A Hands-on Project With Sunny Prospects

The solar industry is at the heart of what is happening. For 2023, Solar Power Europe expects that 341 GW will be newly fed into the electricity grid worldwide – which would correspond to a growth of 43 percent compared to the previous year. A development that is strongly boosting the production of solar cables and cables for the expansion of infrastructure.

The solar industry was already booming in 2022. 239 GW of new solar energy have been installed worldwide. “That is 45 percent more solar power capacity than in the previous year. The positive market developments in the first months of 2023 promise another solar boom year,” explains Solar Power Europe. In 2023, 341 GW are expected to be newly fed into the electricity grid, a further increase of 43 percent. An increase of up to 800 GW per year would be possible as early as 2027. Sunny prospects.

The energy transition has reached the people
A major growth driver, for example, is the solar industry in Germany. In the first seven months of 2023, for example, about 593,000 new solar systems with 7,927 MW were already connected to the grid. For the same period in 2022, there were “only” 198,200 new plants with 4,239 MW. “The high solar growth clearly shows that the energy transition in Germany has reached the people and has become a hands-on project,” says Dr. Norbert Allnoch, Director of the International Economic Forum for Renewable Energies (IWR). The IWR attributes the enormous expansion to the boom in small balcony solar systems in the private sector in particular.

Companies that want to make themselves independent of unpleasant price jumps in their energy supply with solar systems also contribute an important part to record growth. For example, the pipe manufacturer Uponor is installing a photovoltaic system on the roofs of the factories at its German headquarters in Haßfurt in order to minimize the ecological footprint. For this purpose, photovoltaic modules are installed on an area of 4,300 square meters.

New production capacities for the boom
The solar industry is responding to the significantly increased demand by building new capacities. For example, HoloSolis SAS, a company founded in 2022 by EIT InnoEnergy, IDEC GROUP and TSE, plans to set up a production line for PV solar cells and modules near the Franco-German border in the Sarreguemines district. “The manufacturing facility is scheduled to go into operation in 2025, with a production capacity of five gigawatts per year at full capacity,” reports the Fraunhofer ISE Institute, which is supporting HoloSolis with technology selection and factory planning in the conceptual design and construction phase. From 2025, production will be gradually ramped up to ten million photovoltaic modules per year with products for the private and commercial PV market.

Efficient and safe solar cables
Cables play a central role in photovoltaic systems. They connect the individual modules, which consist of several solar cells, to each other and wire them to the inverter. Alternating current is in turn transferred from the inverters to the household grid. Specially designed cables are used to make this possible. Because UV rays, heat, cold, moisture and chemicals are special challenges for solar cables – and quality products from cable manufacturers are therefore a must.“Despite these sometimes adverse environmental conditions, the solar cables must function reliably in the long term: Manufacturers and operators calculate with a service life of the systems of 20 to 30 years,” explains the cable manufacturer Helukabel. Therefore, special sheath materials and insulating materials are used. However, the insulation is not comparable to that of normal cables. This is because conventional cables in photovoltaics could lead to safety problems and failures; they are rather used to supply power to electrical devices.

In addition to safety and durability, efficiency is also important for the transport of solar power. The choice of suitable cables is therefore crucial. In addition to conductivity and dielectric strength, the cable cross-section plays an important role – it allows the current to be transferred with minimal losses. If a cable is too thin, it can overheat and, in the worst case, lead to fires.

Grid expansion must be driven forward
As a result of the solar boom, reliable and high-performance solar cables from manufacturers are in greater demand than ever. However, not all is sunshine. “Solar growth represents a revolution for Europe’s power grids, which were originally designed for centralized power generation,” explains Solar Power Europe. “Interconnection delays due to grid congestion and lengthy grid expansion permits drive up PV installation costs and jeopardize the competitive advantage of solar energy.” That is why the industry advocacy group demands that states should ensure that “network planning covers all aspects, taking into account the need for infrastructure expansion as well as network digitization and flexibility provision”. Only when the surrounding infrastructure of solar systems is developed can they fully unfold their enormous potential – and secure a place in the sun for their users.

https://www.wire-tradefair.com/

 

#modernplasticsindia #indianplasticmagazine #modernplasticsaward #plasticnews #modernplasticsgermany #ginujoseph #modernplastic #plasticindia  #plasticrecycling #sustainability #modernplasticsglobalnetwork #modernglobalnetwork #modernplasticsaward2023 #plasticmagazine #PlasticIndustry  #modernplasticsmiddleeast #indianmagazine #innovations #modernplasticsamerica #modernplasticsbangladesh #modernplasticsasia #modernplasticsitaly

The Importance Of Material Selection In Micro Molding Applications 

Paul Runyan, VP Sales & Marketing, Accumold

In the precision-demanding realm of micro molding, the selection of appropriate materials is not merely a step in the manufacturing process, it’s the cornerstone upon which the performance and reliability of the final product rest. This article delves into the intricacies of material selection, highlighting how critical properties such as strength, flexibility, and thermal resistance shape the functionality of micro molded components, and positions Accumold as an expert in this meticulous selection process.

