Siegwerk has Developed Inline Printable Barrier Coatings
Siegwerk recently developed a fully recyclable mono-PE bag which was created through the use of CIRKIT functional coatings and it is suitable for holding dry pet food. Siegwerk is a global leader when it comes to providing inks and coatings for packaging applications and labels.
Through several partnerships with Windmöller & Hölscher who are printing machine manufacturers and also B&B who is a bag making and machine producer, the companies collaboration resulted in the production of the new high-barrier mono-material packaging solution. This product is brilliant as it offers much more than simply effective packaging, as it is also suitable for pet food and it is completely recyclable.
Due to the excellent quality of the material that was chosen for this project, the new mono-PE bag is able to offer the same amount of protection that a plastic, non-recyclable form of packaging would be able to, except it also provides the benefit of being recyclable. The whole product is created out of a combination of an inline printable grease barrier coating from Siegwerk’s CIRKIT GreaseBar, plus a coating from CIRKIT HeatGuard, which is ideal for high-end sealing process efficiency. Both of these coatings from CIRKIT are solvent-based, are deinkable after delamination and can also be printed inline, whilst always maintaining their full performance ability. Furthermore, all of these materials and any dyes that are used for printing, align with the rules and guidelines that have been set out for the packaging industry, this includes guidelines stated by German Minimum Standard and RecyClass.
Whilst a lot of packaging currently needs to be redesigned, pet food containers need to be food safe, whilst they also need specific barrier properties and also need to maintain their shape. Head of Brand Owner Collaboration at Siegwerk, Belal Habib, talks about the requirements for altering packages, “New approaches are needed to meet the upcoming regulatory requirements for circular packaging. The challenge is to find a recyclable design that also meets the respective performance requirements of the packaging.” Habib continues, “The problem: they are not recyclable. This is where innovative barrier coatings applied in thin layers and inline with regular printing inks can help to switch from an incompatible multi-material structure to a fully recyclable mono-material solution in the sense of a Circular Economy.”
Habib added, “This development success once again underlines the importance of collaborating along the packaging value chain, combining the specialized know-how of industry experts. Together, we have succeeded in developing an innovation that is circular, delivers on performance and maintains current process efficiencies due to inline and high-speed conversion. This shows that, by joining forces, we are in a position to make recyclable mono-plastic packaging a reality and thus counter the still wide presence of multi-material laminated structures with future-oriented flexible packaging solutions made for circularity.”
Efficient Processing of Solid Silicone (HCR) on an Electric Allrounder Injection Moulding Machine
Reliable: Silicone processing with an electric Allrounder 570 A
Continuous: Material feed via ACH Turnmix in the new M size
Soft, yet hardwearing: Bottle opener made of solid silicone (HCR)
Arburg will be presenting its extensive portfolio for elastomer processing at the German Rubber Conference DKT in Nuremberg, Germany. The exhibit at Arburg stand 327 in hall 9 will produce bottle openers made of solid silicone (HCR, high consistency rubber) for demonstration purposes. For this, the electric machine will be equipped with a material feed in the new M size from partner company ACH Solution.
With its presence at the DKT in Nuremberg, the international industry meeting place Arburg has its sights firmly set on manufacturers of elastomer components as well as processors of rubber, HCR and liquid silicone (LSR). It sees great potential in fields such as the automation of silicone processing and multi-component technology, as well as e-mobility, fuel cells and medical technology.
Energy and production efficiency on an Allrounder 570 A
The energy- and production-efficient injection moulding of solid silicone (HCR) will be demonstrated by an electric Allrounder 570 A with a clamping force of 2,000 kN and a size 400 injection unit. The material processed will be Elastosil R plus 4001/70 from Wacker Chemie. Dosing system ACH Turnmix, now available in M and L versions along with the proven S size, provides constant and bubble-free feed at continuous pressure. This enables this production of silicone parts ranging from small to large shot volumes. The exhibit will be equipped with the new M size, which is particularly suitable for medium-sized injection units and HCR with a wide range of Shore hardnesses. The cavities of the 4-cavity mould will be injected directly via a cold runner system. This prevents burr formation and avoids the need for finishing work on the injection moulded parts. Four bottle openers at a time will be produced in a cycle time of around 60 seconds. As part of the silicone equipment package, the injection unit features a special screw geometry, cylinder temperature control and nozzle technology. The equipment, which is precisely adapted to the processing of solid silicones, transforms the Allrounder in conjunction with the ACH Turnmis into a compact and cost-effective injection moulding solution.
Pioneer in silicone processing
Arburg is a pioneer in the processing of liquid and solid silicones as well as multi-component injection moulding, and boasts an extensive portfolio of injection moulding machines and automation through to complete turnkey systems. The large selection of machine sizes, drive versions, equipment options, automation and peripheral equipment provides the perfect starting point for perfectly tailored solutions. A special feature is the 3D printing of liquid silicone components. For this, Arburg’s range includes the LiQ from innovation and the matching LAM (liquid additive manufacturing) process. With its expertise, Arburg also meets the needs of highly industrialised markets for digitalisation opportunities as well as minimisation of the carbon footprint.
