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SABIC Demonstrates Its Expertise in the Building & Construction Market at K 2022 With Solutions for Enhanced Sustainability and Energy Efficiency

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SABIC Demonstrates Its Expertise in the Building & Construction Market at K 2022 With Solutions for Enhanced Sustainability and Energy Efficiency

SABIC Demonstrates Its Expertise in the Building & Construction Market at K 2022 With Solutions for Enhanced Sustainability and Energy Efficiency

SABIC, a global leader in the chemical industry, invites visitors of the company’s booth D42 in Hall 6 during K 2022 in Düsseldorf, Germany (October 19–26) to experience a comprehensive portfolio of high-performance polymer solutions for the building & construction (B&C) industry. An increased global population and growing urbanization has created a dramatically rising demand for more sustainable, resource and energy efficient material solutions.

To meet these megatrends, SABIC has developed a number of specialized thermoplastic resin and sheet products that will be featured at the show with a focus on four B&C market segments – energy solutions, pipe solutions, structural glazing and solid sheet. Highlights in this exhibition area, include all of the B&C sheet products offered by the company’s Functional Forms business, which can be ‘walked through’ by means of a large-screen Explorer providing a virtual building environment that showcases various different applications in greater detail. For pipe solutions, SABIC’s new BiAx pipe technology will be on display. This technology offers substantial improvements over incumbent polyolefin pipes across the entire range of performance criteria.

The vast array of lightweight, robust and energy-efficient material and application samples on display includes:

Energy solutions
Renewable energy sources are vital for the world’s transition towards a carbon-free landscape, and solar energy can yield high results to make the change real. To further drive down energy consumption within buildings, solar roof panels are an effective solution but often hindered by the fact that many industrial roofs are not strong enough to carry glass photovoltaic panels. SABIC’s material solutions can make a difference in this field:

Floating photovoltaic panels: SABIC PP Compounds used in floaters for solar panels combine good UV resistance and recyclability for modular, stackable injection-molded floaters that are lightweight and easy to transport. Potentially they can be made by using post-consumer recycled PP and certified circular and renewable grades from SABIC’s Trucircle portfolio. Another solution is SABIC HDPE material, designed for blow molded floating modules offer long-term outdoor performance. Read more.

Lightweight photovoltaic panels: Solar panels made by Solarge using SABIC PP compounds show more than 50% weight reduction over incumbent glass-based competitors and can achieve a carbon footprint reduction of more than 25%. They can be used for both new and retrofitting installations on roofs that cannot sustain the weight of PV glass panels over larger areas, they are fully recyclable and free of toxic components such as potentially hazardous per- or polyfluoroalkyl substances (PFAS). Read more.

Photovoltaic encapsulant film: SABIC Fortify (POE) elastomers used for encapsulant films in bi-facial high-power glass-glass PV panels combine outstanding stability at elevated temperatures and UV exposure with improved potential induced degradation (PID) performance compared to commonly used EVA (ethyl vinyl acetate) based encapsulants. PID performance of SABIC’s elastomers for encapsulants in PV panels help the power of the module over time, maintaining low leakage current, thus extended service life. Read more.

Pipe solutions
Growing population and urbanization is increasing the demand for safe and secure potable water, sanitation, fluid and other critical piping above ground or below. SABIC offers material solutions that are more sustainable by increasing the performance and lifetime of pipes used in infrastructure, industrial, domestic and agricultural market areas. Read more.

Domestic: SABIC polyolefins have a proven fit in domestic piping. Newly developed grades support the growing need for more reliable, safe and cost-effective pipe systems in clean water supply, waste water discharge, heating and cooling installations.

Industrial: Pipes at industrial sites are often exposed to high pressures as well as aggressive fluids or abrasive substances. SABIC offers a range of polymer solutions tailored to meet these demanding challenges.

Infrastructure: To aid in the supply and distribution of renewable energy from solar and wind farms, underground power lines are an attractive alternative to traditional overland lines. SABIC offers a custom solution for power cable ducts to help drive the change towards renewable energy. In addition, the company has developed a new biaxial pipe technology together with partners, offering up to 30% of material savings over incumbent polyolefin pipes and superior resistance to slow-crack growth, which facilitates cost-efficient trenchless installation across geographic landscapes.

