ECI Group Signs Two New License and Engineering Agreements for Confidential Client

• ECI Group will provide the technology, engineering design, and training for the facility, and support through commissioning, start-up, and production for two new high-pressure polyethylene
  plants.
• Repsol will offer its knowledge in the production and operation for the ethylene vinyl acetate (EVA) copolymer plant and ethylene butyl acrylate (EBA) copolymer plant, and know-how regarding the development of EVA and EBA differentiated applications.

ECI Group has signed two license agreements for Process Technology and Engineering Design with a confidential client in China. The two lines will be capable of producing 50,000 tonnes per year of Ethylene Butyl Acrylate (EBA) and 100,000 tonnes per year of Ethylene Vinyl Acetate (EVA) respectively, with the ability to produce other associated high-pressure copolymers in the future.

The plants will be part of the client’s refining and petrochemical integrated project, a mega complex to be located in the Province of Jiangsu. ECI Group will provide the technology, design, and training for the two lines, as well as support through commissioning, start-up, and production.

Repsol, the multi-energy company, is the technology partner of ECI Group and will provide its extensive technical expertise on these kinds of plants and products. Repsol has several LDPE, EVA, and
EBA plants in its industrial complexes in Spain and Portugal and has over 40 years of experience producing polymers in high-pressure facilities.

The plants will use high-pressure autoclave technology that has its roots in the heritage ICI process to manufacture of Polyethylene. ICI first created LDPE in the 1930s, and ICI partnered with ECI Group’s subsidiary company Simon Carves over five decades to deliver over 67 operating reactor lines around the world. The ECI Group design offers significant improvements in the product range, reliability, and expandability to the original ICI technology, and is optimized to make use of modern materials, design techniques, standards, and industry best practices for construction, operation, and maintenance.

While the client declined to provide a comment citing project confidentiality, they noted that they had reviewed a number of technology options and made the decision to select ECI Group’s autoclave technology for a number of important reasons including the unmatched product range, lower operating costs and the design built for future expansion of capacity and product development capabilities. They also recognized Repsol’s reputation as a long-standing producer of high-quality products, and expressed their desire to work with both partners for a fruitful long-term cooperation.

“These agreements include the first EBA license and ECI’s fourth high-pressure copolymer license in 12 months,” said Joaquin Flores, President and CEO of ECI Group. “These achievements serve to establish ECI’s position as the technology of choice for producers of high-pressure polyethylene. ECI Group is already recognized globally as the world’s leading provider of engineering and technical services for high-pressure polyethylene facilities, having worked with every major current producer and licensor. Once again, we have been able to demonstrate the benefits Repsol’s in-depth product knowledge and market reputation to further enhance ECI Group’s established expertise. We look forward to a long and successful partnership with this well-established client who have made a great impression on us during our discussions with their level of integrity, vision and professionalism.”

Cosmo Films appoints Justin Glass as President for North America operations

Cosmo Films Limited, a Global Leader in Films for Packaging, Labelling, Lamination and Synthetic Paper and an emerging player in Specialty Chemicals, Polymers & Pet care, appointed Mr. Justin Glass as President for their business operations across North America. In his new role, Justin will be responsible for devising growth strategies and expanding business in the North American region for the organisation. In this new role, Justin will report to Mr. Kulbhushan Malik, Sr. Vice President and Head of International Operations, Cosmo Films Limited.

A seasoned business leader with over 25 years of experience, Justin comes to Cosmo Films with diverse experience and expertise in plastics and packaging industry. Justin started his career in plastic industry as a Process Engineer for Bi-axially oriented polypropylene (BOPP) tape films in the extrusion & coating functions and moved on to various technical functions across several
primary polymer markets.

Justin holds 15 years of expertise in handling commercial & finance related business strategies and planned execution for large multinational packaging manufacturers serving the food,
consumer packaging, pharmaceutical & medical packaging verticals. In his past tenures, he has been associated with DS Smith as Director Commercial Operations; Klöckner Pentaplast as
Commercial Director Americas – Food & Consumer packaging; and other organizations.

Welcoming him, Mr. Pankaj Poddar, Group CEO, Cosmo Films Limited said, “With more than two decades long career in films and packaging industry, Justin holds proficiency in leading
teams across functions including engineering, sales, marketing, and operations. His expertise in leadership, strategy and business acumen will prove significant to Cosmo Films operations in
North America. I am delighted to have him onboard and look forward to his contributions in achieving our strategic goals in thoughtful and innovative ways.”

Commenting on his new role, Mr. Justin Glass, President, North America, Cosmo Films, “Cosmo’s market domination and growth in different film segments is testimony of the
dedication of Cosmo team, vision of its leadership, and Cosmo’s Product Quality and Customer service. I am thankful that the leadership has entrusted me with the responsibility of leading and growing their business in North America. I look forward to leveraging the innovative teams at Cosmo Films to help unlock new market opportunities with our partner brands.”
Justin is a Bachelor of Science in Mechanical Engineering from Virginia Tech University, and an MBA from Averett University.

