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Compamed 2022: The Halls Are Fully Booked, and There Are Important Impulses for the Medical Technology Industry

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Compamed 2022: The Halls Are Fully Booked, and There Are Important Impulses for the Medical Technology Industry

Compamed 2022: The Halls Are Fully Booked, and There Are Important Impulses for the Medical Technology Industry

Integrated professional forums offer an overview of top trends in research, product development and production

The world of medical technology looks confidently towards Düsseldorf. From 14 to 17 November, the internationally leading trade fairs Compamed, for suppliers, and Medica, for medicine, are being held here in parallel. Based on the current number of bookings, far more participants than last year are expected for both events. At Compamed 2022, almost 700 companies from 36 nations will take part; at the parallel Medica 2022, there will be more than 4,200 from 70 nations combined. For Compamed 2022, this means it is fully booked at its traditional location, trade fair halls 8a and 8b. “The impulse given by a combined Compamed and Medica is of enormous importance for the industry. Participants from all areas of the healthcare industry right now need direction and a comprehensive overview of reliable supplier options and business partner alternatives that are available quickly,” explains Christian Grosser, Director Health & Medical Technologies at Messe Düsseldorf.

Important elements of the Compamed programme are the two integrated forums for presentation and discussion: the Compamed High-Tech Forum by IVAM (organised by the IVAM Microtechnology Network) and the Compamed Suppliers Forum by DeviceMed (content supplied by trade magazine DeviceMed). The Compamed High-Tech Forum offers an inside look at current research and development phases of the processes and products presented at Compamed, explains technological trends within the sector, and offers information on relevant foreign markets for medical technology. There is a focus on the areas of new materials, production techniques, nanotechnology and micro system technology, which will all be presented by qualified specialists and leading experts.

“Europe meets USA – High-Tech for Medical Devices”

On all four days of the trade fair, the forum organised by IVAM in Hall 8a (booth G40) offers an international programme. One of the highlights of the forum is the new session on internationalisation “Europe meets USA – High-Tech for Medical Devices”, which is aimed at improving cooperation within medical technology between manufacturers of components and devices as well as users from both Europe and the USA. “The disturbance of our economic relations caused by Covid-19 and the war in Ukraine has shown how fragile our supply chains are. Many of our high-tech companies are looking for closer cooperation with countries with which we share common ethical values, e.g. the USA”, says Dr. Thomas R. Dietrich, CEO of IVAM. At the High-Tech Forum, companies participating in the neighbouring Medica 2022 will also present their products and talk about their expectations towards manufacturers of components.

The topic of microfluidics, a key technology in the field of diagnostics, has received a huge boost through the Covid-19 pandemic. At the forum in Hall 8a, this is reflected in the large number of professional presentations on this topic, so that for the first time this year, two sessions have been added to the programme: „Microfluidic Session Part I: Microfluidic Platforms – Shortcut to a Product” and “Microfluidic Sessions Part II – Microfluidics: The Bits and Pieces to Make Up a System“. Further important topics for the 2022 presentations are “Printed Electronics for Next Generation Wearables and Diagnostics”, “Smart Sensor Solutions” and “Laser and Photonics Applications”.

The entire process chain from a close practical perspective

In Hall 8b, throughout the four days of the trade fair, the Compamed Suppliers Forum presents current developments along the entire process chain, with a special emphasis on practice. The focus lies on mechanical and electronic components as well as on innovative basic materials, manufacturing processes, all kinds of custom manufacturing, aspects of design and usability, as well as quality assurance. Keynote speeches on new markets complete this diverse programme. Among the main topics of interest are Additive Manufacturing, Electronics, Regulatory Affairs, Cyber Security and Wearables.

Speaking of wearables: This area of application is becoming more and more important for supplies in the medical technology industry. For example, Coat-X has developed ultra-dense casing technology for wearable or implanted electronic components and PCBAs (printed circuit board assemblies). The Swiss company is a leading provider of leak-proof solutions of critical importance and an expert for thin-film encapsulation. At the forum, CEO Dr. Andreas Hogg will share information about the company’s innovative encapsulation technology for the protection of critical components inside wearables.

A member with a huge network and 25 years at Compamed

MedNet has been present at Düsseldorf for over 25 years: “Since the first opening, Compamed has been an important meeting place for the industry, for customers as well as for suppliers and partners. Every year, the international manufacturers we represent in Europe participate at our shared booth,” says Matthias Heinz, CEO of Med Net. The company acts as a competent service provider and supplier for the medical product and pharmaceutical industry, with a large portfolio of standard components by known manufacturers as well as their own product lines, for example for interventions in radiology and infusion technology. Beyond that, they offer a global, well-established network for comprehensive material and manufacturing technologies.

“We use our network to offer all-in-one solutions directly at our booth: from standard medical components to custom parts. Our spectrum covers high-performance polymers, biomedical compounds and alloys as well as custom metal components, thermoformed parts and precision blades. Our newest partner, Arkema, a leading producer of high-performance polymers, also supplies bio-based and recyclable polymers,” says Heinz. Arkema will also hold an informative presentation on this topic at the Compamed Suppliers Forum, as the importance of sustainability is growing for medical technology, too.