THE INTERPLAY OF MATERIAL STRENGTH AND MICRO COMPONENTS

When looking at micro molding, the imperative of strength in material selection cannot be overstated. Micro molded components are often required to bear significant mechanical loads, despite their diminutive size. This is particularly evident in the medical sector, where components like the tiny gears found in a medical pump must perform flawlessly under the pressures of constant operation. The materials used for such components must be chosen for their high tensile strength, a measure of a material’s resistance to being pulled apart, which ensures that the gears can transmit force and motion without succumbing to the stress of use. Failure to select a material with adequate tensile strength can lead to catastrophic component failure, resulting in device malfunction and potentially severe consequences in medical applications.

Expanding further on this point, the operational stresses that micro-sized components are subjected to can be both varied and intense. These stresses include dynamic loads that fluctuate with the device’s operational cycle, as well as static loads that are constantly applied. In addition to tensile strength, materials for such components must also exhibit adequate fatigue resistance, meaning they can withstand repeated stress cycles without failure. This becomes particularly critical in life-sustaining medical devices, where component reliability is not just a matter of performance but of patient safety. Therefore, engineers and material scientists must work collaboratively, often at the frontiers of material science, to identify and utilize materials that offer an optimal balance of strength and endurance. This ensures that micro molded parts will function as intended over their entire designed lifecycle, which can involve millions of operational cycles in some medical devices.FLEXIBILITY — BENDING WITHOUT BREAKING

Flexibility in material properties plays a crucial role, particularly in applications where a certain degree of elasticity is indispensable. This characteristic is vital for ensuring that micro molded components can endure bending and flexing without losing integrity or breaking. For instance, micro-sized flex circuits, which are fundamental to the functioning of numerous portable electronics, must be manufactured from materials that retain their electrical properties even when bent or twisted. This kind of material malleability allows for the creation of devices that are not just functional but also durable and adaptable to the physical demands of daily use. Materials selected for such applications must, therefore, exhibit an excellent balance of pliability and strength, enabling them to bend without fracturing and maintain their structural integrity over time.

Consider the flex circuits in a folding smartphone, for example. These intricate components must withstand thousands of folds without any degradation in performance. The material for these circuits is not chosen solely for its initial flexibility, but also for its ability to maintain that flexibility over the product’s lifetime. Engineers must ensure that the materials can recover their shape and continue to function after each flex. This requires an in-depth understanding of the stress-strain relationship of potential materials and the resilience they can offer. Consequently, materials for these applications often include advanced polymers or composite materials that are specifically engineered to balance flexibility with the necessary tensile properties, ensuring longevity and reliability in the rapidly evolving world of portable electronics.

THERMAL RESISTANCE — ENDURANCE IN EXTREME TEMPERATURES

Thermal resistance is a critical factor in the selection of materials for micro molding, especially for parts that will face significant temperature variations throughout their operational life. This attribute is crucial for ensuring that the micro molded components can perform reliably under varying thermal conditions without experiencing physical or chemical degradation. For example, in automotive applications, electronics are frequently situated in close proximity to the engine, where temperatures can be exceedingly high. The materials used to create these micro molded parts must not only tolerate these elevated temperatures but also maintain their mechanical and electrical properties despite the heat. This necessitates materials with a high melting point and low thermal expansion coefficient to prevent warping, melting, or other forms of degradation that could impair functionality.

Further detailing the necessity for thermal resistance, consider the micro molded connectors and sensors located throughout an automobile. These components must consistently operate within a range of temperatures that can span from the extremely cold conditions of winter to the searing heat of a summer day, often in rapid succession. Materials with excellent thermal stability ensure that these critical components do not become brittle in cold temperatures or soften in the heat, which would severely impact their performance and reliability. It’s not just a matter of enduring the temperature extremes but doing so repeatedly over the lifespan of the vehicle without any loss of structural integrity or performance. Engineers and material scientists must therefore rigorously test and select materials that have been specifically designed or treated to resist such thermal challenges, ensuring the longevity and safety of the vehicle’s components.

THE ESSENCE OF MATERIAL SELECTION IN MICRO MOLDING

Micro molding represents a significant advancement in the field of precision engineering, one that has been instrumental in transforming the production landscape of small-scale components. This innovative technology is particularly critical in sectors where the miniaturization of parts is not just a convenience but a strict requirement, such as in medical devices and electronics. The materials chosen for these minute components are a critical factor in determining their final functionality and reliability.

The selection of the appropriate material in micro molding is not just a matter of matching specifications, it is a complex decision-making process that considers the intricate interplay of material properties and the expected performance of the component in its final application as we have seen. A slight miscalculation or oversight in material properties can lead to significant deviations in performance, potentially resulting in component failure under the high-stress conditions of real-world use.

For medical device applications, the material choice is further complicated by the need for biocompatibility and sterilizability. Materials must be carefully chosen not only for their mechanical properties but also for their ability to interact with the human body without causing adverse reactions. Furthermore, these materials must maintain their integrity after repeated sterilization cycles, which can involve exposure to harsh chemicals and high temperatures.

In the realm of electronics, micro molded components must adhere to stringent electrical standards. The material must insulate effectively or conduct electricity with precision, depending on its role within the electronic assembly. The miniaturization of electronic devices demands materials that can support complex circuitry in an incredibly compact space, while also dissipating heat and resisting the wear and tear associated with regular use.

