plastics economy is exemplified through deploying Hydro PRSTM at the newest advanced recycling facility in Germany, which will enable us to dramatically increase recycling capacity. Through our collaboration and Dow’s extensive global reach, we can accelerate the pace and scale at which a circular plastics economy becomes a reality worldwide.”

Mura’s Hydro PRS (Hydrothermal Plastic Recycling Solution) advanced recycling process is unique, as it uses supercritical steam to convert most forms of plastics – including flexible and multi-layer plastics, which have previously been deemed ‘unrecyclable’ – back into the original oils and chemicals from which they were made. These can then be used to create new, virgin-equivalent plastic products which are even suitable for food contact packaging.

With Mura’s process, the same material can be recycled repeatedly, meaning it has the potential to eliminate single use plastic and prevent it from going to landfill or being incinerated. This has additional carbon benefits, with advanced recycling processes expected to save approximately 1.5 tons of carbon dioxide per ton of plastic recycled, compared to incineration and reducing reliance on fossil-based feedstocks.

 

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Clariant Oil Services Launches D3 Program to Support Carbon Reduction and Sustainability in the Oil Industry

Petra Löwer (Germany)
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Clariant Oil Services Launches D3 Program to Support Carbon Reduction and Sustainability in the Oil Industry

Clariant Oil Services Launches D3 Program to Support Carbon Reduction and Sustainability in the Oil Industry

  • Clariant Oil Services introduces novel Program to help customers reduce carbon emissions and enhance safe operations
  • The initiative optimizes customers’ onshore and offshore operations and introduces more environmentally acceptable formulations as energy demand soars
  • The D3 Program features an exceptional range of proven products, including Foamtreat Wet, phasetreat Wet, and Waxtreat SZ

Clariant Oil Services, a leading provider of chemical solutions, has launched the D3 Program to introduce more sustainable solutions to the oil and gas industry. The initiative leverages advances in the oilfield and helps operators reduce carbon emissions and enhance safe operations, while avoiding disruptions to ongoing operations.

D3 is comprised of three key pillars. Decarb utilizes nanotechnology and ingredients from renewable sources to reduce carbon emissions in customers’ operations; Densify facilitates logistics improvements and furthers sustainability initiatives through a new application with concentrated products; and Detox incorporates formulations with more environmentally acceptable raw materials.

“The oil and gas industry has taken enormous strides to accelerate sustainable development. In response to mounting environmental regulations around the world, we are collaborating with customers to proactively introduce more environmentally friendly solutions and applications to their portfolio,” said Jonathan Wylde, Global Head of Innovation at Clariant Oil Services. “As the energy landscape barrels ahead to meet world energy demands, we are nimbly satisfying customer needs, as they provide critical natural resources and reduce their carbon footprint.”

Key benefits of the Program include simplifying logistics for both transportation and storage, introducing concentrated ingredients that require smaller dosage in the application, optimizing onshore and offshore operations, introducing more environmentally acceptable formulations, and improving operational safety.

Clariant Oil Services’ D3 Program is a global initiative featuring an exceptional range of proven Clariant products, including:

  • Foamtreat Wet: Eliminates foaming during the primary treatment stage while reducing the carbon footprint;
  • phasetreat Wet: Provides a more efficient separation of oil and water; and,
  • Waxtreat SZ: Inhibits the precipitation of paraffin, ensuring optimum oil flow.

 

 

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Xeikon Installs CX300 Digital Printing System at Koehler Etiketten

Petra Löwer (Germany)
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0
Xeikon Installs CX300 Digital Printing System at Koehler Etiketten

Xeikon Installs CX300 Digital Printing System at Koehler Etiketten

This label printer with a rich tradition is making the investment based on increasing order volumes and changing market conditions

Reducing gaps in production capacity and ever decreasing lead times were the key driving factors for Rudolf Koehler Etiketten GmbH (www.koehler-etiketten.com) to invest in a Xeikon CX300 digital printing system. The system was installed in June 2022 to complement a Xeikon CX3, which has been delivering excellent results for the last six years. “We have seen a significant need for expansion over the last three years, particularly during the pandemic, when the supply chains in the packaging industry were broken, resulting in increased demand for labels as an alternative medium,” explains Michael Markus, Managing Director at Koehler Etiketten.

