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Borealis and Borouge to present fully recyclable monomaterial pouch solutions at K 2022

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Borealis and Borouge to present fully recyclable monomaterial pouch solutions at K 2022

Borealis and Borouge to present fully recyclable monomaterial pouch solutions at K 2022

  • Combining optimum performance on packaging lines with excellent in-use properties, consumer appeal and circularity
  • The solutions developed with value chain partners enhance properties and recyclability
  • Partnership is embodiment of the Borealis EverMinds spirit of taking action to accelerate the move towards plastics circularity

Borealis and Borouge PLC (“Borouge” or “the Company”) (ADX symbol: BOROUGE/ ISIN: AEE01072B225), leading providers of innovative, value-creating plastics solutions, have announced the launch of three all-polyethylene (PE) pouch concepts developed in extensive collaboration with technology partners across the entire value chain to meet the most demanding challenges in flexible consumer packaging.

As many brand owners have pledged to make 100% of their packaging reusable, recyclable or compostable by 2025, there is a growing demand for more sustainable monomaterial film solutions capable of replacing incumbent, nonrecyclable multi-material structures without compromising processability and packaging performance. In line with the Global Commitment initiated by the Ellen McArthur Foundation, the vision of a circular plastics economy also requires major advances in using recycled and/or renewable feedstock to minimise fossil depletion and plastic waste.
The three designs will be on display at K 2022 in October and address the need for significant improvements in monomaterial barrier packaging, carbon footprint reduction and design for recycling (DfR). They closely align with the EverMinds approach for joint projects with committed value chain players to accelerate the transition of the plastics packaging industry from a linear to a circular economy.

New solutions with proven products 

Key challenges identified by Borealis and Borouge for a new generation of fully recyclable monomaterial pouch solutions included reliable sealability, mechanical properties, thermal stability as well as different levels of barrier performance depending on end use. Addressing the needs of various different applications, three monomaterial concepts were developed that share the same proven DfR product platform:

1. Laminated PE pouch for gas barrier packaging of oxygen sensitive products including modified atmosphere packaging, such as nuts or cheese.
2. High-barrier PE laminate pouch for packaging of moisture sensitive food products, such as crisps, biscuits and confectionary.
3. New PE pouch with 35% Ecoplast low density polyethylene (LDPE) low-gel post-consumer recycled (PCR) for non-food applications, such as detergent powder.

In all three PE monomaterial pouch solutions, BorShape and Borstar provide the required mechanical and thermal stability performances, while Anteo and AnbiqTM combined with Queo deliver outstanding sealing performances.

The full PE monomaterial approach eliminates the use of non-recyclable multimaterial solutions. At the same time, it supports the aesthetic consumer appeal (look and feel) of the pouches as well as their end-of-life mechanical recycling in existing flexible PE waste streams.

Enhanced sustainability through partner technologies

The concepts were thoroughly validated and their sustainability was further optimised together with leading industry partners. Hosokawa Alpine provided MDO (machine direction orientation) PE film extrusion line and technology, and multiple trials were run with various different pouch formats on GEA packaging equipment. Mechanical recyclability was optimised by using a solvent-free lamination adhesive from Henkel and digital watermarking technology from Digimarc. The HolyGrail 2.0 compatible digital watermark can be read using smartphones or scanners, which facilitates packaging waste sorting but does not interfere with pouch print appearance. For very sensitive goods requiring robust protection with higher moisture and gas barriers, vacuum metallisation technology from Metlux offers a cost-efficient process without compromising the mechanical recyclability of the pouches.

“We firmly believe that we can accelerate circularity only by collaborating with competent partners across the value chain to jointly re-invent essentials for sustainable living,” summarises Peter Voortmans, Global Commercial Director Consumer Products at Borealis. “The results of this major joint initiative have demonstrated the feasibility of full PE monomaterial pouch solutions for demanding packaging applications that will help our customers drive and implement their sustainability targets as they strive for carbon neutrality.”

“Borouge is committed to providing innovative solutions to advance circularity and help address global challenges. We are excited to collaborate with partners from across the value chain to develop the right solutions for our customers without compromising on the performance and productivity required for advanced packaging applications,” said Mr Youssef Taha, Senior Vice President, Marketing & Innovation, Borouge.

Physical promotional samples of the new full PE pouch concepts can be requested for evaluation, supported by full technical documentation and extensive test results of performance on various packaging lines.

K 2022 will take place from 19 to 26 October 2022 in Düsseldorf, Germany.

We invite you to “Innovate Collaborate Accelerate” together with us by visiting Borealis and Borouge in Hall 6 at Stand A43, where the new monomaterial pouch solutions will be on display.