Agri- and Aquaculture: Securing the efficient and reliable production of food across plantations, farms and large greenhouse operations requires modern irrigation systems, especially where crop water demand exceeds the average rainfall and precious fresh water resources must be preserved. SABIC HDPE materials enable the manufacture of long-lasting and dependable pipes and tapes used for pressure-and drip irrigation as well as for fish farm cages.

Structural glazing
Lexan solid and multiwall sheet solutions help architects, builders and contractors implement aesthetic, energy efficient, high-impact and cost-effective glazing concepts from urban infrastructure to stadium roofs. For roofs and skylights of high-rise buildings, strength, weight and transparency have long remained a challenge. Multiwall panels from SABIC’s Functional Forms business offer extremely lightweight and easy-to-handle solutions. The following product examples and many more are also included in the interactive virtual building Explorer at SABIC’s booth.

Solar control: Lexan Thermoclear Solar Control IR multiwall sheet delivers a unique combination of very high thermal insulation and solar control performance to enhance energy conservation, light transmission, aesthetics and comfort while providing high strength and stiffness and impact resistance. By allowing up to 90% of natural daylight to enter, the sheet also saves on electricity for artificial lighting.

Greenhouses: The broad portfolio of Lexan Thermoclear sheet for greenhouse glazing applications may help operators to achieve significant overall cost reductions, energy savings and improved yield of crops. Next to ease of installation, excellent thermal insulation and UV resistance, it is also available with proprietary Easy Clean and Dripgard coatings to reduce maintenance costs and prevent condensation damage of crops. Last but not least, Lexan Thermoclear sheet is also resistant to hail impact, which avoids the damaging of the greenhouse façade and roofing, resulting in lower insurance costs. Read more.

Façade claddings: Besides various Lexan Thermoclear sheet products for vertical building applications, Lexan Thermoclick sheet system was specifically developed to enable visually striking profile-free façade installations. The system consists of UV-protected multiwall sheet panels with a profiled tongue and groove connection for interlocking, which eliminates the need for additional vertical profiles. Read more.

Solid building sheet systems
The wide range of solid Lexan sheet solutions provides a superior choice over other thermoplastic and glass products available in the B&C market for protective glazing, cladding, partition walls, signage etc. The proven portfolio combines outstanding light transmission, UV resistance and impact strength with exceptional freedom of design for complex, curved and thermoformed shapes. All B&C solid sheet products from Functional Forms, including classical Lexan 9030, Lexan Exell D and Lexan Margardsheet, can be experienced in great detail using the interactive virtual applications Explorer at SABIC’s booth. Two more recently introduced new examples:

SABIC demonstrates its expertise in the building & construction market at K 2022 with solutions for enhanced sustainability and energy efficiency.

 

Outdoor protection: With proprietary coatings on both sides, novel Lexan Extrite sheet is a solid transparent material that provides the required abrasion, scratch and weathering resistance for a growing number of demanding outdoor applications, such as bus shelters, soundwalls and walkways. It has an expected lifetime of at least 30 years, comes with a 15 year written limited warranty and is 100% recyclable. Read more.

Hospital wall claddings: Opaque and low-gloss Lexan Cliniwall sheet is a unique new specialty product that was developed for cleanroom surfaces and interior wall claddings in public facilities and hospitals. It meets stringent European fire regulations for building materials, shows excellent chemical resistance e.g. to blood and urine stains as well as common hospital cleaners and disinfectants, and can be supplied in specific grades with anti-bacterial properties. Read more.

Visit SABIC during K 2022 from October 19 to 26 in Düsseldorf, Germany, in Hall 6, Booth D42 to learn more about these and other advanced building & construction solutions. The company’s experts will be available at the booth to discuss how SABIC’s materials portfolio and design services can help you accelerate your journey towards circularity and reduce the climate impact of your products. See also SABIC’s dedicated K website for B&C solutions.

 

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Clariant Launches New Additives at K 2022 to Support Plastics Sustainable Evolution

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Clariant Launches New Additives at K 2022 to Support Plastics Sustainable Evolution

Clariant Launches New Additives at K 2022 to Support Plastics Sustainable Evolution

  • Anti-scratch additive for PP & TPO formulations boost reuse potential of plastics used in consumer applications
  • Extend service life of agricultural mulch films with new light stabiliser solution
  • Novel bio-based lubrication and nucleation additive for polyesters in E&E and transportation sectors

K 2022 visitors can look forward to new Clariant additive solutions to progress more sustainable plastics and reduce resource use. New developments give applications greater resilience to support longer use and reuse on the path to circularity. Plus, solve production challenges while achieving better efficiency and lower carbon footprint during compounding and processing (Hall 8a Booth J11).

