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REIN4CED and DIEFFENBACHER form strategic partnership Collaboration to accelerate large-scale production of thermoplastic carbon bicycle frames

REIN4CED and DIEFFENBACHER form strategic partnership Collaboration to accelerate large-scale production of thermoplastic carbon bicycle frames

A shared vision for using thermoplastic manufacturing to produce more durable and sustainable carbon bicycle frames has led DIEFFENBACHER, the Germany-based manufacturer of turnkey composite systems, and REIN4CED, the Belgian developer of a new, patented impact-resistant composite material, to announce a strategic partnership. Traditional carbon used in high-end bicycle frames is light, strong and stiff, but highly impact-sensitive. REIN4CED resolved brittle fracture issues by adding small amounts of steel fibers to specific locations inside the carbon material.

“The partnership with our longtime supplier DIEFFENBACHER seeks to make thermoplastic manufacturing the go-to method for producing unbreakable carbon bicycle frames,” says REIN4CED CEO Johan Miermans. “Together, we’ll accelerate and enhance process efficiency, robustness and flexibility to move toward our shared vision,” states CTO Michaël Callens.

DIEFFENBACHER is a leading manufacturer of press systems and complete production plants for the forming industry. The company helps manufacturers produce complex and robust composite components used in the automotive, aerospace, e-mobility and lightweight construction industries. The sports and leisure industry, which includes bicycle frame manufacturers, is another growing market for the composites components produced using DIEFFENBACHER technology.  

“Long-term, trusting partnerships with our customers are one of our core values and the basis of our entrepreneurial success,” says DIEFFENBACHER CEO Christian Dieffenbacher. Georg Obermaier, who leads DIEFFENBACHER’s forming business, explains that partnerships like the one with REIN4CED help DIEFFENBACHER advance technology innovation across their customer base. “The bicycle frame project is an ideal example of a cooperation that benefits both parties but can also help move the forming industry ahead,” he says.

REIN4CED’s ongoing cooperation with DIEFFENBACHER resulted in the world’s first serial production line for thermoplastic bicycle frames based on DIEFFENBACHER’s Tailored Blank Line, which consists of the Fiberforge tape-laying system and the Fibercon consolidation system.

DIEFFENBACHER Fiberforge is the fastest UD tape-laying system in the world. The Fibercon system consolidates the continuous fiber-reinforced tape layups into near-net-shape laminates with excellent quality. Fiberforge and Fibercon can be used to manufacture structural composite components or to provide local reinforcements. This provides components with excellent deflection behavior, strength and impact resistance, all essential properties of bicycle frames.

“REIN4CED’s feedback provides valuable insights into how our technology is used and its potential for further development,” Obermaier concludes. “In the form of further product developments and process improvements, this will ultimately benefit all our partners and customers.”

https://dieffenbacher.com/de/

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Stadler And Krones Close The Plastics Circular Economy Loop At The Las Vegas Polymer Center – The First Of Its Kind In North America

Stadler And Krones Close The Plastics Circular Economy Loop At The Las Vegas Polymer Center – The First Of Its Kind In North America

STADLER Anlagenbau GmbH, in collaboration with Krones, has designed and installed the new Republic Services Polymer Center in Las Vegas, Nevada, which processes plastic bottles, jugs and containers to produce plastic materials ready for use in new packaging. The first of its kind in North America, this facility closes the circular economy to meet the rising demand for high-quality and food-grade recycled plastic. 

Republic Services, a leader in the U.S. environmental services industry, has opened North America’s first vertically integrated plastics recycling facility, producing recycled resins for use in sustainable packaging. Krones, acting as general contractor in the project for the new Polymer Center in Las Vegas, worked hand in hand with STADLER, which was responsible for mechanical sorting on the PET and PO lines. The new plant will produce more than 100 million pounds per year of recovered resin products that are returned to the circular economy. 

The new Polymer Center processes presorted plastics collected by Republic Services across the Western United States to recover PET, which is converted into recycled PET (rPET) flakes ready to be turned into new bottles, and Polyolefins (PO) ready for use in the production of new bottles, jugs and containers. 

