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FIBRES FOR STRONGER PLASTICS TRENDS IN TITANIUM DIOXIDE SCREEN-CHANGER DEVELOPMENTS FAKUMA EXHIBITION PREVIEW
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contents
05 Industry news
PAGE 17
The latest compounding industry news including international acquisitions and alliances, plus new investments and plant openings.
21 Reinforcing progress
Jennifer Markarian examines the latest technology developments and market trends in bre reinforcements for thermoplastics.
PAGE 29
PAGE 43
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www.compoundingworld.com October 2012 | COMPOUNDING WORLD 3
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September in an opening ceremony attended by Dr Matthias Wolfgruber, chairman of BYKs parent company Altana; Frank Bannert, administrator of the local Saalekreis region; Klaus Dieter Besser, managing director of BYK Kometra; and Dr. Uwe Zakrzewski, managing director marketing and sales at BYK Additives & Instruments.
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Frank Bannert, Klaus Dieter Besser, Dr. Uwe Zakrzewski and Matthias Wolfgruber (left to right) bring the first reactor into service
October 2012 | compounding world 5
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Victrex PEEK is replacing metals in tough applications such as these components for a harvesting tool Victrex and Solvay have separately announced plans to increase their production capacity for high-performance PAEK (polyaryletherketone) and PEEK (polyetheretherketone) polymers by 70%. Victrex, which is the market leader for these polymers, plans to add 2,900 tonnes/year of capacity at its site at Thornton-Cleveleys in Lancashire in the UK, taking its total production capability to more than 7,000 tonnes/ year. The expansion is due on stream in early 2015. The company recently announced record sales of 2,904 tonnes for the financial year ending 30 September 2012. It says that this performance combined with a strong pipeline of future applications supported its investment decision. Solvay has also announced a 70% capacity expansion for
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production of its KetaSpire PEEK (polyetheretherketone) and AvaSpire PAEK (polyaryletherketone) polymers at its facility at Panoli in India. The expansion will be completed by the middle of 2013. Panoli is the companys largest production unit for the two high performance polymers. Solvay began production of its KetaSpire PEEK polymers at the former Gharda Chemicals site in 2008 with an initial capacity of 500 tonnes/year. Solvay is delighted with the growth of its line of polyketone materials and we are very excited to be adding capacity for this business that we launched just a few years ago, said Augusto Di Donfrancesco, general manager of the companys global Specialty Polymers business.
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TZ Minerals International (TZMI) recently published its annual review of the global titanium dioxide pigment industry. TZMIs Sue Fitzgerald outlines some of the major factors shaping this US$17 billion market
volumes dropped by a massive 47% compared to the second quarter of 2011. As the TiO2 producers recovered protability in 2011, it became clear that the mineral sands producers were next in line. The principal product of the mineral sands industry is titanium raw minerals used as feedstock for the production of primarily TiO2 pigment and, to a lesser extent, titanium metal. Of the TiO2 feedstock mined and processed, more than 90% is used in the chloride and sulphate methods of TiO2 pigment production. The year was marked by a global shortage of feedstock primarily from depleting
17
Pigment producers starting pushing up prices from mid-2010 assisted by the global shortage of pigment. Price increases were announced on almost a monthly basis throughout the second half of 2010 and continuing in 2011. The last major round of price increases was announced in March 2012, with most of the larger producers indicating product prices increases effective 1 April. There is some evidence that there has been customer resistance to further price increases and prices have remained fairly high, but static into 2012 as a result of high inventory and somewhat depressed demand. During 2011, most TiO2 pigment producers reported record prots and margins as pricing increased at a much faster rate than operating costs. In the rst quarter, and for some in the second QUARTERLY SALES AND ADJUSTED EBITDA FOR SELECTED PIGMENT ( TZMI 2012) COMPANIES: 2010-2012 resources combined with a lack of investment in the industry in the past 10 years. quarter of 2012, producers have continued to enjoy healthy revenues at the higher pricing points (compared to the same time one year ago). However, looking forward, increasing feedstock costs will have an impact on pigment producer margins, particularly for those that use higher TiO2 content material to feed plants.
TiO2 demand
The coatings sector accounted for 58% of TiO2 pigment demand in 2011, with architectural coatings comprising 36%. Demand for architectural coating is driven by home re-sales, new construction, home maintenance and urban development. Plastics makes up the next largest demand driver for TiO2 pigment, accounting for 22% of demand in 2011. This was followed by paper which dropped to 9% of demand. In 2011, global TiO2 demand grew by 1.4% to 5.39 million tonnes, with Chinas share of global demand increasing from 11% in 2000 to close to 22% in 2011.
Outlook
As long as pigment producers can remain nancially stable and are able to manage suitable inventory levels with variations in production, TZMI expects supply and demand to remain relatively balanced in the next three to ve years. The probability of signicant new greeneld capacity coming on line outside of China is limited, given the limitations in feedstock supply and nancial risks associated with the large investment. TZMI expects global TiO2 pigment demand to grow to 5.51 million tonnes in 2013. So far demand growth in 2012 has contracted and the slowdown in Chinas economic growth and continuing debt woes in Europe may present further challenges to the industry going forward.