 

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Oerlikon HRSflow Hot Runner Systems in Action: Live Molding Demo at K2022

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Oerlikon HRSflow Hot Runner Systems in Action: Live Molding Demo at K2022

Oerlikon HRSflow Hot Runner Systems in Action: Live Molding Demo at K2022

Intricate applications of Oerlikon HRSflow hot runner systems produced in cooperation with project partners in the fields of polymer materials, mold making and machine manufacturing, will be presented at the upcoming K Show. The live molding demonstrations will be available at the partners’ booths.

Thin-walled 150ml IML Yogurt cup: the evolution towards a fully recyclable packaging

At Netstal booth (Hall 15, Booth D24), the ELIOS 4500 Injection Molding Machine will produce a thin-walled 150ml IML yogurt cup (6.4 g) from a certified renewable PP polymer by Sabic , highlighting the importance of human and environmental health. The material is based on tall oil, a waste product from paper production. The powerful and energy efficient Netstal injection molding machine compensates for the slightly thicker label in the injection molding process with a correspondingly thinner wall thickness of the cup. Wall thickness of the 5.4 g cup without label measures only 0.32 mm. This high-performance application runs with a fast 3.9 s cycle time.

The new Xp nozzle Series from Oerlikon HRSflow, specifically engineered for thin wall packaging, ensures a reliable process and an increased productivity at the lowest cost per unit. The result is a low thickness component (0.4 mm) injected with ambitious cycle times and decorated with a new generation label: the NextCycle IML™ from MCC Verstraete. The NextCycle IML labels allow that a fully decorated PP IML package can be recycled without any impact of the label on the RPP material. These labels will also feature digital watermarks from the Holy Grail 2.0 initiative. The project was developed in cooperation with Netstal, IML Solutions, MCC Verstraete, Sabic, Oerlikon HRSflow.

Eco-friendly fruit box: maximum precision combined with sustainability

Haitian (Hall 15, Booth A57) will showcase the injection molding of an eco-friendly fruit box which marks a key step in Oerlikon HRSflow’s approach to Circular Economy. The selected hot runner configuration is specifically designed to process APS PE compound with recycled Tetra Pak carton package Alu Foil. The 4 drop Flexflow servo-driven valve gate system, running on a Haitian Jupiter Series (JU4500III), ensures the production of a flawless part with the complete filling of all the ribs and walls and a high process repeatability. For an optimal gate vestige quality, Oerlikon HRSflow’s new patent pending TTC cooling bushing avoids pin’s sticking issues even with fast cycle times. Project partners are Haitian, Mundimold, Tetra Pak , APS, Oerlikon HRSflow.

Sustainable tool case: complex shapes made masterfully

Arburg will present at its stand (A13, hall 13) the injection molding of a complex tool case requiring the use of 4 hot runner systems from Oerlikon HRSflow. For the manufacturing of the two covers from a PC/ABS blend in a family mold, a 2 drops screwed-in system are used. Moreover a 3D Design Film is overmolded on the covers. Particular attention will be also given to the inner tray, the handle as well as the lateral latches made of Pet Recopound by KURZ. The result is a stable and robust end product with illimited possibilities of decorations. Project partners are Arburg, Hofmann, Leonhard Kurz, Oerlikon HRSflow.

2K Rear-Panel: futuristic smart automotive surfaces

ENGEL (Hall 15, Booth C58) will present the injection molding of a smart 2K rear panel composed by a PC+ABS frame overmolded with PMMA or alternative PC. During the first injection phase a hydraulic 2 drops system from Oerlikon HRSflow will be used while for the second one a Single nozzle from Ga Series will be employed. The part will be finally decorated with a capacitive and aesthetic film directly in the mold for an innovative result. To implement such complex requirements, exact rheological analysis calculations were necessary. Project partners: ENGEL, Schöfer, Leonhard Kurz, Röhm, Oerlikon HRSflow.

3 component coffee-to-go cup: hot runner solutions for 100% recyclable parts

At Booth C06, Hall 15, Wittmann Battenfeld will show the manufacturing of a 3-component coffee-to-go cup with a lid. The rotational mold with 3 separate injection units is equipped with three different single nozzle systems by Oerlikon HRSflow optimized to process the 100% recyclable PP Bornewables™ (non-petroleum-based feedstock) from Borealis.The Bornewables™ – made of renewable raw materials derived from waste and residue streams – perfectly meet the functional requirements of the molded part without compromise in terms of quality and sustainability standards. The cup, with a thickness of 2 mm, is produced in clear optic in the first cavity and over-molded in the second cavity with an insulated shell. The insulating effect is obtained by foaming the melt through the special Cellmould technology which enables the production of lightweight, rigid parts without sink marks. Project partners are Wittmann Battenfeld, Haidlmair, Borealis and Oerlikon HRSflow.

