DESIGN COLLABORATION IS KEY TO SUCCESS THIN-WALL PACKAGING BENEFITS STACK UP PLASTIC-METAL HYBRIDS: PROCESS INNOVATIONS - Yudu
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JANUARY/FEBRUARY 2019 ISSN 2052-9376
DESIGN COLLABORATION IS KEY TO SUCCESS
THIN-WALL PACKAGING BENEFITS STACK UP
PLASTIC-METAL HYBRIDS: PROCESS INNOVATIONS
Bringing the plastics industry together
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CONTENTS
PAGE 4
4 News
PAGE 17
14 Consolidation in capsules
AMI Consulting’s Martyna Fong highlights key developments
analysed in a new report on single-serve capsules
17 Design collaboration is key to material success
Resin manufacturers continue to develop materials that not only
meet performance needs, but also deliver the aesthetic qualities
that product designers are looking for. Mark Holmes reports
PAGE 24
24 LFTs in the spotlight in US
With interest in lightweight structural parts on the rise, especially
in automotive, we preview AMI’s first North American Long-Fiber
Thermoplastics conference
27 Thin-wall packaging benefits stack up
Despite the hostile public environment for plastics packaging,
injection moulders can continue to progress in their pursuit of
thin-walled packaging excellence thanks to technology
improvements. Peter Mapleston reports
41 Seeking a bond between plastics and metal
PAGE 41
Polymer-metal hybrid composites are proliferating in automotive
applications. Peter Mapleston surveys the latest developments
in over-moulding and other processes
PAGE 27
54 Diary
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www.injectionworld.com January/February 2019 | INJECTION WORLD 3
NEWS
RPC in the spotlight as Apollo bids
Private equity firm Apollo the financial community due
Global Management has to its high-profile M&A
agreed to buy UK-based programme. At the same
RPC Group, the rigid and time, media hysteria was rife
flexible packaging com- against plastic.”
pany, for £3.3m through a RPC had been in negotia-
newly formed subsidiary. tions with Apollo and another
The week after the deal was potential bidder, Bain
announced, US packaging Capital, since 2018. Bain
giant Berry Global said it RPC agreed a new three-year rigid packaging supply deal with pulled out ahead of the
was also considering a cash Norwegian dairy group TINE in January December deadline, though
offer for RPC Group to rival this had to be extended
the Apollo bid. recommend that sharehold- culmination of the process three times before Apollo
The £7.82/share offer ers accept. Pike reiterated the board had started to finally made its offer. Apollo
from Apollo represents a that in July 2018 he had said resolve the situation. previously owned the
15.6% premium on the that “differing investor views “It is not all that surprising US-based Berry Global and
company’s share price on on the appropriate level of to see another UK PLC has had many other invest-
the last day before the offer gearing was constraining the disappear from the public ments in chemicals down the
began. RPC chairman Jamie group’s ability to pursue market in this manner,” said years. In early February, it was
Pike and the board of opportunities for growth Nicholas Mockett, head of reported RPC management
directors said they believed and, as such, putting packaging M&A at Moor- would have talks with Berry
the terms to be “fair and pressure on RPC’s valuation”. gate Capital in the UK. “RPC about its potential offer.
reasonable” and will This, he added, was the had fallen out of favour with � www.rpc-group.com
Patrimonium Hella in car lighting partnerships
takes stake Hella, the German supplier of communication and lighting autonomous driving and
in Hübner lighting technology and
electronic products for the
features”, according to
Laurent Burelle, chairman
individualisation redefine
vehicle interiors. The two
Patrimonium Private automotive sector, has and CEO of Plastic Omnium. companies had already
Equity, a division of formed two partnerships with Faurecia’s and Hella’s showcased what they called
Switzerland’s Patrimo- Tier 1 suppliers: one with strategic partnership will “a unique ambient lighting
nium Asset Management, Plastic Omnium on integrat- jointly develop “lighting experience for a more
has acquired a majority ed car body lighting and the with high-technology comfortable, dynamic and
stake in C. Hübner, which other with Faurecia for the content in the domain of versatile environment
specialises in surface development of interior surface-lighting and integrated into a cockpit of
technology. Hübner lighting systems. Terms were dynamic-lighting for a more the future” at the Paris Motor
employs over 200 people not disclosed in either case. personalised cockpit Show in October 2018.
in tool making, plastic The collaboration with environment”, as trends like � www.hella.com
injection moulding and Plastic Omnium will involve
plastic electroplating at engineering and design
three sites in Marktober- experts from both compa-
dorf, Bavaria. It mainly nies, and will be based in
supplies the sanitary, Germany. The focus will be
automotive and consum- on new systems integrating
er products markets. innovative lighting technolo-
Thomas Hübner, the gies, and intelligent exterior
third-generation man- systems, at the front and at
ager of the family-owned the rear of the car, including
firm, will remain MD. “smart bumpers and
� www.patrimonium.ch tailgates, enriched with Hella and Faurecia are already collaborating on car interiors
4 INJECTION WORLD | January/February 2019 www.injectionworld.com
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NEWS
Over 200 exhibitors join
Cleveland plastics shows
More than 200 companies have
already booked booths at three
exhibitions focused on plastics
extrusion, recycling and compounding.
The free-to-attend tradeshows and
their associated conferences will take
place at the Huntington Convention
Center in downtown Cleveland, Ohio,
USA on 8-9 May 2019.