“By extending a product’s service life and by boosting reuse potential, the plastics industry can contribute positively towards reducing wasteful consumption, and increase circularity in key segments. Adopting ways to reduce material waste and energy use in production brings further sustainability advantages and improves product carbon footprint. With these new additives, including renewable-based solutions, in our portfolios, we’re excited to offer plastic processors and value chains more support to collaborate and further innovate together,” comments Martin John, Head of Advanced Surface Solutions at Clariant.

New anti-scratch additive to extend the service life of consumer goods
Surface aesthetics play a crucial role in the perceived quality of consumer goods. Clariant’s new renewable raw material-based anti-scratch additive for polypropylene (PP) and thermoplastic olefins (TPO) formulations – Licowax AS 100 TP – enables molded plastic goods across a wide range of consumer applications to maintain their original look and feel for longer. This offers significant potential to extend service life and improve properties’ retention and parts’ reuse.

The new additive helps to prevent scratches and mars on the surface of goods during handling, transportation, and end-use. This is particularly beneficial for otherwise scuff-prone applications such as interior automotive parts like dashboards and door panels, household appliance casings, cosmetics packaging, and lightweight luggage.

New light stabilizer supports more sustainable agricultural films
Mulch films perform an important role in optimizing crop growing conditions, by protecting both crops and soil from contamination and from the loss of moisture and nutrients that could jeopardize yields. New AddWorks AGC 970, Clariant’s latest light stabilizer solution for polyethylene agricultural films, offers the mulch segment a step up in product durability. Addition of the additive enables converters to extend the service life of their products, in particular by increasing UV resistance and resistance to high levels of agrochemicals. The granular additive can be dosed directly during conversion which supports more tailored use.

New bio-based wax for reduced cycle times & easier processing of injection molded polyester compounds
Benefit from a unique combination of lubrication and nucleation in engineering plastics for greater efficiency in compounding and processing. Compared to more conventional products, new bio-based Licocare RBW 560 TP Vita is able to withstand higher processing temperatures thanks to excellent thermal stability and low volatility, and works more effectively at low dosage. It also has outstanding color stability. The combined benefits make it particularly attractive to formulators of polyester compounds for use in the E&E or transportation industries.

The new additive promotes easier mold release which improves the surface quality. Productivity-wise, it also means fewer polyester parts get stuck in the mold and therefore less injection molding downtime. The risk of short shots and rejects is reduced too. It is possible to produce more parts per machine hour due to faster cycle times driven by shorter cooling cycles. As a result, energy consumption is reduced.

Licocare RBW 560 TP Vita is the latest extension to Clariant’s Licocare range of high-performing additives based on renewable, non-food-competing feedstock. They are derived from crude rice bran wax, a by-product from the production of rice bran oil. Vita designated products use real renewable content of at least 98% Renewable Carbon Index (RCI), thus offering the advantage of a lower carbon footprint compared to state-of-the-art alternatives.

Clariant has submitted an application for FDA food contact approval for its entire range of Licocare RBW additives. This will open up their use by plastics compounders and masterbatch producers in an even wider range of plastics applications.

Clariant’s additive products and solutions offer exciting opportunities for the plastics industry to strengthen the links between efficiency and sustainability, safety and performance, value and low carbon footprint. For more information on these featured new additives, as well as Clariant’s wider support to meet sustainability and circular economy challenges, meet the team at K 2022 Hall 8a Booth J11.

 

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Reifenhäuser Extrusion Systems and Maku AG Enter Into Strategic Partnership for Automation System in the Field of Slot Dies and Coextrusion Adapters

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Reifenhäuser Extrusion Systems and Maku AG Enter Into Strategic Partnership for Automation System in the Field of Slot Dies and Coextrusion Adapters

Reifenhäuser Extrusion Systems and Maku AG Enter Into Strategic Partnership for Automation System in the Field of Slot Dies and Coextrusion Adapters

Reifenhäuser Extrusion Systems (RES) – the Reifenhäuser Group’s business unit specializing in extrusion components – announces a strategic partnership with maku AG at K 2022, the world’s largest plastics trade fair. The aim of the cooperation is the joint marketing and further development of the automation system designed by maku for coextrusion adapters and slot dies.

