A new graphene nanotube product for thermoplastics allows automakers to increase cost efficiency

• OCSiAl has launched a new graphene nanotube concentrate for PA, filled PPS, ABS, TPU, and PC.
• The new product provides targeted conductivity in thermoplastics produced by injection molding at working loadings starting from 0.1 wt.% of nanotubes in the final system.
•  This approach allows makers to optimize the painting process and reduce the final production cost.

Painting of exterior automotive parts, such as fenders, bumpers, tanks flaps, grilles, mirror housing, exterior trims, and rear quarter panels, is complicated by the necessity of separate operation lines for metallic and polymer components, as plastics are insulative, which makes in-line electrostatic spray painting impossible. This leads to additional expenses and slows down the whole painting process.

To overcome this, manufacturers of automotive parts should wisely choose temperature-stable thermoplastic grades and modify these systems with electrically conductive additives. The most widespread is carbon black. However, because of their high working dosage required, car end parts with additives demonstrate worsened mechanical properties and processing challenges.

OCSiAl, the world’s largest manufacturer of single-wall carbon nanotubes, also known as graphene nanotubes, has launched the new easy-to-use TUBALL MATRIX 822 graphene nanotube concentrate specifically designed for PA, filled PPS, ABS, TPU, and PC compounds for injection molding. Introducing these nanotubes creates a permanent and homogeneous electrical conductivity without “hot spots” in the range of 10^5–10^9 Ω·cm, while retaining the original key mechanical properties, such as durability and strength, and minimally impacting the host polymer matrix. Furthermore, a low working dosage of 0.1-0.3 wt.% of graphene nanotubes demonstrates only a limited effect on rheological properties and processability.

Graphene nanotube concentrate now enables in-line e-painting of plastic exterior parts together with metal components using electrophoresis, where previously, separate production lines were required. Manufacturers of polymer injection molded parts for automotive, industrial, construction, mining, and other applications now have opportunity to reduce production costs and the number of rejected final parts without changing standard operating processes by using high-performance graphene nanotubes.

“The new product will also be valuable for improving automotive safety and tracking systems: graphene nanotubes allow makers to produce high-quality electrically conductive thermoplastic products without compromises in terms of overall product mechanical performance or durability,” said Vladimir Kravchenko, Development and Support Leader for Thermosets, OCSiAl Group. “We already see demand from manufacturers of fuel system parts including quick connectors, fuel pumps, valves, filter housings, EV-battery caps, and other car components.”

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Arkema to increase its global Pebax elastomers production capacity by 25%

Arkema announces a 25% increase in its global Pebax  elastomer production capacity by investing in Serquigny in France. This investment will notably enable increased production of the bio-circular Pebax  Rnew and traditional Pebax  ranges.

This new capacity will produce a variety of highly specialized grades to meet growing demand in numerous demanding applications thanks to the lightweight, flexibility and excellent energy return of these materials. These properties are particularly appreciated in sports equipment, such as soles for running shoes, ski boots or technical textile, in consumer goods such as smartphones and flexible screens, as well as in other markets such as medical equipment.

Derived from renewable castor seeds, Pebax  Rnew advanced bio-circular materials offer a sustainable solution to our customers who are increasingly driven by sustainability and social responsibility. Compared to other elastomers on the market, these materials have a carbon footprint that is up to 50% lower and can be fully recycled. In addition, this investment, which is scheduled to come on stream mid-2023, will lower the water consumption of the site by 25% thanks to process optimization.

“We are very excited to commit to an expansion in our Pebax  elastomers capacity” said Erwoan Pezron, Senior Vice-President of Arkema’s High Performance Polymers Business Line. “The Serquigny plant has a long proven legacy in the production of these advanced materials, and we are delighted to add this new capacity to support our customers’ growing demand for high-performance sustainable materials. We will also continue to produce many of these materials at our Birdsboro plant in Pennsylvania”.

https://www.arkema.com/

Preconfigured Feeders Offer Plastics Industry A Powerful and Efficient Feeding Solution Coperion K-Tron Announces All-New ProRate PLUS Feeder Line

ProRate feeders are highly standardized and include a variety of design features to optimize performance and ease of use. Simple access for cleaning and maintenance, even within a cluster, is provided thanks to a patent-pending rail system called “ProClean Rail”.

ProClean Rail makes it possible to retract the base unit toward the rear of the feeder and rotate it for access to the feeding section and screw element. This allows for maintenance and cleaning of the feeding unit while keeping the feeder in position.

In addition, the bellows and screw use the latest magnet technology for simple but robust mounting. The magnet connections allow these parts to be released without tools while at the same time providing the required holding force for optimal and safe operation. Thanks to the high level of standardization of the feeders, the number of spare parts required for the emergency stock is minimal. Many parts are identical for all three models and can be used as exchange parts for all devices.

