Highlights and Innovations from Promix Solutions at K 2022

At the upcoming K trade fair, Promix Solutions will be presenting solutions for mixing, foaming and cooling of polymer melts, saving raw material costs, reducing the carbon footprint and increasing production capacity. For manufacturers of light foams, such as XPS, XPP, XPE, XPET, Promix will show how P1 cooling mix technology can be used to achieve better mechanical properties and lower foam densities. Promix displays clever solutions for efficient cooling or tempering of viscous media and for inline viscosity measurement. At K 2022, Promix Solutions can be found in Hall 9, booth E18.

From foam extrusion to Promix Microcell Technology
Promix Microcell Technology creates a microcellular foam structure in the polymer by adding environmentally friendly atmospheric gases (N 2 and CO 2 ). This reduces the product weight by 20 – 50 %, which leads to massive savings in raw materials. The saved plastic also results in fewer CO 2 emissions and your company makes an important contribution to more sustainable

For the mechanical properties of physically foamed components, a foam structure that is as fine-cell as possible is a decisive advantage. Especially in the case of films and sheets for the packaging
industry, a homogeneous, extremely fine-cell foam structure is essential, since the gas bubbles introduced are deformed again in the subsequent thermoforming process. If the cells are too large, the mechanical strength of the component is weakened and, in the worst case, defects occur.

During the Covid-pandemic, Promix conducted intensive research into the further development of physical foam extrusion and carried out various tests in its in-house technical center. With the new Promix Microcell Technology, an important milestone was reached with regard to cell size. It was possible to halve the previous cell size of 100 micron on average. The extremely fine-cell structure leads to very good mechanical values, which are comparable to those of non-foamed trays of the same thickness. Top Load tests have confirmed: With Promix Microcell Technology, weight savings of around 20% can be achieved without sacrificing mechanical properties.

In addition to its use in packaging films, Promix Microcell Technology is also suitable for sheets, foam core and corrugated pipes as well as profiles, cable sheathing, blow molding and blown films. Promix will exhibit relevant key components at the K and will provide information on possibilities within specific fields of application. In the meantime, more than 250 industrial references are in operation and various machine manufacturers are successfully integrating the technology into their plants.

Promix Microcell Technology can be used for almost all raw materials. For example, for PP, PE, PET, TPE, TPU, PA, hard & soft PVC and bioplastics. The technology is available both for newly planned extrusion lines and as a retrofit solution

Alphagary, Orbia’s Polymer Solutions brand, introduces EVOPRENE ECO 1000 – TPE compounds built with sustainable ingredients.

Alphagary, a global leader in the design and manufacture of specialty polymer compounds and a division of Orbia’s Polymer Solutions business group, introduced today the first of a new series of SEBS-based thermoplastic elastomer (TPE) compounds, under the brand EVOPRENE, that are formulated with sustainable raw materials.

This new family of EVOPRENE compounds, the ECO 1000 series, underlines Alphagary’s commitment to sustainable development. The EVOPRENE ECO 1000 series is formulated with bio-based raw materials, reducing reliance on traditional fossil-based raw materials. These compounds are designed for both extrusion and molding general-purpose applications. Having a natural base, these materials can be easily colored.

Extensive lab testing was conducted on EVOPRENE ECO 1000. Comparing a compound with twenty-five (25) percent bio-based raw materials against a compound formulated with traditional fossil-based raw materials, Alphagary found consistent mechanical properties (such as specific gravity, durometer, and tensile strength), good heat resistance, and consistent flow characteristics and surface finish compared with traditionally formulated compounds.

Said John Jaddou, Alphagary’s Global Business Development Director, “As part of Orbia’s mission to Advance Life Around the World, Alphagary is expanding our portfolio of sustainable materials as well as investing in new technologies that allow our customers to achieve their own sustainability initiatives. Additionally, we are exploring methods that will allow us to quantify the reduction in greenhouse gas emissions from formulation through manufacture of these compounds”. John went on to say, “Our approach is holistic – it goes beyond formulating with bio-based raw material and recycled content. We are carefully listening to our customers’ own business goals and reimagining ways we can work together to advance common sustainability ambitions. Programs that partner with customers to prevent waste to landfill, using alternate materials that have lower carbon footprint, and choosing ingredients that are less harmful to the environment are all ways we are demonstrating our commitment to sustainable development.”