Organised by AMI, the Plastics
Extrusion World, Plastics Recycling
World, and Compounding World The Cleveland event will build on the success of AMI’s first free-to-attend exhibitions
Expos will feature a wide range of held in Essen, Germany last year
processing machinery, auxiliary
equipment, polymer materials, Buss, BYK, Cabot, Chemours, Clariant, booths are being filled on a daily basis.
additives and related services. Cloeren, Colines, Coperion, Cumber- Prices start at $3,400 for a 100 sqft
“Visitors to the focused shows will land, Davis-Standard, Dover Chemi- booth. To find out more about exhibit-
be able to compare a huge range of cals, Dr Collin, Entek, Erema, Exxel ing at any of the expos, visit https://
suppliers and new technologies in one Polymers, Farrel Pomini, Ferro, Gneuss, www.ami.international/exhibitions.
convenient location,” said Andy Greiner Extrusion, Heritage Plastics, “The exhibitions will build on the
Beevers, AMI’s events and magazines JSW, Konica Minolta, KraussMaffei success of AMI’s first tradeshow for the
director. “In addition, they’ll be able to Berstorf, Kuhne, Leistritz, Lubrizol, plastics compounding and recycling
learn from expert speakers in the five Maag, Maguire, Matsui, Milliken, NFM, sectors, which took place in Essen,
free conference theatres and network Nordson, Oden Technologies, Omya, Germany last year and attracted more
at the after-party at Cleveland’s Rock Pall, Parkinson Technologies, PSI-Poly- than 4,000 visitors,” said Rita Andrews,
and Roll Hall of Fame,” he added. mer Systems, Reifenhauser, SI Group, adding: “We are confident it will be the
The 200+ companies that have Starlinger, Struktol, Vecoplan, Wacker, biggest plastics industry gathering in
already booked booths include: Alpha Zoltek, and over 150 more suppliers the USA this year”.
Marathon, Addex, Advanced Blending from around the world. To book your free ticket visit:
Solutions, BASF, Brabender, Buhler, The limited number of remaining � ami.ltd/Register-AMI-Expos
Freudenberg Medical expands with new HQ
Freudenberg Medical has announced 13485-certified with ISO Class 8
plans to build a new medical manufac- cleanrooms for medical moulding and
turing facility at Beverly, just north of assembly. It should be operational in
Boston, in Massachusetts, US, which the second half of 2019, employing
will also be its global HQ. It will about 70 people.
relocate operations from nearby “Our decision to expand here is a
Gloucester, where it has made testament to the strong growth of
medical components and devices Freudenberg Medical in this region
since 1989, and will expand the and locating our global headquarters
operation. in Beverly demonstrates the global
The company said that it will invest role and international orientation of
over $3m at the site, which will cover the Boston medical device cluster,”
3,350 m2, with potentially 1,860 m2 said Max Kley, President and CEO of
more for future expansions. The facility Freudenberg Medical.
Freudenberg device development will be FDA-registered and ISO � www.freudenbergmedical.com
6 INJECTION WORLD | January/February 2019 www.injectionworld.com
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NEWS
KraussMaffei gains Sweden’s
KB buys in
from listing in China Canada
The KraussMaffei Group has As a part of the recon-
completed its listing on the struction of the Vari-Form
Shanghai stock exchange Group, Sweden’s KB
and is moving forward with Components has
its plans in China, which acquired the assets of PM
include manufacturing Plastics based in Wind-
injection moulding machines sor, Canada, and re-
there for the local market. named it KB Components
As part of the share Canada. The new entity
listing, KraussMaffei’s will have sales of $10m
majority owner ChemChina per year from a facility
transferred its stake to a with 20 injection mould-
listed subsidiary, Qingdao ing machines of up to
Tianhua Institute of Chemis- 500 tonnes. KB Compo-
try Engineering (THY). This nents already serves one
will give KraussMaffei full of the site’s major
access to the Chinese In January, KraussMaffei executives visited the University of customers, Kautex, in
capital markets. THY has Duisburg-Essen in Germany for the handover of a PX 120-380 China and Mexico.
taken over ChemChina’s injection moulding machine to the plastics engineering faculty “A global presence is a
production site in Sanming. necessity for many of our
“With the additional launched its Digital Service district to Parsdorf/Vatter- customers and through
production site in Sanming, Solutions business unit for stetten, just east of the city, the establishment of KB
we can further expand our this purpose. starting in 2022. Four new Components Canada, we
presence in China. At the KraussMaffei will still be factory halls, a tech centre will offer production in
same time, we will drive our based in Munich, with and two office buildings will Sweden, Lithuania,
international business from German co-determination be built, occupying a total Slovakia, China, Mexico
Germany,” said Frank Stieler, rights and no change to its area of 250,000 m². Krauss- and Canada,” said
CEO of KraussMaffei. He legal status or employee Maffei said it will follow a company president
added that access to the and union agreements. The “smart factory concept” Stefan Andersson. For PM
Chinese capital market will rights to technologies also which it expects will achieve Plastics’ customers, he
contribute to the company’s remain bundled in Germany. “a substantial increase in added, this will create
‘Compass’ strategy to The group also an- productivity through digitali- access to increased R&D,
expand its business models, nounced plans to relocate sation and state-of-the-art production capacity and
especially in digital services. its main plant and corporate logistics”. technological know-how.
In July 2018, KraussMaffei HQ from Munich’s Allach � www.kraussmaffei.com � www.kbcomponents.com
Dri-Air expands US manufacturing
Ancillary equipment group Dri-Air Industries parts in one facility for faster lead times.
has announced a “significant addition” to its Dri-Air mainly supplies dryers for custom
main facility at East Windsor, Connecticut, drying and conveying systems, which are
US. This will increase manufacturing and used by plastic injection and extrusion
warehousing capacity by about 50% and will processors. The company’s recent growth
“allow us to stock larger hoppers and has been driven by the need for manufactur-
components for our fastest growing seg- ers to reduce energy use, which is offered
ment, our large dryer market,” said president by its closed-loop temperature-based
Jason Sears. It will also boost the company’s regeneration process.
ability to integrate manufacturing of all dryer � www.dri-air.com
8 INJECTION WORLD | January/February 2019 www.injectionworld.com
May 8 – 9, 2019 REGISTER NOW
Huntington Convention Center, FOR YOUR
Cleveland, Ohio, USA FREE TICKET!
