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Compounding World Feb-2011
1. February 2011
recycling technology takes oFF
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4. news
dSm buys into russian
compounding plant
dSm has established two joint owned by dSm. it will focus on DSM’s Nico Gerardu
ventures with KuibyshevAzot growing the market for pA6 in says that the JVs
(KA) of russia covering the russia and the ciS. it will will capitalise on
sales and production of target both pA6 compounds anticipated PA 6
polyamide 6 in russia and the and high-viscosity applica- growth in Russia
commonwealth of independ- tions, including film.
ent States (ciS). As part of the As part of the strategic nico gerardu, member of capitalise on this anticipated
agreements, dSm Engineering agreement, KA is licensing the dSm board with responsi- growth.”
plastics will acquire 80% of dSm’s cyclohexanone technol- bility for performance KA is a leading producer of
KA’s compounding plant in ogy which will allow it to materials, said: “russia is an caprolactam and pA in russia
Togliatti, russia. increase pA6 capacity at its increasingly important market and the ciS, and is among the
dSm says that this produc- plant in Togliatti to help meet for engineering plastics and it world’s 10 biggest producers
tion JV means that it is the first the anticipated increase in is expected that the market for of these products. it had net
western pA 6 supplier with its demand created by the new pA6 will double in the next five sales of uS$505 million in
own manufacturing presence JVs. dSm Fibre intermediates years. with our partnership 2009 and employs around
in russia and the ciS. The will also have drawing rights with KA, i expect that dSm 5,500 people.
other JV, which covers sales for part of the increased Engineering plastics will be in ❙ www.dsm.com
and marketing, will be 51% capacity. an excellent position to ❙ www.kuazot.ru
rhodia acquires pi polymer to Spanish toy
makers add
grow pA compounds in india conductivity
rhodia is acquiring pi Spain’s Toy research
polymer, the engineering François Hincker says that institute (AiJu) is leading a
plastics compounding acquisition will dramatically research project to examine
business of the indian accelerate Rhodia’s growth the use of new conductive
company pi industries. The in India plastics compounds to
deal is expected to be complet- control electromagnetic
ed by the end of march 2011. interference entering and
pi polymer forecasts leaving electrical and
revenues of approximately electronic toys.
uS$13 million for the 2010/11 The collaborative
fiscal year. its plant in panoli, project, called Emitoy, will
gujarat, employs more than 80 examine the use of carbon
people and produces a range François Hincker, president of Following the sale of pi nano-fibres in polyolefins to
of technical compounds rhodia Engineering plastics, polymers, pi industries will improve electromagnetic
including pA, pc, pBT, ABS said: “we have identified focus on the production of screening, electrostatic
and pp as well as some TpEs. strong synergies with our agro-chemicals and the dissipation and electrostatic
According to rhodia, the engineering plastics business custom synthesis of fine painting. it is receiving
acquisition is part of its in terms of product range and chemicals and pharmaceutical regional government
strategy to grows it share of customer portfolio that will intermediates. funding as well as support
india’s pA compounds market dramatically accelerate our ❙ www.rhodia.com from the European union.
to more than 15% by 2015. growth in india”. ❙ www.piindustries.com ❙ www.aiju.info
compounding world | February 2011 www.compoundingworld.com
5. news
cereplast and colorTec Eu plans
13.8% tax
to benefit from bag ban on chinese
cereplast of the uSA has
entered a distribution agree-
natureworks and BASF’s
Ecoflex compostable copolyes-
have made the use of bioplas-
tic garbage bags mandatory
glass fibres
ment with the italian master- ter. it can be processed on from the start of this year. The European union (Eu) is
batch marker colorTec existing blown film lines and is cereplast already has a deal in likely to impose import
covering the sale of bio-based claimed to offer high strength. place to supply its composta- duties of 13.8% on glass
and compostable plastics com- “recent environmental ble 3000 film grade resin to fibres imported from china.
pounds in southern italy and legislation, such as the plastic another italian masterbatch if approved later this
Slovenia. The companies bag ban that went into effect maker, ri.mE, which is using it month, the tariffs will be
expect to tap into growing this year in italy, is driving to produce colour masterbatch imposed from 17 march
demand for such materials as demand for bioplastics,” said for the European market (see 2011 and will run for a
a result of italy’s highly cereplast’s cEo Frederic Compounding World, October period of five years. glass
controversial ban on non- Scheer. “we are confident that 2010, page 7). yarns will be excluded from
compostable plastic bags. demand will continue to rise in l cereplast has also signed a the import duties.
under the terms of the Europe as stores in italy alone deal with another European As reported in Com-
agreement, cereplast will use approximately 20-24 compounder, Euroink pounding World, Septem-
provide colorTec with its billion plastic bags a year, romania. This company will ber 2010, the Eu imposed
compostable 3000 film grade which accounts for one-fifth of use cereplast’s bio-based and an extra duty of 43.6% on 16
resin for the production of all European use”. compostable resins to produce September for a period of
masterbatches for the colorTec has a strong colour masterbatch for the six months, while further
manufacture of shopping and market position in southern romanian market. investigations into the issue
garbage bags. The resin is a italy and works closely with the ❙ www.cereplast.com were carried out.
blend of ingeo plA from country’s municipalities that ❙ www.colortec.it The increase has been
supported by glass fibre
producers who have
Americhem invests in three complained about the
dumping of chinese
new compounding lines material at illegally low
prices. However, it has been
fought by the users of
Americhem has added three fibreglass who believe that
compounding lines at its plant the increased tariff will lead
in concord, north carolina, to material shortages and
uSA, to increase capacity for increase their costs.
colour and additive master- The European compos-
batches. The expansion will ites industry Association
help to meet growing demand (EuciA) welcomes the
from the polyester bulk proposed reduction in the
continuous filament (BcF) tariff, but argues that a
market. Americhem has added 13.8% duty will still be
Two of the new lines are set three compounding lines harmful for European users
up to produce high-quality at its Concord plant of glass fibres. it also points
products in large lot sizes for out that the tariff was only
the polyester floor covering “with the floor coverings our customers grow and gain supported by four of the 27
industry. The third is optimised market increasingly shifting to the competitive edge,” said Eu member states, with
for the production of small lots the use of pET BcF fibres over Jim cook, the company’s plant most countries abstaining
that meet the critical specifi- staple and polyolefin-based manager in concord. in the vote.
