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A Revolutionary Die Lip Adjustment System Set to Be Introduced by Nordson at K 2022

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A Revolutionary Die Lip Adjustment System Set to Be Introduced by Nordson at K 2022

A Revolutionary Die Lip Adjustment System Set to Be Introduced by Nordson at K 2022

The new, patent pending EDI Prodigi system takes extrusion and coating processes to another level by fully automating the lip gap adjustment – making it faster, safer, and repeatable.

At a time when the industry is demanding more efficiency from its resources, Nordson plans to debut a new automated lip adjustment system for their EDI extrusion and fluid coating dies at the K 2022 trade fair. This new system achieves saving tolerances four times faster than conventional thermal bolt systems, supporting operations’ need for increased sustainability.

For years, automated lip adjustment has been achieved using thermally actuated bolts. Thermal bolts are highly influenced by external factors, so thickness uniformity and consistency are sometimes hard to realize. Thermal bolts also typically require manual pre-tuning, so the process is not fully automated and hard to repeat consistently. Though effective and proven, it became clear that manufacturers needed a next level solution to meet their production needs.

“When we spoke with global customers, it was clear that they need more than excellent product uniformity – they need increased automation. When skilled workers are hard to find, straight-forward process control with less operator intervention is key to increasing a production line’s overall profitability. We knew there must be a better way,” says Scott Smith, Global Product Managing Director for Nordson’s EDI die business.

And there is. After an initial concept was developed and specified, Nordson selected the Proflow family of actuators by Honeywell’s Process Solutions team (NASDAQ: HON) to bring the new Prodigi die to market as quickly as possible. Instead of using thermal bolts to control the lip adjustment, the Prodigi die relies on a series of motorized actuators connected to the die’s flexible lip. The installed actuators smoothly translate motor rotation into precise linear movement to locally open and close the lip. Accomplishing this away fromthe hot die, at a user interface, creates a process that is much faster, safer, and more energy efficient.

 

A Proven Success for Extrusion and Fluid Coating Applications

To evaluate the system, Nordson conducted a series of extrusion and fluid coating trials at its EDI Technology Center in Chippewa Falls, Wisconsin, USA, as well as a series of extrusion trials at the Fulton, New York, USA laboratory of Davis-Standard, LLC. As a world-class line supplier, Davis-Standard has been one of the EDI business’ preferred partners for several years and provided the perfect test environment for the first production-ready Prodigi die. “We are pleased to be the Systems Integrator for the measurement and Prodigi die systems, raising the performance bar for all of our customers,” stated Ricky Keller, Vice President-Market Development with Davis-Standard’s Converting Systems line of business.

“We achieved great results when we evaluated this new technology,” says Sam Iuliano, EDI Chief Technologist.”During our initial lip gap setting trials at Davis-Standard, we successfully closed the lip by 0.015″ in only 35 seconds. With a conventional automatic die, this procedure would involve using feeler gauges and iterative manual adjustments, which, in stark contrast,takes about 15 minutes to complete with reasonable accuracy.”

The first round of tests at Davis-Standard, using multiple LyondellBasell resins and an NDC Technologies scanning system, also clearly showed how beneficial the Prodigi system is when it comes to both product uniformity and control speed.

“We set the desired lip gap, and when we started, the initial thickness variation was +/- 25%. Within a matter of 44 seconds, the thickness variation decreased significantly, and after only three minutes from engaging Automatic Profile Control (APC), we had an almost perfect gauge over the complete length of the die. This compares to an average of 12 minutes to achieve the same tolerances using conventional thermal actuators. Customers will save significant time and be able to exactly repeat their production cycles. This will create much less scrap and add more productive time since final tolerances are achieved so quickly,” explains Iuliano.

“We have tested the Prodigi die system in comparison to current thermal bolt dies and the Prodigi system has proven to raise the performance bar an order of magnitude. I have witnessed step changes in APC over the past 40 years and the Prodigi system is definitely a large step forward for profile control of flat dies,” noted Ricky Keller of Davis-Standard.