PERPETUA ALTA: Constantia Flexibles introduces recycle-ready laminate with improved chemical resistance

The world’s third-largest flexible packaging manufacturer launches the first ready-to-be-recycled mono-material based on polypropylene (PP) with high chemical resistance for pharmaceutical products.

“We highlight the need for more sustainable packaging in the pharmaceutical packaging business with our innovation PERPETUA ALTA,” states Joerg Adrian, Vice President Technical Organization & Innovation Pharma of Constantia Flexibles. The newest addition to its product portfolio combines “Design for Recycling” guidelines with high chemical resistance against aggressive liquid or gel formulations. The mono-polymer solution replaces the multi-material packaging for chemically aggressive products such as pharmaceutical liquid and gel compositions. “It was our goal to achieve a high-performance ready-to-be-recycled solution. Although designed for highly aggressive pharma products, PERPETUA ALTA may also find applications in other market segments requiring high chemical resistance, e.g., food applications,” added Joerg Adrian. On top, third-party certification from the German Institute cyclos-HTP confirms the material recovery of up to 96%, depending on the final material configuration.

Performance: high chemical resistance

Traditional multilayer packaging for pharmaceutical products is not recyclable due to combination of different materials. Alternatives, such as recyclable mono-polyethylene or mono-polypropylene laminates, fulfill the recyclability factor but do not provide the required performance with respect to chemical resistance. “It was a challenge. Our R&D and product management team worked hard to get where we are today: a full polypropylene recyclable solution with high chemical resistance (HCR) towards aggressive filling goods,” explained Roberto Martin, Head of Innovation Laminates at Constantia Flexibles’ plant in Logroño, Spain. PERPETUA ALTA can withstand, e.g., hydro-alcoholic gel under accelerated aging conditions, similar to aluminum-containing multi-material laminates compliant with HCR requirements. Compared to a conventional laminate solution, this innovative laminate offers optimal product protection from oxygen, water vapor, and light at a reduced weight and increased yield. PERPETUA ALTA is a drop-in solution for existing packaging formats based on laminates like stick packs, sachets, and strip packs. Important for the production: The packaging machines do not have to be replaced, the existing equipment can be used.

Cutting Plastic – Mondi Develops New Sustainable Packaging for Kao’s Salon Hair Cosmetic Brand Goldwell

• Mondi creates new recyclable, lightweight packaging for leading Japanese consumer goods company Kao and its salon hair cosmetic brand Goldwell.
• Professional stylist hair lightening products now packed in an innovative stand-up pouch, reducing plastic by 80% compared to the former packaging.
  Pouch replaces rigid plastic box and helps Kao work towards its Zero Waste goals as part of its overall sustainability strategy.

Mondi, a global leader in packaging and paper, has partnered with Japanese consumer goods manufacturer Kao to create a recyclable, lightweight packaging solution for its Goldwell hair lightening products. The new stand-up pouch reduces plastic usage without compromising on strength and durability and thus supports Kao and its salon business in their efforts to reduce their environmental footprint and to help salons run their businesses more sustainably.

Goldwell is a salon-quality brand of Kao Salon Division, the fourth biggest professional hair care business in the world. Its broad offering of hair care, styling and colour products also includes a range of hair lightening products created for in salon use. These were previously packed in rigid plastic containers, however working with Mondi and along its EcoSolutions approach, Kao is reducing the overall amount of plastic in individual packs by 80%.

Mondi’s innovative solution packs the powdered products in flexible, re-closable stand-up pouches that are made of mono-material, meaning they are recyclable. The pouch is provided to the user together with paper instructions inside a carton box, enabling the pouch to be stacked when stored, and results in a lower carbon footprint compared to the previous packaging alternative.

The empty pouches can be folded flat to ensure efficient transport to the factory. When filled, they provide optimum protection for the product, preventing contact with moisture or vapour coming in, which would render it unusable. The packaging is completely safe as chemicals cannot diffuse through the tightly sealed packs. For convenience, the packaging is also easy to reclose with a recyclable top slider and temper-evident membrane.

Iris Ross, Regional Sales Consumer Flexibles, Mondi, says: “The solution we developed with Kao contains a chemical-based product that is particularly sensitive, so we needed to consider safety and quality at all times. The new packs are completely secure during shipment when filled and easy to transport. Kao is passionate about making the right changes for a more sustainable world while ensuring the high quality and user-friendliness of its products, to deliver the best customer experience. It was a pleasure to work with the Kao team on creating this product.”