Supply in 2011
Seven global producers make up more than 64% of the global nameplate capacity: DuPont, Cristal Global, Tronox, Huntsman, Kronos Worldwide, Sachtleben and Ishihara Sangyo Kaisha (ISK). DuPont and Tronox operate only chloride route plants, while the other global producers operate plants that use both sulphate and chloride route technologies. European producer Sachtleben is the largest sulphate-only producer in the world. In 2011, industry production capacity grew from 6.00 to 6.38 million tonnes, with most of the expansion occurring in China. The 60-plus plants in China now combine to account for 21% of global TiO2 capacity, exceeding that of DuPont with 19%. Asia-Pacic is now the biggest region in terms of capacity, with North America a distant second. Output peaked in the second quarter of 2011, but was negatively impacted by demand slowdown in the second half of 2011.
18 COMPOUNDING WORLD | October 2012
More information
TZMIs 2012 TiO2 Pigment
Annual Review provides a comprehensive review of the global titanium dioxide pigment industry, with detailed analysis of supply and demand, trade, pigment plant economics, markets and producer proles. For more information, visit:
S www.tzmi.com
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Reinforcing progress
Suppliers of bre reinforced thermoplastics continue to push towards improved properties in order to penetrate higher-performance markets. For example, reinforced nylon is vying for applications that currently use metals, driven by the desire for lighter weight and other advantages. At the same time, reinforced polypropylene is moving into areas previously occupied by reinforced nylon, driven by the desire for reduced cost. Improved impact resistance, tensile strength, stiffness and other properties can be achieved in several ways. Fibre sizing, which both improves bre processing and provides interfacial adhesion between the bre and the matrix, plays a signicant role in improving properties, notes Yves De Smet, global bres and composites business unit manager at Ohio-based Michelman. Michelmans new generation of FGlass bre sizings targeted for PP reinforcements, for example, are designed to help meet the need for improved properties. The trend to improved products encompasses not only improved nal product properties, but also
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Jennifer Markarian examines the latest technology developments and market trends in bre reinforcements for thermoplastics
improved bre-making efciency and composite production, notes Andy Brink, global technology manager at Michelman. Projects can involve different parts of the supply chain, and sizing-producer Michelman works with both bre producers and composites manufacturers to customize properties. Longer bres can also improve properties. The industry is using more and more long-bre reinforced thermoplastics (see Automotive industry demands drive LFTs markets ahead in Compounding World, January 2012 . While long bres have so far primarily
October 2012 | COMPOUNDING WORLD 21
Lanxess is adding capacity at its glass bre unit at Antwerp to meet growing demand for reinforced resins
been used in PP, in the last few years more PA compounds have been made using such reinforcements. Glass bre still dominates the bre reinforced thermoplastics market, but other types of bre are nding increased use. For example, while carbon bre in the recent past was used mostly in epoxy thermosets and high-temperature thermoplastics (such as PEEK), it is now being used more in PA and even PP, says Brink. The industry is seeing a new focus on localized development. While in the past, multinational bre producers focused on the big US market and then pushing those products into the rest of the world, they are beginning to focus more on regional needs, such as developing bres specically for applications in China, notes De Smet. Owens Corning, for example, opened its China Composites Center in September. The state-of-the-art science and technology facility will enable us to work closely with our customers in China to develop solutions specic to this market, says Steve Zirkel, general manager of the global thermoplastics business at Owens Corning.
thermoplastics will need to be lighter, stronger, and stiffer in order to allow thinner parts. Particularly in hand-held consumer electronics, thickness can be measured in millimetres. AGY is responding to this trend for materials that deliver performance beyond the traditional E-Glass chopped bre by developing specialty materials, says Drew Walker, president of AGY. The company announced in May that it has increased production of its S-2 Glass bre reinforcements by 20%, with the capability to further increase volumes if needed. S-2 Glass bres are used particularly when higher part stiffness and higher temperature performance is needed, says Walker. PPG introduced three new ChopVantage chopped strand bre products this year that target benets needed in key applications. G ChopVantage HP3270 is a 10 micron chopped strand bre for PP that offers improved chemistry for dry-asmoulded (DAM) properties and high performance in hot detergent solutions. Target applications include automotive and appliances, such as in washers and dryers where white colour characteristics are critical. G ChopVantage HP3613 is a 13 micron bre with proprietary sizing chemistry for PA applications. It offers high hydrolysis resistance in long-life coolant systems and meets US Food and Drug Administration and EU food compliance requirements as well as potable water guidelines. G ChopVantage HP3730 chopped strand bre glass offers excellent dry-as-moulded properties and hydrolysis resistance in thermoplastic polyesters. It can also be used to improve mechanical properties in biodegradable plastics such as PLAs (polylactic acids), PHAs (polyhydroxyalkanoates) and PTTs (polytrimethyleneterephthalates). Applications include transportation, electric and electronic appliances, and computer housings and components. Johns Manville has also been growing its portfolio of
Key markets
Glass-bre reinforced thermoplastics are expected to grow at 5-6% annually over the next several years, driven by increasing demand in automotive, electrical/ electronics and household appliance applications, notes Zirkel. They offer unique value compared to traditional materials. In automotive, in particular, glass reinforced thermoplastics offer value by reducing weight and increasing strength and design exibility. The needs of automotive applications are a signicant driver for bre development. Owens Cornings 248A and PerforMax 249A short glass bres for PP, introduced last year, are being used in automotive applications that require high-perforOwens Corning is targeting automotive applications with its latest short glass bres for PP mance mechanical properties, such as door modules, front ends and air intake manifolds. It is claimed that compounds made with the bres can compete with short glass bre polyamide (PA) and LGF-PP. The bres have improved processing and allow users to meet increasingly high standards while reducing system cost. These benets present new opportunities for PP compounders to expand into new areas, adds Zirkel. In electrical and electronics applications, the next generation of bre reinforced
22 COMPOUNDING WORLD | October 2012
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2015 to comply by submitting necessary data in support of inclusion of their constituents within the PIM, although this may change. Food contact applications such as household appliances, to which PIM applies, are a small but growing market for fibre reinforced thermoplastics. In addition, many companies want all components, regardless of application, to meet food-contact requirements. However, some traditional fibre sizings include components that are not on the PIM positive list. For example, sizings designed for polyamides (PAs) often use polyurethane chemistry that may contain hydrazine, which is not on the PIM positive list.