At Orbia, sustainability is deeply embedded in our businesses, is a core component of our growth strategy, and drives our culture. Our purpose-led focus on addressing the world’s most pressing challenges drives our business agenda and our strategic approach to sustainability. In living these values, Alphagary’s sustainability goals include actions at its manufacturing facilities. Said Rick Correia, Alphagary’s Global Operations Director, “The approach we take in our operations is as important as the innovative products we offer. Our investments to contract green energy, upgrade equipment efficiencies, and capture precious resources such as heat back into our facilities all help to reduce our carbon footprint and demonstrate our unwavering commitment to protect our environment.”

High-performance Additives for Polyamides and Recycled Polyolefins

Brüggemann (www.brueggemann.com) is presenting performance-enhancing additive innovations at K 2022. These range from electrically neutral heat stabilizers for polyamides in electrical and electronic applications, forexample for e-mobility, to high-performance stabilizers for exposure to moderate to very high temperatures and additives for stabilizing recycled polyolefins. A further focus is on efficiency-boosting flow enhancers which enable shorter cycle times and low wall thicknesses for components made of polyamides and polyesters (PBT).

Electrically Neutral Heat Stabilizers for Polyamides
BRUGGOLEN TP-H2062 and TP-H2217 are opening up a new class of metal- and halogen-free heat stabilizers for reinforced and unreinforced polyamides in E/E
applications. They do not corrode metallic components such as overmolded sensors and have no impact on the polymer’s electrical properties. They also enable continuous service temperatures of 170°C with peaks of 200°C, so meeting more stringent automotive industry requirements and surpassing the limits of conventional systems, such as phenol- and copper-based stabilizers. Both BRUGGOLEN additives are available as easy-to-process masterbatches. BRUGGOLEN TP-H2217 is particularly suitable for heat-stabilizing halogen-free flame retardant polyamides. Brüggemann has thus made it possible for compounders to produce polyamide materials specifically tailored for e-mobility which have a V-0 classification to UL94, electrical neutrality and long-lasting heat resistance at 180°C.

“Best in Class” at 190°C
BRUGGOLEN TP-H1804 is a new heat stabilizer for aliphatic polyamides used at service temperatures of 160°C to 190°C. It distinctly outperforms copper salt- based stabilizers in terms of mechanical property retention of the materials to which it is added. BRUGGOLEN TP-H1804 thus complements BRUGGOLEN ® TP-H1805, which was presented at K 2019 and stabilizes reinforced aliphatic polyamides for continuous service at 200°C for PA6 and at 230°C for PA6.6.

Efficiency-boosting Flow Enhancers
BRUGGOLEN TP-P2201 is a new addition to Brüggemann’s range of flow enhancers which will be presented at K 2022 and is specifically tailored for applications in e-mobility
and flame retardant polyamides. BRUGGOLEN ® TP-P1810 is particularly suitable for processing partially aromatic polyamides, while BRUGGOLEN ® P1507 is optimized for
aliphatic polyamides and TP-P1924 for PBT. All these additives help to save energy production while simultaneously enabling very high fiber contents for injection molded parts with long flow paths and/or low wall thicknesses.

Polyolefin Recycling
Brüggemann had already presented its wide range of additives for the mechanical recycling of polyamides at K 2019. These include long-term heat stabilizers, process
stabilizers, flow promoters, reactive chain modifiers, nucleating agents and other processing auxiliaries. Products for recycling polyolefins will now also be presented at
K 2022. Specially developed technology repairs defects in the molecular chains which arise during the processing and use of polyolefins and degrade quality. The result is recycled polymers with improved mechanical properties which do not require the addition of virgin material.

Using BRUGGOLEN TP-R2090, it is possible to recycle polypropylene from post- industrial and post-consumer waste. TP-R8895 is specifically suited to recycling polypropylene from battery cases. Both additives result in recycled materials of a quality which cannot be achieved by conventional re-stabilization, even at high rates of addition.

