Westeria at the IFAT 2024: Airstar Evolution Launches A New Era of Material Separation

At IFAT 2024, which takes place in Munich from May 13 to 17, the German machine manufacturer Westeria will be presenting the AirStar evolution air separator, which has been developed from scratch, to the general public for the first time (Stand B6.329/428). This sets new standards in terms of efficiency and flexibility, adapted to the individual needs of users. The completely redesigned air guidance system offers a high degree of flexibility in fulfilling specific tasks, the new control panel facilitates adjustment and process monitoring, and the design is optimized for ease of maintenance. Energy consumption is significantly lower than before. Available in working widths from 1,000 mm to 3,000 mm, the AirStar evolution is suitable for throughputs of up to 400 m³/h. Thanks to its modular design, it can be perfectly adapted to the task at hand, transported in a space-saving manner and assembled on site in just one day.

An essential part of almost all recycling processes, windsifting enables highly efficient separation of the components contained in waste streams based on their weight and ballistic properties. Westeria air classifiers are used worldwide for applications ranging from household waste, plastics, waste wood, refuse derived fuels, mixed construction waste, waste glass and industrial waste to scrap recycling. The AirStar, by far the manufacturer’s best-selling model, is based on 40 years of development history.

NotusAir air management system optimizes sorting results

The air management system of the air classifier plays a decisive role in the efficiency and precision of the process and therefore the sorting quality. Accordingly, Westeria on. The result of numerous simulations, flow analyses and tests with different materials is the new NotusAir air management system. Its newly designed, controllable fan enables precise control of the air flow and can therefore reduce energy consumption by over 30 % compared to a conventional air throttle valve, which is also noisier. To optimize results, the separator drum can be adjusted horizontally, the feed belt vertically and the nozzle angle fully electrically. The specially designed air routing and a large-area hood over the light material chamber also optimize the entire separation process. This makes it possible for the first time to return a large proportion of the process air to the separation blower, reducing the amount of air to be extracted by two thirds. This makes the overall system very compact and – in addition to the energy consumption – also significantly reduces the investment volume.

Proven advantages inherited from the previous AirStar technology include the downward angle in the integrated acceleration conveyor, which prevents heavy parts with a larger surface area from being carried into the light material fraction, and the shaftless separating drum as a measure against material jamming or winding between the drum and housing. The patented, automatic misalignment control in the acceleration belt ensures even more reliable belt misalignment correction thanks to an improved sensor and new algorithm.

Intuitive operation, convenient access for all maintenance work

For the first time, the AirStar evolution enables the electrical adjustment of all separation parameters from a central and easy-to-understand control unit as standard. On delivery, the optimum settings determined for the customer’s material in Westeria TechCenter are already preset. Saving individual separation recipes enables the system to be set quickly and precisely for changing materials. The separation process and its adjustment can be observed directly through the large viewing windows on the machine. The new, intuitive user interface is so simple that even untrained personnel can operate the machine. The system can also be connected to the operator’s central system control via the usual interfaces.

The new design of the AirStar evolution includes a well thought-out maintenance concept. The signal lights, visible from all sides, provide clearly recognizable information about critical machine statuses. In the event of faults, all critical points can be reached easily and in the shortest possible time. Large swing doors allow access to the separation unit from both sides, while additional convenient doors at the rear provide access to the feed conveyor. Thanks to the maintenance flaps in the lightweight material chamber, easy access is also possible here.

Numerous options for every application

A large number of possible extensions make the AirStar evolution a stationary cross-flow air classifier for all applications. Thanks to the established DiscSpreader material distribution system, narrow, irregular material feeds can be distributed across the entire belt width without the need for additional installation space. To create a third fraction, the new air separator can be equipped with the DuoDrum system, which uses two separating rollers arranged one behind the other. Alternatively, the AirLift overband extraction system, which has also been optimized, can be integrated into the lightweight material chamber to remove ultra-light materials.

www.konsens.de

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Exciting exhibits from ARBURGadditive – 20 years 3D printing showcase in Erfurt

• ARBURGadditive: Specialised range for industrial
3D printing
• Exhibits: Freeformer 750-3X and LiQ 5 3D printer process granulate and liquid silicone
• Good things come in threes: Congress, 3D printing exhibition and networking

Rapid.Tech in Erfurt has established itself as an important event in the 3D printing scene, and ARBURGadditive will be among those taking part in its 20th anniversary event from 14 to 16 May 2024. The company will be presenting two exciting exhibits: a large 750-3X Freeformer, which works on the basis of plastic granules, and an LiQ 5 for 3D printing liquid silicone (LSR). Visitors will find ARBURGadditive in Hall 2/2-215 at Rapid.Tech.

