SABIC debuts new PP compounds for foam injection molding, providing both light weight and exceptional aesthetics for automotive interiors

SABIC, a global leader in the chemical industry, today introduced a specialized portfolio of SABIC® PP compounds for foam injection molding (FIM). New mineral-reinforced SABIC® PPc F9005, PPc F9007 and PPc F9015 grades can help deliver excellent aesthetics for visible automotive interior parts with complex geometries, such as door panels and trim, seat and trunk cladding, A/B/C/D pillar covers and center consoles. Unlike standard FIM materials, which typically exhibit surface defects, the new advanced PP compounds feature uniformly high surface quality similar to solid injection molded parts. Compared to solid components, foamed parts made with SABIC PP compounds offer significant weight savings that can help cut emissions. According to a cradle-to-grave life cycle assessment study (pending third-party review), the advanced new materials can help OEMs lower carbon dioxide (CO2) emissions by as much as 15 percent.

“The automotive industry continues to look for new weight-out strategies that can advance energy efficiency and sustainability goals,” said Abdullah Al-Otaibi, general manager, ETP & Market Solutions, SABIC. “Although foam injection molding produces desirable lightweight parts, manufacturers have been forced to sacrifice aesthetics, until now. We applied our extensive expertise in foaming technology to develop these new compounds to help resolve the issue of surface quality and open new application opportunities for foamed parts.”

Solving the FIM Aesthetics Challenge
Previously, the FIM process was essentially limited to non-visible parts, restricting its usefulness in automotive applications. Foaming can underperform in surface aesthetics: silver streaking, swirl lines and dimples are common defects. SABIC PP compounds for foamed interior parts deliver low-gloss textured (grained) surfaces with uniformly high quality, including the elimination of streaking and swirling. Talc filler in these grades acts as a nucleator that promotes the generation of finer bubbles, which contribute to a consistent surface appearance. For enhanced aesthetics, these grades are currently available in selected automotive interior colors with custom coloring also available.

Optimizing Weight-out Benefits
Weight reduction results with SABIC PP compounds depend on several factors, including the type of FIM technique used. Short-shot molding, which uses the same tooling as an injection molded part, can reduce weight by up to 10 percent. SABIC PPc 9007 is formulated for short-shot FIM and low-impact applications. Core-back molding, which requires part redesign and new tooling, can lower weight by as much as 30 percent. Both SABIC PPc 9005 and PPc 9015 grades are formulated for core-back molding and deliver medium stiffness and impact.

The choice between the short-shot and core-back techniques, with their different tooling requirements, also helps to determine whether FIM with SABIC PP compounds is cost neutral or delivers cost savings. Additional cost savings are possible from cycle time reductions from flow improvements inherent in FIM.

Another consideration is the foaming process, which can use chemical or physical agents. The new SABIC PP compounds are good candidates for use with chemical blowing agents, which are typically preferred for visible foamed parts. These agents are introduced to the molding machine in the form of a masterbatch, along with the plastic pellets, and activate during the melt phase to release gases for foaming.

Supporting FIM Application Development and Processing
SABIC fully supports its new PP compound portfolio with extensive expertise in foamed part design, development and processing, as well as predictive engineering capability. For instance, the company can provide guidance on the selection of the appropriate chemical blowing agent for each grade. SABIC’s technical team will collaborate with customers to achieve excellent aesthetics at the lowest possible part weight.

To drive future developments in polymer foams, SABIC operates a Foam Innovation Center in The Netherlands. This center, which is equipped with foam process capabilities as well as analytical equipment, enables the company to develop new foam solutions and technology innovations and collaborate with customers.

The new SABIC PP compounds have launched in Europe, with upcoming availability in the Americas and Asia/Pacific.

Returns to Plastics Industry Association as Vice President, Industry Engagement

The Plastics Industry Association (PLASTICS) is pleased to announce that Ashley Hood-Morley has returned to fulfill the role of Vice President, Industry Engagement, effective immediately.

As a member of the Senior team, Ashley will be an integral part of PLASTICS’ growth and engagement. Ashley will lead strategy on membership acquisition and retention as well as oversee industry relationships and programs for PLASTICS stakeholders and key strategic partners.

“We are excited to have Ashley rejoining the PLASTICS team,” said Glenn Anderson, Chief Operating Officer of the Plastics Industry Association. “Ashley brings a diverse and significant set of executive skills to our association and is highly regarded by our members. In her new role, Ashley’s leadership will be instrumental as we work to rebuild the culture of our association.”

