Injection World April2014

TPE: MORE THAN A SOFT TOUCH
PLASTICS SHINE IN LED LIGHTING

CHINAPLAS 2014 SHOW PREVIEW
THE INSIDE STORY ON COLOUR
ISSN 2052-9376
April 2014
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www.injectionworld.com April 2014 | INJECTION WORLD 3
04 News
11 Arburg sets timetable to 3D print
Arburgs senior management used the companys annual open house to outline
commercialisation plans for its Freeformer 3D printing technology.
17 Much more than a soft touch
TPEs have to deliver more than a soft touch in todays demanding market. Suppliers
are working hard to meet end user requirements, writes Peter Mapleston.
26 Conference preview: Injection World Moulding Forum
Injection Worlds new moulding conference takes place in Philadelphia in June. We
preview the event and some of the key presentations and speakers.
29 Moulding masterclass: Make use of specications
In the nal part of his guide to moving moulds between machines, John Goff explains
the value of understanding your machine specications.
33 Colour & masterbatch: Appearance is everything
Americhems R&D manager Ron Beck explains how colour works, how it is perceived,
and how it is measured in plastics. Plus, an update on the latest colour developments.
43 E&E: Bright future ahead for LEDs
Energy efcient LED technology presents new opportunities for plastic moulders.
Chris Smith looks at some recent applications.
53 Chinaplas preview: Spotlight falls on Shanghai
Chinaplas will be this years biggest plastics trade show. We take a look at some of the
new injection moulding innovations that will be on display.
63 DFM: Integrate your DFM data
Andre Eichhorn explains why and how you can ensure the maximum value is derived
from the data developed during your product development process.
67 Product update
72 Diary
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INJECTION WORLD | April 2014 www.injectionworld.com 4
news
Synventive has opened a
service centre at Windsor in
Ontario, Canada, to support
its hotrunner customers in
the locality. The new centre
will be equipped with
substantial machining
capabilities and will be able
to run select moulding trials,
the company said. It will also
stock a wide range of spare
parts. Synventive said its
business in the Windsor
region has been expanding
as the US automotive
industry recovers.
www.synventive.com
Rexam has reached
agreement with US-based
Berry Plastics to sell the
remaining part of the
Containers and Closures
division of its Healthcare
business for $135m. The deal
requires regulatory approval
and consultations with the
works council at the French
production location but is
expected to complete in the
middle of the year. Rexam
sold the pharma devices and
prescription retail parts of the
business to Montagu Private
Equity in February for $805m.
www.rexam.com
www.berryplastics.com
Canadas Montel Plastics
has added Mucell injection
moulding technology from
Trexel to its capability slate,
which already includes
gas-assisted moulding, IMD
and FIM processing. The
Mucell system has been
installed on a 2,500 tonne
Engel Duo moulding machine
and will be used to develop
lightweight moulding designs.
www.montelplastics.com
news in brief
Festo wins Arburgs
2014 energy award
German automation systems
company Festo won Arburgs
seventh Energy Efciency
Award for its investment in a
new energy-optimised
production facility under
construction at Saint Ingbert.
Festo has a long standing
relationship with Arburg it
was the rst company to use
its Freeformer 3D printing
system. When the company
decided to build its new
production facility, it invited
the injection machinery maker
to be a key advisor.
Collaboration at such an
early stage was quite new for
us, said Arburg managing
director of technology Herbert
Kraibhler who presented the
award at the companys
Technology Days event.
Arburg carried out a
detailed analysis of the 45
thermoplastic and 12 vertical
elastomer Allrounder ma-
chines to be used at the
centre, devised optimal
machine concepts (including
tting of speed regulated
drives), recommended
insulation of moulds and
plasticising cylinders, and
optimised pre-drying and
materials handling.
We are very pleased to
receive the Arburg award. It
has a very big meaning for us
because it stands for innova-
tion but it also stands for
thinking across boundaries
and for keeping a location in
Germany, said Dr Claus
Jessen, Festos director of
product supply.
www.festo.com
www.arburg.com
US gun maker Smith &
Wesson has acquired injection
moulder and key plastics
component supplier Tri Town
Precision Plastics, based at
Deep River in Connecticut.
Smith & Wesson is paying
$23m for Tri Town, which
operates 45 injection moulding
machines at its 8,800m
2
plant.
Aside from moulding, the
company also offers mould-
making, prototyping and
assembly services.
Smith & Wesson said the
company has been a long
standing supplier of polymer
Gun maker buys into plastics
frames and related compo-
nents across the its range,
including almost all of its
popular M&P handguns. The
company accounted for around
60% of Tri Towns production
by value.