“Throughout the trials, we were impressed by how fast the Prodigi die system is. We launched a saved lip profile recipe from a previous run and produced xceptionally flat film in only 30 seconds,” says Iuliano. “Davis-Standard stated that they usually need 8 minutes to achieve the same tolerances from recipe launch with conventional thermal actuators.”

To gain an industry user’s perspective, global packaging supplier, Amcor, was also invited to the development trials. “The performance of the Prodigi die, with its reproducibility and speed, will be a game changer for converters. We are always looking for tools to help reduce losses and improve our Overall Equipment ffectiveness (OEE) as we move toward shorter run sizes. This new technology from Nordson will enable converters to achieve these goals safely and efficiently,” reports Brent Martins, R&D Fellow with Amcor PLC.

The Prodigi system will also support fluid coating applications since its accuracy is so refined. “The coating line tests in our lab were extremely promising, and we will be able to support fluid coating customers with equally impressive results,” notes Iuliano.

 

 

A Win for Efficiency

Another benefit of the Prodigi system is its high energy efficiency since the motorized actuators operate at a much lower temperature than thermal bolts. While the thermal bolts need constant heat during a production run, the Prodigi motorized lip actuator system uses little to no power after achieving steady state operation, reducing the overall energy consumption and environmental impact.

In fact, it is projected that the Prodigi actuator system, under normal use and on an annual basis, would consume less than 1% of the electricity needed to operate a comparable thermal die bolt system.

“Finding technical solutions requires imagination and creativity. We used both to create this innovative system that has the potential to change the industry and prepare producers for the future. We are enormously proud of what we achieved,” says Smith. Iuliano adds, “We cannot wait to bring this to K 2022 and show our industry colleagues the latest in EDI die technology.”

Nordson and Davis-Standard will provide brief technical presentations on Prodigi systems and the development trials during K 2022. To learn more, add Nordson to your Show Planner.

 

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Ascend Focuses on Reducing Product Carbon Footprint

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Ascend Focuses on Reducing Product Carbon Footprint

Ascend Focuses on Reducing Product Carbon Footprint

Ascend Performance Materials announced today two efforts to reduce the carbon footprint of its products. The company has made its global compounding operations carbon neutral, making it the first integrated polyamide producer to decarbonize a substantial part of its operations, and it has secured ISCC+ certification for the use of bio-based materials.

Ascend’s seven compounding sites in North America, Europe and Asia produce the company’s Vydyne, Starflam and HiDura engineered materials used in EVs, batteries, renewable energy systems and countless other applications.

Carbon neutrality for the sites’ scope 1 and 2 emissions was accomplished through a mix of process improvements, and renewable energy and carbon offsets. Annually, this achievement is equivalent to eliminating the emissions from 4,000 passenger vehicles.

On the other end of the company’s fully integrated production, Ascend is now certified to use bio-based feedstocks to produce acrylonitrile, adiponitrile, hexamethylene diamine and polyamide 66 utilizing a mass-balanced approach. With this certification, Ascend’s PA66 polymer can now be made with up to 40% bio-based materials.

“Reducing our carbon footprint is a major part of our sustainability effort,” said Chris Johnson, Ascend’s director of sustainability. “We are focused on meaningful, long-lasting improvements that balance environmental and product performance, and benefit our people, neighbors, customers and consumers.”

Ascend, a fully integrated producer of durable materials, has committed to an 80% reduction of its GHG emissions by 2030. Toward that goal, the company has invested in emissions abatement technology at its Pensacola, Florida, nylon plant and cogeneration units at its Decatur, Alabama, adiponitrile plant. And 30% of the energy used at Ascend’s acrylonitrile plant in Alvin, Texas, is derived from a utility-scale solar farm through a power purchase agreement.

