Frigel Introduces the Latest Developments in Advanced Mold Temperature Control Units and Adiabatic Cooling Solutions at FAKUMA 2024 (Hall A5-5123)

Frigel Group will participate in Fakuma 2024, the International Trade Fair for Plastics Processing, in Friedrichshafen (Germany) from 15 to 19 October, presenting the latest process cooling solutions, designed. especially for the following Plastics fields: automotive, packaging, medical, household and technical molding.

Frigel is a Global Solutions Provider for cooling and temperature control applications, with more than 10.000 customers worldwide. Our innovation and expertise offer uniquem systes, designed to match the specific needs of each industrial process.

Our innovative solutions are focused on:
• Maximizing productivity through highly innovative mold cooling technologies
• Reducing overall operating costs, through significant energy and water savings
• Highest sustainability standards, with the lowest environmental footprint in the market.

Visit us and meet our engineers, as they will be able to show you the best solutions for your precise industrial process. Learn about our important innovations:

• New Turbogel B4: a new generation of Mold Temperature Control Units, specifically designed for cycle-time reduction for all injection molding and packaging applications achieving up to 40% increased productivity
• New Microgel™ RSY: Unique Mold temperature Unit with patented SYNCRO Variotherm Technology, provides unprecedented increase in productivity of high-quality technical molding parts – up to 60%
• Ecodry Adiabatic Cooler 4DK: centralized closed-circuit adiabatic cooling systems designed to replace the old cooling tower technology
• 3PR 4.0 control system: complete real-time control of the entire cooling system (parameters, functions, alarms, etc.)
• Thermogel TDK Series: High precision Single Zone pressurized water TCUs
• A wide range of Microgel RSM/RSD provides an optimized mechanical design, increased reliability and a wide range of options. Powerful pumps and precise temperature control up to 90°C ensure long-term high performance and product quality improvement with minimal cycle cooling time.

NEW TURBOGEL B4 Series – The unique “Profit Booster TCU”

Frigel launches for the first time in market history, a New Generation of Mold Temperature Control Units, specifically designed for cycle cooling time reduction. The advantages for the customer are easily understood, increased productivity and profitability of a single production cell, against an investment with an average payback time of few weeks.
The unprecedented performance of these units guarantees a significant reduction of the cycle time by increasing the heat transfer efficiency between recirculating water flow and mold cavities, thus drastically reducing the cooling time of the actual cycles, over traditional TCUs.

This complete range of units comes in several versions covering most applications:

Turbogel “S” – for INJECTION MOLDING:
This new generation of temperature control units offers to all molders a unique tool to highly improve productivity and optimize their process keeping high quality of molded parts. As an immediate replacement
of standard TCUs commonly used in the industry, these new units have proven uctiviprodty increase of at least 20% in most existing molds and up to 40% in some cases. They are available in single zone (B4SM) and dual zone (B4SD) configurations. Each unit includes a high-performance booster pump per zone, actuated modulating cooling valve, and 6 to 24 kW heater per zone

Turbogel “P” – for PACKAGING:
This unique TCUs are designed for high performance mold cooling in low temperature applications, including packaging molding, closures and thin-walled containers, blow molding, and extrusion applications.
Replacing the direct cooling from Central chillers, these units reduce cooling cycle time of processes running with chilled water by highly increasing the heat transfer efficiency of the mold, obtaining productivity boost between 10 and 20%.

These units are available in single zone and dual zone configurations, including a high-performance booster pump per zone (with or without inverter), actuated modulating cooling valves and cooling capacities capable of servicing the highest throughputs.

NEW MICROGEL™ SYNCRO RSY – A paradigm shift for high-end Technical Molding

“Simply Synchronized Proven Results”
Frigel presents to the market MICROGEL SYNCRO RSY, the most innovative Mold temperature Control Unit featuring patented SYNCROVariotherm Technology, integrated water-cooled chiller and double zone booster pumps.

The new machine-side unit, that revolutionizes the temperature control method for technical injection molding, allows for a drastic reduction of cycle time -up to 60%-, while maintaining the surface quality, dimensional characteristics and mechanical properties of the finished technical products.

The reduction of the total cycle time is obtained thanks to the use of chilled water – provided by the integrated chiller – only during the cooling phase of the cycle, through the digitaltio synchronizan with the molding process, that provides the signal for “deep cooling only when it is needed”, obtaining a significant reduction of the cooling time while keeping the cavities warm during injection phase. The Microgel SYNCRO product line features more than 10 models, with cooling capacities from 16 kW to 56 kW and heating capacities from 12 kW to 24 kW.