PA6filledwithglassfiberandMica HLP100TestResultsShrinkage
Krntner Montanindustrie (KMI) is a world leading mining and processing company dealing with MicaceousIronOxide(MIOX) KMI uses unique processing technologies for micronization of highaspectratiominerals KMIsproductrangeincludes
Krntner Montanindustrie (KMI), located in Austria, is the market leader inMicaceousIronOxide(MIOX). KMI, as a specialist in micronization of PA6filledwithglassfiberandMica HLP100TestResultsHDT high aspect ratio (HAR) minerals, extended their product portfolio to Mica (Muscovite, Phlogopite) and Wollastonite. These minerals have a higher aspect ratio, either platy or acicular, and they heavily influence the crucial properties of thermoplastic polymers, such as stiffness, heat distortion temperature, dimensional stability and surface scratchresistance.
Krntner Montanindustrie
Mica has a significant influence on the shrinkage; it reduces the overall shrink age and balances the anisotropism compared to the pure glass fiber com poundandcomparedto theadditionof glassspheresaswell;alsoHDTishigher andmechanicalpropertiesareideal.
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RTP is using recycled carbon bres from Boeing to produce compounds for kayak paddle blades
achieve the properties required in these markets. Natural bres are often considered in such applications because they do not detract from the percentage of bio-content, and new bio-based bre reinforcements are being introduced. Evonik recently launched Vestamid Terra HS and Terra DS rayon-bre reinforced, bio-based PA compounds. The rayon (man-made cellulose) bres are produced from wood residues. They are claimed to offer improved reinforcing properties compared to conventional natural bres, some of which also have problems with odour in the end product. Natural bres, however, are not typically able to achieve the same property improvements as glass bres, making glass a good option for some bioplastics applications, notes Udo Erbstoesser, representative for Lanxess, which is in the process of increasing capacity at its Antwerp glass bre plant by 10%. To meet the trend for eco products, Lanxess recently began offering milled bres based on recycled glass bres. Similarly, a new product from breglass company 3B, designed to be in line with the companys sustainability vision, is milled bre MF 01 ER (which stands for eco-responsible). It is the rst product in a new generation of milled bres made from glass valorising material, a manufacturing by-product. The product provides cost-performance between mineral llers and standard glass reinforcements. Its reinforcement and ammability performance enable it to be used in thin-walled electrical and electronic applications, as well as other areas, such as automotive and consumer goods. Another way to make bre reinforcements sustainable is recycling carbon bres. The Aircraft Fleet Recycling Association is a composite recycling network that has been involved with recovering carbon bre from aircraft for several years. Compounder RTP Company is using carbon bres Click on the links for more information: reclaimed from Boeing airplane manufacturing scrap to produce compounds that are moulded into kayak paddle blades. The premium, aircraft- grade carbon bre was able to meet performance requirements at a lower bre loading, which allowed the moulder to also meet the aesthetic requirements. The moulder noted that the system cost difference between the recycledcontent carbon bre compound and the alternative virgin bre was insignicant. Another company, Germany-based CarboNXT, is dedicated to producing recycled carbon bres. The company was founded in 2010 by its holding company, Karl Meyer Group, an environmental and disposal service provider, which also runs the where CFK Valley Stade Recycling company that provides the recycled carbon bres to CarboNXT for chopping or milling.
S www.3b-breglass.com S www.agy.com S www.afraassociation.com S www.carbonxt.de S www.evonik.com S www.jmbers.com S www.glassber.lanxess.com S www.michelman.com S www.owenscorning.com S www.ppg.com S www.rtpcompany.com
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Alignment of the extruder barrel and screw, when done properly, ensures that equipment will be productive for much longer, explains Scott Glover*
system were to operate for 5,000 hours prior to failure, it would be productive for 625 shifts (8 hours/day, 5 days/week) or about 2.4 years prior to a component failure. There arent many production facilities operating at such low rates. Most work at least two shifts per day, for six days a week. With the same 5,000-hour Mean Time Between Failure (MTBF), the system will last for just one year before breaking down. As well as lost production revenues, the cost of a screw can be US$30,000 or more (depending on size and application). A failure in the feed section of the extruder is even more expensive. Catastrophic failures can even cause component failures in the drive components (gearbox). An extruder system can be aligned in less than eight hours, and typically in less than four. That four-hour investment is likely to extend the life of the extruder barrel and screw and keep your facility doing what it is meant to do: make product and move it out of the door. When operating a misaligned extruder system, wear between the screw and the barrel opens up the design
Properly aligned and maintained extrusion processes will be protable long after poorly installed equipment has failed
29
centre of the through hole. The eyepiece of the borescope has a precision crosshair, focused to infinity. The operator can then sight down the barrel and measure the displacement of the optical target at multiple points along its length. However, accuracy can be low and can cause an apparent accurate alignment to fall outside the required tolerances. Laser-based extruder alignment systems offer better accuracy (typically to 0.001in), speed of measurement and reporting on the alignment of the barrel to the thrust shaft rotational centre. But the higher cost of such a system, and the time needed to learn to use it properly, can be daunting for a maintenance department. Simply buying a laser system does not qualify someone to perform precision alignment. A laser transmitter can quickly be qualified to project the true rotational centre of the thrust shaft at any point along the barrel. The laser beam strikes the surface of a Position Sensitive Detector (PSD) mounted in the barrel. Rather than using a crosshair and scale to measure displacement, the PSD accurately measures the centre of the laser beam to less than half a micron (0.0005mm). Depending on operator and machine configuration, laser-based barrel alignment measurements can be completed in about 30 minutes with alignment data documented at each barrel support and at the feed throat.