“We remain committed to leading the industry in sustainability, even as we grow to meet the needs of our customers globally,” said Phil McDivitt, Ascend’s president and CEO. “These milestones are a big step toward ensuring that every pound of our product, whether made in Suzhou or Pensacola is made with the smallest environmental impact possible.”

Ascend will be showcasing its sustainability efforts, including its low-carbon-footprint products, under its Advancing Together theme at K 2022 from 19-26 October in Hall 6 Stand A07.

 

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Tracing and Recycling Plastics

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Tracing and Recycling Plastics

Tracing and Recycling Plastics

The cross-company cooperative project R-Cycle was officially launched. The objective is to ensure the recyclability of plastic packaging through seamless documentation of all recycling-relevant packaging properties. Only in this way can recyclable waste be precisely identified during the recycling process and reprocessed to make a wide range of high-grade plastic products.

Currently the plastics machinery manufacturers Arburg, Brückner Maschinenbau, Kautex Maschinenbau and Reifenhäuser participate in the project, along with the Institute for Plastics Processing (Institut für Kunststoffverarbeitung – IKV) at RWTH Aachen University. They are supported by GS1 Germany, a neutral skills and service center that aims to optimize cross-company business processes throughout the value chain. The project’s official kick-off took place in June at the headquarters of the Reifenhäuser Group in Troisdorf.

 

R-Cycle is set to become a cross-sector, globally-implementable standard that will subsequently be openly available to all companies and industries throughout the life cycle of plastic packaging. R-Cycle will therefore contribute to meeting the objectives of the EU’s Circular Economy Action Plan.

R-Cycle relies here on field-proven marking and tracing technologies similar to those already used for fresh produce in the food industry. This ensures that physical products are supplemented with digital information throughout the entire supply chain. Numerous pilot projects with partner companies — including worldwide raw material suppliers, retail companies, global brands and independent institutions — are already in progress.

 

 

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Comexi and Reifenhäuser Produce Fully Recyclable All-PE Pouches

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Comexi and Reifenhäuser Produce Fully Recyclable All-PE Pouches

Comexi and Reifenhäuser Produce Fully Recyclable All-PE Pouches

Reifenhäuser, the experts for plastics extrusion, and Comexi, leading provider of packaging machines, are starting a pilot project for the high-quality recycling of flexible pouches. The collaboration intends to demonstrate that harnessing the R-Cycle concept can optimize the recycling process by storing recycling-relevant production data and affixing a clear ID mark on recycled packages.

Ralf Wiechmann, Head of Film Innovation at Reifenhäuser and project initiator, explains: “This is the only way to avoid downcycling these applications and achieve a genuine circular economy for plastic packaging.”

Cross-Industry Coopration

The project was started by selecting two different film recipes for two different pouch types, both based on PE raw materials only. This makes them much better to recycle than PE/PET laminates that are in common use today. The film was produced on a Reifenhäuser EVO Ultra Stretch blown-film line.

Film conversion (printing and lamination) take place at Comexi, a provider of complete solutions for conversion into flexible packaging. This solution integrates the latest developments for sustainable Gelflex Inks from Wikoff and a highly energy-saving electron-beam dryer from ESI. The actual pouches are produced by Wolf Verpackungsmaschinen.

Traceability In The Recycling Process

The secret during production is to store recycling-relevant data from each production step so that they are available for the sorting process before recycling. With the present state of the art, a sorting plant equipped with customary NIR sensors is only capable of scanning the surface of a packaging and sorting it in predefined fractions (e.g. PE, PP, mixed plastics, drink cartons). However, in the past, information about the exact contents of the packaging, the various plastic layers, the printing ink, and the adhesive contained in the packaging has remained with each producer along the process chain.

Since the two pouch types are now marked by an individual, machine-readable ID, the sorting plant can even allocate the PE pouches to two different recycling fractions. To the end-consumer the code in the mark printed on the packaging is invisible. The result? High-quality recyclate based on clean sorted recycling fractions can now be recovered to make high-quality products.