cations of the textile industry. fibres, Americhem can help ❙ www.americhem.com ❙ www.eucia.org
www.compoundingworld.com February 2011 | compounding world
6. news
Foster opens medical plastics lab
Foster corporation has opened “As the market for medical
its medical plastics innovation devices evolves, materials of
center at its headquarters in construction become more
putnam, connecticut, uSA. critical,” said Foster’s cEo
The facility will be used to larry Acquarulo. “For
develop advanced polymer example, within the last 20
formulations for leading edge years the outside diameter of a
medical devices. it offers typical angiographic catheter
polymer compounding, has decreased by 70%, while
materials testing and process the working pressures have
evaluation for moulding and increased well over 100%. This
extrusion. was made possible by
particular areas of focus at improvements in polymer
the new development facility technologies.”
will include nanocomposites A subsidiary of the polyme-
and melt-filtered materials, as dex discovery group, Foster
well as anti-microbial has been producing thermo-
additives for infection control plastics compounds for The new facility is built around
materials. Tailored polymers medical applications for more twin-screw extrusion for
will also be developed for than 20 years. compound development
long-term implants. ❙ www.fostercomp.com
Altana buys Kometra Schulman shuts plants
Altana is to acquire the in italy and Australia
Kometra, the polymer
modifier producer based in A. Schulman is closing its administrative office will
Schkopau, germany. The manufacturing plants in remain at Verolanuova.
company will be integrated Verolanuova, italy, and All production at the
into Altana’s BYK additives Breaside, Australia, with the Breaside plant, near mel-
business. loss of approximately 40 to 60 bourne, Australia, will be
Kometra’s products jobs. Both facilities produce moved to other facilities in the
include specific surface- powders for rotomoulding region. The company has a
active copolymers which are applications and were plant in Brisbane, Australia, as
used as impact modifiers and BYK’s Dr Roland Peter says previously owned by ico well as facilities in malaysia,
adhesion promoters. They are that sales of Kometra’s poly- polymers which Schulman indonesia and china.
marketed under the Scona mer modifiers will benefit acquired in April 2010. The closure of the Breaside
brandname and are produced from his company’s global production lines from the facility was primarily the
using a patented solid-state sales network Verolanuova plant will be result of the ongoing deterio-
grafting process originally relocated to Schulman’s site in ration of the rotomoulding
developed by dow. that BYK’s global sales gorla maggiore, italy, by early business in Australia. in
“with Kometra’s technol- network is well positioned to 2012. The latter facility will be particular, demand for water
ogy there are new fields of open up new market used to develop and manufac- tanks has fallen following a
business which ideally potential for Kometra’s ture value-added technical steady decline in drought
complement and expand our polymer modifier technology powders as well as custom conditions and government
existing activities,” said dr worldwide. colour masterbatches and rebates have been withdrawn,
roland peter, president of ❙ www.altana.com compounds for the local says the company.
the BYK division. He added ❙ www.kometra.de market. A commercial and ❙ www.aschulman.com
compounding world | February 2011 www.compoundingworld.com
7.
8. news
lanxess clariant spearheads
starts to
build plant reach registrations
in india clariant has begun work on “we are delighted to have
lanxess has started phase Two of reach legislation completed the task assigned to
construction of its new following its successful us,” commented Hariolf
20,000 tonnes/year com- registration of 152 substances Kottmann, clariant’s cEo.
pounding plant in Jhagadia, under phase one, ahead of the “our achievement in complet-
gujarat, india. it is due on december 2010 deadline. The ing phase one registration
line at the start of 2012 and second phase involves more inside the deadline required a
will be used to produce pA than 300 chemicals and should lot of long, hard work, and an
and pBT compounds. A be completed by 1 June 2013. intensive use of resources”.
ground-breaking ceremony in phase one, clariant was l if you need to know more
was held at the site in the lead registrant for 81 out of about registering substances
January. lanxess is investing the 152 consortia and Sub- for reach, click here to
more than E10 million in the stance information Exchange download the latest edition of Clariant’s CEO Hariolf
facility which will create 60 Forums. The work covered the EcHA’s 123-page publica- Kottmann says that Reach
new jobs. finished products, intermedi- tion, guidance on registration. registration has required “an
❙ www.lanxess.com ates and raw materials. ❙ www.clariant.com intensive use of resources”
Australian court dismisses Fox plans to
oxodegradable claims recycle in
mexico
The Federal court in Adelaide, the Australian standard. in of the oxodegradable bags, Fox petroleum is planning
Australia, has declared that addition, the bags did not nupack Australia, had the to form a plastics recycling
goody Environment engaged in biodegrade, disintegrate, or same claims dismissed for the subsidiary in Tuxtla
misleading and deceptive compost in accordance with same reasons. gutierrez, southern mexico.
conduct and made false the standard. dr michael Schraper, the it expects that it will be able
representations about its According to Justice lander, Accc’s acting chairman, said: to process up to 2,300
plastics bags which contain goody contravened sections 52 “Environmental claims are tonnes/year of industrial
oxodegradable additives. and 53 of the Trade practices powerful selling tools as many and consumer waste
in 2009, the company had Act and the company has been purchasers want to do the plastics.
claimed that its goody- ordered to publish corrective right thing for the environ- The city has one million
branded plastic bags were notices on its website and in ment. it is important that they people, but currently there
biodegradable and composta- The Advertiser newspaper. it are given accurate information are no recyclers of plastics.
ble in accordance with the was also instructed to and can feel confident in the “There is an enormous
Australian Standard AS4736- implement a trade practices purchasing decisions they demand for recycling from
2006 and could be legally compliance and education make.” both the private and public
supplied in South Australia. programme, and to contribute l Click here to download the sectors throughout mexico,
The court declared that this AuS$65,000 (E48,000) towards Accc’s four-page publication but specifically in Tuxtla
was not the case because the the costs of the Australian providing practical guidelines gutierrez, the leading city in
bags contained the heavy competition consumer on making biodegradable, the state of chiapas,” said
metal molybdenum in amounts commission (Accc). degradable and recyclable william lieberman,
that exceeded the maximum in a previous court decision claims on plastic bags. president of Fox petroleum.
concentration prescribed by in october 2010, the distributor ❙ www.goody.com.hk ❙ www.foxpetro.net
compounding world | February 2011 www.compoundingworld.com
9.