Highlights at the shared IVAM booth

The professional association IVAM is not only responsible for the programme of the Compamed High-Tech Forum, but also organises the shared booth and the product market “High-tech for Medical Devices”. The focus here lies on innovations in the key sectors of microtechnology, nanotechnology, photonics and new materials. International companies and research institutes are regular participants at the shared booth with its more than 600 m². This year, the IVAM area is home to almost 50 companies and institutes from nine nations. There is an especially strong presence of Swiss companies specialising in optics and precision technology. On site, there are many different microcomponents (microelectronical, optronical, microoptical, microfluidic), sensors, actuators and sensor systems, micropumps, coatings, smart textiles as well as manufacturing and processing procedures to be seen. All in all, optical components and procedures are becoming increasingly important.

No defect undetected, no matter how small

The company Mabri.Vision will be present at Compamed for the first time via IVAM, bringing automated systems for optical quality assurance to Düsseldorf. Using a variable lighting system, transparent and opaque materials, like microfluidic chips, can be checked for defects, scratches, particles or cracks and their geometrical properties evaluated. The evaluation system “MV.Eye MI1” for microfluidic chips is an inline-capable solution for automated 100-percent inspections of large-surfaced and microstructural components. Rapid, high-resolution image generation, paired with an analytical software powered by AI, allows any defects to be reliably detected and evaluates the dimensional accuracy of the chips.

Optical components and procedures gain importance

Several Swiss companies are presenting microoptics for use in medical technology and life science applications. Among them is the company Fisba, which offers high-precision microlenses starting at a diameter of 0.3 mm. At Compamed, the company wants to focus on their competence as a provider of all-in-one solutions. Their motto is: “From engineering to volume production. All from one source. All from Fisba.” Suss MicroOptics presents refractive and diffractive microoptics for imaging, sensor or focused beam applications. Mikrop presents miniaturised optics for high-tech applications, e.g. spherical lenses, optical assemblies and high-quality miniature objective lenses for medical technology.

An eternal success story at Compamed: Sensors

Sensors are always a focus of interest. Sensirion from Switzerland are presenting tiny flow sensors for smart inhalers and digital health applications, as well as a sensor for liquids for subcutaneous administration of medicines. ES Systems from Greece are developing and manufacturing innovative, intelligent sensors based on microelectronic technology. These MEMS-based sensors (MEMS = microelectronic mechanical systems) measure pressure, gas flow, the properties of liquids and the temperature. Products by ES Systems are used in sophisticated control and monitoring applications, among other things in medical technology, either as independent components or as integral parts of other equipment. With a view towards the newest challenges, the company has also developed smart, autonomous, energy-saving, wireless sensors which are ideally suited for integration into the Internet of Things.

Photonics helps fight against tuberculosis

Eight companies and non-university research institutes have teamed up to use photonics in the fight against tuberculosis, which is often aggravated in developing countries by a lack of laboratory infrastructure. At the beginning of 2022, relevant solution strategies by the project “FluoResYst” were first presented. The project has received a three-year grant from the German Federal Ministry of Education and Research (BMBF). The project aims to develop a rapid detection system for multidrug resistances in tuberculosis infections, in order to ensure a quick diagnosis and efficient treatment of affected persons. microfluidic Chip Shop specialises in the development and manufacture of Lab-on-a-Chip systems, also termed Point-of-Care (POC) or patient-centred diagnostic applications. Within the “Fluo Res Yst” project, the company from Thuringia is working on an analysis cartridge, inside which novel detection technology carries out a tuberculosis assay. Following the initial progress of the project, established Lab-on-a-Chip solutions will be presented by microfluidic Chip Shop at their booth.

Custom patient-specific implants

Since their founding in mid-2000, 3di from Jena has focussed on patient-specific implants for facial and cranial applications, for example following traumatic injuries, tumour excisions, surgical access or when functional-aesthetic corrections are required. To manufacture such implants, the company has developed a proprietary method that enables them to be fitted individually to each patient. Modelling, construction and manufacture are fully planned in virtual space. With respect to aspects of surgical techniques it is therefore possible to produce implants specific to a single patient – in special cases even within 48 hours. To make his happen, 3di needs CT/MRI data provided either on CD-Rom or via a secure internet connection. Any bone structure within the human skull can be modelled. The accuracy of the model deviates by less than 0.5 mm. The development by 3di is used in neurosurgery, trauma and cancer surgery, plastic surgery, cranio-maxillofacial surgery and ENT medicine.

The developments and instances of applied medical technology mentioned here represent only a selection of highlights from the broad spectrum of topics and innovations found at Compamed 2022. The spectrum ranges from packaging lines in cleanrooms to technology for the tiniest of microsystems. Due to the exhibition’s focus of interest, there is also a heavy representation of manufacturers of consumer goods, production equipment and various services. The innovative base of Compamed is made up of companies producing materials, raw materials and adhesives. This diversity offers many opportunities for cooperation, especially regarding those companies that also participate in the parallel Medica fair.