Getting a reference
Care must be taken to use the correct reference when aligning extruder barrels. If the bore of the thrust shaft is used as the reference, it must be very accurate: the Even the largest, most sophisticated screw and barrel systems can benefit from laser alignment clearance and affects output: one major US manufacturer of barrels and screws estimates that a diametrical wear of 0.025-0.030in could reduce output by 60lb (27kg) per hour. How long would it take to notice this decrease in production? Are losses of half that amount small enough for the problem to continue unnoticed? These numbers quickly get very big, but this can be minimised with proper alignment at the time of installation. bore of the thrust shaft must be precisely concentric at both ends with the rotational centre of thrust shaft. A deviation as small as 0.002in can lead to severe barrel misalignment. If run-out in the thrust shaft bore is visible to the naked eye, it is in excess of 0.020in. It may not sound so bad, but the 0.020in of run-out alone is not the problem: the run-out divided by the length of the thrust shaft produces the error in the reference and the catastrophic error in the alignment at the die end of the barrel. Consider this 0.020in run-out. The thrust shaft on this machine was 30in long, giving a measurement error of 0.00066in per inch of barrel length. This was a 7in diameter barrel with a 24:1 L/D ratio, giving a 168in barrel length. But its 0.00066in per inch angular error creates a 0.110in error in the measurement, if the thrust shaft bore is used as a reference for the alignment. A borescope operator will be reading close to zero, when in fact that position is almost 0.125in out of alignment. This is why the rotational centre of the thrust shaft
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Alignment methods
Historically, three methods have been used to align the extruder barrel to the gearbox thrust shaft: a level; a borescope; and laser alignment. Using a level can lead to misalignment because it does not take account of the horizontal position of the barrel: misalignment in the horizontal plane is as serious as that in the vertical plane. Another method is to use an optical borescope. A precision bore-mounted telescope is installed in the gearbox thrust shaft and bucked-in to the mechanical
30 compounding world | October 2012
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rather than the mechanical centre must be used as a reference to align extruder barrels. If this example was a 40:1 extruder barrel, the misalignment would be 0.180in. If the run-out were only 0.002in, misalignment would equate to 0.011in for the 24:1 and 0.18in for the 40:1 which is greater than our allowable alignment tolerances.
Twin-screw extruders
A twin-screw extruder barrel has the same alignment tolerances as a single-screw barrel. Although the measurement procedure is slightly different, the overall goal is exactly the same: eliminate unnecessary wear and fatigue failures due to barrel misalignment. Laser measurement is much better for this type of barrel alignment. Typically, there is no thrust shaft with a line of sight hole to allow mounting of a borescope. However, a laser transmitter can be mounted on the gearbox output shaft quite easily and barrel alignment can be measured in the same manner as a single-screw extruder. We have performed an alignment on a 23mm twin-screw extruder, which had a history of screws failing in less than 30 days. Typically, the screw would shear at the coupling end between the barrel and the gearbox (the thinnest section of the screw). We found the barrel out of position at the die end by 0.065in in the horizontal plane and 0.019in too high. Adjustments were made to the die end of the barrel in both the horizontal and vertical planes, which xed the problem. Some straightforward engineering analysis provides an approximation of some of the forces applied to the barrel and screw when there is 0.060in of misalignment at the die end of the barrel. A 1.5in, 24:1 screw will need around 450lbs of force to bend it 0.060in. For a 4in, 24:1 screw, this number rises to 9,500lbs of force. The force value for the 1.5in diameter screw is compelling on its own and is the equivalent of operating the extruder with a motorcycle suspended from its mid-point. importantly, to provide a structurally sound method of making precise vertical and horizontal adjustments to align the barrel with the thrust shaft rotational centre. Extruder barrel supports often have no mechanism for alignment, making the job more difcult and expensive. The lack of jacking bolts or shims should not be justication for believing that the alignment process is unnecessary. As the extruder barrel heats up it will expand. If it is supported from below, it will rise in elevation as the barrel temperature reaches a stable operating point. This elevation affects barrel alignment. Thermal growth at the die end of the machine, as well as at any other supports, should be measured and accounted for as part of the alignment process. Our measurements have conrmed a 0.0125in change in the elevation on a 3in diameter barrel when heated to around 600F. That is a diametrical change. The centreline change in the vertical plane will be exactly half that (0.00625in). This means that a barrel, aligned to zero in the horizontal and vertical planes when cold, will be slightly misaligned at its working temperature. Every effort should be made to account for these changes when aligning the barrel in its cold state, but this is relatively easy to do with the latest measuring equipment. Todays manufacturing environment demands maximum production at minimal cost. Modern methodologies and measurement tools can streamline installation and maintenance to save time, money and frustration. Extrusion processes that are properly installed, aligned and maintained will continue to be protable long after poorly installed and maintained equipment has failed. * Scott Glover is president of The Advanced Team (www.theadvancedteam.com), an extrusion alignment specialist based in Mooresville, North Carolina, USA