It is the triple combination of congress, exhibition and networking that makes this event special and interesting for the entire industry. As Dr Victor Roman, Managing Director of ARBURGadditive, explains: “Alongside the world’s leading trade fair Formnext in Frankfurt, Rapid.Tech is one of the most important German trade fairs in the field of additive manufacturing. It offers researchers and developers in particular a great platform for exchanging ideas.”

Focus on automotive, aviation and medical technology
The main areas of focus will be transport, aviation and medical technology, as well as software/AI and design for additive manufacturing and 3D-printed electronics. Commenting on the ARBURGadditive exhibits, Dr Victor Roman adds: “Demand for additively manufactured components for industrial applications is increasing and the requirements for part quality and material properties are becoming more stringent as a result. With our Freeformers and 3D printers from the TiQ and LiQ series, ARBURGadditive offers a suitable solution for practically every requirement.” The LiQ 5 3D printer will be demonstrating LAM (liquid additive manufacturing) technology for processing liquid silicone. This can be used to produce customised orthopaedic accessories and products for the food sector, for example.

Freeformer 750-3X – a very hot machine
With the large Freeformer 750-3X in the high-temperature version, the build chamber can be heated up to 200 degrees Celsius, with plasticising taking place at up to 450 degrees Celsius. This means that geometrically sophisticated ventilation ducts for the aerospace industry can be produced from Ultem 9085, for example. With its large build chamber (max. 330 mm x 230 mm x 230 mm), the Freeformer 750-3X also offers the option of additively manufacturing larger functional parts or small batches industrially – such as orthopaedic insoles up to shoe size 50. The possibility of additively manufacturing components from soft materials and high-temperature plastics or in hard/soft combinations is an impressive illustration of the machine’s wide range of applications. Short fibre-reinforced parts made of PA with 25 percent glass fibres and sealing components made of coloured LSR are other innovations that will be presented on the trade fair Freeformer in Erfurt.

The “comprehensive carefree package” from ARBURG
However, it is not only the premium-quality AM systems that make ARBURGadditive products so attractive to customers. The company also offers extensive and intensive training courses at the Arburg headquarters in Lossburg. Highly qualified application and service technicians also support customers on site with commissioning and trials as well as with material qualification in the form of a constantly growing material database.

www.arburg.com

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“OPC UA delivers significant client process simplification”

Industry interview with Georg Kiesl, General Manager, Billion SAS

Mr. Kiesl, why is Billion working to promote the OPC UA standard in the USA?
For us, the biggest advantage is interoperability, which enables the use of different machine types, but also different brands of the same type within a factory’s digital network. This interoperability is a basic building block for many existing concepts, such as predictive maintenance – plus it is extremely important for future concepts. One single system for the entire factory, into which everything can be integrated, is a major advantage, and also the reason why we are strongly in favour of it.

That said, you and the other players in the plastics machinery industry will initially incur costs for your efforts. 
Yes, there are advance payments on our part, that are necessary to win our customers over. Networking machines with digital instruments as part of Industry 4.0 has been around for some time. Until now however, it has often been the case that everyone has tried to bring their own approaches closer to the customer. These are always individual implementations with individual communication protocols. By launching a standardised product, we can make it clear to customers that it will simplify their processes. It is true that OPC UA entails initial implementation efforts, but all subsequent steps are much simpler because the implementation logic remains the same. This means that the implementation costs for the second, third or fourth application are significantly lower.