 

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A Success: 30 Years of Arburg Subsidiary in Malaysia

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A Success: 30 Years of Arburg Subsidiary in Malaysia

A Success: 30 Years of Arburg Subsidiary in Malaysia

  • Anniversary celebration: Over 100 guests in Petaling Jaya
  • Demonstration: Gestica machine control in the showroom
  • Open house event: Big celebration Oktoberfest style

An important milestone for Arburg’s presence in Asia: On 23 September 2022, the subsidiary in Malaysia celebrated its 30th anniversary. Visu Nagappa, Branch Manager Arburg Malaysia, David Chan, Managing Director Arburg Asean, and Ruben Sander, Director Operations Arburg Asean, expressed their gratitude for the trust and support from customers and employees. The more than 100 guests invited to the celebration were able to see the benefits of the Gestica machine control system for themselves in the showroom and then celebrated the anniversary in Oktoberfest style.

Hans-Günther Zimmermann, Senior Sales Manager Asia/Africa, conveyed congratulations on behalf of the German Arburg headquarters. David Chan had this to say to the employees: “We would like to celebrate and sincerely thank you for your support and service to our customers over the past 30 years. He further emphasised: “We assure you that we will continue to provide exceptional service and the best quality injection moulding technology in the years to come.”

Highlight: Gestica controller
The focus of the anniversary celebration was the presentation of the Gestica control on a hybrid injection moulding machine Allrounder 570 H. The Gestica control has “smart” assistance functions that actively support the customer. “Our goal was to be able to offer modern injection moulding solutions in Malaysia,” says Visu Nagappa. The Gestica touchscreen control has met with great interest among customers. After the performance, there was a big celebration styled like an Oktoberfest.

Successful development
Arburg Malaysia’s activities began in 1989 with the sale of two Allrounders. In the early days, our customers were still supported via a trading partner. Due to the good trend in the market, Arburg opened its own subsidiary already in 1992. Four years later, the subsidiary moved to new premises, doubling the usable area to 250 square metres and making it possible to expand the range of services. Today, over 1,200 Allrounder injection molding machines are in operation in Malaysia. The subsidiary offers its customers an expert hotline, a spare parts warehouse, a 160 square meter showroom with an Allrounder for trials with customer moulds, and a wide range of courses and seminars. In addition, there is a sub-branch on Penan Island, which also covers sales, service, applications and spare parts.

 

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SABIC Introduces New LNP ELCRES FST Copolymer Resins for Rail Seating, Compliant With EN45545 Standard

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SABIC Introduces New LNP ELCRES FST Copolymer Resins for Rail Seating, Compliant With EN45545 Standard

SABIC Introduces New LNP ELCRES FST Copolymer Resins for Rail Seating, Compliant With EN45545 Standard

Company to exhibit materials and applications at InnoTrans 2022

SABIC, a global leader in the chemical industry, launched today four new LNP™ ELCRES™ FST copolymer resins that comply with the European railway standard EN45545 R6-HL 2 for train seating. Designers can benefit from these new material solutions, which not only meet the new regulatory requirements but also provide expanded opportunities to create sleek seating designs. Compared to thermosets and aluminum, the new ELCRES resins offer lighter weight and efficient processing without requiring secondary operations. To achieve a seamless aesthetic look in an all-in-one seat unit or a design with a separate back shell without painting, SABIC offers precision color matching for its extrusion grade (LNP ELCRES FST2732E resin) and injection molding grade (LNP ELCRES FST2432 resin). For customers that require more-sustainable solutions, SABIC supplies bio-based version of each grade. These new materials, and several other new products, will be spotlighted at InnoTrans 2022 (Hall 5.1, Booth 332), September 20-23 in Berlin, Germany.

“Since the EN45545 standard came into effect, the rail industry has faced challenges in obtaining compliant thermoplastic materials – and SABIC has been proactive in providing solutions,” noted Brian Rice, Senior Manager, Global Product Management, LNP/NORYL, Specialties, SABIC. “With our new LNP ELCRES FST products, we not only met customers’ high expectations for compliance, performance, aesthetics and manufacturability, but we also addressed their sustainability goals with bio-based versions. With multiple grades to choose from, manufacturers can once again leverage the advantages of thermoplastics in their seating applications.”

Meeting Customer Requirements for Compliance with Stringent EN 45545 Standard
LNP ELCRES FST copolymers address demands from customers like Monte Meão, a Portuguese rail seating provider, for high-performance thermoplastics that help address the stringent requirements of the harmonized European rail fire protection standard, EN45545.

Fernando Cerqueira, CEO of Monte Meão said, “We needed an injection molding material that complies with the safety requirements set forth in the EN45545 standard for railway seating and offers long-term durability for our customers. SABIC’s LNP ELCRES FST2432 copolymer provided a good combination of physical properties and a flexible processing window.”

