PLASTICS RECYCLING AND GRANULATORS INNOVATIONS IN MULTI-LAYER PACKAGING EXTRUDER DEVELOPMENTS l MINERAL FILLERS - OCTOBER 2020 - YUDU
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OCTOBER 2020 ISSN 2053-7190
PLASTICS RECYCLING AND GRANULATORS
INNOVATIONS IN MULTI-LAYER PACKAGING
EXTRUDER DEVELOPMENTS l MINERAL FILLERS
Bringing the plastics industry together
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CONTENTS
PAGE 13
5 Industry news
13 Squaring the circle: recycling and granulation
Machinery and materials suppliers are offering a variety of ways to
PAGE 25
help film and sheet producers increase the amount of recyclate in
their products
25 Need for speed: extruder developments
The latest extrusion lines have faster output, greater use of
recycled polymer and multi-layer capability – with some even
capable of being installed remotely
37 Film stars: multi-layer packaging
Multi-layer film is used to add barrier properties or higher
strength to packaging – and is increasingly being achieved in a
mono-material format
PAGE 37
45 Enhancing performance: mineral fillers
Inorganic fillers for film can perform a wide range of vital functions
in polymer formulations – from improving optical properties to
reducing damage
49 Technology: Materials PAGE 45
51 Technology: Machinery
58 Extruder of the month: AMB
60 Dates for your diary
COMING NEXT ISSUE
� Thin wall packaging � Sheet materials � Construction � Active/intelligent packaging
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www.filmandsheet.com October 2020 | FILM & SHEET EXTRUSION 3
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NEWS
Investment fund takes over
Italian film producer Irplast
UK-based investment fund
Cheyne Strategic Value
Credit has taken control of
Italian film producer Irplast.
The new finance includes
issuing of a bond for €39
million, while Banca IFIS has
prepared a short-term credit
line for €20m and capital
funds invested will increase
by a further €3m, which will
ensure “new liquidity to
reinforce the assets of the Investment from Cheyne Strategic Value Credit will help Irplast make key investments
company”.
“This will allow us to Canti becomes a director on this year some “small further polymers to make its
make some key investments, the new board. growth” in sales. S-BOPP range of products.
which are required for our The company’s goal is to Over time, the company Naomi Lunadei, sustain-
business development plans maintain the sales growth plans to optimise its film ability manager at Irplast,
– particularly in the area of trend of recent years and manufacturing process, said: “We have now brought
environmentally sustainable accelerate margins further. which will increasingly use out two new innovative
products,” said Fausto Cosi, Because it is a key supplier raw materials from renewable product lines: one reduces
CEO of Irplast. to the food industry, the sources and from plastic-to- the carbon footprint of
Cosi will retain his company has managed to plastic chemical recycling. BOPP flexible packaging;
position in the company, maintain production during n Irplast has already begun the other introduces the
along with COO Luca de the Coronavirus pandemic. using more renewable possibility of entering the
Bartolo, and Gabriele In 2019, Irplast generated plastics by joining SABIC’s circular economy.”
Corradi as president of the a turnover of just over €97m, Trucircle initiative. Here, it � www.irplast.com
board of directors. Matteo and estimates that it will end has chosen renewable � www.sabic.com
Ineos adds flexible recyclate grades
IMAGE: INEOS
Ineos Olefins & Polymers Europe has secured a supply
agreement with waste management company Saica Natur
covering recycled LDPE and LLDPE – which will enable it to
extend its Recycl-in range to include flexible packaging
applications with over 60% post-consumer recyclate (PCR).
Recycl-in combines recycled plastic with what Ineos calls
“highly engineered virgin polymers” to give properties
equivalent to standard virgin grades. According to the resin
producer, this new development “pushes technical bounda-
ries” by incorporating higher levels of PCR for demanding
applications such as stretch and lamination films.
Saica Natur is a subsidiary of the Saica Group, one of
Europe’s largest suppliers of recycled paper.
n Our feature on recycling and granulators begins on page
13.
Ineos will extend its Recycl-IN polyolefins to stretch film grades � www.ineos.com
www.filmandsheet.com October 2020 | FILM & SHEET EXTRUSION 5
NEWS Econcore’s recycled PET cores used in concept electric car Econcore of Belgium has recommended using a supplied its recycled PET polyester non-woven fleece honeycomb core for a – which is compatible with sustainable concept car. the adhesive and composite The company has worked skin layers – to cover the with the TU/Ecomotive team surface of the honeycomb at Eindhoven University of core. Technology for four years. A thin PET barrier film This year, it has supplied ensured the glue did not more than 20m² of recycled flow through the fleece into PET honeycomb cores. the honeycomb cells. The TU/Ecomotive team Econcore has supplied its recycled PET honeycomb core for the Wouter Winant, technical has used the cores in the Luca concept electric vehicle manager at EconCore, said: design of its Luca electric “The Luca car demonstrates vehicle. the composite skins, the on gluing the recycled PET how versatile the recycled The chassis was made lightweight panels were core to a composite sheet PET honeycomb core panels using the honeycomb core used in most of the struc- comprising flax fibres and a are – not just in automotive material, as were other areas tural parts of the car. recycled polyolefin matrix terms but in other applica- such as the seat support As well as supplying the from other partners. The two tions where strength, rigidity structure, parts of the material, EconCore provid- materials do not work well and light weight are dashboard and the battery ed technical advice and together when using important characteristics.” housing. After laminating consulting – such as advice adhesive. EconCore � www.econcore.com Recycling Danimer to go public after returns in private equity firm takeover Russia Bioplastics producer It currently produces the public company,” said Messe Dusseldorf says Danimer Scientific is to go material on an industrial Croskrey. “We are at an Interplastica – the plastics public, following a takeover scale level at a facility in inflection point in our show that it organises in deal with Live Oak Acquisi- Winchester, Kentucky in the growth trajectory and this Russia – will run its ‘Recy- tion. USA. It supplies the resin to will fuel the next phase of cling Solutions’ again at Stephen Croskrey, companies including our commercial expansion.” the next edition of the Danimer’s CEO, will remain PepsiCo and Nestlé for He said the partnership show. in his position. applications including food with Live Oak would allow Interplastica 2021 is The company’s products and beverage containers further scaling of production scheduled to run on 26-29 include its Nodax polyhy- and flexible packaging. to meet strong customer January 2021. It is one of droxyalkanoate (PHA) Based on signed and demand. the few plastics industry polymer, which is made pending contracts, Danimer “We believe PHA has the events not to have been from natural resources is sold out of all production ability to eliminate pollution cancelled or rescheduled rather than petroleum. The from its production facility. It caused by single use plastics due to Covid-19. material is biodegradable says it will use its increased worldwide and are well It will be held concur- and uses canola oil as its capital base to increase positioned to expand our rently with Upakovka, primary feedstock. Danimer production, to meet the products to a wide range of which covers processing says that Nodax is the first needs to its customers. plastic and speciality and packaging. PHA to be certified as “We are excited to applications,” he said. � www.interplastica.de marine degradable. transition Danimer to be a � www.danimerscientific.com 6 FILM & SHEET EXTRUSION | October 2020 www.filmandsheet.com
NEWS
LCA study: recycled plastic is
‘best option for packaging’
Reducing or recycling “Findings indicate that in processing and manufactur- Kirkman, chief technology
plastic packaging are better the applications it is used, ing generate,” said the and innovation officer at
options – from a carbon most of the time, plastic study’s authors. Veolia UK and Ireland.