The manufacturers of injection moulding machines have been working on the so-called Companion Specifications for a long time. What is the current status?
From our perspective, the basic framework has been established. There are basic Companion Specifications, plus we already have customers who are utilising them. At present, it’s a matter of expanding these specifications and adapting them to individual customer requirements, but because we have the basic concept, we can already demonstrate the benefits to customers. Our major French customer Schneider Electric is very much in favour of OPC UA. For example, they are looking to connect all the machines in their factories to their predictive maintenance tools, regardless of the machine type.

Are American customers more risk-averse? 
American customers know very well that sooner or later they will not be able to avoid networking their systems. However, some aspects there are different to Europe: the market in the US is very dynamic and open to new technologies. As a result, you see a lot of technologies come and go there. That’s why American customers are more cautious and don’t want to jump    on the first bandwagon that comes along. We have to convince customers that OPC UA will still be around in five, ten or even twenty years’ time. It’s a standard that makes a lot of sense, and that’s why it’s here to stay. There is an initial implementation effort, but that will decrease over time.

In other words, the system is able to grow with little effort.
Exactly, and even if new Companion Standards materialise that are perhaps not yet foreseeable, the server-client logic will always remain the same. If everyone uses their own individual Industry 4.0 approach, then the basic logic will be so diverse that someone who wants or needs to connect multiple brands and machine types to their network will have to start from scratch every time. With OPC UA standards, there is an initial hurdle for the implementation, after which everything is reusable: this is the main point for our American customers to consider.

How important is it for Billion that American customers accept OPC UA?
It is very important for us for two reasons: firstly, the USA is a huge sales market. On the other hand – and this is even more important for us at Billion – the USA is a significant economic trendsetter. The American influence is very strong in North, Central and South America – regions in which Billion has multiple operations. American thinking and American standards are widespread there, which is why it’s important to have the Americans on board with OPC UA. If you’re really looking to create a global language for machines, you can’t bypass the Americans.

www.vdma.org

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SABIC Signs Memorandum of Understanding with Pashupati Group to Target Recycling Opportunities in India

• Memorandum of Understanding (MoU) agreement with SABIC designed to explore, evaluate and develop local business opportunities for recycling of used plastic in India, including potential for advanced conversion to pyrolysis oil as feedstock for SABIC’s certified circular polymers.
• Collaboration aims to contribute to Asia’s increased shift towards circularity, as SABIC experiences a growing demand for recycled products from its TRUCIRCLE portfolio of circular polymers.

SABIC, a global leader in the chemical industry, has signed a Memorandum of Understanding (MoU) with Pashupati Group, a leading Indian recycler of plastic waste and supplier of high-quality recycled products, including polyolefin pellets and recycled packaging bags, with operations in North, West & Southern parts of India. The MoU is targeted at developing local recycling opportunities in India, and expanding SABIC’s global network of qualified recycling partners.

As part of the MoU, both companies will share best practices and exchange knowledge in the various processes of used plastic material, including developing methods and to add value in processing using virgin polyolefin and recycled polyolefin, to both compounded and non-compounded finished products.

Sanjay Mishra, General Manager, Engineering Thermoplastics & Performance Polymers at SABIC, states: “We are very pleased about collaborating with Pashupati Group. This is a crucial first step in our efforts to support and accelerate the transformation of India’s plastics economy towards circularity. At the same time, it expands our collaboration with experienced local recyclers in Asia as we are continuously sourcing valuable feedstock to meet the growing demand for our TRUCIRCLE portfolio of recycled, circular polymers.”

Under the execution of the MoU, Pashupati, will bring in its expertise in the mechanical and chemical processing of used plastic, while SABIC will focus on the marketing and sales of recycled products. The agreement also provides for an advanced recycling project to convert used plastic into pyrolysis oil which SABIC will then be able to use in the production of certified circular polymers with the same performance properties as virgin plastics.

Bankey Goenka, Managing Director at Pashupati Group, adds: “This MOU is an amalgamation of two champions in their own fields: Pashupati Group, a leader in plastic recycling providing quality recyclates (PET & Polyolefin) including recyclates from mountain and ocean bound plastics to the global market with a proven track record over two decades, and SABIC, a market leader driving innovative products and solutions for a circular plastics economy. This is a testament to the commitment of both SABIC and Pashupati Group towards the circular economy and contributing to the conservation of our planet.”