10. Polymers in Cables
2011
The International Conference and Exhibition for the Plastics Cable Industry
CliCk Here
for more
deTailS
March 31- April 1, 2011
Hilton Miami Downtown,
Images courtesy of: Miami, Florida, USA
Omya and Imerys
Performance Minerals
final reminder – book now!
Organized by: Sponsored by:
Applied Market
Information LLC.
marissa Hann – Conference Coordinator mh@amiplastics-na.com Ph: +1 610 478 0800 fx: +1 610 478 0900
11. news
linpac sells cabot starts to construct
recycling
business
chinese masterbatch plant
cabot has begun construction increase masterbatch capacity already the largest master-
linpac recycling, one of the of a new black masterbatch at the site to 80,000 tonnes/ batch producer in china,
uK’s largest plastics facility at its site in the Tianjin year in the future. thanks to its plant in Hong
recyclers, has been bought Economic development Area Sean Keohane, vice Kong. it is also growing in the
by chamonix private Equity (TEdA), china. it is investing president and general middle East with the opening of
along with four other uS$20 million in the com- manager of cabot’s perform- its 25,000 tonnes/year facility in
businesses from the linpac pounding plant which will have ance Segment said: “demand dubai, uAE, in August last year.
group. They are described an initial capacity of 45,000 for masterbatch in china and The latter plant’s capacity can
as “non-core” to linpac. tonnes and is scheduled to be the broader Asia pacific region be trebled if required.
linpac recycling, which completed in mid-2011. is growing rapidly. Having a The company’s European
recycles post-use rigid in 2009, cabot doubled local manufacturing facility masterbatch production is
plastic into recycled carbon black production producing high-quality being consolidated into its
compounds for a wide capacity at its TEdA plant to products to serve our custom- loncin and pepinster sites in
range of moulding applica- 300,000 tonnes/year. The ers will be a significant Belgium. it closed its uK
tions and end-use markets, company says that the addition competitive advantage for us”. compounding plant in dukin-
will change its name to of the compounding facility will Target markets will include the field in Summer 2009 and it is
regain polymers. make it the world’s first fully pipe, wire, cable and automo- ending masterbatch production
❙ www.linpac.com integrated black masterbatch tive sectors. in grigno, italy, this month.
❙ www.regainpolymers.com plant. it will be possible to in volume terms, cabot is ❙ www.cabot-corp.com
npE 2012 attracts high levels of interest
representatives from more the previous npE show, which
than 650 exhibiting companies was held in chicago in 2009.
travelled to orlando, Florida, After 38 years in chicago, the
uSA, last month to take part in event is being relocated to
the draw for stand space at the orlando in 2012 in a move that
npE 2012 exhibition, north is designed to save costs for
America’s leading plastics exhibitors and visitors.
industry event. The triennial show is
with over a year to go, more organised by the Spi, the uS
than 750 companies have plastics industry association.
contracted almost 62,000 m2 of its senior vice president of
space. This is already equal to trade shows gene Sanders
87% of the occupied area at said: “The booth selections
thus far almost completely fill
NPE 2012 exhibitors
the west Hall of orlando’s
gathered in Orlando
orange county convention
to select their stand
positions and tour centre, and the South Hall is
the new venue filling up quickly”.
npE takes place on 1-5
April 2012. The SpE’s AnTEc
annual technical conference
will take place alongside the
exhibition.
❙ www.npe.org
www.compoundingworld.com February 2011 | compounding world 11
12. news
BASF boosts production news in brief
of biodegradable plastics
❙ Spartech Polycom is
restarting production at its
pp compounds plant in
lockport, new York, uSA,
The new Ecoflex biodegradable plastics BASF has started up its expanded Ecoflex after it was closed in late
plant adds 60,000 tonnes of new capacity plant in ludwigshafen, germany, increasing 2009 as a result of declining
production capacity for the biodegradable demand from the automotive
polyester from 14,000 to 74,000 tonnes/year. it market and in particular the
is also increasing compounding capacity for delphi Harrison Thermal
Ecovio, which is a blend of Ecoflex and plA Systems plant also located in
bioplastic. the same town.
Ecoflex is a synthetic plastic that has www.spartech.com
properties similar to those of polyethylene, but
is fully biodegradable under industrial ❙ Cray Valley has signed an
composting conditions in accordance with din agreement with the Grolman
En 13432. Ecovio is also biodegradable, but Group for the distribution of
contains up to 75% renewable raw materials. its products to the plastics
Typical applications include shopping bags, markets in germany,
mulch films for agricultural applications, bags Switzerland, Austria and
for organic waste and food packaging. BASF Benelux. grolman will focus
says that demand for biodegradable and bio- on selling cray valley’s
based plastics is currently growing at more specialty low-molecular-
than 20% per year. weight functional additives to
❙ www.basf.com compounders and master-
batch makers.
www.grolman-group.com
cytec grows stabilizer capacity www.crayvalley.com
❙ EnerPlastics of dubai has
cytec industries is increasing plastics and coatings is l in a separate move, cytec begun production of oxode-
production capacity for light growing,” explained domenico has sold its building block gradable additive master-
stabilizers by more than 30% romanino, global business chemicals business to an batch for use in polyolefins.
at its plant in willow island, director for polymer additives affiliate of Hg capital for called Ep oBd, the product
west Virginia, uSA. The at cytec. “we are expanding our uS$180 million. The product is claimed to meet French
expansion is expected to be manufacturing capabilities for lines include acrylonitrile, standards for oxodegradation
completed by the beginning of several product lines including sulphuric acid and melamine and has been certified by the
2012, says the company. cyasorb THT and cyasorb which are produced mostly for centre national d’Evaluation
“global demand for high- cynergy Solutions stabilizers to sale to third parties. de photoprotection in France.
performance uV protection for meet customers’ needs.” ❙ www.cytec.com www.enerplastics.com
❙ A Schulman has been
Adeka invests in polyester additives for pVc awarded a 2011 deal maker
Award from the Association
Adeka is expanding production The expansion will increase The polyester additives are for corporate growth’s
of polyester-based additives capacity for polyester-based used as plasticizers, predomi- cleveland chapter in ohio,
for pVc applications at its additives at the chiba plant by nantly in pVc and rubber. uSA. The company was
plant in chiba, Japan. The 5,600 tonnes/year. Along with Adeka says that demand is recognised for its three
company is investing ¥1.5 additional plants in Japan, expanding for applications in acquisitions in 2010 – ico
billion (E13 million) in the china and Thailand, it will take construction materials and polymers, mccann color and
project which is scheduled to Adeka’s total capacity for the automotive interiors. mash compostos plasticos.
start production in April 2012. products to 22,000 tonnes/year. ❙ www.adeka.co.jp www.aschulman.com
12 compounding world | February 2011 www.compoundingworld.com
13.