Customers from the elastomer processing sector also benefit from Arburg’s comprehensive consultation services, from procurement and technical equipment, process optimisation, mould tests and machine comparisons to training on cross-linkable moulding compounds in the Arburg Customer Center in Lossburg and in its subsidiaries worldwide.
Cannon Viking Introduces the Laydown Master to Complete its Offering for PU Slabstock Foam Producers Using Solid Fillers
Cannon Viking, a company of the Cannon Group and a market leader in technologies, processing and molds for polyurethanes and urethane elastomers, introduces the new LayDown Master at UTECH Europe to complete its offering for PU slabstock foam producers using Liquid Laydown technology.
Based on the experience gained over many years, Cannon Viking’s LayDown Master is a distribution device which has been inspired by the CarDio gatebar. It is aimed at slabstock producers using a conventional Liquid Laydown or Maxfoam Trough machines. The LayDown Master has been specifically developed and made available as a kit for evenly distributing the liquid PU across the width of the foaming conveyor before reaction, requiring less modifications to the existing hardware and suitable to be (retro)fitted to virtually all existing foam production lines.
“The advantages of the LayDown Master are numerous,” says Richard Doublet-Stewart, Regional Sales Manager at Cannon Viking. “The technology avoids the use of a traversing mixing head, whilst providing uniform foam laydown across the whole width of the conveyor, delivering a more regular cell structure across the block. The LayDown Master is especially suitable for highly reactive foam grades, such as MDI, Viscos and HR foams. It produces optimum quality foams due to liquid laydown by avoiding pinholes and build-up, typically seen with Maxfoam trough technology.”
As the Laydown Master is available as a kit, it requires a short installation time on existing production lines, ensuring only a minimal impact on the production and machinery. It is suitable for low-pressure, partial high-pressure and high-pressure technologies, and allows for a quick change of grade and colour, shortening the transition phase between foam grades, reducing the amount of scrap foam and thus saving valuable raw materials.
The LayDown Master features a slot that is wide enough to allow for the use of very viscous formulations and solid fillers, which are key to ensure consistent quality for the foam standards. The slot can be easily adjusted between different foam grades by inserting spacers, reducing downtime to the absolute minimum.
Cannon Viking offers several technologies aimed at foam producers with continuous and discontinuous block foaming methods. Under the CarDio brand this includes complete production lines as well as conversion kits for existing lines for using liquid CO2 expansion technology, while the new LayDown Master is aimed at new and existing lines with Liquid Laydown technology. Together with its foam block size and profile control technologies, Cannon Viking now has a full range of equipment available to cover all possible PU slabstock foam market needs.
PET Wine Bottle Made by ALPLA Cuts Carbon Emissions by Up to 50 Per Cent
Launch of a 0.75-litre bottle in Austria with white wine from Wegenstein
Safe, affordable, and sustainable: the plastic packaging specialist ALPLA is launching a recyclable wine bottle made of PET. The bottle weighs approximately only an eighth of a glass bottle, reduces the carbon footprint by up to 50 per cent and allows for price savings of up to 30 per cent. It can be made entirely of recycled PET (rPET). The packaging solution is available now in 0.75-litre and 1-litre bottle sizes and is already being used in Austria by the pilot customer and development partner Wegenstein.
The global packaging specialist ALPLA has added a PET wine bottle to its product range. The 0.75-litre bottle weighs just 50 grams – around eight times less than the alternative made of glass. The
ALPLA ein Wegenstein introduces PET wine bottle from ALPLA
first white wine bottles belonging to the Wegenstein winery recently went into circulation in the Austrian wine market, making them part of the Europe-wide bottle-to-bottle loop. The sustainable solution reduces carbon consumption by 38 per cent compared to the glass alternative – and that’s even without rPET content. The PET bottle is now also available in a 1-litre version. ALPLA plans to already be manufacturing several million units a year from 2025 and is planning solutions made entirely of rPET.
‘PET is light, unbreakable and recyclable, and can be moulded with little energy needed, making the plastic the ideal packaging solution. With it, winemakers can improve their environmental footprint and lower their costs,’ emphasises Daniel Lehner, Global Sales Director Food & Beverage at ALPLA. The plastic packaging meets all the quality requirements, is available as a transparent or a green bottle and is suitable for all types of wine.
PET-Weinflasche von ALPLA ALPLA’s PET wine bottle
Sustainable, inexpensive and compatible The lower material consumption and energy-saving manufacturing reduce carbon consumption. The use of rPET further increases the reduction. Even with 30 per cent rPET, 43 per cent is saved, while the ecological footprint of the solution made of 100 per cent rPET is even halved at minus 50 per cent. The high-quality recycled material is provided by ALPLA from its own ALPLArecycling recycling plants. The low weight of the packaging also has positive effects on shipment. And there is a cost advantage too. ALPLA’s PET wine bottles are up to 30 per cent less expensive than glass bottles, depending on the requirements.
