Relaxed mould making with stress-relieved HASCO steel

Developing and producing high-quality, high-performance moulds for plastic injection moulding is a complex process. With its products and services, HASCO, the Lüdenscheid-based standard mould component manufacturer, enables its customers to configure their processes in simple, flexible, and cost-optimized methods when possible. The company attaches particular importance to achieving consistently high and reliable quality in the standard components it produces. Alongside a large number of other criteria, reducing the inherent stress in the materials used is a key quality factor for all HASCO plate products.

Consistent stress reduction

When steel is produced and processed, stresses are automatically introduced into the material. This cannot be completely avoided. If these stresses are not consistently reduced through various methods and measures, they can lead to warpage after machining. Stressed processed plates are then of no use to the mould builder, and costs and delays will be incurred. HASCO minimizes this risk of warpage over the length of the entire value-added process – from the production of the steel at the supplier’s works to the processing of the plates at HASCO, then right through to the provision of support for its customers in achieving the optimum design of mould.

Stress-reduced right from the start

At the steelworks, the steel used by HASCO for manufacturing plates is first produced by uphill casting and then formed to the desired dimensions by open die forging or rolling. Stresses develop in the steel as a result of heating, cooling, and processing. To achieve a clear reduction in these stresses, HASCO has an agreement with the steel producers and suppliers that they should incorporate an additional production stage, namely stress relief annealing. The material is slowly heated to 550 to 650°C in an annealing furnace and kept at this temperature for up to two hours according to its size, which considerably reduces the stresses that have developed. Following this, the steel is cooled down gradually in order to prevent the build-up of new stresses.

Gentle separation and machining

The steel produced in line with HASCO’s requirements is delivered in big slabs, to begin with. These have to be divided into smaller-sized plates for further processing. HASCO employs a high-performance, automated sawing technology for this. The gentle separation process with a precision circular saw minimizes the amount of stress introduced into the material’s edge structure through continuous cooling of the saw blade and the material, among other measures.

During the subsequent milling operation too, the company not only ensures that convincing surface results are achieved in the typical HASCO quality but also pays further attention to keeping stress to a minimum. A completely homogeneous structure is achieved by removing the rolling or forging skin from the unfinished slabs absolutely uniformly on both sides, using consistently sharp milling and cutting tools to avoid surface heating. The careful clamping of the plates with a specially developed clamping fixture additionally contributes towards further minimizing the inherent stress in the material. At the end of the HASCO production process, low-stress standard components are obtained with a minimized risk of warpage for the customers.

Support for mould makers

HASCO has been dealing intensively with the subject of stress reduction for many years. The company has acquired comprehensive experience and built up the corresponding specialist knowledge, which it passes on to mould makers and designers. Klaus Zimmermann, a technical salesman at HASCO and an expert on stress reduction: “We do everything possible, over the full length of the value-added chain, to ensure that our standard components have only a low level of inherent stress, keeping the risk of warpage as low as possible for our customers. In addition to this, we support our customers in optimizing their processes in respect of warpage too. This starts with the design of the moulded parts. Over-sized slide tracks, for example, mean that too much material has to be removed through machining. The level of inherent stress in the material then increases, as does the risk of warpage. We are pleased to advise our customers in cases such as these and support them with our experience in finding optimum solutions.”

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ALPLA Group continues international growth trajectory

The ALPLA Group, the global packaging solutions, and recycling specialist increased its turnover in the 2021 financial year by 8.4 percent to four billion euros. The number of employees worldwide increased to 22,100. In addition to investments in recycling and in the development of bio-based and biodegradable plastics, the company expanded through acquisitions and participation.

 ‘We have put ourselves in a strong position internationally in recent years, invested in the recyclability of plastics and in new technologies and materials, and achieved a new sales record in 2021. We want to secure this positive development sustainably and in the long term,’ emphasizes ALPLA CEO, Philipp Lehner. With an increase in turnover of 8.4 percent to four billion euros, the previous year was significantly exceeded.

 Expansion and globalization of recycling

Since 2021, the ALPLA Group has invested an average of 50 million euros annually in the expansion of recycling activities. By 2025, the recycling loops are to be closed in as many regions as possible. ‘Our customers’ demand for high-quality recycled materials is also growing outside Europe. In the long term, we want to cover between 70 and 80 percent of demand with our own production,’ says Philipp Lehner.

Outlook 2022

Growth of three to five percent is the target for the 2022 financial year. ‘Numerous projects and acquisitions in the USA, Mexico, Asia-Pacific region and Western Europe enable us to strengthen existing and enter new product and market segments,’ Lehner emphasizes. With the new Asia-Pacific (APAC) region coming on stream in early 2022, ALPLA is also expanding the reach of its industry-leading mould technology in the growing Asian market and driving the expansion of the circular economy in the region.