This MoU follows SABIC’s 2021 collaboration with Malaysia-based plastic recycling company HHI, to create polymers from recovered ocean bound and ocean plastics. The polymers have since been used to manufacture new products, including the Microsoft Ocean Plastic Mouse, as well as the Microsoft Surface Thunderbolt 4 Dock.

SABIC’s TRUCIRCLE portfolio and services includes certified circular polymers, design for recyclability, mechanically recycled products, certified renewable polymers from bio-based feedstock and closed loop initiatives to recycle plastic back into high quality applications and help prevent valuable used plastics from becoming waste.

www.sabic.com

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The Ecosupply P Core Minimizes Paint And Rinsing Agent Losses

The new EcoSupply P Core is a modular paint   supply system based on pigging technology. This paint supply method   has already proved beneficial in the automotive painting world, but Dürr   has gone one step further and enhanced it for use in other industries for   the first time. The EcoSupply P Core is now adaptable wherever different   paint colors are applied in small quantities, such as in the construction, woodworking or automotive supplier industries. This system efficiently recovers unused paint, minimizing rinsing agent consumption and  speeding up color changes. Dürr will demonstrate how this works at the  PaintExpo from April 9-12 in Karlsruhe, Germany.  

The desire for a comprehensive color palette extends beyond the automotive industry. Customers use their color preferences as unique identifiers in other industries, whereas companies use distinctive colors as a unique selling point for themselves and their products. Manufacturers from the construction and plastic industries, for example, require a multitude of available shades to cater to their customers’ needs. However, each color change in the supply line results in paint and rinsing agent waste during the painting process. This can involve disproportionately high costs, particularly with very small quantities. This is because current paint supply systems clean the hoses using solvent and compressed air to remove all paint and rinsing residues left behind before preparation of the next color run can begin. This process is laborious and time-consuming, with longer and thicker hoses resulting in higher paint losses.

Pigging technology reduces paint consumption

For pigging technology, Dürr uses a fitting body tailored to the internal diameter of the hoses – the so-called pig – to make the process more efficient and reduce paint and rinsing agent consumption. The paint, flowing through the pigging hose, pushes the pig from the source to the destination module. This process removes any rinsing agent residue in the hose. Distributor stations, with the option of integrating up to four into one pigging line, provide the connection to the application technology. After the paint application, compressed air blows the pig back towards the source module. In the process, the paint left in the hose is transported back into the paint container. Rinsing agent then flows through the pigging hose towards the destination module. After cleaning, the process repeats.

Faster color changes and simplified maintenance

The EcoSupply P Core comes in single-pass and circulating versions and is suitable for applying both water and solvent-based paints. In both instances, reduced effort makes for faster color changes. Additionally, the modular design simplifies maintenance, allowing flexible configuration of individual components to adapt to user requirements and integrate into existing systems. Thus, the EcoSupply P Core can also integrate with other Dürr systems, such as the EcoSupply2 Core paint supply station.

Starter kit with everything you need

Dürr’s starter kit contains all important components, including a source and destination module, a distributor station for connecting to the application technology, hoses (which come in lengths of up to 100 meters), and the pig
itself. The starter kit also includes sensors for monitoring the pig position, maintenance and commissioning tools, and EcoDocu-technical documentation in digital format, complete with system examples.

Twenty-five years of experience in pigging technology

The EcoSupply P Core offers the manufacturing sector a cost-effective, easy-to- use paint supply solution for smaller quantities and applications in the low- pressure range. The new development is the culmination of Dürr’s 25 years of experience with the pigging technology featured in the EcoSupply P. Globally recognized, this tried-and-tested paint supply system with pigging technology has established its effectiveness in automotive painting. PaintExpo attendees can learn about the new EcoSupply P Core at Dürr’s stand 3320 in hall 3. The sales launch for the EcoSupply P Core is planned for early summer.

https://www.durr.com/en

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