Accumold, a leading innovator of the art of micro molding, is expert in navigating these complex material considerations. The company’s approach to material selection is grounded in a deep understanding of polymer science and a commitment to quality and precision. Accumold engages in extensive research and development to identify the materials that not only meet the required specifications but exceed them, ensuring that every micro molded component produced performs reliably under the most demanding conditions.

Accumold’s process begins with a comprehensive evaluation of the intended application of the micro molded part. It considers factors such as the mechanical load the part will bear, the environmental conditions it will be exposed to, and the longevity required by the application. This initial assessment is crucial in developing a material specification that is both precise and practical.

Following this evaluation, Accumold leverages its expertise in material science to explore a vast array of polymers and composites. Materials are assessed not only for their basic properties such as strength, flexibility, and thermal resistance but also for more nuanced characteristics like creep resistance, fatigue endurance, and moisture absorption. This meticulous attention to detail is what sets micro molding experts like Accumold apart in the industry.

Moreover, Accumold’s expertise extends to the customization of materials. Recognizing that off-the-shelf materials may not always provide the optimal performance for specialized applications, the company collaborates with material suppliers to develop custom formulations. This capability allows Accumold to fine-tune material properties to an unprecedented degree, creating bespoke solutions for its clients.

Quality control is another area where Accumold’s commitment to excellence is evident. Each potential material undergoes rigorous testing to ensure it meets the company’s high standards. These tests simulate the operational environment of the component, challenging the material’s mechanical, thermal, and chemical resistance. Only materials that pass these stringent tests are considered for use in production.

In the rapidly evolving sectors of medical devices and electronics, Accumold’s ability to anticipate and respond to emerging material needs has positioned it at the cutting edge of the micro molding field. The company’s ongoing investment in research and development ensures that it remains at the forefront, ready to tackle the challenges of new applications and technologies.

SUMMARY

The role of material selection in micro molding cannot be understated. It is a vital component of the manufacturing process that determines the success or failure of the final product. Through its extensive expertise and unwavering dedication to material science, Accumold has established itself as a leader in this field, delivering components that not only meet the demands of today’s precision-driven markets but also pave the way for future innovations.

www.accu-mold.com

First Use of Makrolon RE in light Switches And Sockets

• Significantly reduced carbon footprint.
• Over 80 percent share of bio-circular raw materials.
• Excellent UV stability in signal white coloring.
• Material properties identical to those of purely fossil-based compound counterparts.

For the first time, a Makrolon RE polycarbonate from Covestro is being used in the manufacture of switches, plugs and multimedia sockets. ABB – a leading international energy and automation technology group with a strong focus on sustainability – uses the polycarbonate in its SAGA product range. “Currently, around 75 percent of our SAGA range is manufactured with attributed bio-circular materials. In the long term, this will reduce annual emissions by around 400 tons of CO2 equivalents. We want to further increase the proportion of these attributed bio-circular plastics in the future. This is because as thermoplastics they can be recycled and therefore enable the creation of resource-saving material cycles,” explains Sven Werdes, Global Product Line Manager at ABB.

The Makrolon RE used by ABB has a very low carbon footprint; at best, it is climate-neutral. In addition, the raw materials used in the synthesis of its starting materials are largely derived from mass-balanced organic waste and residues such as used cooking oils and fats.

Climate neutral** across the entire value chain as a common goal

“We are delighted to be able to effectively support ABB in its ambitious sustainability goals. Basically, we are doing everything we can to help our customers and their clients with more sustainable product solutions in the development of climate-neutral and resource-saving material cycles,” emphasizes Lily Wang, Global Head of the Engineering Plastics Business Entity at Covestro. 

ABB manufactures the majority of the SAGA range in its climate-neutral factory in Porvoo, Finland. With the help of a highly efficient energy management system, the plant uses only renewable energy and processes low-emission materials such as Makrolon RE. “Porvoo is one of the first milestones in our Mission to Zero program, which aims to achieve climate neutrality for both our own sites and those of our customers. Materials such as Makrolon RE are an important building block in our sustainability strategy,” says Mikaela Ahlnäs-Mäkeläinen, Local Product Group Manager at ABB.

Highest quality standards met

The Makrolon RE variant used by ABB is colored in signal white (RAL 9003) and is characterized by excellent UV stability. For example, it easily passed a test that simulates two years of horizontal, two-dimensional UV exposure under northern European light conditions. In addition, its electrical properties – such as high dielectric strength and tracking resistance – meet all electrical safety requirements. “The Makrolon RE compound is a successful example of how aesthetics, performance and sustainability can be harmonized with just one material,” explains Dr. Niklas Meine, Senior Marketing Manager and responsible for Marketing Electrical Engineering and Electronics EMEA at Covestro. 

Drop-in solution without compromising on performance

The proportion of attributed alternative raw materials in the compound is over 80 percent. It is mass-balanced and certified in accordance with the established ISCC PLUS standard (International Sustainability and Carbon Certification). In principle, the material variants of Makrolon RE are completely identical to their purely fossil-based counterparts in terms of chemistry, physics and processing behavior. “Our customers can therefore replace these counterparts as a drop-in solution in ongoing production processes without having to change processing parameters on the injection molding machines,” explains Niklas Meine.

