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Sep 1st, 2007                                Print this article

K 2007 Preview

By Mpw Staff

Injection molding

Expect an all-around array of molding technology

Nine machines spread across its multi-story, 1400-m² stand will offer plenty for attendees to see at Arburg. Among the injection molding machinery running on the stand will be the largest Arburg machine, the Allrounder 920 S with a clamping force of 5000 kN, which will be outfitted with the size 4600 injection unit for the first time. The maximum shot weight of the new unit, which can also be used on the Allrounder 820 S, is 2583g of polystyrene, about 700g more than the previous largest injection unit from the firm.

If not center stage, then at least much of the Arburg stage will be filled with its Alldrive all-electric machines: four will be brought to the K show. Michael Hehl, managing partner and spokesperson for Arburg’s management, says new features to the Alldrive range of machines include larger installation dimensions for larger and more complex molds and automation plus an adaptive clamping force control for higher part quality. The safety guard of the Alldrive machines, which is open at the top, has been enlarged at the rear of the machine, providing not only more space for cooling and electrical connections to the mold, but also allowing more comfortable mold changes. Also, the small 70-size injection unit is now available for processing of small and micro components. This new small injection unit will be running at the stand on an Allrounder 370 A with a clamping force of 600 kN.

Larger is an Allrounder 470 A with a clamping force of 1000 kN and a distance between tiebars of 470 by 470 mm. This press will run a two-component (LSR/ thermoplastic) application at the K.

A third Allrounder Alldrive, the 520 A, will mold medical parts, and the largest machine in the range, the 570 A (2000 kN clamp force), will run an inmold-labeled packaging application. Arburg, Stand 13A13

Engel shooting for global #2 in PET

Officials from the Austrian manufacturer of injection molding machinery told MPW during the firm’s pre-K press event that it has long-term plans to leap ahead of the competition and be a solid second on the PET preform processing machinery market. The undisputed #1 in the field is Husky, with Switzerland’s Netstal at #2. Engel CEO Peter Neumann said his company must pass at least two manufacturers to attain second place. “We’ve developed a system that, technically at least, we think will earn us the market’s attention,” said Neumann. He said the firm would speak further on the topic during the K. Engel, Stand 15C58

Molding machines compete for small-volume compounding business

Injection molding machine manufacturer Engel will introduce, at the K, its newly developed HTS (High Throughput Screening) system, with which a wide variety of plastic compound formulations can be rapidly plasticized, compounded, molded into test specimens and then tested. The target group for these systems is not only injection molders who develop their own formulas, but also material suppliers and compounders. Engel officials told MPW the system could process up to 50 different recipes per week, to include different colors. According to Georg Steinbichler, VP R&D at Engel, conventional compounding systems are limited to about 10-20 different recipes/week, and that’s without providing the injection molded samples.

Engel developed HTS with polyMaterials and plastics supplier Bayer. The system includes a gravimetric dosing system, controlled independently from cycle to cycle, so that a user can quickly shift to new recipes. Steinbichler said Engel also intends to develop and market an inline compounding/molding system. Engel, Stand 15C58

New control now available in all ranges

At the Fakuma trade show in October 2004, machine manufacturer Battenfeld Injection Molding Technology first publicized its new Unilog B6 control system with touchscreen control. Now the control is available for all of the firm’s machines.

From K 2007 onward, all Battenfeld machines of the HM series in the 350-650-tonne clamping-force range, including multicomponent models, the TM (50 -650 tonnes), the Vertical (40-270 tonnes) and the EM (30-180 tonnes) will be available with the Unilog B6 control system. Via its 15-inch touchscreen, it helps users quickly and easily call up, enter, and change all functions required for process control. Moreover, the most important functions have been integrated on just a few screens so that an operator can quickly navigate through the menu.

New process monitoring and documentation features have been added, such as online cycle time analysis for process optimization, and an extended quality table for complete documentation and evaluation of production data. Peripheral equipment such as printers can be integrated via plug-and-play USB connections. The online help system contains the complete operating instructions including circuit diagrams and parts lists; in the event of malfunctions, preplanned remedial action is initiated automatically. The control system is able to dispatch emails of its own accord. Battenfeld Injection Molding, Stand 16D22

Need more space between those platens?

Battenfeld Injection Molding’s HM two-platen series, available in four sizes from 350 to 650 tonnes, comes with a substantially shorter footprint than its predecessor series, while also offering more generous platen space. For example, the platen space of the new HM 400 is now equal to that of the older HM 500, the next higher clamping-force size. All of the new range is available in multicomponent versions, and in fact the entire range is marketed as especially attractive to molders requiring the added platen space due to complex, multimaterial processing. Platen space requirements are trumping machine clamp force as the critical machine determinant for many multicomponent projects.

At the K, a decorated toolbox weighing about 1.5 kg will be manufactured within a cycle time of 40 seconds on an HM 400/3400H/750S, a two-component machine with 400 tonnes of clamp force, equipped with the firm’s new Unilog B6 control system and a second injection unit mounted diagonally above the main aggregate. Gas injection is used in the process to form hollow carrying handles, and an inmold labeling system is running. Also, transparent polypropylene (PP) viewing windows are molded on each longitudinal side of the boxes. To accommodate the final injection of the viewing windows, the mold is designed as a slide mold (with the slide being moved by core pulls). Inserting decorative labels into the mold, removing the finished toolboxes and depositing them on a conveyor belt that transports them out of the production cell is all handled by a servo-driven Unirob R10 S linear robot from Battenfeld; the linear robot can be mounted directly on the fixed platen.

In another production cell featuring a HM 210/100 Unilog B6 (with 210 tonnes clamping force), a reclining adjuster arm for car seats is manufactured from polyamide (PA); a Unirob R5 S linear robot removes the 220g parts, picks off sprues, and deposits the finished part on a conveyor belt. Water injection technology (Battenfeld’s Aquamold WIT technology) is used to hollow out the adjuster arm. Battenfeld Injection Molding, Stand 16D22

Big development for smaller PET preform units

Swiss injection molding machine manufacturer Netstal will exhibit its new PET-Line machine for smaller cavity molds; the one at the show can hold either a 24- or 48-cavity mold. These new machines are based on a platform with 2000 kN (200 tonnes) clamping force, and are the firm’s answer to the rising demand from the beverage and food packaging sectors for preform units this size.

The model shown at the K Fair is equipped with a 48-cavity mold from Otto Hofstetter AG of Switzerland. Equipment for material handling and dry air for the mold is supplied by Eisbär, with its Drypack system developed especially for the new PET-Line. Netstal, Stand 15D24.

Cleanroom medical application running on stand

Netstal will run one of its Elion 800 machines processing polypropylene pipettes on a 36-cavity Schöttli mold at a cycle of just under 6 seconds under clean-room conditions. Automation equipment from Switzerland’s Zubler is used in the cell. Thanks to its encapsulated and water-cooled electric motors, the fully electrically driven Elion machine is particularly suitable for cleanroom processing, says Netstal. Netstal, Stand 15D24

How do your flowers grow? In these pots, of course

An Elion 1750 (175-tonnes clamp force) all-electric injection molding machine will run at Netstal’s stand, demonstrating—via its molding of flower pots—the energy savings processors can reap from this machine range. Netstal credits its recuperation of the braking energy of the mold-closing unit in an intermediate circuit for energy savings of up to 50%.

The flower pots will be formed at 1.7-second cycles on a 4-cavity Glaroform mold, using Gimat parts removal equipment. Netstal, Stand 15D24

Fore! Golf spikes formed in multimaterial molding

Injection molding machine maker Netstal is running a 16-cavity Polarform mold for golf shoe spikes on one of its SynErgy 2C 1750 machines, to impress upon show attendees the firm’s competence in multicomponent injection molding. Two grades of thermoplastic elastomers (TPE) are used for the spikes.

Netstal will also highlight the services offered by its ’Netstal Support Concept’. At the K attendees can assess an installed remote maintenance system in operation and obtain information, through interactive presentations, on the different services available and the possibilities of service contracts (maintenance, calibration, etc.). Netstal, Stand 15D24

Mold, metallize and print in one cell

Exhibitor Singulus is best known as market leader for optical disc production lines. However, its work with injection molder Balda (Bad Oeynhausen, Germany) led to the development of its Decoline technology for the production and finishing of three-dimensional plastic surfaces. According to Singulus, and to the best of MPW editors’ knowledge, the machine is currently the only production line available that completely integrates injection molding, metallizing, and painting (of antiscratch finishes) in a single production cycle while automatically moving the parts through all process steps.

The production line will be shown at stand 8bF37 at the K. Steffen Runkel, technical director optical coatings at Singulus, adds, “The integration of the individual processing steps into a complete production line is surely unique. For us, the presentation at the K in Düsseldorf marks an important milestone in the market launch of the new machine concept.” The lines are targeted at processors serving the cosmetics packaging, appliances and automobile industries, among others. Singulus Technologies, Stand 8bF37

Dr. Boy keeps it clean

The stand of injection molding machine maker Dr. Boy will feature a Boy 22A configured with a cleanroom from Max Petek Reinraumtechnik to demonstrate for molders a relatively inexpensive alternative to conventional cleanroom production systems. Infusion bottle catheters will be processed.

The cell’s special feature is the inclusion of a sterile packaging unit, so no further sterilization measures are required. The specifications for a Class 6 cleanroom are met.

Air ionization, a sprue picker, and sterile packaging are integrated within the machine’s footprint. A laminar flow box (type LMP) is mounted on the machine’s safety gate to ensure clean air flows through both the clamping unit and the packaging unit.

Within the safety gate of the clamping unit, an integral sprue picker grips and drops the sprue into a container via a chute. The molded parts drop into a packaging bag that is immediately sealed airtight. The finished and sealed parts are then transferred via a belt conveyor. Dr. Boy GmbH & Co. KG, Stand 13A43

Xaloy’s induction barrel saves energy

The screw and barrel manufacturer will introduce ’Indx’, a patents-pending induction barrel heating system for injection molding that it claims sharply cuts energy costs and improves temperature control compared with conventional heater bands. The Indx system uses a high-frequency power supply and helical induction coils to generate heat directly within the barrel wall. A thermal insulating layer is interposed between the coils and barrel to combat heat loss, increase efficiency and improve control response.

This new non-contact heating system offers 95% efficiency, well above that of heater bands, says Xaloy. This leads to energy savings of about 70%, which are compounded by additional energy savings—up to 35% more—due to reduced air conditioning load. The system heats up at twice the rate of heater bands, says Xaloy, and also offers more heating capacity—typically triple the wattage into the barrel. Higher barrel temperatures help processors mold high-temperature thermoplastics.