The existing Xeikon CX3 was operating at such intense levels, that it was time to act. In addition, up to a further five machines for producing and finishing labels needed to be utilised. Another deciding factor to acquire a further Xeikon digital press were the ever shorter lead times customers were demanding. “We urgently needed additional capacity to avoid having to change the web widths and substrates every day on a single Xeikon press," says Markus.

Several factors contributed to that press being another Xeikon machine. Firstly, operators are already familiar with the manufacturer’s dry toner technology. Secondly, the dry toner concept is ideally suited for food labels, which is a mainstay of Koehler’s label business. Another benefit is the huge variety of substrates the Xeikon press is able to handle without the need for any special surface treatment, as is the case in inkjet printing, for instance. Last but not least, Markus points to Xeikon’s pricing structure as a decisive factor: “The absence of click charges enables us to decide on the use of consumables ourselves, which was a key driver in our decision to purchase our first Xeikon press.”

From short runs to millions of copies

The Xeikon CX300 is a full-colour printing system including opaque white in a single pass. It comes with a food-safe toner, reaches a maximum speed of 30 m/min and achieves a high-quality image with a resolution of up to 1,200 dpi. Koehler Etiketten uses the press for jobs ranging from 300 to millions of units in a wide variety of formats. This includes high-quality sleeves for shipping in a 320 x 500 mm format and customised mini labels with consecutive barcodes, for instance. Koehler Etiketten chose VariOne, the AI-inspired software solution from Xeikon, enabling the company to print 100,000 labels or more with a different background in a single batch.

In addition to white ink, which comes with the Xeikon CX300 press as standard, Koehler was also impressed with the possibilities of printing with metallic tones. As a result, silver was installed with the new press and is being used for premium labels for the cosmetics and pharmaceutical sectors. In particular during the current paper shortage, Koehler Etiketten is harnessing the high printing quality of the Xeikon CX300 press, purchasing grass paper as a partial substrate substitute. By applying Xeikon white ink underneath the printed images, such as text or free spaces, the fact that the paper used isn’t white is hardly noticeable at all, enabling Koehler to maintain its ability to supply its customers, particularly in the food sector.

From self-adhesive to modern labels

Koehler Etiketten was founded by Rudolf Koehler in 1939. The company has been producing self-adhesive labels using traditional book printing, flexo, screen printing (both rotary and flat) as well as modern digital printing ever since. In 2005, Michael Markus took over as Managing Director from the founder’s daughter, now running the business alongside his wife and son. With its 20 staff members, the company achieves an annual turnover of around 3 million euros. Its core business activities include labels for food, cosmetics and pharmaceuticals, and chemical products. Koehler Etiketten is DIN EN ISO 9001:2015 certified, meeting all required standards for the pharmaceutical and food industries. With a renowned customer base from the EU, Switzerland and England, the majority of labels is delivered within Germany, including to pharma giant Bayer.

 

 

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Ascend Bringing New Materials to Battery Show

Petra Löwer (Germany)
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Ascend Bringing New Materials to Battery Show

Ascend Bringing New Materials to Battery Show

At The Battery Show North America, Ascend Performance Materials will feature its new flame-retardant nylons for EV safety applications and its Trinohex Ultra electrolyte additive, which improves lithium-ion battery safety, extends cycle life and boosts performance.

Safer, higher-performance battery chemistry
Ascend, a fully integrated producer of performance materials, will showcase its Trinohex Ultra electrolyte additive; now Reach-registered in Europe and China.