SAGA is designed for the electrification of commercial and public buildings, private residential buildings and the hospitality sector. It can be integrated into the ABB i-bus KNX and ABB-free at home building automation systems and will initially be marketed in Northern Europe.

https://www.covestro.com/

OE-A at LOPEC: Printed Electronics Powers Sustainability

The “OE-A Competition 2024” shows the many possibilities of flexible, organic, and  printed electronics with inspiring products, prototypes, and fresh designs live at  LOPEC 2024, the leading international exhibition and conference for flexible, organic, and printed electronics in Munich. 

Frankfurt, February 06, 2024 – “This year’s OE-A Competition impressively demonstrates  how printed electronics is the technology to create sustainable electronics through low energy non-hazardous chemicals, additive manufacturing processes and the use of  recyclable materials.” says Dr. Klaus Hecker, Managing Director of the OE-A, an  international working group within VDMA. The OE-A (Organic and Printed Electronics  Association) is the leading international industry association for the emerging technology of  flexible, organic, and printed electronics. 

The proof will be provided at LOPEC 2024, the international platform for printed electronics,  from March 5 to 7, live at the ICM in Munich. This year, 17 projects from international  companies, research institutes and universities are participating in the “OE-A Competition  2024” to present their new products, prototypes, and concepts. The submitted projects will  be judged by a jury of representatives from renowned international companies and institutes  in three categories: “Prototypes & New Products”; “Freestyle Demonstrator”; and “Publicly  Funded Project Demonstrator”.

Henkel and OE-A foster young talents 

In addition to the established competition, Henkel AG & Co. KGaA and the OE-A Working  Group Education have for the first time launched an “Open Innovation Challenge” for  graduate and undergraduate students on the topic of Smart Living and Smart Mobility. “Together with our member Henkel, we challenged young students to develop and prototype  an innovative idea for a printed electronics application that addresses the Smart Living or Mobility markets. To bring their ideas to life, the students were provided with the Henkel Sensor Kit, which includes 5 types of printed sensors” explains Klaus Hecker. A jury  consisting of Henkel, OE-A and other industry representatives will select the winner of the  “Open Innovation Challenge”. The winning project will be showcased at the OE-A booth at LOPEC, along with all other OE-A Competition projects. 

Enabling more sustainable products 

Inspiring printed electronics projects guided by the idea of sustainability participate in this year’s OE-A competition. Here a sneak peek into three of them: 

IEE from Luxembourg competes with a multifunctional busbar connector for battery packs. This product is designed to reduce battery costs in e-mobility. The solution combines multiple functionalities in a single, flexible, and lightweight busbar “sandwich”, that enhances drivetrain electrification. With a single compound, customers have a product that performs multiple functions such as voltage monitoring, cell balancing, temperature sensing, electrical isolation, and busbar connection. The integrated bus bar connection demands less  manipulation than would be required with more components. This increases manufacturing  efficiency and reduces manufacturing costs. 

The CEA research institute in France, in collaboration with its industry partner, contributes a medical device use case with a flexible printed circuit board (PCB) within the EU-funded project ECOTRON. The first generation of the use case (GEN1) demonstrates that a conventional PCB can be replaced with a flexible printed one to create more sustainable  healthcare and wearable devices with no compromise on performance. The flexible printed circuit board is produced in an additive manufacturing process that uses less energy and chemicals. The future use case generations will include dismantling technologies (GEN2)  and bio-based/recycled materials for substrates and inks (GEN3) developed in the project.  

Another approach to a more sustainable future is offered by Fundación Tekniker of Spain  with its integrated de-icing system for wind turbine blades. In cold weather, ice build-up on  the blades reduces the efficiency of wind turbines. The de-icing system detects ice at the  initial stage of formation on the wind turbine blade and eliminates it with an integrated  heater. The ice detection sensors and the heating system are printed with conductive inks on continuous fiberglass mats, and this printed fiberglass is embedded in an epoxy/glass  composite by infusion. Wind turbine run time is maximized in icy conditions, reducing the  need to generate backup power. 

Public Choice Award  

All visitors are invited to vote for the Public Choice Award at the OE-A booth at LOPEC (this  time in the Foyer of ICM, FO.33) on March 6. The winner of the Open Innovation Challenge  and the winners of the OE-A Competition will be announced on the evening of Wednesday,  March 6, during the LOPEC Get-together & Award Show. In addition, all award winners will  present their demonstrators during a web seminar on April 25. 