Polymer Center

“The Polymer Center is the first facility of its kind in North America,” says Pete Keller, Vice President, Recycling and Sustainability at Republic Services. “It’s the first time a single U.S. company has managed the entire plastics recycling stream, from curbside collection to production of high-quality recycled resins ready for use in sustainable packaging.” 

This was an important project for Republic Services that required careful planning and research to select the best partners: “We started to think about the Polymer Center business model in 2019,” explains Pete Keller. “We chose STADLER and Krones because we think we’re going to produce the highest-quality and highest-value product in the marketplace. We had familiarity with STADLER’s equipment and people, and we knew we were going to get a solid design. We consistently heard that the Krones wash line produced the highest-quality rPET flake in the marketplace. These systems give us the ability to produce both food-grade and color-sorted materials in a way that hasn’t been available to the market in the past, enabling greater material circularity.”

Dual Line plant closes the loop with high-quality, food-grade recycled plastic

The Polymer Center in Las Vegas sorts and processes the materials, which are delivered in bales, on two lines: one for PET and one for mixed plastics, each with a capacity of 5t/h. “This is the largest Dual Line plastics recycling plant in the USA,” comments Mat Everhart CEO, Stadler America LLC (a subsidiary of STADLER Anlagenbau GmbH). It is expected to put 100 million pounds of plastics a year back into the circular economy by producing high-quality, food-grade recycled material ready for use in packaging. 

The materials fed into the PET line undergo mechanical separation and the singulated material is cleaned of ferrous particles. A STADLER STT2000 ballistic separator sorts the material into rolling (3D), flat (2D) and fines fractions. 

The fractions go through sensor-based sorting with Near-Infrared (NIR) sorters. Caps, rings, and the 2D fraction go to compactors. The 3D fractions are directed to a STADLER Label Remover to remove the labels. The clear PET, caps and rings are directed to the Krones washing line, which granulates and cleans the material, while the color PET is compacted into bales. 

On the Mixed Plastics treatment line, mechanical separation sorts the infeed into fines and sieve overflow – the latter further separated into light and heavy fractions. The heavy mixed plastics fraction is sorted into four Polyethylene (PE) products – Natural, White, Red/Orange/Yellow, Other/Color – and two Polypropylene (PP) products – Natural/White and Other/Color.

PET is sorted out of the remaining material and sent to the PET line. The products of the Mixed Plastics line are conveyed to storage bunkers where a semi-automatic feeding program allows for materials to be discharged by grade to be fed into the baler.

A successful collaboration to achieve a true plastics circular economy 

The Polymer Center in Las Vegas is part of Republic Services’ plans for a nationwide network to help customers achieve a true plastics circular economy: “Republic Services is committed to challenging every truckload we collect from customers and advancing circularity for key materials,” explains Pete Keller. “The Polymer Center will help enable true bottle-to-bottle and package-to-package circularity for plastics, helping customers achieve their own sustainability goals. Our integrated regional hub-and-spoke model will ensure nationwide coverage. We’ve received an overwhelming response from the industry and potential customers, which has accelerated the development timeline for our second and third Polymer Centers.”

The company plans to build three more Polymer Centers to address the gap between supply and the fast-rising demand for recycled plastics driven by regulations and a shift in consumer preferences for sustainable packaging. A report by the Recycling Partnership estimates that the gap between the current US supply of rPET for use in bottles and the projected demand in 2025 is close to 500,000 tons.

Following the positive experience working with STADLER on the Las Vegas Polymer Center project, Republic Services has decided to extend this collaboration: “Our strong partnership with STADLER and Krones, the design and quality of equipment, and successful implementation in Las Vegas has given us the confidence to purchase systems 2 and 3 for our centers under development,” concludes Pete Keller.

http://www.w-stadler.de/en/index.php

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GRC Welcomes TotalEnergies Fluids Dc Cooling Biolife To Its Electrosafe Fluid Partner Program

GRC Welcomes TotalEnergies Fluids Dc Cooling Biolife To Its  Electrosafe Fluid Partner Program

GRC (Green Revolution Cooling), the  global leader in immersion cooling for data centers, announced today that the Special Fluids  division of global multi-energy company TotalEnergies has joined GRC’s ElectroSafe Fluid  Partner Program, a platform for collaboration to advance the performance and environmental  footprint of single-phase immersion cooling fluids. 