Xaloy plans to adapt the system for use with extruders, blowmolding machines, dies, rolls and other plastics processing equipment. Xaloy, Stand 12C34

Hybrid from Nissei gets European preview

Nissei Plastic Industrial will exhibit and demonstrate operation of the PNX40-5A hybrid injection molding machine and the NEX50-5E all-electric injection molding machine at the K. The 392-kN (40-ton) PNX40 is a hybrid electric/hydraulic machine shown for the first time in Europe, molding bar flow samples at the show. These machines take advantage of Nissei’s Hybrid X pump system, an adaptation of its X Pump system that employs a servomotor to drive the hydraulic pump. By controlling the rotation of the servomotor, the motor provides driving power only when required (it stops when not required: for more, see December 2005 MPW, p. 46). Nissei reckons European processors’ broad use of injection-compression will spark their interest in its machines.

Nissei says the Hybrid X Pump system leads to about a 55% reduction in energy consumption compared with its hydraulic machines.

Plus, it says the injection ramp-up time of these is on a par with all-electric machines. Maximum injection speed on these is 550 mm/sec (on the PNX40-2A press) but, on the other end of the speedometer, stable control at injection speed of just 1 mm/sec also is possible. The clamping mechanism is the same direct clamping type as that employed in Nissei’s well-established (10,000 sold) hydraulic FN (PN) series. Nissei Plastic Industrial, Stand 13D76

Changing clamp force on the fly

Injection molding machine manufacturer Nissel Plastic Industrial will run one of its NEX505E, 490-kN (50-ton) clamping force, all-electric machines from its established NEX Series of all-electric presses. A two-cavity mold will form 2.5-inch-thin lightguide panels.

Nissei highlights the machine’s automatic correction of clamping force as well as its high-precision metering control. The function for automatic correction of clamping force was developed in order to realize a ’direct-pressure-type’ toggle mechanism, enabling use of a toggle clamping mechanism with effects similar to direct clamping. Automatic correction of clamping force in the toggle clamping mechanism, as a result of temperature change in the mold or other factors, is possible during continuous operation. In addition, the clamping force can be altered during automated operation.

Processing can begin before the tiebar shaft temperature is constant, and the mold protection function has been improved, enabling detection of ultrathin contaminants.

High-precision metering control lets a user select either “pre-pack” or “precision metering” as the control mode. “Pre-pack” enables control using a standard screw, with metering density and injection volumes fixed, and the response of the non-return valve is stabilized. “Precision metering” further stabilizes the metering stop position, useful at high-speed screw rotations during fast cycle molding. Nissei Plastic Industrial, Stand 13D76

New PUR/thermoplastic options emerge

Among the more than 20 machines displayed or running at the KraussMaffei stand during the K show will be a revamped version of the firm’s established injection molding compounder (IMC) that now also integrates polyurethane processing into the manufacturing cell. Called the KM 3001400 CX IMC, and mating an IMC with an injection molding machine from the firm’s CX range, at the K it will process an automotive part consisting of three components: a load-bearing body and collar molded of Ultramid PA66 supplied by BASF, with these joined via the third component, a vibration damping element made of cross-linked Elastollan TPU thermoplastic urethane from the same supplier. Cycle time for this part will be about one minute; according to KraussMaffei officials, at least one automotive Tier supplier has said it currently requires 15 minutes to make the same parts. This is the first time an IMC has been coupled with multicomponent molding.

KM partnered with Elastogran to develop the process. A crosslinking agent is added to the TPU’s melt as a liquid prepolymer and the two materials are mixed on the IMC. In the two-stage molding process, using a four-cycle rotary table mold, the polyamide parts are molded on a modular bolt-on unit (the CX injection unit) mounted to the IMC. Then the collar is overmolded with a star-shaped crosslinked TPU connecting element. In the third cycle, the TPU-X is injected into the shape’s remaining cavities. K-M says injecting the TPU-X through two cycles helps shorten total cycle time for thick-walled parts. The mold’s final rotation is for parts removal, with the mold designed to allow for parts removal even when closed. No release agent is required, also novel when compared to other reactive injection molding systems.

The machine manufacturer also will display a further advance of the SkinForm unit it introduced at the last K show in 2004. The production cell at this K will combine a KM 2300-120000 MX SpinForm spin-platen injection molding machine with reaction injection molding to process thermoplastic parts with a PUR coating. Processed will be an automotive interior trim application with specific areas coated with PUR to give parts a two-tone effect in a one-shot process. The PUR mixing head is mounted on the moving platen of the molding machine. Pigment is metered only in the mixing head, so that PUR color can be changed from shot to shot. Two six-axis robots complete the cell: they are responsible for applying release agent to the mold, parts removal and for sprue and flash removal. The robots also attach fixing clips to parts so that they leave the cell ready for assembly. KraussMaffei, Stand 15C24

Negri Bossi brings four

Four injection molding cells fill the stand of Negri Bossi. One molding cell, based around a two-platen hydraulic VH1200, features integrated molding and post-processing (deburring, cutting, insert insertion, and such). The VH1200 is the smallest machine in Negri Bossi’s BiPower series, targeted especially for automotive parts processing and available sized from 1200-6000 tonnes.

The second molding cell will process eyeglass lenses, and includes a Canbel series VE70 press plus a vision system from parent firm Sacmi and a coating system from sister firm Ghiotto. The coating system carries the lenses from a loading area through a deionization station en route to the actual coating station, then an IR radiation station to eliminate solvent, and finally to a reticulation area with UV radiation.

The third cell is reminiscent of one the firm displayed at the Plast event in Milan in 2005, as it features an integrated molding and metallization plant for optical elements for front vehicle headlights. A 210-tonne Cambel electric press with plasticizer modified to process PES, is used. Metallization with a sputtering system is integrated on the injection machine.

The fourth work station shows includes a new Canbel series VE480 press and an in-line quality control solution developed by Sacmi Group’s Advanced Research and Development Office. Interesting is that the Q/C is not for a part’s size but rather ensures it meets specified performance requirements. Specifically, a check is made of the frequencies absorbed by the part in the IR spectrum. The absorption values are then processed to identify any defects. Negri Bossi, Stand 15A05

IML systems purring

Waldorf Technik will for the first time exhibit at its own stand at the K Show. The firm’s inmold labeling systems will be running as part of molding cells at the stand of machine manufacturer Arburg (13A13) or interested processors can find more information on these at the Waldorf stand (7aB02).

“Together with our exhibition partner, the injection molding machine manufacturer Arburg, we will show an IML system with 360-degree-label application,” said Wolfgang Czizegg, CEO of Waldorf Technik. The labeling of yogurt cups will be done in a six-cavity Otto Hofstetter mold on a 270A-2000-800 (200-tonne) Arburg press.

During the show a magazine table with only one plate will be fixed to the back of the injection molding machine and the magazine will be filled only once per day; during normal use a fast magazine changer would be used. Explains Czizegg, “The labels are placed into the magazine, and the system takes the labels from the horizontal table by servo axis. They are given to the brush station where the six labels are brushed on dummy cores and are held by vacuum.” The ’mold open’ signal drives the servomotor controlled, water-cooled D3S into position. The six dummies place the labels in the matrix cavity of the tool. The finished cups are removed on the core side. Total cycle time is less than 5 seconds. Waldorf Technik, Stand 7aB02

Sacmi shows PET molds and machines

The PET division of Sacmi will display completed 48- and 72-cavity molds—hot runner and cold half—plus an electronic visual inspection system for preforms. The control vision system checks the quality of the preforms by sampling directly in-line with the injection machine. The range of presses provided by Sacmi PET includes three tonnages (120, 180, and 350 tons). Molds sized up to 96 cavities are available. Sacmi PET, with subsidiaries Negri Bossi, BM Biraghi, and Oima, designs and builds the hot runners, molds, and injection presses plus its post-cooling robots. Sacmi, Stand 15A05

New range targets packaging applications

The Italian molding machine manufacturer will introduce its new Stratos KP series of injection molding machines for packaging. One Stratos 2220.300 KP will be part of an IML (inmold labeling) production system for an ice cream container and lid, and a second machine, a Stratos 1370.220 KP, will run a multi-cavity mold made by parent firm Sacmi, processing patented one-piece sport caps.

This series of machines has a completely redesigned hydraulic plant, with all machine movements powered by hydraulic accumulators, and closed-loop control of speed and pressure through dedicated servovalves. New plasticizing screw profiles of a proprietary design, sized 25 L/D, are said to improve plastification. A high-torque electric drive system is directly coupled to the plasticizing screw. Oima, Stand 15A05-2

Closure molding unit hits the streets

Introduced during its open house last year, now Ferromatik Milacron has recorded commercial sales of its cap-Tec machines, designed for highly efficient molding of closures. A Cap-Tec 300 (300-tonne clamp force) will be one of seven machines, four of them injection molding machines, on the stand of Milacron.

The Cap-Tec presses have been stripped of anything not essential for forming closures and caps, helping to lower their cost as well as boost their efficiency; Ferromatik claims these have the fastest clamp force buildup around. The one at the show will house a 72-cavity mold from Austria’s KTW to form thin-walled closures at outputs expected to exceed 100,000/hr. Thicker-walled closures such as those on carbonated beverage bottles can be molded at 60,000-80,000/hr rates. “The cycle times will turn some heads,” claims Winfried Stöcklin, GM of the K-Tec business unit at Ferromatik; Cap-Tec presses are built on the firm’s proven K-Tec machine base. The Cap-Tec machines feature electrically driven plasticizing units. The manufacturer intends to extend this machine series to include smaller 200-tonne and larger 400-tonne models. (Much more on Cap-Tec, introduced at Ferromatik Milacron’s 2006 open house, in our November 2006 issue; more on KTW in the September 2005 issue). Ferromatik Milacron, Stand 15B05

Elektra evolution range evolves, adds sizes

Ferromatik Milacron has filled some of the gaps in its Elektra evolution all-electric machine range, adding the 230-tonne model to fill the gap between the 180-tonne and 300-tonne ones (other smaller models also are available). The 230 offers standard tiebar spacing of 660 by 660 mm. Molding during the K on the machine will revolve around polystyrene razor blade dispensers on a 12-cavity mold (76g shot weight) built by Germany’s Braunform for Schick Wilkinson Sword. Wittmann supplies the complete automation system. Cycle times of about 10-sec are promised. Ferromatik Milacron, Stand 15B05

Service takes center stage

This manufacturer of injection molding machinery has opened a new business unit, called Servtek, to highlight the increased role that service plays not only among processors but also at the firm. Service may once have been about routine maintenance and the occasional service call, but now involves ensuring a machine’s maximum efficiency is achieved through the very long life of the machine. The firm says a large space at its stand will be devoted to discussing its service package. Ferromatik Milacron, Stand 15B05

RIM, PUR, and the K

With one player on the block (Hennecke), and another becoming a turnkey machine/mold/system supplier in the last year (KraussMaffei), K promises interest beyond the show halls for reaction injection molding (RIM). KraussMaffei (Münich, Germany) gave a K preview of sorts at a June open house, including a new application for its RIM/injection molding hybrid SkinForm technology that launched at K 2004 (for more on SkinForm, see the K injection molding preview on p. 60).