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Support act
The support structure under the barrel is critical to the life of the system and the quality of the alignment as the machine reaches normal operating temperatures. Most extruders have one or more mechanical supports under the barrel, which have three basic functions: to support the barrel and prevent it from sagging due to its weight; to act as an axial guide, allowing the barrel to grow in length as the system heats up; and, most
32 COMPOUNDING WORLD | October 2012
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enough to behave like a KC machine, offering instant screen movements on softer polymers, and a KCN, offering great performance on hard thermoplastics. In compounding
applications, uniform extrusion pressure is required to ensure quality mixing as well as rate control in the extruder. Because the KCH can move the screen very slowly across the melt stream there is no pressure disruption throughout the entire production run. In addition, the unit can be adapted to match the conguration of a twin-screw extruder to maximise the ow area. The KCH uses a dedicated PLC to monitor extrusion pressure and quickly react by moving the screen to keep this pressure uniform. It has demonstrated its ability to process polymers ranging
from TPEs and TPOs with Shore A hardness values as low as 30, through to thermoplastics such as PP, PC, HDPE, PET and R-PET. This can be achieved on the same machine running the same screen and with leak-free, uniform pressure operation. The KCH has also successfully run a nylon blend ltering down to 40 microns. Parkinson Technologies is very excited about this new machine. Its a highly costeffective solution for many ltration applications where high performance, productivity and reliability are required, says Peter Termyn, the companys president and CEO.
S www.keylters.com
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Germanys largest plastics show of 2012 is taking place this month. We take a look at the latest compounding related machinery and materials that are being shown at Fakuma
ment of interest to the compounding community. Over the following pages we take a look at some of the compounding-related products that are being displayed across the Fakuma 2012 fairground.
Fakuma 2012
Date: 16-20 October 2012 Venue: Messe Friedrischshafen, 88046 Friedrichshafen, Germany Hours: 09:00 17:00 (Saturday 09:00 16:00) Admission: Daily ticket 25.00 (Two-day ticket 40.00) Organiser: PE Schall, Gustav-Werner-Strasse 6, 72636 FrickenhausenLinsenhofen, Germany Website: www.fakuma-messe.de
October 2012 | COMPOUNDING WORLD 43
94 mm, the new machine is offered with a wide range of equipment option and accessories, while the screws can be supplied in a variety of steel grades from nitrided steel to special HIP alloys.
S www.feddem.com
Automatik Plastics Machinery (Hall A6, Stand 6202) is showing the new generation of its Sphero 50 underwater pelletizing system. This features improved ergonomics and is designed for quick start-up and reliable processing even with difcult materials. It is the smallest model in the Maag subsidiarys Sphero range, suitable for handling throughputs from 70 to 600 kg/h. Target applications include testing plants and technical centres as well as smaller production plants. The pelletizers compact design incorporates all its KraussMaffei Berstorff is showing its optimized ZE-UT-R twin-screw extruder for higher ller loadings bulk densities, according to the company. Higher ller loadings require longer processing sections to ensure that the particles are fully incorporated into the plastics matrix, so the ZE extruders for this task feature processing section lengths ranging between 50 and 56 D. Two side feeders provide additional options for feeding additives into the processing section, while three atmospheric degassing systems and one vacuum degassing unit are used to efciently remove unwanted gases from the extruder. In the course of the last two years, KraussMaffei Berstorff has already sold 15 lines for the production of highly lled PE or PP compounds with a talc or chalk share of up to 80%, reports Dr Thomas Winkelmann, head of twin-screw extruder process technology at KraussMaffei Berstorff in Hannover. The compounds are used in applications such as blown lm for carrier bags, sacks or construction lm. Econ (Hall A6, Stand 6104) is using Fakuma to introduce its optimized underwater pelletizing system with an integrated band lter system. This is directly incorporated in the process water circulation and enables full ltration of the water stream immediately after initial separation of the pellets. The system was developed specically for processing highly Feddems new FED 26 MTS twin-screw extruder is the smallest model in the range Feddem (Hall A6, Stand 6312) is introducing its new FED 26 MTS twin-screw extruder. This latest addition to the MTS range has a screw diameter of 26.6 mm, a Do/ Di ratio of 1.55, screw speeds up to 1,200 rpm and drive power up to 28 kW. Its modular design allows it to be extended from 32 D to 42 D, 52 D or longer. It is the smallest model in the MTS range and it can be used as a laboratory extruder or for small-scale production of a wide variety of products including masterbatches and high-performance polymers. Production rates range from 10 to 150 kg/h. The design is similar to the larger MTS machines for reliable process scale-up. Its complete electrical system is integrated into the frame and the machine stands on castors, making it mobile and easy to move. As with larger models in the range, which go up to
44 COMPOUNDING WORLD | October 2012 www.compoundingworld.com
components on a mobile frame that can be freely accessed from all sides for simplied cleaning and product changeovers. Special attention was given to the new design of the cutter head in order to ensure the production of evenly shaped, high-quality pellets. In addition, the ow pattern inside the chamber has been optimized to minimize dust generation from brittle materials, reduce wear when handling bre reinforced materials, and combat agglomeration with thermoplastic elastomers.