For recycling polyethylene, Brüggemann has developed BRUGGOLEN ® TP-R2162 which again includes the new repair technology and is particularly suitable for recycled LLDPE
for use in film extrusion. All the stated additives are supplied in the form of compact, dust-free blends.

Solvay Develops Industry-First Specialized UV-C Stabilizers for the Protection of Polyolefin Surfaces

Proprietary technology designed to protect UV-C disinfected surfaces against degradation and discoloration

Solvay, a global market leader in specialty materials, has announced the development of an innovative new portfolio of UV-C stabilizers. They are designed for use in demanding hygiene applications, where polyolefin surfaces are treated with ultra-violet (UV) light of the UV-C spectrum (200-280 nm) to fight against COVID and hospital-acquired infections. The new proprietary stabilization technology represents an important milestone for the polyolefin industry, as it is the first to address the risk of polyolefin degradation, discoloration and micro-crack formation, which is caused by frequent exposure to UV-C irradiation.

“Healthcare and other markets, such as aerospace and shared mobility, are increasingly using UV-C light to disinfect high-contact surfaces in an effort to combat pathogens, including coronaviruses,” says Sophie Poelmans, Global Marketing Manager for Polymer Additives at Solvay Materials. “Our new UV-C stabilization technology helps end users achieve effective UV-C disinfection levels on surfaces made from polyolefins without compromising the performance of the material.”

UV-C radiation can deactivate microorganisms and has been scientifically proven to be effective against coronaviruses. However, the proven germicidal action of UV-C also exposes the treated surfaces to much higher ultraviolet energy than that covered by traditional UV-A and UV-B stabilizers, resulting in the potential for faster material degradation. Solvay, a member of the International Ultraviolet Association (IUVA), has leveraged its extensive expertise in polymer additives to develop a technology that is purpose-engineered to enable the use of UV-C light as an anti-microbial disinfectant on polyolefin surfaces, while safely protecting them against UV-C induced degradation.

Solvay’s new UV-C stabilization technology is targeted at a wide range of polyolefin applications, including medical equipment in operation and patient rooms, aircraft and shared vehicle interiors, and sporting venues. You can find out more on the Solvay website or by visiting Solvay at the K 2022 in Düsseldorf, from October 19-16 in Hall 6, Booth C61.

Sidel proves “the perfect fit” for Mai Dubai installing the fastest water line in Middle East, Africa and Asia

A PET complete bottling line at leading water company Mai Dubai LLC has been hailed as the fastest single line in the Middle East, Africa and Asia. Sidel’s Super Combi solution, adapted to optimise space and increase efficiency, is helping the UAE-based company deliver high-quality water and take another step towards becoming the region’s number one water brand. Sidel has provided what Mai Dubai’s Director of Operations Mohamad Usman called the “perfect fit.”

Water makes up nearly one-third of soft drinks sales in the UAE and sales are forecast to grow by 436m litres, more than any other category, by 2026. In addition, buying habits in the UAE are changing, with consumers becoming more concerned about shopping responsibly and demanding climate-friendly packaging and larger pack sizes in response to spending more time at home with family during the pandemic. [1]

Mai Dubai was established in 2012 and is one of the leading bottled water companies in the UAE. It is fully owned by Dubai Electricity and Water Authority (DEWA). Mai Dubai represents Dubai, a global brand which stands for high quality, high standards and an impressive consumer experience. Aside from the UAE market, the company has also been supplying its products internationally and since 2015, it has supplied Emirates Airlines.

Mai Dubai recently benefitted from Sidel’s expertise with the installation of a new complete packaging line. The line fills 86,000 bottles per hour (bph) in three different formats (200ml, 330ml and 500ml). But speed was just one consideration when it came to selecting Sidel, as Mai Dubai CEO Alexander van ’t Riet explains:

“Our key considerations were the optimal use of space, high consistent quality and efficiency with flexibility. Sidel’s digital capability was very attractive, too, with its Efficiency Improvement Tool (EIT®) enabling us to track the performance of every part of the line.

Sidel also added extra value by using its design expertise to help us to strengthen our 500ml bottle without compromising its iconic design. Finally, Mai Dubai is a leader in sustainability and Sidel’s solution supported our low energy requirements.”