K exhibitor, GlasCraft Inc. (Indianapolis, IN), offers a variety of hydraulic and pneumatic machines and specialized guns, including its GlasCraft Prober P2, for protective coatings of polyurea, polyurethane, and hybrid fast-set materials. In addition, GlasCraft will have a new technology for fiberglass replacement projects (FRP), where chopped fibers can be added to foam or coatings. Depending on the length and loading, the fiber can act as a filler or as structural enhancement. On the closed-mold side, GlasCraft will have information at K on its RTM (resin transfer molding) and Lite RTM processes.

RIM machinery supplier The Cannon Group (Trezzano sul Naviglio, Italy), is planning “Technological Islands” for K, covering its entire machine range. Its A-Compact high-pressure pump-driven metering unit will be at the company’s stand, running a low-output small-part free-pouring operation. Cannon will also have information on its new Cannon JL mixing head, featuring an L-shaped design, as well as its low-pressure B range of machines, including dedicated gasketing lines.

On the composites side, the company will discuss its dedicated plants for continuous production of sandwich panels, as well as co-injection and reinforced spray technologies, including SoliStream filler and solids mixing heads.

The Cannon Group, Stand 13B77; GlasCraft Inc., Stand 7AC25; Hennecke, Stand 13B63; KraussMaffei, Stand 15B24

Resins/compounds

Two new PP grades

Two of 20 new and upgraded polypropylene (PP) grades are featured by this polymer maker at next month’s show in Düsseldorf. Grade DR7032.00 is a random copolymer PP intended for thin-wall injection molding applications. It has a good balance of stiffness and impact properties, can be processed easily, and is said to have good optical properties. Lids, caps and closures, media packaging, and housewares should benefit from this resin, which has a melt-flow rate of 100 g/10 min. Its sister grade, DR7023.00, also a random copolymer PP, offers the same characteristics but includes improved taste and odor performance. Dow Europe, Stand 8aK47

Wire, cable PE grades

For more than a decade, the production of crosslinked/scorch retardant polyethylene (PE) using vinyl silane copolymers has become widely established with the introduction of Visico grade PE. These low- and medium-density grades in natural or black provide good cable performance, low scorch, and easy processability on high-speed extrusion lines. The company’s Ambicat technology further develops this potential as a highly active tin-free catalyst system for the ambient curing of Visico. Main applications of Visico PE grades are for 1 kV underground, industrial, and overhead cables. It is also seeing use in telephone and automotive wires as well as track resistant floor heating and fire safety cables. Borouge, Stand 6C58

Innovation lessens load in white goods production

This detergent-resistant, glass-reinforced polypropylene (PP), GB266WG, is cost-effective but provides long-term performance in home appliances. It can be used for the interior of washing machines and dishwashers and it reduces the number of materials needed for processing in the production process. It is lightweight, and durable, making it an effective alternative to steel parts such as dishwasher frames. It prevents additional ageing effects of light, oxygen, and usage-induced wear and tear that can cause loss of strength, discoloration, scratching or loss of gloss. Previously different PP materials were needed to survive corrosive effect of detergents. The producer says this is no longer necessary since GB266WG allows OEMs to reduce their inventory of materials with just this one PP grade. Borealis, Stand 6C58

Processors on outlook for tailor-made specialties

The portfolio of this K exhibitor includes a wide range of flame-retardant, self-lubricating, and radiopaque compounds. Among the newest developments to be shown are highly-filled Latigloss grades of nylon 6 or 6.6 that permit uniform, smooth, and glossy surface molded parts. Although not new, Latiohm-brand compounds that provide antistatic and electrically conductive finish are finding new uses. Based on nylon or acetal (POM), they provide good mechanical and thermal characteristics for applications needing very high impact strength even at low temperatures. One typical field of application for these electrically conductive composites is the processing of filter housings and other automotive components that come in direct contact with fuel. Lati, Stand 6D80

TPEs help pep up Pepper Pad computer

The handheld Pepper Pad computer that allows on-the-go individuals to squeeze more out of their digital lives has become a bit more compact and rugged thanks to a housing that makes a wide use of thermoplastic elastomers (TPE). The unit uses Dynaflex G7970 TPE molded around the bezel and Versollan OM126NX1 overmold grade TPE for the end caps, a special PC/ABS blend. The overmolded TPE has the advantage to allow the Pepper name and logo to be visualized through the TPE. Further the TPE enables users to grip the unit securely during operation and move the scroll wheel without difficulty. These grades were elected because the pigmented gray and silver-gray TPEs are reportedly easily molded and overmolded on the producer’s existing injection molding equipment. GLS Corp., Stand 8aD08

New WIT-suitable grades premier

Plastics supplier BASF is introducing a number of new polyamide-based compounds for injection molding using the water injection technique (WIT). During WIT, a mold’s cavity is filled with melt, and then water is injected to expel the internal melt volume before the melt solidifies.

The supplier has developed a hydrolysis-resistant PA 66, Ultramid A3HG6 WIT, which is chemically resistant, prevents leaching (so that the reinforcing fibers are not exposed) and offers high resistance to coolant fluids. Another grade, SI (Surface Improved), is reinforced with 50% glass fiber, as is Ultradur B 4040 G10 Wit, based on polybutylene terephthalate (PBT). Both of these have passed mechanical component tests for automotive roof rails, with testing conducted by Tier supplier Decoma, part of the Magna group. BASF also says it has worked with a Tier 1 supplier and will soon supply its WIT-suitable materials for a commercial cooling water pipe. Potential future WIT applications include bus seating or automotive seat backrests. BASF, Stand 5B21

Inline e-coating of new polyamide

Scheduled for market introduction during the K show is Ultramid TOP 3000, an impact modified, mineral-filled, partially aromatic polyamide from supplier BASF. It is designed to be suitable for e-coating inline with metal parts at temperatures up to just above 200º C, for instance on automotive manufacturing lines.

According to Jörg Schnorr, application development expert for automotive exterior/interior parts at the supplier, this new material is a substantial improvement over the PPE/PA6 blends (GE Plastics’ Noryl, one can assume) already marketed for exterior applications, especially with regards to the Ultramid’s lower coefficient of thermal expansion. For this new grade, its CTE remains constant between 25ºC and about 80ºC, and then it rises gradually to about 100 at 185ºC. It also retains its stiffness even when moist, again when compared with a PPE/PA6 blend, and its slow water absorption and release makes it less sensitive to climate fluctuations than other plastics used for these applications.

Schnorr allows that a nanocomposite mineral filler is used at about a 10% loading, but would not indicate which material it is. Weight savings compared to metal can be up to 3-5 kg/part for automotive fenders. BASF, Stand 5B21

High-heat material bridges gap

Officials at plastics supplier Ticona (Kelsterbach, Germany), during its pre-K press event, said the firm is developing (and can discuss at the K show) a material that will bridge the heat resistance gap between two materials it already offers—polybutylene terephthalate (PBT) and liquid crystal polymer (LCP). These officials also said they will be able to discuss work done at the supplier to improve the processability of semicrystalline thermoplastics.

Ticona also plans to highlight a number of recent ’success stories’ among its customer base. These will include the use of the supplier’s Hostaform EC140XF polyacetal (POM) to dissipate electric charges in fuel supply units on the new Ford Transit; the Tier supplier for these is Siemens VDO. The plastic was modified to ensure dissipation of static charges. Additionally, a special hot diesel stabilizer was added to the material to account for the higher temperatures in diesel engines. Ticona, Stand 6A07

Scratch-resistant acrylic parts in single step

Degussa will be presenting a series of innovative solutions for plastics processors at K including a system solution comprised of Plexiglass acrylic molding compounds and an acrylate-based reactive system for production of molded parts with a scratch-resistant coating.

In the new system, Plexiglass compounds are molded using injection-compression molding and coating using an acrylate-based liquid reactive system while still in the mold to impart scratch resistance in a single step. The coating is cured in two steps: the new functional surface is cured in the mold to such a degree that the shaped part can be removed from the mold without damage. Curing is then completed by UV irradiation. The new system solution for scratch resistant coating of plastic parts has been developed jointly with the machine manufacturer KraussMaffei (Stand 15A23/24/C24), who is demonstrating it at K.

In terms of new materials, Vestamid LX9020 is a polyamide 12 molding compound with outstanding UV and ageing resistance, which is also less affected by air and seawater than the materials currently used in supply lines for oil extraction. Supply lines serve to transport energy as well as all the required chemicals and hydraulic liquids to the drill head.

Flameproof, impact resistant, and heat resistant Europlex PPSU (polyphenylsulfone) sheets, meanwhile, have been extensively tested by leading manufacturers of fire helmets and approved for production of visors. The material has already entered the relevant international standards for fire protection equipment, replacing the polycarbonate that has been primarily used to date. Degussa, Stand 6D24

Plastic shapes help shape your business

At Quadrant Group several new products will make their public debuts at the K show. Zurich-based Quadrant Group is a global supplier of high-performance semifinished and finished polymer products (sheet, rod and tube), with locations in 18 countries. Represented at K will be three of its operations, Quadrant Engineering Plastic Products (sheet, rod and tube); Quadrant Plastic Composites (glass mat thermoplastics or GMT), and Quadrant Creative Molding & Systems, a custom injection molder.

New products and technologies the company is unveiling at K include:

• Symalite PVDF Architectural Films, intended for use as translucent membranes in textile architecture

• Rigid machinable sheet made from glass-mat-reinforced thermoplastic (GMT) composites to replace metal, in a range of demanding applications

• A new grade in the company’s Fluorosint range of very-high-performance TPFE-based highly filled compounds that can operate in extreme environments at temperatures anywhere from -240ºC to 260ºC

• A new polyimide semi-finished product series, aimed at applications that require the polymer’s combination of high temperature resistance, mechanical performance and chemical resistance;

• A new technology to bond a thin strip of PTFE with a thermoplastic carrier in a single-step overmolding process, yielding strong parts with a low-friction, chemical-resistant surface. (See August MPW, p. 75 for more on this.) Quadrant Group, Stand 6E23

TPVs boast ultralow hardness

SO.F.TER. (Stand 6E28) has augmented its thermoplastic vulcanizate (TPV) range with two new materials of very low hardness that will formally debut at K. The new grades, measuring 20 and 30 ShA, respectively, belong to the 6SD Forprene family, which is a new TPV generation for injection molding combining the traditional characteristics of these materials with translucent color, improved processability, low fogging value and an odor level suitable for car interiors.