OE-A booth at LOPEC  

At the OE-A booth at LOPEC 2024, LOPEC visitors will gain a comprehensive insight into  printed electronics applications. A visit to the OE-A booth is also worthwhile to learn about  the latest results of the new business climate survey and the activities of the numerous  international working groups. “Stop by the OE-A stand in the foyer of the ICM, I promise  there will be a lot to discover. We are proud to present all projects of the OE-A Competition  and the winning student project of the Open Innovation Challenge. And last but not least, the  Public Choice Award needs your voice, so please cast your vote for your favorite  demonstrator,” concludes Klaus Hecker.

www.oe-a.org 

#modernplasticsindia #indianplasticmagazine #modernplasticsaward #plasticnews #modernplasticsgermany #ginujoseph #modernplastic #plasticindia  #plasticrecycling #sustainability #modernplasticsglobalnetwork #modernglobalnetwork #modernplasticsaward2023 #plasticmagazine #PlasticIndustry  #modernplasticsmiddleeast #indianmagazine #innovations #modernplasticsamerica #modernplasticsbangladesh #modernplasticsasia #modernplasticsitaly

MEAF Supplies First Food Grade R-Pet Sheet Production Line To Lithuania

By mating its energy efficient sheet extrusion lines with Kreyenborg’s IR-CLEAN Super-Clean process for post-consumer recycled PET, MEAF Machines can now offer its customers a cost effective alternative for the production of FDA/EFSA approved single layer PET food grade sheet. A first R-PET extrusion line combining the two, has recently been installed at Pack Klaipėda UAB in Klaipėda, Lithuania, for the production of meat packaging. The line is also suited for the production of PP trays without alterations, providing the customer with even more flexibility.

Founded some 12 years ago, Pack Klaipėda UAB initially focused on expanded PS containers for take-away food. However, three years ago the company decided to move into other food packaging, notably for meat and poultry. “We looked at several potential suppliers, but found MEAF to have the same output at a much smaller footprint than competitors’ offerings,” says Darius Kontrimas, CTO at  Pack Klaipėda. “Because of rising energy costs, energy efficiency was high on our list and MEAF’s machines are probably best in class when it comes to that. Once we made our decision, we were pleasantly surprised by the level of support we received. Being new in the sheet extrusion business, we had tons of questions. MEAF answered all of them and provided us with all the info we needed and more,” he concludes.

 “This new line perfectly fits the current global trend to produce ever more with 100% Post Consumer Recycled (PCR) material such as bottle-flakes and works also with other thermoforming regrind,” says Roald de Bruijne, Sales Manager at MEAF. “However, the process needs to ensure that the cleaning and decontamination is properly done in order to adhere to the strict FDA/EFSA regulations. This requires processors to invest substantially in dedicated equipment to upgrade their sheet production. At MEAF we believe our affordable, energy-efficient and flexible solution allows our customers to make the transition to recycled material more easily.”

Kreyenborg’s IR-CLEAN is specifically designed as a cost-effective solution for the direct reprocessing of post-consumer PET flakes for food packaging, combining crystallization and drying in a single process. The  system operates without vacuum technology and can be retrofitted on existing extrusion lines. The efficiency of the cleaning process has been verified by a Letter of Non-Objection from the US Food and Drug Administration (FDA), while tests have shown compliance with the European Food Safety Authority (EFSA) criteria for the use of recycled materials for direct food contact packaging.

Roald continues: “At MEAF we already have a good reputation for energy efficient, affordable and flexible extrusion machines. When it comes to the use of R-PET for packaging, bottle-to-bottle is relatively easy as the mechanical properties of the regrind are pretty stable. However, the tray-to-tray recycling process is a lot harder. We are therefore now working hard on the development of a compact unit for IV level increase that can be fully integrated in new and existing extrusion lines. This will further support customers in their transition toward true circularity.“

www.meaf.com/

#modernplasticsindia #indianplasticmagazine #modernplasticsaward #plasticnews #modernplasticsgermany #ginujoseph #modernplastic #plasticindia  #plasticrecycling #sustainability #modernplasticsglobalnetwork #modernglobalnetwork #modernplasticsaward2023 #plasticmagazine #PlasticIndustry  #modernplasticsmiddleeast #indianmagazine #innovations #modernplasticsamerica #modernplasticsbangladesh #modernplasticsasia #modernplasticsitaly

Digitization Of Packaging – A Great Opportunity At Drupa!

At last. drupa is back, with less than a year to go the anticipation is building. Trying to work out what the theme of the show will be tricky, after eight years and the impact of COVID.

The drivers of sustainability, automation and workflow as the world continues to digitise dominate most print and packaging operations. Recruiting and retaining skilled staff is increasingly difficult for many businesses as baby boomers retire and the younger digital native generations demand a different approach to their working life.
Digital print developments will be centre stage across all graphics, industrial and packaging and there will be further announcements this year at drupa. Digital packaging offers many opportunities for commercial printers looking to move into new sectors as many traditional print applications continue to decline. The same dynamic is encouraging more equipment suppliers to offer digital printing systems for labels, corrugated, cartons, flexible packaging, rigid plastics, glass and metal packaging.

The figures show how the suppliers of digital print equipment for labels and packaging has developed since this technology map was first produced in 2019. There has been a steady stream of new entrants, from established analogue print equipment suppliers and new providers leveraging their digital print expertise.

On top of these there are digital overprint systems and sophisticated bespoke integrations, some operating as a part of manufacturing and filling lines. While there has been consolidation in the supply side it is striking that there have been few exits from the sector, the high number of players now competing in the wide range of packaging applications, offering new capabilities and functionalities, with steadily increasing productivity and lower costs.