ProRate PLUS feeders are suitable for use in hazardous locations rated NEC Class II, Div. 2, Group F & G and ATEX 3D/3D (outside/inside).

Accurate weight measurement and reliable control modules for efficient operation. All ProRate PLUS feeders are equipped with P-SFT load cells, featuring reliable Smart Force Transducer weighing technology. They operate under compression and provide accurate, stable, and reliable digital weight measurement under a broad range of operating conditions.

The load cells supply a direct digital weighing signal and the onboard microcontroller ensures excellent repeatability and stability. P-SFT load cells have a high tolerance to vibration and electrical
noise. They feature built-in over and underload protection.

Each feeder comes equipped with its own pre-wired ProRate PLUS PCM control module. The PCM is mounted to the feeder stand, with adjustable height positioning. Each PCM is pre-tested in Coperion K-Tron’s manufacturing facility prior to shipping. There are two models of PCM to choose from: a basic motor control unit (PCM-MD) or an advanced version with an integrated user interface and line control functionality (PCM-KD). Within a group of up to eight feeders, one feeder must be equipped with the PCM-KD while the PCM-MD is sufficient for the others.

The PCM-KD comes with all the software the ProRate PLUS feeder will need for continuous applications and supports all three feeder models. The connection between weigh feeders, operator interface and smart I/O is via an industrial network. All motor setup, diagnostics, and operator interface functions are integrated into the PCM-KD user interface. The PCM-KD is equipped with a host communication port (Ethernet IP or Profinet).

A variety of service offerings to keep processes running smoothly

Coperion K-Tron’s dedication to customer satisfaction has also led to the creation of a unique new portfolio of service offerings for the launch of this product line. A variety of Start-up and Service Packages are available for ProRate PLUS feeders to ensure each customer can get exactly the level of service they need. Coperion K-Tron also offers quick and easy remote services for ProRate PLUS.

From an online portal to 24-hour phone support and even remote start-up assistance, trained service technicians are available to keep systems running around the globe. In all, the brand new ProRate PLUS feeder line offers a simple, robust and reliable solution for feeding a variety of free-flowing bulk materials in plastics processing applications.

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Game-changing recycling plant to be built in Melbourne’s west  

Belgium: TotalEnergies increases its production of high- performance polymers for specialty markets

TotalEnergies Polymer plant in Feluy, Belgium, announced the startup of a new production of high-performance polymers with the commissioning of a new reactor in its polypropylene unit.

Through this investment, TotalEnergies strengthens its leading position on the high value- added polymers market. The Company is therefore increasing its production of grades that meet the highest quality standards and technical requirements of specialty markets, including medical and automotive.

Thanks to their many properties, such as lightweight, impermeability or resistance, plastics have become an integral part of our daily lives. In the automotive sector for example, the use of polymers as replacement for metal contributes to reducing the overall weight of vehicles, thereby allowing reductions in CO2 emissions by as much as 10%. In the medical sector, polymers also play a crucial role in the supply of medicines, particularly by ensuring their protection and packaging.

Valérie Goff, Senior Vice President, Polymers at TotalEnergies, stated: “The commissioning of this new reactor in Feluy will enable us to meet the growing demand from our customers, including the automotive and medical specialty markets, for ever more efficient polymers that contribute to reducing the carbon footprint of end-use applications.”

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https://modernplasticsindia.com/

TPEs make work outs easier and fun

Going to the gym is not only a recreational past time for adults but also a path for them to achieve their health and fitness goals. The desire to stay fit and healthy has never been more relevant than now. In addition, with the latest, innovative gym equipment and cable motion technology, fitness enthusiasts are able to expand their exercise possibilities to build balance, strength and power.

Furthermore, today’s gym equipment has evolved and it is no longer bulky but instead compact, to allow for space savings, and far more aesthetic. To achieve ergonomics and cost effectiveness in gym equipment, manufacturers are turning to TPE compounds.

KRAIBURG TPE, a global TPE manufacturer of a wide range of thermoplastic elastomer products and custom solutions for multiple industries, offers custom-engineered TPE compounds that are durable, flexible, and allow for wear and tear and chemical resistance. Thus, the compounds are suitable for gym equipment applications such treadmills, skipping ropes, weight training deep stations, upright bikes, etc.

VS/AD/HM series: keeping fit with TPEs

KRAIBURG TPE’s VS/AD/HM series of compounds can be used in gym equipment applications. The compounds are known for their chemical resistance as well as resistance to abrasion and scratches, which makes the
compounds ideal for gym equipment applications where the surface is in constant contact with human sweat and strenuous physical activities.

This series of TPE compounds offers a consistent colourability, allowing for the possibility of more attractive equipment. Also, the TPE compounds render a soft, velvety surface feel to products, making them suitable for handles and grip applications in equipment. The excellent adhesion property to nylon, PA6 and PA12, as well as other polar thermoplastics like PC, ABS, ASA and SAN, allow for flexibility in product development.