footprint perspective – than packaging performs better From the LCAs studied, “Paper, metals and glass
replacing it with alternative than its alternatives, mainly the Imperial College are widely recycled, but
packaging materials, says a due to its very lightweight researchers found that if all plastic is a newer material.
study by Imperial College properties,” according to plastic were recycled it could We need the right policy
London in the UK. the report’s executive result in mean annual savings drivers in place, backed by
The study, Examining summary. of 30m-150m tonnes of CO2, consumer and manufacturer
material evidence - the “Recycling always wins equivalent to stopping awareness, to allow us to
carbon fingerprint, commis- over virgin production on all between 8 and 40 coal-fired build the new recycling
sioned by Veolia UK, environmental indicators. power plants globally. infrastructure.”
reviewed 73 publications on For plastics, there seems to “With only 9% of plastics The full report can be
life cycle analyses (LCAs) be consensus that recycling recycled worldwide, there is accessed here.
comparing different types of saves 30-80% of the carbon still a lot to do to improve � www.imperial.ac.uk
packaging. emissions that virgin plastic things,” said Richard � www.veolia.co.uk
AMB buys PTS of Germany Lactips
to boost European footprint plans new
Italian food packaging
facility
manufacturer AMB has Lactips of France is to
bought Prime Tray System open a new plant to
(PTS) of Germany – which produce its soluble
develops innovative biodegradable plastic.
industrial packaging The new plant, in the
solutions. Gier Valley, was formerly a
PTS has also acted as a whipped cream factory,
distributor of AMB products but closed in 2018. The
over the last 20 years. With 12,000 sq m site includes a
the takeover AMB says it will 2,500 sq m production
strengthen its market building.
position, particularly in It is scheduled to open
Germany, Austria and in 2021, after which it will
Switzerland. AMB now has five production locations in Europe be capable of producing
“The acquisition will help 3,000 tonnes/year of
AMB further widen our This is AMB’s second a full-service provider for pellets – which doubles the
European footprint to be acquisition in the last 12 packaging design, rigid and company’s existing
more local to our clients months. In June 2019, it flexible films and tool capacity. Lactips has a
from the heart of Europe,” acquired UK-based TDX manufacturing. production target of
said Bruno Marin, CEO of (Europe), which makes PET The combined company 10,000 tonnes/year.
AMB. and R-PET films, and will have five locations in The new facility was
“We have always had a laminated rigid films for the Europe, employ around 435 acquired as part of a €6
clear vision to extend our food and packaging people and has a turnover million real estate project,
reach. Acquiring PTS is the industries. AMB says this of over €160 million. said Lactips.
next step on this journey.” takeover helped it become � www.ambpackaging.com � www.lactips.com
8 FILM & SHEET EXTRUSION | October 2020 www.filmandsheet.com
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Also sponsored by:NEWS
EuPC: waste tax on
plastics packaging
will harm recycling
European plastics industry groups recycling of plastic waste in Europe,”
reacted strongly after the EU Council said Alexandre Dangis, managing
of Ministers approved a plan in July to director of EuPC. “Instead, it will
tax unrecycled plastic packaging further increase the cost of plastic
waste. recycling and encourage the shift to
The Council reached agreement other packaging materials with a
on a new Multiannual Financial bigger environmental impact.
Frame-work to aid economic recovery Landfilling of plastic packaging waste
from the Covid-19 pandemic, would be more efficient.”
containing the proposed tax among GKV, the German plastics proces-
other measures. The plan involves a sors association, agreed that an EU
€0.80/kg levy on non-recycled plastic land tax would be better.
packaging waste which would be “The EU plastic tax is withdrawing
paid by member states into the EU valuable investment funds from the
budget. It would take effect from 1 member states who do not yet have a
January 2021. good recycling infrastructure,” said
The European Plastics Converters Oliver Möllenstädt, general manager.