14. M
M A S T E R B AT C H
2 0 1 1
Integrating Colour and Design
CLICK
HERE FOR
DETAILS
HEADLINE SPONSOR
7-9 June 2011
The Imperial Riding School Vienna,
a Renaissance Hotel, Vienna, Austria
Organised by: Also sponsored by: Media sponsor:
Applied Market
Information Ltd.
Sabine Prack – Conference Coordinator sp@amiplastics.com Ph: +44 117 924 9442 Fax: +44(0)117 311 1534
15. Colour trends | news
Clariant colours in the future
Each year Clariant’s experts movement, evolution and “natural hues that evoke the dabra that is described as a
predict the global plastics surprise – bright, lively and magic of ancient mythologies”. mysterious violet.
colour trends that lie ahead. quirky hues and special effects Examples include: Echo of Building on the “In-Fusion2”
We take a first look at their – will prove popular in 2012. At Silence, a delicate sand colour; theme from last year, “In-
brand new tips for 2012 the same it predicts that the Itzamná, a terracotta orange Fusion3” recognises the
public will be seeking soft, overlaid with burgundy red ; blending of the human and the
Global colour trends are being muted, earthy and organic and Inner Strength, a deep, technological through
driven by economic, technologi- tones that convey introspec- dark non-black with a tinge of augmented reality created by
cal, political and philosophical tion, stability and personal primal green. digital media, 3D entertain-
changes, according to Clariant responsibility. It says that this The “Creative Confusion” ment and motion gaming.
Masterbatches. The rapid apparent contradiction may be trend is said to represent the Colours in this grouping are
changes that are happening in because confusion is also an ambiguity and surprise sought otherworldly. For example,
these areas have been taken element in some of the major by people who no longer want Hyperlight is made up of
into account in its new societal trends. mass-produced sameness and different glitter colours that
ColorForward 2012 report. This The four themes for 2012 blandness in their product pur- can only be reproduced in
is designed to help designers include “Me... Under Con- chases or in their lives. The moulded plastic, while
and brand managers make struction”, reflecting the need colours are bright and fun, StarLED is a purplish blue
successful colour choices for for introspection and self- taking advantage of special colour co-injected with a layer
plastics products and packag- questioning at times of rapid effects and combinations. of silver starburst.
ing that will be marketed a year change. It also acknowledges Examples include Bizarre, a The final trend, “Re-
or more in the future. the ending of the Mayan fusion of translucent purple Volition” is a response to the
Clariant forecasts that Calendar on 21 December and yellow that creates a negativity that has gripped the
colours that mirror a sense of 2012. The palette incorporates strange green, and Abraca- world in the latter part of the
last decade and the way that
people look inward to seek a
resolution. The palette is
described a pure and unadul-
terated, featuring solid colours
without special effects.
Examples include: Mind
Switch, a lively yellow/orange;
Collaboraction, a warm red;
and New Equilibrium, a stable
pearlescent brown.
The colours reproduced
here are for indication
purposes only as many use
special effects that that cannot
be illustrated accurately on
screen. The ColorForward
2012 pack contains moulded
plaques to accurately repre-
sent the colours. Click here to
request one and click here to
see an animated presentation
of the ColorForward 2012
predictions and full details of
the different colours.
❙ www.clariant.masterbatches.com
www.compoundingworld.com February 2011 | CoMpouNDING worLD 15
16. news | Technology
Researchers use carbon dioxide to
impregnate plastics with additives
Researchers in Germany are conducted with silica and
investigating how compressed flurbiprofen, the anti-inflam-
CO2 can be impregnated into matory active pharmaceutical
plastics to act as a carrier for ingredient, have also been
dyes and additives. The work is successful.
being carried out at the At a temperature of 30.1oC
Fraunhofer Institute for and a pressure of 73.8 bar, CO2
Environmental, Safety and goes into a supercritical state
Energy Technology (UMSICHT) that gives the gas solvent-like
in Oberhausen. properties. When it is in this
The researchers say that state, it can be introduced into
the technology provides a polymers and used as a carrier
route for impregnating plastics for dyes, additives, medical
with heat-sensitive additives or compounds and other
pigments that cannot with- substances.
stand the high temperatures of Manfred Renner, a scientist
injection moulding or other at Fraunhofer UMSICHT,
processes. In addition, the explains the process: “We
technology can be used to pump liquid CO2 into a high-
apply expensive additives and pressure container with the This phase diagram shows how Co2 beComes
pigments in a thin layer at the plastic components that are to superCriTiCal aT CerTain pressures and TemperaTures
part’s surface where they are be impregnated, then steadily
normally needed, rather than increase the temperature and The process takes a few One potential application
throughout the whole volume pressure until the gas reaches minutes – the researchers highlighted by the researchers
of the component. the supercritical state. When quote five minutes to dye a is in contact lenses. The
Early tests have involved that state is reached, we plastic part yellow at 90oC and process could be used to dye
impregnating polycarbonate increase the pressure further. 200 bar. Once the process is the products as well as
with nanoparticles that give it At 170 bar, pigment in powder- completed, the container is enriching them with pharma-
antibacterial properties, form dissolves completely in opened and the gas escapes ceutical compounds that would
completely killing off e-coli the CO2 and then diffuses with through the surface of the be slowly released to the eye
placed on its surface. Work the gas into the plastic”. plastic, leaving behind the throughout the day. An
pigment or additive. example would be replacing
This plastic According to the UMSICHT eye drops for treating glau-
propeller was researchers, the process is coma.
dyed yellow in suitable for impregnating l Fraunhofer is Europe’s
five minutes partially crystalline and largest application-oriented
at 90oC and amorphous polymers such as research organisation with
200 bar PA, TPE, TPU, PP and PC, but more than 80 research units,
it cannot be applied to including 60 Fraunhofer
crystalline plastics. They Institutes, at different locations
emphasise that CO2 is non- in Germany. It employs more
flammable, non-toxic and inex- than 18,000 people and has an
pensive, and although it annual research budget of
behaves like a solvent, it does E1.65 billion. UMSICHT
not present the health and focuses on process engineer-
environmental issues often ing technologies.
associated with solvents. ❙ www.umsicht.fraunhofer.de
16 COMPOUndInG WORld | February 2011 www.compoundingworld.com
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18.