The so-called PAM system (precise, autonomous, mechatronic) is available immediately and exclusively as an automation option for new Reifenhäuser dies and adapters, as well as for aftermarket dies across all manufacturers. PAM enables producers in the field of flat film and sheet production as well as extrusion coating to precisely control the entire hot part (coextrusion adapter and die) via the line’s control panel. This is significantly faster and more accurate than conventional control by hand or expansion bolt automation. It enables faster start-up of good production, higher output with lower energy consumption, and thus significantly improved overall equipment efficiency (OEE). The decisive advantage lies in the use of motorized manual adjustment bolts that replace conventional thermal expansion bolts. Reifenhäuser presented the system for the first time at the K 2022.

Uwe Gaedike, Managing Director of Reifenhäuser Extrusion Systems, explains, “The technology and experience of maku ideally completes our hot part competence. As RES, we manufacture extruder, coextrusion adapter and die completely in-house and thus know the entire extrusion process. With the automation option, we can now offer our customers a perfectly coordinated overall system that is second to none. Together with maku, we will establish the technology in the market and continuously develop it further. The special thing about this is that we also offer it as part of our refurbishment portfolio for all lines in the market.”

 

PAM coextrusion adapters automate the setting of the layer distribution.

 

Reto Maeder, Managing Director and Co-Owner of maku AG, adds, “We are very pleased to have found a strong partner in Reifenhäuser to now market our technology even more effectively globally. Together we will exploit the full potential of our cross-process know-how and create clear competitive advantages for our customers. This is nothing less than the best hot part competence combined with the highest possible level of automation in the market. At the same time, maku AG will continue its classic retrofit business on existing dies unchanged. Reifenhäuser’s worldwide service network puts us in a position to offer our system to even more customers outside
Europe.”

 

The decisive advantage of PAM dies lies in the use of motorized manual adjustment bolts that replace conventional thermal expansion bolts.

 

 

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Upcycling of Polyolefins With Innovative Stabilizers

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Upcycling of Polyolefins With Innovative Stabilizers

Upcycling of Polyolefins With Innovative Stabilizers

At K 2022, Brüggemann will present three new additives for improved stabilization of polyolefin recyclates. These additives result in recyclates with very good mechanical and processing properties, making the need for the addition of virgin material unnecessary. All Bruggolen R grades are supplied as dust-free additive blends in compacted granule form for easy and homogeneous distribution.

Two of the new stabilizers are intended for polypropylene recycling. Bruggolen TP-R2090 can be used to recycle post-industrial and post-consumer waste, whereas Bruggolen TP-R8895, through its increased acid scavenger content, is especially suitable for recycling polypropylene from battery cases. Both additives result in recyclates of quality that cannot be achieved via conventional re-stabilization.

For polyethylene recycling, Brüggemann has developed Bruggolen TP-R2162, which also contains the new repair technology and is particularly suitable for LLDPE recyclates used in film extrusion. Here, the repair mechanism results in film with increased initial mechanical strength and a significantly reduced number of defects. Laboratory tests, for example, show an increase of around 25% in tensile strength and 10% in elongation at break, even at minimal dosage levels of 0.3%.

These outstanding properties of the polyolefin recyclates are made possible by a specially developed technology. For the first time, it is possible to repair defects to the molecular chains that occur during processing and subsequent use and which impair quality. The recyclate is not only protected from further damage by re-stabilization, but, by repairing the polymer chains, the resultant mechanical strength more closely matches that of virgin polymer.

With the newly introduced Bruggolen R grades, Brüggemann complements its broad portfolio of additives for mechanical recycling of polyamides. These include long-term heat stabilizers, process stabilizers, flow improvers, reactive chain modifiers, nucleating agents and other process auxiliaries.