Network with leading players in the industry May 8, 2019
Discover solutions to current and future challenges
Rock & Roll
M eet vendors and make informed
Hall of Fame
purchasing decisions Networking Party
Keep up-to-date with industry advances
Don’t miss out!
and the latest technology
200+ EXHIBITORS
120+ SPEAKERS
across the three expos
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Brought to you by:
Bringing the global plastics industry together
NEWS
MB buys
another
Total Corbion starts up
BiPower PLA plant in Thailand
MB Spritzgusstechnik of Total Corbion announced
Total Corbion’s PLA plant in
Marktoberdorf, Germany, the start-up of its 55,000 tpa
Thailand is now in operation
has installed a second PLA bioplastic plant at
Negri Bossi BiPower Rayong in Thailand in
VH2700-56000, a December. The move makes
two-platen machine with the company the world’s
27,000 kN clamping second largest player in PLA
force and injection capac- after US-based Natureworks.
ity of 28 kg of HDPE. MB The facility will produce a
has been in operation for full range of PLA resins,
15 years and has 30 which will be sold under the
machines. It converts Luminy name, including
recycled plastics into standard and high heat and the Americas. The new partnership to offer
industrial pallets. resistant grades. It is subsequent increase in turnkey plant for production
The new machine integrated with a 100,000 global PLA capacity will of PLA bioplastics. The
features servo electric tpa plant producing lactides enable manufacturers and PLAnet partnership is
screw rotation and a from locally-grown sugar brand owners to move into intended to support
special screw profile for cane and is located on the the circular economy and construction of plant with a
complex recycled same site as Total-Corbion’s produce bio-based products throughput of up to 100,000
materials, with complete 1,000 tpa pilot plant, which with lower carbon foot- tpa. It brings together
Sytrama automation and will provide a product prints,” said Total Corbion Futerro’s proprietary
a Kuka six-axis robot. The development capability. CEO Stephane Dion. technology for production
injection unit, according “The start-up of this � www.total-corbion.com of lactic acid and raw
to Negri Bossi, is de- state-of-the-art plant lactides, Sulzer’s lactide
signed so that a uniform establishes Total Corbion as n In a separate move, purification and polymerisa-
melting and homogenis- a world-scale PLA bioplas- process equipment produc- tion know-how, and Tech-
ing of the recycled tics producer ideally located ers Futero, Sulzer and nipFMC’s plant design and
material is possible. to serve growing markets TechnipFMC have an- engineering skills.
� www.negribossi.com from Asia Pacific to Europe nounced the formation of a � www.lactic.com
EuPC survey shows recyclate quality concerns
Converters are Most European plastics convert- (29%) as important measures. converters from 21 countries
looking for ers (76%) believe that improved EuPC said an increase in the completing the online question-
consistency in collection and sorting of plastic volumes of recyclate being naire. It is described as part of
recyclate waste would be the most suitable incorporated into new products, the association’s ongoing work to
way to increase the quality of as envisioned in the Plastics address the technical issues
recycled plastic materials, Strategy, “is practically impossi- related to the recycling of
according to the second ble under the current conditions”, polymers and the use of recyclate
survey carried out by the because the supply is only by converters.
European Plastics adequate for two of the polymers A third survey will take place
Converters Association included in the survey. In quality this year. The EuPC is also
(EuPC). terms, only PET supplies are currently working on a project to
They also said that good enough, they added. develop a single, unified online
they saw investments in The EuPC carried out the tool to monitor the use of
better recycling technolo- survey in the first nine months of recycled material in the European
gies by recyclers (53%) and 2018 in partnership with Polymer plastics converting industry.
better design for recycling Comply Europe, with 376 � www.pceu.eu
10 INJECTION WORLD | January/February 2019 www.injectionworld.comLong-Fiber
Thermoplastics
Detroit / 2019
Capitalizing on advances in LFT materials,
processing technologies and applications
March 5-6, 2019
The Dearborn Inn, A Marriott Hotel, Dearborn, Michigan, USA
CLICK
HERE FOR
DETAILS
Media supporters:
Bringing the plastics industry together. @Contact_AMI #AMI_Polyamides
@Contact_AMI #AMILFTSUSNEWS
Westfall Technik buys US-Swiss
toolmaker
two more firms tie-up
Acquisitive US injection gate hot runner technology said Westfall CEO Brian Accede Mould & Tool in
moulding group Westfall for precision plastic parts, Jones. “Keeping ahead of the US and Kebo, based
Technik has continued its from the smallest sizes to critical industry needs, such in Switzerland, have
buying spree in the past two shot weights of over 180 kg. as miniaturisation, is very agreed to a cooperation
months. In December, it It recently introduced a new important in our business. partnership, providing
acquired Mold Hotrunner series of injection moulding Also, the next generation their respective
Solutions (MHS), the machines called M3, with valve gate technology MHS customers responsive
supplier of high-perfor- patented technology to offers for high-cavitation sys- regional service
mance melt delivery make micro-sized plastic tems and other high-end capabilities in North
systems with operations in parts without scrap, thus cut- moulds is in a class of its America and Europe.
Canada and Germany. In ting costs when using own, outperforming Accede offers tooling
January, Westfall also expensive resins in medical anything that’s out there.” and turnkey services
acquired Mold Craft, which device production. � www.westfall-technik.com mainly for the consumer
makes precision injection “The M3 really caught our packaging and medical
moulds for micro-moulding attention at NPE 2018,” and labware markets. Its
and high cavitation applica- core competencies are
tions, at its facility in high cavitation two-shot,
Willernie, MN, US. stack and SpinStack
The company said that technology. Kebo makes
this “further strengthens the moulds for high-output
comprehensive manufactur- production in the
ing capabilities” it is putting medical, pharmaceutical,
together. Westfall was Westfall said the laboratory and cosmetics
formed in 2017 when it MHS M3 industries, plus thin-wall
bought Fairway Injection micro-moulding packaging, in-mould
Molds and Integrity Mold in machine caught labelling and closures.
the US. its attention at � www.accedemold.com
MHS specialises in valve NPE 2018 � www.kebo.com
Sumitomo (SHI) Demag makes changes
Shoichi Ohira has been named chief management. His task in Europe, said
operation officer and head of production at Sumitomo (SHI) Demag CEO Gerd Liebig,
injection moulding machinery maker will be to “follow through with the already
Sumitomo (SHI) Demag. Chief collaboration initiated investments in our facilities in
officer Hideki Kuroiwa is returning to Japan Schwaig, Wiehe and Ningbo”.
to head global planning and coordinating In November, the company revealed that
future joint projects in the group. This it had appointed a new member of the
follows on from a strategic alignment of its management team, Martin Fischer, as
management structure and expansion of its responsible for operations, including
management team late last year, which production and purchasing, with effect from
included Kuroiwa’s appointment. 1 October. At the same time, Paolo Zirondoli
Ohira, a certified production expert, had was named general manager of sales, Liebig
established himself as an injection moulding took charge of engineering and quality
machine expert with the Japanese parent management and Dieter Schuster was
company Sumitomo Heavy Industries, rising named head of quality management.