Garden tool: 2K irrigation connector

Additionally at K show, Oerlikon HRSflow will showcase at Billion’s booth (Hall 15, Booth B24) the injection molding of a garden tool, specifically an irrigation connector. The part will be produced through a 2K tool equipped with two different hot runner systems with one nozzle. During the first phase, a face-to-face torpedo system is used to inject styrenic compounds (ASA polymer), while for the second phase, a screwed-in cylindrical valve gate system is employed to inject elastomer compounds (SEBS). During the second phase, the molded part can be easily customized thanks to the marking operations directly embedded in the tool cycle process. Among the special features the automatic and quick change of the mold version enabling the production of the three different components – in this case the coupling diameters – without disassembling the tool or stopping the manufacturing activities. Project partners are Billion, Groupe Pernoud, Actemium, Sepro Group, Resinex, Lifocolor and DeViris, Oerlikon HRSflow.

High Gloss B Pillar: accurate injection, perfect appearance

The Injection Molding Machine manufacturer Tederic (Hall 15 Booth D40) will showcase the production of a high gloss B pillar. The molded part is obtained through a 2K hot runner system developed by Oerlikon HRSflow. The hot runner solution enables the perfect appearance of the component thanks to a gentle, low-stress injection. During first phase a 2 drops conical valve gate hydraulic system combined with ICM Technology are used to inject PMMA polymer, while for the second one (ABS material) a 6 drops system is developed. The project was conceived in cooperation with Tederic, Yuyao Skymold, Piovan and Technotrans Solutions GmbH, Oerlikon HRSflow.

 

 

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Constantia Teich Celebrates 110 Years

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Constantia Teich Celebrates 110 Years

Constantia Teich Celebrates 110 Years

2,000 guests celebrated the 110th anniversary of Constantia Teich on Saturday, October 1, 2022, in Weinburg, Pielachtal. At the open house, the company looked back on its history and gave visitors a glimpse behind the scenes of the flexible packaging manufacturer.

Where once the brothers Richard and Ernest Teich laid the foundation for today’s Constantia Flexibles Group, there was a festivity over the weekend. “It was a successful celebration with guests from the surrounding area and our employees and their families,” says Dr. Gerald Hummer, Managing Director of Constantia Teich. The production halls, where then as today foil is rolled and prepared for further processing in the industry, were open to 2,000 guests on Saturday. On the tracks of the aluminum raw material, it was possible to follow how the packaging for cat and dog food, coffee capsules, yogurt lids, chocolate, and pharmaceutical products are produced. Nearly 70,000 tons of aluminum foil are rolled yearly at the Weinburg site near St. Pölten. “You could wrap Vienna twice with that amount,” says Gerald Hummer.

Clear number 1: an employer with greatness

Constantia Teich operates the largest foil rolling mill in Austria. “We produce primary packaging, i.e., packaging that comes directly into contact with the food or pharmaceutical product,” explains Gerald Hummer and continues, “the rolling mill is used to roll one billion square meters of aluminum foil every year.” This makes the company the world’s number one in the production of yogurt lids. And within the Constantia Flexibles Group, Constantia Teich is also among the largest plant supplying materials to its sister companies. However, the company does not limit itself to rolling aluminum. ” We cover the entire value creation chain for internal production of flexible packaging materials – from the rolling and printing to final production,” summarizes Gerald Hummer. Around 1,000 employees work in production, administration, and the company’s own research and development center. Constantia Teich is one of the largest employers in the Pielach Valley. “We are a global player with a local presence. Our most valuable asset is our employees!” says Hummer proudly about the workforce. “Great loyalty of the employees towards the company, excellent training of the apprentices as well as the high level of know-how, are among our strengths and makes us a reliable producer and supplier, even in times of crisis. All this makes Constantia Teich a solid employer in the region,” continues Dr. Gerald Hummer.

Outlook on the future

“An anniversary like this is not something you celebrate every day. Our employees are primarily responsible for our success. Without them, Constantia Teich would not be what it is today: an important international company. A big thank you and congratulations on the anniversary to the entire team,” honors Pim Vervaat, CEO of Constantia Flexibles the valuable work of the workforce. To ensure the company remains successful, investments are being made. 34 million euros will be invested in a new coating and laminating machine, including an extension, as individual markets, such as the coffee market, are growing strongly.