19. plastics recycling | factory report
Just over a year after
a fire destroyed its
sorting facility, uK
recycler Eco plastics
is back, bigger and
better than ever.
Nadya Anscombe
finds out more about
Europe’s largest
plastics bottle
recycling plant
Bottle recycler bounces back
Visitors to a plastics recycling facility expect to see a dirty when the fire happened,” says Short. A mechanical The Eco Plastics
environment, especially when the plastics being recycled failure in a fan in the sorting facility was found to be the plant processes
are post-consumer waste. But visitors to uK recycler Eco cause and the sorting facility was burnt to the ground. around 100,000
plastics (formally AwS Eco plastics) are often surprised “luckily the processing facility, which houses the bigger tonnes/year of
how clean and efficient the company’s facility is, investment, survived,” says Short. post-consumer
according to managing director Jonathan Short. now, instead of being housed in a 1940s aircraft plastics bottles
The company, which built its first sorting plant for hangar, the sorting facility is in a larger, modern, light and plans to
plastics waste in 2006, is now by far the largest facility which has enabled the company to improve grow this by 40%
producer of food-grade recycled pET (rpET) in the uK efficiency. “instead of trying to fit a process into a space,
and also has the largest plastic bottle recycling facility
“
in Europe. “we don’t really see ourselves as plastics
recyclers anymore,” says Short. “But rather as a We don’t really see
manufacturer of food-grade plastics that happens to
use post-consumer waste as its raw material.” ourselves as plastics
The company has seen a huge rise in demand for
food-grade rpET and has been expanding to meet this
recyclers anymore, but rather
demand. But the brand-new E20 million sorting facility
located in Helmswell, lincolnshire, is not just a result
as a manufacturer of food-
of this increased demand. A year ago a devastating fire
grade plastics that happens to use post-
”
ripped through the old sorting facility and the company
had to work hard to rebuild its business. “we had just consumer waste as its raw material
gone through an expansion phase, installing Sorema
hot-wash lines and Erema compounding machinery Eco PlAstics’ MD, JoNAthAN short
www.compoundingworld.com February 2011 | compounding world 19
20. factory report | plastics recycling
Left: The we were able to first design an efficient process and build and can handle up to 11 streams of plastic material. it is
company’s 17 the building around it,” says Short. For example, because this ability to deal with many different plastics that has
Titech optical the new facility is taller, it makes more use of gravity, resulted in very low waste levels. “most plastic recy-
sorters can reducing the need for conveyors and cutting maintenance clers have about 25% process waste,” says Short. “ours
now do their costs. it also enables more straight process flows which is around 8% and that is mainly dust and evaporation.
job more result in improved sorting. Straight process flows mean we can recover all the different kinds of plastic
effectively as the product is more spread out and the company’s 17 including bottle tops and other parts.”
the material is Titech optical sorters can do their job more effectively. The company is now unrecognizable from the small
spread more “our new facility is also future-proof,” says Short. “we sorting facility set up in 2006 which exported all of its
evenly are already planning our next expansion phase.” products to the Far East. “Some of our product is still
The company currently processes around 100,000 exported, but we want to limit our exposure to the Far
Right: The new tonnes/year of post-consumer plastic bottles but plans to East,” says Short. “As china becomes wealthier and its
purpose-built ramp that up to 140,000 tonnes by 2011. This represents people consume more, the chinese will have their own
facility has nearly half of all the post-consumer plastic bottles waste to deal with and will not need ours any more. This
meant improved collected in the uK today. in 2006, when Eco plastics was is why it is so important for countries like the uK to
material flows first set up as a sorting facility, the uK collected 108,000 build their own infrastructure and recycle their own
tonnes of plastic bottles. By 2009 this had risen to nearly waste plastic.”
260,000 tonnes and a recent report by recoup shows with this, and the increasing amount of plastic being
300,000 tonnes will have been collected during 2010. collected in the uK, in mind, Short expects more
“Supply is plentiful,” says Short. “And so is demand. we companies to jump on the bandwagon. “But the
are the largest producer of rpET in the uK, but demand challenges of recycling post-consumer plastic waste
is three or four times what we are producing.” into a product suitable for direct food contact are not to
This is why the company plans to ramp up its food- be underestimated,” he says. “Anyone can go and buy
grade rpET production from today’s 15,000 tonnes per the equipment, but having the know-how of how to
annum to 40,000 tonnes by mid-2012. This equates to make the most of that equipment and how to get high-
88% of the current uK total. quality product out of it is the key to our success.”
This will of course mean more investment in
compounding equipment. The company currently has More information
one Vacurema extruder from Erema for pET and is Click here to see an interactive diagram showing the
planning to invest in “at least one more” in order to layout of Eco plastics’ Helmswell plant along with
fulfill these expansion plans. details of each component.
As well as food-grade rpET, Eco plastics also sells ❙ www.ecoplasticsltd.com
rpET flake to thermoformers. while pET and HdpE ❙ www.sorema.it
bales are its main products in terms of percentage of ❙ www.erema.at
input, the company processes a very mixed feedstock ❙ www.titech.com
20 compounding world | February 2011 www.compoundingworld.com
21. Ralf Simon
Managing Director
„ With steady innovations
we remain your reliable
and safe partner.“
BKG pelletizer
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The advance into a new performance dimension of processing technology. The new ZSK Mc18
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vide you with a unique advantage in technology. That’s what we mean when we say “confidence
through partnership”. www.coperion.com
22. COMPOUNDING PROCESSING 2011
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23. recycling equipment | processing feature
Focus on plastics recycling machinery
With growing volumes of plastics being the recycling process as well as the market including extruders, shredders,
recycled, equipment manufacturers quality of the end product. dryers, separators and filtration
have been responding with new On the following pages we look at systems designed for tough recycling
technology to improve the efficiency of some of the latest equipment to hit the applications.