GRC’s ElectroSafe range of liquid coolants is available globally and deployed with GRC  immersion cooling systems in twenty-two countries. The range provides a broad spectrum of  high-performance, earth-friendly, synthetic coolants that have undergone a thorough testing  process. Under the ElectroSafe Fluid Partner Program, TotalEnergies Fluids and GRC will  jointly evaluate and gather fluid test data through a proprietary protocol to optimize material  compatibility, safety, and thermal performance. This will provide GRC’s customers around the  world with an expanded range of trusted fluids for their unique data center requirements. 

“TotalEnergies Fluids is proud to join GRC’s ElectroSafe Fluid Partner Program and expand  its presence in the data center immersion cooling space,” said Dominique Vincent, VP  Special Fluids. “Our DC Cooling BioLife is the first biosourced, biodegradable, and high performance dielectric fluid specifically designed for immersion cooling. It exhibits one of the  lowest viscosities in the market and fully contributes to our ambition of commercializing 30%  low carbon solvents by 2030.” 

As a member of the ElectroSafe Fluid Partner Program, TotalEnergies Fluids will provide its  sustainability focused BioLife Immersion Cooling Fluids. BioLife coolants are manufactured  from 100% traceable feedstocks coming from the circular economy and certified by ISCC  PLUS. Biosourced fluids deliver incomparable environmental benefits, with a significantly lower  carbon footprint than fluids from fossil or synthetic hydrocarbons and no compromise on  efficiency. They deliver excellent thermal management performance, with very low viscosity,  high fluid stability for enhanced safety, and strong electrical component compatibility. 

“TotalEnergies Fluids provides an excellent addition to our family of ElectroSafe coolants,” said  Ben Smith, Chief Product Officer at GRC. “BioLife’s focus on environmental friendliness  enables our most sustainability-focused customers to obtain the advanced data center  performance they require without compromising on their commitment to reducing drastically  the carbon footprint of their data center operations.”  

https://totalenergies.com/ 

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UFlex to Showcase Advanced Machine Technology at PlastFocus 2024

UFlex to Showcase Advanced Machine Technology at PlastFocus 2024

India’s largest multinational flexible packaging and solutions company, is participating in PlastFocus 2024, and will feature its advanced machine technology at Booth No. A 51, Hall 1, at Yashobhoomi (IICC), Dwarka, New Delhi from February 1-5, 2024. Recognized as an ideal platform for the plastics and packaging sector, PlastFocus 2024 will feature UFlex’s state-of-the-art machine technology, primed to redefine industry standards.

At the event, UFlex will highlight the technological prowess and capabilities of two of its groundbreaking machines:

CI flexo Machine: UFlex presents its CI flexo Machines, including the first-ever made-in-India gearless central  impression  flexo  printing  machine, introduced in 2017. Building on this legacy, UFlex has ventured into manufacturing a central impression, up to 10 colours, 800-1600mm web width CI flexo printing press. This collaborative endeavor with Italy-based Comiflex has resulted in a machine that offers unparalleled performance. With a printing speed of up to 400 meters/minute, this system is equipped with modem connectivity to UFlex’s service team for remote monitoring, diagnostics, and troubleshooting, ensuring real- time assistance to clients.

Combi Lamination Machine: UFlex’s Combi Lamination Machine features a digital AC vector drive and AC vector grade motor technology. This versatile model facilitates the lamination of two different substrates seamlessly using any of the two modes at a given time. The machine includes unwind and rewind features, a solvent-less coating unit, a gravure coating unit, a lamination unit, and a drying tunnel. With a speed of up to 300 meters/minute for solvent- based operations and 450 meters/minute for solvent- less operations, this machine sets new benchmarks in efficiency and performance.