Shoichi Ohira to be head of production and quality � www.sumitomo-shi-demag.eu
12 INJECTION WORLD | January/February 2019 www.injectionworld.comNEWS
Producer alliance to invest
$1.5bn to end plastic waste
Some 30 major companies from the Suez, SCG Chemicals, Sumitomo value from them post-use;
plastics and consumer goods value Chemical, Total, Veolia and Versalis. Education and engagement with
chain have joined to found a not-for- David Taylor, CEO of Procter & Gam- governments, businesses and commu-
profit global alliance “to advance ble has been named chairman. He nities to mobilise action; and
solutions that reduce and eliminate commented that this “is the most Clean-up of concentrated areas of
plastic waste in the environment, comprehensive effort to date to end plastic waste, particularly the ten rivers
especially in the ocean”. The Alliance to plastic waste in the environment”. The in Asia and Africa, that carry the
End Plastic Waste (AEPW) has commit- association aims to develop and scale majority of it to the ocean.
ted over $1bn and aims to invest new means to minimise and manage The AEPW said that it will also work
$1.5bn over the next five years. plastic waste, including promoting the with governments, intergovernmental
The AEPW’s founding members are: recovery of plastics to help create a organisations, academia, NGOs and civil
BASF, Berry Global, Braskem, Chevron circular economy. Four key areas for society to invest in joint projects to
Phillips Chemical, Clariant, Covestro, projects will be: eliminate plastic waste from the
CP Group, Dow, DSM, ExxonMobil, Infrastructure development to environment. However, some NGOs are
Formosa Plastics, Henkel, LyondellBa- collect and manage waste and highly sceptical of an alliance dominat-
sell, Mitsubishi Chemical, Mitsui increase recycling; ed by plastics producers and environ-
Chemicals, Nova Chemicals, Oxy- Advancing and scaling up new mental group Greenpeace has criticised
Chem, PolyOne, Procter & Gamble, technologies that make recycling and the level of investment as inadequate.
Reliance Industries, Sabic, Sasol, Shell, recovering plastics easier and create � www.endplasticwaste.org
50 years of...
CUSTOMER SERVICE
BEC AUSE WE C AN
F O L L OW U S ATNEWS | MARKET STUDY
Consolidation in capsules
AMI Consulting’s Martyna Fong highlights developments Figure 1: Penetration with mono-layer PP and PBT
analysed in a new report on single-serve capsules, and of compatibles are now being re-specified.
opposite PTI reviews technical requirements High barrier technologies
include: co-extrusion
Single-serve capsules are a overall profit pool and the thermoforming, co-injection,
dynamic market segment way consumers make their Compatible barrier IML, barrier
(23%)
with a complex value chain. choices. coatings and barrier
The rigid capsules (metal Market reach, new compression moulding.
and plastic) market is channels and increased Thermoformed
estimated at 60 billion units efficiencies have led to single-serve capsules
in 2018. While rigid heightened M&A activity Original account for nearly 70%
capsules are conventionally in the segment. In this (77%) of global plastic capsules
associated with metal context, Douwe Egberts demand. The bias towards
formats, the popularity of merged with Jacobs (JDE), thermoformed formats has
plastic alternatives means JAB took over both JDE and been created with the
they have largely overtaken Keurig, Keurig merged with designs, but only 10% of interlinked success of such
the metal ones. Dr. Pepper Snapple Group, them are said to be able to systems as Keurig K-Cups in
There are several coffee Nestlé struck a deal with deliver on quality. North America and Nescafé
brewing systems available Starbucks and Blue Bottle Nespresso is changing Dolce Gusto in Europe. The
with proprietary capsule coffee, Coca-Cola took over elements in the machine share of injection moulded
designs. Nespresso and Costa Coffee, Lavazza design cyclically, and the capsules has grown versus
Keurig are brands that bought Carte Noire from compatibles suppliers are thermoformed capsules,
pioneered the segment and JDE and now there are forced to play catch-up. driven by “value” capsules
have the highest machine rumours of their potential Anti-trust rules dictate that (low oxygen barrier) that are
instalment rates globally. merger. The industry is likely Nestlé makes design compatible with Nespresso
Nevertheless, the expiration to consolidate further, which adjustments public with a machines. This type of
of their design patents in will lead to withdrawal of lead time of six months to capsule is relatively easy to
2012 brought about some capsule systems in allow fair competition. produce and the investment
disruptive changes in the favour of others. Compatible single-serve in the injection mould can
supply chain. The changes AMI Consulting estimates capsules have now become be easily amortised with
created new opportunities the volume of all compatible fully embraced by quick returns. Barriers for
for both end-users and capsules (both plastic and consumers. They are market entry for moulders
converters to tap into this aluminium variants) in 2018 accepted as good-quality are much lower than for
growing market segment. is equivalent to 23% of the alternatives. Mainstream producers of thermoformed
In addition, the supply single serve capsules market commercialisation of capsules with integrated
chain of capsules is rapidly worldwide, driven by compatible brands has extrusion. Additionally,
losing its oligopolistic nature Nespresso, K-Cup and leveraged their need to compression moulding
and the former dominance Nescafé Dolce Gusto differentiate and add value. technology was recently
of major suppliers is chal- machine penetration in Quality and shelf impact commercialised for the
lenged as the market households. There are dictate high barrier production of capsules and
expands. A more fragment- around 200 Nespresso- specification for capsules. is gaining strong supporters
ed supply chain affects the compatible plastic capsule Compatibles formerly made in the industry.