gneuss wins order for its
largest mrS extruder
The K show proved very The Gneuss MRS
successful for german eight-screw
machinery maker gneuss, with extruder
several orders completed at the offers very
show including the sale of an high levels of
mrS 200 extruder to a custom- devolatizing
er in Brazil. The extruder, which performance
has a throughput of up to 2
tonnes/hour, is the largest a gneuss rSFgenius 150 melt
gneuss has sold to date and will filter and ViS on-line viscom-
be used in the customer’s state- design, the devolatilizing direct extrusion into films or eter. The turn-key system is
of-the-art pET bottle-to-bottle performance is claimed to be fibres. The machine also capable of processing waste
recycling line. The extruder 50 times greater than that of a provides excellent decontami- material at 500-700 kg/h to
features gneuss’s multi- conventional single-screw nation performance. last year produce material that is
rotation system (mrS) which extruder – and this at a the uS FdA issued a letter of comparable with virgin
enables the processing of pET vacuum of only 25 to 40 mbar. non-objection for using the polymer according to gneuss.
post-consumer waste without This eliminates the need for a extruder for reprocessing The sales of mrS extruders
pre-drying. high vacuum system and pre- material for the food industry. have contributed to consider-
mrS is a drum containing drying. At K 2010 gneuss launched able growth at gneuss. The
eight satellite single screws, in the three years since a complete line for the direct company has invested heavily
driven by a ring gear and gneuss introduced its mrS recycling of pET fibre or film in new buildings: a new
pinion transmission. The extruder at K 2007 it has sold scrap. Built around its mrS assembly workshop and a new
“barrels” cut into the drum are more 16 lines for the process- 110 extruder, the system processing technical centre
approximately 30 % open and ing of pET post-consumer features an integrated cutter/ have doubled the production
provide optimum exposure of flakes without pre-drying, feeder supplied by ngr area in order to meet demand.
the melt. Thanks to this either for repelletizing or for recycling machines as well as ❙ www.gneuss.de
Titech opens waste separation test facility
Titech has opened a 1,500 m² ballistic separator, the test be accurately simulated. manager, commented: “The
sensor-based test facility for facility uses all of Titech’s during testing, changes can facility allows us to work with
plastics sorting at its head- sorting and recycling technolo- be made which ensure that the customers to ensure that the
quarters in mülheim-Kärlich in gies. it has been designed to sorting systems are calibrated systems will be deployed to
germany. allow several different to deliver optimum levels of their sites and immediately
Set out in a loop which processes to run concurrently sorting and recycling for begin working as efficiently as
prepares the waste by so that a customer’s facility specific requirements. possible.”
screening it and using a and operating environment can ralph uepping, test facility ❙ www.titech.com
www.compoundingworld.com February 2011 | compounding world 23
24. processing feature | Recycling equipment
Kreyenborg
builds largest
New Lindner shredder
infrared dryer concept boosts flexibility
Kreyenborg Plant Technol- Lindner reSource has range of different square- filling capacity ensures a
ogy has developed a large launched the Micromat Plus blade or point-blade rotors can constantly high material flow.
infrared drum dryer for series of variously configura- be fitted. Easily replaceable Production waste with different
drying PET bottle flakes ble single-shaft shredders for screens with 10 to 300 mm material characteristics, such
with a throughput of 3,500 recycling plastic waste. hole diameters make for even as hard plastics, filaments or
kg/h. The system, with Available in three sizes, these greater versatility, while the films, can therefore be
drum dimensions of 2,500 units are designed with low patented maintenance hatch shredded just as efficiently as
mm diameter and 5,400 energy consumption and high facilitates the replacement of post-consumer plastics such
mm length, is the largest productivity in mind. blades and counter-blades. as PET bottles, agricultural
built by the company. Three different drive The shredder’s newly film or carpeting.
It features 540 kW of concepts are offered to developed internal force feeder Selecting the optimum rotor
installed radiator output accommodate specific can be adapted to a given and blade types will depend on
and is designed to dry PET application needs, while a application, and an increased the application. For shredding
bottle flakes with a bulk problematic material such as
density of about 0.35 kg/ Lindner’s Micromat Plus can big bags, filaments or stretch
dm³, from maximum 1 % be configured to shred film, Lindner proposes its
‹
initial moisture to 0.05% wide variety of point-blade rotor providing
and to crystallize it at the waste plastics high cutting precision. The
same time. Due to the short square-blade rotor is optimized
residence time of 10-15 for hard plastics and combines
minutes, there is signifi- superior pull-in control with an
cantly less material in the energy-saving power require-
drying process, eliminating ment and RPM level.
the need for huge drying All rotors are available with
vessels to process high wear protection and can be
throughputs of low-bulk- equipped with cooling
density flakes. capabilities.
❙ www.kreyenborg.de ❙ www.lindner-resource.com
Rapid expands granulator range
Rapid has developed its largest granulation applications. operator can gain access to the
‘open hearted’ granulator to Bengt Rimark, Rapid’s rotor and cutter at the heart of
date, by adding a 1,500mm marketing director, said: “The the machine in three simple
wide model to its 600 series. 600-Series uses the same steps, without needing any
The series, which has a 600 patented technology as the tools. The granulators also
mm diameter rotor, is already 300, 400 and 500 series come with Rapid’s
available 900 mm and 1200 granulators. The concept is Mineral Composite
mm widths. It is designed for completely modular and can Technology (MCT)
the high volume granulation, be tailored to any application base, which is a
and can handle throughputs up within the plastics processing vibration-absorbing
to 3,500 kg/h. There are 45 and recycling industry.” heavy platform that
standard base configurations The ‘open-hearted’ design of helps to reduce noise
available, so it can be tailored the 600 series means that, levels during operation.
to suit the majority of large during a production change, the ❙ www.rapidgranulator.se
24 CoMPouNDINg WoRLD | February 2011 www.compoundingworld.com
25. TPEI Compounding Lines
Featuring Free Rotor™ Continuous
Mixers J-Block™ Extruders
For over 25 years TPEI has
been in the forefront of
innovation in the design and
manufacture of state-of-the-
art compounding machinery
for the plastics and rubber
processing industries.
High Output, Low Maintenance Compounding Lines
• E-mixer™ designs for hard to feed and fluffy materials.
• Patented sealing arrangement for mixer.
• Fully automated grease lubricated and water cooled bearing blocks.