Until now, such hardness was only obtainable by means of styrene-based TPEs. Particularly if compared to TPEs of equal hardness, these new grades provide better grip, better resistance to high temperatures and greater chemical resistance to sporadic contact with petrol and oils.

A comparison with traditional TPVs indicates a 50% improvement in processability, which allows the optimal molding of complex pieces and makes possible to shorten considerably the cycle times, with a positive impact on production costs. An extrusion version is also available. SO.F.TER, Stand 6E28

High-temperature, wear-resistant resins sans lubricants

Solvay Advanced Polymers is launching an enhanced line of high-temperature, wear-resistant plastics at K. Dedicated to friction and wear applications in both dry and lubricated environments, the new formulations are specifically designed for wear-resistant applications requiring long-term use in temperatures between 120–265°C and short-term use up to 280°C.

Enhancing current wear-resistant offerings in Amodel polyphthalamide (PPA) and Torlon polyamide-imide (PAI), Solvay Advanced Polymers has also announced wear-resistant formulations in its KetaSpire PEEK, AvaSpire modified PEEK, and Ixef polyarylamide plastics. In addition to being conventionally processable, many of the grades are available in stock shapes.

“What’s truly unique avbout this new suite of products is that you can achieve impressive performance even absent lubricants. That can be an enormous advantage for industries such as healthcare and food processing where lubricated contaminants must be avoided at all costs,” says Nate Harry, Senior Global Market Manager for Wear Resistant Polymers at Solvay Advanced Polymers. Solvay Advanced Polymers, Stand 6D76

Vibration-, sound-damping TPEs to debut

GLS Corp. brings to the K a new technology portfolio of specialty vibration- and sound-damping TPE alloys, which enable manufacturers to mitigate the negative effects of noise and vibration for products. Target markets for this technology include hardware tools, footwear, electronics, building materials, personal protection, and acoustic control applications.

Traditionally, designers have managed noise and vibration control by appropriate design with limited help from materials. However, GLS’ new damping technology is the first of its kind in providing true material damping by utilizing unique chemistries for sound deadening across a wide frequency range (10–20,000 Hz). Along with damping, it provides wide hardness (20– 80 Shore A) and specific gravity (0.9–1.3) ranges, which relax some of the limitations imposed by materials currently used, offering more design freedom. GLS customers can specify grades for overmolding onto a variety of substrates and choose from a range of hardness and custom colors. These materials also offer excellent UV protection and can meet UL specifications.

GLS will also showcase a new suite of customizable blowmolding TPEs under its Versaflex brand. These materials offer a range of hardness from 35A up to 40D and will be available in both clear and translucent grades. They are extremely flexible and resilient, retaining their shape after demanding, prolonged use. GLS is targeting both the medical and consumer products market sectors with this new family of engineered TPEs where barrier and/or flexibility are required. GLS Corp., Stand 8aD08

Additives and fillers

Filler options aplenty, for pipe and more

Mineral modifiers supplier Onya will present its product range for calcium carbonates, talc and dolomites. The firm has expanded globally, including adding capacity in Finland for its Hydrocarb 95T, targeted at window profile manufacturers in Eastern Europe. Other expansions in the plastics portfolio include factories in India, Vietnam, Egypt, Russia and the Czech Republic.

The firm plans to highlight new calcium carbonate filler options to increase pipe ring stiffness and reduce total costs during extrusion of PE. The firm also can discuss a new means to adding calcium carbonate directly to an extruder during PVC pipe extrusion, and thus avoid the hot/cold mixing process.

Processors of flexible films also can discuss the supplier’s Omyafilm modifiers, already used in standard film and bags but also finding use in agricultural film such as greenhouse or mulch film, where light transmission and good mechanical properties have to be tuned for the profit of end users.

Blowmolders will want to learn about Omya’s work on introducing fine coated calcium carbonates in blowmolded bottles. Tests have shown that at constant weight and improved ESCR, top load and drop impact can be preserved, granting substantial cost savings for processors. Omya, Stand 6D75

Carbon nanotube applications shown

Injection molding machine maker Nissei Plastic Industrial also has invested in development of carbon nanotube fillers, and intends during the K to exhibit samples and panel displays showcasing the technology, including examples of plasimposed by materials currently used, offering more design freedom. GLS customers can specify grades for overmolding onto a variety of substrates and choose from a range of hardness and custom colors. These materials also offer excellent UV protection and can meet UL specifications.

GLS will also showcase a new suite of customizable blowmolding TPEs under its Versaflex brand. These materials offer a range of hardness from 35A up to 40D and will be available in both clear and translucent grades. They are extremely flexible and resilient, retaining their shape after demanding, prolonged use. GLS is targeting both the medical and consumer products market sectors with this new family of engineered TPEs where barrier and/or flexibility are required. GLS Corp., Stand 8aD08

Additives and fillers

Filler options aplenty, for pipe and more

Mineral modifiers supplier Onya will present its product range for calcium carbonates, talc and dolomites. The firm has expanded globally, including adding capacity in Finland for its Hydrocarb 95T, targeted at window profile manufacturers in Eastern Europe. Other expansions in the plastics portfolio include factories in India, Vietnam, Egypt, Russia and the Czech Republic.

The firm plans to highlight new calcium carbonate filler options to increase pipe ring stiffness and reduce total costs during extrusion of PE. The firm also can discuss a new means to adding calcium carbonate directly to an extruder during PVC pipe extrusion, and thus avoid the hot/cold mixing process.

Processors of flexible films also can discuss the supplier’s Omyafilm modifiers, already used in standard film and bags but also finding use in agricultural film such as greenhouse or mulch film, where light transmission and good mechanical properties have to be tuned for the profit of end users.

Blowmolders will want to learn about Omya’s work on introducing fine coated calcium carbonates in blowmolded bottles. Tests have shown that at constant weight and improved ESCR, top load and drop impact can be preserved, granting substantial cost savings for processors. Omya, Stand 6D75

Carbon nanotube applications shown

Injection molding machine maker Nissei Plastic Industrial also has invested in development of carbon nanotube fillers, and intends during the K to exhibit samples and panel displays showcasing the technology, including examples of plasics and metals utilizing CNTs. Nissei Plastic Industrial, Stand 13D76

Specialty effects colors add new dimension

Studies of consumer behavior show an increasing return to traditional values without wanting to abandon standards of living, comfort, or color variety. That is the background for this manufacturer to have developed its Colour Vision Edition 2007/2008 which will showcase 36 new colors for plastics that reflect the change in consumer behavior and requirements. These are grouped into three theme trends: European Identity, Home Skills, and Effective Design. European Identity is a variety of blue and violets, dark purple, new copper nuances with colored iridescent shimmers and warm gold shades with a touch of copper. The Home Skills sector includes delicate creams and white tones, yellow variations, gold and brass, red nuances, as well as bright green. The color palette Effective Design presents the new trend color white with shimmering silver and gold with light reflection ability. Gabriel-Chemie, Stand 5J27

Expanded product range has something for everybody

Since this materials producer acquired Uniqema in 2006, it has increased its product portfolio and incorporated Uniqema’s Atmer anti-fog and antistatic additives previously marketed by Ciba Specialty Chemicals. The Atmer anti-static agents include both internal and external products. When included in the polymer during extrusion, they migrate to the surface to give long-lasting effect to the plastics part with as little as 0.2% addition levels. The company’s Crodamide slip and anti-blocking agents enable easier processing and handling of polyolefins. These include a variety of primary and secondary amides and secondary bis-amides. They reduce surface friction that can result in difficulties in winding film rolls, bag production, packaging operations, and mold release. Croda Chemicals Europe, Stand 7.2B27

Processing aid helps eliminate melt fracture

Complementing the existing Viton FreeFlow family of fluoroelastomer processing aids are two new grades making their first appearance at this year’s show. Z110 and Z210 eliminate melt fracture and reduce extrusion pressure, amperage, torque, and die build up. The two products target moderate mixing situations during processing including solution-produced linear low-density polyethylene (LLDPE), masterbatches with more than 2% process aid, blown film using 1-3 MI LLDPE, and extrusion under low shear conditions. Vitron also celebrates its 50th anniversary of commercialization this year at the fair. The first application in 1957 as the world’s first fluoroelastomer was used for sealing and containment of aggressive fluids used in the aerospace industry. DuPont Performance Elastomers, Stand 6D27

Ingredient offers clear advantages for PP

This manufacturer plans to provide full-time customer support during the show stationed at its 530m2 stand for customers and prospects having specific questions regarding the new REACh regulations on material use and documentation. One of the highlights the company plans to present is its Irgaclear XT 386 clarifier for polypropylene. The material, first introduced late last year, is said to provide good see-through quality and gloss, and no unpleasant organoleptics, as well as thermal and chemical stability. Studies have shown that it retains its performance in regrind and recyclate and the maker claims processors can use 12 times less than competitive clarifiers to achieve the same effect. Added benefit is a cycle-time reduction in thin walled injection and blowmolded applications. Ciba Specialty Chemicals, Stand 6A27

World’s largest additives maker has range to match

The current families of flame retardants, anti-oxidants, UV stabilizers, and other processing aids from this company, said to be the world’s largest such producer, are becoming even larger. At this year’s show it plans to introduce Mark OBS organic-based stabilizers as cost-effective alternatives to calcium-based materials for both rigid and flexible vinyl processing. Two new Firemaster grades of flame retardants, 600 and 602, are said to be 10% more efficient for protecting polyurethane foams than other products on the market. For show visitors looking for coupling agents for applications requiring very low melt viscosity, Polybond 1103 offers a solution. Additionally the company will be talking about most recent developments in improved coupling agents and lubricant products for wood/plastics composite extrusion. Chemtura, Stand 6C07

Wide range of products aids processing needs

This manufacturer with 15 years experience in the blowing-agents field says it can offer a broad range of products such as endothermics, exothermics, as well as combination endo/exothermics that are compatible with polyolefins, styrenics, nylon, polyester, polycarbonate, vinyl, and thermoplastic elastomers. New grades to be highlighted at the show include materials for packaging, decorative ribbons, and tapes from polypropylene. Also shown are grades for themoforming of coextruded three-layer polystyrene sheet for yoghurt tubs and ice cream containers, as well as multilayer polystyrene, PP, and PET sheet for thermoformed barrier food packaging trays. Blowing agents for injection molded synthetic wine corks, PVC coextruded pipes, profiles, and rigid vinyl boards and sidings will also be featured. Adeka Palmarol, Stand 6A11

Moldmaking supplies & hot runners

D-M-E showcasing broad range of mold products

D-M-E Company’s K offerings include a broad range of new components for molds, including a product that improves the speed and longevity of molds: lube-free bushings. These lube-free bushings have a high-viscosity lubricant inside that provides high resistance against wear and galling without requiring additional grease. The new bushings are ideal for cleanroom conditions or other applications where external lubricants are prohibited such as for certain medical, electronic or food-related applications.