 

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Advanced Hardcoat Technologies for the Automotive Industry

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Advanced Hardcoat Technologies for the Automotive Industry

Advanced Hardcoat Technologies for the Automotive Industry

At K 2022 Momentive Performance Materials will be presenting the latest developments in Silfort hardcoat technology for use in demanding automotive exterior applications. Among other things, the precise and material-saving digital coating of three-dimensional moulded parts with the optimised inkjet technology can be experienced live at the trade fair. Other topics include easy-to-clean paint surfaces for sensor elements and protective coatings with improved sustainability.

Highly transparent Silfort Hardcoats from Momentive are high-performance siloxane resin-based scratch-resistant coatings that expand the range of uses for plastics in exterior and interior applications. Applied to surfaces in ultra-thin layers, they reliably protect against damage caused by UV radiation as well as mechanical and chemical stresses. As a result, their colour, gloss, light transmission and other physical properties are preserved over long periods of time. In many cases, plastic parts which are protected in this way, can replace conventional, heavier materials such as metals and glass and thus contribute to reduced CO 2 emissions.

Three-dimensional inkjet printing saves material

Together with FPT Robotik, Momentive has further developed the use of digital inkjet printing for such applications in a way that these requirements can be met and also combine ecological with economic advantages. With the correspondingly optimised process, only the single drop which is actually needed leaves the nozzle. This free-form digital printing process can be used over large areas and delivers high-quality results on component edges and on parts with complex shapes. At stand B15 in hall 6 visitors can experience live how the digital coating process is used. There, the print head is guided robotically over the component in a pilot booth and simulates how the scratch-resistant coating is applied to the contours of a three-dimensional polycarbonate component using drop-on-demand inkjet technology.

Momentive will also provide information on other new technologies, including easy-to-clean paint surfaces for sensor elements such as Lidar or cameras, as well as protective coatings with improved sustainability benefits. On the one hand, the focus is on shortening the application process for curing the coating systems to save energy and time. On the other hand, products with reduced solvent content will be presented.

Application-optimised portfolio

Momentive’s hardcoats are approved by and in use with the world’s leading automotive manufacturers. Silfort AS4700-SP1 is a protective clearcoat that gives automotive exteriors in clear and black polycarbonate high scratch, abrasion and weather resistance. This special coating was developed for the use of bell spraying on large parts with complex shapes and facilitates long-term cleaning of the surfaces. Silfort UVHC5000K1 is the latest generation of UV-curable, highly weather-resistant protective clearcoats for automotive exteriors and meets the most important global regulations for automotive headlamp applications.

The Silfort TAC2000 anti-fog coating, applied to the inside of headlamps and sensor covers, prevents condensation.

Silfort UVHC7400 is a highly scratch and chemical resistant UV-curable clearcoat for automotive interiors and displays. It is suitable for application with the new digital inkjet printing.

 

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A.J. Plast and Brückner Maschinenbau Contracted Another Highlight Project for a High-Speed BOPP line at K Show

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A.J. Plast and Brückner Maschinenbau Contracted Another Highlight Project for a High-Speed BOPP line at K Show

A.J. Plast and Brückner Maschinenbau Contracted Another Highlight Project for a High-Speed BOPP line at K Show

A.J. Plast, one of the leading film manufacturers in South-East Asia, and Brückner Maschinenbau have one of the longest partnerships in the BO industry. Their current joint project is already Brückner’s 15th film production line: a 5-layer, 10.4 metre wide BOPP line with a line speed of 600 metres per minute and an output of 7.5 tonnes per hour.

The project impresses with high production efficiency and takes an important step towards zero emissions, energy saving and carbon reduction. The technology used will not only drastically reduce energy consumption, but also reduce water consumption. The newly designed double air heat exchanger in the kiln process preheats fresh air and takes energy recycling to a new level.

A.J. Plast owner Kittiphat Suthisamphat says: “With our new line we increase productivity and reduce our energy consumption at the same time. That’s two of our major goals for our future film production focusing on environmental sustainability – and with Brückner at our side we will reach them.”

Xaver Sedlmeier, Sales Director at Brueckner Group Asia-Pacific: “We are very proud of this new project. In close cooperation we have designed a film stretching line that is completely tailored to the needs of A.J. Plast and the needs of the markets. It is always a pleasure to master challenging projects with the A.J. Plast team.”