• Proprietary J-Block™ extruder technology.
• T-orientation of mixer to extruder.
• Ubangi™ flow channels used in extruder dies and adaptors.
• Compounding rates from 50lbs/h to 15,000 lbs/h.
24/7 Service Technical Support
Whatever your needs, if we don’t stock it, we’ll build it!
892 Blakeslee Blvd. Drive West
Lehighton, PA 18235
Ph: (570) 386-4777
Fax: (570) 386-4120
Email: tpeguest@ptd.net
www.tpei.com
26. processing feature | recycling equipment
conair and
rajoo work
together on
pET project
At the recent K show, indian
extrusion machinery
Screen-changer
supplier rajoo Engineers
demonstrated an extrusion
line running recycled pET
(rpET) sheet. The line,
which produced a three- meets recycling challenges
layer clear pET sheet
intended for thermoforming The latest generation of collected in a permanently backflush filter changes to the
of disposable containers, screen-changers from maag flushed accumulating space operating mode and starts the
featured a full range of now meets all requirements of and will then clean the dirty fully automatic cleaning of the
crystallizing, drying and direct recycling processes, screen cloth outside the screens which is controlled by
material handling equip- such as the fabrication of food- production process by pressure or time and depends
ment supplied by conair. wrapping films from pET bottle backflushing. in this way, on the level of dirt accumula-
The sheet line incorpo- flakes in one process step. variations in pressure and tion. The recycling screen
rated two extruders – a 90- maag’s new cSc/BF-pE volume are largely avoided and changers are based on the
mm / 30d / 76-kw unit that screen-changers feature fully the effects on the final product well-proven double-piston
processes the rpET flake automated cleaning which can are minimized. design which does not need
that makes up 90% of the be adjusted to any kind of Specific set points can be any additional seals and
finished sheet, and a 50-mm process. The quantity of programmed into the control ensures a reliable and leak-
/ 30d / 22-kw unit that runs material which is needed for system to suit the process. proof operation.
the virgin pET that forms the backflushing of the screens is when these are reached, the ❙ www.maag.com
outer layers of the sheet.
conair supplied the
materials handling and
conditioning equipment
upstream from the extrud-
Extricom supplies ringExtruder
ers, including a cr42 Extricom has delivered a tion of material taking place in Extricom is supplying one
crystallizer, which efficiently ringExtruder rE7 XpV for a double helix: around the of its 12-screw RingEx-
processes amorphous pET high-quality bottle-to-bottle stationary core and around truders to a PET bottle-to-
flake at temperatures up to recycling to a customer in each screw. bottle recycling plant in
177°c (350°F) with continu- Eastern Europe. The high-duty ❙ www.extricom.de Eastern Europe
ous agitation to prevent plant has a throughput of 3,500
agglomeration. conair’s kg/h pET bottle flakes
carousel plus dryers were equating to an annual capacity
used for processing the of 27,500 tonnes recycled pET.
materials, while its drying The company’s ringExtrud-
hoppers provided mass er design features 12 screw
material flow and uniform shafts arranged symmetrically
air/heat distribution. in a ring. They all rotate in the
rajoo has supplied more same direction, each on its
than half a dozen rpET lines own axis. The outer barrel
within the past 12 months. and the stationary core
❙ www.rajoo.com enclose the screws with a
❙ www.conairgroup.com narrow gap with transporta-
26 compounding world | February 2011 www.compoundingworld.com
27. The international conference and exhibition for
The international polypropylene film industry
the bi-oriented conference and exhibition for
A TURN AHEAD
The international polypropylene film industry
the bi-oriented conference and exhibition for
The international polypropylene film industry
the bi-oriented conference and exhibition
The internationalconference and exhibition for for
TO MORE
the bi-orientedpolypropylene film industry
the bi-oriented polypropylene film industry EFFICIENCY.
SAV
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8-30u AT
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.
d. AMI’s BOPP Film conference is now well
. AMI’s BOPP Film conference is now well
established as theconference is now well
AMI’s BOPP as the leading forum for the
AMI’s BOPP Film leading is now well
established Film conference forum for the
world industry. the conference is now well
established as
AMI’s industry. the leading forum forfor the
established Film leading forum the
world BOPP as
world industry.
world industry.
established as the leading forum for the
The conference usually attracts over 200
world industry. usually attracts over 200
The conferenceover 30 attracts over 200
delegates from usually countries. over 200
The conferenceover 30 countries. Delegate
The conference usually attracts
delegates from over 30 countries. Delegatethe
delegates from Delegate
companies represent30 countries. over 200
The conferenceover more than 50% of the
delegates from usually attracts50% of
companies represent more than 50%Delegate
world’s output of BOPP film than 50% over 2
companies represent more (equal of the
companies represent30 countries. to over 2
delegates fromof BOPP film than Delegate
world’s tonnes ofoverresin purchase). of2the
world’s output
more (equal
million output ofBOPPmore than to to over 2
PP film (equal 50% of the
over
world’s tonnesof PP resin purchase).
companies represent film (equal to
output of PP resin purchase).
million tonnes
million of BOPP
million output BOPP film (equal to
world’s tonnes of PP resin purchase). over 2
To viewtonnes of PP resin purchase). here
details on this event click
million moredetails on this event click here
To view more
To view more details on this event click here
To view more details on this event click here
To view more details on this event click here
28 -30 June 2011
28 -30 June 2011 Technology made by Gneuss:
AustriaTrendJune 2011
28 -30 Savoyen Hotel,
28 Trend Savoyen Hotel,
Austria -30 June 2011
Austria Trend Austria Hotel,
Savoyen
28Vienna, Austria Hotel,
Vienna, Savoyen
Austria -30 June 2011
Trend
Vienna, Austria
Vienna, Austria
Austria Trend Savoyen Hotel,
Vienna, Austria
For furtherdetails please contact:
For further details please contact: Thanks to their high performance and constant
mode of operation, our technologies developed
Becky Merriott, Conference contact:
Becky Merriott, Conference Manager
For further details please contact:
For further details please Manager for the plastics-processing industry increase the
E-mail:Merriott, Conference Manager
rm@amiplastics.com
Becky rm@amiplastics.com
E-mail:Merriott, Conference Manager
Becky rm@amiplastics.com
For further details please contact: cost efficiency of every production process. Your
E-mail: 117 924 9442
Tel: +44
Tel: +44rm@amiplastics.comManager
E-mail: 117 924 9442
production line benefits from maximum availabili-
Becky Merriott, Conference
Tel: +44 117 924 9442 ty while at the same time guaranteeing optimum
Tel: +44 117 924 9442
E-mail: rm@amiplastics.com product quality, even when using 100 % recycled
Tel: +44www.amiplastics.com
117 924 9442 material.
www.amiplastics.com With Gneuss you are always a decisive turn ahead!
www.amiplastics.com
www.amiplastics.com
Organised by: Sponsored by:
Organised by: www.amiplastics.com Visit us at CHINAPLAS!