Internal mold identification simplifies the molding operation by providing accurate, reliable part marking. The D-M-E Multidater provides the advantage of double index capability of the U/Y/M range from 4 mm diameter. Given the trend for smaller parts, the Multidater provides a major advantage, and offers an entire range of Multidaters that are interchangeable with existing date stamps like UYM and FYM. The D-M-E Multidater consists of three rings having standard information of 12 months and six years. This allows the customer to use this stamp for a six-year period without needing to change the inserts. Furthermore, it removes the need to mount two separate date stamps for month and multiyear information. D-M-E, Stand 1F08

Thinswitch helps protect molds, Bakra helps change them

D-M-E’s new Global Thinswitch, a limit switch specially designed for use in injection molds, is now available in metric sizing, and comes with 3-mm and 4-mm rest buttons to verify that the ejector plate assembly is fully returned before allowing a mold to close after part ejection. A polyurethane dome and wire seal protect the internal switch mechanism from water or oil contamination, providing a longer switch life. The Global Thinswitch is compliant with CD directive IEC 60730-1, and is suitable for use in environments up to 80°C.

D-M-E now has eight different groups of lifting products that cover all hoisting needs for molds, tools, and dies. From small and compact units with very high lifting capabilities to a stainless steel version ideal for clean-room environments to the TSR-type that prevents the hook from scraping the tool when in traction at 90º. The SEB-type is ideal for multipurpose use, and the DSP-type is equally effective with ropes and small hooks. All D-M-E hoisting products have a safety factor of five times the rated load, exceeding the European regulation that requires four times the rated load.

The patented Bakra quick-change clamping system from D-M-E allows moldmakers to change molds in as little as five minutes. This innovative new technology uses self-locking bayonet rings to allow fast and secure mold changes, and allows a single operator to make a mold change. The new Bakra quick-change clamping system lowers costs and increases competitiveness in molding operations. The Bakra system consists of adapter plates mounted to the molding machine and lock to special locating rings on the mold. Installation is simple with three steps including hoisting the mold in place, inserting the locating ring into the adaptor plate and locking with the supplied wrench. Once installed, the Bakra system allows for a quick and easy interface between the mold and molding machine. D-M-E, Stand 1F08

Screenchangers

Melt filtration made simple, and cost-effective

Gneuß brings a number of melt filtration innovations to this year’s K Show headed by a new generation of the SFXmagnus filtration system featuring enhanced performance with lower investment costs. The drive system for most of the model sizes has been completely revised and operates pneumatically instead of hydraulically—a major advantage as no hydraulic power pack is required. This has resulted in a reduction of the investment costs of up to 20% compared with the previous design. A new heating concept, meanwhile, means that the polymer melt can be filtered even more gently. The completely encapsulated system also prevents chemical reactions with oxygen or airborne moisture. Specially developed retaining plates ensure perfect location and sealing of the filter elements even at filtration fineness of 10 µm. Active filtration area up to 9 cm2 is offered.

Gneuß will also introduce version VI of its RSFgenius filtration system at K 2007. The new generation is characterized by a newly developed insulation for the compact screen changer that has resulted in a reduction of the energy necessary for heating the unit. A new control system also enables even more possibilities for programming of the operating processes, which now include the filling and speed of the RSFgenius back flushing piston. The larger units have also been redesigned with a new cavity shape that provides, together with an optimized melt channel geometry, a 20% increase in the active filter area. Gneuß, Stand 9B37

Low maintenance with this screenchanger

Cofit brings to the K Show floor its new series of AP continuous screen changers featuring self-cleaning and online screen replacement. Low maintenance requirements on account of no moving parts to be driven by hydraulic or pneumatic power units are another plus. Cofit, Stand 9D24

Extrusion

Plug and play for wood/plastic composite profiles

The market for wood (or other fiber)/plastic profile extrusion is growing strongly, but many of the new participants cannot point to a plastics processing background. As a result, Cincinnati Milacron Extrusion Systems will feature at the K its plug-and-play system for these applications. This complete extrusion line, which includes required downstream machinery, offers processors a turnkey system for rapid market entry and high-volume processing.

According to Dave Bertke, VP and GM for Cincinnati Milacron, these systems are an inexpensive and relatively easy way to enter the WPC market. They are priced low enough (less than $750,000) so that a processor can acquire even 6-8 of these at a cost below a full-blown standalone blending system feeding multiple extrusion lines, he says. At the heart of the plug-and-play line is a TC68 twin-screw conical extruder, capable of processing WPC formulations with up to 70% fiber content at throughputs to 635 kg/hr.

Milacron has installed about 280 lines for WPC extrusion globally. The one at the K will go to the firm’s Magenta, Italy facility for customer testing, unless it is bought at the show. Cincinnati Milacron Extrusion Systems, Stand 15B05

Wide variety from Welex

Welex will be at the K show this year with a small information stand in the North American pavilion. The extruder manufacturer will be showing videos of a wide variety of Welex sheet lines in full production mode, including a 2000+ kg/hr V-PET sheet line, rotary inline thermoforming systems, a five-layer corrugated sheet line, and a six-layer barrier sheet line. Welex President Frank Nissel will be in stand from Oct. 24-27. Welex, Stand 13B59-5

Innovative blown-film line handles agro, stretch web

The Innoex Coex 3 coextrusion blown-film line is targeted to produce three-layer agricultural as well as stretch film. Each extruder is equipped with six-component gravimetric blending units. The latest generation CBH700 coextrusion die has axial symmetric distribution to reduce the residence time the melt is required to withstand within the die. Its design allows production of agricultural films in thickness of 25 µm or industrial stretch films that are 12 µm. The CBH700 die can be configured with inserts ranging from 400 mm to 650 mm. Blow-up ratio (BUR) of the film, which has a net layflat ranging from 2000 mm to 2250 mm, is 2.45 and 2.72. The CMG cooling ring, CR650, together with an automatic thickness regulation system, can achieve tolerances of less than +/-2% for 25-µm web and +/-3% for industrial stretch. CMG Srl, Stand 17A55

(Artificial) grass grows greener from an extruder

Demand for artificial grass for sports stadiums, landscaping, and golf greens is, according to this monofilament and strapping tape extrusion machinery maker, currently growing at high levels: in landscaping alone it is 50%/yr. In 2006 more than 7500 sports fields, for 20% growth/yr, were equipped with artificial grass filament greens.

The equipment maker says the range of polymers for such applications as grass, screens, netting, technical fabrics, and seals from polyolefins, various nylon grades, polyester, vinyl, fluoropolymers, and thermoplastic elastomers is also growing. One of the topics of discussion at its stand will be something that might be marketable by K 2010—development of multilayer grass filaments. Development of such technology is already underway at the manufacturer with a university partner. For this technology, an outer layer of specialty linear low-density polyethylene combined with active agents such as nano silver are supported by an inner core of nylon. These nano-functionalized multilayer monofilaments could include a hollow space within the filament for water circulation to help reduce playing field temperatures. Reimotec Maschinen- und Anlagen, Stand 17A21

SWESY is no sissy when it comes to die changes

The patented quick changeover system SWESY die head allows for fast changes and low downtime. The pre-heated and complete changeable set of dimension tooling allows processors to remain profitable longer yet achieve a degree of flexibility needed in today’s market for corrugated pipe and tubing. For drainage-pipe applications extruded from single-wall PVC, the company offers the RP 200 and 315 model perforators to create water entry slots in corrugated pipes having diameters ranging from 50-315 mm. Up to eight rows of slots at pipe circumference are possible. The unit’s pneumatic resetting cutting units enable change of cutting knives during production. Fränkische Rohrwerke, Stand 17C38

Virgin-like material PET discharged from Vacurema

This patented technology turns post consumer PET waste into PET bottle flake recylate that meets the most stringent demands for food grade packaging cleanness around the world. The latest process, Vacurema Prime, consists of a Vacurema Basic reactor-extruder system with two parallel, batch-mode operated upstream vacuum pretreatment vessels. It produces ultraclean material and treats thin-walled flake under vacuum to increase the IV to a stable level. Since flake has, compared to pellets, a larger reactive surface related to its volume and weight, IV-increase occurs quickly, therefore lowering the specific energy consumption needed for the process. This unit has been specified by Amcor Pet Packaging North America for bottle-to-bottle recycling with output ranging from 2000-2500 kg/hr. EREMA, Stand 9C21

Productive compounder dispenses top quality

CP (Compact Processor) compounders are designed to handle highly filled or pigmented materials requiring good mixing and homogenization. By having accurate, independent control of the integrated continuous mixer and extruder, the processor has greater control of end-product quality, flexibility in product changes, and energy efficiency. The CP family includes a patented three-piece rotor for quick removal of mixing-rotor elements, and requires no specialty lubrication system. One machine is able to handle multiple applications. The self-cleaning action of the elements permits fast compound and color changes. Farrel, Stand 9A24

Big can be extra beautiful for wide film applications

Geomembranes are in high demand today to handle an ever increasing problem of industrial and residential refuse and waste. According to this processing equipment maker, the demand has opened a new market for blown film processors around the world. Preventing pollution and ingress into ground water, many landfill areas are protecting the earth’s surface with thick, flexible films that provide puncture protection, can withstand pressures, and have high chemical resistance.