Polymer injection
moulding represents a
signicant element of our
production process, said
Smith & Wesson president and
CEO James Debney. Acquiring
this capability allows us to
vertically integrate a key
component of our
manufacturing
operations with
increased exibility, and is
expected to thereby lower
our production costs and
reduce risk within our
supply chain.
www.ttplastics.com
The Festo team receive the 2014 award. From left, Dr Claus
Jessen, Herbert Kraibhler (Arburg), Klaus Hilmer, Michael
Hehl (Arburg), Curt-Michael Stoll, Eugen Hehl (Arburg), Michael
Maas and Christian Leonhard
Tri Town
Precision produces
plastic mouldings
for Smith & Wessons
M&P handguns
news
Engel steps up Chinese activities
Austrian machinery maker
Engel is stepping up its
activities in China with the
creation of a new wholly-owned
subsidiary WINTEC that will
manufacture and sell standard-
ised machines aimed at the
mainstream Chinese injection
moulding sector.
The new WINTEC factory is
being built at Changzhou
around 120 miles north-west
of Shanghai, where Engel
already has a manufacturing
operation for large two platen
machines, and will begin
production in the summer. It
will have its own sales and
service capabilities and will
operate completely indepen-
dently of Engel in China.
This strategic decision
allows us to open up a new
target group for Engel and
strengthen our foothold in Asia
at the same time, said Engel
CEO Dr Peter Neumann. Our
goal for WINTEC is to appeal to
processors looking for
relatively standardised
machines with a limited range
of options.
Engel, which generated
global sales of E950m for the
last nancial year, has had
considerable success in Asia.
The region now accounts for
18% (E145m) of its sales, half
of which comes from China.
However, the companys
success has been in the high
technology sectors, where it
Swedish technical moulding
group Nolato reported its best
ever results for 2013 with sales
up by 17% to reach SEK4,522m
(E498m), boosted by strong
contributions from its medical
and telecoms divisions.
Sales in the medical division
were up by 10% on the previous
year to SEK1,274m (E140m),
telecom sales were up by 34%
to SEK2,079m (E229m).
Nolato posts record 2013 result
competes with other European
and Japanese machine
builders.
WINTEC will be competing in
the much larger market for
commodity machines, where it
will be up against Chinese,
Taiwanese and Korean rms.
Last year, Neumann told
Injection World he estimated
commodity machine sales in
China to amount to around
14,200 units a year, compared to
just 1,000 high technology units.
The WINTEC operation will
be headed up by Peter Auinger,
who has moved to take on the
role of CEO from Engel Mexico.
The requirements of Asian
commodity manufacturers for
energy efciency, precision as
Industrial was unchanged at
SEK1,170m (E129m).
In recent years we have
focused on creating a balanced
group structure with three
business areas, which we have
achieved along with continu-
ous enhancement of our prot-
ability. Amongst other things,
this strategic direction has led
to a series of successful
acquisitions at Nolato Medical,
which is currently responsible
for around 30% of group
turnover, said Nolatos
President and CEO Hans Porat.
Porat said he was disap-
pointed that the company had
not met its acquisition goals in
full during the year. However,
he said that the company was
continuing to explore further
opportunities.
www.nolato.com
well as supplier services have
increased sharply over the past
years. Local suppliers, however,
do not sufciently meet these
requirements. he said.
While the new business will
operate separately from
Engels other operations, it will
be integrated into the com-
panys global quality manage-
ment system. The key
difference between the product
lines will be in WINTECs more
standardised designs. This will
allow the company to offer
more competitive pricing and
shorter delivery lead-times.
There is hardly any overlap
with the series of Engel, said
Auinger. Until now, commodity
manufacturers in Asia have
mainly used injection moulding
machines from Taiwanese,
Korean, and Chinese suppliers.
With WINTEC we are develop-
ing new target markets.
Engel already manufactures
high technology injection
moulding equipment in Asia. It
builds tiebar-less machines at
a plant at Pynugtaek City in
Korea and larger Duo two-
platen machines at Shanghai.
www.engelglobal.com
Exploring further acquisitions:
Nolato CEO Hans Porat
Architects impression of the
WINTEC plant in China
news
Shipments of plastics machin-
ery in the US remained strong
in the nal quarter of 2013,
according to the latest
statistics from the Committee
on Equipment Statistics (CES)
at the Society of the Plastics
Industry (SPI).
An estimated $335m worth
of primary plastics processing
machinery was shipped during
the fourth quarter of 2013,
making it the strongest
quarter of the year and a near
all-time record. Taken as a
whole, however, total ship-
ments in 2013 were up by 8%
on the previous year.
Injection machinery
US Q4 machine sales up
S UK-based Carclo said it
plans to close its Carclo
Technical Plastics injection
moulding plant at Harthill in
Scotland. The company said
it has commenced consulta-
tions with staff at the facility,
which it said had been
loss-making for some years.
However, sales for the
Technical Plastics division as
a whole are good, it reported,
with a number of major
contracts secured for its
operations in the US and the
Czech Republic.
www.carclo-ctp.co.uk
S Switzerlands AdvalTech
has bundled all its mould-
making activities which
include the Foboha, AWM and
Omni operations - under the
AdvalTech Foboha brand.
