From customized requirements to marketable products

During our morning ablutions of dental hygiene or shaving, on our way to work, at the workplace and perhaps when exercising later – we are constantly surrounded by products that are made entirely or partly of plastic materials: toothbrushes and razors, high-quality pots of cream or make-up, reusable cups, numerous office materials, ergonomic bicycle handles, mats, even our pets’ favorite toys.

Actega provides the SOFT EST.® TPE portfolio with a wide range of functions for a variety of consumer goods applications. The ProvaMed® TPE portfolio provides suitable material solutions for applications in the medical and pharmaceutical sectors. Actega thus specializes in customized developments with a wide range of functional possibilities. In order to meet these requirements, Actega has invested heavily in its in-house technical center and application laboratory, which includes the tie-bar-less Engel Victory 120 tech for injection molding. In addition, Actega as a whole invests around nine percent of its turnover in research and development every year. This gives rise to a large development team with experienced plastics technicians, excellently equipped laboratories, and extensive R & D capacities for the development of new, future-oriented products from the initial requirements profile to the marketable product. The details of project work are described below.

A look into the laboratory area shows the practical implementation. This department comprises Research and Development, Analytics, Quality Control, and Technical Service. The first step usually involves the customer drafting an extensive requirement catalog. A team of experts is on hand to provide advice right from the start. On this basis, the raw materials that may come into question are examined very closely and it can be checked whether or which products in the range meet the customer’s requirement criteria. If it turns out that no relevant material can be identified, the next step would be a new development. Initial material ideas with different raw material components – tailored to the requirement profile – are conceived and these are then produced on a laboratory extruder. Subsequently, extensive tests are carried out on the granulates and test rods produced from the material approaches (including ageing, sterilizability, solvent adhesion). Thanks to a comprehensive machine park in our own in-house technical center and the corresponding application technology, additional test rods and specimens can be manufactured once satisfactory material compositions have been found, thereby testing the processing properties of the compounds. This enables new development products to be tested and parametrized in advance and the development steps accelerated and optimized, as it is possible to establish immediately on site whether the materials developed display satisfactory processing and correspond with customer requirements.

Material properties can also be precisely adjusted to the needs of the respective application in the form of additives during the manufacturing process. Stabilizing agents, for example, extend the service life of the plastic and protect it from harmful influences. Special antioxidants prevent the polymer chains from disintegrating and embrittling through reactions with atmospheric oxygen, or discoloration of the material. Adding colorants – dyes, pigments or effect pigments – enables the otherwise transparent polymers to be dyed.

After further testing in the laboratory and associated departments, samples can be produced for customers to test on their equipment. Once everything is running to everyone’s satisfaction, commercial production can take place in the quantity required by the customer.

Before this, however, the Quality Control department carries out basic checks during the development process and especially during production (cut, homogeneity, flow behavior, etc.). Analytics involves a more detailed approach to the material, testing both raw materials and finished products. This also involves substances which may not be included in accordance with the customer’s test catalog or from a legal standpoint, or substances which could possibly have an influence on flavor, to name just two examples. 

And finally, the Technical Service department is available to customers right on site, offering advice, technical know-how and support when setting up the plants, and ensuring that the compounds are processed.

This is how, for example, the toothbrushes referred to above –
polypropylene (PP) or polyethylene terephthalate (PET) in the hard component, ProvaMed® TPE as a soft-touch element for a secure grip – or interdental brushes are produced. These ProvaMed® TPE are offered in the Shore hardness ranges A-20 to A-80, natural- colored and translucent. They are characterized by their particular softness, individual colorability, pleasant feel, as well as their cleanliness and food-safe properties.

Nanotubes: a promising solution for advanced rubber cables with 60% less conductive filler

• Graphene nanotubes are proven as an innovative solution for the cable industry: from a semi-conductive layer to anti-static jacketing and accessories.
• Being applied in EPDM rubber, graphene nanotubes allow producers to reduce the total amount of conductive filler by 60%.
• Improved compounding and extrusion rate, and high tear strength are the competitive advantages granted by nanotube-modified rubbers for cable parts.

Outstanding resistance to heat, ozone, and weather, combined with high flexibility, make EPDM a prime rubber for the cable industry. But beyond this, a semi-conductive layer and anti-static cable elements require electrical conductivity that is usually achieved by adding a conductive filler into otherwise insulative rubber. Until now, the industry has not had a solution to do this without drawbacks. Depending on the target level of electrical resistance, the loading of carbon black can reach 40 wt.%, which results in a high-dust production process and an increase in compound viscosity, which in turn hinders standard methods of manufacturing of cable products by extrusion or injection molding, as well as causing an increase in hardening and a loss in the elasticity of molded parts.