UFlex invites industry enthusiasts and stakeholders interested in these pioneering technologies to experience live demonstrations of these machines at its Noida manufacturing facility. These exclusive plant visits will provide a first-hand experience of UFlex’s avant-garde manufacturing processes and technological advancements. Moreover, during the visit, engage in discussions about the upcoming launch of the ELS (Electronic Line Shaft) Rotogravure Printing machine models G-24/G- 25, set to be rolled out in the near future.

Join the UFlex team at Booth No. A 51, Hall 1, Yashobhoomi (IICC), Dwarka, New Delhi, to delve into the future of printing technology for converters. The team will be available for discussions, showcasing how these machines can enhance packaging processes, taking efficiency and sustainability to new heights.

corpcomm@uflexltd.com

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Teens Enjoy Real-World Robotics Experience Courtesy of FANUC UK

Teens Enjoy Real-World Robotics Experience Courtesy of FANUC UK

A group of seven young people aged between 14 and 16 have spent a week with leading automation experts FANUC UK, gaining valuable hands-on robotics experience as they learnt what it takes to become an automation engineer. As part of FANUC’s campaign to break down barriers to careers in engineering and build a future manufacturing talent pipeline, the company invited a select group of teenagers into its UK headquarters at Ansty Park, Coventry for five days in August for its first ever Work Experience Week.

Hara Konstantelia, a 23-year-old Technical Sales Support Engineer at FANUC was quizzed by the students and helped run the week-long course.

Hailing from a variety of nearby schools and colleges, the seven teenagers enjoyed a practical insight into the world of automation at the renowned FANUC Academy. Combining hands-on robot programming training with an introduction to project management, the group was also given access to FANUC’s portfolio of industrial robotic and automation solutions, as well as learning about the varied sectors and applications in which they are used – from aerospace and automotive to food & beverage and plastics.

In a bid to understand just what it takes to forge a successful career in robotics, the students also took part in a Q&A session with FANUC staff including Hara Konstantelia, a 23-year-old Technical Sales Support Engineer who herself joined the industry through an apprenticeship programme and helped to run the week-long course.

“I’ve enjoyed seeing the level of passion these young people have shown towards automation, and their excitement to learn new things,” Hara comments. “Having been down this route myself, supporting our work experience students on their own journey and expanding their perception of engineering has been a great experience.”

Attracting Gen Z into a career in engineering is a key aim for FANUC UK. Its Training Academy has recently achieved independent validation, allowing the company to offer accredited courses that can feed into mainstream education. FANUC’s Work Experience programme is showcasing the opportunities available within automation and manufacturing to a cohort that may never have experienced robotics first-hand before. 

“We understand the importance of giving young people the opportunity to have real-world, hands-on experience with industrial robots,” says Tony Bentham, Head of Customer Service at FANUC UK “FANUC’s Work Experience Week aims to ignite a spark in young people by showing just what it takes to forge a career in robotics, as well as giving them access to people who are successfully doing their dream job.”

Combining hands-on robot programming training with an introduction to project management, the group was given access to FANUC’s portfolio of industrial robotic and automation solutions.

For the majority of the participants, this was the first time they had used a robot and the experience was not one to be forgotten. “It’s been a really exciting experience and I’ve enjoyed it so much,” says Nathaniel Sharpe, 16. “I learnt a lot about the different types of robots produced by FANUC – from collaborative ones that you can work alongside, to some that can pick up items with a vacuum or grippers, to ones that can carry huge loads up to 2-3 tonnes. This was my first time using a robot and I thought it would be a lot harder than it actually was – programming it was surprisingly straightforward! The week I spent at FANUC really opened my eyes to the world of robotics and engineering – I’d recommend the work experience programme to anyone.” 