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Constantia Flexibles recognized with an ‘A’ score for climate protection measures

Constantia Flexibles has been awarded for leadership in corporate sustainability by global environmental non-profit CDP (Carbon Disclosure Project), securing a spot on its ‘A List’. The flexible packaging manufacturer belongs to the top 2% of companies evaluated for tackling climate change.

Constantia Flexibles was recognized for its actions to cut emissions, mitigate climate risks and develop a low-carbon economy, based on data reported by the company through CDP’s 2021 climate change questionnaire. The flexible packaging manufacturer is one of 200 high-performing companies out of over ten thousand scored.

“Sustainability and climate-related topics play an essential part of Constantia Flexibles’ business focus/objectives. By fully integrating environmental considerations we can create long-term value. We are delighted that our ambitions are recognized and confirmed by CDP,” says Pim Vervaat, CEO of Constantia Flexibles.

An award for environmental awareness
CDP’s annual environmental disclosure and scoring process are widely recognized as the gold standard of corporate environmental transparency. In 2021, over 590 investors with over 110 trillion USD in assets and 200 major purchasers with 5.5 trillion USD in procurement spend, requested companies to disclose data on environmental impacts, risks, and opportunities through CDP’s platform. A record-breaking 13,000 companies responded.

A detailed and independent methodology is used by CDP to assess these companies, allocating a score from A to D- based on the comprehensiveness of disclosure, awareness, and management of environmental risks and demonstration of best practices associated with environmental leadership, such as setting ambitious and meaningful targets.

Paul Simpson, CEO of CDP, said: “Congratulations to all the companies on this year’s A-List. The scale of the risk of businesses to climate change, water insecurity, and deforestation can no longer be ignored. Our A-List celebrates those companies who are preparing themselves to excel in the economy of the future by taking action today.”

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Perstorp has set Science-Based Targets in line with Paris Agreement

Perstorp Group’s greenhouse gas emissions reduction targets have been approved by the Science Based Targets initiative, meaning they are consistent with levels required to meet the goals of the 2015 Paris Agreement. The targets covering greenhouse gas emissions from Perstorp’s operations (Scopes 1 and 2) are consistent with reductions required to keep warming to 1.5°C, the most ambitious goal of the Paris Agreement.

The Science Based Targets initiative (SBTi), a collaboration between CDP, the United Nations Global Compact, World Resources Institute (WRI) and the World Wide Fund for Nature (WWF) defines and promotes best practice in science-based target setting. It also independently assesses companies’ targets.

“Perstorp has a mission to be the sustainable solutions provider,” says Jan Secher, Perstorp Group CEO. “A part of this is setting targets to reduce the impact within various areas, including carbon emissions. Perstorp wants to actively participate in the transition of the chemical industry, and we are convinced that this will also create value and new business opportunities. We have the possibility to make a great positive impact, by driving change, transforming our production, and enabling new solutions that will help our customers provide sustainable products and offerings to the market. This is our commitment, and aligning with the Paris Agreement is a natural consequence of this.”

Perstorp is committed to reducing absolute Scope 1 and 2 GHG emissions by 46.2 percent by 2030 from a 2019 base year. The company is also committed to reducing Scope 3 GHG emissions from purchased goods and services, fuel and energy-related activities, upstream transportation and distribution, waste generating operations, and end of life treatment of sold products 27.8 percent per ton sold product within the same timeframe. Perstorp’s target for the emissions from its value chain (Scope 3) meets the SBTi’s criteria for ambitious value chain goals, meaning they are in line with current best practices.

Reaching the science-based targets means looking at every aspect of the company to identify possible ways of reducing negative climate impact. Perstorp took an important step towards enabling greenhouse gas emission reductions last December when it began applying Internal Carbon Pricing for Scope 1, 2, and 3. Internal Carbon Pricing is a way to future-proof a company by helping to drive investments that improve sustainability and reduce CO₂ emissions. It is a mechanism to put an internal price on our CO₂ emissions and take this into account in business cases and as the guiding principle for decision making.

“Reaching our science-based targets will require big efforts, including reducing energy consumption at our production sites and shifting to renewable or recycled energy and raw materials sources,” says Anna Berggren, VP Sustainability at Perstorp Group. “The investments and decisions we make today will generate emissions in the long future. Therefore, the informed decisions we make need to take this risk factor into account to support our journey towards our targets in 2030 and beyond. Internal Carbon Pricing is one very concrete way to implement sustainability aspects into our financial decision-making process.”.

Greenhouse gas emissions are categorized into three groups, known as ‘Scopes,’ by the most widely-used international accounting tool, the Greenhouse Gas (GHG) Protocol. Scope 1 covers direct emissions from owned or controlled sources. Scope 2 covers indirect emissions from the generation of purchased electricity, steam, heating, and cooling consumed by the reporting company. Scope 3 includes all other indirect emissions that occur in a company’s value chain.