Other possible applications where the VS/AD/HM series can be used include fitness ab wheels, bicycle cushion covers, buttons, etc. EC series: aesthetic features in gym equipment KRAIBURG TPE’s EC series of compounds is an electric conductivity series with low resistivity, which is a fundamental property of a material that measures how strongly it resists electric current.

This holds the EC compounds in good stead for potential applications in gym simulation vests, required for stimulating the muscles, for work-outs and bodybuilding. The use of weight vests as a tool for fitness has increased significantly, especially in the tactical fitness industry, with weighted calisthenics, speed and agility, and other weighted running workouts.

Another attribute of the EC series is that it has a soft, non-sticky haptic surface, which provides comfort to the user when wearing the vest. Furthermore, it is halogen-free, for safety in applications, and has good
adhesion to polypropylene (PP) resin, allowing for a wide variety of applications.

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New Customizable PET Solution Maintains Carbonation in Beverages, Energy Drinks

Ring Container Technologies, a leader in the plastic container manufacturing industry, today announced it has developed a customizable PET solution for maintaining carbonation in beverages and energy drinks.  

Energy shots and beverages with BarrierGuard Enhance technology are customizable into unique shapes, creating on-shelf brand differentiation for smaller size carbonated PET bottles.

“Enhance is break-through bottle technology allowing beverage and energy drink manufacturers to re-imagine their carbonated drink space and brands,” said Tim Ferrel, Vice President of Business Development at Ring. “After a successful launch of BarrierGuard  OxygenSmart  and other technology solutions, we look forward to expanding this market and continuing to exceed our clients’ expectations.”

Traditionally, smaller PET packages have been difficult to carbonate and maintain carbonation, due to the volume and surface area. However, Enhance uses technology that enables carbonation in a PET bottle and preserves it for the duration of the product’s shelf life. Enhance beverage bottles are also resealable for consumers to enjoy later.

Enhance can leverage Ring’s APASS  guidance to design an optimal e-commerce solution for carbonated beverages and energy drinks to avoid costly Amazon handling fees. In addition, Enhance bottles are shatter proof and dent resistant, compared to metal cans that may dent during transportation, causing increased retail rejection and inventory cost.

“Enhance bottle technology can integrate the use of post-consumer recycled (PCR) materials to help meet recycled content goals of new state and federal legislation,” said Paul Kelley, Vice President of Product Development at Ring. “Enhance is another great example of how Ring’s technology portfolio continues to grow with an eye on both the environment and consumer packaging advances.”

https://www.ringcontainer.com/

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Milestone for more cost-effective production of high-performance rotor blade

Covestro receives first DNV adjustment certification for partial reduction factor γm1 of wind turbine blades using aging-resistant PU.

Covestro has now received the first adjustment certification from DNV, the wind power industry’s certification organization, for the so-called partial reduction factor γm1 of wind turbine blades made of aging-resistant polyurethane (PU). This factor is an important indicator of the long-term aging resistance of rotor blades and is also used to measure the long-term service performance of the blades. It is also the first time that DNV has evaluated and adjusted this factor.

To do so, DNV evaluated complex and rigorous comparative tests as well as theoretical analysis by Covestro. Based on design standards for wind rotor blades (DNVGL-ST-0376:2015), DNV confirmed and adjusted the partial reduction factor γm1 of polyurethane resin processed using the vacuum infusion process. This certification applies to the Baydur 78BD085 PU resin and the Desmodur 44CP20 hardener from Covestro.

Longer and lighter rotor blade designs

Resin materials must prove their long-term aging resistance before they can be given lower safety margins that allow for broader rotor blade design and application. For the first time ever, DNV has lowered the γm1 factor of polyurethane resin, marking an important milestone for Covestro.

Compared to epoxy resin, which is often used to manufacture rotor blades, polyurethane resin shows better mechanical properties. With a lower γm1 value, rotor blade designers can take full advantage of polyurethane and also achieve greater design freedom. As the need for longer and larger rotor blades increases, so does the weight of the blades.

Therefore, weight reduction has become an important issue in the rotor blade industry. Polyurethane resin enables the production of lighter blades of the same length, which greatly improves the efficiency of blade production and its applications.

Dr. Irene Li, vice president of research and development for Covestro’s Tailored Urethanes business entity in the Asia Pacific, remarked, “We are pleased that the excellent performance of polyurethane has been recognized by a wind power industry’s certification authority.

As more and more polyurethane rotor blades are installed, we look forward to furthering innovations in polyurethane resin and the rapid development this will bring to the wind power industry.”