The success of its first ever Work Experience Week and the positive feedback from the participants has prompted FANUC to consider running similar events in the future, as Hara concludes: “Activities like this are so important as the skills required for engineering today are not always accurately represented in the media, especially on platforms aimed at younger people. I hope the students left the week inspired and with a clearer idea of what opportunities are available to them.”

www.fastloopmedia.com 

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EnEWA Research Project Aims to Unlock The Untapped Potential Of Recyclable Paper In Mixed Waste

EnEWA research project aims to unlock the untapped potential of recyclable paper in mixed waste

The world produces and consumes vast amounts of paper for a wide variety of uses. However, while the paper industry has made significant strides in increasing the sustainability of its production by increasing the recycled content of its products, there is much room for improvement. In fact, a smaller portion of paper produced than might be expected is recovered for recycling, despite separate waste collection being widespread. For example, in Germany, as much as 20% of the paper produced is not returned into the recycling value stream – and a part of this paper is discarded in mixed waste streams. 

“Regulations mandating the minimum content of recycled material in new paper products will require a significant increase in recovered paper for recycling. Even if we were to recycle all the paper collected separately with the existing process, there would not be enough to meet these targets,” explains Annika Ludes, Product Engineer at STADLER. An award-winning research initiative, the EnEWA project, is looking at a solution to fill the gap by unlocking the untapped potential of obtaining recyclable paper from the lightweight packaging, residual waste and commercial waste streams. While the project analysis is based on the paper from mixed waste streams as they are collected in Germany, the solution it is developing will be applicable, with some adaptations, to local situation in other countries. The project kicked off in December 2021 and is due to be completed in November 2024.

“Participating in the EnEWA project is important for us at STADLER. Research projects such as this help us in our search for ways to support the recycling industry as we evolve towards a circular economy,” adds Annika Ludes. “We want to drive change, build these plants to expand the sources of secondary fibers for the paper industry. We also want to work with packaging producers to design packaging that is better for recycling.”

EnEWA project: recovering paper from mixed waste streams

The members of the EnEWA project – Universität Siegen, RWTH Aachen University, LEIPA Group, PROPAKMA, TOMRA and STADLER – are developing a solution for recovering and recycling paper from the lightweight packaging, residual waste and commercial waste streams. They have set clear objectives: increase recycling rates in paper production and reduce primary energy requirements and CO2 emissions. The goal is to achieve an overall recovered paper return rate of 90% – including both separate paper collection and special collection systems, which today have a 78% return rate, and the residual, commercial and lightweight packaging streams from which barely a small part of paper is currently recovered.

The project is also looking at what can be done to create the conditions for maximizing the amount of paper returned to the recycling loop. This includes discussions with German and EU regulatory authorities with recommendations for updating waste management guidelines to improve the waste streams feeding the sorting process; communication campaigns aimed at raising awareness among consumers about the correct separation of their household waste; and collaboration with producers for the design of packaging that is better for recycling.

The task for STADLER in the project is to provide, in collaboration with TOMRA Recycling, technical solutions to extract paper from the mixed streams and sort it into different paper qualities for recycling. Alena Spies, M.Sc., Research associate at the Chair of Anthropogenic Material Cycles of RWTH Aachen University, comments: “STADLER brings its great experience in waste processing technology and plant engineering, which are of great importance for the holistic consideration of material cycles and the development of recycling processes on an industrial scale towards a circular economy. For us, its most important contribution has been the joint planning and implementation of industrial-scale sorting trials at its Test and Innovation Center.”

Industrial-scale trials at STADLER Test Center: early results are promising 

In March, STADLER completed extensive industrial-scale trials at its Test Center in Slovenia to identify and resolve the issues arising in sorting paper from lightweight packaging, residual and commercial waste streams. The sorting process begins with the income stream going through STADLER’s ST2000 ballistic separator, followed by optical sorting with TOMRA Recycling’s AUTOSORT®.

The process was tested on waste collection samples from different areas of Germany, and in different conditions that may affect the sorting process, such as wet or dirty materials. “This is important because the waste collection processes vary from country to country, but also domestically at regional level, and even on a seasonal basis. Also, waste from these streams is often dirty and may be wet. This means that the solution must have the flexibility to manage this variability,” says Annika Ludes. 