 

 

 

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Solvay Launches Solvalite Surfacing Film for Automotive Body Panels at CAMX 2022

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Solvay Launches Solvalite Surfacing Film for Automotive Body Panels at CAMX 2022

Solvay Launches Solvalite Surfacing Film for Automotive Body Panels at CAMX 2022

Fast cure and impeccable flatness for large Class A painted surfaces,compatible with advanced prepregs for high-volume applications

Solvay has announced the launch of SolvaLite SF200 surfacing film, a light tack film for ‘Class A’ paintable body panels. The new product will officially be introduced to the market at the Composite and Advanced Materials Expo (CAMX) in Anaheim, California, where Solvay will be exhibiting its comprehensive composites offering from October 17 through 20, 2022, at Booth W56. “With a curing time of less than 10 minutes at 150 °C, our new SolvaLite

SF200 Surfacing Film lends prepreg layups for high-class automotive body panels a very smooth cured surface where impeccable flatness is an indispensable prerequisite for painting,” says Dan Eskelsen, Head of Product and Asset Management Adhesives at Solvay’s Composites business unit. “The product is based on our latest fast-cure technology and compatible with autoclave curing. It combines a longer outlife than previous surface films with good adhesion to automotive paints and primers, and minimizes the required rework prior to painting.” Moreover, SolvaLite

SF200 provides a one-stop solution for OEMs and tier suppliers who wish to receive a perfectly matched prepreg and surface film package from a single source. The new surfacing film is targeted at large body panels used on premium sports and other luxury class vehicles. It complements Solvay’s new series of SolvaLite 714 Prepregs available in a wide range of unidirectional carbon fiber reinforced and woven-fabric formats for automotive and other high-volume press-cure applications.

 

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SML’s Presents Its PowerCast XL Stretch Film Line With a Patented, Brand-New Triple Turret Winder on K 2022

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SML’s Presents Its PowerCast XL Stretch Film Line With a Patented, Brand-New Triple Turret Winder on K 2022

SML’s Presents Its PowerCast XL Stretch Film Line With a Patented, Brand-New Triple Turret Winder on K 2022

SML comes with a world debut in stretch film manufacturing to K2022: A patented triple turret winder for the PowerCast XL stretch film line. The W4000-4S-3T is the first winder in the market for manufacturing 2” stretch film hand rolls on a 4.5 m wide line. SML’s new “three-turrets-in-one-frame” concept enables significantly higher production speeds for maximum output quantities – especially at the lighter 2” rolls.

“The PowerCast XL with the new turret winder W4000-4S-3T has yet to meet its match. The possibility to manufacture also 2” rolls on that 4.5 m wide increases the product diversity and productivity of our PowerCast stretch film line significantly,” says SML Product Manager Thomas Rauscher. Until now, it was only possible to
run 2” hand rolls on lines up to 3 m width, thus the new development boosts the output of hand rolls by about 50 %. As before, 3” hand rolls, machine rolls and jumbo rolls an also be manufactured, with ease, with this new solution.

Brand-new and patented winding technology

“The trigger to develop a new winding system for 2” hand rolls for our 4.5 m wide PowerCast XL line came right from our customers. As a starting-point for our development works we took the proven double turret winder W4000-4S”, Thomas Rauscher explains. The technical basis of the new winder W4000-4S-3T is the patented
‘three turrets-in-one-frame concept’. Compared to other winders for wider lines, the three winding shafts with 1.5 m each are relatively short. This guarantees very stable production processes and allows significantly higher production speeds, especially at hand rolls.

Resource-saving winding technology

The new turret winder W4000-4S-3T can be equipped with a range of cutting-edge winding technologies for stretch film production:

Thin Core Technology: This well-proven concept allows to run thinner and therefore lighter paper cores on specific winding shafts. A reduction of the core weight of approx. 50 % minimises the raw-material consumption in the core production – and with it the CO2 emissions in the same way.

Coreless Winding: Even better than winding on thinner paper cores, is to use no cores at all. SML’s Coreless Technology was developed for the coreless production of hand and machine rolls. Beside considerable sustainability effects, this winding method has also a significant impact on production costs.

Modified Edges: ME is a patented SML technology to reinforce the edges of stretch film, making them nearly indestructible. The whole process is very efficient as it completely takes place in-line. Higher residual stretchability and puncture resistance are the key-characteristics of stretch film with modified edges.

Designed for SML PowerCast XL

The 4.5 m wide PowerCast XL in combination with the winder W4000-4S-3T is the latest step forward in SML’s PowerCast series, successfully uniting maximum output volumes of up to 3.400 kg/h net with highest flexibility in production. Like all stretch film lines from SML, the PowerCast XL is able to process up to 80 percent post-consumer recyclate, i.e. from LLDPE/LPDE.

Observing machine values at K 2022

Moreover, the machine features BitWise, SML’s in-house developed user-friendly data monitoring and analysing solution, that is open to the OPC-UA standard. Visitors who have downloaded the Umati web app and scanned the QR code displayed on the machine, have the opportunity to observe some real-time production values of
the PowerCast XL.