Bio-based Materials Increase Sustainability
SABIC’s bio-based versions of both the extrusion and injection molding grades were developed to expand the sustainability benefits of the LNP ELCRES FST materials beyond paint elimination and weight reduction. LNP ELCRES FST2732EB (extrusion) and LNP ELCRES FST2432B (injection molding) products incorporate 55 percent renewable feedstocks from crude tall oil and other waste products. Both are potential drop-in solutions that deliver the same high performance and regulatory compliance as the fossil-based grades. An Intergovernmental Panel on Climate Change (IPCC) carbon dioxide (CO2) equivalent analysis showed these bio-based products reduced carbon emissions by 33 percent vs. their fossil-based counterparts.

Custom Color and Chemical Resistance Enhance Aesthetics
The new LNP ELCRES FST copolymers offer molded-in color options from a broad palette, including custom colors, to help enable OEMs and railway operators to brand their seats as part of the interior Molded-in color eliminates the need for secondary painting, thereby reducing cost and CO2 footprint. To maintain the attractive appearance of rail seating over its lifetime, the SABIC materials provide excellent chemical resistance that simplifies graffiti removal, and a good balance of stiffness and impact resistance to improve durability and extend useful life. Also, the increased stiffness of the LNP ELCRES FST grades compared to standard PC allows the same part to be manufactured using less material, for potential cost savings.

“Our new LNP ELCRES FST copolymers are the result of a major technological breakthrough that helps ensure compliance with stringent fire protection requirements of the European railway standard,” commented Luc Govaerts, Director, Formulation & Application, Specialties, SABIC. “By bringing together a proprietary copolymer material and an enhanced additive package, our team delivered the outstanding flame-smoke-toxicity performance that customers are seeking. We took this major development effort one step further by formulating drop-in, bio-based versions of both grades to offer the industry new options for increasing the sustainability of rail seating.”

New Copolymers to be Featured at InnoTrans
SABIC’s Specialties business will feature the new LNP ELCRES FST materials at the company’s exhibit at InnoTrans 2022. Parts to be displayed will include the back of an R6 train seat (injection molded) and a portion of an R6 seat (extruded and thermoformed). The Specialties business will share the booth with SABIC’s Functional Forms business.

At the show, the company will also be featuring a new pellet-fed additive manufacturing (PFAM) grade that is well-suited for rail seating and other large parts.

 

 

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Scientists Crack Upcycling Plastics to Reduce Greenhouse Gas Emissions

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Scientists Crack Upcycling Plastics to Reduce Greenhouse Gas Emissions

Scientists Crack Upcycling Plastics to Reduce Greenhouse Gas Emissions

Scientists have developed a breakthrough process to transform the most widely produced plastic — polyethylene (PE) — into the second-most widely produced plastic, polypropylene (PP), which could reduce greenhouse gas emissions (GHG).

“The world needs more and better options for extracting the energy and molecular value from its waste plastics,” said co-lead author Susannah Scott, Distinguished Professor and Mellichamp Chair of Sustainable Catalytic Processing at UC Santa Barbara. Conventional plastic recycling methods result in low-value plastic molecules and, thus, offer little incentive to recycle the mountains of plastic waste that have accumulated over the past several decades. But, Scott added, “turning polyethylene into propylene, which can then be used to make a new polymer, is how we start to build a circular economy for plastics.”

“We started by conceptualizing this approach and demonstrated its promise first through theoretical modeling — now we have proved that it can be done experimentally in a way that is scalable and potentially applicable to current industry demands,” said co-lead author Damien Guironnet, a professor of chemical and biomolecular engineering at Illinois, who published the first study outlining the necessary catalytic reactions in 2020.

The new study announces a series of coupled catalytic reactions that transform PE, which is #2 and #4 plastic that make up 29% of the world’s plastic consumption, into the building block propylene that is the key ingredient to produce PP, also known as #5 plastic that accounts for close to 25% of the world’s plastic consumption.

This study establishes a proof-of-concept for upcycling PE plastic with more than 95% selectivity into propylene. The researchers have built a reactor that creates a continuous flow of propylene that can be converted into PP easily using current technology — making this discovery scalable and rapidly implementable.

“Our preliminary analysis suggests that if just 20% of the world’s PE could be recovered and converted via this route, it could represent a potential savings of GHG emissions comparable to taking 3 million cars off the road,” said Garrett Strong, a graduate student associated with the project.

The goal is to cut each very long PE molecule many times to obtain many small pieces, which are the propylene molecules. First, a catalyst removes hydrogen from the PE, creating a reactive location on the chain. Next, the chain is split in two at this location using a second catalyst, which caps the ends using ethylene. Finally, a third catalyst moves the reactive site along the PE chain so the process can be repeated. Eventually, all that is left are a large number of propylene molecules.

“Think of cutting a baguette in half, and then cutting precisely-sized pieces off the end of each half — where the speed at which you cut controls the size of each slice,” Guironnet said.

“Now that we have established the proof of concept, we can start to improve the efficiency of the process by designing catalysts that are faster and more productive, making it possible to scale up,” Scott said. “Since our end-product is already compatible with current industry separation processes, better catalysts will make it possible to implement this breakthrough rapidly.”