Rising demand for high-performance materials, together with a growing number of industries affected by new standards, compel the cable industry to take an innovative approach. Graphene nanotubes from their largest manufacturer OCSiAl have proven themselves as a comprehensive solution for rubber cable parts. Long, flexible, highly conductive, and strong, nanotubes create conductive reinforcing networks inside rubber that provide electrical conductivity and improve mechanical properties at ultra-low dosages, starting from 0.15 wt.%.

The use of nanotubes to obtain conductive compounds with a stable electrical resistance below 50 Ohms, as required for a semi-conductive cable layer, allows producers to remove a large portion of carbon black, decreasing the overall conductive filler loading in rubber by 60%. The low amount of nanotube additive in paste form allows makers to avoid high-dust manufacturing, reduces viscosity, and improves extrusion rates, along with lowering the impact on hardness and elasticity.

For the anti-static EPDM compounds used for cable connectors, bushings, and jacketing, graphene nanotubes also enhance the production process. The addition of graphene nanotubes at a loading of just 0.15–0.2% provides electrical resistivity below 10^6 Ohm/sq (which is stable during a product’s service life), low hardness, and improved tear and tensile strength. Scale-up tests by a European cable component manufacturer have proven the stable performance of nanotube compounds, without carbon to the surface after the extrusion process. Moreover, graphene nanotubes allow rubber cable elements to benefit from a previously impossible combination of stable anti-static properties and an opportunity for coloration.

Providing a combination of previously unachievable properties, graphene nanotubes open up opportunities for enhanced cable parts with more durable and stable performance to meet new industry standards.

Learn more on graphene nanotubes in rubbers at tuball.com.

Anniversary 25 years of Arburg Turkey

• Festive: anniversary event with around 180 guests and high-profile representatives from the parent company
• Since 1996: Arburg’s own subsidiary in Turkey
• Today: increasing demand from electronics and medical technology

In 1996, Arburg established its own subsidiary in Turkey. Due to corona restrictions, only 40 customers in small groups could attend the Open House in December 2021. Then, on 1 June we were at last able to officially celebrate 25 years in business. The exclusive anniversary event was attended by around 180 enthusiastic guests. High-profile representatives from the parent company were Renate Keinath, Managing Partner, and Gerhard Böhm, Managing Director Sales and Service.

The backdrop to this unique evening was an atmospheric boat trip with gala dinner on the Bosporus. “I am delighted to celebrate with you in these very special surroundings the 25th anniversary of our Turkish subsidiary, and I am very impressed with the team’s achievements over the past decades,” Renate Keinath stated in her speech. “A presence on the Bosporus has always been particularly important for us because it builds a bridge between the countries of Europe and the Arab states.” On behalf of the owner families and the entire Arburg organisation, she thanked Engin Malcan, Managing Director of Arburg Turkey, and presented him with the anniversary sculpture.

Arburg’s 55 year presence on the Bosporus
Back in 1967, Arburg sold the first Allrounder injection moulding machine to Turkey via its then trading partner BHK Makine. Its customer was Teksan, the first national manufacturer of water meters. For strategic reasons, a separate organisation was founded in 1996 – Arburg Plastik Enjeksiyon Makinaları San. ve Tic. Ltd. Şti with four employees at the time.
Since 2001, Managing Director, Engin Malcan, has been driving the dynamic development in Turkey with his 17-strong team:
“In the meantime, we are the market leader for premium injection mouIding machines in our export-oriented country. Arburg Turkey is a forward-thinking organisation and is constantly endeavouring to improve and to strengthen its market position.”

Growing demand for high-quality machine technology
In Turkey, Arburg is experiencing growing demand for high-quality injection moulding machines, including an increasing number of electrically driven series. Allrounders are particularly sought after for the production of electronic and medical technology products, as well as in the automotive and packaging industries.
Arburg is now a market leader in premium injection moulding machines in this export-rich country. In 2005, the subsidiary moved into its current building in Beylikdüzü near Istanbul. It also has a 210-square-metre showroom with space for three to six Allrounders for training, tests, and mould trials.
Besides sales, consulting and service play a very important role in Turkey. The subsidiary offers its customers a 24-hour hotline and globally networked logistics. Around 90 per cent of all spare parts ordered are at the customer’s site within 24 hours. The team includes long-standing employees with extensive expertise. One of them is Adem Vardar, a service technician who has been with the subsidiary from the very beginning and who now puts his many years of expertise to good use in an executive position as Service Manager. Since 2021, Arburg’s Turkish Service has also been supporting customers in Egypt, Iran, Syria, Saudi Arabia, Dubai, and Bulgaria with maintenance and commissioning for projects.