In third-party testing, Trinohex Ultra demonstrates superior cathode protection across cathode and electrolyte chemistries. This protection has been shown to reduce harmful gas generation, improve capacity retention and lower impedance growth, especially in extreme conditions.

“Battery safety, performance, cost and material availability are the biggest obstacles to mass adoption of e-mobility and renewable energies,” said David McNeece, Ascend’s senior product manager for sustainable specialties. “Trinohex Ultra is a drop-in solution to these challenges and can be easily integrated into existing battery chemistries and manufacturing processes.”

High-voltage safety
Ascend will also debut two new polyamide technologies in its Starflam® FR portfolio: X-Protect and color-stable orange.

Starflam X-Protect is a crosslinkable, flame-retardant nylon 6,6 designed to withstand EV battery thermal runaway. Tested in accordance with SAE AS5127 (a test originally designed for aerospace applications), Starflam X-Protect was rated fireproof to 1100°C for 15 minutes.

“In open-flame tests, Starflam X-protect outperforms standard FR nylon and even aluminum,” said Ian van Duijvenboode, Ascend’s e-mobility director. “In the event of a catastrophic battery failure, that added protection provides the time needed to ensure all passengers remain safe.”

Additionally, Ascend has developed a color-stable orange for its Starflam 525K for high-voltage connectors and cables. The new orange masterbatch ensures the material retains its color over 5,000 hours of heat aging without sacrificing performance.

“As EVs become more prevalent and age, the technicians and first responders working on these vehicles need to know where high-voltage systems are,” said Mr. van Duijvenboode. “Our orange will stay orange well into the operational life of the vehicle, clearly indicating areas of high-voltage.”

 

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Step Up Oil Purification With Clariant’s Latest Tonsil Adsorbents at Oils+Fats 2022

Petra Löwer (Germany)
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Step Up Oil Purification With Clariant’s Latest Tonsil Adsorbents at Oils+Fats 2022

Step Up Oil Purification With Clariant’s Latest Tonsil Adsorbents at Oils+Fats 2022

  • Clariant’s ever-expanding purification portfolio and powerful technical support enriched with new solutions
  • New all-in-one blend for coconut oil & high-throughput adsorbents for reliable filtration
  • Meet our purification experts at Booth C3 611 oil+fats 2022

With increasing quality, efficiency, and product-range demands on oil refineries, take full advantage of Clariant’s ever-expanding and powerful purification support at oils+fats 2022 to boost impurity removal and sustainable processing (Booth C3 611, September 12-16).

“Whatever the oil type, we can support you with a broad portfolio of adsorbents and exceptional expertise. Clariant’s high-quality Tonsil bleaching earth powders and granules gently remove impurities and also cover the reduction of many process contaminants, including 3-MCPD pre-cursors. We have new adsorbents in development to tackle the removal of mineral oil saturated and aromatic hydrocarbons, and our global and regional production networks enable us to provide premium service with a clear focus on emerging markets,” comments Guido Appl, Head of Business Segment Purification & Feed, EMEA

Clariant offers an extensive range of high absorption solutions, based on responsibly mined bentonite clay, aimed at reducing impurities and adsorbent dosage for the increasing variety of edible oils required by consumers and food production companies.

Show visitors can look forward to several new products introduced in 2022 to improve the purification of in-demand healthier oil options and specialty oils. This includes an optimized all-in-one solution to purify coconut oil, and new high throughput adsorbents which enable fast filtration in difficult-to-treat oils, and allow safe and continuous usage in refineries.

Customers have access to technical support during every step of the process to find the right products and conditions to optimize their finished product quality. Utilizing the adsorbents to their fullest potential can also reduce dosage requirements, which often translates into less transport and less waste generation, and better total cost of ownership.

Clariant’s steps to ensure high product quality come from selective mining of the bentonite clay, careful activation and controlled washing, as well as strict quality control. This applies across its portfolio.