Brückner Maschinenbau GmbH & Co. KG, the world market leader for film stretching equipment, is part of the Brückner Group in Siegsdorf, Upper Bavaria, a family-owned, medium-sized group of companies with a total of more than 2,900 employees at 21 locations. Other members of the group are the service provider for film stretching technology, Brückner Servtec GmbH, Kiefel GmbH, one of the leading manufacturers of machines for plastics processing, and the Swiss PackSys Global AG, a globally renowned manufacturer of state-of-the-art packaging machines.

 

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” All Machines Must Speak the Same Language”

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” All Machines Must Speak the Same Language”

” All Machines Must Speak the Same Language”

Interview with Thorsten Kühmann, Managing Director of VDMA Plastics and Rubber Machinery, at the K 2022

Mr. Kühmann, OPC UA, a global language of production is considered a prerequisite for machines to be able to communicate with each other across manufacturers. This topic is playing a major role at K. What can be seen here?
Here at the K, some 40 companies from eight countries are participating in an OPC UA demonstration project. To do so, they have selected a total of 85 machines at their respective hall locations. Each of these machines has an OPC UA logo and a QR code that visitors can scan with their smartphones. They are then taken to the UMATI internet platform, where they can see live data from the respective machine. For greater clarity, we have installed a large dashboard in the VDMA Dome where visitors can navigate each individual machine to see what defined data it provides. The most important factor is for all machines to speak the same language, and all use the same system. We have noticed that the interest of the visitors is quite considerable, as are the number of enquiries.

Does that mean that OPC UA is driving digitalisation in production?
Yes, in two respects: the direct benefit is the very fast creation of transparency. You know what data is present, and you can pick and choose which data is important. This transparency then enables a better control of processes. But the much greater benefit lies in the possibility of offering digital services in the future. To do this, you absolutely need a large amount of data from the field. At the moment, this is not yet available, because the entire infrastructure is not yet in place, but this is where the greatest potential lies. OPC UA is paving the way for this, so to speak.

How far have you advanced in the implementation of plastics and rubber machinery?
We have already come quite far in some core machine areas, such as injection moulding or extrusion. Now we are moving on to particle foaming, for example, and of course to the periphery. So, for example, this includes temperature control units and hot runner units, or liquid silicone metering. This is the horizontal level: the machines that are next to each other in a production hall can communicate with each other. Another strand is vertical networking to the MES system that centrally processes the data of a factory. And now the material flow is also included. At K, the new interface for Material Supply System will be presented: the OPC 40086-1. This is a so-called Release Candidate. That means it is conceptually ready but can still be supplemented and adapted, which signifies that we have already established a solid foundation for OPC UA in the area of plastics and rubber machinery.

What are the next steps?
We’re aiming to close the gaps. We still have machines that are not integrated. In addition, in spite the solid progress it has made, internationalisation must be pushed further. Because the whole thing only really makes sense when as many countries as possible are involved; only then can you really communicate across manufacturers. At the moment, we have reached the point where we can collect a lot of data. The next thing we need is a trustworthy platform to which this data can be delivered.

Don’t many companies shy away from sending their own production data off-site?
Processors in particular are still very cautious about OPC UA applications. They are worried that their data will not be handled carefully and that, in the worst case, their competitors may even gain access to their data. Part of the problem is that such data platforms have so far only been offered by individual companies or small consortia. Users obviously don’t trust them. That’s why we are heading in a completely different direction. We are trying to establish a trustworthy, neutral platform, and as the VDMA, we are therefore participating in the Manufacturing-X funding project launched by the German government, which aims to do just that. Once the framework of the platform has been set, i.e. once questions of governance, data security or even liability have been clarified, anyone can basically use this platform under these conditions. It is important that we establish such a platform, because otherwise we run the risk of big data providers taking over the whole thing, which is something no one in the industry wants, either on the customer side or on the machine manufacturing side.

To what extent will this benefit the circular economy project, once everything is well established?
First of all, through the rapid transparency, which makes it possible to better control machines and processes with the help of the collected data. This is important for the circular economy because it allows you to improve energy efficiency, for example. You can see exactly where and how much energy is being utilised within the entire system, allowing for a better grip on the energy cycle. In the case of the material cycle, the aim is to improve the processing of recycled materials in a manufacturing company, for example. This is more challenging than with virgin materials because recycled materials are sometimes less homogeneous. With the help of OPC UA and the associated exchange of information, the processing parameters of the machines and devices involved can be coordinated more precisely, and in a more targeted manner. These are important examples of optimised cycle management.