Elmar Mussenbrock, Director Sustainability, Kao Salon Division adds: “Sustainable packaging is one of the key elements of our ESG strategy and reducing plastic is our first priority – what hasn’t been produced cannot cause any harm. With its great expertise and professional approach, Mondi has enabled us to deliver a much more progressive pack for our Goldwell LightDimensions SilkLift range, reducing the carbon footprint of the packaging by 65% compared to its former box.”

D.R. Joseph Reveals Auto-Gauge Air Ring with Innovative Approach on Lower Lip Control and Component Modularity

The TDK-500 is a new automatic gauge control air ring introduced by D.R. Joseph Inc, world leaders in Internal Bubble Cooling and air flow control systems. The new air ring will be available to blown film producers in Fall 2022 which is designed to be used with the company’s forthcoming InstaGaugeTM auto thickness control system which also will be introduced this fall. The unique design
equips the TDK-500 with a host of innovative features which boost versatility and provide a faster control response with higher resolution than current offerings

The TDK-500 air ring is a result of five years of development which drew from DR Joseph’s 30+ years of internal bubble cooling (IBC) controls design experience, 30+ years of air ring design experience from Techflow Design of Mississauga, Canada, and 30+ years thickness measurement experience from Kündig Control Systems of Ruti, Switzerland. The combined experiences created innovations which focused on making an auto gauge control air ring easier to install, easier to operate efficiently and much easier to modify and maintain. Further, all of these same innovations will be adapted to conventional air rings later next year.

The new dual-lip TDK-500 has four important innovations while retaining the high performance expected from dual lip air rings:

1) Instant setting lower lip adjustment technology (patent pending Techflow) which completely eliminates the traditional threaded mechanism. Operators can find and secure the perfect lower lip adjustment in a matter of seconds. The adjustment includes a scaled indicator for SOP purposes. This intuitive design eliminates the intimidation factor of managing bubble stability because operators can quickly “test” the entire setting range within 10 seconds. Anyone who has struggled with the endless rotating of the lower lip adjustment can appreciate the instant nature of this setting.
2) Affecting change to the film for consistent gauge control is made more difficult when high performance is also a requirement. The TDK-500 isolates the primary lip cooling from the gauge control adjustments made using the secondary lip cooling air streams. This keeps the bubble locked consistently to the forming cone for all conditions. The innovated part of this design is the constrained zone design (patent pending Techflow). The air flow from each control zone constrained in an independent channel that extends to just before the secondary lip exit. This eliminates zone cross mixing and provides a more direct and effective control response to the film.
3) Instant access for cleaning the lower lip exit technology (patent pending DRJ) allows the operator to release the locking feature without tools and safely lift the secondary and
cooling collar assembly to a designed cleaning position within the air ring in less than 60 seconds. IBC hardware need not be removed. Optional weight reduction is available for easier lifting is available from a 3D printed polycarbonate cooling collar (patent pending). Additional 3D printed components are still under development.
4) Instant lip set swapping technology (patent pending DRJ) allows the primary and secondary lips to be removed and replaced without tools and without lifting the entire air
ring off of the die. A time and cost saving measure which expands the versatility of the air ring. For instance, an operator can change the lower lip geometry to provide a custom air flow impingement angle or to handle lower blow-up ratios within 5 minutes (excluding the time required to remove the IBC exhaust stack).

Again, the TDK-500 is a high performance dual-lip design established from years of experience for the widest range of materials including ultra-low melt strength materials.

Repsol choose BUSS LSHC Technology to Produce High-purity XLPE Cable Compounds

First-of-its-kind plant for the production of EHV AC & DC cable insulation materials to be built in Tarragona,

The new, patented LSHC™ process (“Linear Short Hyper Clean“) has been developed by Buss AG in close cooperation with P&M Cable Consulting LLC, a Swiss based consulting
firm in the field of cable compounds. It offers access to, among others, various High Voltage (HV) and Extra High Voltage (EHV) insulation materials, exhibiting superior product quality and process efficiency compared to the well-known soaking technology. XLPE grades for both, alternating (AC) or direct current (DC) cable applications are readily produced with this innovative and flexible process.

The LSHC technology relies on direct peroxide injection and gentle compounding of a newly developed additive cocktail by using BUSS state-of-the-art COMPEO co-kneader series, allowing at the same time for significantly reduced capital expenses and clean room requirements. Further advantages are the compact plant design without high-rise soaking tower and improved cleanliness and physical-electrical properties of the produced materials.

Buss AG is proud to work with Repsol on the realization of this first-of-its-kind industrial production plant and will eagerly continue the excellent collaboration towards the scheduled
start-up in mid-2024. The LSHC technology is available to BUSS customers world-wide on the basis of a competitive licensing model. A corresponding pilot plant for production of HV EHV materials will be available around the end of this year at the BUSS Campus in Pratteln, Switzerland.