Both groups used virgin plastics and similar chemistries. However, the Science team used a different process in an enclosed batch reactor, requiring much higher pressure — which is energy intensive — and the need to recycle more ethylene.

“If we are to upcycle a significant fraction of the over 100 million tons of plastic waste we generate each year, we need solutions that are highly scalable,” Guironnet said. “Our team demonstrated the chemistry in a flow reactor we developed to produce propylene highly selectively and continuously. This is a key advance to address the immense volume of the problem that we are facing.”

Dow researchers were also involved in this work. “Dow is taking a leading role in driving a more circular economy by designing for circularity, building new business models for circular materials, and partnering to end plastic waste,” said Dow senior scientist and co-author Ivan Konstantinov. “As a funder of this project, we are committed to finding new ways to eliminate plastic waste and are encouraged by this approach.”

 

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Recyclass Approves VOID Technologies Cavitation Solution Enabling 35% Material Reduction in Polyethylene Films

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Recyclass Approves VOID Technologies Cavitation Solution Enabling 35% Material Reduction in Polyethylene Films

Recyclass Approves VOID Technologies Cavitation Solution Enabling 35% Material Reduction in Polyethylene Films

Materials science company VOID Technologies has received RecyClass approval for its VO+cavitation technology, developed to accelerate the transition to more sustainable flexible packaging by reducing the amount of solid plastic in polyethylene (PE) film.

Cavitated Machine Direction Orientation (MDO), PE films produced using VOID’s new ‘VO+ PE Masterbatch’ offer 35% material saving achieved via density reduction and downgauging, and also opacity without TiO2.

The technology has now been accredited as fully compatible with the European polyethylene recycling stream, paving the way for its adoption by film and packaging manufacturers across the European Union.

VO+ is an extensively patented cavitation technology that replaces solid plastic with micro- and nano-scale air pockets to create high performance products with a reduced environmental footprint, without any gas injection or heavy mineral fillers.

VO+ films are produced by blending the masterbatch with PE as part of the film extrusion process, before the film is MDO stretched. The orientation process causes the VO+ additives within the masterbatch to separate from the primary polymer to create a non-breathable nano- and micro-voided structure. The combination of MDO and cavitation leads to improved film performance including puncture, toughness, and high opacity via light diffraction without the need for TiO2.

VO+ technology offers two clear benefits for the recyclability of PE films. The first being, VO+ PE films have low density – even when very high opacity is required – meaning the films will always float in separation systems, as opposed to conventional PE films, which often sink due to high loadings of TiO2 pigments. In addition, during the recycling process, VO+ films will turn from white to clear and will retain similar properties to recycled PE resins.

RecyClass Recyclability Approval – awarded following independent laboratory testing in accordance with its Recyclability Evaluation Protocol for PE films – confirms that VOID’s ‘VO+Masterbatch Technology’ will not have a negative impact on current European PE flexible recycle stream . As a result, it will contribute to improving plastic packaging circularity, whilst reducing plastic usage.

“VOID is at the forefront of developing innovative and commercially scalable technologies to support the packaging industry’s drive towards greater sustainability. The RecyClass Recyclability Technology Approval is the flagship validation programme in the EU, and we’re delighted that VO+ Technology has secured approval status,” says James Gibson, VOID Technologies’ Chief Executive Officer and Co-Founder.

“We now look forward to working alongside film producers, packaging machinery manufacturers and end-user brands to harness the capabilities of VO+ Technology.”

 

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Graphene Nanotubes Offer an Advanced Set of Properties to Meet Ev Battery Pack Standards

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Graphene Nanotubes Offer an Advanced Set of Properties to Meet Ev Battery Pack Standards

Graphene Nanotubes Offer an Advanced Set of Properties to Meet Ev Battery Pack Standards

  • Graphene nanotubes make it possible to preserve high thermal and chemical resistance together with stable electrical conductivity
  • Nanotube-enhanced electrically conductive PPS for battery packs perfectly complies with Li-ion battery pack system standards.
  • Manufacturers have a solution for optimizing performance, energy output, and cost structure of their battery packs to meet the trends of the booming EV market.

Some 6.6 million electric vehicles were sold around the world in 2021. Market trends are leading electric vehicle battery pack manufacturers to improve battery characteristics, design, and cost-efficiency, aiding their adoption by the mass market.

A leading Chinese company in engineering plastics and new composite materials, Genius, together with OCSiAl, the world leader in the production of graphene nanotubes, has developed an advanced engineering solution for battery packs. They utilize reinforced glass fiber filled polyphenylene sulfide (PPS), with 0.3 wt.% graphene nanotubes replacing 10 wt.% conductive carbon black. The final parts show surface resistivity of 103 Ohm/sq after injection molding and fully meet the high battery standard.

Traditional agents added into thermoplastics have numerous drawbacks, increasing the number of out-of-spec parts and forcing producers to make compromises in performance: carbon black can’t provide stable and homogenous electrical conductivity, while carbon fiber can’t provide targeted low resistivity.