 

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Belden Q3 2022 Launches Support Automation, Fast Deployment, and Space Savings

Petra Löwer (Germany)
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Belden Q3 2022 Launches Support Automation, Fast Deployment, and Space Savings

Belden Q3 2022 Launches Support Automation, Fast Deployment, and Space Savings

New releases include OpEdge-8D Industrial Edge Gateway Device and DataTuff Fiber Optic Cables

Belden, a leading global supplier of specialty networking solutions, announces 8 Q3 2022 product launches that strengthen automation and security, support fast and clean installation, and maximize square footage to reduce total cost of ownership.

Data Orchestration & Management

Belden macmon NAC Network Access Control tracks which devices are connected to a network—and where to find them—and supports guest and employee device management. All network devices can easily be identified, monitored and protected with this centralized security authority that protects networks against intrusion from unauthorized devices.
Hirschmann OpEdge-8D Industrial Edge Gateway Devices leverage the latest technologies to unite IT and OT data and make edge computing possible. The devices help industrial sites transform operational information into actionable insights that improve efficiency, maximize uptime and drive continuous process improvement.
ProSoft Technology Universal QuickServer Two-Port Building Automation Gateways allow users to connect automation-driven networks with industrial control networks for improved management and control. The gateways can support 250, 500, or 1,000 points of application data.

Belden announces exciting product launches for Q3 2022.

 

Data Acquisition & Transmission

Belden DataTuff Fiber Optic Renewable Grade Cables feature a robust, industrial-grade design to withstand renewable energy applications. Gel-free constructions are available, and the cables can be direct buried to reduce costs.
Belden FiberExpress ECX Single Cassette Holders are durable metal fiber patch panels that hold one ECX fiber cassette to host fiber connections in small, tight spaces and reduce the network’s footprint. An extension of the ECX product family, this cost-effective solution can be mounted on a wall or DIN Rail for installation in nearly any indoor environment.
Belden Gel-Free Fiber Optic Cables speed up installation time, support a cleaner installation and reduce implementation costs with a compact, rugged design that delivers reliable, robust connectivity.
Belden RemoteIP Cables offer an IEEE-standards approach to solving real-world problems in applications where Category cabling falls short. They supply data and power to remote IP devices up to 215 m away, reducing costs and maximizing square footage by eliminating the need for new telecommunications rooms or costly media converters and extenders.
Lumberg Automation M8/M12 Field-Attachable Connectors with IDC Termination are compact, ruggedized and easy to install featuring quick termination. Their performance and reliability ensure dependable visibility and control to reduce maintenance costs, boost safety, improve efficiency and decrease downtime in consumer packaged goods, automotive and machine building applications.

Belden announces exciting product launches for Q3 2022.

 

 

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Koch Technology Solutions And Ioniqa Technologies Partner To Disrupt Plastics Industry Through Advanced Pet Upcycling Technology

Petra Löwer (Germany)
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Koch Technology Solutions And Ioniqa Technologies Partner To Disrupt Plastics Industry Through Advanced Pet Upcycling Technology

Koch Technology Solutions And Ioniqa Technologies Partner To Disrupt Plastics Industry Through Advanced Pet Upcycling Technology

Koch Technology Solutions (KTS), a Koch Engineered Solutions company, and Ioniqa Technologies B.V. (Ioniqa) today announced a partnership to scale up and commercialize Ioniqa’s advanced Polyethylene Terephthalate (Pet) recycle technology in the plastics industry. As part of this collaboration, KTS has committed to invest up to €30M in Ioniqa.

Ioniqa has developed an innovative process that utilizes low-grade post-consumer Pet to infinitely produce a feedstock that displaces virgin raw materials used in the production of polyester products. Ioniqa has successfully demonstrated this technology in The Netherlands’ 10KTA production facility.