S www.maag.com
S www.kraussmaffei.com
lled compounds or for masterbatch applications where efcient ltration of the process
Images courtesy of: Aspla S.A., Britton Unterland GmbH, Frilvam S.p.A., RKW SE
Rocio Martinez Conference Organiser rmm@amiplastics.com Ph: +44 117 924 9442 Fax: +44(0)117 311 1534
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water is required. Contaminants and fines are held back by the filter and when they have built up to a certain point the filter wheels turn and the filter area is renewed. Seals ensure that no contamination passes into the circulating water.
www.econ.eu
Ancillary equipment
K-Tron (Hall A6, Stand 6507) is displaying a complete materials handling system for continuous plastics processing. It features the companys vacuum loaders and receivers, which can be used for various applications such as hopper loading, refilling loss-in-weight feeders and handling a wide variety of bulk materials. Also included are K-Tron feeders that ensure the accurate addition of high-value minor and micro ingredients to the batch or continuous process. The K-Tron display also includes the companys K-Vision Line Controller, an operator interface that simultaneously controls up to 16 feeders via an easy-to-use colour LCD touch screen. Other items of equipment on show include a bulk solids pump with a C100 venturi type loader as well as a quick change The Kreyenborg display (Hall A6, Stand 6404) features the groups screen-changers, melt pumps, pelletizers, dryers and automation systems. The stand includes Kreyenborgs latest K-SWE-4K75-V/RS back-flush screen-changer (which is covered feeder with a 2410 vacuum conveying receiver.
www.ktron.com
Automatiks Sphero 50 pelletizer features improved ergonomics
costly multiple feed controller for small installations. Protec is exhibiting for the first time at Fakuma since Schoeller Plast acquired the business unit from Mann+Hummel earlier this year. That move brought the Protec Somos materials handling equipment range together with Schoellers OHL recycling systems for PET.
www.sp-protec.com
Materials
Clariant (Hall B2, Stand 2217) is focusing on colour masterbatches that are registered to the UL safety standard for flammability. The company says that materials specifiers often overlook the fact that colorants can affect the fire behaviour of flame-retarded polymers. It has worked with UL so that it can provide a Econ now offers an integrated band filter system with its underwater pelletizing systems in detail in this issues melt filtration round-up), plus an Infrared Drum (IRD) for the efficient drying and crystallisation of PET. The Groups BKG Bruckmann & Kreyenborg Granuliertechnik subsidiary is exhibiting one of its underwater pelletizing systems. Its full range covers throughputs from 2 kg/h to 35,000 kg/h, plus it offers the CrystallCut inline crystallisation system for the economic processing of PET. large number of masterbatch and polymer combinations to meet fire-performance or flammability classifications. UL-listed colour masterbatches from Clariant are individually formulated for compatibility with both the polymer and the flame retardant system, and then subjected to UL test procedures that ensure the required flammability ratings are met. This portfolio is available from over 20 UL-certified manufacturing sites worldwide.
www.clariant.com
Colloids (Hall B4, Stand 4402) is showcasing its Pace
www.kreyenborg-group.com
Materials handling systems maker Motan-Colortronic (Hall B1, Stand 1111) is showing examples from its latest range of blending, dosing and crystallising equipment. The display includes the Gravicolor batch gravimetric K-Tron is displaying a complete materials handling system for continuous plastics processing dosing and blending systems, which range from the 30MD microdosing units up to models able to handle throughputs of 2,200 kg/h. The units feature a modular construction and can be configured to handle up to six ingredients. HDC series crystallisers are designed for enhancing PET prior to processing. Offering throughputs from 80 to 900 kg/h, the modular units are designed with frequency-controlled blower drives to help minimise energy usage. series of engineering polymer specific masterbatches that include PA, PET PBT and PC grades. One highlight for PA applications is Pace Black 11452
www.motan-colortronic.com
Protec Polymer Processing (Hall B3, Stand 3119) is showing a new gravimetric batch dosing system designed to handle up to four components, together with a new conveying control unit. The Somos BB150 batch doser is designed for direct mounting onto the feed throat of the processing machine, the unit can handle throughputs of up to 150 kg/h and can be equipped with optional suction conveyor loaders if required. Also new is the MH5 conveyor control system, which can operate as a single or multiple feed unit in networks of up to 12 conveyors, avoiding the need for a
48 compounding world | October 2012 www.compoundingworld.com
www.kraussmaffei.com
Clariant is focusing on colour masterbatches that meet the UL safety standard for flammability
ers and electronics heat sinks. Ensinger is also launching the first product in its new Tecamold LDS range for manufacturing moulded interconnects using the direct laser structuring technique. The first compound in this new line is based on PEEK resin; the company says it is currently developing additional grades using alternative hightemperature resins.