There is an urgent need to
Single-Serve Capsules report and events review the materials used for
capsules production in search
A new report from AMI Consulting, in cooperation with Plastic Technologies Inc, is an of more sustainable options.
authoritative and comprehensive deep-dive analysis of the global Single Serve Capsules Compostable capsules
market. It analyses the global market opportunity and maps out the complex supply chain are gaining market
structure. Order the report here. presence following
AMI is also organising two conferences for the single serve capsules industry in 2019: development of materials
in Atlanta, USA (5-6 March), and Berlin, Germany (24-25 September). and technologies.
14 INJECTION WORLD | January/February 2019 www.injectionworld.comMARKET STUDY | NEWS
PTI reviews single-serve capsule
technical requirements
The consumer demands continue to with every new system created for challenging. We are talking about a
grow for single-serve capsules. The different applications over the years. package dimension of 12-55 cm³. The
complexity of the capsule may not be We get excited about all these ratio of volume to surface is critical and
easily apparent and should not be possibilities of the next state-of-the-art the material/barrier used for the
considered a “simple” package. PTI’s system. However, reality sets in and we capsule should be at a 3-4 times lower
recent research base lined the must focus on the primary function of permeation rate, to overcome the poor
materials being used, the structures the package, which is to dispense and area to volume ratio.
they were assembled into, the resulting protect the contents. Since the The other significant finding from
barrier (oxygen, water vapour contents are a food product, the research is that the way in which
transmission rates) attributes and the protection is the primary factor and if the capsule’s individual structural
impact on taste to produce we fail at this there is no need to talk components are assembled to create
comprehensive analysis on the about sustainability benefits or cost. the final container also impacts barrier
package type. PTI’s research found that that the characteristics. The PTI’s research also
The data reviews requirements, Barrier Improvement Factor (BIF) details oxygen and water vapour
which may start with an iconic design varied as much as 380 times across the permeation, overall dimensions,
to build brand equity. This iconic shape 18 capsule samples tested (the minimum wall thickness, 3D scan to
will be directly interacting with the capsules selected represent most of determine active barrier surface,
dispensing appliance, so this design the major commercially available manufacturing process, layer-structure
must be intuitive enough to make the systems). This is significant since, due analysis and summary mapping were
consumer experience as simple and to the small size of the package, the characteristics reviewed for each
pleasurable as possible. barrier requirements are more coffee capsule type.
Once in the appliance this
About PTI
“package” becomes an integral
element of the appliance itself. Even in
the less sophisticated systems the
capsule will have at least one or two Plastic Technologies, Inc. (PTI) is
functions like filtration, opening, recognised worldwide as the
dispensing. In more advanced systems, preferred source for preform and
the capsule will trigger the opening package design, package
process, create the right amount of development, rapid prototyping,
foam or crema, communicate with the pre-production prototyping, and
appliance about the contents, adapt to material evaluation engineering for
pressure and temperature, provide the plastic packaging industry.
proper dissolution or mixing. This list of For further information, contact Thierry Fabozzi, President and CEO,
functions and requirements has grown tel: +1 419 867 5403, email: t.fabozzi@pti-usa.com
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New generation in high tenacity PP fibres for lightweight Development of PP building blocks to serve technical
geotextile compounders in the automotive industry
Mr. Tim Vromman, Technology Manager, Dr. Michele Grazzi, Senior Scientist,
BEAULIEU FIBRES INTERNATIONAL, Belgium LYONDELLBASELL, Italy
Innovative polypropylene solutions based on non-phthalate Hybrid, graphene-reinforced multifunctional polypropylene
Ziegler-Natta catalysts nanocomposites
Dr. Cornelia Tranninger, Group Leader “Flexible Polymers”, Dr. Dimitrios G. Papageorgiou, Research Associate
BOREALIS POLYOLEFINE GmbH, Austria NATIONAL GRAPHENE INSTITUTE, UNIVERSITY OF MANCHESTER,
United Kingdom
Making appliances more sustainable
Ms. Gisela Lehner, Senior Application Marketing Manager, Distracted drivers, rapid industry change & PP parts for great car
BOREALIS POLYOLEFINE GmbH, Austria interiors
Mr. Matt Defosse, Market Development Manager
PP and PE, used as engineering plastics POLYONE, Luxembourg
Mr. Oscar Brocades Zaalberg, Managing Director,
BPO nv, Netherlands Novel antioxidant solutions for polypropylene with enhanced
colour performance
A recent solution for halogen-free flame-retardant PP Dr. Warren Ebenezer, Research Manager for Polymer Applications
Dr. Camillo Cardelli, Materials Division SI GROUP, United Kingdom
IPOOL, Italy
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Bringing the plastics industry together @Contact_AMI #AMIPPPPRODUCT DESIGN | MATERIALS Design collaboration is key to material success Resin manufacturers continue to develop materials that not only meet performance needs, but also deliver the aesthetic qualities that product designers are looking for. Mark Holmes reports Material suppliers for the injection moulding Eastman’s copolyester and cellulosic resins.” Main image: industry are increasingly required to work closely Eastman and DW Designs tested each of the Embr Labs with product designers to achieve the aims of the polymers for both cumulative spectral decay (CSD) chose Coves- brand owner, while also striving to meet the and total harmonic distortion (THD). Data indicated tro’s Makrolon performance characteristics that the product the copolyester outperformed the polycarbonate, 2407 polycar- needs. The look of the final product may be vital to while the cellulosic offered superior results, both in bonate, a catch the eye of the consumer, differentiate the terms of clean response and lower distortion. UV-stabilised product in a crowded market place or highlight Specifically, the polycarbonate had the most peaks grade that important safety features, for example. for resonance whereas the cellulosic had the lowest offers proven Eastman has collaborated with DW Designs to overall level of measured THD. performance mould and test beryllium models in ear monitor Eastman says that data demonstrated that Tritan for electronics, housings using a variety of materials, highlighting copolyester and Eastman Trēva engineering IT and telecom- the audio clarity of Eastman Tritan copolyester and bioplastic both have superior damping characteris- munications Eastman Trēva engineering bioplastics. “Eastman tics relative to polycarbonate. Furthermore, expert applications, for wished to understand how our polymers might listener feedback demonstrated that consumers the Embr Wave improve acoustic performance in audio applica- were able to hear fine details better and preferred temperature tions,” says John Quigley, Senior Application the acoustic performance of Tritan and Trēva. bracelet Development Engineer for Eastman. “We worked Eastman has also worked with Solac to intro- with DW Designs to test housings moulded in an duce the first double blender made with Tritan incumbent polycarbonate material, as well as copolyester. The Solac Orbit is driven by a powerful www.injectionworld.com January/February 2019 | INJECTION WORLD 17
MATERIALS | PRODUCT DESIGN
Right: The Solac Orbit is the first enables production of aesthetically appealing
double blender made with Tritan surfaces. The new compound is developed to offer
copolyester from Eastman well-balanced mechanical properties and easy
processability, making it a promising alternative to
incumbent ABS materials in these markets.