Generally produced from carbon black-filled, high-density polyethylene (HDPE), the films in typical thickness of 1.5-3 mm are being extruded in layflat widths up to 8m. This company has blown film lines able to handle outputs of up to 1700 kg/hr of such films. The three-layer coextruded vertical bubble provides biorientation of the film to give it tear resistance that would not be possible on cast-film lines. This line features three extruders with screw diameters of 200, 85, and 85 mm. Screws have an L/D of 30:1.The 2300-mm-diameter die has spiral channels and internal bubble cooling. The two-section, motorized bubble calibration basket is included in the 25m-high cooling tower. Luigi Bandera SpA, Stand 17C21

Maximizing processors’ performance is key

Cutting costs but increased production will be emphasized by this extrusion equipment builder during the show. One of the main features will be a new development related to its biaxially oriented polypropylene (BOPP) film stretching technology. The unit’s twin screw extrusion technology includes additional direct fluff dosing in order to optimize the production process. The unit’s machine direction orientation (MDO) equipment is equipped with direct drive to allow flexible gap selection for sensitive skin layers. The traverse direction orienter (TDO) includes a heat recovery system to help reduce energy use. The linear motor-equipped LIWIND winding system is said to produce perfectly wound mill rolls for all film types and speeds. For BOPET production, the company is showing a unique multi-gap MDO stretching unit that permits production speeds above 400 m/min. Brückner Group, Stand 3C73

Film quality is what separates the players

This blown-film extrusion equipment maker says the proof is in the film that comes out. That is why it has concentrated on improvements to its conventional multilayer lines as well as its AquaFrost downward blown water-quenched process introduced at K 2001. The BE I-Flex family of gauge controls includes a heated lip and flex-lip devices. They are said to deliver precise gauge control to allow processors to save on material costs and produce superior film quality. The I-Flex family is an intelligent system that should show immediate results. The Italycs-4 control system is able to monitor, manage, and control all line variables to produce product with consistent specifications. The company’s SCD3 stackable modular die permits production of up to 10 layers. Melt residence time is said to be short and temperature bleed from one pancake die module to another does not occur, thanks to special insulation. Brampton Engineering (Stand 17A22)

Gearbox designs tackle toughest jobs

K 2007 visitors will be able to see this manufacturer’s heavy-duty, high-torque gearboxes operating on extrusion equipment at a number of machinery manufacturers’ stands, including Krauss-Maffei’s, on a single-screw extruder (Stand 15B24); at Reifenhäuser’s on a twin-screw counter-rotating extruder (Stand 17A21); and on a line at the Luigi Bandera stand (17C22).

Zambello, which is celebrating its 50th anniversary this year, also has its own section displaying drive products at screw and barrel producer Bernex Bimetall (Stand 11E41). More than 60% of this producer’s gearboxes are exported, with German extrusion equipment builders taking the lion’s share (25%). For visitors interested in wood/plastics composite extrusion, a high-torque (15% higher torque and speed than conventional gearboxes) gearbox will be demonstrated live at the Reifenhäuser R&D center at its Troisdorf, Germany-headquarters during an open-house running concurrent to the show. Zambello/Bernex, Stand 11E41

Device helps web keep its cool

Blown-film cooling can allow higher outputs, which are increasingly in demand. This manufacturer has come up with a patented device, the Enhanced Cooling Package (ECP), as a standalone module to achieve continuous output of more than 300 kg/hr from a 175-mm die without falling short of product stability. The symmetrical cooling of the bubble is effected on the outer and inner sides of the film through a combination of air and water. The IBC, installed inside the bubble, has a water-cooled surface.

The Perfect Cool system guarantees transfer of heat on its inner side without the film coming into contact with the real cooling medium (water), or with the surface of the IBC stack. Exterior cooling is achieved through the laminar airflow of a double-lip cooling ring. With this system, the producer says that up to 50% of the required cooling capacity can be applied to the inner side of the film to help avoid blocking, while maintaining good output. Kiefel Extrusion, Stand 17C42

Cast-film line features improvements

The nine-layer Filmex cast-film line is able to produce an asymmetric polypropylene (PP) barrier film at an output rate now in excess of 1000 kg/hr. Part of the magic behind the higher output, says the company, comes from a newly designed screw, SMB (smooth barrier screw), which provides higher throughput along with improved melt quality. It is targeted at gentle treatment of the melt at the entry and exit sides of the barrier zone. It combines the advantages of a barrier screw with those of a conventional screw concept, the company says. Another new Filmex feature is a redesigned and upgraded chill roll unit which is laid out for a broad spectrum of web in tolerances of 10-300 µm. It features a maximum of three chill rolls that have separately controlled temperatures. They are driven by high-torque motors for high production speeds with maximum precision. To improve the optical quality of the film, the primary chill roll works in conjunction with a pivoting three-roller cleaning assembly that almost completely eliminates roller flow marks, says the manufacturer. Windmöller & Hölscher, Stand 17A59

WPC set to play big role in profile, siding markets

This processing equipment maker promises a number of surprises during the show. Top on its list is a focus on commercial Wood/Polymer Composite (WPC) extrusion for such items as decking, siding, and window or door profiles —a technology the manufacturer said was in its prototype phase at K 2004.

The company is counting on an increased environmental awareness among home purchasers who see the Bio-trend offering both cost saving advantages as well as a wiser use of natural resources. The company has a complete line using both new Bitruder and Reitruder series extruders with improved durability of screws that will be shown during the exhibition processing 70% wood flour with 30% polyolefin.

The Bitruder is a counter-rotating twin-screw extruder that has larger depth of flights for more output as well as a new gearbox. Co-rotating twin-screw extruders in the Reitruder series for this application include a new cooling technology, and specialized armored screw geometry that promises higher output. The equipment maker worked together with Kosche, the largest processor of WPC in Germany, to develop this concept. The company says it is now the market leader in WPC equipment in Europe. Reifenhäuser, Stand 17A21

Wide machinery offering highlights builder’s stand

One highlight of this year’s show for this extrusion equipment maker will be its triple-layer, ECH845 extrusion head which will be presented in a cutaway version for better understanding of the advantages of distributor positioning and layer configuration. The head is used for heating- and plumbing-pipe production, with or without coextruded striping. The MXC80-24D extruder at the stand is said to have improved cooling, depending on resin processed, of up to 30% compared to previous models thanks to its triple axial air cooling system. The unit’s new Cinegran optical material control provides immediate feedback on volume input and is said to be highly reactive even during startup phases and speed transitions. Maillefer Extrusion, Stand 12C06

Economies offered through customer-specific solutions

This manufacturer is showing its new KT209 calibration table that has been fitted with automatically reproducible adjustments of the calibration carrier. This design offers a degree of flexibility for longitudinal, vertical, and lateral adjustments as well as millimeter-accuracy in the changeover of calibration, says the company. A fully-automated SPS controller permits the operator to quickly bring the table into any desired position. An actuator module can process up to 60 different stored profile settings. The company’s RA306 caterpillar haul-off has also received a new design. Now it is offered in models with contact length of up to 2500 mm. The two separately driven caterpillar pairs are fully synchronized. Blake Kunststoffproduktionsanlagen GmbH, Stand 16A56

Wide-ranging processing solutions introduced

A new, economical single-screw extruder concept for direct processing of PET thermoforming sheet without the bother of drying highlights this manufacturer’s offering. Output of this line is between 800-1000 kg/hr. It includes the combination of the single screw with a modified planetary roller section for good degassing of the melt, says the producer. For higher speed than previously offered, the BEX 17534 is also capable of processing thermoforming sheet from polyolefins, styrenics, polyester, and polylactic acid polymer. With 1500 rpm, it reaches an output of up to 2.4 tonnes/hr. On the pipe and profile side, the new BEX 2135V+ extruder offers processors a 30% throughput increase (1000 kg/hr) compared to previous models. To achieve this it is equipped with a powerful T1max transmission and direct drive. Along with the machinery from this manufacturer, processing equipment members of the same company, Extrusion Kempen (Germany), American Maplan (U.S.), Battenfeld Extrusion Systems (China), and Kabra Extrusionstechnik (India) are featured at the stand. Battenfeld Extrusionstechnik, Stand 16D22-2

More quality, performance offered in expanded kneader

The Quantec EV kneader is said to have about 20% more internal capacity than the standard version. By increasing the material residence time at the same operating speed, this further improves dispersion on challenging PVC recipes and enhances product quality, says the manufacturer. The barrel capacity of the EV (Expanded Volume) has been increased with a 10% larger internal diameter with unchanged screw core diameter.

The external barrel diameter remains unchanged because the liner shell thickness has been reduced. The length of the kneading bolts has been increased to exploit the additional space available in the barrel.

All other parts of the machine, including the single-shaft discharge extruder, remain unaffected. Buss, Stand 16A59

Stacks polish PET film to perfection

The use of PET thermoforming films has grown in the last decade and this equipment maker will be demonstrating its new polishing stacks for value-added use at this year’s show. The unit has horizontal arranged rolls that produce film with low stress. The physical dimensions and specification of the roll pairs are calculated to optimize maximum parallelism of the bending axles of the rolls. This unit includes a motor-driven gap adjustment. It has a special drive technology to reduce chatter marks. The design allows variable contact length on the main cooling roll. Rolls are tempered for high-heat applications. SML Maschinengesellschaft, Stand 16D42

Producer gets in gear for gearless motors

This extrusion equipment maker has decided to source gearless torque motors, based on the AC Synchro-brand motors, for its processing machinery exclusively from German electronics giant Siemens (Stand 10A40). These are used on as much of its primary and downstream equipment as possible, says company president Alessandro Macchi. The company already offers gearless extruder drives for selected models, including its coextrusion CoexFlex film lines, as well as haul-off and winding drive systems. The strategy of the company is to accelerate usage of torque motors by grouping its marketing position with the global strength of its motor supplier. It is believed that with increased use of such motors, processors will be able to generate more economies of scale to help cut costs. This new technology is being offered to film processors without a surcharge. Macchi, Stand 17C09

Winding

Large volumes need big handling systems

High-volume production of labelstock, flexible sheet, and film requires slitter/rewinders that can handle big output while ensuring no drop in quality. Atlas-brand slitter rewinders include units that take 2m-wide films, yet rewind web as delicate as 60 µm at speeds up to 750 m/min with rewind diameters up to 1250 mm. New automation is said to dramatically reduce machine downtime for changeovers. The company’s Titan division, manufacturer of secondary slitter rewinders for flexible packaging, labelstock, and web, will be talking about the SR8 cantilever slitter rewinder, which is suitable for narrower-width slitting of labelstock. The unit handles web width up to 1800 mm, it has AC drives, includes laser line core positioning, and automated knife positioning for accurate cutting. Bobst Group, Stand 3D52

Thermoforming

New tilt mechanism speeds ejection, stacking

A new punch-and-die thermoforming machine with tilting platen will be on hand at Meico’s stand. Called the FT 700, this new model features a tilting system on the lower platen, which rotates by 75° to allow ejection and stacking of the parts. The new platen tilting mechanism, along with the stacking system, is patent pending by Meico’s parent company, TFT Srl, of Monza, Italy.