The sustainable packaging solution works with conventional metal screw caps and is compatible with winemakers’ bottling lines, meaning it is flexible. Wegenstein fills the PET bottles on the same bottling lines as its glass bottles. ‘The bottle has been perfectly tailored to the bottling and shipment processes. The close cooperation with the Wegenstein team significantly sped up the market launch,’ reports Sebastian Rosenberger, project manager at ALPLA. ‘The PET bottle lives up to what it promises. It is visually appealing, ensures our quality and is practical. We are making an innovative offer to consumers who care about our environment and our climate,’ explains Herbert Toifl, managing director of the Wegenstein winery.
NORMA Group Achieves Solid Results and Improved Profitability in the First Quarter of 2024
Adjusted operating result (EBIT) increased by 13.9 percent to 25.7 million euros
Adjusted EBIT margin increased by 1.1 percentage points to 8.3 percent
Sales in Q1 2024 fell slightly by 2.0 percent compared to the same quarter of the previous year to 308.5 million euros
Step Up improvement program has a positive effect
NORMA Group started the 2024 financial year with improved profitability. The company was more profitable compared to both the previous quarter and the same period last year.
Group sales fell slightly by 2.0 percent to 308.5 million euros compared to the same quarter of the previous year . Organically, sales fell by 1.0 percent in the first three months of 2024. Negative currency effects reduced sales by an additional 1.1 percent compared to the previous year. The recently acquired water management company Teco made a positive contribution to sales growth of 0.1 percent.
Adjusted earnings before interest and taxes (adjusted EBIT) rose significantly by 13.9 percent in the first quarter of 2024 compared to the same quarter of the previous year to 25.7 million euros . The adjusted EBIT margin was 8.3 percent and also improved significantly. More efficient production and declining inflation in material costs had a positive impact on the margin. However, higher personnel costs as a result of inflation-related wage increases and the reduction of production backlogs as well as higher interest rates were challenging. The operating net cash flow was -2.3 million euros in the period January to March 2024, significantly above the value of the comparable quarter of 2023 .
CEO Guido Grandi: “We started the year successfully and have significantly improved our profitability. Our robust business model with three business areas offers us attractive opportunities even in a mixed economic environment. With the Step Up program launched a year ago, we have set the right course and become more efficient, especially in Europe. We will continue to build on this to ensure sustainable, profitable growth for NORMA Group.”
Heterogeneous development in the business units
In the EMEA region (Europe, Middle East and Africa), sales fell slightly by 1.2 percent to 136.5 million euros in the first quarter of 2024 . The three customer industries developed differently. Sales in Industrial Applications fell due to the subdued economic situation in Europe. The business with water management solutions, however, grew significantly in the region. Among other things, the acquisition of the Italian water specialist Teco, completed in February 2024, ensured positive momentum. In the area of connection technology for vehicles (Mobility & New Energy), sales remained stable at the same level as in the same period last year. Profitability in the EMEA region continued to improve in the first quarter of 2024: Despite the slight decline in sales, adjusted EBIT rose to 10.6 million euros . The adjusted EBIT margin was 7.4 percent, significantly higher than the same quarter of the previous year . The higher profitability is based on the one hand on lower costs for energy and materials and on the other hand on internal improvement measures in production and logistics.
In the Americas region, sales revenue fell slightly by 1.6 percent to 135.4 million euros in the first quarter of 2024 compared to the same period last year. The main reason for the decline is negative currency effects in connection with the US dollar (-1.1 percent). In the Industry Applications area, postponements in investment decisions due to an expected, but still pending, interest rate cut depressed demand. Business in the water management area, on the other hand, grew noticeably in the period January to March 2024. In the Mobility & New Energy division, the business volume was below the previous year’s figure. Adjusted EBIT in the Americas region was 15.2 million euros in the first quarter of 2024, slightly below the comparable value . The adjusted EBIT margin, however, showed a slightly positive development at 11.1 percent.
In the Asia-Pacific region, sales in the first quarter amounted to 36.6 million euros (Q1 2023: 39.1 million euros). Organic sales fell by 1.5 percent; Negative currency effects reduced sales growth by an additional 4.9 percent. In the Industry Applications area, the continued hesitant economic recovery in China in general and the tense situation in the construction sector in particular led to reduced demand. In Water Management, sales were also below the figure for the same quarter of the previous year. Business was stable in the Mobility & New Energy sector, which in the region is primarily driven by the Chinese automotive industry. Despite lower sales, the adjusted EBIT in the Asia-Pacific region was 2.7 million euros in the first quarter of 2024 (Q1 2023: 2.6 million euros). The adjusted EBIT margin improved to 6.9 percent (Q1 2023: 6.3 percent).
Efficiency measures are having an impact
NORMA Group launched the global growth and efficiency program Step Up in spring 2023. So far, over 1,300 individual measures have been identified, more than half of which are currently being implemented or have already been completed. The measures are divided into growth plans for the three strategic business units Industry Applications, Water Management and Mobility & New Energy and measures to increase operational efficiency. NORMA Group will identify and implement further measures in the coming years.
Annual General Meeting in attendance
The NORMA Group’s general meeting will take place on May 16, 2024 as a face-to-face event in Frankfurt am Main. Among other things, the re-election of Supervisory Board Chairman Mark Wilhelms is on the agenda. Mark Wilhelms has been a member of the committee since 2018 and has been chairman since May 2023.