Sales will be coordinated by
Germany-based Foboha,
which will also be the group
centre of excellence for
multi-component and cube
mould technology. The thin
wall mould competence
centre will remain in
Switzerland.
www.advaltech.com
S Bayer MaterialScience has
sold the bulk of its carbon
nanotube (CNT) and gra-
phene patents and technol-
ogy to German carbon
composite company Future-
Carbon. BMS ended its
Baytube activities back in
May last year, saying it could
not see commercial opportu-
nities in the foreseeable
future. FutureCarbon has
been a long-standing
development partner.
www.materialscience.bayer.com
www.futurecarbon.com
news in brief
Production of plastics and
rubber machinery, equipment
and moulds declined by 2.5%
in 2013 to end the year at a
value of 3.9bn, according to
sector trade association
Assocomaplast.
The association said,
however, the headline gures
mask a considerable improve-
ment in export orders in the
nal quarter of 2013. As a
result, it expects business for
the rst half of 2014 to be
while Italy sees 2.5% decline
reasonably good.
Exports of injection
moulding machines was
particularly strong, said
Assocomaplast, with export
sales up by 32% to more than
126m.
S www.assocomaplast.org
shipments were down by 5% in
Q4 2013, but that is more a
reection of the unusually
strong performance in the nal
period of 2012, SPI said in its
summary of the years activity.
Ancillary equipment orders,
including robotics, tempera-
ture control and materials
handling systems, were up by
1% on the 2012 nal quarter,
reaching a value of $101.3m.
When it is combined with
the data reported by the
federal government, the CES
data indicates that the
recovery in the plastics
machinery sector was gaining
momentum at the end of last
year, said Bill Wood, the
plastics market economist who
carried out the CES analysis.
These strong gains
notwithstanding, the trends
indicate that the manufactur-
ing sector is poised for further
growth in the coming quarters.
This will generate further
gains in the plastics machinery
data, says Wood.
His view is supported in the
CES market sentiment survey,
which showed 95% of respond-
ents expected US plastics
business conditions to hold
steady or improve over the
coming 12 months.
S www.plasticsindustry.org
Italian market for plastics and rubber machinery, equipment
and moulds ( millions)
2012 2013 Change (%)
Production 4,000 3,900 -2.5
Exports 2,575 2,550 -1.0
Imports 625 590 -5.6
Domestic market 2,050 1,940 -5.4
Trade balance 1,950 1,960 0.5
Source: Assocomaplast
Primary plastics
equipment
shipments
Source: Society of the
Plastics Industry
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ARBURG GmbH + Co KG
Postfach 11 09
72286 Lossburg / Germany
Tel.: +49 (0) 74 46 33-0
Fax: +49 (0) 74 46 33 33 65
e-mail: contact@arburg.com
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news
Sacmi sells Negri to US group
Italian machinery group Sacmi
has sold its Negri Bossi
injection machinery operation
to Kingsbury Group, a
US-based industrial equip-
ment group with activities in
automotive and electronics.
The sale includes the Negri
Bossi injection machine
business based at Cologno
near Milan in Italy, the
Bi-Power large two-platen
machine division of Sacmi
PolyOne has appointed
Robert Patterson as its new
president and CEO with effect
from 15 May. Patterson takes
over from Stephen Newlin,
who retires from the role he
People on the move
has held since 2006 but will
remain on the PolyOne board.
Patterson joined the company
in 2008 and is currently
executive vice president and
COO. He is a business
administration graduate.
US-based TPE maker Star
Thermoplastics has appointed
Jennifer Tomes as its rst
director of marketing. Tomes
joins Star from medical device
rm Medline Industries. She is
an experienced business-to-
business marketing profes-
sional and communications
graduate.
Robert Patterson
Dale Westerman
Dale Westerman has been
promoted to the post of
president and CEO of injection
moulding technology company
RJG Inc. Westerman joined the
company in 1998 as engineer-
ing manager and was most
recently operations manager.
He takes over the role from
Matt Groleau, who has held
the position since 1999.
Groleau will become director
of marketing.
KraussMaffei Group has
announced the appointment
of Patrick Bolliger to manage
sales for the groups Netstal
brand in Mexico. The move
follows the consolidation of
the companys KraussMaffei,
KraussMaffei Berstorff and
Netstal brands in the country
in January this year.
Spanish plastics institute
Aimplas has opened its new
technical centre on the
Technology Park Paterna, near
Valencia.
The 4,500m
2
facility is
equipped to carry out research
into nanomaterials, composites
and polymers from renewable
Aimplas opens new
R&D technical centre
resources for application in the
packaging, automotive and
aerospace industries.
The new building uses a
high proportion of plastic
materials, the most striking
being the polymer-based
exterior wall cladding.
www.aimplas.es
Group, and the Roboline-
Sytrama robotics business
also near Milan.
This sale is in keeping with
Sacmis desire to streamline
management and focus more
on the ceramics and packaging
sectors said Sacmi Group
general manager, Pietro
Cassani.
The Kingsbury Group
undoubtedly has the skills
needed to give this business,
currently worth some E100m,
a further boost, he said.
Cassini will become a
member of the Kingsbury
board on completion of the
deal, the company said.
Sacmi said Kingsbury
intends to maintain the current
Negri Bossi manufacturing
operation at Cologno and the
Italian group will continue to
supply large Bi-Power ma-
chines from its plant at Imola.