SABIC PP PPA20 polymer is aimed to provide a
combination of high gloss, high scratch resistance
and low stress whitening over regular impact
copolymers together with balanced impact strength
and stiffness. In comparison with other potentially
more costly and overdesigned solutions, high-gloss
SABIC PP PPA20 is engineered to deliver compara-
ble optical properties and scratch resistance along
with good processability. In many application cases,
the company says that it can offer brand owners,
moulders and OEMs a significant cost and energy
dual-motor base and comes with a 2.5 litre blender savings potential based on its lower density, higher
jar and two 500 mL 2GO! containers. Spanish flow and faster crystallisation than currently used
company Solac introduced the double blender in materials, resulting in potentially shorter cycle times.
Mexico during the last quarter of 2018 under the Further energy savings may be leveraged as the
name Orbit. The collaboration between Solac and material eliminates the need for pre-drying and can
Eastman arose from the need to offer the market a be injection moulded at lower mould and barrel
durable and high-quality product. temperatures compared with ABS.
“One of most used household appliances in the Low density and high flow also open conceiv-
kitchen is the blender,” says Maria Fernanda Riestra able new material and weight saving design
Ampudia, Solac’s Senior Manager of Marketing opportunities for more resource-efficient and
and Product for Mexico and Central America. “The waste-reducing products, such as sleek housings
Orbit provides the home and professional seg- with lower wall thicknesses. Targeted applications
ments with excellent performance, power and of SABIC’s new high-gloss impact copolymer range
durability at a fair and accessible price. By offering from household appliances and food storage
the practicality of performing two grindings at the containers to toys and furniture. Typical examples
same time, it also can reduce preparation time.” include coffee makers, steam irons, vacuum
The large blender jar utilises both blender cleaners, personal hygiene appliances and
drives to grind food ingredients at a cellular level aesthetic fascia for white goods, such as washing
without leaving fibrous residues or chunks of food machines and refrigerators. SABIC says that PP
and ice. The 2GO! containers provide single-serve PPA20 addresses the needs of designers and
preparation flexibility. All Tritan vessels are shatter- moulders in these markets for aesthetic as well as
resistant and easy to clean. Eastman says that Tritan cost-efficient and more sustainable materials with
offers many advantages over glass and traditional higher performance characteristics for functional
plastics, including the ability to resist stains innovation and enhanced consumer
and withstand temperature changes experience. Already available in the
without cracking or crazing. After Europe, Middle East and Africa
Right: SABIC preparing hot beverages, users can regions, SABIC PP PPA20 is to be
has launched a simply wash the container and blend phased in commercially in the
new impact an ice-cold drink without losing clarity or Americas in 2019.
copolymer durability. The Solac Orbit blender will be SABIC has also introduced new
(ICP) grade available in Europe in 2019. Thermocomp HMD-D high modulus
suitable for SABIC has launched a new PP impact ductile glass-reinforced polycarbonate
household copolymer grade – SABIC PP PPA20 (PC) compounds with increased
consumer – targeted at demanding home design freedom, suitable for
goods, such as appliances as well as high-end challenging structural compo-
coffee makers cosmetics packaging, furniture nents in the consumer electron-
and other household consumer ics, healthcare and transporta-
goods. The material offers tion sectors. The new series of
designers high gloss features that six grades offers a combination of
18 INJECTION WORLD | January/February 2019 www.injectionworld.comPRODUCT DESIGN | MATERIALS
high modulus and ductility to enable lighter, offer both better ductility and dimensional stability/
thinner and stronger parts that advance design warpage control than other high-modulus PC-
innovation and ease of use. based materials. This distinctive combination of
“From smartphone cases to medical device attributes allows, for example, the creation of
housings and mass transit interior panels, there is thin-wall devices that may withstand stringent drop
an urgent need on the part of OEMs to replace testing without cracking. The new compounds use
metal and other traditional materials to reduce special glass fibres that minimise warpage. Grades
weight, expand design freedom and cut with different glass fibre loadings (10-50%) are
processing costs and complexity,” says Joshua available to meet various modulus requirements.
Chiaw, Director of Compounds at SABIC. Thermocomp HMD-D products also Left: SABIC has
“Thermocomp HMD-D compounds not only deliver good strength for metal introduced new
avoid the drawbacks of metal, they also add replacement while reducing weight Thermocomp
value with breakthrough ductility due to their low specific gravity. They HMD-D high
performance and excellent stiffness, which provide an excellent surface modulus ductile
open opportunities for use in a wide range of appearance by minimising the glass-reinforced
structural applications.” floating of glass fibres to the polycarbonate
The company says that in order to surface and improved melt flow, compounds
achieve lighter weight and which, unlike parts made with with increased
thinner geometries in structural various competitive materials, design freedom
applications, Thermocomp are not affected by heat and in consumer
HMD-D compounds deliver moisture ageing. Together with electronics
high performance in key good colour-matching applications
mechanical properties that capability and colour stability,
previously were mutually these characteristics help
exclusive. The materials manufacturers appeal to
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Bringing the global plastics industry togetherMATERIALS | PRODUCT DESIGN
inlays in car doors, central consoles or dashboards.