Ralf Wiechmann adds, “R-Cycle really becomes interesting when current developments are applied to post-consumer waste – developments such as de-inking, solvent-based sorting of PA in PO packaging or large-scale chemical recycling. When that happens, R-Cycle will be able to provide special fractions for specific recycling.”

 

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Polifilm Extrusion Starts Pilot Project For the Wholesale Trade

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Polifilm Extrusion Starts Pilot Project For the Wholesale Trade

Polifilm Extrusion Starts Pilot Project For the Wholesale Trade

Polifilm Extrusion starts an R-Cycle pilot project for the wholesale trade. The aim is to demonstrate how R Cycle works using the example of stretch film in a real application in order to ensure the recycling and reuse of film scrap. Test partner is Metro Gastro based in Düren near Cologne, a specialist wholesale store for catering customers.

The Metro Gastro hypermarket supplies its customers to order with a wide variety of different catering products of very different shapes and weights on custom-packed pallets. Before the products are transported to the customer, the staff at outgoing goods must wrap the entire pallet with stretch film. This may require up to 150 meters of film per pallet. Consequently, there is a high recycling potential here since large quantities of stretch film is consumed in the logistics sector.

Germany’s leading stretch film producer, Polifilm, is now supplying about 130 kilometers of PFE Power machine stretch film to the Metro Gastro hypermarket in Düren as part of a recently started pilot project. The stretch film is collected separately after use to produce new stretch film from the sorted film scrap. In essence, this sets up a genuine circular economy for this plastic. “For us at Polifilm, this is a major step to complement our activities in the use of recyclate, for example our PCR stretch film,” says Hikmet Kalkan, Division Manager and Managing Director of Industrial & Agricultural Films Polifilm.

Before the film is produced, the cast-film line at Polifilm was networked to the R-Cycle data platform. All recycling-related data is stored in real time during production of the film rolls. Standards from GS1 Germany, known for everything to do with barcode standards and solutions, are used for cross-company data transfer. The data is retrieved during the sorting and recycling process by a mark on the film to separate the film scrap into sorted fractions. This is the only method to recover clean recyclate from waste film and produce new stretch film based on the cradle-to-cradle principle.

Frank Groth, Head of Category Management Food at Metro Deutschland, explains, “We believe it is extremely important to design our processes as sustainably as possible and most importantly, to minimize plastic waste. R-Cycle allows us to assume our own responsibility and to recycle waste into reusable materials based on the principle of a circular economy.”

 

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Consortium Members Present Pilot Projects at Second Face-to-Face Meeting

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Consortium Members Present Pilot Projects at Second Face-to-Face Meeting

Consortium Members Present Pilot Projects at Second Face-to-Face Meeting

On October 6 all the members of the R-Cycle Consortium met for their second strategic face-to-face meeting. Arburg, Kautex Maschinenbau, Reifenhäuser, the Institute for Plastics Processing (IKV) at the RWTH Aachen, and GS1 Germany all accepted the invitation of Brückner Maschinenbau to meet at their headquarters in Siegsdorf at Chiemsee.

As currently usual most operational meetings take place virtually – but this was not effecting the progress within the pilot projects at all. The workshop focused on presenting practical applications for R-Cycle and on further progress in developing the fundamental standard. Project managers and CEOs of the consortium members were able to exchange views personally and collaborate on future strategic directions of R-Cycle.

Dr. Benedikt Brenken, Director of the R-Cycle Initiative, explains: “Even though we collaborate very efficiently on digital platforms, personal contact is vital – despite face masks and/or social distancing – so that we can evaluate project results and discuss new strategies. It is impressive to see the progress the project has made in only three months since the official kickoff in June. We have been able to demonstrate that R-Cycle works successfully under real conditions and in a number of different applications. The transition from theory to practice is a decisive factor for the further development and success of the initiative.”