Well, the good news for us print techies is this diagram will get even more crowded this year. Smithers tracks the developments in this sector, publishing reports and running conferences on digitally printed packaging. The European, American and Asian events bring together hundreds of brands, retailers, packer/fillers, converters, agencies and designers together with equipment, substrate and ink/toner suppliers, with workflow and logistics companies also involved. These are excellent forums and over the years the discussion moved from technology issues into tangible benefits and improved business processes from adopting digital printing, and increasingly digital finishing.

Today quality, reliability and productivity are no longer issues for inkjet and electrophotography packaging presses. At drupa there will be sheetfed inkjet machines offering the equivalent of process colour sheetfed litho at speeds of 11,000 B1 sheets per hour, while web presses offer speeds in excess of 400m per minute up to 2.8m wide. These are mainstream alternatives to litho, flexo and gravure alternatives.

The printhead and press manufacturers are developing methods to eliminate inkjet artefacts, compensating for nozzle outs and deviations in real time that extend the life of the heads and machine uptime. Inkjet will be the real winner, with faster machines being shown, particularly in flexible packaging. Ink technology is improving, with UV and water-based inks being employed for specific applications. There will be more highly pigmented formulations helping reduce the inkfilm thickness while lowering the total cost of ownership further boosting the share of digital print.

It is not just printing. Some vendors will show single pass, highly automated systems to print and finish corrugated boxes, cartons and flexibles in a single pass. The enabler is the combination of digital print with digital finishing. These will feature automated control systems that drive the press, measure and check the print then track through finishing which may be coating, laminating, cutting, creasing, folding and gluing, together with a wide variety of embellishments. The digital front end controllers are becoming increasingly powerful, automating and driving the digital print unit while at the same time measuring and controlling quality and then to set and drive the finishing technology. This approach helps replaces the traditional skills of press minders and finishing journeymen operators – important as skilled labour resources become scarcer.

While new digital presses are the shiny and sexy headline grabbers, even more important is the enabling workflow software. The only way of making money from a digital press is to produce saleable output and powerful workflow is vital to prepare the artwork files and keep the print queue well stocked. This can be a barrier for packaging converters entering the sector as many do not have the necessary prepress and data handling skills. drupa will see many companies providing solutions, integrating with management information systems to automate the administration needed to handle many short run jobs. Workflow will become increasingly collaborative, with new designs produced and approved, then loaded into job queues for automated colour management and imposition with no manual involvement at the converter. The MIS is linked, ordering substrates and planning the production on printer and finishing to meet the customer requirements and optimise capacity at the converter.

Digital workflow can be daunting for packaging converters used to handle a few large jobs but it is the way of the world. Companies can explore solutions at drupa to simplify supply chains that will be key to future success supplying packaging and labels. The market leaders offer a broad variety of creative software. They will show new methods to automate the repetitive processes involved with packaging design, approvals and prepress taking time and cost out of the process. Other players will offer specific solutions for integration and to optimise colour management, imposition and providing variable data capability.

All these packaging developments are ultimately driven by end customer expectations, or rather demands. In the increasingly connected world these demands and expectations are changing, with more engagement and interaction to improve the consumer experience of the brand. Digital printing allows brands to make content decisions later in the supply chain, closer to the consumer that helps packaging offer additional valuable functions. These additional functions move packaging beyond the traditional containment and protection functions, with information and promotion. A unique digital print can be connected to the cyber world, opening new opportunities of logistical efficiency and greater consumer engagement.

drupa is the most important print show, because the exhibitors (and all the important ones will be there) show what they have, while using the event to showcase what they are working on to gain feedback. And digital packaging print (plus finishing) will very much be on the agenda. There will be more machines for labels; corrugated – post and preprint, replacements for litholam; for folding cartons; for flexible packaging; for metal and there will be direct-to-shape machines doing interesting things on cans, aerosols, plastic and glass. Established players will show improvements to quality, speed and formats, with new inks and toners broadening the types of packaging they can produce.

I am really looking forward to seeing the newcomers who have already announced developments that they will be showing off and I know of several potential developments sadly under NDA that I am not allowed to mention, which is the bane of a technology correspondent. That will change when drupa opens.

https://www.drupa.com/

#modernplasticsindia #indianplasticmagazine #modernplasticsaward #plasticnews #modernplasticsgermany #ginujoseph #modernplastic #plasticindia  #plasticrecycling #sustainability #modernplasticsglobalnetwork #modernglobalnetwork #modernplasticsaward2023 #plasticmagazine #PlasticIndustry  #modernplasticsmiddleeast #indianmagazine #innovations #modernplasticsamerica #modernplasticsbangladesh #modernplasticsasia #modernplasticsitaly

THERMPROCESS China 2024 – High Potential For The Global Thermal Process Industry On The Chinese Sales Market

International companies benefit from exhibiting in the German Pavilion in Shanghai from 25 to 28 September 2024.