“In contrast to conventional additives, graphene nanotubes used at an ultra-low effective concentration make it possible to preserve the outstanding chemical and thermal performance of high glass filled PPS, including its dimensional stability at ambient conditions. What’s more, they preserve the required MFI level and impact viscosity, thereby providing acceptable injectability, which is hard to achieve using multi-wall carbon nanotubes,”- said Loyes Zhi, Managing Director of Sales and Commercial for Greater China & SEA, OCSiAl Group.

Graphene Nanotubes Offer an Advanced Set of Properties to Meet Ev Battery Pack Standards

An easy-to-handle pre-dispersed concentrate of nanotubes, Tuballtm Matrix, allows good processability and the freedom to incorporate other functional ingredients. Permanent homogenous resistivity without “hot spots,” retained color, good surface quality, and high performance of the battery pack reduce the assembly costs of battery enclosures, increasing their safety, durability, compliance, and affordability, which are the major drivers on the EV market.

 

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ArburgXvision Broadcast: Plastics and the Environment – Plastics Industry Presents Technical Solutions

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ArburgXvision Broadcast: Plastics and the Environment – Plastics Industry Presents Technical Solutions

ArburgXvision Broadcast: Plastics and the Environment – Plastics Industry Presents Technical Solutions

  • Topic of the 13th broadcast arburgXvision: “Using plastic to protect the climate as a way out of the environmental crisis”
  • Cooperation: “Plastic is only a recyclable material when it circulates.”
  • Great response: Over 1,250 viewers live, another 1,300 in the follow-up

It almost sounded provocative: “Using plastic to protect the climate as a way out of the environmental crisis” was the topic of the interactive Internet TV programme arburgXvision on 22nd November September 2022. Gerhard Böhm, Arburg Managing Director Sales and Service, Bertram Stern, Sustainability Manager at Arburg, and Prof. Dr.-Ing. Hans-Josef Endres, Managing Director of the Institute for Plastics and Recycling Technology (IKK) at Leibniz University, joined host Guido Marschall in the TV studio to discuss the apparent contrasts and prospects in plastics processing.

The issue is a concern for society, science and industry alike: What do we have to do to live with plastic as a recyclable material and find a way out of the environmental crisis in the process? Around 1,250 viewers followed the programme live and made active use of the opportunity to ask the experts questions via chat. In the follow-up (as of 26 September 2022), a further 1,300 interested people found out more about this exciting topic on the event website and in the social media channels.

Circular economy: the whole value chain in demand
Three issues were of crucial importance in the expert discussion for a successful circular economy: Design for Recycling, high recyclate quality and the need for all parties involved in the manufacturing of plastic products to work closely together along the entire value chain.
First of all, there is the original material. For Gerhard Böhm, one thing is certain: the fewer materials there are in a package, the simpler and more cost-effective, and thus also more profitable, the recycling process is. It is also important to design the product features in a sensible way. “Why is coffee packaged in capsules that have a shelf life of ten years or more? Hardly anyone keeps coffee for so long,” says Gerhard Böhm as an example. We also have to think about whether it makes sense, for example, to wrap plastic yoghurt cups in paper. While it is good to increase consumers’ awareness of material separation, if such containers are completely disposed of in the yellow bag, efficient, recycling by type into new products becomes impossible. This in turn touches on the issue of sustainability. For Prof. Dr Hans-Josef Endres “a hot potato”. The clear goal is less combustion and less exports. “We are working to drive recycling rates upwards.” After all, the quantity and quality of recyclates is an important building block in finding a way out of the environmental crisis.

Application expert from Lossburg joins in
A contribution from the Arburg headquarters in Lossburg was a fitting accompaniment. Christian Homp, Group Manager Applications & Industries, presented projects and technologies such as “R-Cycle” or “HolyGrail” for innovative labelling and single-sort recycling of plastic products. He also invited customers to come to Lossburg or to the K trade fair to test the processing of alternative materials together and to discuss new solutions.

Getting consumers on board
The quality of the recyclates is the key question, says Bertram Stern. But here, too, all those involved have to work together, as only closed loops are effective! Prof. Hans-Josef Endres added that the advantages of plastics must be made much clearer to the consumer. For example, that regenerative energy would not even be possible without the use of plastic. “The processing of recyclates is an innovation driver,” Gerhard Böhm emphasised and suggested getting consumers on board and explaining what progress the industry has made in the last three or four years. He believes that there has already been enough said about what is not possible. Now it is time to show what the industry can already achieve, for example at K 2022 in Düsseldorf. In this context, all participants regretted that the world’s leading trade fair is only open to trade visitors and not to the general public.