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http://www.perstorp.com/

New additional service in the run-up to K 2022 in Düsseldorf: Monthly K-Talk starts online on January 20, 2022!

Topic of the first K-Talk: “Climate protection and plastics – do they go together?”
Outlook, orientation, hot topics +++ exciting live discussion rounds with industry experts, users, and representatives from the media and politics +++ K-Talk enables global dialog even before the Leading Trade Fair in the fall +++ on-demand service

On October 19 this year, K 2022, The World’s No. 1 Trade Fair for Plastics and Rubber, will open its doors for eight days. For the 22nd time, K in Düsseldorf will be the performance barometer for the entire industry and its global marketplace for innovations.

K 2022 already offers a real highlight to get you in the mood for the major industry event: the new K-Talk. For the first time on January 20 and then once a month until the trade show in the fall, the K Talk offers exciting discussion rounds with changing international participants, such as industry experts, scientists, representatives of the user industries, from politics, media or NGOs. In doing so, K Talk provides valuable insights, focuses on the application areas of plastics, highlights technological innovations and discusses current challenges of the industry such as circular economy, climate protection and digitalization. Whether concrete best practice examples or long-term strategies for the future – the visions and different perspectives of the panelists are intended to inspire, provide orientation and encourage international exchange.

The K-Talk will be broadcast live via k-online.com and will each last 45 to a maximum of 60 minutes. The international format is in English. Active exchange is encouraged, so questions can be submitted throughout the talk via the chat function. The last quarter of an hour of K-Talk is then devoted exclusively to answering questions from the audience.

K-Talk premiere on January 20, 2022

For its premiere on January 20, 2022, K-Talk will pose the question at 3 p.m. (CET): “Climate protection and plastics – do they go together?” Panelists will be Ulrich Reifenhäuser, CSO Reifenhäuser Group, Chairman of the Plastics and Rubber Division of VDMA and Chairman of the K Exhibitor Advisory Board; Don Loepp, Editorial Director of the Global Polymer Group at Crain Communications and Editor of Plastics News (USA); and Dr. Feliks Bezati, Global Circular Packaging Director Mars, Incorporated (NL). The K-Talk will be moderated by Guido Marschall.

Comexi’s Innovative Technology Enables Wipak UK to Provide More Sustainable Solutions

 The innovative technology of Comexi, a global supplier of solutions for the flexible packaging printing and converting sector, translates into significant benefits for its customers. Wipak UK, a company specializing in the production of sophisticated, high barrier films for food products, has purchased a Comexi S1 DT slitter with double-sided laser scoring. The new capabilities resulting from this investment will allow the family-owned company to further develop its sustainable packaging portfolio.

Ramon Jonama, the Comexi Area Manager for the United Kingdom region, explains that this “innovative technology patented” by the company not only allows “for saving costs regarding the addition of labels,” but simultaneously makes “the perforation laser on both sides of the film. This results in cost reduction, plastic savings, and increased productivity.” The S1 DT slitter, which is already in operation at Wipak UK’s site in Welshpool (Powys, Wales), is one of the few machines installed around the world that can perform these sophisticated applications.

Andrew Newbold, Wipak UK’s Managing Director, comments that the inclusion of this machine in Wipak’s largest project investment in the United Kingdom, which was announced in 2020, is key to the production of packaging that has a low carbon footprint, contains recycled content and is kerbside recyclable. He further explains that Comexi was chosen as the supplier due to its technical expertise and track record of supplying machines for the wider Wipak Group.

The Comexi S1 DT, with laser in-line, is a slitter that provides excellent results in both quality and productivity, even in regard to the most demanding jobs, due to its state-of-the-art control elements and a high degree of automation. Cores, knives, laser heads, photocells, and almost every adjusting element of the machine are self-calibrating, as a result of an extremely interactive and easy-going user interface. This unique automation of the Comexi S1 DT gives the operator, without the need to intervene, the possibility to load the reel into the machine and deliver finished reels.

The turreted version of the Comexi S1 DT is capable of performing jobs that require a large number of output reels and is also able to work with the thickest materials used in the flexible packaging market, including aluminum, wax, and other special or complex materials on the market.

Furthermore, this machine includes Comexi’s laser module. This system allows every converter to run any imaginable flexible packaging laser, including easy-open, micro-perforations, windows, resealable, and a long etcetera list. Comexi’s in-line laser patented systems facilitate subsequent applications and processes, increasing productivity, capacity, and customer benefits.

The Comexi S1 DT allows for a high degree of customization, as well as many automated options, such as splicing tables, automatic reel unloading, video camera inspection, and label robotization of finished reels, thus fully guaranteeing complete system control and an exceptional increase in productivity.