One of the pilot projects shows how R-Cycle works in the sustainable use of stretch film in logistics. Germany’s leading stretch film producer, Polifilm Extrusion, produces a special film to wrap transport pallets at Metro Gastro, the specialist hypermarket for catering customers in Düren. Before the film is produced, the cast-film line at Polofilm was networked to the R-Cycle data platform. All recycling-related data is stored in real time during production of the film rolls. Standards from GS1 Germany, known for everything to do with barcode standards and solutions, are used for cross-company data transfer. The data is retrieved during the sorting and recycling process by a mark on the film to separate the film scrap into sorted fractions. This process recovers clean recyclate from waste film and produces new stretch film based on the cradle-to-cradle principle.

Besides the pilot projects, further progress was made on networking the consortium with additional partners along the value chain – from plastic packaging producers through to the subsequent recycling process. Michael Baumeister, Managing Director Technology & Logistics at Brückner Maschinenbau, said, “We are delighted to host the R-Cycle Consortium meeting this time. The initiative is a decisive basis for our industry to implement a functioning circular economy for plastic waste. The overarching cooperation and the addition of further partners along the value chain underscore the importance of the objective.”

 

 

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STEINERT – Leading Supplier of Recycling Sorting Systems – Joins R-Cycle

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STEINERT – Leading Supplier of Recycling Sorting Systems – Joins R-Cycle

STEINERT – Leading Supplier of Recycling Sorting Systems – Joins R-Cycle

STEINERT GmbH – market leader for the supply of magnetic separator and sensor sorting systems – is joining the R-Cycle consortium. Recycling plants all over the world use STEINERT systems for the automatic detection and sorting of recyclable materials in complex waste streams and return them to the value chain.

This is the exact purpose of the R-Cycle initiative which is based on an open and globally applicable standard to trace plastic packaging along the life cycle. The goal is to provide and pass on recycling-relevant information to the complete value chain. This information is essential to recycle plastic products, among other things. Part of this chain is the precise identification of packaging in order to process the resulting recyclate to produce a wide variety of high-quality plastic products. Identification uses techniques such as digital watermarks which are incorporated in the print image of the packaging for sorting systems to read. The aim of R-Cycle is to permit cross-company data transfer and provide all the relevant information on each packaging.

Peter Funke, CEO of STEINERT GmbH, explains: “Our advanced sensor sorting systems are already capable of detecting and selecting a wide variety of recyclable materials with extreme precision for further recycling. The R-Cycle concept is based on new principles that focus on the increasing use of digital product information. We are looking forward to contributing our expertise to the development process.”

Dr. Benedikt Brenken, Director of the R-Cycle Initiative, adds: “We are delighted to have STEINERT on board as another important partner for our initiative. It will allow us to test and optimize the essential interface between data generation and data usage. The basis for a functioning circular economy can only be achieved if the packaging and the recycling industries collaborate on a joint approach.”

 

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Brückner Maschinenbau Tests PU-based Printing Inks for Improved Recycling

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Brückner Maschinenbau Tests PU-based Printing Inks for Improved Recycling

Brückner Maschinenbau Tests PU-based Printing Inks for Improved Recycling

When it comes to recycling packaging, it is mostly the plastics used that are considered. However, a large proportion of the plastic films used for this purpose are printed and, with the printing ink, contain a further ingredient that has a decisive influence on recyclability. The recyclate quality from printed film waste is particularly often low, since the color, odor and processability are only sufficient for simple applications. The black trash bag is then often the second and at the same time last cycle of many plastics.

R-Cycle member Brückner Maschinenbau is therefore researching design optimizations for printed films together with other partners as part of the Print CYC project. The latest finding: a PU (polyurethane)-based ink system significantly increases recyclability. The test showed that the alternative ink formulation leads to a significant improvement in the mechanical recycling process on a production line typically used for reprocessing printed film waste materials in practice. Due to the high temperature resistance of the inks (> 240 °C), neither volatile by-products, nor odor or gels were observed. Under these conditions, high-quality recyclates with color-stable properties could be produced. An initial assessment of the environmental impact also revealed lower greenhouse gas emissions and lower energy consumption in the mechanical recycling of the films compared with the production of virgin material.