www.ensinger-online.com
The display on the ExxonMobil stand (Hall B4, Stand 4310) focuses on polymers for the production of lightweight automotive components. The company claims its Santoprene TPVs and Exxtral polyolefins are helping car makers produce lighter components that match or exceed the mechanical and aesthetic requirements of currently used alternatives. which contains an impressive 50% concentration of Solvent Black 7 in PA 6, allowing the masterbatch to be used at lower loadings. The company has developed a solvent black masterbatch based on PA 66 Pace N54/1066. Another new addition to its PA range is Pace EL 4303, a predispersion of 40% molybdenum disulphide in PA 6. Molybdenum disulphide is well known as a low friction and wear reducing additive in oil formulations, but Pace EL 4303 allows these benefits to be realised in solid polyamide formulations. For PET applications, Colloids has enhanced its range of black masterbatches with the addition of Pace PET 13721 which offers additional nucleating capability for CPET. It has also developed new products that use a novel pigmentation system which is not based on carbon black. These allow PET waste to be segregated for recycling as they do not interfere with the infra-red detection systems currently in use. Pace Black 4357 has been developed by Colloids for PC compounds, mouldings and extrusions. It uses high A BKG underwater pelletizer is being shown on the Kreyenborg Group stand High performance electronics solutions are being displayed on the Ensinger Compounds stand (Hall B1, Stand 1222). The company is showing its highly filled graphite compounds for injection moulding of bipolar plates for both high and low temperature fuel cells. These high thermal conductivity grades are also said to be suitable for the production of heat exchang50 compounding world | October 2012 www.compoundingworld.com
It is also highlighting applications of its Vistamaxx propylene-based elastomers in applications such as food and beverage containers and rigid packaging and storage, where the resin can help to cut cost and improve environmental performance.
www.exxonmobilchemical.com
FKuR (Hall 5, Stand 5126) is highlighting Braskems sugar cane ethanol-based PE resin. FKuR is the distributor for the Brazilian companys Green PE in Europe and it has also developed a range of bio-based PE compounds which are marketed under the Terralene name. All are 100% recyclable and fully compatible with petrochemical-based PE. FKuR is also showing its own biodegradable plastic compounds, including its Biograde injection moulding product line. The latest addition to the Biograde portfolio is the cellulose-based C6509 product, which is said to offer high transparency, good flexibility and easy colouring making it suitable for applications such as cosmetics packaging.
strength, high jetness carbon black in a carrier system comprised entirely of PC with no additional lubricants or dispersion aids which can have an adverse affect on the compounds impact strength.
www.fkur.com
www.colloids.co.uk
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Geba Kunststoffcompounds (Hall B4, Stand 4210) has expanded its range with the launch of its Gebamic TPU micro pellets that it says are particularly suitable for masterbatch production and micro injection moulding applications. They offer advantages over plastic powders as they are produced in a single step rather than two stages, plus they are dust-free. The company has installed a new underwater pelletizer system at its Ennigerloh plant in Germany that enables it to produce micro pellets with sizes below 400 microns. Other target applications for the TPU micro pellets include rotational moulded slush skins for car dashboards and the coating of conveyor belts, fabrics, textiles and ooring. Geba intends to expand the product line with additional thermoplastics in the near future.
VW 50180 and VDA2761 emission standards and VW 44045 heat ageing test. The company is also providing details of its new Biocolen colouring joint venture with Sensient Imaging Technologies, which allows it to add food colourings to bioplastics by encapsulating the colorant in silica. The silicate matrix is said to protect the colorant from oxidation, increase its resistance to solvents and water, and minimise migration from the plastic matrix. The Biocolen technology currently includes brown, green, orange, yellow, red and violet products. Colloids is showcasing black masterbatches in a range of engineering polymers
S www.geba.eu
Compound and masterbatch maker Grafe (Hall B5, Stand 5306) is displaying its latest innovations, including a low emission PP compound for the automotive industry and a new colouring technology for bioplastics. The new PP compound is suitable for injection and blow moulding and is said to meet the requirements of the
S www.grafe.com
GSDI, a subsidiary of PolyOne, is promoting its range of liquid colours and additives for silicone engineered materials at Fakuma 2012 ((Hall B2, Stand 2119). The company has recently opened a distribution facility in Limburg, Germany, which has signicantly reduced lead
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Its colorants range includes Silcogum for high consistency silicone rubbers, Silopas for liquid silicone rubber and room temperature vulcanizing applications, plus various special effect pigments such as sparkles, metallics and scents. Additive products include Silcosperse for improving the demoulding of silicone parts, and Silcocat peroxides for improved productivity.