NPE2024: SABIC Showcasing Progress in Plastic Innovation for a More Sustainable Future
Under the theme of “Collaborating to Create the Future,” SABIC’s presence at NPE2024 showcases plastic innovations and work across the value chain in multiple industries.
SABIC emphasizing value of its plastics as enablers for transformation – to a circular, electric and more sustainable future.
Booth reinforces company’s strong commitment to local supply and application development support to power innovation.
SABIC, a global leader in the chemical industry, is highlighting at NPE2024 (Booth #S19005; May 6-10 at the Orange County Convention Center in Orlando, Florida) a wide range of solutions that demonstrate the value of plastics for a more sustainable future. Under the theme “Collaborating to Create the Future,” the company is presenting innovative solutions that are available today and others that are on their way to broader adoption. This includes examples of the company’s work with manufacturers and others across the value chain on circular plastic solutions available under its TRUCIRCLE program and new approaches with plastics under its BLUEHERO initiative that can help in the shift to electrification.
“Since the last NPE in 2018, SABIC has taken giant strides forward in creating pathways for plastics to make valued contributions toward resolving critical global challenges and driving circularity,” Sami Al-Osaimi, executive vice president, Polymers, SABIC, said. “The progress that we have made is on display in our booth and it would not have been possible without the ingenuity of our people and teams and the focus we have had on collaborating with value chain partners who share our passion for creating a brighter future. We are so thrilled to be with everyone in Orlando and use this time to invite more purpose-driven, like-minded innovators to join forces with us to drive meaningful change and transformation.”
Examples of SABIC’s developments in plastics and its collaborations are evident across spaces in the booth covering the spectrum of the following industries: advanced packaging, automotive/transportation, building and construction, consumer goods, electrical and electronics, and hygiene and healthcare. Within each of those areas, visitors can see end-use applications produced with polymers from the company’s TRUCIRCLE and portfolio of solutions – certified circular, renewable and mechanically recycled content and closed-loop solutions.
SABIC’s support of the mission to enable electrification is on display in two areas: a space within the Transportation section of the booth showcasing the company’s BLUEHERO initiative and an area for visitors to experience racecar simulators that help highlight SABIC’s role as Principal and Innovation Partner to the Formula E electric racing series.
The topic of sustainability is woven throughout SABIC’s booth, emphasizes SABIC’s commitment to becoming carbon neutral by 2050, including its goal of a 20% reduction in absolute greenhouse emissions (Scope 1 and 2) by 2030. Outside of its booth, SABIC is participating in NPE’s new Sustainability Hub. Open to all registered attendees, this exhibit area shows the many steps the plastics industry is taking toward enhancing its sustainable footprint. SABIC will be part of the Materials section, providing an additional touch point for visitors to learn more about its offering of circular products and services.
SABIC’s primary booth space with its diversity of exhibited solutions speaks to the company’s broad plastics portfolio, from its highly engineered thermoplastics to its polyolefin-based materials, which includes polypropylene (PP) and polyethylene (PE) – and with the latter including grades from the company’s PE plant in San Patricio County, Texas, which began operating in early 2022 as part of Gulf Coast Growth Ventures, a joint venture of ExxonMobil and SABIC.
Advanced packaging: Various solutions developed in collaboration with manufacturers. This includes: frozen seafood packaging that uses certified circular SABIC PE resin, made with ocean-bound plastic (OBP) feedstock; and the winner of a Gold-level 2023 Edison Award in the Green Remediation category.
Automotive / Transportation: The Hyundai IONIQ 6 electric sedan, which features LEXAN resin used in the front and rear LED lighting and flame retardant PP compound in key battery module components. The latter material, developed under SABIC’s BLUEHERO initiative, enables compliance with relevant electric vehicle (EV) fire safety regulations. Improved flow properties of the material help double manufacturing productivity, while the reduced molding temperatures required support energy use and emission improvements.
Building & Construction: In addition to several examples of pipe made from high-density PE and PP well suited for transporting oil, natural gas and water, visitors can learn about SABIC’s new SABIC BiAx pipe technology. This solution offers up to 30% in material savings over incumbent polyolefin pipes and higher resistance to slow-crack growth, which facilitates cost-efficient trenchless installation across geographic landscapes.
Consumer Goods: Solutions with certified feedstock content from advanced recycling of post-consumer plastics or with certified renewable feedstock content, which are compliant with food or cosmetic industry safety standards. This includes Mattel’s new MEGA and Matchbox toy products using certified renewable PP polymers, in which MEGA BLOKS Green Town is the first-ever toy line available at mass retail to be certified carbon neutral.
Electrical & Electronics: The housing of the Charge Amps Dawn EV charger contains in the range of up to 50 percent certified renewable LEXAN polycarbonate resin from SABIC’s TRUCIRCLE portfolio, supporting the EV charger provider’s commitment to develop the circular bio-economy and help mitigate climate change issues. SABIC is also showing a full-scale demo model of an outdoor EV charger post with PP and engineering thermoplastic solutions well suited for the exterior housing, frame and internal components.