“KTS has a long history in the polyester industry, and we recognize the value proposition of this disruptive technology that will fundamentally change how recycling is done,” said Adam Sackett, President of KTS. “With an aligned vision on the future of Pet recycling, we’re excited to launch this partnership with Ioniqa and leverage our complementary capabilities to advance solutions which are tailored to the needs of the market.”

KTS and Ioniqa’s partnership will work to address the growing demand for recycled content in the 30 million metric tonnes per annum Pet market. Ioniqa’s technology offers a solution to Pet waste that is currently non-recyclable, turning the waste into materials suitable for high quality food grade applications such as beverage bottles. KTS and Ioniqa consider the technology as a disruptor in the Pet industry providing a sustainable economic recycle proposition to conventional manufacturing routes. The partnership will drive a circular process that addresses environmental impacts of the current Pet industry.

Tonnis Hooghoudt, CEO and Founder of Ioniqa said “After the scaling of our technology to a 10KTA depolymerization plant in The Netherlands, this KTS partnership is a major stepping stone for Ioniqa in commercializing its technology on a global level. Our expertise in breaking down plastic waste into virgin-like monomers matches seamlessly with KTS’ track record in designing and licensing Pet production processes worldwide. We believe that together we can meet the strong market demand for recycled Pet materials by jointly providing licenses and cleaning up the planet”.

 

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Molding Solutions at K Show

Petra Löwer (Germany)
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Molding Solutions at K Show

Molding Solutions at K Show

Networking for Sustainable Production: männer, foboho, Synventive, Thermoplay, Priamus, and Gammaflux in Hall 1, Booth C 50

“Share and Bundle” is the theme for the K Show in October. Convinced that the global challenge of more ustainable production can only be solved by working together,Molding Solutions – a business within Barnes – is bundling its expertise with partners and will be represented with its mold and hot runner technology and controls at the booths of Arburg, Netstal, Yushin, Fanuc, and Krauss Maffei.

Digital Watermark Technology
At its own booth in Hall 1, the Molding Solutions network will show how digitization is helping to simplify recycling of packaging materials. Packaging made of a certified bio-based material is given a digital watermark so that recycling centers can automate the separation of these digitally marked products in the waste stream. The mold inserts were laser engraved to apply the digital watermark onto the mold, which then applies it to the part when molded. A special camera detects the watermarks in the plastic part. By scanning the product with a digital watermark app,consumers can access a digital product passport with recycling-relevant information.

Barnes Connectia tm Cloud & moldmind
moldmind, the “digital cockpit” of the injection mold, is a recording system that documents relevant process data and events of an injection mold in real-time throughout the entire life cycle of the mold. The intelligent monitoring system detects problems quickly to minimize downtime.The data can be accessed directly on the device or in the Barnes Connectia Cloud, which will celebrate its premiere at the K Show.

Focus on hot runner process control at Synventive
Synventive will showcase a new electric valve gate. Synventive’s new compact egate tm Sync will complement the legacy egate system. The cost-effective eGate Sync impresses with its plugand-play installation and simple user interface. Quality is improved by increasing shot-to-shot consistency – all with significant energy savings compared to hydraulic systems.

Hotrunner.shop – 3D data within minutes
With the new hot runner configurator, 3D data of 2-, 4-, or 8-drop hot runner systems with topselling nozzles from männer and Synventive can be created within minutes. The step-by-step configuration can draw on a material database of more than 12,000 resins. Customers generate customized 3D data easily and quickly through the application check, which includes a follow up with an application engineer for applications outside of guidelines. männer and Synventive’s configurators are available today, while Thermoplay’s is expected to soon follow.