Sacmis compression
moulding technology for
production of plastic caps and
closures is not included in the
Kingsbury deal.
Negri Bossi has been
owned by a number of
industrial groups since 1970,
including Ingersoll Rand and
John Brown. It was taken over
by Sacmi in 2001.
www.negribossi.com
www.sacmi.it
The new Aimplas R&D
centre at Valencia
in Spain
moldmasters.com
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Trends and technical developments in the international closures industry
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CLICK HERE FOR DETAILS
Arburg technology days | news
Arburgs senior management
used its annual Technology
Days event to outline plans for
introduction of its Freeformer
3D printer and to update on
investment and technology
plans. Chris Smith reports
Arburgs annual Technology
Days open house event set a
new record this year, attracting
a record 6,900 attendees 25%
up on 2013. The packed event,
held at the companys factory
at Lossburg in the Black Forest
region of Germany, saw more
than 40 injection moulding
machines running production
tasks ranging from technical
component production through
to thin wall packaging. The
Freeformer 3D printing
technology launched at the K
fair also occupied a prominent
place and the companys
management detailed plans for
its commercial introduction.
Freeformer is an additive
building 3D printing system
that differs from currently
available systems in its use of
a proprietary material
preparation technology, which
allows it to run conventional
granular polymer materials.
Arburg says this gives users
access to a much wider range
of additive-building plastics
and reduces material cost by a
factor of up to 100. Interest in
the Freeformer is overwhelm-
ing, as is demand, said
Arburg managing director
Michael Hehl.
Four Freeformer systems
were demonstrated in
production during the Technol-
ogy Days, where visitors could
also explore the companys
new Freeformer Technology
Centre. However, Arburg is
taking a typically cautious
approach to the market to
ensure customers are fully
supported. Because this is a
completely new technology we
place great value on cooperat-
ing with users in the qualica-
tion of materials and design of
components, said Hehl. For
this reason, the market launch
of the Freeformer will take
place in 2014 solely in Germany
and only involve special
selected pilot customers.
A number of companies
have already been trialling the
technology, including the
automation systems company
Festo (winner of the 2014
Arburg Efciency Award),
which will continue to work
closely with Arburgs Free-
former development team.
Arburg managing director
of sales Helmut Heinson said
the companys commercialisa-
tion strategy is to deliver the
rst production machines to
pilot customers in the middle
of this year, with introduction
rolling out to the rest of
Europe from the beginning of
2015. Freeformer technology
will be launched to Arburgs
US customers at the NPE show
in Orlando next spring.
Wide interest
Heinson said interest in the
Freeformer is coming from
across the market. Custom-
ers are in various areas, the
automotive industry and
general industry, he said. He
said the company expects to
have supplied between 100 and
300 units by the end of next
year.
Arburg clearly sees
considerable potential in the
Freeformer technology, but the
company is certainly not
neglecting the injection
moulding technology on which
it has built its reputation. The
company has just commenced
the latest extension of its
factory at Lossburg. The
18,600m
2
two-storey extension
will increase total production
space by 13% to near
165,000m
2
and will provide
additional assembly space
required for larger machines,
which are taking up a growing
share of the companys sales
(Heinson said the share of sales
taken by machines in the
200-500 tonne range grew from
2% in 2012 to 19% last year).
The German machine maker
is also currently building a new
2,500m
2
headquarters for its
US operations at Rocky Hill in
Connecticut in the US, is in the
process of expanding its
operation in the Czech
Republic, and has committed to
construction of an 800m
2
new
building for its Polish subsidi-
Arburg lays out timetable for
3D-print commercialisation
Arburg will install the rst commercial Freeformer 3D printers with selected German customers
in the middle of this year
news | Arburg technology days
ary. Last year it completed the
construction of an enlarged
warehouse at Shanghai in
China, allowing it to offer
machines from stock to shorten
lead times for its growing
number of Chinese customers.
The company has also
committed to a six gure
investment in a 30% expansion
of its solar power generating
capacity at its Lossburg plant.
Arburg already produces
around 30% of its annual
energy requirements via a
combination of CHP, wind and
photovoltaics. Hehl said
expansion of this side of its
activities is one of its key goals
for the future.
Arburg expects its nal 2013
result to amount to around
E470m, according to Heinson.
That is a little lower than its
record result of E488m in 2012,
which he attributes largely to
customer delays. Some large
projects were delayed into 2014
and will be invoiced later, it is
not a drop-back in incoming
orders, he said.
The 2013 result was helped
by a big improvement in the
US, which is now Arburgs
largest export market. The US
market has developed well. In
2009 it was about 1,200
machines, now it is around
3,600. We feel that the industry
in the US is winning back work
from the lower cost countries.
And we see the same now in
the UK, said Heinson, who
predicts a very good and
solid 2014 result.
Processing exibility
The 40 or so processing exhibits
running across the Lossburg
site covered a wide range of
applications. Some, such as the
thermoplastic composite sheet
overmoulding of an automotive
seat lever on a 400 tonne
Allrounder 820s machine
equipped with the companys
direct LFT compounding
technology, had been demon-
strated at the K fair last year.