Hygiene & Healthcare: Among other solutions, SABIC materials that can help address the growing need for self-management of chronic diseases such as diabetes. This includes new medical-grade VALOX HX325HP resin, developed for potential use in high-precision parts used in insulin delivery pens, insulin pumps, auto-injectors and continuous glucose monitors. Also, visitors can see a sample prototype application made with SABIC’s Edison Award winning LNP ELCRES CRX copolymer, which has the exceptional chemical resistance capabilities needed to enhance the durability of medical devices and equipment housings.
Specialties: This space of SABIC’s booth is dedicated to its portfolio of high-performance specialty materials. Among the solutions featured is the Eos Z3 battery module from Eos Energy Enterprises, a leading provider of sustainable zinc-based energy storage systems. This specific module weighs up to 70% less than previous product generations and allows streamlined manufacturing, while achieving lower cost and higher performance. For this application, Eos Energy utilizes SABIC’s 2024 Edison Award winning LNP STAT-KON high electrically conductive compounds to replace traditional titanium in energy storage batteries. In addition to energy storage, visitors can see sample solutions with specialty materials in automotive, including EV batteries, healthcare and infrastructure.
Application Development: A display area educating visitors on the expertise that SABIC can provide to support customer product innovation in a range of ways along the entire application development cycle – from new materials development and predictive design and engineering to design for sustainability, prototyping, testing, validation and more.
Husky Launches Hypet 6e Platform at NPE 2024 – Engineered to Set Unprecedented New Standards in Sustainable Molding
Husky Technologies, a pioneering technology provider enabling the delivery of essential needs to the global community, today announced the launch of its next generation HyPET 6e platform. Building upon the industry-leading technology of the company’s flagship PET preform injection molding system, HyPET 6e is the ideal combination of proven technology and innovation engineered to work together to deliver new, unprecedented standards in sustainable molding.
“The plastics industry is at a pivotal moment and as industry leaders we must deliver by proactively developing circular solutions to address plastic waste management,” said Robert Domodossola, Husky’s President of Systems and Tooling. “Our new HyPET 6e platform meets this need as it’s designed so that all system components are integrated to work together to deliver on the unique requirements of sustainable molding, including superior rPET capability, enhanced energy efficiency, and closed-loop quality control, while simplifying operation and still delivering the lowest total production cost.”
The evolution of sustainable molding
Visitors to Husky’s booth at NPE 2024, located in the West Hall , will be the first to see the company’s new HyPET 6e technology in action. Engineered to be the market’s fastest system with unprecedented integration of machine, mold, auxiliary, and real-time remote monitoring, HyPET 6e achieves the ideal balance between high throughputs and quality without compromise
Running at the show all week, a HyPET HPP6e 400 system is producing a lightweight 5.89 gram, 100 percent rPET preform at a 4.5 second cycle time on a 144-cavity, 45-pitch mold – a configuration designed to enable up to double the production output. The system’s industry-leading performance and integration enables this preform to be blown into the market’s lightest, functional, industrializable 20oz (591ml) Factor 101 bottle, which is the evolution of the 2016 lab scale Factor 100 concept.
Superior rPET capability
A number of improvements have been made to enable the new HyPET 6e platform to optimize processing of lightweight preforms made from up to 100% rPET. An integrated drying solution enables accurate material blending, metal contaminant removal, and consistent material preparation when running up to 100% rPET. A high throughput screw design is optimized to deliver superior rPET melt quality while optimized melt delivery enables uniform melt flow for lightweight applications. To reduce rPET color variability, an integrated, self-adjusting, real-time inspection system enables closed-loop color correction and automatic color adjustments.
Industry-leading energy consumption
HyPET 6e has been designed with regenerative, system level energy management that delivers on demand performance. This enables the system to intuitively reduce energy consumption, resulting in a considerable decrease in operating costs for producers. At the heart of the platform is intelligent, adaptive technology that uses feedback from pressure and actuator sensors to determine the optimum pressure required to effectively and efficiently mold every application. This adaptive system monitors and automatically adjusts for optimal energy consumption without impacting system capability, cycle time or part quality.
Simplified operation to maximize efficiency
To simplify operation, HyPET 6e has adopted additional features so that operators of all skill levels are able to achieve maximum productivity and part consistency. Intelligent, connected mold features yield advanced, real-time monitoring, extended mold life and support increased levels of rPET while maximizing uptime. Uniform preform cooling minimizes cycle time and yields superior preform quality. Simplified machine greasing performed during operation reduces maintenance time, enhanced conveyor features ensure gentle part handling to minimize defects, and automated preform sampling supports enhanced quality inspection. All systems are equipped with Advantage+Elite remote connectivity for real-time, proactive, predictive, transparent monitoring and the introduction of a new online Husky Complete Portal delivers instant access to on-demand maintenance videos, posters, manuals, and OEM parts resources.