Innovative materials in focus

For a long time, epoxy resin was the main material used in the production of wind rotor blades. For years, Covestro has invested in research into polyurethane resins to improve rotor blade performance and reduce manufacturing costs. Today, polyurethane – new material in the field of wind rotor blade manufacturing – is rapidly gaining recognition in the market. With this innovative solution, Covestro aims to drive the use of renewable energy and, in the end, the shift to a circular economy.

Kim Sandgaard-Mørk, executive vice president of DNV’s Renewable Energy Certification Division, said, “Wind turbine blades are becoming lighter and larger, while favorable feed-in tariffs for wind energy are gradually being reduced. This poses a challenge for cost control in wind rotor blade production and development.

The wind power industry is therefore looking for new material applications while optimizing designs to reduce costs while ensuring optimal performance. By demonstrating the performance of polyurethane under the new blade standards and obtaining a new safety factor certification for its resin products, Covestro is blazing a new trail for blade design.”

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https://modernplasticsindia.com/

Way2K: Industry interviews in the lead-up to the K 2022 fair “We have the role of an ambassador”

Interview with Peter Steinbeck, CEO of Windmöller & Holscher KG

Mr. Steinbeck, what can a machine manufacturer like Windmoller & Holscher do to close plastic loops?

We can ensure that the machines are able to handle the recycled materials coming out of the loop and process them into new products in the best possible way. However, it’s also about designing products to make them recyclable in the first place. One example would be using mono materials that are easy to recycle, but have the same properties as multi-layer films. We can give customers machinery that can optimally handle the challenges of recyclate processing. But most importantly, we can also provide the right advice to help our customers deal with the requirements of the end customers in their countries in the best possible way. Sustainability is an important consulting topic in each of our discussions with customers. 

Some countries in Asia or Africa often don’t even have a garbage collection system, so where would you start?

Our possibilities with our own machines are limited, as waste systems and recycling plants are not part of our portfolio. However, we are making headway all over the world. We can help companies there to network and show them how to get the soiled material back, how to recycle it and where to get recycled goods. We see promising projects on our travels and can tell others in the regions about them. We have the role of an ambassador. In countries like Indonesia or Vietnam, where the circular economy is not yet considered, it’s
about generating lighthouse customers who are also motivated to tackle the issue of the circular economy, and subsequently offering them the right technology for their requirements.

Don’t we need to do more though if we want to reduce the amount of waste in the oceans?

Definitely. The great thing is that a lot is happening right now. I would also like to see the circular economy being promoted through city partnerships in developing and emerging countries. After all, every city in Germany has twin cities today; these are mostly cities in the West, however. Why not enter into a partnership with Surabaya in Indonesia with the aim of setting up a municipal waste disposal system there? Such a commitment would achieve much more than banning disposable drinking straws.

How is W&H represented with its own machines in these countries?

W&H machines are in use all over the world. Our customers appreciate the innovative strength of a German machine manufacturer and the partnership- based advice from W&H – especially on the subject of recycling management right now. In India, China and many other countries in particular, however, there are also companies that are not yet connecting to our high-tech machines. Nevertheless, our developments will also benefit them. This is comparable to cars, where technical innovations are initially implemented in the high-end segment. In time, however, they will also reach the mid-range, and finally every small car. So in the end, German technology can make a major contribution to the further development of the entire industry here as well.

One problem of the circular economy is the insufficient availability and even lower consumption of recyclates. What needs to be done here?

We in Germany, or even across Europe, need to set a good example. This also includes ensuring that the yellow bags that we all collect so diligently are no longer exported, but actually remain in the country. If it is cheaper to sell them to Malaysia, then this must be prevented, also at EU level. Politicians must put a stop to this. Incidentally, all the major film manufacturers – our customers – have been dealing with PCR, i.e. material obtained from plastic packaging waste, for some time now. They need machines that can be operated economically, even with lower quality materials.

Digitalisation is closely interwoven with the circular economy. How are you positioned in this regard?

With RUBY, we have developed an IoT platform that connects our customers’ machines within our process chain. It provides the data for our machines. Via apps, customers can make evaluations or also get help for the operators. This is becoming increasingly important because it is becoming more and more difficult to find highly trained skilled workers. We help the customer with internal networking and by evaluating their data via a cloud solution. The circular economy needs transparency, and digitalisation is the basis for more transparency – not just for the circular economy, but also for sustainability in general: for example, it helps to work more efficiently through automation, to use less material or less energy.

Is the willingness there to act across company boundaries?

The common goal of sustainability has given the industry a development boost, and there are now more collaborations emerging than ever before. We have existing long-term partnerships, for example with raw material manufacturers, in which we are now also quickly tackling these issues together. 

And we benefit from the fact that we have three processing steps in our own portfolio: extrusion, printing and processing. For example, we can directly test the effects of new, more sustainable formulations on printing. Sustainability is only possible together, along the value chain. This applies to digitalisation, efficiency and the circular economy.

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