From 25 to 28 September 2024 the international thermal process industry will meet at THERMPROCESS China presenting numerous technological innovations and a line-up of high-calibre side events in parallel with the world-leading Düsseldorf trade fairs for wire, cable and tube and pipes, wire and Tube China, at the Shanghai New International Expo Center (SNIEC). In 2020, the total output value of China’s heat treatment industry was approximately USD17 billion, of which approximately USD 14 billion were accounted for by the sale of heat treatment processes and about USD 3 billion by the sale of heat treatment equipment and process materials (including USD 2 billion for heat treatment equipment and USD 1 billion for process materials).

In recent years, the number of companies and the market size of China’s heat treatment industry has grown steadily, and the demand for high-quality heat treatment equipment, instruments and application software has increased year by year. As a result of China’s “Dual Carbon” strategy, the Chinese heat treatment industry will vigorously promote the upgrading of equipment and technical research in the fields of energy conservation and eco-friendly manufacturing.

This trade fair for the Chinese market has formed part of the “Bright World of Metals” since 2020, thereby complementing the international THERMPROCESS portfolio in Düsseldorf. It is held every two years. With this trade fair, the organisers Messe Düsseldorf (Shanghai) Co., Ltd. and MC-CCPIT will again offer the international thermal process technology sector a comprehensive business platform for showcasing the latest products, technologies, solutions and services. The complete spectrum of thermal process technology will be on show: industrial furnaces, industrial heat treatment plants, plant construction, drive technology, firing technology, power and heat engineering, heat treatment and technology, heating systems, heat pumps and other accessories.

Companies can apply for participation in the German Pavilion with the Federal Ministry of Economy and Climate Protection as of now

Due to the good reputation THERMPROCESS China enjoys in the industry and the growing market interest numerous international exhibitors have already voiced their willingness to repeat participation in THERMPROCESS China 2024. German enterprises from the thermal process technology industry receive official funding for their trade fair participation and attractive special conditions from the Federal Ministry of Economics and Climate Protection (BMWK). Interested companies can register online with the BMWK and secure their exhibition area at the German Pavilion: https://registration.german-pavilion.com

 Red-hot side events come care of the Heat Treatment Technology Seminar

At the Heat Treatment Technology Seminar held during the trade fair, the Shanghai Heat Treatment Association will provide an overview of current developments and innovative approaches in heat treatment technologies. The agenda lists renowned speakers from the industry as well as lectures on the heat treatment of automotive parts and pipe-casting dies. The seminar offers industry experts an opportunity to exchange knowledge and network.

The latest THERMPROCESS China registered 332 companies participating from 14 countries. This means a 30% increase over the first event in 2020. More than 22,000 trade visitors from 53 countries travelled to Shanghai (figures include the concurrently held wire and Tube China). These included numerous buyers from the automotive industry, the chemical industry, the oil and gas industry, the energy sector, aviation and aerospace, and other user industries.

www.thermprocess.de/de/Overview

#modernplasticsindia #indianplasticmagazine #modernplasticsaward #plasticnews #modernplasticsgermany #ginujoseph #modernplastic #plasticindia  #plasticrecycling #sustainability #modernplasticsglobalnetwork #modernglobalnetwork #modernplasticsaward2023 #plasticmagazine #PlasticIndustry  #modernplasticsmiddleeast #indianmagazine #innovations #modernplasticsamerica #modernplasticsbangladesh #modernplasticsasia #modernplasticsitaly

Alio Industries Promotes Monolithic Design To Ensure Ultra-Precise Motion Control Solutions

ALIO Industries’ adoption of monolithic design in its motion control systems is a strategic decision to ensure unparalleled precision and reliability in its products. The monolithic design promotes stiffness, and integrates all essential components into a single, compact unit, which eliminates the mechanical complexities and alignment challenges associated with modular designs. This integration is crucial for applications where even the slightest discrepancy can lead to significant errors, making the precision and stability provided by monolithic design essential for the success of ultra-precise operations.

Bill Hennessey, President of ALIO says, “The monolithic design choice is particularly beneficial in sectors where precision is non-negotiable, such as metrology, ultra-fast laser processing, digital pathology, and semiconductor processing. For example, in digital pathology, ALIO’s monolithic, low-profile, open-center X, Y, Z electromagnetic driven stages are critical for achieving the high-speed, high-throughput, and low-friction motion needed for precise sample analysis. The integrated design allows for better pre-scan images by maintaining consistent motion with sub-micron variation, which is essential for capturing all data points in one pass.”

ALIO’s commitment to ultra-precision is also evident in its focus on nanometer-level accuracy and repeatability, which surpasses the commonly found micron-level precision in the industry. By prioritizing nanometer precision, ALIO’s monolithic designs cater to advanced applications that require the utmost accuracy, thus differentiating its products and positioning the company years ahead of its competition​​​​.

Moreover, ALIO’s innovative approach extends to incorporating novel materials into their monolithic designs, leveraging properties such as high stiffness and low thermal expansion. These materials contribute to the stability and precision of the motion control systems by minimizing thermal fluctuations and vibrations, which are critical factors in maintaining accuracy over time and under various environmental conditions​​. 

Hennessey continues, “ALIO ensures that its monolithic motion control solutions are future-proof, designed not just for current needs but with the foresight to adapt to evolving application requirements. Our product configurator tool exemplifies this approach, enabling customers to specify solutions that are tailored for both present and prospective challenges, thereby offering a smart investment for long-term operational efficiency​​. This forward-thinking strategy underscores ALIO’s dedication to providing customers with motion control solutions that deliver persistent ultra-precision performance in a rapidly advancing technological landscape.”