S www.gsdi.com
Kraiburg-TPE (Hall 5, Stand 5303) is highlighting its latest material developments, headed up by its Copec compounds for the consumer electronics sector, Thermolast V grades for high temperature applications, and its medical grade Thermolast M products. Copec grades have been formulated to deliver the velvet-like tactile effect sought after by manufacturers of consumer electronic products. Offering good resistance to skin lipids and most common cleaning products, the grades provide good mechanical properties and bond well to ABS/PC blends. Kraiburg is also showing its Thermolast V grades for high temperature applications and medical grade Thermolast M products. The V series TPEs are intended for automotive and industrial applications requiring resistance to temperaNovosystems can create any colour from the industrystandard Pantone range tures up to 140C. Features include good compression set performance, with the latest developments providing an improved bond to PA. Thermolast M grades have been developed for medical and pharmaceutical applications requiring good bonding to PA and ABS. PolyOne (Hall B5, Stand 5316) is focusing on the metal replacement potential of its polymer compounds. These include OnForce LFT long bre reinforced grades, Milliken is supplying its Millad NX 8000 clarier to Slovnaft Petrochemical for the production of a new range of polypropylene random copolymers for thin-wall rigid packaging applications. Slovnafts Tatren RM 85 52 Clear and RM 45 55 Clear grades offer high levels of clarity plus energy savings through low temperature processing. Visitors to Fakuma can see Tatren RM 85 52 Clear being used to mould a food packaging container on the Haitian Europe stand (Hall A6, Stand 6107). Gravi-Tech high-density formulations, Therma-tech thermally-conductive materials, Stat-Tech static dissipative products, and XECarb carbon bre reinforced plastics. In the automotive industry, we have improved our customers manufacturing efciency and sustainability using the latest polymer innovations and design support, including mould-lling simulations and part and mould design assistance, says Holger Kronimus, vice president, Europe and general manager, Engineered Materials Europe, PolyOne. We see many opportunities to help our customers win with metalreplacement in other industries including appliances, electronics and electrical goods and a variety of industrial applications. Nilit Plastics Europe (Hall B1, Stand 1213) is promoting its range of nylon compounds including its broad selection of ame retardant products as well as standard engineering grades plus specialty products such as
54 COMPOUNDING WORLD | October 2012
low wear and friction, conductive and carbon bre reinforced materials. The company benets from vertical integration with its PA 66 polymerization capabilities.
S www.nilit.com/plastics
Germanys Novosystems (Hall B3, Stand 3209) is launching its Novotone Main Colours, which allow it to create any colour from the industry-standard Pantone range. The Novotone system is available for both liquid colour and the companys Novopearls microbatch products. The company says the user has only to choose the colour required and it will replicate it using its predetermined colour mixing recipes. More than 2,000 shades can be reproduced using the Novotone standard colour range.
S www.novosystems.de
S www.kraiburg-tpe.com
S www.milliken.com
S www.polyone.com
Netherlands-based Purac (Hall B4, Stand 4207) is showing a range of packaging and disposable foodware items produced using its new Puralact heat resistant
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has a matt surface effect. Another Rowa Group company, Tramaco is expanding its range of Tracel foaming agents for extruded and injection moulded TPE and TPU. The portfolio now includes foaming agent pellets with various polymer carriers, different types of microspheres and different active contents. Other new additions include food-contact and high-temperature grades.
www.rowa-group.com
Styrolution is exhibiting a range of components produced using some of its Luran SAN and ASA based compounds at Fakuma (Hall B4, Stand 4308 and Hall A5, Stand 5214). These include front grills and B-pillar Wacker is launching new Elastosil silicone-rubber grades for pacifiers/ dummies Rowa Group companies are showing some interesting Teknor Apex is showing its Beetle E line of cost optimised PA compounds new compound developments at Fakuma (Hall B1, Stand 1212). For example, Romira is using the event to showcase its new generation of halogen-free flame retardant ABS/PC compounds. The Romiloy 9130 grades are said to offer increased thermal stability, reduced density, improved UV resistance and significantly higher Vicat softening temperatures compared to PC/ABS blends containing brominated flame retardants. Target applications include electronic and medical devices. Romira is also introducing its streak-free ASA compounds which were developed in conjunction with KVS, a supplier of plastic panels and films. Rotec ASA EXP 2158 is suitable for injection moulding and extrusion applications and provides a high gloss surface. The other new streak-free grade, Rotec ASA EXP 2191 is designed for injection moulded parts and Wacker (Hall A6, Stand 6217) is introducing new Elastosil silicone-rubber grades for manufacturing pacifiers/dummies and bottle nipples for young children. The liquid-rubber and solid-rubber products have been developed to provide high tear resistance. The soft, bite-resistant Elastosil LR 3040 liquid silicone rubber grades have very short curing times and are offered with 30 and 45 Shore A hardness. The new Elastosil R plus 4020 solid silicone-rubber grades are available in Shore A 40 and 50 versions for application in pacifiers and bottle nipples respectively. The solid grades offer even higher tear strength than the liquid versions more than 50 N/mm when measured under ASTM D 624 B. This enables the design and production of components with thinner wall thicknesses. polylactic acid polymers. It claims its L and D-based lactide homopolymers lift the performance of the bioplastic into the 80-180C temperature range, opening up opportunities in areas such as automotive and electronics, as well as packaging. covers for Skoda cars, window profiles from Veka and Wegalux solar roof tiles. Also on show is a Renault centre console produced using Terblend S NM-31, an ABS/PA blend.
www.styrolution.com
Fakuma presents the first opportunity for Teknor Apex (Hall B4, Stand 4107) to show its expanded range of engineering thermoplastics in Europe. The latest addition to its Beetle range of PA, PET and PBT-based compounds is the Beetle E line, a cost optimised range of non-reinforced and glass reinforced polyamide products available in black or natural colours. The company is also showing its new Chemlon 800 series of PA 6,12-based compounds for used in the production of fuel line components.
www.purac.com
www.teknorapex.com
www.amiplastics.com
56 compounding world | October 2012
www.wacker.com
www.compoundingworld.com
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