(EuPC) industry body criticised the Martin Engelmann, general
basis of the tax, presented by the manager of the IK plastic packaging
European Commission as “contribu- group in Germany, warned of
tion to the EU budget designed to unwanted side effects: talk of a plastic
incentivise member states to increase packaging tax in Italy has already led STRETCHING
recycling from plastic waste” – warn- to a switch from plastics to plastic-
THE LIMITS
ing it might have the opposite effect. paper composites – which is more
“As the revenues of the EU plastic difficult to recycle than plastics
tax are not earmarked to be invested packaging, he said.
into the waste and recycling infra- � www.plasticsconverters.eu
structure, it will not increase the � www.gkv.de
High Quality Film
Production Lines:
Constantia signs up new Efficiency
flexpack customer in India
Productivity
Flexibility
Constantia Flexibles has signed up a a water vapor and oxygen barrier,
new customer for its EcoLamPlus and can also contain volatile products
flexible packaging: Indian healthcare such as alcohol.
company Nuvae Healthcare. “Health and safety is one of our key
Nuvae, based in Ahmedabad, pillars and that’s why Nuvae Health-
makes products such as hand care is such a strong partner for us,”
sanitiser in small batches. Its Gosan, a said Tony Sirohi, executive chairman
70% alcohol-based sanitiser, will now of Constantia Flexibles India.
be available in recyclable packaging “We are looking forward to further
made of EcoLamPlus. joint projects.” www.brueckner.com
The mono-polymer packaging has � www.cflex.com
www.filmandsheet.com October 2020 | FILM & SHEET EXTRUSION 11FILM AND SHEET EXTRUSION
New dates
November 3-4, 2021
CLEVELAND, OHIO, USA
Highlights from 2019
From across the co-located expos
Total number Total number Number of countries Combined budget
of exhibitors: of visitors: represented: of visitors:
261 4,375 42 $8.9BN+
BOOK
YOUR
To book your booth, contact: Find out about the BOOTH
exhibition_sales@ami.international Plastics Extrusion
+1 610 478 0800 World Expo, Europe
Brought to you by: Colocated with: Proudly supported by:RECYCLING AND GRANULATORS | PROCESSING
Machinery and
materials suppliers
are offering a
variety of ways to
help film and
sheet producers
increase the
amount of
recyclate in their
products
Squaring the circle: latest in
recycling and granulation
The use of recyclate in film products is becoming RKW plans to install a similar line at its site in Main image:
more prevalent – whether the film is for consumer Ville le Marclet, France – where it produces films for RKW’s new film
packaging, industrial applications of a host of other food and beverage packaging – in the near future. line in Finland
end uses. runs formula-
RKW has begun production of lawn and garden PCR for packaging tions with a
films on a five-layer line in Pori, Finland. Nova Chemicals has agreed a long-term deal with higher
The line is running new formulations that use a a Canadian plastics recycler to supply it with proportion of
higher proportion of regranulate – including post-consumer recyclate (PCR) – which will be regranulate
post-consumer recyclate (PCR). blended with virgin resin and used to make
“Our customers are delighted with the quality, consumer packaging.
feel and appearance of the products,” said Pekka The deal, with Merlin Plastics Supply, marks
Saariluoma, director of the site. Nova’s debut in PCR resin.
Lawn and garden films need high printability, “This partnership – and our forthcoming suite of
opacity and puncture resistance, among other PCR-containing resins – will help meet our custom-
properties, he said. er and brand owner needs and expand high-quali-
“We aim to increase the share of recycled PCR ty PCR supply for use in consumer packaging,” said
material while not sacrificing on materials quali- Luis Sierra, president and CEO of Nova Chemicals.
ties,” he added. Nova will finance a multi-million-dollar project to
PCR is typically used to manufacture lower-quali- accelerate Merlin’s expansion into PCR for food
ty end products such as garbage bags, says the contact applications, making it a source of such
company. Making higher quality film with a high resin for its customers. Nova says this is one of
proportion of PCR places “high demands on several collaborations it is pursuing to build its PCR
development and application technology”, it added. offerings with commercial quantities, beginning in
www.filmandsheet.com October 2020 | FILM & SHEET EXTRUSION 13PROCESSING | RECYCLING AND GRANULATORS
Right: After 2021. Ultimately, it plans to offer 100% recycled PE,
two years of and PCR blended with its virgin grades including
research, LLDPE, LDPE, and HDPE.
EconCore has Tony Moucachen, president of Merlin Plastics,
commercial- added: “With this agreement, we will be able to
ised a honey- turn more recycled plastic packaging into valuable
comb core new source material for consumer products and
made from packaging.”
recycled PET
R-PET honeycombs
Recycled PET (R-PET) honeycomb is now commer-
cially available to license from EconCore. The
company conducted two years of research, to
develop the best way of processing used PET into
a continuously produced honeycomb core.
The company was awarded a grant to fund volume, high-specification applications such as rail
research over a two-year period from Flanders transport and aerospace where strength and low
Innovation and Entrepreneurship (VLAIO), a weight are important.”
Belgian government agency that finances strategic
and industrial research. Film from recycled PP
The R-PET honeycomb core is typically made Taghleef Industries has introduced a new range of
from more than 95% recycled PET from a variety of films called Relife, which incorporates recycled
sources such as bottles and food packaging. It is a polypropylene (PP).
cost-effective solution as it does not require much The films can be used in a number of packaging
pre-production processing to achieve a product and labelling applications, depending on the type
that outperforms PP honeycombs. of recycled PP that they contain. Films containing
Wouter Winant, technical manager at EconCore, either chemically recycled PP, or granules repro-
said: “Our technology has been proven to work with cessed from internal production, are food-contact
many thermoplastics. Adapting it to use PET and compliant. Those that contain mechanically
R-PET honeycomb is another great step forward. By recycled PP are not.
adjusting the content of additives or fillers, we can The films are suitable for most of the same
optimise the performance characteristics.” applications as traditional film grades, and ensure the
Part of the project involved adapting the same technical function and performance, says TI.
equipment in order to increase production
efficiency, which was done in partnership with Fuel from plastic
extruder manufacturer Meaf. Additives manufacturer Clariant, in collaboration
While companies can now license EconCore with Slovak fertiliser producer Duslo, has converted
technology to make honeycomb core sandwich plastic waste into winter fuel distillate.
panels from R-PET, the development is ongoing. The process has been proven in a pilot plant in
“We will continue to push the boundaries for Slovakia. As plastics and fuels are both mainly
more demanding applications,” said Winant. “We composed of natural gas or crude oil, turning one
are learning how to adapt our technology for lower into the other has major implications for sustainable
Clariant has
teamed up
with fertiliser
producer Duslo
to convert
plastic waste
into liquid fuel
14 FILM & SHEET EXTRUSION | October 2020 www.filmandsheet.comFrom state of the art dosing units to complete
turn key automated solu�ons
Suitable for Flexible Film applica�ons
Con�nous extrusion control
Be�er blend homogeneity
Maximum dosing accuracy and versa�lity thank to
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Efficiency of produc�on and equipment up�me
Utmost flexibility and traceability in materials
managementPROCESSING | RECYCLING AND GRANULATORS
Right: Toyo Ink and lucrative fuel production, says the company.