The machine at the K will have a 32-cavity tool to form 200-cc, rim-rolled drinking cups, each weighing 2.5g. Output is 76,000 cups/hr at 40 cycles/ minute. The maximum overall tool dimensions are 705 by 410 mm, and the clamping force is 400 kN.

The machine comes with a servomotor drive for its plug system, which is included in the basic package along with zoned heating controls for both the upper and lower heater banks.

The manufacturer also will display a new vertical trim press with a trimming area of 1000 by 350 mm. This trim press, called the VTP 1000, has been designed to be installed in a modular configuration after a thermoforming unit. The manufacturer says it overcomes limitations of horizontal presses in stacking and counting operations, and that the tool life is longer thanks to its vertical movement. Meico says a more precise adjustment of the punching tolerances is obtained by means of an optical-electronic positioning system for the foil feeding. Easy access to its counting and stacking areas eases maintenance and tool changes. The VTP trimming presses may be installed in combination with existing thermoforming units. Meico, Stand 3A16.

Double pack of new machines

Gabler, collocated with U.S. partner Lyle, will display two new thermoforming machines at the show. Both are designed to highlight the firms’ experience in designing and manufacturing thermoformers for processing of PP and PET.

The first new machine, called focus, is designed to meet processors’ need for a machine able to run minimum-cost tools with multi-station technology. Gabler says special attention was given to maximizing clamping forces and plane parallelism in the forming and punching station, with a sophisticated tool change system making the machine suitable for a wide range of products. A counter-rotation concept was developed for the drive motors to ensure extremely smooth running of the focus (form cut and stack) thermoforming machines.

Also on the stand will be an M98 tilt technology thermoforming machine. Co-developed with Dutch thermoforming tooling specialist Bosch-Sprang, the machine is an extension of the established Gabler M72, M92 and M93 series. Output rates in excess of 100,000 PP cups/hr are possible.

Gabler says its officials also will be eager to discuss energy-saving measures for thermoforming. GABLER Thermoform GmbH & Co. KG/Lyle Industries Inc., Stand 3D35; Bosch-Sprang, Stand 3B73

Compression molding

Compression molding PET preforms and more

At K 2007, Sacmi will present its compression molding machine for processing of PET preforms. The manufacturer already offers a range of these machines for closure molding, providing processors a competitor to injection molding machinery for this application; now it also will do so for preforms. The PAM (Preform Advanced Molding) unit shown will be a 48-cavity prototype machine running at 27,000 preforms/hr, producing a 23g CSD preform with 28PCO neck finish. In comparison to injection molding of preforms, with preforms cooled and then dropped onto a conveyor for later orientation, preforms exit a compression molding machine already oriented, for ease of inline quality control and, possibly, inline stretch blowmolding.

Sacmi claims that compression molded preform require less reheating in the blowing phase because the crystals of the material are differently oriented. It also says that PET bottles formed from compression molded preforms have better performances than same-weight injection molded preforms, due to a higher homogeneity of the material distribution. Also, compression molded preforms can be stretched in the bottom of the bottle, as there is no injection gate there.

Sacmi also says it has been expanding its compression molding equipment so that it is suitable for applications beyond closures, and plans to position itself as a major player in markets such as dairy and pharmaceutical. One new, patented system is designed to make plastic containers using a continuous rotary system “with output rates that, until now, would have been unimaginable,” according to the firm.

For closure molders, Sacmi will display its new CCM64M, good for about 100,000 caps/hr. Sacmi, Stand 15A05

Blowmolding

Uniloy launches first hybrid machine

Uniloy is using the K as the platform to launch the firm’s first hybrid (hydraulic/electric) blowmolding machine, the UMS 16H.S, which will process 10-L jugs on a single blowing station. The containers weigh about 350g and are produced at rates of about 180/hr. Two post-cooling stations plus mold cooling help ensure the necks, shoulders, handles and bottoms of the containers are sufficiently cooled. Except for the clamp, all movements on this system are electrically driven, which Uniloy says cuts electricity consumption by about 22%. A specially developed flash separation system ensures no flash falls into the containers. A leaktester and weight scale is installed inline and is linked to the machine’s controller. Uniloy Milacron, Stand 15B05

Recip screw machine for multilayer bottles introduced

Though not displayed at the K, Uniloy officials will be eager to discuss the firm’s newly developed reciprocating screw blowmolding machine capable of producing three-layer extended shelf life (ESL) bottles. The firm claims output on these will beat wheel and shuttle machines by 10-20% in a smaller footprint, with 10-25% less energy use. The first machine in the range can process 5400, 1-L handled bottles/hr on 12 blowing stations. These bottles weigh 30-g and have 43-mm necks. Uniloy is building a 16-parison machine. Uniloy Milacron, Stand 15B05

Stretching SBM to the limit

Stretch blowmolding (SBM) advances at K can be summed up as faster, greener, lighter. Machinery leaders Sipa (Vittorio Veneto, Italy), Krones (Neutraubling, Germany), and Sidel (Cedex, France) are all promoting equipment with reduced energy needs, faster cycle times, and overall increases in throughput. Krones AG will highlight its Contiform S14 stretch blowmolding machine for polyethylene terephthalate (PET) packages that is BLOC synchronized with a filler line.

Krones says the new modular oven design promotes optimized bottles and energy efficiency by allowing processors to specifically tailor the preform-heating function of the process to the necessary length. Krones will also use K to highlight a lightweight bottle based on a new preform design, which lowers the amount of neck-ring material. The company says the design also eliminates the need for base cooling between the machine and the filler.

Krones plans to display its PETView inspection module for process monitoring, and has green on the mind, providing information on closed loop PET processing for bottle-to-bottle recycling.

Italian counterpart SIPA will bring the latest model of its rotary blowmolding machines, the SFR 12 EVO, to K, representing the latest iteration of the machine launched in 1999. SIPA says enhancements include boosted performance, less energy consumption, lower maintenance costs, and increased flexibility. Specifically, SIP says EVO has lifted productivity from 1800 bottles/hr/cavity to 2000 bottles/hr/cavity for total output of 24,000 bottles/hr. By altering the chain pitch, the machine also allows production of a wider range of neck finishes. The oven’s position has been reconfigured allowing hot fill and optimizing the preform’s thermal profile, which ultimately increases energy efficiency.

SIPA has also redesigned the air-supply system to use double air-recovery via an auxiliary tank, reducing blow times and air consumption. This also lessens energy usage. In addition to the SFR 12 EVO, SIP will have its latest linear blowmolding machine, the SFL6/4, which can create hot-fill, oval, and adjustable-neck containers up to 8 liters.

In addition to highlighting bottle design, especially sustainable packaging with lightweighted and polylactic acid (PLA) bottles, Sidel will promote additions to its SBO machine line and its new Equinox blowmolding monitoring/control software. NoBottle from Sidel is a 500-ml water bottle that weighs only 9.9g compared to comparable packages of 13-16g. Fully 25-40% lighter, NoBottle is in part possible due to a shape memory polymer advance called Flex. Sidel will run the NoBottle on its new SBO 24xs Highspeed line. Sidel will continue the green theme with a 10-liter, 140g PLA edible-oil container.

On the machinery side, the company will launch the aforementioned SBO 24xs Highspeed and SBO 2XL Compact. The 24xs Highspeed is intended for small still-liquid and carbonated soft drink containers. Largely single-serve and less than 700ml, these containers make up more than 60% of the growth in plastics packaging worldwide, according to Sidel. The company’s lines serving this market offer throughputs ranging from 40,000 to 60,000 bottles/hr.

The 2XL Compact is for larger PET bottles up to 10 liters that are primarily used for water and edible-oil containers. Sidel says the new machine has a guaranteed efficiency of 95% with production rates of 2400 bottles/hr.

Sidel will also launch what it calls the first automatic blowmolding process regulation system that will be built into rotary-style machines. Equinox not only monitors but corrects bottle-molding processes by sensing set-weight deviations and readjusting parameters without machine downtime. Sidel feels it will be especially useful for lightweight bottles that are sensitive to material distribution.

In addition, Sidel will highlight its REAL (remote expert assistance for lines) program, where Sidel customers use a headset with viewfinder, cameras, and microphone to remotely walk Sidel experts through any line problems with Sidel service technicians able to communicate with and walk through issues in real-time with their customers.

On the injection stretch blowmolding (ISBM) front, Japan’s Nissei ASB will feature a one step all-electric ASB-15N/10E ISBM machine, which it says reduces electricity consumption by 60% compared to an equivalent hydraulic line. Nissei will also display a preform molding machine, the PM-70/65N, with a 16-cavity capacity, and a new “re-heat” SBM machine with a 6-cavity capacity called the NB-6N.

In multilayer extrusion blowmolding (EBM), Kautex Maschinenbau GmbH will highlight its long-stroke KLS series, with a KLS 6-100 at the show running a 65-ml dairy bottle. The container will be produced in a 12-cavity mold at a rate of 4600 bottles/hr, with three extruders creating a three-layer wall, where barrier could be integrated into the middle. The machine has a quick-change system for faster tool changes, and it also features integrated leak testing of containers. In addition to its presence in Düsseldorf, Kautex welcomes attendees to an open house at its Bonn headquarters. Kautex Maschinenbau GmbH, Stand 14A18; Krones AG, Stand 13A73; Nissei ASB, Stand 14C52; Sidel, Stand 13B89; and Sipa, Stand 13B11.

Heat-resistant Al tooling

In conjunction with Graham Packaging (York, PA), ISBM and filler line supplier Sidel (Cedex, France) will launch a line of aluminum tooling at K that it says can withstand hot-fill or pasteurized beverages, while being three times lighter than stainless steel. Added benefits include easing the load on machinery, which increases output, and shortening lead times due to aluminum’s machineability compared to stainless steel normally used for heat resistant (HR) molds.

These F300 molds can withstand temperature as high as 180°C and can run in all style of blowmolding machines producing all manner of bottles. The lighter mold also shortens the time needed for tooling changes.

Graham, which collaborated with Sidel on the tools, is also acting as a beta site, running more than 100 F300 molds at several U.S. plants for a variety of containers and end markets. In running the tools, Graham has seen another benefit—the improved heat conductivity of aluminum over steel has meant they cool and warm more quickly, shortening cycle times. Sidel, Stand 13B89,

Rotomolding

Wide range of equipment provides processor solutions

The Rotaut A3C/2500 rotationary molding machine is a carousel unit with two, three, or four independent arms for continuous processing of large applications. The unit is equipped with a separate cooling chamber with air/water vapor mix for good temperature control of process goods. The A3C/3500 model has no such cooling chamber but is equipped with separate, self-moving electric fans. The units include Easy Drive operator interface panels with touch screen for operator ease. Alarm screen include self-developed descriptions for trouble-shooting during processing. Caccia Engineering (Stand 9C04)

Auxiliaries

Energy-efficient drying

At K, auxiliary supplier Conair will feature its EnergySmart drying system, which recycles process heat normally lost through the exchanger, and thereby cutting power consumption by two-thirds. The system is geared towards high-temperature drying above 250°F (121°C), with target materials including polyethylene terephthalate (PET; for an initial report on the EnergySmart, reference July MPW Tech Trends). Conair reports that residual moisture above 0.0005% can affect PET physical properties, and that in facilities where PET is processed, conventional dryers can consume 12% of energy plant wide, including 25% of energy used in preform creation.