 

Technical features of PowerCast XL + W4000-4S3T:

  • Output up to 3,400 kg/h net
  • Compact design – 240 m² floor space
  • Ø 1,600 mm chill roll – the biggest in this sector
  • 7 or 67 layers
  • Ready to manufacture PIR and PCR
  • Maximum flexibility: 2” hand rolls 3” hand rolls, machine rolls and jumbo rolls
  • ThinCore technology
  • Coreless technology
  • Modified Edges

 

 

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New LSR Grades for Alternative Drive Concepts and Low Curing Temperatures

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New LSR Grades for Alternative Drive Concepts and Low Curing Temperatures

New LSR Grades for Alternative Drive Concepts and Low Curing Temperatures

At K 2022 Momentive Performance Materials will present the newly developed product family of Nevsil LSR and HCR silicone rubbers, which is geared towards the requirements of modern mobility concepts, i. e. New Energy Vehicles. The new generation of LTC-LSRs from Momentive, which cure at particularly low temperatures, is especially suitable for thick-walled parts and combinations with temperature-sensitive materials.

Nevsil for alternative vehicle drive systems

Momentive’s new LSR and HCR-based Nevsil product family is suitable for a wide range of sealing applications in vehicles powered by alternative energies, including e-mobility, hybrid concepts and fuel cell technology. In addition to a generally low compression set, their wide range of grades includes high temperature resistance as well as flame retardancy, self-lubricating, low viscosity, low stiffness, fast curing, increased crack and ageing resistance, good colourability, and thermal conductivity.

The flame retardant Nevsil FR LSR and HCR grades with Shore A hardnesses ranging from 35 to 70 meet the requirements according to UL94 V-0 for 1 mm thickness with balanced mechanical properties and very good heat resistance. Typical applications include connectors and heat ageing resistant moulded components such as gaskets, O-rings, etc.

Included in the Nevsil FR portfolio are two Nevsil SLFR grades, offering both UL94 V-0 flame retardant properties (1mm) coupled with self-lubricating functionality. Both grades are peroxide cured HCR grades offering balanced physical properties in addition to high heat and temperature resistant characteristics.

Resistance to high heat is the outstanding property of the Nevsil HTHR HCR compounds, with Shore A hardnesses ranging from 30 to 80. Properly catalysed, these products qualified to the demanding SAE/USCAR-2 temperature classification T5 (-40 °C to +175 °C at 1008 h) are suitable for demanding environments with long-term exposure to temperatures up to 300 °C. They combine very good mechanical properties with good miscibility, creating a series which is easily blendable to achieve varied hardness levels. Typical applications are O-rings, seals, gaskets, and other moulded parts for high temperature applications.

 

Sealing of bipolar plates in fuel cells is the typical application of the new LSR Nevsil FC140.

 

In addition, the Nevsil portfolio offers thermally conductive silicone technologies in both LSR and HCR offerings. Nevsil TC LSR grades provide hardnesses in both 30 and 60 Shore A, while the HCR version provides a thermally conductive solution in a 60 Shore A durometer. Additional capabilities include Momentive’s ability to custom tailor the thermal conductivity to meet demanding application needs while optimizing the thermal management properties. All grades are easy to process with high reactivity and exhibit low compression set even at low temperatures. Typical applications here are heat dissipating pads and gaskets as well as battery seals.

Dedicated to sealing bipolar plates (BPP) and membrane electrode assemblies (MEA) in fuel cells is Momentive’s new translucent LSR grade Nevsil FC140. Its low viscosity enables a lower injection pressure, critical when overmolding sensitive substrates. In combination with the company’s XP81-A6361 primer technology, the material offers good adhesion properties to both stainless steel and graphite. With its fast cure and low compression set properties without post curing, Nevsil FC140 offers significant advantages over RTV products used in similar applications.

LTC-LSR: Halved curing time at low curing temperature

Momentive’s LTC-LSR (Low Temperature Cure) grades cure at particularly low temperatures, enabling shorter curing times for thicker-walled articles, for example for applications in e-mobility and general high-voltage technology. At the same time, the lower processing temperature allows energy savings in mould heating. For two-component parts, LTC-LSR can also be used to produce material combinations that would not be economical to manufacture with conventional curing LSR due to the low temperature resistance of the material to be overmoulded.

By optimising the reactivity, Momentive was able to realise these diverse advantages with curing times that are acceptable in practice and was already able to demonstrate this at Fakuma 2021 with the LTC type LSR 5650. An even further, productivity-increasing reduction in curing times at low curing temperatures has now been achieved with the development of the LTC generation LSR-K2022. Thanks to further increased reactivity at temperatures between 90 °C and 130 °C, this cures 30% to 50% faster than the previous version. The pot life is more than a week, whereas for conventional curing systems with similarly high reactivity it is less than 24 hours. This means that the efficiency of processing into high-quality moulded parts is significantly higher, not only due to the higher reactivity, but also due to a lower curing in the conveyor system.