The requirements of the automotive industry
regarding emissions and odours were also taken
into account during the development.
New high-performance materials for improving
the comfort and safety of autonomous driving are
also being developed at BASF. Sensors in the car
are important in assisting the driver and are an
indispensable part of the development of
Surface-optimised Ultramid SI from BASF has been autonomous driving. These include radar,
used for the fully plastic frame and armrests for the LiDAR, IR or ultrasonic sensors, which
lightweight Aula chair designed by Wilkhahn, function as lane assistants, collision warning
offering new aesthetic and functional characteristics systems and distance control, and assistance
with the emergency brake function. Design-
fashion-conscious consumers of ers are using a broad range of BASF
electronic devices and to patients products, such as the hydrolysis
who use home medical devices. All resistant Ultradur HR polybutylene
grades feature halogen-free flame terephthalate (PBT) and the Ultramid
retardancy to support sustainability EQ PA for these sensitive electronic
efforts. applications.
New opportunities for designers are The expanded range of Ultradur
now possible with a number of new now includes: Ultradur B4330 G6 HR
material developments at BASF. For example, High Speed, a particularly flowable and
speciality polyamide Ultramid Deep Gloss is now laser markable grade with 30% glass fibre rein-
available in new colours. The company says that forcement; Ultradur B4330 G10 HR, a highly
this offers versatile possibilities for car interior reinforced grade with 50% glass fibres; and
design. The material offers resistance to scratching, Ultradur B4331 G6 HR, the next generation with
plus high chemical and good UV resistance. In optimised processing characteristics. Ultradur
addition, the high gloss level reproduces structures B4331 G6 HR is available from now on as uncol-
with faithful detail, allowing a highly contrasting oured grade, in a black laser markable version, and
mix of light and shadow – without additional in orange for components in electric cars.
coating. Designers of household goods are also benefit-
Ultramid Deep Gloss was awarded the German ting from new materials from BASF. Surface-opti-
Innovation Award 2018 in the category Materials mised Ultramid SI has been used for the fully plastic
and Surfaces. The award is presented by the frame and armrests for the lightweight Aula chair
German Design Council to recognise products designed by Wilkhahn, offering new aesthetic and
from different industries that offer additional functional characteristics. Employing BASF’s
benefits compared to previous solutions. BASF simulation software Ultrasim, the design ensures
says that Ultramid Deep Gloss combines the that every part of the chair frame can be produced
chemical resistance of semi-crystalline polyamides from Ultramid SI, meaning a steel core was unnec-
with the high gloss and depth of amorphous essary. This resulted in a new lightweight chair, at
plastics. It is therefore particularly suitable for only 6 kg or 6.7 kg with armrests. The versatility and
automotive interior components which are high- performance of Ultrason, BASF’s polyarylsulfone, is
gloss and yet demand chemical resistance. also opening up new application possibilities for
Car interior components made of Ultramid household appliances, for example. For devices
Deep Gloss have a high-gloss surface that for the such as deep fryers, Ultrason grades can meet
first time does not require an additional protective requirements where food safety, temperature
coating as the gloss surface is achieved with resistance and design are successfully combined.
vario-thermal moulding technology. The speciality Functional solutions made of polycarbonate
PA allows designers to realise unusual textures from Covestro are being used in the most con-
such as ripples, waves, hammer finish, lines and fined spaces for an automotive front module
diamonds with a piano-black look, or to structure concept in a new design. With vehicle construction
surfaces with haptic design elements. According to under major review, alternative drive technologies
the company, Ultramid Deep Gloss is suitable for such as electric mobility, new forms of connectivity
components such as air vents and decorative trims, and autonomous driving require totally new car
20 INJECTION WORLD | January/February 2019 www.injectionworld.comPolymers
in Footwear
Boston / 2019
Capitalizing on advances in polymer materials and processing
technologies for footwear applications
March 5-6, 2019
The Hilton Boston Woburn, Boston, Massachusetts, USA
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@Contact_AMI #AMIFootwearUSMATERIALS | PRODUCT DESIGN
Appliance, at Covestro in the US. “We collaborate
early on with our customers, helping them to
overcome their product design, engineering and
materials challenges. This approach accelerates
innovation, which is particularly critical given the
rapid electronics product life cycle.”
As an example, a highlighted development was
Embr Wave – an intelligent bracelet that allows
people to alter the way they feel temperature.
According to manufacturer Embr Labs, the brace-
Above: concepts, says the company. Covestro says the let’s scientifically developed waveforms precisely
Automotive front section of future cars will be characterised by stimulate a person’s thermoreceptors, leveraging
front module three-dimensional, joint-less and glass-like surfaces the body’s natural systems to make the wearer feel
concept in a – the classic radiator grille will be obsolete. cooler or warmer by up to five degrees in just a few
new design According to the company, this enables manufac- minutes. The technology is based on a break-
made of turers to differentiate their models from the through physiological insight: warming or cooling
polycarbonate competition, while integrating more functions in specific parts of the human body can make some-
from Covestro less space. one feel more comfortable without changing his or
New design opportunities will also be available her core body temperature. This is because thermo-
using a new material from Covestro with a positive receptor stimulation – for example, at the wrist – trig-
eco-balance. Covestro and its partners have gers the specific regions of the brain that control
developed a high-performance thermoplastic thermoregulation and pleasure, says Embr Labs.