Using a two-stage system, the EnergySmart takes process air that’s still around 200°F, and instead of taking it through a heat exchanger and cooling it to 120°F, air leaving the drying hopper is filtered, reheated, and reintroduced to the drying hopper via an inlet cone in the hopper’s middle.

The second stage, or circuit, of the EnergySmart is a dehumidified-air circuit. That portion of the system uses a standard, if smaller, Conair Carousel Plus dryer to dry air to the -40°F dewpoint. That air is introduced to the drying hopper via an inlet cone at the bottom of the unit.

Conair says with less air going through the dehumidifying air circuit, less energy is needed to heat the smaller volume and a smaller, more-efficient dryer can be used. EnergySmart also features the Conair Drying Monitor that uses a long probe with six temperature sensors to register hopper conditions. Conair, Stand 10B74

European vacuum drying launch at K

Maguire Europe will use K for the European debut of a compressed-air/membrane-resin dryer, which it also promotes on the basis of energy efficiency. The NovaDrier offers throughputs up to 68 kg/hr, and eschews desiccant in favor of flowing compressed air through an adsorption membrane. The company claims that process air registers the required dewpoint of -40°C less than four minutes after startup and the membrane has been shown to last up to 20 years under demanding conditions.

NovaDrier systems come in six models with throughputs ranging from 3.2-68 kg/hr and hopper capacities from 14-490 kg. Standard process temperatures are 177°C (150°C for the 68-kg/hr model), and no cooling coils are required for high-heat applications. Maguire Europe will warehouse, sell, and service the equipment, which will be built by U.S.-based Novatec Inc. Maguire, Stand 10A26

Wheel of drying

In addition to working with Maguire to launch the NovaDrier in Europe, Novatec will debut a rotating wheel dryer that continuously cycles through regenerated desiccant. The company bills the NovaWheel as a simpler, more compact, lower-cost alternative to conventional twin-tower dryers. The dryer uses a steel-link chain drive versus a belt to rotate the wheel, which Novatec says results in reduced dew point variation.

In a standard twin-bed system, after the desiccant adsorbs moisture from a stream of hot air that has passed through the resin, it must be heated to 205°C to evaporate that moisture then cooled so it can again adsorb moisture. This batch process can take four hours, but Novatec’s design performs the tasks simultaneously using a cylindrical wheel with a desiccant-impregnated honeycomb split into three sections. NovaWheel dryers are available with throughputs from 45-2270 kg/hr, and Novatec estimates investment costs for smaller units run 10-15% less than for similar-throughput twin-tower dryers. Novatec, Stand 10B65

IRD at K

Apart from desiccant-, desiccant-wheel, or vacuum-drying systems, Kreyenborg will bring infrared drying to K with its IRD line. For PET, the IRD heats, crystallizes, and dries materials while imparting less thermal stress. The IRD uses short-wave infrared to directly heat resin from the inside out. Kreyenborg has redesigned the infrared module, disposing of the aluminum-oxide integrated reflectors. The air-cooled module is lined with functional ceramics and Bruckmann Steuerungstechnik GmbH is now supplying touch-screen controls, which feature a modem for online, remote service. In addition to crystallizing and drying PET, the IRD has also been used for crystallizing and drying polylactic acid (PLA) resin, with Kreyenborg reporting that four machines have been commissioned for that task.

Also on the infrared dryer front, UPM Machinery Sales Ltd. will display its IRD unit at the SB Plastics Machinery stand at K. The company reports that it has sold its fiftieth unit, with the latest dryer headed to India. There resin and fiber maker Reliance Industries will use the 3000-liter capacity IRD to crystallize and dry 43 tons/day of amorphous PET. UPM reports that IRD’s have been installed as far afield as South Africa, Japan, North America, Europe, and now India. Kreyenborg Infrarot Technologie, Stand 9A42; SB Plastics Machinery (UPM), Stand 10B50

Compact press-side drying

Mann+Hummel will have the Somos T/TF eco-compact dryer series at K, which offers an economical system with continuous-operation for press-side drying. The Somos features an integrated conveyance line for resin supply to processing machines, and it has the ability to match the volume of drying air to material throughput.

Hopper sizes come from 5 to 10 liters with throughputs from 600 to 4000 g/hr or 1300 to 8000 g/hr, targeting injection molding machines from 125 to 500 kN. The maximum drying temperature with depressurized air is 160°C, with a dew point of -20 to -25°C. Mann+Hummel, Stand 9D60

Gravimetric feeding, blending

Conair will highlight gravimetric blending and feeding, as well as pneumatic loading, with its TrueBlend, TrueFeed, and Access lines. The TrueBlend comes in standard and high-heat models that can process pre-dried material with throughputs to 10,000 lb/hr. The loss-in-weight TrueFeed metering/feeding units are now self calibrating, and the Access loaders are angled and have a hinged lid to ease operator use. They also have consolidated control terminals and modular valves with common seals. Conair, Stand 10B74

Fully combined K-Tron at K

K-Tron’s stand will feature the newly integrated Premier Pneumatics brand, which the company purchased in late 2006 (see December 2006 MPW First Look for initial report). In addition to the full Bulk Solids Pump (BSP) feeder line, K-Tron will display the Multiweigh and K4G blenders, as well as the K-Vision feeder operator interface. Premier Pneumatics products will include integrated vacuum receivers, Smart Flow Meter, enhanced MT 12 Micro feeder, Quick Change feeder, and single- and twin-screw loss-in-weight feeders.

K-Tron’s new Gravimetric Extrusion Control will be shown to attendees via a computer demonstration. The system gravimetrically measures extruder throughput, adjusting speed to maintain desired rates for consistent end-product quality. The system is intended for single-screw extruders running mono- and co-extrusion profiles, sheet, film, cable coatings, and laminates.

Also new at K will be an updated iteration of the Micro Cone low-rate feeder that uses a screwless rotating tube or cone for dosing as low as 0.02 to 6 dm3/hr. The product has been in beta testing in Europe and the U.S. over the last year. Also debuting will be Premier’s Heavy Duty (HD) and Maximum Duty (MD) Aerolock rotary valves and a number of Series 2400 vacuum receivers. K-Tron, Stand 10A74

Window on loading

Novatec will have the European debut of the GlassVu vacuum-loading system, which allows a clear view of resin flow; easy cleaning and draining access; and simplified installation. The system includes cylindrical loaders, receivers, and machine-mount hoppers with a wrap-around glass mid-section to view filling.

The loaders’ and receivers’ slanted lids allow access to the interior without disturbing material or vacuum lines, and flat bottoms provide large openings for resin discharge. The loaders’ and receivers’ slanted bottom panels also operate pneumatically as a slide-gate. For machine-throat installations, Novatec has a glass hopper base, which the GlassVu loader is mounted to. The unit pivots out of the frame to drain residual material. Novatec, Stand 10B65

Size reduction/Recycling

Full-stream scrap to pellets

NGR has extended its X:Gran range of granulators to throughputs of 2000 kg/hr with the X:Gran 185 and 205 units. The units feature NGR’s patented cutter-feeder-extruder combination, which directly connects a single-shaft cutter and feeder to a single-screw extruder so that heat generated by shredding the scrap isn’t lost as granulate is introduced to the extruder for reprocessing.

NGR says the machine can handle thermoplastics in a variety of shapes, sizes, and applications, including lumps, plates, and pipes, as well as fibers and nonwoven materials. For the new X:Gran 185 and 205, the energy requirement per kilogram of pellets produced is 0.3-0.4 kWh/kg. The machine’s footprint is 8 by 15m, and it includes a belt with metal detector to transport material to a silo hopper with an approximate volume of 4m3. The size of the feed orifice allows the machine to accept unwieldy scrap like balls and rolls. Material is constantly fed through the process by a hydraulic clamp, and a vacuum pump undertakes double degassing of materials in the extruder. NGR—Next Generation Recyclingmaschinen GmbH, Stand 9D05

Total access granulators

Rapid Granulator AB will introduce its 600 Series of ’open-hearted’ granulators, building off a concept launched in 2006 that allows complete access to the rotor and cutter house during production changes, simplifying cleaning and maintenance. The 600 Series will have three models and handle throughputs to 2500 kg/hr. In addition to the new 600, Rapid will display the 300, 400, and 500 series, with two additions to the 400 Series: a 400-60 HD for tough applications, and the 400-120, which is the widest model in the series and can handle items like thermoforming scrap. Rapid Granulator AB, Stand 9E19

Measurement & Testing

Flexible friction tester offers universal options

Among highlights at Lloyd Instruments is the ’2 in 1’ FTPlus friction tester, which can either be used as a dedicated friction tester conforming to the requirements of the key ASTM D1894, ISO 8295 and TAPPI T549 friction testing standards or, when used together with NEXYGENPlus software and appropriate sample clamping fixtures, configured as a powerful universal testing machine to perform tensile, compression, flexural and other mechanical tests up to 1 kN. The FTPlus can be used for measurements of static and kinetic coefficients of friction, peak load and average load.

The LFPlus, LRXPlus, and LR10Kplus universal testing machines with 1 kN, 5 kN and 10 kN maximum force respectively, can also be seen. Lloyd Instruments, Stand 11D03

Rheological testing made easy

The SmartRHEO from CEAST is a compact bench top capillary rheometer that carries out full rheological characterization, featuring PVT and thermal conductivity (Ï) ancillary devices and VisualRHEO software modules to support research, quality control, and process simulation.

CEAST’s new Melt Flow Tester, meanwhile, has been updated to include touchscreen computer controls and an improved automatic multi-weight testing system. A series of standard masses can be applied in any sequence, and software collects data and also calculates the flow-rate ratio or shear sensitivity.

Also at K is the HDT Vicat 500 Aloxide, a revolutionary instrument for HDT and Vicat testing on advanced engineering plastics such as PEEK and LCP at temperatures from 50° up to 500°C. Testing takes place within a completely safe testing environment thanks to a fluidized powder bed heating medium. CEAST, Stand 10J18

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