Boosting quality and efficiency

The complete high-performance line provided by Sidel delivers optimum water quality. It includes the all-in-one Super Combi solution for blowing, labelling and filling, with the unique ground level preform infeed system, EasyFEED, and the top ergonomic cap feeder, Gebo OptiFeed. These pieces of equipment all ensure that Mai Dubai’s high quality standards are met including:

Safe and clean conditions are ensured by EasyFEED with its UV lamps. In addition, a dedusting system for preforms is integrated into the blower, while a deionizing system on the caps chute further boosts the hygienic conditions.
At the labelling stage, quality and efficiency are also met by three labelling stations, all equipped with an auto-splicing system, delivering consistent uptime by ensuring non-stop production. Bottles are scuff- and scratch-free, improving the quality of the end-product. This is due to the ease of handling of lightweight bottles, enabled by labelling between the blowing and filling stage.
The accurate, reliable no-contact filler features a reduced enclosure kept in overpressure with high-efficiency particulate-absorbing (HEPA) filters. This results in a protected environment around the filling valves, and an easier to clean area using less sterilising agents and time.
Gebo OptiFeed’s features enable smooth cap handling. Its inspection system improves efficiency by automatically detecting cap quality and colour.

Continuing down the line, the seamless shrink-wrapper EvoFilm meets Mai Dubai’s key requirements for maximising efficiency by minimising downtime. It also manages nested packs – where bottles are offset so they can be closely packed – and gives stability while reducing the pack’s footprint, bringing cost savings in logistics.

Additional features of the new line include, the high-speed, high-level pack infeed, PalLinear palletiser. It features a fully robotic layer preparation, RoboSmart, offering flexibility and saving time as well as being easier to operate.

In addition, Mai Dubai was so impressed with Sidel’s Efficiency Improvement Tool (EIT), the all-in-one line performance software, that it has now installed it on its other packaging lines.

Exceeding expectations

Mai Dubai appreciated Sidel’s smooth implementation of the line and ability to meet deadlines but exceed expectations:

“We were very impressed with Sidel’s adaptability and understanding of our requirements,” says Mohamad Usman.

“They delivered a line that was faster than our original specification. Sidel also met our additional request for bottle strength improvement. Within 15 days they had done a Failure Mode and Effects (FME) analysis and come up with a solution. With Emirates Airlines as a flagship client, premium, distinctive and reliable packaging is important to Mai Dubai.”

Meeting consumer demand

The new installation is enabling Mai Dubai to respond to the growing demand for bottled water in the UAE, which already has one of the world’s highest per capita water consumption, as consumers opt for healthier products and move away from sugary drinks to no-calorie options.

Achieving sustainability goals

Consumers are also increasingly influenced by the environment when making purchasing decisions. Mai Dubai promotes PET as a sustainable product and runs education initiatives about plastic recycling with local schools. The company’s clear commitment to sustainability is also demonstrated through its energy strategy. The entire plant is run on renewable energy, generated from its more than 52,000 rooftop solar panels – an area equivalent to all the windows in the Burj Khalifa, the iconic Dubai skyscraper and the world’s tallest building. For the past two years Mai Dubai has been net positive, generating more power than it uses.

“Sidel is, of course, one of the respected suppliers in the industry,” concludes Alexander van ’t Riet.

“When we compared the services that we needed, the equipment, the digital technology, and the solutions that were important to us such as energy consumption, we decided that Sidel would be the right partner for us.”

Inspection and classification: Effective evaluation & distribution of raw materials such as polymers or flakes

Pellet inspection ensures 100 % control during the production or compounding process. Many manufacturers in the field already offer the inspection systems as well as units for the production of polymers. The pioneering inventor Thomas Alva Edison once said: “If there is a way to make something better: Find it!“. That is exactly what OCS have done. What is thebenefit of detection, classification and sorting? Be part of the leading international event for the process industries, Achema in Frankfurt am Main, Germany from 22 – 26 August 2022. With live demonstrations, OCS will provide the customers and visitors insights into the fascinating possibilities of this inspection and classification technology.

Classification of polymers – optimised product mix
OCS devices and systems not only provide the appropriate image processing system for inspecting such defects, they can also be classified directly on the basis of specific measurement parameters. Product quality begins with the selection of only high-quality raw materials and top-notch production OCS Optical Control Systems GmbH has been developing innovative and efficient
customer-specific solutions for quality control and assurance for more than 30 years now.