Hood-Morley has worked in the plastics industry for more than 15 years, and most recently, has focused on plastics recycling and sustainability. She returns to PLASTICS after serving as the Strategic Initiatives Manager on Eastman’s Corporate Sustainability team where she led the advancement of sustainability integration into business strategies and supported the success of the Circular Economy platform. In previous roles at Eastman, she worked in new product development, manufacturing, quality assurance, and product stewardship, all of which supported Eastman’s Specialty Plastics business. Ashley also spent more than 6 years at the Plastics Industry Association, where she managed new business development as well as PLASTICS’ portfolio of recycling, sustainability, and material initiatives across the organization.

“We absolutely could not have found someone more perfectly suited for this role than Ashley,” said Matt Seaholm, President and CEO of PLASTICS. “Her first-hand understanding of our members from multiple perspectives, as well as her industry expertise, makes her an ideal advocate on behalf of our association.”

“I am excited to return to PLASTICS and grateful for the opportunity to lead the membership and engagement teams,” Hood-Morley shared. “I am personally committed to the plastics industry and the people that this association represents. I am extremely optimistic about the great things we can accomplish on behalf of our members and looking forward to working with Matt, Glenn, and the leadership at PLASTICS.”

Since 1937, PLASTICS, the only organization that supports the entire plastics supply chain, has been working to make its members and the industry more globally competitive while advancing recycling and sustainability. To learn more about PLASTICS educational initiatives, industry-leading insights and events, networking opportunities and policy advocacy, and the largest plastic trade show in the Americas, NPE: The Plastics Show, visit plasticsindustry.org or go to This Is PLASTICS.

Lightweight construction technologies advance energy and material efficiency

• Hybrid Lightweight Technologies WG meets for general assembly at
TRUMPF in Ditzingen
• Focus on CO2 savings and recycling of lightweight components
• Networks for technology transfer and cooperation
• New board elected, Marc Kirchhoff, TRUMPF, continues as chairman

The member companies of the VDMA Hybrid Lightweight
Technologies Working Group share the same fate that many industries are currently experiencing: Order books are full, but sales are stagnant. COVID-19 has already caused supply chain problems over the last two years; these are now being exacerbated by the of the Ukraine war. They are now coupled with sharp price increases and supply bottlenecks for raw materials and energy.

However, the latter in particular offer great opportunities for the use of hybrid lightweight construction technologies. At their yesterday’s general assembly at TRUMPF Laser- und Systemtechnik GmbH in Ditzingen, the members of the VDMA Working Group Hybrid Lightweight Technologies made clear that they have the expertise to find solutions when it comes to significant savings in energy and materials – and thus also in CO2 emissions. But the requirements for sustainable concepts go far beyond. Therefore, the recycling of lightweight products was also one of the hot topics on the agenda.

Networks for cooperation and technology transfer
The development and marketing of complex lightweight construction concepts requires a close cooperation across the technological boundaries, but also the dialogue with the customer industries. Lightweight construction concepts are seen as key technologies to respond to social trends and to master the upcoming challenges.

This is why the Initiative Leichtbau Baden-Württemberg is an important partner for the working group members. With its network, it connects all levels: Technology, application and politics. This will be highlighted at the symposium “Lightweight construction in urban systems” that follows the members’ meeting, where examples of climate protection through sustainable building design are being presented.

Another important pillar for cooperation is the Lightweight Construction Technology Transfer Programme of the Federal Ministry for Economic Affairs and Climate Protection, which is promoting the cross-sector and cross-material transfer of knowledge and technology.

Mondi handles Diamant’s packaging needs with recyclable paper solution

Mondi has teamed up with German bike manufacturer Diamant to wrap and protect its branded mountain and trekking bikes.
Diamant is replacing its plastic bubble wrap around bike handlebars with Mondi’s pre-made paper Protector Bags.
The new system will protect bikes during transportation and reduce Diamant’s plastic packaging by around 85% per year.

Mondi, a global leader in packaging and paper, has entered the bike packaging market with its Protector Bags, providing a new sustainable solution for Diamant to replace plastic wrapping used around the handlebars of its Trek and Diamant brands.

Germany’s oldest bike manufacturer will now use Mondi’s recyclable Protector Bags that are made from renewable materials. The change means that Diamant will reduce its plastic use by 16 tonnes every year – around 85% of its previous consumption – as well as saving costs in logistics and transportation.