 

At a cross-linking temperature of 90 °C, the LTC-LSR grade from Momentive presented at K 2022 achieves a curing density of 60 % after only half the time required by the predecessor LTC grade LSR 5650.

 

 

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Archroma Launches Appretan NTR Barrier Solutions for Food Packaging Based on a Renewable Natural Ingredient Component

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Archroma Launches Appretan NTR Barrier Solutions for Food Packaging Based on a Renewable Natural Ingredient Component

Archroma Launches Appretan NTR Barrier Solutions for Food Packaging Based on a Renewable Natural Ingredient Component

Archroma, a global leader in specialty chemicals towards sustainable solutions, today announced that its ground-breaking Appretan NTR range based on 30% renewable raw material can now be applied to impart barrier properties to selected types of food packaging.

Consumers are increasingly frowning upon being served their favorite street foods or fast foods in polystyrene or plastic based boxes and wrappings. Paper-based packaging can offer a much more sustainable alternative if they are not lined with a plastic film which can make them unsuitable for recycling and composting. The solution is to carefully select paper coatings and barriers solutions which are fit for purpose and that are designed to make food packaging both safe for food contact and more recyclable.

Archroma is well known for its innovations and sustainable solution systems aimed at helping packaging & paper manufacturers to optimize productivity and/or create value in their markets. Just a few months ago the company launched Cartaseal VWAF, a PFC-free and ammonia-free barrier for odorless paper-based food packaging, as well as in 2019, a ground-breaking binder, Appretan NTR, made with 30% active content based on natural, renewable raw materials, designed for use in nonwoven articles such as tea bags and coffee filters.

In line with the principles of “The Archroma Way to a Sustainable World: Safe, efficient, enhanced, it’s our nature”, the paper & packaging R&D experts of Archroma decided to explore the properties of Appretan NTR for paper-based packaging applications.

They investigated a new specific application aimed at providing a more sustainable barrier option for general food packaging used with a short contact time, such as burger or sandwich paper wraps.

The Appretan NTR range is made with over 30% renewable raw material component, allowing the reduced use of fossil fuel based resources without compromising on the needed performance of water, oil and grease resistance. It is a more sustainably responsible option for packaging manufacturers and food retailers willing to help tackle the impacts of our food consumption habits.

The Appretan NTR range is therefore at the core of Nature Bites, a barrier system just launched by Archroma. In this new system, Appretan NTR can be combined with Cartacoat primers suitable for food contact that will seal the paper surface for further increased performance.

“Consumers are increasingly questioning how products are made, and expecting them to be harmless for themselves and their loved ones, and the planet”, comments Andy Bell, Head of Competence Center Paper Chemicals, who adds: “That is why it is critical that major food and beverage brands and retailers have a close look at their packaging supplier, and ensure that they work only with leaders in sustainable innovations such as Archroma. Appretan NTR and the Nature Bites system illustrate once again the commitment of Archroma to drive sustainable innovation in everything we do. Because it’s our nature.”

 

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Borealis and Value Chain Partners Develop More Sustainable Flexible Packaging Formats Containing 50% Post-Consumer Recyclate

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Borealis and Value Chain Partners Develop More Sustainable Flexible Packaging Formats Containing 50% Post-Consumer Recyclate

Borealis and Value Chain Partners Develop More Sustainable Flexible Packaging Formats Containing 50% Post-Consumer Recyclate

  • Application development with partners Plastotecnica and ACMI results in fully recyclable multilayer collation shrink film with appealing optics and pack stability
  • Co-operation with Rani Plast produces fully recyclable tissue packaging boasting excellent processability, printability and packaging line performance
  • EverMinds in action: leveraging packaging and mechanical recycling expertise to lower the carbon footprint of flexible packaging

Borealis announces that two separate collaborations with long-standing value chain partners have resulted in new, fully recyclable flexible packaging formats, which incorporate 50% post-consumer recyclate (PCR). The use of new low density polyethylene (LDPE) PCR grades developed and produced by mechanical recycling expert Ecoplast, a member of the Borealis Group, have made it possible to achieve a 35% carbon footprint reduction in raw material production when compared to virgin polyolefins, whilst maintaining the same film thickness as with virgin materials. Co-operation in the spirit of EverMinds is accelerating plastics circularity by fulfilling industry demand for sustainable flexible packaging solutions with lower environmental impact.