Sabic Testing Shows High Potential of Phase-Change Thermoplastics in Preventing Thermal Runaway in Ev Batteries
SABIC, a global leader in the chemical industry, is reporting here at NPE2024 test results that underline the high potential of thermoplastic-based thermal runaway barrier solutions to help prevent fire spread in electric vehicle (EV) batteries. The SABIC sub-system level test series showed that a battery module box made from the company’s STAMAX 30YH570 long glass fiber polypropylene (PP) resin with intercellular thickness as low as 1mm has a potential to act as an effective thermal barrier solution by preventing thermal runaway propagation in 18650 cylindrical cells. It provides the necessary thermal insulation and flame resistance to reduce the chances of cell-to-cell propagation in a thermal runaway scenario and thus mitigate the risks of a catastrophic safety incident. This material in combination with compressible foams also has shown promising results to contain thermal runaway propagation in prismatic and pouch cells.
Visitors to SABIC’s NPE booth can view the tested thermoplastic battery module box in a display area dedicated to BLUEHERO, an initiative designed to help the automotive industry shift to electric power and a low-carbon future. They can also explore other EV battery components made with SABIC’s materials, such as module enclosures, busbars and end plates, on display at the booth.
The new results build upon previous independent evaluations of SABIC’s STAMAX 30YH570 resin. In 2023, the product earned the UL Verified Mark from Underwriters Laboratories for effective flame delay performance. The assessment was based on UL 2596, the Test Method for Thermal and Mechanical Performance of Battery Enclosure Materials, using the thermal runaway box test.
Cylindrical battery cells arranged within a thermal runaway barrier
“We are pleased to share this additional validation of our thermoplastic solutions’ strong potential for use in EV battery components and systems,” Fahad Al-Harthi, global director, Automotive, SABIC Polymers, said “Our portfolio of flame-retardant materials, combined with our expertise in application design and fire-polymer interaction, can help enable new thermal runaway barrier approaches. We look forward to continued collaboration across the automotive value chain to help improve the safety, efficiency and performance of EV battery systems.”
Thermal Runaway Barrier Testing
The thermal runaway propagation tests, highlighted here at NPE, are performed using a cluster of 15 commercial 18650 and 11 21700 lithium-ion battery cells enclosed in a steel chamber, with and without injection-molded STAMAX 30YH570 resin blocks serving as a thermal barrier.
Initiating cells were thermally abused by heating them through an electrical tape to begin thermal runaway. In tests without the thermal barrier in place, the electric and chemical energies stored in these cells were discharged in the form of high-temperature gas, open flame, high-speed particles, and a sudden increase of pressure inside and around the test chamber. The thermal runaway immediately propagated to all neighboring cells due to the uncontrolled heat transfer, creating fire hazards and severe damage to the EV battery pack.
Conversely, in the tests using the thermal barrier made from STAMAX 30YH570 resin, heat transfer and thermal propagation from thermal abuse of initiating cells were effectively suppressed, and all remaining cells remained safe and intact.
This flame-retardant material changes phase from solid to liquid and gas and removes heat via latent heat and intumescent capabilities during severe thermal events, allowing it to act as an effective thermal shield to mitigate heat transfer and fire spread.
Potential Solutions for EV Batteries and More Automotive Applications
SABIC is also highlighting at NPE EV battery applications that successfully use the company’s advanced thermoplastics. One is the battery module from the 2023 Hyundai IONIQ 6. This application uses SABIC polypropylene compound H1030 for module enclosures. This is a 30 percent glass fiber-reinforced, non-halogenated flame-retardant material that meets China’s GB/T 41467.3-2015 fire safety regulation for EVs surviving five minutes at 1,000°C.
Additional EV battery components on display, such as enclosures, end plates and busbars, either in production or developed as prototypes, help demonstrate various performance advantages of thermoplastics over conventional metals for these applications. They include weight and cost reduction, increased functional integration, and enhanced electrical and thermal insulation.
SABIC has a display zone in its booth dedicated to automotive thermoplastic solutions. In addition to materials well suited for use in EV battery components, the company is highlighting technologies and expertise to support possible/potential solutions for automotive structural applications such as tailgates, lighting and smart panels.
An additional display zone in the booth focuses on SABIC’s capabilities to support customers’ product development efforts. Included in this space is a small-scale model of an EV battery pack enclosure with a cover and tray. Visitors can learn how the company developed this part, which includes integrated thermal runaway barrier features to support fire suppression and temperature management.
NPE 2024: Reifenhäuser Presents Solutions for Sustainability, Digitalization and Productivity Michael Ziegler
• U.S.-based project management, technical support, ready-to-ship spare parts inventory and local production
• Sustainable production technologies as a competitive advantage
• Vendor-independent digital solutions: c.Hub and ExtrusionOS
• First time at NPE: Kdesign technologies for blown film lines The Reifenhäuser Group will be represented at America’s largest plastic
trade show, NPE 2024,Under the Reifenhäuser motto “The Time is Now”, the extrusion specialists will show producers of plastic films valuable solutions for the three major topics of the industry: sustainability, digitalization and productivity (Booth W6751).
The highlights range from production systems for fully recyclable barrier films, EFSA/FDA-compliant food contact films made from 100% recyclate to performance-enhancing components and digitalization solutions. Reifenhäuser will also outline its North American sales and customer service, which includes U.S.-based project management, technical support, ready-toship spare parts inventory as well as a local production site for its popular highly wear-resistant Reiloy screws and barrels.