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K 2022 from 19 to 26 October 2022 in Düsseldorf: Global plastics and rubber industry jointly active for climate protection, the circular economy and digitalisation

Exhibitor database now online +++ High internationality +++K-Talk, K-MAG and K-monthly now already provide pooled know-how

At the start of the K year it becomes evident once again that the plastics and rubber experts all agree: K in Düsseldorf is the most relevant meeting point for the entire industry worldwide. Exhibitors from throughout the world come to Düsseldorf to demonstrate the operational excellence of the industry and actively chart the course for the future together with visitors. And this course clearly leads to climate protection, circular economy and digitalisation – and these are also the three declared guiding themes of K 2022.

The open exchange and dialogue on solutions-oriented innovations and sustainable developments across national borders and continents will also be in focus at this year’s K in Düsseldorf. It fulfils the ideal prerequisites for engaging in intense global networking and for jointly advancing projects. Because nowhere else is the plastics and rubber industry gathered in one place with such a high degree of internationality.

Suppliers from Europe, especially from Germany, Italy, Austria, Turkey, the Netherlands, Switzerland and France will be particularly well represented again this year, but also from the USA. At the same time, K clearly reflects the changes affecting the global market: the number and presentation areas of companies from Asia have remained at a constant high for several years now. We can expect impressive appearances, especially from China, Taiwan, India, South Korea and Japan.

The approximately 3,000 exhibitors from 61 countries will occupy Düsseldorf Exhibition Centre in its entirety. The exhibitor database of K 2022 is accessible at www.k-online.com/2410

K 2022 is already now providing pooled expert know-how with its K-Talk. Once a month this digital live talk in English features exciting panel discussions with a changing line-up of international participants dealing with different focal themes but always with a focus on the three guiding themes of K 2022. The first K-Talk, already held on 20 January under the heading “Climate Protection and Plastics – Do they Go Together?” – like all following K-Talks – is still available on-demand. The K-Talk in February will be all about plastics in medicine while the discussion in March is dedicated to mechanical engineering.

Launched last April, the online magazine K-MAG targets all industries related to K and delivers facts, news, stories and trends from the international plastics and rubber industry in German and English all year round.

K-monthly is the name of the new Newsletter of K in Düsseldorf. Subscribers not only receive the most interesting news and stories from the K-MAG via e-mail on a monthly basis but also current information revolving around K in Düsseldorf and the international trade fairs of the K-Global Gate family of products. Subscription is possible on the K website or the K-MAG.

INEOS O&P Europe announces exciting new applications for its Recycl-IN polymer grade range.

INEOS Olefins & Polymers Europe are today announcing an exciting new application of a new polymer grade to its portfolio of products that comprise post-consumer recyclates (PCR). The range of recycled polymer grades (Recycl-IN) is growing as INEOS and its partners develop and explore the displacement of virgin polymers with PCR materials.

 In this latest development, and working closely with the technical team at COVERIS in Winsford, Cheshire, a new stretch-hood packaging film, containing a minimum of 30% recycled material, has undergone a series of rigorous testing and trials at INEOS’ manufacturing facility in Grangemouth, Scotland intended for distribution of INEOS’ palletized polymer resin.

 These trials have demonstrated that the product integrity and quality is maintained and that the new recycled stretch-hood covering for pallets performs to the same standards as a previous solution made from 100% virgin material. It has been introduced ahead of UK legislation for packaging materials that will require a minimum content of recycled polymers.

 “This is a significant breakthrough,” says INEOS Polymer Business Manager, Graham MacLennan. “Palletised distribution of goods is increasing and a stretch-hood covering helps prevent waste, damage, and loss to products transported in this way. By substituting virgin polymer content with recycled polymers, we are actively working towards our targets to adopt a more circular approach, signaling our clear commitment to using more recycled plastic as a raw material. Our new product, developed in close partnership with COVERIS, is a clear demonstration of this. Within INEOS we remain committed to Sustainability, to achieving Net Zero in our operations and bringing solutions to the market that enable others in the supply chain to lower their carbon footprints too.”

This, and other Recycl-IN polymers, are proving that plastics remain a valuable resource, even after initial use. INEOS O&P continues to pursue technological and engineering solutions to increase the recycled content of the materials they produce, and to demonstrate to customers, supply chain partners, and the wider world that their new range of Recycl-INpolymers perform to the high standards that they expect. 

 Mike Richardson, Technical Director, Coveris Winsford said, “Coveris has extensive experience of producing high-performance films with significant recycled content. Our collaboration with INEOS has enabled us to develop a new stretch hooding product with 30% PCR content, without increasing gauge or compromising on performance. Supporting our vision of NO WASTE and the wider industry sustainability goals, the new solution offsets the need for virgin plastics whilst maintaining full recyclability, as well as being fully compliant with UK plastics packaging tax. This will allow our customers the benefits of palletised transportation using plastic tertiary packaging without compromising their sustainability and circular economy goals.” 

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