Borealis, Plastotecnica, and ACMI jointly develop collation shrink film with 50% PCR content

Plastotecnica, a major European producer of polyethylene (PE) packaging; and ACMI SpA, a leading Italian manufacturer of high-tech and flexible bottling and packaging lines and machines, worked together with Borealis to incorporate more PCR material into the multilayer shrink wrap of a beverage multipack. In developing the application, the partners were able to identify the ideal material solution to achieve optimal mechanical and packaging performance (particularly pack stability) whilst obtaining outstanding film optics and printability: the soon-to-be-launched LDPE PCR grade Ecoplast CWT 100VL with very low gel content; BorShape FX1003, a mechanical booster based on the proprietary Borstar technology; and Anteo FK2715, a key ingredient for ensuring higher performance and more sustainable multilayer applications. The result is a fully recyclable film containing 50% PCR and a 35% lower carbon footprint in the raw material production process. The shrink film packaging trials were conducted by ACMI.

“Working together with Borealis and ACMI enables us to come nearer to achieving our own objectives with regard to both sustainability and technological innovation,” says Valentina Betto, R&D and Sustainability manager at Plastotecnica. “We have been able to make real progress towards reaching specific goals. These include offering our customers solutions containing high levels of recycled material, exploiting downgauging potential to reduce film thickness, optimising processing parameters and performance, and minimising waste wherever possible.”

Borealis and Rani Plast develop new tissue packaging incorporating 50% PCR content

As a member of the Rani Group, a leading Nordic producer of smart packaging solutions, Rani Plast used its film and production expertise to work together with polymers experts at Borealis to develop a film structure for more sustainable flexible packaging used for tissue paper products such as kitchen roll (paper towels) and toilet paper. As an improved version of its predecessor NAV 101, the soon-to-be-launched Borealis LDPE PCR grade NAV 101L is best in class when it comes to balancing gel performance and circularity. Manufactured using household post-consumer and commercial waste, its gel content is significantly lower in order to provide excellent processability. It also offers excellent printability and optics. Combined with the Borstar technology-based mechanical booster BorShape FX1003, the grade delivers optimal mechanical performance, thus enabling the incorporation of more than 50% PCR content without increasing film thickness. Finally, Anteo FK2715 provides enhanced sealing, good optics and reinforced stiffness performance.

“As a fellow participant in the Finnish R&D initiative SPIRIT – Sustainable Plastics Industry Transformation – we are glad to deepen our co-operation with Borealis in the area of flexible packaging,” says Mats Albäck, Sustainability and Development Director at Rani Plast. “This successful project is proof that we as an industry can do more with less when we take joint action: improved material performance and greater sustainability, but with reduced consumption of natural resources and energy.”

 

“It’s gratifying to see the accumulation of sustainability success stories originating within the EverMinds platform for accelerating plastics circularity,” says Peter Voortmans, Borealis Global Commercial Director Consumer Products. “Mechanical recycling plays a crucial role in our integrated circular cascade approach. We offer a wide portfolio of versatile materials of consistently high quality, which are fit for a broad range of needs and demanding applications. Together with our partners, we are re-inventing essentials for sustainable living.”

K 2022 will take place from 19 to 26 October 2022 in Düsseldorf, Germany.

We invite you to “Innovate Collaborate Accelerate” together with us by visiting Borealis and Borouge in Hall 6 at Stand A43, where the flexible packaging solutions developed with value chain partners Rani Plast as well as Plastotecnica and ACMI will be on display.

 

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The New Benchmark for Digital Productivity in Plastics

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The New Benchmark for Digital Productivity in Plastics

The New Benchmark for Digital Productivity in Plastics

At K 2022 in Dusseldorf (Hall 14, booth B19), Coperion will present C-Beyond, the next level of its digital platform for machine and plant management. C-Beyond bundles all its digital products and service applications together, with the focus on creating secure digital solutions for the polymer industry and other processing industries that add real value. Amongst the numerous additions and upgrades to the platform, the OEE dashboard (OEE = Overall Equipment Efficiency) is presented at the show for the first time.

Optimizing Productivity with OEE Dashboard

C-Beyond uses data from Coperion’s extruders, compounding machines, and other systems to provide a comprehensive digital representation of the production currently in progress on a user-friendly interface. On the scalable OEE dashboard, production managers can receive an overview of the ongoing production performance of individual machines or entire plants at any time. This allows, for example, the fast and precise evaluation of plant productivity using OEE analysis.

Deviations in output and quality can easily be detected on the platform and their causes are diagnosed more quickly without complex laboratory tests. C-Beyond provides real-time production process data, allowing managers to make even more informed business decisions.The live dashboards can be customized by the user to best fit their needs.

Also, maintenance concepts based on data analytics, like predictive or condition-based maintenance, can be implemented easily with C-Beyond. This allows Coperion to proactively support their customers in maintenance work and preparation which will reduce effort on the customer side. With the AI-supported data analytics and downtime tracker, unexpected downtime or failures can be prevented, optimizing uptime.