As an immediate replacement of standard TCUs commonly used, this new technology has the great advantage of not requiring modifications to the mold itself or any of the molding parameters, making the system communicate with the press while remaining completely autonomous and easily implemented by the operators. The advantages for the customer are easily understood increased productivity and profitability of the single production cell, against an investment with an average payback time of few months.

visit  : www.frigel.com

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PET Bottle-to-bottle Recycling: Ganesha Ecopet’s Powerful way to Mitigate the Effects of Climate Change

The Indian PET recycling specialist ramps up its PET bottle-to-bottle recycling capacities with two Starlinger recycling lines to a total of 42,000 tons per year. It aims to recycle 25 % of India’s PET bottle waste by 2026.

The two new Starlinger recoSTAR PET 165 HC iV + recycling lines are set up at the recycling facility of Ganesha Ecopet Private Ltd. in Warangal, Telangana State. The company, a subsidiary of Indian PET recycling pioneer Ganesha Ecosphere Ltd., already produces recycled PET flakes and pellets for food-grade packaging as well as for filament yarns and fibres on two Starlinger lines installed in 2022. The new recycling lines are in operation since mid-2024 and triple Ganesha Ecopet’s annual production of bottle-grade rPET, raising it from 14,000 tons to a total of 42,000 tons.

EPR and consumers drive demand for sustainable products

The increasing demand for food-safe recycled PET in India has two main reasons. On the one hand, the Indian government has introduced Extended Producer Responsibility (EPR) for importers, brand owners and plastic waste processors as part of its Plastic Waste Management (Amendment) Rules in 2022 to ensure systematic collection of plastic waste. In addition, the rules stipulate that brand owners and producers must include a 30 % share of post-consumer recycled content in PET bottles by 2025, with the share being gradually increased each year to reach 60 % by 2029.

On the other hand, consumer preferences in India are changing, with sustainability being one of the top five factors for purchasing a product. Especially the large number of young consumers —i.e. millennials and generation Z— are increasingly demanding products and packaging that do not harm our planet. Brands respond to that by creating supply chains and packaging that are circular and sustainable. Recycled PET is one of the most convincing options for plastic packaging, given its continuous recyclability and lower carbon footprint compared to other alternatives, while not compromising on production scale, durability or quality.

“Our goal is not only to recycle plastics, but to create premium-quality, sustainable and viable circular solutions for brands,” said Sharad Sharma, Managing Director at Ganesha Ecosphere. “Recycling is not just an environmentally responsible choice; it is a powerful way to reduce CO 2 emissions and mitigate the effects of climate change. Starlinger’s superior food-grade PET recycling technology, combined with the operational expertise we have built up over the last 30 years on the Indian waste recycling market, enables us to push the boundaries of what is possible in PET recycling. Today, we proudly provide the best quality of recycled PET: like-to-like in properties with virgin PET, but with huge environmental savings in carbon emissions and energy. Various global FMCG brands like Coca-Cola have placed their trust in us to make their packaging circular while ensuring utmost safety and quality for the consumers.”

“Ganesha Ecosphere is one of the trailblazers for a circular plastics economy in India,” said Paul Niedl, Commercial Head of Starlinger recycling technology. “With their vast experience in the Indian plastics recycling sector and their willingness to invest in state- of-the-art technology they are able to transform post-consumer scrap into a high-quality secondary raw material for plastic packaging producers. As a technology developer and supplier, we are proud to support Ganesha Ecosphere on their way to ensure a clean, healthy and liveable future for our children.”

Focusing on sustainable production, Ganesha Ecopet also minimized the process-related carbon emissions by recycling and reusing 95 % of the consumed water as well as increasing the use of renewables in plant operations. With a total production capacity of 42,000 tons of food-grade recycled post-consumer PET per year the PET recycling company caters to Indian, US, and European markets. “We are grateful for the partnership with Starlinger and especially applaud their highly advanced, food-safe bottle-to-bottle recycling technology as well as their continuous support that has made this feat possible and circular economy a reality,” Sharad Sharma concluded.

Incentives for improving the Indian waste management sector

Ganesha Ecopet sources post-consumer PET bottles from every possible channel: online, offline, and through more than 300 suppliers and aggregators across India. The Indian government has set a focus on improving the waste management sector. Due to the size and efficiency of the already existing informal waste collection network, through which around 95 % of PET waste —one of the highest rates worldwide— in India is collected and recycled, the main goal is to optimize the current systems. There are various start- ups that are tackling multiple aspects, from piloting deposit return/refund schemes to online scrap marketplaces. The government also plays an important role by setting incentives for better Environmental, Social and Governance (ESG) practices and taxing unsustainable practices.