Europe’s new “Upgrading gas oil fractions to more valuable
Lioplax black products has become essential for improving
plastic refinery economics,” said Stefan Heuser, senior vice
masterbatch president and general manager at Clariant Catalysts.
allows NIR Clariant’s Hydex E hydro-dewaxing catalyst was
sorting and used in a pyrolysis process to make the conversion.
material The technique can convert a variety of plastic waste
recovery – including PE, PS, PP and PET – into diesel fuel. It
thermally degrades the plastic above 300°C (530F)
into liquid oil comprised of various hydrocarbons.
Recently, Duslo’s Vucht research institute devel-
oped a way to further convert the liquid oil into a
high-quality fuel distillate known as winter diesel.
Following the pilot plant testing, Vucht now detected by NIR sensors during the sorting stage at
plans a custom-built demonstration plant with a material recovery centres. This allows dark-col-
fuel distillate capacity of 40 tonnes/year. oured packaging to be sorted and integrated back
Branislav Brežný, Vucht’s managing director, into the value chain as a reusable raw material
added: “Scaling up to near-plant capacity was the through recycling.”
ultimate test of the process. It could not have been Its NIR black colorants are certified according to
achieved without Clariant, whose new dewaxing the Cotrep recyclability test protocol and received
catalyst has delivered beyond expectations.” positive results at both Pellenc and Tomra testing
centres, he said.
Plastics sorted The Lioplax series of NIR-sorting black master-
Toyo Ink Europe has developed a new range of batches are formulated for use in PP trays, PET
Lioplax black plastic masterbatch that allows preforms, films, bottles and other packaging
near-infrared (NIR) sorting and material recovery. applications. Different grades are available in
Most optical sorting methods use NIR wave- varying black colour shades, grades of resins
lengths. Standard black masterbatches are typically (polyolefins, PET) and processing compatibility
made with carbon black – which absorbs IR light, such as extrusion or blow moulding.
making identification by optical sensors impossi-
ble. This results in undetected black or dark-col- Recycling dark plastics
Below: BASF oured packaging waste being sent to landfill or BASF has developed Sicopal Black K 0098 FK, a
says its Sicopal incineration. colorant which it says allows smart recycling of dark
Black K 0098 Toyo Ink Europe has developed an alternative to plastics such as food containers.
FK colorant standard carbon black in this masterbatch. Carbon black is typically used in these applica-
allows smart “We have developed a sustainable alternative to tions, but hinders recycling because it absorbs NIR
recycling of carbon black, enabling packaging to integrate the technology – which is commonly used by sorting
dark plastics recycling loop,” said Xavier André, technical and systems. This means that the plastic is more likely to
such as food research manager at Toyo Ink Europe. “Packaging be incinerated or landfilled. However, the Sicopal
containers using a new Lioplax black masterbatch can be grade overcomes this – so is an effective replace-
ment for carbon black, says BASF.
“Our research and development team has taken
on the industry need for recyclable black plastics
that can pass through infrared sorting at materials
recycling facilities,” said Christof Kujat, head of
global technical industry management for plastics
at BASF. “Building on our Sicopal Black technology,
we have developed a new member of the pigment
family that is optimised for use in packaging.”
The NIR-reflective grade allows the reliable
detection of the polymer even at high pigment
content. With its high processing stability, it can be
used for multiple processing steps and closed loop
recycling, says BASF. �
16 FILM & SHEET EXTRUSION | October 2020 www.filmandsheet.commacchi@macchi.it www.macchi.it
PROCESSING | RECYCLING AND GRANULATORS
“We have packed an established test and analysis
method into a handy portable format,” said Adrian
Vogel, sales and business development Manager for
spectroscopy solutions at Trinamix. “The product
miniaturisation and its wireless connection to the
cloud make it possible to use NIR spectroscopy
anywhere and at any time for precise material
identification.”
The device can identify common plastics in
seconds, says the company. The spectrum ranges
from materials such as PE, PP and PVC to PET, ABS
and polyamide. Other materials can be added
according to customer requirements.
Individual plastics spectra are stored in the
cloud and matched with the measurement data
Above: Cotnyl NIR sorting from the spectrometer. The user receives the name
of Argentina Trinamix, a BASF subsidiary, has developed a new of the identified material in the app. Results can be
has installed application for its mobile near-infrared (NIR) spec- displayed on mobile devices and on the customer’s
a Gneuss troscopy solutions in plastic sorting and recycling. PC. This allows both rapid ad-hoc analyses as well
processing A portable handheld device, using Trinamix as further evaluations and downloads.
unit with MRS technology, can determine the precise composi-
extruder and tion of different plastics. Sophisticated data analysis PET project
RSFgenius can now be processed in the field via wireless The demand for sheet made wholly or partially
filtration cloud uploading. The device is slightly larger than a from recycled PET is growing – yet manufacturers
system mobile phone. must often invest in machinery that can processVia Venezia 232 - 21050 Marnate - Italy
info@bgpl ast .it
Phone: +39 0331 365 865PROCESSING | RECYCLING AND GRANULATORS
the multi-screw section with degassing zone. This
ensures a large degassing and decontamination
performance, says Gneuss. Recyclate processed on
the line has received food contact approval.