Others were new for the event.
Among the new exhibits
was a multi-layer production
system for thick polycarbonate
LED lenses. The system was
running on an all-electric 150
tonne Allrounder 520A
equipped with two injection
units using a Wilhelm Weber
rotary tool that rotated by
increments of 45between
eight stations three injection,
four cooling and one removal.
The process involved injection
of a preform at the rst
station, followed by indexing
through three cooling stations,
overmoulding of the second
layer at the fth station,
cooling at the sixth station,
overmoulding of a third layer
at the seventh station, then
part removal while the mould
was closed at the eighth
station. This reduced cycle
time from around 180s using
conventional technology to
55s, according to Arburg.
Internet of Things
Production efciency is not
only a matter of machine and
mould technology, however,
and engineers in the com-
panys Efciency Centre had
put together a demonstration
production cell to show how
the internet may change
plastics production in the
future. Industry 4.0 is a
German government-backed
programme intended to
develop strategies for smart
manufacturing based on The
Internet of Things concept of
full connectivity.
The exhibit itself was the
relatively mundane manufac-
turing of a simple toy car - the
technology was the hidden
data collection. Each visitor
was able to identify their car
by a simple scan of their visitor
badge, which then pro-
grammed a laser to place a
unique QR code on the
moulding immediately after
removal from the moulding
machine. Every process
parameter and quality check
in this case machine data,
validations of correct assembly
and function of the nished car
were assigned to that part
and stored in a central
computer system.
We are manufacturing a
part that is collecting data
throughout the process and it
is all stored, said Dr Thomas
Walther, head of Arburgs
Application Centre. This is
data integration at the highest
intelligence level. If this was a
safety critical part for the
automotive industry, for
example, this would be really
valuable.
www.arburg.com
Arburg applied Industry 4.0 techniques to production of this toy
car, capturing and storing all production data against a unique
QR code
This thick section LED lens was produced in an 8-station Wilhem
Weber rotary mould on a 150 tonne all-electric Allrounder on a
55s cycle
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news | Arburg technology days
Arburg managing director of
technology Herbert Kraibh-
ler handed over to successor
Heinz Gaub after the Technol-
ogy Days event, ending his 50
years with the rm. Chris
Smith spoke to both about
past and future innovations
The 2014 Technology Days
event marked a further
milestone in Arburgs corpo-
rate history as the last to be
overseen by long-serving
managing director of technol-
ogy and engineering Herbert
Kraibhler, who retired and
passed over his role to Heinz
Gaub on 1 April.
Kraibhlers 50-year career
with Arburg began in 1964,
when he joined the Lossburg
company as a machine tter.
He went on to study engineer-
ing and plastics technology
under an Arburg scholarship
scheme at Karlsruhe, joining
the companys development
department in 1972 and
working his way up to the post
of managing director of
technology in 1996.
As the companys technical
and engineering head for close
to two decades, Kraibhler
steered Arburg through some
big technology shifts. One of
the biggest was the change
from hydraulic to electric
machines, he told Injection
World. In hydraulics, it is all
pistons and cylinders. For the
electric machines we had to
change to toggle systems and
spindles. From our side, that
was an important point in the
focus of what we could buy and
what we could make.
Kraibhler lead the
companys development of its
Retiring Arburg technical director Herbert Kraibhler (left) in conversation with his successor
Heinz Gaub pictured during a walk around the Arburg factory
Kraibhler bows out after 50 years
patented and own-manufac-
tured spindle system and the
recruitment of the many drive
engineers that the electric
technology called for. He also
led development of the
Selogica control system, which
he said he considered to be
ahead of its time and its
competitors. The basic
principle of Selogica is not so
far away from the mobile
phones and apps we see
today, he says.
Few people today can match
Kraibhlers long career with
just one company. The man
who takes over his role, Heinz
Gaub, has already held posts in
a number of rms - most of
them medium-sized, interna-
tionally-active family-owned
businesses such as Arburg. He
studied engineering at the
Technical University of Berlin
and gained an MSc from the
Massachussetts Institute of
Technology in the US.
Gaub joined Arburg nine
months ago and has been
working closely with Kraibh-
ler in the run up to the
handover. He is already
prepared to share his ideas of
what developments may lie
ahead. Over the course of the
next years we will certainly see
a lot of developments in
controls and drives in terms of
speed, technical performance
and in terms of the human
machine interface, says Gaub.
If you look at machine
operation in general plastics
or anywhere it requires a lot
of experts. Future develop-
ments will provide more expert
technical help to the operator.
Gaub cites the Freeformer
additive build system as an
example of how machines may
develop. The only button [on
the Freeformer] is the on-off
switch. Everything else is
phone-style. In some respects,
the Freeformer is a technology
driver for us it shows the
difference.
Arburgs introduction of the
Freeformer at the K show last
year surprised many that see
additive manufacturing as a
potential threat to injection
moulding. Gaub, however,
agrees with his predecessor
that it is a natural addition to
the companys injection
moulding machinery activities.
It is a new core technology
but the technical philosophy is
close to what we use on our
injection moulding machines.