We are pleased to present our U.S.-based services as well as the global portfolio of the Reifenhäuser Group at the NPE. Our goal is to empower plastics manufacturers with know-how and immediately applicable solutions – to turn challenges into opportunities,” explains Steve DeSpain, Vice President Reifenhauser Incorporated.
Making sustainability a driver for success
Sustainability not only benefits the environment. Plastics manufacturers who invest in the right production technologies now can also gain a competitive advantage.
CENTRO-Freeze
The use of Reifenhäuser’s patented EVO Ultra Stretch stretching unit enables blown film producers to produce all-PE mono-film – e.g. for barrier food pouches. The necessary barrier effect is achieved with an EVOH content of less than five percent and thus meets all the requirements for complete recycling. EVO Ultra Stretch increases the barrier effect of the EVOH and thus reduces the necessary share of EVOH content while maintaining the barrier effect. The all-PE mono-film can be further processed and converted without any problems. Thanks to the patented position of the stretching unit directly in the haul-off of the blown film line, the film is stretched at the ideal time and from the first heat, which makes the process particularly efficient and stable.
With EVO Fusion technology, Reifenhäuser now offers blown film producers a technology that makes the previously impossible possible: Turning any recycling content – even lowest quality – as well as production scrap such as PET/PE film into sellable blown film. To reconnect PET and PE after melting despite chemical incompatibility, the line makes use of twin-screw technology, breaking down and distribute the components of the input material much better than single-screw extruders. EVO Fusion also masters degassing from printing ink. Twin-screw extruders offer a significantly larger free surface in the outgassing zone than single-screw extruders. The surface is also renewed much faster, so that a high degassing performance is achieved. It is sufficient to completely remove the interfering components of the printing ink.
Reifenhäuser Screws
When it comes to flat films Reifenhäuser will be presenting its EFSA/FDA approved PET sheet line to the NPE audience. This production process enables PET recyclate to be processed directly into food-safe films without pre-drying. The process meets the criteria of both the US Food and Drug Administration (FDA) and the European Food Safety Authority (EFSA). The process uses a co-rotating twin-screw extruder and a specially developed high-performance vacuum system that enables producers to process PET recycling material directly. Processors thus save the investment in an additional line component and avoid additional energy and maintenancen costs, which leads to significant savings. Fast material and product changes are also possible, for example between post-consumer PET bottle scrap (PCR), post-industrial PET production waste (PIR) and virgin PET. The end product, for example a meat tray, meets the highest hygiene standards and can be used safely in direct contact with foodstuffs in accordance with the criteria of the authorities.
Profit from digitalization
Reifenhäuser pursues the approach that – regardless of the company size – plastics extrusion manufacturers should benefit from digitization without becoming dependent on either specialists, systems or vendors. The core of the Reifenhäuser digital solution is the so-called c.Hub, a middleware that ensures the secure exchange of data between different IT systems, applications, extrusion machines and line controls. This includes Reifenhäuser systems as well as third-party systems. The c.Hub becomes the single point of truth for all production-relevant data by merging and harmonizing production data streams.
To enable customers to easily connect all their equipment in production, Reifenhäuser offers out of-the-box connectors for the most important industrial protocols. They enable fast and complete acquisition of all production data. The associated ExtrusionOS software provides userfriendly applications and dashboards that help monitor, manage, store and analyze this data. Line operators can, for example, monitor the condition of their connected equipment and adjust it optimally based on the knowledge gained. They also have the option of monitoring defined thresholds and KPIs and, if desired, receiving notifications when thresholds are exceeded. c.Hub and Extrusion OS is developed by RE: GmbH, a tech start-up of the Reifenhäuser Group, specialized in digital solutions for the plastics extrusion and packaging industry.
Getting the best of installed assets
Productivity is essential for success. Of course, it is about higher, faster, further, about innovation. But it is also about good service, well-trained staff, and digitalization, so manufacturers can become as productive as possible. Reifenhäuser offers a broad portfolio of components and services to help its customers get the best out of their installed systems.
Reifenhäuser will be exhibiting at NPE its latest automation option PAM (precise, autonomous, mechatronic) for flat film extrusion lines. PAM calibrates coextrusion adapters and dies automatically for best comfort, quality, and productivity. The high level of automation makes the machine operator’s work significantly easier, thus increasing line productivity and film quality. Reifenhäuser will show at its booth how the PAM adjustment works fully automatically and mechatronically – precisely controlled on a die. Once recipes have been set, they can be stored and recalled at the push of a button – even by inexperienced line operators. PAM also offers a decisive advantage in terms of occupational safety, as the operator does not even have to touch the hot parts of the extrusion line. In addition, energy consumption is significantly reduced compared to an automatic thermal expansion bolt system, as the actuators only need to be supplied with power during the adjustment process and not permanently.