A separate South American manufacturer has
invested in an MRS 130 with a capacity of around
1,000 kg/h, plus a Gneuss Processing Unit – which
includes an RSFgenius 150 and an online viscom-
eter. The viscometer is also available separately
and is ideal as a retrofit solution. It measures the
temperature and pressure of the melt that is
diverted into the slot capillary during production.
“Installing these key components makes it
possible to process recycled material and still
Above: recycled materials. produce a high-quality PET sheet,” said the company.
Vecoplan’s One way to overcome this – which Gneuss of
VEZ 3200 Germany recently carried out for a South American Red Dot pre-shredder
pre-shredder packaging producer – is to retrofit existing machin- The new VEZ 3200 pre-shredder from Vecoplan is
has won a Red ery with components that allow these materials to one of this year’s winners of a Red Dot award for
Dot award for be processed. product design.
product design Cotnyl, based in San Martín in Argentina, says it It was developed to produce refuse-derived fuel
has become the first company in the country to (RDF). Vecoplan focused on a contemporary
obtain local approval to produce packaging made appearance when creating the VEZ – and took on
of 100% recycled PET. an industrial design company as a partner -- but
Gneuss says that an existing South American said it was not “just about colour and shape”.
customer has been using its Rotary Filtration “For us, the design was not all about appear-
Systems for several years to produce PET thermo- ance: ergonomics was also an important factor,”
formed trays with 70% recycled content. The filter said Werner Berens, CEO of Vecoplan.
discs operate automatically, continuously, and with He said that the design influences the machine
constant pressure. construction – making the shredder easier to
Fluctuating levels of contamination in the input handle for operators. The company has already
material is a major problem when processing sold around 15 machines worldwide.
recyclate. This can cause screens to get dirty
quickly – which increases upstream pressure and Blade discount cuts costs
possible temperature and viscosity fluctuations. CMG Granulators of Italy, which supplies a wide
The RSFgenius filtration systems have back-flush- range of size reduction equipment, is offering
ing technology to help overcome this. Screen discounts on its range of replacement blades and
cleaning is carried out automatically during screens.
production via an integrated back-flushing piston. The company says that, as companies look to
Only a small portion of filtered melt is cut costs in difficult times, many will
Right: CMG regularly shot through the be looking to replace these common
Granulators dirty screen via a narrow ‘wear and tear’ items – rather than
is offering gap by means of high-pres- invest in new machinery – but all
discounts on sure pulses. Even with high within lower budgets.
its range of contamination, the screens of the “The involvement of
replacement RSFgenius can be reused up to 400 every party, internal or
blades and times – allowing automatic external, in the production
screens production without the need for of blades and screens –
personnel for several weeks. from fabrication all the way
Cotnyl has invested in a to packaging – allows us to
Multi-Rotation System (MRS) offer a discount of 40%,” said
extruder from Gneuss, which is Giorgio Santella, general
based on a single screw extruder. manager of CMG. “These
It processes PET melt gently and spare parts help our custom-
provides a large melt surface in ers to keep operating effi-
20 FILM & SHEET EXTRUSION | October 2020 www.filmandsheet.comPROCESSING | RECYCLING AND GRANULATORS
11 metres, it will have enough space for assem-
bling large granulating systems.
“We urgently need the extra space to accelerate
handling of the large volume of orders which we
have won since K2019,” said Mark Hellweg, the
company’s managing director. “We have also been
seeing a trend toward large and complex ma-
chines. In future, we will be able to assemble and
test these in our own facilities and ensure trouble-
free commissioning on our customers’ premises.”
CLICK ON THE LINKS FOR MORE INFORMATION:
� www.rkw-group.com
� www.novachem.com
� www.merlinplastics.com
Above: Hellweg ciently and safely.” � www.econcore.com
has begun The promotional sale of blades and screens has � www.ti-films.com
construction of will be kept in place until September 2020, he said. � www.clariant.com
a new hall at its � www.toyoink-europe.com
HQ in Roetgen, Facility expansion � www.basf.com
Germany Granulator manufacturer Hellweg Maschinenbau � www.trinamixsensing.com
is building a new production shop at its Roetgen � www.gneuss.com
headquarters. � www.vecoplan.com
The facility will provide around 500m2 of � www.cmg.it
additional manufacturing space. With a height of � www.hellweg-maschinenbau.de
UP TO 50% MINERAL
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davis-standard.com
tel +1 978-281-1800Identifying opportunities and
overcoming obstacles in the
single-serve capsules industry
www.ami.ltd/attend-capsules
24 - 25 November 2020
Berlin, Germany
LIMITED
Join us at the fourth edition of this
international conference for the
single-serve capsules industry.
SPACES • Discover dynamic new
applications from food companies
looking at the capsule format
REMAINING • Network with key stakeholders
from the entire capsules supply
chain
• Explore different approaches
to sustainability from material
innovations to end-of-life choices
This conference is almost at capacity,
book today to secure your place.