The tests have generated vast amounts of data, and the analysis is still in the early stages. The RWTH Aachen University team is examining the results of manual and sensor-based analysis of the waste streams to get a good understanding of the ballistic separator’s operation with these materials. It is analysing separation of three main streams: pure paper, separation of paper out of the plastic waste stream, and separation of plastics out of paper. 

In terms of the sorting process, the analysis so far has revealed that every paper fraction from the different waste streams has its own characteristics and that, due to its modularity and the range of possible settings, the STADLER STT2000 can be used effectively for sorting non-separated collected paper. 

Samplings made earlier in the project to analyse the material composition and paper content of the different waste streams have revealed that approximately 50% of the paper in the lightweight packaging stream could have been disposed of within the separate paper collection. This finding highlighted the need to address the waste collection processes in order to ensure a more effective separation of the streams and, consequently, higher paper recovery rates.

The project is also looking beyond the sorting process, as Alena Spies explains: “Different dissolution and stock preparation options as well as a procedure for the hygienisation of biological contamination and the separation of hazardous substances have been investigated. An additional focus is on the recovery of rejects that arise during paper recycling processes. Last year a complete recycling process have been conducted from the separation of paper and board from lightweight packaging waste till the production of new cardboard including several sorting and processing steps. In addition, the project is continuously accompanied by an ecological and economical assessment and the transfer of knowledge of the results to the paper industry. With this project, we hope to establish the developed recycling process into the paper industry to achieve a material recycling of paper and board from lightweight packaging, residual and commercial waste.”

Environmental benefits include potential savings of 270,000t CO2 

The paper industry has already improved its carbon footprint through optimization of their plants and reducing the energy requirements in the reprocessing of recovered paper. By redirecting the paper from the residual, commercial and lightweight packaging streams into the recycling loop, the process developed by the EnEWA project has a potential according to initial calculations to save some 270,000t of CO2 a year. 

http://www.w-stadler.de/

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Drupa Prize 2023 Awarded To Acelya Bakir

Drupa Prize 2023 Awarded To Acelya Bakir

For her outstanding doctoral thesis historian Acelya Bakir receives the drupa Prize 2023. With this award drupa honours and promotes outstanding young academics in the Philosophical Faculty at Heinrich Heine University Düsseldorf every year.

The drupa Prize comes with prize money of EUR 6,000 and was presented by Wolfram N. Diener, President & CEO of Messe Düsseldorf, Erhard Wienkamp, Managing Director of Messe Düsseldorf,  Dr Martin Goch, Chancellor of Heinrich Heine University Düsseldorf and Dr Frank Meier, Dean of Studies at the Faculty of Philosophy of Heinrich Heine University Düsseldorf, at a ceremony on 28 August 2023 at the Messe Dusseldorf.Dr. Andreas Pleßke, Spokesman of the Board at Koenig & Bauer and Chairman of the drupa committee, congratulated the prize winner on her performance in a personal video message.

Innovative access to the topic

The doctoral thesis rated summa cum laude bears the title “Sehen, Hören, Mitmachen: Die mediale Inszenierung der Moskauer Schauprozesse und die Mobilisierungskampagne in der Sowjetunion, 1936-1938” (See, Hear and Join in: The Media Staging of the Moscow Show Trials and the Mobilisation Campaign in the Soviet Union, 1936-1938” and was supervised by Prof. Dr. Beate Fieseler. Acelya Bakir pursued a particularly innovative approach in her studies: she placed the Moscow show trials centre stage as a mobilisation campaign for the first time and, hence, not only their staging in the court room but also the accompanying media mediation for the local population.