New and proven hot runner and control technology for multi-cavity applications
männer is expanding its packaging and slimline product range with additional valve gate nozzles. The packaging range for high-speed molds is complemented by the “MCN-EP,” with a small diameter and permanently centered valve gate pin. The design of the nozzle tip facilitates high-precision gating and enables the correction of tip protrusion without reworking (patent pending). Like the proven MCN 8 and MCN 6.5, the new MCN 5 valve gate nozzle from the slimline series is ideal for tight installation conditions in high-cavity molds. männer has not only the nozzle in mind, but also the optimization of the manifold. A 3D printed manifold designed using artificial intelligence is used to show how the design of flow bore helps a non-symmetrical 6-drop hot runner system achieve perfect balancing.

Thermoplay has added two nozzles to its “TFS” series – the open nozzle series for side injection – for larger part volumes. Additional Thermoplay innovation is aimed at special applications. For example, Thermoplay has created nozzles for a 45° gate to produce conical parts as well as multi-tip nozzles for small parts that are gated with several gating points. Thermoplay sees 3D printing as an option for fast delivery times and is introducing a new multi-nozzle with an
additively manufactured collar.

Gammaflux rounds off the portfolio with its proven hot runner temperature control technology.With its in-house riangulated control techonology and up to 192 zones, the G24 is the top seller among temperature controllers on the market.

Processing PCR and biomaterials with digital intelligence

Adding digital intelligence to high-precision mechanics is a high priority for Molding Solutions. When processing new PCR and biomaterials, injection molders struggle with material fluctuations, which makes process-reliable production difficult. The fillcontrol process monitoring system from Priamus identifies and corrects material fluctuations that contribute to decreased quality through dynamic process control by adjusting the manipulated variables of pressure and temperature signals.

External exhibition
The Molding Solutions network will display an additional five molds and several hot runner systems, as well as temperature controllers and process control systems at partner booths.

Closed loop recycling
KraussMaffei will demonstrate how material can run through several product life cycles in the future at its booth in Hall 15. Medical consumables are produced from PP in männer’s 96-cavity mold, after which the material is granulated and fed to the production of automotive parts, also at the KraussMaffei booth.

Diagnostics Accelerated
Pipette tips are manufactured and removed under this specification at Netstal in Hall 15. The turnkey system consists of a 64-cavity pipette tip mold with hot runner from männer, a Netstal Elion 2800-870, and high-speed automation from MA – micro automation. The network of experts show that the close integration and coordination with product specialists can make it easy for customers to configure a high-performance production cell with a clear ROI.

High-speed production with lateral removal
At its booth in Hall 11, Yushin will rely entirely on lateral demolding robots. Blister packs are produced in a 16-cavity männer mold and removed laterally, in a Netstal Elion 800. Thanks to the cycle time-optimized männer mold, the performance of the Netstal injection molding machine and the high-speed robot from Yushin, cycle time can be reduced by up to 3.5 seconds.

Balancing and energy efficiency optimization
The development of foboha’s 48-cavity mold was the result of focused efforts to produce the best design of a high-cavity hot runner system in terms of balancing and energy efficiency. Each cavity has been equipped with a Priamus sensor to offer complete system monitoring and optimized use of the Priamus process control system. The 48 molded parts will be removed by a robot equipped with grippers from Gimatic, Molding Solutions’ affiliated business within Barnes.This mold will run at Fanuc’s booth in Hall 14.

CITI Technology
CITI stands for “Cube Inclusive Turning Inserts” ‒ a technology patented by foboha that is particularly suitable for producing multi-component parts, where the second material is desired on both sides of the basic body. A 3-component functional part is produced in an 8+8+8 cavity cube mold, where a frame of PP is first injected into the moving nozzle side. After a 2 x 90-degree rotation of the cube, the component is sealed with TPE on both sides of the fixed nozzle side and a functional element made of POM is molded on the part.

The Molding Solutions network will showcase molds from männer and foboha, hot runner technology from männer, Synventive, and Thermoplay, temperature controllers from Gammaflux, and process control systems from Priamus at the K Show in Hall 1, Booth C 50.