Future Packaging to redefine India Pharma industry growth: InnoPack Pharma Confex

CPhI Conferences India, a division of Informa Markets in India is back with the most influential show, the 11th Annual InnoPack Pharma Confex slated for 9th and 10th June 2022 at Sahara Star, Mumbai, presented by West Pharma. The show will offer a unique combination of an exhibition floor, semi-scientific conferences, and a dedicated spotlight for innovations allowing the pharma packaging fraternity to discover the latest trends and revolutionary technologies transforming the packaging industry.

India has multiple challenges and providing the best healthcare to a burgeoning population is most critical. Despite improvements in the healthcare sector, chronic diseases are surging at a rapid pace. As per a WHO report, 20% of the country’s population suffers from at least one non-communicable disease and the treatments are estimated to cost India USD 6.2 trillion by 2030. Research and development at pharmaceutical companies have driven the growth of the pharmaceutical packaging market in India.

The Innopack confex is a perfect platform for exhibitors to demonstrate their latest developments in the fields of pharmaceutical packaging, labelling, drug delivery device design, and engineering. It will also provide fledgling companies to discover whether their products can match market expectations. The confex also offers myriad content-driven sessions on the entire value chain for packaging drugs and devices along with extensive networking opportunities and innovative crossover solutions to support capital investment decisions. It will also include Packaging Workshops, a Packaging Leaders Round Table session, and the most celebrated – India Packaging Awards. The Confex is expected to draw over 50 exhibitors, 40 speakers & trainers, and 100+ nominations for the awards.

Speaking on the announcement of the 11th Annual InnoPack Pharma Confex, Mr. Yogesh Mudras, Managing Director, Informa Markets in India said, “We are pleased to announce that the InnoPack Pharma Confex will return to its flagship in-person format with a focus on the pharmaceutical packaging industry which will no doubt facilitate its growth to reach an estimated $3 Billion by 2030, coupled with Government incentives and rebate programs. The Confex will provide the industry stakeholders a unique platform to see a comprehensive range of packaging and processing technologies while also affording them the scope for productive, in-depth discussions with vendors to solve pain points and address challenges.”

The Government of India has introduced the Production Linked Incentive (PLI) scheme for encouraging domestic manufacturing and achieving an Atmanirbhar Bharat. The adoption and compliance with regulatory norms in pharmaceutical packaging, along with standards regarding packaging recycling have bolstered the growth of the pharmaceutical packaging market in India. The Indian pharmaceutical packaging market size was valued at $1434.1 million in 2020 and is projected to reach $3027.14 million by 2030 at a CAGR of 7.54% from 2021 to 2030.

The event will witness the presence of various Policy Makers, Industry Captains from Associations, and the Participation of Leaders from top pharma & biopharma companies. It has been well received by both MSMEs and large companies in form of participation and associations. Some of the key delegates include representations from companies such as Aurobindo, Dr. Reddy’s. Zydus, Piramal, Wockhardt, Glenmark, Cipla, GSK, Alembic pharma, Reliance Lifesciences, Macleods pharma, Sanofi, Indoco Remedies, J&J, among others.

The pharma packaging sector in India gained the much-needed impetus to be considered the preferred packaging partner worldwide. The conference agenda intends to accelerate the growth of this industry. The sessions over the two-day conference will be delivered by Vishwanath Swarup, Chief Operating Officer, Bharat Serums and Vaccines Limited, Dr. Aravindan Raghavan, Corporate Head – Global Operational Excellence, Syngene International Limited, Sriman Banerjee, Head of Packaging Development & CDE, R&D Pharma Sci, Takeda Pharmaceutical Company Limited, Rajendra Vidwans, Biopharma Consultant, Ami Polymer Pvt. Ltd., Ravi Kumar, Head-Supply Chain , Johnson & Johnson Pharmaceuticals(Janssen) and amongst other key packaging experts.

Following the Confex, Informa Markets in India is all set to bring in the 7th edition of India Packaging Awards and continue its legacy of honoring the leaders driving the industry, in the midst of a global audience. Slated for 9th June 2022, the stage is all set, and eager to felicitate the best from the Pharma Packaging Industry. The Awards platform will comprise presentations, and exclusive product launches, along with the awards and recognition ceremony.