BOOK
YOUR
Sponsored by: Media supporters:
PLACE
Bringing the plastic industry together.EXTRUDER DEVELOPMENTS | MACHINERY
The need for speed:
the latest extruder
developments:
The latest extrusion
lines have stepped
up their game: faster
output, greater use of
recycled polymer and
multi-layer capability –
with some even being
installed remotely
Outputs in film and sheet extrusion continue to PP – up to 38% higher than that of its predecessor, Main image:
increase, and in response machinery suppliers are says PTI. For PET, output is 4,000 lbs/hour (1,800 PTI’s new
having to develop products that keep pace with kg/h) – an increase of around 33%. SGHS3500
this trend. While the design of the SGHS3500 needed to extruder has a
Processing Technologies International (PTI) of add 18in (about 8.5%) to overall extruder length, it throughput
the US has developed a new high-speed sheet yielded a 20-25% increase in manufacturing nearly 40%
extruder – the Super-G HighSpeed SGHS3500-36D. footprint efficiency. Other original design features higher than its
The extruder, which can handle multiple resins have been re-scaled for the new version. predecessor
(HIPS, PP, and PET), claims higher regrind recovery The extruder also uses PTI’s patented M-Atex yet has a
rates, reduced maintenance costs and increased barrel glide supports for assistance in managing similar
throughput – despite minimal changes to the thermal expansion and the two-stage Super-G lobe footprint
footprint of the earlier SGHS3000 model. screw technology to ensure good mixing, melt
Like its predecessor, the machine will operate up quality and temperature control. These features
to 1000 rpm, but with higher levels of both output play a key role in maintaining consistent sheet
and regrind consumption, said Dana Hanson, gauge thickness and achieving high clarity for
president of PTI. crystalline and semi-crystalline polymers, said PTI.
To do this, specific design changes were The new extruder also uses CoolTough barrel
necessary. A re-engineered – and increased – screw guards to minimise heat emission on the surface,
diameter from 3 to 3.5in (90mm), an L/D of 36:1, a while the ‘out-the-back’ screw removal simplifies
600hp motor and a larger feed opening are the access to the screw.
main characteristics of the new model. A production scale machine is available for
With a 40% increase in area, the feed arrange- process trials at PTI’s Technology Development
ment allows a 70% increase in regrind recovery Center (TDC). Its downstream configuration
rates while maintaining consistent output. These incorporates a G-Series configurable roll stand,
design changes are the basis for a maximum TRC-66 transfer roll coater, Scantech X-ray gauge
output capacity of 3,600 lbs/hour (1,600 kg/hr) for scanner, sheet accumulator and winder, plus a Titan
www.filmandsheet.com October 2020 | FILM & SHEET EXTRUSION 25MACHINERY | EXTRUDER DEVELOPMENTS
Right: Plus control system – which allows
Coperion has data logging, trending and
developed a analytics of process run conditions
closed-loop while producing rolled stock.
approach that
re-uses up to Greenhouse effects
100% of Greenhouse panel manufacturer
multi-layer film Staal og Plast of Denmark has installed a
production sheet extrusion line from Battenfeld-Cincinnati,
waste which has a throughput of up to 3,000 kg/h.
The line is used to supply sheet for a thermo- “The outer layer,
forming line that transforms 3mm thick, extruded, which comes into contact
semi-finished polystyrene (PS) sheet into what is with the plant pots, is a
known as ebb and flow trays for greenhouses. The distinctive feature of our trays,” said Sörensen. “It is
installation has helped to company to quadruple approved for food production and is resistant to
production at its Danish facility, while simultane- UV radiation and chemicals.”
ously establishing a US subsidiary.
“Especially in North America, there is an enor- Closing the loop
mous demand for our so-called ‘Danish trays’,” said Coperion has developed a closed-loop concept
Jacob Sörensen, managing partner of Staal og for the production of flexible multi-layer film.
Plast. “The reason is the increasing cultivation of Recycling multi-layer film is often complicated,
cannabis, which is not only grown for medical due to the presence of multiple materials. How-
purposes, but due to its legalisation in several ever, Coperion says it has developed a closed-loop
federal states is more in demand.” approach that can reprocess and re-use up to
For the three-layer sheet line, Staal og Plast built 100% of multi-layer film production waste.
a new hall with a total length of 65m – which also Multi-layer film waste is shredded, then fed into
gave enough space for the thermoforming a ZSK extruder via pneumatic conveying and
machine. In the new co-extrusion line, a 1-75 T6.1 feeding. There, the material is homogenised and
high-speed extruder is used as the main extruder devolatilised in a co-rotating ZSK Mc18 twin screw
for a total capacity up to 3 tonnes/hour. The melt’s extruder. Within the extruder, dispersion and
residence time inside the extruder is long enough devolatilisation performance, gentle product
to achieve optimal homogenisation, but short handling and good mixing (even at high through-
Below: enough to prevent mechanical or thermal damage, put) help to achieve high product quality.
Staal og Plast says the company. Following homogenisation, the recycled
of Denmark The high-speed extruder plasticises the material material is added back into the multi-layer film
has installed a for the main layer, with in-house scrap resulting production process – with a high proportion of
3,000 kg/h from changeovers and cutting/stamping being added recyclate causing no loss in quality. This
sheet extrusion added to the virgin material. The material for the helps to ensure that multi-layer film manufacturing
line from outer layers of the three-layer composite is can be done sustainably and efficiently.
Battenfeld- provided by two 1-75 T2.1 co-extruders, with Coperion is developing a recycling system of
Cincinnati outputs of up to 500 kg/h. this type for an unnamed customer.
Semi-customised line
US-based sheet producer Airlite Plastics has expand-
ed production at its plant in Nazareth, Pennsylvania
with a semi-customised Davis-Standard sheet line.
The new line supports various thicknesses and
textures of Airlite’s thin-gauge sheet production,
including its Orthoform sheet used in making
orthotics and prosthetics.
Davis-Standard engineered the line for strict
repeatability, gauge control, product consistency and
low scrap, which are essential to Airlite’s processes.
Airlite operates five sheet lines at the plant.
Tony Alfieri, vice president and general manager
26 FILM & SHEET EXTRUSION | October 2020 www.filmandsheet.comEXTRUDER DEVELOPMENTS | MACHINERY
of this division of Airlite, said that the correct equip- roll configuration to ensure quality and consistency. Above:
ment combination is important because thin-gauge “Engineering and installing a complete sheet Bandera ran a
sheet production is challenging. His plant sched- line is a huge undertaking with a lot of attention to livestreaming
ules operations around processing a mix of sheet detail,” said Alfieri. “Knowing we have the technol- event to
thicknesses from 0.16 to .25in (4-6mm), and with ogy to make that happen is critical.” demonstrate a
different textures ranging from smooth to haircell. new machine
For instance, sheet used for Orthoform is drape- Compact cast line
formed using a very specific resin. Colines has developed its Polycast Evo line, to
Key components of the new line include a produce both cast polypropylene (CPP) and
Thermatic III extruder, DS-eVue control system, polyethylene (CPE) film. The company says that the
screen changer package, die, melt pump, and XP line satisfies the market’s technical requests at a
Express PS series roll stand system with a unique good best price-performance ratio.