What is the benefit of sorting out contaminated material and how can we use this? Depending on the end product, product mixes can be used, for example, and the scrap can be used efficiently. customer,
for example.
What are the advantages of direct online quality control with OCS measuring systems?
• Optimised product mix on the basis of precise results
• Optimisation of system flexibility through remix
• Significant shortening of transition times
• Possibility for direct intervention

However, also the sales team can use this qualified data to actively promote a certain raw material to their customers.

Digitalisation – Industry 4.0
For example, several options are available for data communication. Customer-specific data preparation and transfer as well as remote control (via communication protocol or digital I/O). Easy
integration of external devices (e.g. colour measurement), OPC Server Industry 4.0, easy data transfer to CSV. Further interfaces can be implemented on customer request.

Customer Benefits of Inspection Equipment by OCS:
– Consistently high quality of polymers / defect prevention / scrap minimisation
– Individual and trend-setting solutions
– Best life-cycle costs and performance
– High ROI

OCS Communication Software COM100
COM100 Modul
▪ To process values of our devices
▪ Prepare the process values for the customer control system
▪ Display the process values
▪ Send the process values to the customer control system via a protocol
▪ Receive control information from the customer’s control system
▪ A COM100 module can exchange data with a COM100 module

COM100 Software
▪ The COM100 software can also monitor process values and display historical events
▪ The COM100 software can run as a service on a customer system

Teknor Apex replaces standard PA66 GF (Glass Filled) materials with PP GF resulting in several processing advantages for an AdBlue Tank Cover

Replacement reaped economical and visual benefits from the new compound

Teknor Apex, known for its customer centric approach, has become the global market leader in compound manufacturing through the efforts of its 2,300 employees at 16 locations worldwide. In the city of Rothenburg ob de Tauber – Bavaria / Germany, Teknor Apex is represented by around 140 employees in a wide range of areas. In mid- 2020, the new plant in Rothenburg was completed, providing space for further growth.

“Teknor Apex Germany is one of the most important European manufacturers of engineering thermoplastics and thermoplastic-elastomers for high performance applications, the range of our
products is articulated in a huge range of formulations, ready-to-use or tailor-made on request, and are exported worldwide for the electrical and electronics, industrial, and automotive and transportation sectors,” said Mr. Joseph Leforestier, Account Manager – Export.

Thanks to its innovative spirit and the know-how of its chemists, Teknor Apex Germany has developed a family of glass-filled engineering polypropylene with E-modules that reach 11,000 MPa
and a HDT that reaches 160°C. The purpose of this development was to replace glass filled PA66 and PA6 with modified glass filled PP, in an effort to offer customers alternative solutions that have similar properties to but are more economical than glass filled PA.

Some advantages of the Teknor Apex engineering glass filled PP are:

• Easy to process material even through existing molds
•  Similar shrinkage to PA
• A more environmentally conscious process as there is no need to pre-dry the material and
  the melting temperature, processing temperature, and mold temperature are all lower than
  those of PA
•  Very good dimensional stability (no water or moisture absorption)
•  Temperature resistance (130°C/3000h) and UV stabilized.
• Superior surface aesthetics
•  Laser marking ability
• and more …

To date, the Teknor Apex modified PP has replaced several glass filled PA66 and PA6 applications
on existing molds. Here is one example of these PA application replacements:
• Former material: PA66 GF30
• Current material: Teknor Apex PP GF45
• Application: AdBlue Tank Cover for Mercedes

AdBlue, or diesel exhaust fluid, might be still unfamiliar to some motorists but owners of modern diesel cars with engines that are Euro 6 compliant will be familiar. AdBlue is a liquid used to reduce the nitrous oxide emissions of diesel engines and is made up of a mixture of urea and deionized water that is sprayed into the exhaust system. Its widespread introduction coincided with the
current Euro 6 emissions standards, which are part of ever more stringent emissions targets that car manufacturers are now required to meet. Without AdBlue, it would be much more difficult to lower the emissions of diesel cars and get them to comply with the latest standards