“Connecting systems is becoming increasingly important”

Interview with Lutz Busch (CEO) and Maik Krüger (Head of Business Development) at Kampf Schneid- und Wickeltechnik GmbH & Co. KG

How has digitalisation gained momentum at Kampf?
Busch: Seven years ago, we conducted a survey to find out what significance Industry 4.0, at that time the term for digitalisation in industry, held for customers. We found out that our customers were very interested in getting more data about the production process and receiving earlier information about necessary maintenance or the replacement of parts, in order to be pro-active regarding any disruptions to production. Back then, we’d already developed a digital tool that could be used to generate up-to-date status reports of machines. Since then, we have initiated further developments, and now have a complete IIoT platform that helps us operate with our customers and also with our suppliers.

Krüger: It’s becoming increasingly important to connect systems with one another if we want to survive and stand one’s ground against the competition. Towards K, we will present another stage in our IIoT platform. Digitalisation continues to develop; products are becoming increasingly sophisticated, and technological leaps are occurring at ever shorter intervals, which always results in new applications and opportunities.

Where is that coming from, the customer or Kampf?
Busch: In order to even enter the discussion, we have to communicate to our customers that we offer solutions in the area of digitalisation. But customers also approach us. This goes so far that, for example, we have developed a prototype for a completely new highly automated machine with a customer, to whom we have now been able to sell ten of these machines. We have entered a new business field, so to speak. High automation and digitalisation go hand in hand in these projects. The more a customer is looking to automate, the more necessary digitalisation becomes.

Can digitalisation in production lead to alleviating the skilled labour shortage?
Busch: That’s where we’re facing a dilemma. Automated processes will gradually replace personnel in simple repetitive activities. At the same time, quality and process analyses and optimisations are becoming increasingly crucial when it comes to competitive advantage. In our experience, people need to receive better training for this, and the level of qualification must be higher because the tasks will become much more complex in order to fully utilise the potentials of digitalisation.

How is digitalisation changing customer communication?
Busch: First of all, it must be made clear that the data we collect is of course the property of the client. They decide how it is used, and that data is collected at the machine and remains in the company. But the customer can also make them available for a cloud-based solution, where we process them anonymously. This is our preferred solution, because you can only develop targeted algorithms with the largest possible amount of data. If we have as many data as possible on the operating states of our machines, we can, for example, identify any regularities in error situations that occur. From this, we can derive recommendations for action from which our customer benefits.

Krüger: In addition to higher operational reliability, digitalisation can also help in the creation of new efficient contact options such as customer portals. In our daily lives, we use digitalisation as a matter of course. We simply order many things on the Internet. This can be transferred to the B2B sector. Processes can be simplified, and important information and solution offers around the products used can be shared. Important spare parts, upgrade options or training content can be quickly identified, availability and costs can be checked, and orders easily processed.

Many companies are still reluctant when it comes to data exchange. Can you understand them?
Busch: That’s like saying we’d rather not build cars because they are involved in accidents from time to time. All the advantages of the car, the mobility, would be completely negated by that. It’s true, the danger of hacker attacks is real. We see that here, too. Just a few years ago, we would have said: What could possibly happen to us in the event of a hacker attack? That has indeed changed completely. You simply have to invest more in security. But I would not be able to make use of technical progress if I said that cybercrime was so very suspicious to me.

How does digitalisation help with the goal of operating more sustainably?
Busch: For example, it is an important prerequisite for the circular economy. It can only be achieved if everyone works together and networks. Let’s take the example of the digital product passport. This is necessary so that plastic products can be traced, and we know exactly what they contain. Only in this way is sensible recycling possible. To make a film, material is first melted, then it is stretched, cut and often also printed. There is information in every step. This can only be collected and made available as information if everyone contributes their data. Years ago, we developed a digital roll protocol together with cooperation partners from the value chain. Today, we are an active partner in a large industry initiative for the realisation of digital product passports.

Krüger: Already today, widespread, high-quality packaging, such as bags for crisps, can be produced with a high recycled content and high quality. We do not yet know how many cycles such a bag can actually undergo but we are convinced that plastics are a valuable material on our way to climate neutrality. To exploit the full potential, we need a circular economy based on data exchange and transparency along the entire life cycle of plastics.

Arburg has had its own subsidiary in Denmark since 1997. To mark the 25th anniversary, an open house and a festive evening event were held on 2 June 2022. As a high-ranking representative from Lossburg, Guido Frohnhaus, Managing Director Technology & Engineering, presented an anniversary sculpture to Michael Kylling, Managing Director of the Danish subsidiary, in the presence of Steffen Eppler, Director Sales Europe. At the Open House, interested customers were able to see for themselves the Allrounder injection moulding technology and the Freeformers for additive manufacturing..