Against this backdrop, it is clear that not only information about the actual plastic, but about all of its ingredients is important for recycling plastic packaging. R-Cycle transports this information through the entire value chain – from the producer to the processor of plastic waste. In this way, products recorded and marked with R-Cycle can be reliably identified and recycled to a high standard.

 

 

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Specialist for Plastics Recycling Machines Erema Becomes R-Cycle Partner

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Specialist for Plastics Recycling Machines Erema Becomes R-Cycle Partner

Specialist for Plastics Recycling Machines EREMA Becomes R-Cycle Partner

 

The EREMA Group – a world leader in the development and manufacture of plastics recycling machines and system components – joins the R-Cycle consortium. Founded in 1983 as a pioneer in the industry, the corporate network now comprises 7 companies and has placed more than 6,500 systems on the market around the globe, producing a total of over 14.5 million tonnes of plastic granulate per year.

As part of a functioning circular economy, EREMA’s technology links the life cycles of plastics: recycled plastic waste is used to produce new (re)granulate (or recyclate) for the manufacture of new high-quality plastic products. In order to produce high-quality recyclate, however, precise waste sorting is also required. This is exactly the declared goal of R-Cycle. By documenting recycling-relevant data of plastic packaging and subsequent identification in the recycling process via so-called digital watermarks, fully recyclable mono-material packaging, for example, can be reliably distinguished from poorly recyclable composite materials. R-Cycle thus improves the availability of sorted waste fractions for the recycling stream in order to significantly increase the production quantities of high-quality recyclates.

“Our goal is to make recycling an integral part of the plastics value chain, in line with our vision “Another Life for Plastic”. This can only succeed if streams of recyclable materials are actually fed into the recycling process, and R-Cycle can make a very significant contribution to this,” says Manfred Hackl, CEO of EREMA Group GmbH, explaining why the company has joined the consortium.

Dr. Benedikt Brenken, Director of the R-Cycle Initiative, adds: “With the EREMA Group we are gaining the world market leader in the field of plastics recycling machines for our initiative – and thus in-depth expertise in the processing of plastic waste. Together we will further specify the standard for data exchange along the entire value chain and implement it in specific applications”.

 

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Expert for Slitting and Winding Technology KAMPF Becomes a Member of the R-Cycle Consortium

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Expert for Slitting and Winding Technology KAMPF Becomes a Member of the R-Cycle Consortium

Expert for Slitting and Winding Technology KAMPF Becomes a Member of the R-Cycle Consortium

Slitting and winding are decisive process steps in the production and processing of belt-shaped materials. Kampf Schneid- und Wickeltechnik GmbH & Co. KG is a leading expert in this field since 1920. KAMPF now represents another important partner in the R-Cycle consortium on its way towards mapping the entire value chain of plastic packaging.

Following the approach of R-Cycle, all process participants – from the raw material to the finished product to the recycling plant – will be able to read recycling-relevant data, add to it and transmit it to the downstream processors. This creates a data set that can be read out during waste sorting via so-called digital watermarks. Based on this information, more precise waste fractions can then be formed for the production of higher-quality recyclates.

“The digital and cross-company connection of production units has enormous potential to ensure the traceability of recyclable plastics. Therefore, we want to close a link in this chain at an early stage in order to take another step towards circular economy,” explains Lutz Busch, CEO at KAMPF.

Dr. Benedikt Brenken, Director R-Cycle Initiative, adds: “With KAMPF we are gaining a very experienced partner in the field of plastic film processing. Together we will continue to develop the connection of converting machines to the R-Cycle database in order to ensure the seamless data transfer between all participants in the value chain.”

 

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