The plastication is the same,
the only difference is that we
are shooting very small
amounts one hundred times a
second, he says.
www.arburg.com
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Innovation | TPEs
The days when thermoplastic elastomers (TPE) were
relevant only for simple design enhancements and a
soft touch are long gone. These materials have now
become established in a wide range of industrial and
consumer applications with diverse demandseven if
soft touch is still an important one. Efcient processing
in multi-component injection moulding, excellent
mechanical properties also at high temperatures
and low weight make TPEs an interesting material,
says one supplier.
Thermoplastic vulcanizates, or TPVs, are now among
the most common TPEs. Produced in most cases by
dynamic vulcanisation of ethylene-propylene-diene
monomer (EPDM) as it is compounded together with
polypropylene in a twin-screw extruder, they are
available from numerous compounders around the
world, and the diversity is increasing.
Enplast last year launched the EZPrene fully
vulcanized TPVs to complement its Enex general-
purpose partially vulcanized types. There are currently
nine materials in the series, ranging in hardness from
55 Shore A to 50 Shore D. Enplast, part of the Ravago
group, has production operations at its headquarters
location in Turkey and in Texas, US. The company says
EZPrene grades employ a proprietary cure technology
that makes possible production of soft-touch surfaces
in bright colors.
The company also highlights the fact that EZPrene
grades are non-hygroscopic. Processors who are not
equipped for the extensive drying that is normal with
traditional thermoplastic rubber compounds will nd
that EZPrene materials will run readily on conventional
equipment, says Synco de Vogel, marketing and sales
manager.
The new grades are said to be comparable to
conventional TPVs in terms of strength and elasticity.
On two critical counts, though, they outperform other
thermoplastic rubber products that are specially
designed to accommodate colours and eliminate
pre-drying, de Vogel says. EZPrene grades are also
claimed to show greater resistance to oil swell, and are
said to exhibit better resistance to compression set.
Another important TPE compounder, Kraiburg TPE,
says that the Thermolast V range of TPVs it developed
specically for automotive applications is increasingly
popular. Typical uses for the materials include seals,
Above: New
start-up Gobie
H2O is using a
Versaex TPE
from PolyOne
GLS on its
range of
rellable
ltered water
bottles to help
stand out from
its more
established
competitors
Much more than a soft touch
TPEs today must deliver more than just a soft touch.
Suppliers are working hard to meet end-user demands
in all performance areas, writes Peter Mapleston
TPEs | Innovation
cable bushings, timing belt covers and radiator covers.
In addition to good mechanical properties, temperature
resistance up to 140, and very low compression set
(Figure 1), the compounds also feature good adhesion
to non-polar polypropylene and polar polyamides.
Thermolast V compounds are partially cross-linked
TPVs. But rather than containing EPDM rubber,
Thermolast V grades use styrene-ethylene/butylene-
styrene (SEBS)which is where the compatibility with
polyamide comes from. With an ideal conguration of
processing parameters in the two-component injection
moulding process, Thermolast V and polyamide can
achieve good adhesion of more than 5 N/mm, claims
the company.
Chemical cross-linking during the production
process increases the continuous use temperature to
as high as 140C. The company says this means the
materials are comparable to TPV-(EPDM+PP) and
conventional rubber compounds based on EPDM, CR,
NBR and HNBR.
Kraiburg is not alone in emphasizing the importance
of being able to co-mould TPEs with polyamides. Last
year, another major compounder, US-headquartered RTP
Company, licensed manufacturing rights from ExxonMo-
bil Chemical for types of Santoprene (the original TPV)
that bond to polyamides. At the time, RTP said it would
provide current users a seamless supply transition and
would also develop new markets and
applications.
The materials are marketed as the
RTP 6091 Series. They are available
globally with hardness of 55 to 85
Shore A, in various colours. RTP says
the compounds offer superior thermal
resistance (up to 135C), excellent
chemical resistance, and better compres-
sion properties than alternative styrenic-based nylon
bondable TPE materials.
Teknor Apex has an interesting position on styrenics
versus EPDM-based TPEs. Almost four years ago, this
compounding company took over the Sarlink range of
TPVs from DSM. Now it is extending the brand, but this
time with grades based on styrenic (TPE-S) chemistry.
Teknor Apex, which claims to be the most diversied
manufacturer of TPEs, says this will expand the range
of economic and performance alternatives available to
manufacturers of sealing systems and other automotive
components by providing similar, and in some cases
improved, performance.
The new compounds are physical blends of styrene
block copolymers (SBCs) with narrow molecular weight
distribution, and other, unspecied, ingredients.
Properties can be varied easily and widely by modifying
the compound formulation, the supplier says. And there
are some cost advantages.
Unlike the widely used TPV automotive compounds
with which the Sarlink brand has been identied, the
Sarlink TPE-S compounds are not affected by variations
in the price of EPDM rubber, a key ingredient in TPV
manufacture, says Ger Vroomen, senior marketing
manager for automotive. In the past, interest in TPE-S
compounds intensied as a result of sharply increasing
costs for EPDM, but, although TPE-S compounds still
retain an economic advantage, they have also emerged
as practical alternatives to TPVs because of their
properties.