Bakir’s thesis provides not only important and innovative insights into the political communication and mobilisation during the Stalin era but also many an important impulse for better understanding the present, notes the Philosophical Faculty at Heinrich Heine University for her drupa Prize nomination.

drupa Prize 23 E. Wienkamp, Prof. Dr. Beate Fieseler (Institute for Historical Sciences HHU), Acelya Bakir (Prize winner), Sabine Geldermann, Wolfram N. Diener

 About the drupa Prize winner 2023

Acelya Bakir was born in Krefeld in 1985. From 2005 to 2008 she successfully completed her Bachelor studies in History and German studies at Heinrich Heine University Düsseldorf obtaining her Master’s Degree in History in 2012. The same year she started her PhD studies in Eastern European History at the Philosophical Faculty and completed her doctoral thesis “Sehen, Hören, Mitmachen: Die mediale Inszenierung der Moskauer Schauprozesse und die Mobilisierungskampagne in der Sowjetunion, 1936-1938” in February 2022 after a successful viva examination earning her an overall grade of summa cum laude. Acelya Bakir lives and works in Berlin. She is a scientific assistant at the Foundation “Haus der Geschichte der Bundesrepublik” and is press liaison and coordinates public relations for a member of the German Parliament part time.

About the drupa Prize

Every year since 1978, Messe Düsseldorf has presented the drupa Prize with prize money worth EUR 6,000 to an outstanding doctoral thesis produced in the Philosophical Faculty of Heinrich Heine University Düsseldorf. The prize money serves to promote the publication and dissemination of an excellent thesis in the humanities. The drupa Prize is awarded each year by an expert panel composed of the President and Vice-President of Heinrich Heine University Düsseldorf (HHU), the Chairman of the drupa committee and the President & CEO of Messe Düsseldorf.

www.drupa.de.

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Unlocking Efficiency And Precision In Blown Film Production: The DRJ IBC Control System

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Unlocking Efficiency And Precision In Blown Film Production: The DRJ IBC Control System

Not All Internal Bubble Cooling Systems are Created Equal…

In the blown film extrusion industry, the Internal Bubble Cooling (IBC) system plays a pivotal role in line performance. Yet, not all IBC systems deliver on the crucial aspects of production rates, width tolerance, and bubble stability. To bridge this gap, D.R. Joseph offers the market’s best: a superior IBC system designed to transform operations regardless of line complexity or manufacturer.

Unmatched Performance for Every Line

The latest 3rd Generation IBC system from D.R. Joseph redefines excellence across the spectrum, enhancing production rates by 15

– 40% when integrated into blown film lines. It outshines competitors by offering an 8 – 15% boost in production, setting a new standard in rate and layflat tolerance improvements. This leap

is achieved through automated solutions driven by proprietary control algorithms and patented processes, built on from over 30 years of experience.

 

Automated Precision: Elevating Efficiency

What truly sets apart the DRJ IBC Control System is its comprehensive automation. It empowers operators, both novice and seasoned, to achieve peak performance effortlessly. This system handles the toughest tasks, allowing seamless adaptation to a wide array of materials, from HDPE to exotic variants, ranging from .3 mil to 100 mil.

Reliability Beyond Borders

Reliability is not just a promise; it’s embedded in the system’s DNA. Configurable to suit diverse environmental conditions globally, the DRJ IBC Control System thrives on flexibility and sturdy components, ensuring uninterrupted operations wherever it’s deployed.

Features Redefining Standards

The DRJ IBC Control System boasts an arsenal of patented features:

  • Automatic Blower Balance: Maintains airflow balance, detects leaks, and ensures consistent Standard Operating Procedures (SOP).
  • Automatic Layflat Control: Enables “set it and forget it” size changes, minimizing waste and optimizing material
  • Automatic Cage Control: Streamlines size changes and operational consistency, reducing scrap during transitions.
  • Automatic Valve Calibration: Ensures peak performance akin to brand‐new operations, expediting
  • Bubble Break Detection/Extruder Stop: Prevents downtime and damage by detecting and mitigating bubble breaks swiftly.