(HPT) that could be used in many industries, such Embr Labs developed the product through years
as aviation, automotive and medicine in large- of iterative prototyping and customer testing. When
format production processes, which would it came time for the production design, the com-
significantly increase the sustainability and perfor- pany wanted to use a frosted light pipe with LEDs
Right: Covestro mance of products. The challenge now is to as the primary user interface. “We turned to
and its partners enable the continuous production of Covestro to help select the right
have devel- the new plastic on a large scale. This material and optimise the design for
oped a high- is the goal of a research project optical performance,” says Embr
performance coordinated by Covestro and Labs Co-founder Sam Shames.
thermoplastic funded by the German Federal Based on the require-
(HPT) that Ministry of Education and ments, Embr Labs chose
could be used Research (BMBF). Test Makrolon 2407 polycarbon-
in many batches of the new HPT ate, a UV-stabilised grade
industries, such material, which has high that offers proven perfor-
as aviation, hardness and is resistant to mance for electronics, IT and
automotive heat and many solvents, are telecommunications applica-
and medicine already being produced. tions. For the Embr Wave,
in large-format Covestro recently attended CES diffusers and optical brighteners
production 2019 – the Las Vegas exhibition for the were compounded into the resin to
processes latest consumer product technologies – to achieve the desired visual effect.
demonstrate how, as a materials partner, it is able An Italian manufacturer of electric two-wheelers
to help bring next generation technologies to has specified the use of Thermolast K from Krai-
market. Covestro highlighted applications utilising burg TPE for two precision gasketing applications
its polycarbonates and polycarbonate blends on the new battery boxes of a growing range of
tailored to electronics, IT and communications power-assisted bikes and electro-scooters. Askoll,
applications. The company says that these materi- based in Vicenza, is using the thermoplastic
als offer a balanced combination of properties elastomer material for an anti-rattle overmoulding
including high flowability, stiffness, toughness, heat of the battery connector and for water-tight sealing
resistance, flame retardance and good aesthetics. of the battery box. Key requirements to be met
“Successfully taking a product from concept to included reliable direct adhesion to glass-filled PBT
commercialisation requires being able to juggle on small contact surfaces.
multiple factors,” says Joel Matsco, Senior Market- Electric vehicles need innovative materials that
ing Manager Polycarbonates – Electronics and will support their silent travel by eliminating
22 INJECTION WORLD | January/February 2019 www.injectionworld.comPRODUCT DESIGN | MATERIALS
undesired ambient noises and – in the case of Left: The flexible, inter-
external components such as battery boxes on locking and fully articu-
two-wheelers – ensure a weatherable and lated Hexaflex shapes
water-tight enclosure. This is opening attrac- moulded in Thermolast K
tive new application opportunities for thermo- TPE result in a modular
plastic elastomers, says Kraiburg. padding technology for
X
XA F L E
“For the anti-rattle cover of the battery many applications,
connector and the sealing of the redesigned including sportswear,
PHOTO: HE
battery box on our bikes and scooters, we were personal protection
looking for a material that would provide the right equipment and healthcare
balance of gasketing, mechanical and moulding
performance,” says Paolo Trabuio, Project Man- to be an elastomeric solution rather than foam, the
ager Scooter, for Askoll. “Kraiburg TPE went a success of this project was essentially driven by the
long way in supporting our efforts from concept expertise found in collaborating with Kraiburg TPE.
to market, with qualified assistance in material Besides helping us specify the most suitable
selection, design optimisation, adhesion testing thermoplastic elastomer, they supported us with
and moulding trials.” comprehensive assistance from early on in the
Both TPE applications are injection moulded in a design phase through to series production.”
two-component process, which required excellent The Hexaflex shapes can be moulded in various
direct adhesion to the glass-filled polybutylene sizes, thicknesses and custom colours. Thermolast
terephthalate (PBT) resin used for the battery box. is claimed to deliver the long-term flexibility
In addition, the chosen Thermolast K compound required for reliable articulation of the assembled
also had to offer good flowability to ensure a padding throughout the life time of the protectors.
precise, tight and faultless fit of the gasket on the The material has also been shown to minimise Below: Askoll,
narrow contact surface of the lower box compo- rebound when the padding is flexed, which results an Italian
nent. In addition, the compound lends the critical in good shock absorption performance. Further manufacturer of
long-life mechanical properties required to specifications to be met included good mechanical electric
withstand the shocks and vibration of the box when strength and durability over a wide range of two-wheelers,
driving, as well as the wear and tear during temperatures, ease of recycling, as well as the has specified
frequent removal for charging the maintenance- absence of substances of very high concern the use of
free battery on the electric grid at home or at work. (SVHC) in the compound. In addition, the padding Thermolast K
Kraiburg TPE has also collaborated to develop is fully washable and waterproof but breathable from Kraiburg
second skin breathable body protectors with due to integrated ventilation features in the design. TPE for two
lightweight padding using a flexible TPE com- Following its successful use in dorsal protectors, precision
pound. French company Hexaflex has developed Hexaflex is planning to extend the technology to gasketing
a padding technology based on hexagonal-pyram- other sportswear in the near future, including knee applications on
idal shapes moulded with TPE. The thermoplastic and elbow pads for activities such as skateboarding, the new battery
elastomer compound provides the flexibility, light snowboarding, skiing and horseback riding. The boxes of a
weight and full articulation characteristics of the company also sees broad application possibilities in growing range
modular system that lends itself to many shock and personal protection equipment, from helmet inserts of power-assist-
vibration absorbing applications, from sportswear to breathable harnesses, as well as in anti-vibration ed bikes and
and personal protection equipment to healthcare floor padding and various healthcare products. electro-scooters
and other demanding industries.
In a first application, the creative technology is CLICK ON THE LINKS FOR
used for a dorsal protection product covered with MORE INFORMATION:
high-strength aromatic PA stretch fabric for bikers � www.eastman.com
and motorcyclists. The lightweight material � www.solac.com
combination acts like a second skin, and the � www.sabic.com
Hexaflex padding with its interlocking shapes in � www.basf.com
Thermolast K is fully articulated to follow body � www.wilkhahn.com
motion while ensuring maximum shock absorption. � www.covestro.com
“Innovative concepts like our Hexaflex system � www.embrlabs.com
need innovative materials to take them from idea � www.kraiburg-tpe.com
to reality,” says Stephane Desnoyers, Founder and � www.askoll.com
CEO of Hexaflex. “Although we knew it would have � www.hexaflex-technology.com
www.injectionworld.com January/February 2019 | INJECTION WORLDYou can also read