As a special highlight Reifenhäuser will be exhibiting Kdesign technologies for blown film at NPE for the first time. Kdesign is part of the Reifenhäuser Group and offers market-leading technologies in the areas of cooling, measurement, and calibration. At the booth the KARAT air ring, which is well known for maximum output, narrowest film tolerances and easy handling, and the CENTRO-Freeze secondary cooling unit will be showcased. CENTRO-Freeze is a secondary cooling unit against blocking effects that enables blown film producers to increase their output and save anti-block additives – especially at high ambient temperatures. CENTROFreeze is installed immediately before the lay flat and is a supplementary cooling system. The air blow-out elements cool the film tube evenly around the entire circumference and thus decrease the film temperature by up to 16 degrees Celsius, reliably preventing blocking of the film. Kdesign customers benefit from over 20 years of experience in retrofitting existing blown film systems and equipping new OEM systems.
Engineered in Germany, made in America
The Reifenhäuser Reiloy highly wear-resistant screws and barrels regularly sets benchmarks in terms of quality and performance. The components are available for Reifenhäuser and third-party lines offering a demonstrably longer service life, precise matching of raw materials and additives, exclusive alloys developed in-house, and process-optimized surfaces. Manufacturers of injection molded and extruded products thus benefit from the best cost-benefit ratio in the industry. Higher resistance to wear is provided by special iron-based alloys and nickel-based alloys that match the raw material being processed. The decisive factor here is the composition of the alloys, because wear protection depends not only on the hardness of the layer. Thanks to the Reiloy production site in Maize (Kansas), Reifenhäuser offers fast delivery times and local support for the American markets. Reiloy USA’s years of plastic processing experience in many environments combined with metallurgy knowledge affords an integral understanding of the materials available. This expertise enables the ability to offer customers the best solution to fit processing needs.
ELMET’s World Premiere at NPE 2024 TOP 700 LSR Dosing System Raises the Bar for Compact Precision
At NPE 2024, which runs from May 6 to 10 in Orlando, Florida, ELMET premieres its new, ultra-compact TOP 700 dosing system for injection molding liquid silicone rubber (LSR). Newly developed from the ground up, TOP 700, the most compact 20 liter system on the market, meets industry demand for a combination of cost-effectiveness, process-stable efficiency and the smallest possible footprint. Moreover, the TOP 700 provides the same high precision dosing of silicones and additives as Elmet’s flagship TOP 7000 Pro dosing system with its 200 or 20 liter drum size which was launched back in 2021, so ensuring perfect part quality.
efficiency and the smallest possible footprint. Moreover, the TOP 700 provides the same high precision dosing of silicones and additives as Elmet’s flagship TOP 7000 Pro dosing system with its 200 or 20 liter drum size which was launched back in 2021, so ensuring perfect part quality.
Performance and Economy
The TOP 700 can achieve delivery rates of over five liters/minute at a maximum pump pressure of 210 bar, so enabling short cycle times both when filling larger parts and with large numbers of small cavities. Additives and colors can be dispensed from 1, 4 and 20 liter containers. In order to achieve the dosing precision that is particularly vital for very small parts, the volumetric meter for colors has a resolution of below 0.1 μl/l. Depending on requirements, dosing can be carried out simultaneously or in a freely selectable mixing ratio.
Thanks to the optimized design of the follower plates, just 40 ml of residues are left behind when the 20 liter drums have to be changed, resulting in material utilization of up to 99.8%. With a design service life of 20 years or more for all its mechanical components, a modular structure and particular ease of servicing which keeps maintenance costs low, the TOP 700 is synonymous with cost-efficiency. Its very low energy consumption of less than 50 Wh and minimal compressed air consumption also help to keep costs down.
Versatile, Reliable, User-friendly
Designed to be FDA- and EMA-compliant, the new TOP 700 dosing system is also ideal for applications requiring the highest levels of cleanliness such as medical technology, personal care, foodstuffs and optics. Virtually abrasion-free pumping also prevents metal particle contamination of the LSR which would impair its functionality. There are also no limits to the consistency of the processed LSR under real-world conditions because Elmet’s new system can dose any commercially available product with the same precision thanks to its ability to handle viscosities of between 0.001 Pas and 2000 Pas (shear rate 10/s) or 16,000 Pas (1/s). Its optionally OPC UA- and Euromap 82.3-compliant control system can be seamlessly integrated into the injection molding machine’s own control system.
When it comes to safety, the new TOP 700 performs at the highest level, meeting the stringent requirements EN ISO 13849-1 (December 2023) which applies to machines and control systems. To avoid operating errors, the drums can be changed fully automatically from the drum rim from three sides within 2 minutes. Intuitive operation of the system, the use of simple clamp connections, a guided drum change procedure and an integrated cooling system mean even relatively low-skilled personnel can operate it without any problem. Fully automatic venting as standard completes the system’s many and varied safety and convenience features.
All Elmet dosing systems comply with the commonest industry standards such as CE, UL, FDA and EMA.
As Development Manager Thorsten Häuser explains: “We developed our TOP 700 dosing pump to meet customer demand for a space- and material-saving solution from ELMET. We’ve achieved this with a footprint of less than 0.5 m² (799 mm × 600 mm) and our new pump design. As a result, this new dosing system is particularly suitable not only for customers processing high-value, shear-sensitive or abrasive materials but also for R&D, prototyping and small-batch applications. The TOP 700 rounds out our product range while setting new standards in compact dosing technology.”