According to Teknor Apex, TPE-S compounds
generally exhibit strength and elasticity comparable to
TPVs (Figure 2). They provide smoother part surfaces
and equivalent or better long-term UV stability than
TPVs and exhibit a broader processing window in
injection moulding. TPE-S compounds are available in a
Figure 1: Compression set performance of Thermolast V (TV6VNZ grade)
Source: Kraiburg TPE
Right:
ExxonMobils
Santoprene
the longest
established
TPV - has found
widespread
application in
automotive
ducting
P
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O
:

E
X
X
O
N
M
O
B
I
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20
TPEs | Innovation
variety of custom-matched colours, and they generally
do not require pre-drying. On the other hand, the
company says, TPVs exhibit better resistance to oil and
grease and have a higher service temperature around
115C as against 100C for TPE-S compounds.
Teknor Apex divides the injection moulding grades in
the new range into two: high performance and general
purpose. The former, mainly aimed at exterior applica-
tions, have hardnesses ranging from 55 to 70 Shore A.
They have a broad processing window, exhibit smooth
surfaces, and provide high UV stability and heat
resistance. General-purpose injection moulding
compounds for under-hood and interior components go
from 40 Shore A to 50 Shore D. These compounds also
have a broad processing window and exhibit relatively
low odour and fogging.
Italian compounder So.F.Ter is promoting a two-
component injection moulding solution for automotive
soft-touch interiors, based on a glass-reinforced
polypropylene compound overmoulded with its Laprene
8ST.A80 SEBS-based TPE. The SmarTouch 2K solution
combines aesthetics, ecology and convenience,
according to So.F.Ter. The company cites very good
fogging performance, complete recyclability and low
weight at a competitive cost.
The two compounds used in the SmarTouch 2K
concept have a high chemical afnity, which not only
ensures their perfect adhesion, but also makes it
possible to recover and recycle the vehicle panels at the
end of the life cycle, says So.F.Ter. The granulate
obtained by grinding the SmarTouch 2K panels and
production scraps is a polyolen compound with good
impact resistance and can be reused for the production
of other components.
Laprene 8ST.A80 has a density of 0.91 g/cm
3
, so
panels are lighter than those made using alternative
systems based on polar polymers such as TPU (basic
performance data is shown in Figure 3). SEBS is also
rather cheaper than TPU. Laprene 8ST.A80 also passes
all the tests covered by Volkswagens 50180 norm
governing fogging. After seven days of exposure to heat
(85C), there is only a negligible change in colour and
mechanical properties. And the TPE passed Fiats M700
scratch resistance test and LP-463 P chemical
resistance test.
PolyOne GLS Thermoplastic Elastomers unveiled its
Versaex CE thermoplastic elastomers for applications
in the consumer electronics market last year. The
company is targeting such applications as electronic
wristbands, smart watches and mobile devices. It says
the portfolio of standard and custom-formulated TPEs
offers designers a combination of performance, visual
appeal and physical aspects. Designers can combine
outstanding aesthetics, such as silky-smooth soft feel,
with colour and texture, the company says. The grades
also provide very good chemical and UV resistance.
While not providing detailed information, the
company claims that the Versaex CE range incorpo-
rates new TPE technology that addresses several top
challenges, including desirable haptics for high-end
phone and tablet cases and excellent vibration-damping
properties to improve device performance and comfort
in use. It says the range includes products based on
different blends of technologies designed to draw on
GLSs chemistry agnostic approach to leveraging its
strong supplier relationships and using the chemistry
most suited for the application.
Versaex CE grades can bond to
PC/ABS and other substrates
during moulding.
Not surprisingly, other
TPE suppliers are after the
portable electronics
market, too. Multibase,
a business unit of Dow
Corning, has targeted the
sector with its range of
thermoplastic silicone
vulcanizates, or TPSiVs. Mehdi
Abbadi, head of marketing for Dow
Corning in Europe, highlights the
ability of the company to create
compounds compatible with a wide range
of thermoplastics by changing the thermo-
Figure 2: Basic properties of Sarlink TPE injection
moulding grades from Teknor Apex
Sarlink Compounds
High General-
Performance Purpose
Property Test Method TPE-S TPV TPE-S TPV
Specic gravity ISO 1183 1.04 0.92 1.20 0.95
Hardness, Shore A (5 sec.) ISO 868 65 64 62 65
Tensile strength, MPa ISO 37 6.7 4.9 5.1 5.4
Ultimate elongation, % ISO 37 780 417 750 270
100% modulus, MPa ISO 37 2.0 2.3 1.8 3.8
Tear strength, kN/m ISO 34-B
angle, 28 23 22 32
500mm/min
Compression Set 22 hrs @
23 C ISO 815 20 20 24 23
22 hrs
@
70 C Type A 39 35 38 34
Apparent shear viscosity, Pa.s. ASTM D 3835 110 231 120 310
TA Procedure
Source: Teknor Apex
INJECTION WORLD | April 2014 www.injectionworld.com
Right:
Multibase sees
great potential
for its TPSiV
products in
applications
such as smart
watches
Innovation | TPEs
plastic phase in the TPSiV. There are also few limits on
the colourability of the compounds.