The Largest MacroPack Die
For Agricultural Applications
Key Features:
• Up to 2.4 m
• Up to 7 layers
• Layflat up to 8 m
+1 905-5079000 | sales@macroeng.com
sales@macroeng.com |
ADVANCED EXTRUSION SYSTEMS www.macroeng.com | service@macroeng.com
service@macroeng.comMACHINERY | EXTRUDER DEVELOPMENTS
KraussMaffei lays foundation for
new extrusion systems facility
KraussMaffei laid the Left: Construction of
foundation stone earlier KraussMaffei’s new extrusion
this month for its new plant at Laatzen in Germany
66,500m2 extrusion systems is now underway
production plant at Laatzen,
near Hanover in Germany. to production-scale.
IMAGE: KRAUSSMAFFEI
The new facility will be KraussMaffei is working
completed by Q3 2022 and with commercial real estate
will replace the company’s developer VGP on the
Kleefeld factory — the project. It recently completed
traditional home of the construction of a new factory
Berstorff extrusion business for the company’s Burgsmül-
— which it says could not be expanded Innovation Centre, within which ler subsidiary in Einbeck in Germany
any further. It will allow all KraussMaf- customers will be able to run complex and is also building the new Krauss-
fei extrusion activities to be located preliminary line trials under realistic Maffei Technologies HQ at Parsdorf
under one roof. production conditions before ordering near Munich (the foundation stone for
Around 750 people will work on new machines. The centre will house that was also laid this month).
the site, which will include a 10,000m2 20 machines ranging from laboratory � www.kraussmaffei.com
The new cast line has a compact layout and is design, to ensure a maximum differential tempera-
available in a configuration starting from four ture of ±1°C between the two sides of the roll. The
extruders and five layers. Polycast Evo lines can be cooling roller conveyor is 20 m long. This allows
optionally equipped with Colines’ patented MDO the sheet to cool without locking in surface
IR1 (single stage) or MDO IR2 (double stage), which tensions – which could cause shrinkage problems
allow the production of mono-oriented polypropyl- during thermoforming.
ene (MOPP) and polyethylene (MOPE) film.
As with other lines, Colines applies its ‘quick Livestreaming demos
delivery’ police to the Polycast Evo lines. In the face of lockdown, companies must think of
creative ways to interact with their market. Luigi
Cool customer Bandera of Italy recently organised an open house
Amut has delivered a co-extruded sheet line to session – via live streaming – to demonstrate its
Walton Hi-Tech Industries of Bangladesh – adding new HDBFlex five-layer co-extrusion technology.
to the line that the company installed in 2017. The line, which makes heavy duty bags, was first
Walton manufactures components for the demonstrated to a customer who is due to have a
electronics, white goods, automotive and telecom- line installed. This private session allowed the
munications industries. It ordered the new line – to customer to preview the running of the line and
make ABS and PS sheets, with thicknesses of 0.8-5 verify its production parameters. Afterwards, three
mm – in order to fulfil an extension project for live streaming sessions were transmitted in two
refrigerator panel doors and cabinet liners. days, attracting more than 500 customers, potential
The line’s main extruder, an EA 160 40 L/D with customers and suppliers.
venting, can extrude up to 1,000 kg/h of HIPS and “Thanks to digital innovation, the barriers
800 kg/h of ABS using a dryerless process. The imposed by the Covid-19 pandemic have been
co-extruder is an EA 60 40 L/D with venting, for overcome – and turned a time of temporary stagna-
making the ‘glossy’ layer, with an overall capacity tion of manufacture into an opportunity for a rapid
up to 200 kg/h. Both are equipped with bushing on post-Coronavirus recovery,” said the company.
the first zone to guarantee stable feeding of the
material by the screw. VR service
The calender has a 2,400mm nominal width and Macchi of Italy is offering remote servicing via its
cooling rolls with optimised thermodynamic Macchi VR Service, which offers a direct connection
28 FILM & SHEET EXTRUSION | October 2020 www.filmandsheet.comWE DRIVE THE VISIT OUR new
virtuell showroom
ShowHello!
CIRCULAR ECONOMY.
Whether it is inhouse, post-
consumer or bottle recycling:
you can only close loops in a
precise and profitable way if
machines are perfectly tuned
for the respective application.
Count on the number 1 tech-
nology from EREMA when
doing so: over 6000 of our
machines and systems produ-
ce around 14.5 million tonnes
of high-quality pellets like this
every year –
in a highly efficient and
energy-saving way.
CHOOSE THE NUMBER ONE.
2009020ERE_Film & Sheet.indd 1 29.09.20 10:56
SECURE
YOUR 13 - 14 April 2021
PLACE Sofitel Berlin Kurfürstendamm, Berlin, Germany
NOW
This conference is your chance to explore the trends, challenges and
opportunities facing the breathable films industry.
• Explore innovative developments in raw materials and compounds
for breathable films looking at the capsule format
• Discover new ways to optimise production and to add value to
breathable films across multiple end-use applications opportunities
CONTACT US for single-serve capsules
Carole Charrade • Explore next generation testing and measurement solutions for
Conference Organiser breathable films innovations to end-of-life choices
T +44 (0) 117 314 8111
carole.charrade@ami.international
E carole.charrade@ami.international BOOK YOUR PLACE
www.ami.ltd/attend-breathe “Good conference,
wide variety of
papers and very
Organised by: Sponsored by: Media supporters: well organised.”