The pre-made paper bags do not require additional wrapping or taping, as they are ready to use with a tailored closure strip developed specifically for the bicycle industry. Created from two plies of paper, Mondi’s Protector Bags are strong and flexible, making them highly puncture-proof – and they protect the bikes during storage and transport with a softer interior glaze that is friction-resistant. Due to the air permeability of paper, the bags are also breathable. Additionally, handlebar grips made of rubber can emit moisture or gas that can evaporate easily with this new packaging.

Storage and transportation costs have been significantly reduced: the Protector Bags are delivered flat, meaning more can be carried on a pallet, providing a more cost-efficient stacking compared to plastic bubble wrap reels that transport excess air. In addition, Mondi produces the paper bags at its Trebsen plant in Germany, which is only an hour from Diamant’s factory, compared to the previous bubble wrap alternative, which was sourced abroad.

Geoffrey Ziegahn, Senior Engineer, Diamant, says: “Our development team worked very closely with Mondi to create these uniquely tailored bags, which will provide increased protection for the handlebars of all mountain and trekking bikes of our brands Trek and Diamant during transportation. This is a major step towards our sustainability goals: we aim to only use recyclable packaging by the end of this year and replace all plastic and bubble wrap with paper-based solutions. Mondi’s careful and thorough approach to the challenge has demonstrated how we can achieve this – we are saving transportation costs, storage space and are contributing to a better world by making this big change.”

Nadja Nickel, Sales Manager Protector Bags, Mondi adds: “This is a fantastic example of how our EcoSolutions approach can work for customers in a wide range of industries, and we are delighted to make our first foray into bike packaging with our Protector Bags. Diamant’s bikes need to be protected from scratches during transport. While the previous plastic bubble wrap protected the product, Diamant was looking for packaging made from paper. By going onto the factory floor and assessing all areas of manufacturing, storage and transportation, we were able to develop a bespoke version of our existing Protector Bags, which are easily sealed on site, provide all the protection needed, save the customer money and help them achieve their sustainability goals.”

Mondi’s Protector Bags are made from renewable resources, responsibly sourced and are created from two layers of durable kraft paper. They are flexible, cost-efficient and completely recyclable, and can be disposed of safely in existing waste streams throughout Europe.

Polymertal and UBQ Materials Partner to Create Lightweight, Sustainable Material With Metallic Functionalities

UBQ Materials, climate tech developer of advanced materials made from unsorted household waste, announced today that it is partnering with Polymertal, which develops cutting-edge metal plating processes for the creation of cost-effective metal-polymer parts. Through this partnership, Polymertal is releasing SPP-50XX, a new sustainable material with metallic properties that contains UBQ™, a substitute for durable plastics converted entirely from unsorted household waste, including all organics. The inclusion of UBQ™ in SPP-50XX’s base substrate enables this material to achieve a lower carbon footprint – as compared to aluminum, a favored lightweight metal, bringing roughly a 50% reduction in CO2e emissions, as verified by World Watchers.

A key challenge for sustainable materials in competing with lightweight metals like aluminum is to achieve the necessary toughness, thermal resistance andelectromagnetic shielding, features essential to applications across automotive, industrial and consumer product manufacturing.

Polymertal’s SPP-50XX will comprise 20% UBQ™ and 80% polypropylene. On top of this substrate, a layer of copper and nickel of varying thicknesses will serve as the metal plating. Surfacing a polymer substrate with a lean metal plating allows SPP-50XX to remain lightweight and exhibit key metallic properties, including durability, stiffness, heat resistance and electromagnetic shielding.

“We are proud to launch our sustainable materials series, the S series, including SPP-50XX and its climate-friendly thermoplastic, UBQ™,” said Ran Carmeli, CEO of Polymertal. “Countless applications require materials that are lightweight, withstand high-temperature environments, and are thermally and electrically conductive. SPP-50XX exhibits all these features, and the presence of UBQ™ brings sustainability earlier in the supply chain, making it even easier for manufacturers to reduce the overall carbon footprint of their end products.”

“UBQ™️ can be combined with metals to create carbon-reduced products with important metallic properties for functional applications in tough environments,” said Albert Douer, Chairman and Co-CEO of UBQ Materials. “Through work with Polymertal, our novel material is helping manufacturers create products that are socially, environmentally and economically sustainable.”

Crescent Garden Introduces Planters Made with Waste-Based UBQ to Consumer Markets

UBQ Materials, climate tech developer of advanced materials, announced today that its novel bio-based thermoplastic is being incorporated into a new range of planters made by Crescent Garden, a premier provider of gardening containers and self-watering solutions.