ALIO’s relentless pursuit of ultra-precision is further reinforced by its internal standards and practices. The company’s in-house metrology department and advanced machine shop underline its commitment to quality and precision. ALIO’s standards have been recognized by the adoption of their Point Precision approach into the ASME B5.64 standard “Methods for the Performance Evaluation of Single Axis Linear Positioning Systems”. This point repeatability method accounts for 6D spatial errors, providing a true representation of nanometer-precision performance​​.

Hennessey concludes, “The use of monolithic designs underpins ALIO’s strategy to deliver ultra-precise motion control solutions. By integrating components into a single unit, leveraging innovative materials, focusing on future-ready solutions, and adhering to stringent internal standards, ALIO provides its customers with a competitive edge in an array of high-precision industries.”

www.alioindustries.com

#modernplasticsindia #indianplasticmagazine #modernplasticsaward #plasticnews #modernplasticsgermany #ginujoseph #modernplastic #plasticindia  #plasticrecycling #sustainability #modernplasticsglobalnetwork #modernglobalnetwork #modernplasticsaward2023 #plasticmagazine #PlasticIndustry  #modernplasticsmiddleeast #indianmagazine #innovations #modernplasticsamerica #modernplasticsbangladesh #modernplasticsasia #modernplasticsitaly

SABIC’S New LNP LUBRILOY Compounds Extend Portfolio of non-PTFE Lubricated Materials

SABIC, a global leader in the chemical industry, today announced here at MD&M West 2024 (Booth #3287) a significant expansion of its LNP LUBRILOY portfolio of internally lubricated specialty compounds. The new LNP LUBRILOY products can meet customer demands for high-performance alternatives to materials lubricated with polytetrafluoroethylene (PTFE), which is a per- and polyfluoroalkyl substance (PFAS). These new grades extend SABIC’s LUBRILOY technology to additional base resins and feature a novel, patented lubrication technology enabling OEMs to help avoid health and regulatory issues associated with materials containing intentionally added PFAS.

“In the face of proposed European and individual U.S. state regulations severely restricting or banning the use of PFAS, customers in the healthcare industry and other markets are seeking self-lubricated solutions that don’t incorporate these chemicals,” noted Ralph R. Buoniconti, SABIC senior specialist, Regulatory. “SABIC has taken the lead in developing multiple new specialty compounds that can serve as alternatives to polymers lubricated with traditional PTFE. By expanding and enhancing our LNP LUBRILOY portfolio, SABIC aims to help customers successfully navigate the changing regulatory landscape for PFAS.”

Materials Deliver High Performance without PTFE

Internally lubricated thermoplastics have been used for years because of their advantages over externally applied greases or oils, which add processing time and costs and can transfer to and contaminate other surfaces. As an internal lubricant, PTFE is known for imparting very low friction and enhancing wear resistance. However, global concerns about PFAS have prompted customers in a wide range of industries to consider more-sustainable lubricants to replace PTFE.

“SABIC continues to add value to LNP specialty compounds in multiple ways – from expanded choice to improved regulatory compliance,” said Ed Williams, senior product manager, LNP Compounds, SABIC’s Specialties business. “Deep knowledge of polymer chemistry enabled our experts to achieve a milestone by developing a novel lubricant technology and incorporating it into multiple new base resins. Our new-generation LUBRILOY compounds offer customers the opportunity to achieve excellent wear and friction performance while easing concerns about anticipated restrictions on PFAS.”

New Base Resins Offer Broader Choice

The new grades, which include unreinforced and reinforced products with up to 30 percent glass fiber, complement SABIC’s other grades for medical devices. The company’s diverse healthcare materials address a range of performance needs, including withstanding multiple sterilizations, resisting aggressive disinfectants, and improving wear and slip-stick performance in applications like drug delivery pens, gears and bearings.

These new compounds are versatile, with possible use in applications across multiple industries. Besides medical devices, they offer the potential for mobility, industrial and infrastructure applications such as automotive under-hood components and interior parts, water meters, conveyor belt guides and tensioners, and other moving parts.

The new LNP LUBRILOY grades and example applications are on display at the SABIC booth (#3287) at MD&M West in Anaheim, Calif., from February 6-8, 2024. Also, Ed Williams, senior product manager, LNP Compounds, will give a presentation on these materials on Tuesday, February 6, at 12:30pm in the MD&M West Design Alley, The topic is “Solving thermoplastic wear and friction problems in medical devices without intentionally added PFAS.”

https://www.sabic.com/en

#modernplasticsindia #indianplasticmagazine #modernplasticsaward #plasticnews #modernplasticsgermany #ginujoseph #modernplastic #plasticindia  #plasticrecycling #sustainability #modernplasticsglobalnetwork #modernglobalnetwork #modernplasticsaward2023 #plasticmagazine #PlasticIndustry  #modernplasticsmiddleeast #indianmagazine #innovations #modernplasticsamerica #modernplasticsbangladesh #modernplasticsasia #modernplasticsitaly