 

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Asahi Kasei Introduces New Xyron Mppe Grades – Versatile Materials for Improved Efficiency of 5G Applications

Petra Löwer (Germany)
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Asahi Kasei Introduces New Xyron Mppe Grades – Versatile Materials for Improved Efficiency of 5G Applications

Asahi Kasei Introduces New Xyron Mppe Grades – Versatile Materials for Improved Efficiency of 5G Applications

To meet the increasing demand for materials that boost the efficiency of 5G applications, Asahi Kasei, diversified Japanese multinational company, is currently introducing new grades of its modified polyphenylene ether (mPPE) xyron to the European and North American markets. The combination of PPE with other polymers such as polyphenylene sulfide (PPS) or polystyrene (PS) allows this family of high-performance compounds to feature a broad range of properties, exceeding those of conventional materials used for telecommunication applications.

5G networks are expected to offer maximum data transmission speeds about 10 times greater than those of 4G networks. Compared to their predecessors, 5G networks also use higher-frequency electromagnetic signals than previous network generations. However, this comes at a cost. As signal speeds increase, the strength of the signal becomes exponentially weaker, so high-frequency signals like 5G suffer much greater loss than lower-frequency signals like 4G, thus have greater difficulty in reaching their intended destinations. This poses challenges for network connectivity and can serve as an obstacle to ensuring reliable communication. For this reason, 5G networks require more base stations than previous generations, and 5G smartphone terminals must incorporate higherperformance radio systems to ensure reliability and satisfaction.

MID antennas for 5G-compliant smartphones
xyron grades for MID (molded interconnected device) antennas feature low dielectric permittivity,low loss tangent and high hydrolysis resistance. Simulation results indicate that the use of these materials in MID antennas can improve total efficiency by as much as 1 dB compared to the polycarbonate (PC) materials conventionally used for this purpose. This enables operation at higher frequencies and more advanced device functionality, alleviating design space constraints to facilitate.

Antenna covers for 5G base stations
Antenna covers – the outermost layers of antenna assemblies – require lightweight, weather-resistant materials with low dielectric permittivity to improve electromagnetic-wave transmissivity. To date, antenna covers have typically been made from PC or similar materials, which hinders dielectric properties. Asahi Kasei is currently developing a xyron grade with low dielectric permittivity, as well as an excellent hydrolysis and shock resistance that is available in all colors and is compliant with the UL94V-0 flame-retardance standard.

Asahi Kasei is also developing additional xyron grades for various types of equipment covers,including grades with high weatherability, that resist color changes induced by prolonged light exposure.

RF cavity filters for 5G base stations
Base stations commonly incorporate large numbers of metal or ceramic radio frequency (RF) filters that increase system weight, leading to a more complicated installation and operating losses. The greater density of base stations required for 5G networks makes these factors even more important and creates an urgent demand for lighter-weight

xyrontm grades for RF filters – specifically designed for applications to RF cavity filters in 5G base stations – offer high heat resistance, good plating properties, and low linear-expansion coefficients comparable to those of metallic materials, facilitating the industry’s transition to resin-based RF filters.

Recycled PET/PPE alloys for 5G smartphone terminal chassis
Remaining committed to developing innovative materials for sustainable societies, Asahi Kasei is also introducing recycled PET/PPE alloys, which allow bonding to metals, for 5G smartphone terminal chassis as a new addition to the xyron family, especially for the Chinese, US, Indian and Japanese markets. The new recycled grades combine PPE with various recycled resins to yield more sustainable manufacturing without sacrificing the high performance of these unique materials.

The recycled PET/PPE alloys use approximately 40% post-consumer recycled resins – recovered from PET bottles and other items – while retaining the good mechanical properties and lower dielectric properties than PBT and GF materials.

Asahi Kasei will exhibit its xyron grades for 5G applications October 19-26 at the upcoming K 2022, “The World’s No. 1 Trade Show for Plastics and Rubber,” in Düsseldorf Germany (Hall 8a, Booth E23).

 

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