Meeting Sustainability Objectives

With precision IBC Control, resin savings and waste reduction are directly achievable, aligning with sustainability goals. In these instances, production typically generates a width larger than necessary, necessitating edge trim to meet the target width. However, integrating width control systems not only minimizes edge trim but also represents a profitable and measurable investment in sustainable production by curbing resin consumption.

The advantages of width control are multifaceted, notably reducing resin usage by eliminating or minimizing sheeting trim, automating width control during start‐ups and job change‐overs to slash waste production, averting order returns due to width deviations, and preventing die drool by enabling extruder‐stop when the system detects no bubble.

Post‐Consumer Recyclete (PCR) multiplies the challenge of keeping a consistent width and stable bubble due to contaminants, variation in quality and material composition. These inconsistencies add challenges to holding tight layflat. The high‐speed IBC control from D.R. Joseph addresses this significant challenge, making sustainable production with PCR a profitable option.

To learn more about D.R. Joseph IBC Control Systems, please visit: https://www.drjosephinc.com/internal‐bubble‐cooling/ 

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ZAHORANSKY at Fakuma 2023: Producing plastic syringes with screw threads cost-efficiently and safely Manufacturing luer-lock from plastic instead of glass – with the ZAHORANSKY Z.SONIC

ZAHORANSKY at Fakuma 2023: Producing plastic syringes with screw threads cost-efficiently and safely Manufacturing luer-lock from plastic instead of glass – with the ZAHORANSKY Z.SONIC

Even a good 150 years after their invention, the standardized luer connection systems for infusions and injections are still frequently made of glass. At Fakuma 2023 (Hall A2, Stand A2-2309), ZAHORANSKY will be exhibiting the associated Z.SONIC 16 luer-lock syringe injection mold from the PRIMA Z syringe production system, which can be used to manufacture luer-locks from plastic instead of glass. The advantages of the plastic versions are clear: plastic products are significantly more robust and easier to clean, both in handling and storage, compared to their glass counterparts. In addition, syringes made of plastic impress with their pH-neutral surface, a significantly lower heavy metal content, and greater freedom in product design. This results in increased shelf life for highly sensitive medications.

Safe and cost-effective manufacturing
The PRIMA Z production line makes it possible to produce plastic syringes with screw threads – the so-called Luer-Lock – extremely cost-efficiently and safely. Disposable needles, for example, can be screwed on easily afterwards and do not have to be injected during production. Syringes with volumes between 0.5 and 10 ml can be produced as standard, but special sizes of up to 50 ml are also possible. The material can also be varied: ZAHORANSKY injection molds easily process various technical polymers such as COC or COP. Based on customer-specific product designs, a cycle time of 15 to 17 seconds can be achieved on the production lines using the no-human-touch process. In the 16-cavity injection mold version, the Z.SONIC mold is thus capable of producing up to 3,840 parts per hour.

www.zahoransky.com

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Performance Review Institute (Pri) Launches Performance360 A New Customized Critical Manufacturing And Quality Management Service

Performance Review Institute (Pri) Launches Performance360  A New Customized Critical Manufacturing And Quality Management Service 

Performance360 is a new service from PRI for companies seeking to improve business performance by leveraging PRI knowledge, expertise, and technical resources.

Performance360 provides customized services to help organizations worldwide optimize their internal systems and manage their supply chain. It offers internal audits, supply chain audits, audit question development, training and personnel qualification needs assessment, and Non-Conformance Report (NCR) resolution. 

Bob Lizewski, Vice President of Performance360, said: “I am delighted to announce the launch of Performance360. This is an exciting development which will help companies meet specific performance and risk management objectives, while enabling them to probe deeper into their global supply chains.

“Performance360 has the most experienced auditors in the world, with an unrivalled knowledge and understanding of critical manufacturing processes, and quality management systems. We look forward to collaborating with companies worldwide to support and augment their existing capabilities, towards achieving business success.” 

Industries covered by Performance360 include, but are not limited to, aviation, defense and space; medical devices and pharmaceuticals; mobility and transportation; power generation and distribution; oil and gas, marine, and mining.

https://p-r-i.org/performance360/

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