 

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Automation: The Answer to the Lack of Skilled Operators and High Staff Rotation

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Automation: The Answer to the Lack of Skilled Operators and High Staff Rotation

Automation: The Answer to the Lack of Skilled Operators and High Staff Rotation

Automating the end-of-line and reel handling provides benefits, which include doubling production, reducing salary costs, and savings energy consumption

The lack of skilled operators and high staff rotation are two principal headaches for factory managers, which in recent years have been exacerbated by two new problems. On one hand, the increase in the number of jobs offered by service companies has led to a decrease in the number of people willing to work at the factory. On the other hand, Covid-19 has led to a higher food packaging demand, while simultaneously creating staffing problems, due to pandemic casualties and the danger of having direct contact with products.

Automation is the solution to all these challenges. It makes the difference in reference to costs, production, quality of the final product and energy efficiency. Furthermore, as a result of automation, workers do not have to touch the products, as the whole process is automatic. Converters require slitters that are able to simultaneously, manage exceedingly complicated jobs and maintain the highest OEE possible. Changeover is critical. An uncomplicated cantilevered machine is operable only 30% of the time. With the use of presently available added value solutions, such as double turret rewinders, automatic knife positioning, automatic core positioning or automatic taping, this ratio is up to 70% higher. Moreover, a higher percentage is possible if each step occurring after slitting, such as labelling, wrapping, or palletizing using robots connected to the slitters, is automated.

In regard to the primary production plant benefits, the effects of end-of-line and reel handling automation are less dependent on operator experience, as a new operator is able to achieve optimum results within a short period of time. The results include the following: the automated machine simplifies complex processes; increased high quality productivity (owing to automated processes avoid human error and increases productivity); improved labour management (due to reductions of the required workforce, labour costs, and sick leave); sustainability (as a result of automated processes optimizing energy consumption and reducing material waste in eachprocess, thus creating more sustainable solutions and a lowering production carbon footprint); and return of investment in less than one year (due to high productivity as well as immense savings in energy and salary costs).

Comexi is constantly innovating. Presently, the company offers solutions that are more autonomous and effective: Closing Loop automatically reads and corrects the grammage to be applied in the laminating process; GeniusPrint has maximum print setting accuracy at the touch of a button; Automatic Pre-set Positioning is a full setting for slitting machines with maximum time savings and minimum material waste; Automatic Video Inspection is a camera-operated video inspection system to ensure maximum quality with a full-speed operating machine; and the Comexi End of Line Reel Handling that implies less workforce for similar jobs and reduces energy consumption.

 

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Comexi Laser: Key Technology to That Makes a Difference and Optimizes Production

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Comexi Laser: Key Technology to That Makes a Difference and Optimizes Production

Comexi Laser: Key Technology to That Makes a Difference and Optimizes Production

Control, precision, and speed define this tool which customizes, differentiates, and performs a wide gamma of applications and finishings

Comexi, a specialist in solutions for the flexible packaging printing and converting industry, has consistently been a forerunner of converting equipment manufacturers due to the company’s global vision of the entire printing and converting process. Furthermore, since 1954, the company has acquired deep market knowledge and expertise. With the objective to remain at the forefront of converter demands, Comexi has not only identified future trends and needs, but has also begun the development of solutions that will greatly assist converting companies for years to come.

Comexi Laser is the integrated solution that differentiates, the revolution of the flexible packaging industry. This innovative tool customizes, differentiates, and simultaneously, performs a wide gamma of applications and finishings that include: micro perforations, macro perforations, design windows, pre-cut adhesive labels,alpha numeric codes, bar codes, security systems, and easy open applications. All of this is possible with only one piece of single equipment, the Comexi Laser.

Packers have long incorporated lasers into their machines, only to discover that subsequent to their use, packer efficiency is reduced. For this reason, eliminating this step in the process is preferred, and allowing converters to work with lasers, which has led to an increase in the demand for these types of solutions.

The Comexi laser system includes several patents, which includes: one for tension control and another for doubled-sided lasering without a turning bar. The tension control patent ensures material flatness throughout all the entire scoring process, which is mandatory if one layer material penetration is required while maintaining an intact barrier layer. The double-sided lasering patent permits lasering on both sides of the material within the same pass without the use of a turning bar, which would drastically reduce the performance of the machine.