The new range of planters with UBQ™, dubbed Crescent Too O+, are the first and only planters to contain the climate-positive material, and will be available to consumers and commercial gardeners. This is an important breakthrough for those in the horticulture field, where decisions are increasingly focused on what is good for the planet, in addition to what is beneficial in the garden.

“As a company focused on gardening and cultivating a healthier, sustainable environment, we have a deep understanding of why climate change needs to be addressed – and it starts with us, the producer,” said Harry Tchira, President of Crescent Garden. “Through our partnership with UBQ Materials, Crescent Garden is transforming sustainability in both the home and garden spaces with our plant-positive containers that also offer a positive impact on the world.”

A seamless substitute to oil-based plastics, UBQ™ is converted entirely from unsorted municipal solid waste, including organics such as garden trimmings, soiled cardboard, and food waste, that would have otherwise been directed to landfills. UBQ™ has already been adopted by leading industry enterprises and is used for manufacturing durable products with reduced or even positive environmental footprints.

This collaboration’s aim is to introduce more planet-positive variety to Crescent Garden’s containers without inhibiting beauty, function or value. The first styles to launch with UBQ™ inside are the Emma line and TruDrop container inserts, best-sellers that present opportunity for high-volume and high visibility within the portfolio.

The Crescent Too O+ planters will be launched at GAFA in Cologne, Germany, which is taking place from June 19 to June 21, and will be showcasing the UBQ products in its booth, Hall 10.1; Stand #F050 G051

Etilab Responds to Demands For Faster Delivery and Special Embellishments With Xeikon

With an upgraded dry toner press combined with the investment in a new advanced finishing line and color control software, the Polish printer can now offer shorter lead times of best quality labels

A manufacturer of highly processed labels, Etilab Sp. z o.o. specializes in digital printing technology centered around a Xeikon 3300 label press. The company recently took advantage
of the option to double the print speed of their Xeikon 3030, as volumes were growing fast, and more capacity was needed at the production facility in Żory. A new DC350 advanced finishing line has also been installed, giving Etilab larger scope for producing highly embellished digital labels.

Established in 2003, Etilab has invested significantly in organizational, production, and technological advances over the years to offer best-in-class self-adhesive labels to a wide range of customers, ranging from smaller local companies to global corporations from the construction, FMCG, and cosmetics industries in Poland and Germany. The company combines a personal approach and readiness to take on new technological challenges with a high degree of flexibility. Great emphasis is also placed on expanding the product offering with innovative solutions that meet current trends and market needs.

“Being a small company, we can respond dynamically to our clients’ needs and wishes,” said Sylwia Dudek, President of the Management Board. “We invest in great solutions to improve quality and productivity, while maintaining comfort and safety at work. The first Xeikon press we bought four years ago helped us enter the market with technologically advanced labels, printed on metallized film. The additional digital white color further allowed us to achieve interesting tonal effects, such as gold or partly shimmering graphic elements.”

The Xeikon 3300 digital press offers a resolution of 1200 dpi using dry toner electrophotography to print in five colors – typically CMYK + white – however the colors are interchangeable so there is the option to print orange, green, or special colors. The press can print on standard raw materials without primer, and due to the full rotation image transfer, there is no limit on the repeat length, giving Etilab’s customers more flexibility and freedom when creating impositions and gaps between labels. Companies that are just starting their adventure with label printing and have purchased even a basic model, have the option to increase the speed or printing width at a later stage. Etilab took full advantage of this option to double the printing speed of its first Xeikon press.

For food applications, it is important to note that Xeikon dry toners comply with the largest number of standards, including EU Reg. 1935/2004, Swiss Ordinance, and Nestlé Guidelines, and has FDA approval in the US. They are also environmentally friendly due to the absence of odors, VOCs and solvent emissions; and lightfast.

Michał Kuczkowski, Sales Manager at Xeikon, commented, “Etilab provides its customers with products that 3300 is perfect for this purpose and also allows the use of structured raw materials, such as those that are popular in the wine and spirits segment.”

As part of the expansion, Etilab has invested in the Xeikon Colour Services Pro 2.0 software suite to ensure
color predictability and repeatability. This Cloud-based solution delivers automatic color control on the fly by using a built-in spectrophotometer and generating reports after printing to maximize predictability, repeatability, and profitability. The XCS Pro software enables Etilab to guarantee accurate brand colors, save on waste during production, and eliminate the risk of jobs being rejected due to color variations.