 

 

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Mold Sampling During Flow Simulation

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Mold Sampling During Flow Simulation

Mold Sampling During Flow Simulation

Flow simulation data can significantly reduce the time until the real sampling of a tool, and avoid expensive tool modifications. The prerequisite is that the development partners work on the project in a centralised, simultaneous workflow instead of sequentially and contribute their know-how simultaneously. This is the result of a joint project in which Borealis, Oerlikon HRS flow and ENGEL used the example of a demanding mould to show how successfully injection moulding parameters can be optimised in the simulation and transferred directly to the machine as an initial setting proposal, provided that all relevant data of the injection moulding machine, the processed material as well as the hot runner system and other components are available. The experience gained from this close cooperation, the precision of the spot landing achieved with it and possible consequences for practice are presented by the partners in the context of a documentation that can be accessed online and will be presented at K2022.

The simulation was carried out with the aid of Moldflow , using the example of a family mould with three cavities and a weight difference of 1:11 from the smallest to the largest component. ENGEL provided a duo injection moulding machine, detailed values, for example on the geometries of the nozzle used, as well as the sim link data interface for the direct connection of Moldflow to the CC300 control unit of the injection moulding machine. Borealis provided the comprehensive, very precise data on the flow behaviour of the Daplen EE001AI polypropylene, and Oerlikon HRS flow contributed a servo-driven 8-cavity hot runner system that allows the volume flow to be controlled and thus each cavity to be filled individually.

In the traditional process, the parties involved do not discuss possible causes of faults and remedial measures until after sampling has been completed. In the project described here, optimisation with regard to temperature control, injection characteristics and all other pressure and time-related injection moulding parameters started jointly and immediately at the beginning of the simulation. The parameters determined in several iteration steps were then transferred to the machine via sim link. This data exchange between simulation software and injection moulding machine can take place in both directions. It thus also enables the analysis of process data, which in turn provides potential for process optimisation. Access to sensitive design data is not necessary.

The real production start-up underlined the high precision of the settings found via Moldflow . The real filling behaviour and the positioning of the weld lines matched the simulation 100 %. The warpage behaviour of the largest part, the door trim measuring around 600 mm x 400 mm, was predicted to within ±2 mm, and the dimensions across the diagonal of over 650 mm were maintained with maximum deviations of only 0.04 %. After a few optimisation steps and without major manual readjustment, all three moulded parts met the quality requirements.

This joint project has not only shown that real production has run almost identically to the simulation, but the result also opens up potential for more sustainable production. For example, it is possible to see in the design phase whether a machine is suitable for the intended product or whether energy can be saved and production efficiency increased by using a smaller machine. In addition, the setting data suggestion developed in the simulation reduces the number of necessary setting cycles. This leads to fewer rejects and lower energy consumption during sampling.

Markus Kralicek, Business Development Manager at Borealis, Michael Fischer, Head of Business Development Automotive Technologies at ENGEL, and Stephan Berz, Vice President Sales at Oerlikon HRSflow and General Manager DACH, will report on the project itself and many additional details in a free, off-line webinar at https://www.hrsflow.com/ww/en/events/borealis-engel-oerlikon-hrsflow-webinar. In addition, the speakers will present the results during K 2022 at the Oerlikon HRSflow stand (Hall 1, Stand D10) on Thursday, 20.10.2022 at 4.30 p.m. and on Tuesday, 25.10.2022 at 4.00 p.m.

 

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Digitally Networked Production Cell Communicates With Mould and Periphery

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Digitally Networked Production Cell Communicates With Mould and Periphery

Digitally Networked Production Cell Communicates With Mould and Periphery

An especially “smart” exhibit at the Arburg trade fair stand “13A13” and an example for the future of digital production cells is the turnkey system based on a hybrid Allrounder 630 H: the injection moulding machine communicates via the Gestica control system and OPC UA with mould, hot runner controller, material dryer and automation. The “Moldlife Sense” computer system is integrated into the 32-cavity mould provided by Arburg’s partner Hack, and enables monitoring across the complete life cycle.

In this example, the practical advantages of digitalisation and automation in plastic processing are especially evident in the production of blood vials for medical technology.

New interface: machine communicates with mould
The “Moldlife Sense” computer system enables the complete life cycle to be monitored. Arburg has implemented the new solution for communication between mould and machine together with the cooperation and development partner Hack. A hybrid “Packaging” Allrounder 630 H in clean-room design produces, with the 32-cavity mould of Hack, transparent blood vials made of shatterproof PET. The location of changes occurring at the mould can be precisely assigned with the help of a sensor system. Two cameras take images or videos, e.g. of mould separation and parts ejection. There are also four displacement as well as four knock sensors for the tie-bar guidance. In this way, process changes can be detected at an early stage and damage to the mould reliably avoided. The data is passed directly to the machine control system via an OPC UA interface.

The “Moldlife Sense” computer system enables the complete mould life cycle to be monitored.

 

Gestica features for quick and secure workingIn addition to the mould, the central Gestica control system, hot runner controller (Mold Masters), a special PET material dryer (Eisbär) and the automation (Waldorf) are connected to the central Gestica control system via OPC-UA. In this way, the temperatures of hot runner and dryer can be monitored, and the automation started and stopped directly via the Gestica. The hot runner controllers also communicate via the Euromap (EM) 82.2, and the automation via the new interface EM 79. Further features such as the “aXw Control PressurePilot” controller function and the “aXw Control MeltAssist” provide additional process reliability and enable comfortable and quick working.