Applied Market 17.05.11 - 20.05.11
Applied Market
Organised by:Ltd. Hall 5.1, Stand D 21
Information
Information Ltd.
Organised by:
Applied Market
Organised by:
Applied Market
Information Ltd.
Platinum sponsor:
Applied Market
Information Ltd.
Organised by: www.gneuss.com
Information Ltd.
Applied Market a turn ahead
Information Ltd.
28. additives feature | Mineral fillers
Dr Chris DeArmitt was chairman for AMI’s recent
Minerals in Compounding conference in Atlanta,
Georgia, USA. Here he reports on the wide
range of presentations covering the latest
developments in materials and
processing technologies
Making the most of minerals
Interest in fillers is as strong as ever, as illustrated by hard to understand and complex equations are needed
the healthy attendance and the diversity of technologies to fit the data. In fact it turns out that properties depend
presented at the recent AMI Minerals in Compounding upon the volume percentage of the filler and polymer
conference in Atlanta, Georgia, USA. Topics spanned the phases, not the weight percentage. Plotting data that
range from traditional fillers to new entrants and from way often results in straight lines. Another myth is that
additives like dispersants and coupling agents to fillers have lower specific heat capacities than poly-
processing equipment to optimise production through- mers, thus helping reduce heating and cooling times.
put and material properties. Although fillers do indeed speed production through
The conference was kicked off by Dr Chris DeArmitt their high thermal conductivity, it was shown that the
of Phantom Plastics who gave an introduction to filled specific heat capacities of fillers and polymers are
plastics including how different types of filler alter the precisely the same on a per unit volume basis.
mechanical and other properties of plastic materials. Charles-Etienne Houssa of Omya continued with a
Each type of filler has its own niche according to the look at calcium carbonate which is one of the most
Quarzwerke properties of the filler and the size and shape of the popular fillers because it is inexpensive and improves
compared a filler particles. He also emphasized the importance of several properties of polymers such as modulus and
selection of dispersants and coupling agents in optimizing compos- cooling times. In some cases, it can also increase
filler types in ite processing and properties. impact performance and environmental stress cracking
different He then dispelled some myths about filled plastics. resistance.
engineering For example, properties are usually plotted versus the The price of calcium carbonate is more stable than
plastics weight % of filler, often resulting in curves which are polymer prices and has historically increased more
(Left to Right): Muskovite Mica, Phlogopite Mica, Low-aspect-ratio Wollastonite, High-aspect-ratio Wollastonite, Platy Kaolin
28 CoMPoUnDInG worlD | February 2011 www.compoundingworld.com
29. Mineral fillers | additives feature
cooling and therefore higher production output. In PP Mondo
and PA, talc also helps nucleated crystallization leading produces very
to a further increase in production output. high purity talc
Dr Jörg Zilles of HPF The Mineral Engineers, which is using a super-
a division of Quarzwerke, presented studies on mica conducting
(Phlogopite and Muscovite variants), Wollastonite (low- magnet and a
aspect-ratio and high-aspect-ratio) and platy Kaolin all flotation
slowly than that of polymers. For example HDPE prices at 20 weight % in PA6, PBT, ABS, PPS and PSU. Mechani- process
increased 125% from 2000 to 2010. In contrast CaCO3 cal properties were measured comprehensively as well
increased just 50% over the same period. This gives the as the difference in shrinkage parallel and perpendicular
expectation that more and more filler will be used in to the injection direction. The latter measurement gives
future years. an indication of the tendency to warp.
Overall, the fillers tended to increase modulus,
Natural born fillers strength and HDT while reducing warpage. The only
Calcium carbonate filler is formed through a process downside was some loss in impact resistance commonly
known as diagenesis whereby sea organisms are found when adding fillers to polymers. For each plastic
deposited on the sea bed and then converted to calcium there was a filler which provided the best property
carbonate sedimentary rock. It turns out that 300 balance. Phlogopite was found to be the preferable filler
million metric tonnes are deposited in the oceans per for PA 6, while high-aspect Wollastonite showed the best
year but only 75 million tonnes are quarried, making balance of properties in ABS if anisotropy can be
calcium carbonate a sustainable filler. tolerated. Low-aspect Wollastonite gave remarkable
Omya showed some new particle morphologies, increases in modulus coupled with excellent impact
namely microplatelets agglomerated to make spheres. strength in PBT, PPS and PPU. Kaolin and Muscovite
Potential applications were not mentioned but one can mica gave increases in modulus, tensile strength and
imagine that such high surface area particles would be heat deflection temperature, while shrinkage of the
effective for nucleating foam cell growth and for catalyst polymer is decreased in an isotropic way.
supports.
The next presentation by Frans Venema of Mondo Added strength
Minerals focused on talc which has a higher aspect Milliken is well known as the market leader for
ratio than calcium carbonate, leading to improved clarifying agents for PP and nucleating agents for PE
stiffness, HDT and barrier properties. Talc also and PP. However, Normand Niron’s talk focused on its
increases polymer strength and reduces creep (slow new product Hyperform HPR-803 which is marketed as
flow) of polymers. One caveat is that impurities are a filler to replace talc in applications where density and
common, so Mondo performs a flotation process to surface finish are paramount.
remove other minerals. This process is combined with a The push for hybrid cars has added complexity and,
special superconducting magnet to remove magnetic ironically weight to the vehicles. Similarly, the continual
impurities like iron. addition of new features and devices also pushes up the
As with other mineral fillers, talc increases thermal weight of vehicles. The manufacturers therefore seek
conductivity substantially, leading to faster heating and new ways to reinforce automotive plastics to bring the
www.compoundingworld.com February 2011 | COMPOUNDING WORLD 29