Sales Manager FE&C,
NDC TechnologiesMACHINERY | EXTRUDER DEVELOPMENTS
on-site assembly activity live – by smart glasses – to
the Visual Assistance Cockpit at Reifenhäuser.
Reifenhäuser experts assigned to the project
guided the customer’s team through specific
instructions and checklists. They also provided the
customer’s technicians with all the necessary
information on an integrated display.
This is all part of a software platform that
instructs technicians with exactly what needs to be
done in a specific situation at the right time.
Visual Assistance has been used to start up
Reifenhäuser blown-film lines across the world.
Reifenhäuser says that support using smart glasses
is one of a number of IoT solutions in its Visual
Abovev: with Macchi through a dedicated internet call Assistance package.
Reifenhäuser Customers get a real-time view through the In a separate move, the company has converted
used its Visual operator’s ‘eyes’ thanks to the use of Macchi VR another pilot line to make protective medical
Assistance smart glasses. This allows Macchi technicians to garments. It has been used to make 110 tonnes of
technology to highlight drawings or real images with arrows or protective film, which will be converted into
help a new other instructions. Electrical and mechanical draw- medical coveralls for use in hospitals.
customer set ings can also be sent directly to the smart glasses. The increased demand is currently very high for
up a blown film “With Macchi VR, you can increase the produc- coveralls worn to treat highly infectious coronavirus
line in Turkey tivity of your field service organisation and reduce patients. This volume is enough to make more than
critical outage times,” said the company. 1 million coveralls.
There are two levels of service – Premium and
Premium Plus – according to needs. CLICK ON THE LINKS FOR MORE INFORMATION:
� www.ptiextruders.com
Remote start-up � www.battenfeld-cincinnati.com
Reifenhäuser recently helped a customer in Turkey � www.coperion.com
to set up a blown film line remotely – using smart � www.davis-standard.com
glasses. � www.colines.it
The Coronavirus pandemic has severely restrict- � www.amut.it
ed the ability to travel, which affects operations � www.luigibandera.com
such as installing new lines. � www.macchi.it
In this case, the customer’s assembly team sent � www.reifenhauser.com
MAAG Group is the Partner for the Polymer
Processing Industry worldwide. All of our inte-
grated solutions from Pump and Filtration Sys-
tems to Pelletizing and Pulverizing systems to
Recycling Systems have an outstanding perfor-
mance for demanding customer requirements.
NEXT LEVEL
SOLUTIONS
Integrated Systems for Polymer ProcessingThin Wall
Packaging
BOOK
2-3 December 2020
Maritim Hotel
YOUR
Cologne, Germany PLACE
Identifying opportunities and Join us at this conference to
maximising returns in plastic tubs, debate business trends and
pots and trays industry improvements in packaging
technology.
Five good reasons to attend:
• Keep up with new materials and
technology
• Assess the latest packaging innovations
• Network with top international experts
• Learn about sustainability issues
• Review the latest market trends
CONTACT US BOOK YOUR PLACE
Maud Holbrook www.ami.ltd/attend-thin-wall
Conference Portfolio Manager
T +44 (0) 117 314 8111
E maud.holbrook@ami.international
Sponsored by:
Media supporters:
Organised by:FILM AND SHEET EXTRUSION
New dates
1-2 June 2021
MESSE ESSEN, GERMANY
Connect with thousands of
prospective customers
in a cost-effective and time-efficient way at AMI’s focused
exhibition for the pipe, profile and tubing extrusion industry
More than 200 exhibitors have already signed up for the Essen shows including:
BOOK To book your stand, contact: Find out about the
YOUR exhibition_sales@ami.international Plastics Extrusion
World Expo,
+44 (0) 117 924 9442
STAND www.ami.international/exhibitions North America
Brought to you by: Colocated with: Proudly supported by:AGRICULTURAL FILM | VIRTUAL CONFERENCE PREVIEW
AMI is holding the first Global Virtual Summit
in Agricultural Film in October. Get a taste of
the online event in this Q&A with some
speakers from across the value chain
Hear from the experts at
agricultural film summit
The new Global Virtual Summit in Agricultural Film Pierre Sarazin: A good part of our
takes place online over four days on 26-29 Octo- activities are concentrated in mulch
ber. Organised by AMI, the publisher of Film and film production, as well as flexible
Sheet Extrusion, the summit provides a unique packaging material. There are
forum for the global agricultural film industry. great concerns in both industries
Details can be found at the event website. about the waste generated by
Ahead of the summit, AMI spoke to some of the used films. Until now, biodegrad-
expert speakers: Ralf Dujardin (VP Marketing and able mulching films – those made with certified
Innovation, Imaflex), Lindy Savelle (President, compostable resins – have been the only alternative
Georgia Citrus Assn), Michael Lebidakis (Managing to traditional mulching films and I believe that these
Director, Plastika Kritis), Pierre Sarazin (VP R&D and films have a bright future ahead of them.
Sustainability, Polyexpert) and Jan-Torsten Vollmer Nonetheless, in the age of circular economy,
(Head of R&D and QM, Coveris Flexibles). there are a lot of questions being asked about the
end of life of traditional agricultural films after use,
What do you consider to be the most exciting which generates plastic waste. More development
opportunity for agricultural films in the future? in this area is to be expected, without it being
Jan-Torsten Vollmer: I guess the challenging detrimental to film functionality and performance.
opportunity for the agri film market will be finding Lindy Savelle: Several of our growers have used
the right sustainability solution. We think that the landscape fabrics and plastics to cover the beds
plastic discussion, which is ongoing in the consum- beneath their citrus trees. We are seeing more and
er packaging business, will affect the agri film more traditional produce farmers diversify by
business, too. I will present a few developments adding citrus to their product lines. Typically, these
and solutions in my presentation. are the farmers who plant citrus using film. �
www.filmandsheet.com October 2020 | FILM & SHEET EXTRUSION 33You can also read