In-line quality assurance
32 blood vials are produced in a cycle time of around 7.5 seconds, and removed via a side-entry robot made by Waldorf. The encapsulated automation is equipped with four cameras, which check that the components are straight. A QA request can also be called up at the push of a button.

 

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“Economically, Recycling is Perfectly Feasible”

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“Economically, Recycling is Perfectly Feasible”

“Economically, Recycling is Perfectly Feasible”

Interview with Jochen Hirdina, Head of Plastics Technology at Krones AG

Mr. Hirdina, Krones is pursuing its own sustainability strategy. What are the cornerstones?
Krones has set itself very ambitious climate targets for 2030. As a company, we will have reduced our carbon footprint by 80 percent by that time. For our products, we plan to reduce carbon emissions by 25 percent. We will also reduce hazardous waste and drinking water consumption by ten percent. Another important element in our sustainability strategy is to contribute our part towards a closed-loop recycling economy. We want to help avoid plastic in the form of waste. In the beverage industry, we are well on the way to completely closing the loop with PET bottles in Germany, and things are also moving in Europe. The reason for this is, that the European Union has made provisions for recyclates that are forcing our customers and the industry to take action. I’m witnessing a great deal of movement in that regard right now.

Could you give us an example?
First of all, you have to realise how the cycle works. Products are manufactured, which are then returned after use and reprocessed into a new product. Collection is of course the basic prerequisite for a cycle to function, but you also have to know what happens to the material, and where you’ll reuse it. The ideal scenario is to use it again in exactly for the same application it had originally. This works relatively well with short-lived products such as bottles, because there is a high turnover rate. In other areas, it will probably be much more difficult. A large discounter in Germany has started to build its own value chain for a closed loop. For me, this is a kind of blueprint for how the whole process can work.

If we look at the situation in Germany, a lot has happened in recent years. For instance, not all PET bottles were included in the cycle in Germany until now in the beverage sector. Bottles containing fruit juice for example were not included. This has now been standardised, and the bottle deposit now applies to the entire beverage range. We have collection rates of 98 percent for PET bottles, and it has been found that the collected PET quantities are actually used again to produce new PET bottles. So, Germany is already doing very well in terms of the closed cycle.

But when some big companies like Lidl do something like this, there will not be enough left for the many small ones.
That is indeed the reality of today. However, this is due to the fact that we still have too little recycling capacity available. It must of course increase so that the returns can be completely converted into new recyclate. Viewed globally, the current low capacity is a consequence of the lack of economic efficiency of recyclates to date. In recent years, it was simply cheaper to buy virgin material because of the low oil price. Meanwhile, we have very high energy prices, and the use of recyclates is regulated by law. Because of the price development and the increased demand, recycling can now be implemented economically. We will therefore see an expansion of recycling capacities in the years to come. Another factor of course is the raised awareness of sustainability in the industry. For example, a major US beverage company has announced that it will only use rPET for some of its products.

In addition to its core business of bottling plants, Krones also has recycling plants. How did that come about?
We have basically been involved in recycling for a very long time. We gained our first experience in the field in 2000, when we built the first PET recycling plant in Switzerland, together with another company. In addition, we have decades of experience in building cleaning machines for bottles. After all, every recycling plant needs cleaning machines to remove the label and product residues, for example. And we were aware early on that plastic recycling represents the future, so for this and a number of other reasons, we decided to enter the recycling sector in 2009.

We undertake complete project planning for recycling plants, which is a core competence for us as a plant manufacturer. We offer our own core modules for this purpose. MetaPure W, for example, is a washing module for plastics. And to bring plastics back to the desired product properties, we offer a system named MetaPure S. Our recycling business is very important for us, even if we are not the market leader in that sector, which we are for beverage systems. However, our recycling technology is very well received by our customers.

Does it make sense to link such recycling plants with an application, such as a beverage bottling plant?
In principle, it is of course possible to use the material from a recycling plant as a starting material for the production of new preforms. It is also possible to place the interface in a beverage plant and use the recyclate to make new bottles, however, it won’t be integrated into the process. The reason for this is easy to explain: ideally, a recycling plant will be operational for 365 days a year; that’s when it’s at its most efficient. In a beverage line on the other hand, there are fluctuations, because people drink more in summer than in winter, so more bottles are filled accordingly. During the summertime, the lines have to run around the clock, whereas in winter, you can skip a shift or two. One-to-one interlocking would not work and would not make sense economically, either.

How important is cross-company exchange in the circular economy?
This is indispensable in view of the complexity of the circular economy and the many industries involved in it. In the past, these different industries had few points of contact. If we want to get to grips with the common problem of plastic waste, exchange is essential. At present, there is still room for improvement. Everyone has to be open in their dealings with partners, otherwise it will be difficult to implement an end-to-end circular economy. Fifteen or twenty years ago, companies were still extremely secretive towards each other. Fortunately, this has improved, because, if we want to leave a liveable planet for future generations, we all have to pull and work together, and time is currently working against us.

 

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