Smart Hardware Concept: Coperion Control Systems and Service Box CSB 4.0

Production data is recorded directly in the CSpro and Epc NT control systems on the extruders or via the Service Box CSB 4.0, which can be retrofitted quickly and easily to existing Coperion machines. The CSB 4.0 Service Box is unique in that it connects all the product line systems, not only the actual extruder, to the digital platform. This gives users a complete process overview. C-Beyond has also been developed with cyber security in mind. A special two-tier hardware concept – with one gateway for a VPN connection to the internet and another for internal data acquisition within the machines – protects the transmission of sensitive production
data to the C-Beyond online platform against unauthorized access.

The latest version of the CSpro extruder control system offers many smart functions for intelligent diagnosis and monitoring of the extrusion process. The control unit opens up extensive possibilities for remote maintenance by Coperion service engineers.

Application-oriented and secure communication standard

Coperion’s extruders comply with the OPC 40084 standard to exchange data with higher-ranking production control systems, like MES systems. Communications are based on the proven OPC UA (Open Platform Communication Unified Architecture) manufacturer-independent standard for data exchange from automation systems while considering the requirements of the plastics industry. The security of the data at all process stages has been certified by Dekra according to ISO 27001:2013, which means that production and company data are well protected.

 

 

“With C-Beyond, we offer customers a comprehensive and mature digital platform that is consistently tailored to the requirements of the extrusion and compounding sector. We are convinced that C-Beyond will bring significant value to our customers and take the relationship with them to the next level.,” explains Markus chmudde, Head of Research and Development, Compounding” Extrusion, at Coperion.

 

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European Plastics and Rubber Machinery Industry Well Positioned Despite Crisis and Highly Motivated for K 2022

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European Plastics and Rubber Machinery Industry Well Positioned Despite Crisis and Highly Motivated for K 2022

European Plastics and Rubber Machinery Industry Well Positioned Despite Crisis and Highly Motivated for K 2022

The expected production value for plastics and rubber machinery in Europe in 2022 will be – as in 2021 – around 15 billion euros. Looking at the trend of the last twelve years, however, a steady growth in production can be observed. This is also reflected in the development of the global demand for plastics. For the period 2021 to 2026, the forecasts report an increase of 21 percent. The demand for processing machinery and equipment is evident in all major sales markets and will continue to grow. World exports of plastics and rubber machinery doubled from 12 billion euros in 2001 to 24 billion euros in 2021. It is noteworthy here that the share of Chinese exports grew over-proportionately from less than ten to 24 percent. Europe continues to lead the way with a 47 per cent share of deliveries.

Although the order situation is currently restrained, the European plastics and rubber machinery industry does not have a structural problem. However, like the plastics industry as a whole, it is currently facing a variety of challenges. The supply chain problem has still not been eased, the prices for gas and steel are exploding. To put this into perspective, gas only covers a quarter of Europe’s energy needs; before the shortage, 40 per cent of this came from Russia. Currently, it is only 8 per cent, and the gas storage facilities are well filled. However, it is important to develop or expand alternative, regenerative energy sources now.

The approaching leading trade fair for the plastics industry, K 2022 in Düsseldorf, comes at the right time. After three years now, this is the first international industry gathering with exhibitors from 60 countries and full occupancy of the entire exhibition centre as already in 2019. The industry is in the midst of the transformation process towards a circular economy. The current situation with rising energy and raw material prices is seen as a confirmation, rather than an obstacle, to consistently continue along this path. The European plastics and rubber machinery manufacturers stand behind the key themes of K 2022 – circular economy, digitalisation, climate protection. With their technologies, they make a decisive contribution to realising the circular economy of plastics. In the Circular Economy Forum at the K trade fair, they will be demonstrating important stages of the cycle on running machines, from preparation of plastic waste and re-granulation to the processing of recycled materials.

The machinery manufacturers will also be involved in the current discussions at the “Sonderschau” at K. One focus here will also be digitalisation. The networking of machines is the key to more efficiency, traceability, condition monitoring or machine learning.

At K 2022, machinery manufacturers from Europe, China, Japan and Canada will show how their machines send live data to the central umati demonstrator using the world language of production, OPC UA. Visitors can access these data via smartphone and also in the VDMA Dome in the Circular Economy Forum.

By agreeing on OPC UA as the technology in combination with the information models standardised by Euromap, the integration of machines from different manufacturers into a common system has been considerably simplified. A total of around 40 machine manufacturers are taking part in the showcase at K, making the great potential of platform-independent and cross-manufacturer machine-to-machine communication visible and experienceable.

 

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