Comexi’s Removable Label Solution

Converters want to have a removable label solution for single-dose or fast-food products such as snacks or chocolates. Their objective is to be able to eliminate the zipper, which offers long-term benefits, but also has a high cost and more complex manufacturing process. Furthermore, receiving packaging that includes resealable features is the intention of converters.

The current common process for manufacturing resealable packaging includes a label inserter and a die cutting machine. Packaging has a process that begins with the placement of the label, followed by die cutting of the desired shape. This process is extremely inefficient, as die cutting machines are predominantly limited, in regard to width, due to the die cutting roller bending during usage with larger widths. Consequently, the performance of the entire converting line is low; the addition of a label and die cut is a process performed after slitting. This additional step and process increases packaging costs. Furthermore, die cutting rollers must be changed for each application, thus the required flexibility for promotions is extremely limited. The die cutting process is unable to precisely control the depth of the cut, thus consistently destroying the barrier (there is a high risk of damaging the label if the cut depth is not controlled).

Nevertheless, the laser + in-line labelling + slitting system, in which Comexi excels, offers several advantages, including: extreme precision (regardless of material thickness, thus allowing for the penetration of only the necessary packaging layers, and ensuring that the packaging barriers remain closed until opened by the end customer); the use of an embedded laser system software that alters the design shape within minutes (requires no die cutting matrixes, and offers the possibility of using multiple laser heads in order to simultaneously score every up on the web, thus drastically increasing the productivity).

Presently, with the use of Comexi laser systems, a completely new level of high added value applications can be achieved, thus exponentially increasing the usability of flexible packaging

 

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Offset Printing: the Best Choice for Sustainability and Recyclability

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Offset Printing: the Best Choice for Sustainability and Recyclability

Offset Printing: the Best Choice for Sustainability and Recyclability

Comexi continuously distinguishes itself by searching for more innovative sustainable flexible packaging solutions with a lower carbon footprint

Comexi, a specialist in solutions for the flexible packaging printing and converting industry, has made the most transparent commitment to sustainability and Recycling. Repeatedly, the company has distinguished itself by searching for more innovative sustainable flexible packaging solutions with a lower carbon footprint. These include efficient energy management, less material loss, lower ink consumption, as well as plastic usage and solvent reductions. The objective of Comexi is to provide technology that not only makes processes substantially more sustainable, but is also operable with sustainable materials. Comexi believes in solutions that combines automation, high quality, fast changeovers, and flexibility.

As a result, the CI offset printing technology has become the unrivalled option for sustainability and recyclability. This is a solvent free technology, uses curing EB inks and coatings, has no solvent emissions, consumes less ink and less energy, prints a wide range of substrates (including extremely thin films), and facilitates the transition from the traditional laminated and multimaterial structures to monomaterial structures (both laminated, and frontal printed with overprint varnishes).

EB curing provides the optimal solution for recyclable packaging, as it replace several complex laminations with more recyclable and efficient solutions by reducing the number of layers (EB inks and coatings are highly resistant to chemicals, sealing, heating, and scratch). During PE reverse printing, the partial crosslink process increases the thermal resistance of the external packaging layer. In regard to surface printing, the EB coating provides high surface protection.

The Comexi CI offset printing technology perfectly meets the stringent needs for rapid, high-quality printing, while offering the most competitive operating costs

 

Principal Benefits of CI Offset Technology

• Sustainability
Equipped with solvent free technology: curing Electron Beam (EB) inks and coatings. It not only consumes less ink and energy, but is also capable of printing a wide range of substrates, including the thinnest films.

• High Quality Printing
Has the most prominent definition, prints, and high-quality pictures with smooth fading feature. It is the best option for extended gamut processes.

• Fast Time to Market
Has pre-press designs that can be automatically converted. Plates are CTP imaged within a few minutes, and a complete set can be made in less than 20 minutes.

• Competitive Costs
Operates with lithographic plates. New designs can be inexpensively incorporated. It is possible to group designs and print multiple SKU in the same run, thus saving time and waste.

• High Efficiency
Ability to print a wide width at an accelerated speed and is equipped with robotic change of sleeves, thus providing maximum productivity and fast changeover.

 

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