A pioneer in PET recycling

Ganesha Ecosphere looks back on more than 30 years of experience in the PET recycling business. Founded in 1987, the company started out as a yarn production facility. In 1994, it was among the first companies in India to reprocess PET waste to manufacture recycled polyester staple fibre (RPSF) and recycled polyester spun yarns (RPSY). By today, the group operates six production sites located in the Indian states of Uttar Pradesh, Uttarakhand and Telangana, and one in Nepal. In addition to bottle-grade rPET pellets and flakes, Ganesha Ecosphere produces rPET staple fibre for yarns, nonwovens, flame retardant fabrics, and fibre fillings. Its highest quality rPET products are produced by its subsidiary Ganesha Ecopet and marketed under the brand name “Go Rewise”. With over 2700 employees and exports to more than 18 countries, Ganesha Ecosphere ranks among the largest rPET producers in India, recycling 9.4 billion PET bottles per year.

https://ganeshaecosphere.com/

https://gorewise.com/.

www.recycling.starlinger.com

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Shanghai Bozhi Expands Platemaking Capacity With Second ThermoFlexX Imager

Shanghai Bozhi Graphic Reproduction Co Ltd specializes in the production of high quality flexographic plates for customers that serve a multitude of globhttps://globalplasticsnetwok.com/?s=productionl brand owners, such as Procter & Gamble, Johnson & Johnson, Unilever, Disney, Adidas, and Yinlu Foods, as well as fast food restaurant chains KFC and McDonald’s. Applications include wine labels, aseptic packaging, self-adhesive labels, film and soft tubes, and various paper cups, to name a few.

As a member of the Flexographic Printing Branch of China Printing Technology Association, Shanghai Bozhi was among the pioneers in China to embrace ThermoFlexX thermal imaging technology. In 2020, the company decided to install a ThermoFlexX TFxX 60S Imager which has since elevated its standards in terms of both quality and productivity to higher levels. More recently, the company expanded its ambition with a dual-head TFxX 60D Imager supplemented by Woodpecker surface screening technology. “With our first ThermoFlexX Imager, we took a real leap of faith because we believed that this technology from XSYS had the potential to revolutionize our platemaking business, and we have certainly not been disappointed,” said Mr. Weining Huang, GM of Shanghai Bozhi. “That first imager brought us to new heights cementing our reputation for excellent quality and fast, reliable service, so it was an easy decision to implement the new dual-head TFxX 60D machine into our portfolio.”

Second ThermoFlexX Imager with double capacity
ThermoFlexX imaging technology excels through its high speed, excellent quality and remarkable ease of use. Featuring highest levels of automation, itthermal processing is an open system that can image all digital plates, any brand, whether for solvent, water-washable or . The ThermoFlexX portfolio includes five sizes of imagers to handle the widest range of plate dimensions. The two 60 model machines at Shanghai Bozhi’s facility can image plates up to 1067 x 1524mm (42 x 60 inches). Minimizing operator intervention, plates are automatically loaded and unloaded with just one touch of a button, while the FlexTray mobile table facilitates easy plate transport and handling to avoid accidental damage. Importantly, the company’s new TFxX 60D Imager is configured with dual 100W lasers effectively doubling productivity by increasing the output from 6 to 12 square meters per hour at the same high quality of 2540dpi.

Shanghai Bozhi also chose to implement ThermoFlexX Woodpecker surface screening technology which boosts solid ink density and delivers a smoother ink laydown with lower volume anilox, to save on costs and gain a further competitive advantage. Applying microstructures to flat-top dots on the plate surface, Woodpecker screening is introduced at the imaging stage without any changes to the workflow and helps maintain print quality at the highest printing speeds.

Bringing in a new era with ThermoFlexX
Partnering with XSYS to enjoy the many outstanding benefits of ThermoFlexX imaging and Woodpecker screening has also supported Shanghai Bozhi in establishing a dedicated technical department to better serve customers. With a team of experts who have more than 10 years of experience in flexo platemaking and printing, the prepress company can now provide customers with all the technical requirements needed to successfully convert print jobs from offset and gravure to flexo. This not only shortens the lead time for brand owners, but also greatly improves efficiency for the benefits of all stakeholders.

[Mr. Weining Huang] concluded, “The highly innovative ThermoFlexX technology immediately set us on a path of guaranteed growth, giving our company the quality and capacity boost we required. Now with the new dual-head TFxX 60D, Imager we have taken another step up to ensure we stay at the forefront of platemaking innovation in China. We are also grateful for the excellent partnership with XSYS which ensures that we maximize the full power of our two imagers as we bring in a new era for Shanghai Bozhi.”

Commenting on this second investment, Magenta Zheng, GM of XSYS China, said, “With its high level of automation, impressive speed and exceptional quality, there is no doubt that the new ThermoFlexX TFxX 60D digital imager will significantly enhance Shanghai Bozhi’s competitiveness. We are extremely proud to partner with the company and look forward to growing together with this industry innovator.”

visit:https://xsysglobal.com/

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