TPSiVs have been very successful in new consumer
electronics applications over the last two to three years,
especially with smart watches. These devices have
electronics inside the band as well as in the face, and
our materials can be moulded over the electronics as
well as over thermoplastics, says Abbadi. The
companys 4000 Series, which contain thermoplastic
polyurethanes (TPUs), are aimed at these applications.
Abbadi claims an advantage for TiPSiVs over pure
TPUs that are also targeted at these applications, but
which he says lose much of their softness at low Shore
values. Nor is there any problem with skin irritation,
which has been an issue with some smart watches.
Building on silicones
Abbadi says Multibase plans to build on its success with
TPSiVs in consumer electronics with the launch in the
second half of this year of grades developed specically
for soft-touch applications in automotive interiors (there
will also be new grades for baby care products, where
FDA approval and absence of plasticizers is desired).
There will be grades for overmoulding on various
thermoplastics.
The grades will answer concerns in the auto
industry about fogging and VOCs,
since they contain no volatiles,
says Abbadi. Just as we have
done with our grades for
portables, we will be able to
colour match grades for specic
applications, and we can also
meet requirements for UV
resistance, chemical resistance,
dirt pick-up, energy dissipation,
and other properties.
Multibase also offers
SEBS-based TPEs and more
conventional TPVs in its MultiPro
and MultiFlex ranges. All grades
are available from its four sites in France, the US, India,
and China.
Italian compounder API, which specialises in TPEs,
recently launched its Neogol series of elastomeric
compounds whose main matrix consists of Olen Block
Copolymers (OBCs). API says Neogols chemical
structure gives these new compounds excellent
resistance to UV radiation and ageing. Their good
processability also enables production of parts with
high aesthetic qualities, even over large surface areas
and low wall thicknesses.
The Neogol range is characterised by a degree of
crystallization that is higher than common olen
copolymers and derived compounds, with consequential
processing advantages such as cycle time reduction,
says API. The products in the Neogol family are made
with varying hardnesses from Shore A 35 to 90.
API says high compatibility with polypropylene and
polyethylene make Neogol grades a natural choice in
overmoulding applications. Moreover, as a solution to
the ever-increasing demands of styrene-free products,
they are particularly suitable for specic sectors such
as hygiene, child care and toy
manufacturing as well as the auto-
motive, mechanics, electronics &
electrical sectors, it says. The
Neogol range also includes food
contact grades.
Ethylene-octene OBCs were
launched several years ago by
Dow Elastomers under the Infuse
banner. They are aimed at various
applications, including lms,
gaskets, foams and adhesives, as
well as injection moulding. The
company cites several advantages
over alternative polyolen
elastomers, including a better balance of exibility and
high temperature resistance, a higher crystallization
temperature, better elastic recovery and compression
set properties at both ambient and elevated tempera-
tures, and higher abrasion resistance.
Dow says the block structure of OBCs offers an
advantaged performance balance of exibility and heat
resistance compared to random polyolen copolymers.
Elastomeric properties are retained at low tempera-
tures (Tg is -50C). Crystalline melting point is 120C.
Various types of TPE lend themselves to bio-sourc-
ing. Some types based on polyesters, for example, use
Above:
So.F.ter sees
big potential in
automotive
interiors for its
SmarTouch
concept
P
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S
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Figure 3: Mechanical properties
of So.F.Ters Laprene 8ST.A80
Property Value
Shore A Hardness 83
Density, g/cm
3
0,91
Tensile strength, MPa 14,5
Elongation at break, % 800
Modulus 100%, MPa 3,1
Tension set, % 16
Tear strength, N/mm 44
Source: So.F.Ter
TPEs | Innovation
1,4-butanediol (BDO) as a feedstock, and work is well
advanced at several companies to produce this on a
commercial scale from renewable resources. TPEs
containing blocks of polyamide may be able to use
castor oil as a feedstock. Thermoplastic polyurethanes,
too, have the potential to use bio-based feedstocks.
Last year, DSM said it had tested and approved
bio-based BDO made with Genomaticas process for use
in its Arnitel copolyester TPE, which would give it a
renewable content of up to 73%. Timing of commercial
production depends on availability of bio-BDO from
Genomatica licensees, and at the moment, only BASF is
producing commercially available volumes. Any other
announcements related to other licensees are currently
not public information, a Genomatica representative
told Injection World.
Drop-in renewability
DSM conducted in-depth tests with bio-based BDO to
produce PBT (polybutylene terephthalate), one of the
building blocks of Arnitel. The tests proved that
bio-based BDO made using Genomaticas process is
purer than typical fossil-based BDO. It can be used as a
drop-in substitute for petroleum-based BDO and
required no changes in DSMs processes.
DSM already produces Arnitel Eco with a bio-based
content of 22-53% depending on the hardness (this
uses rapeseed oil as a feedstock in place of mineral oil).
The introduction of bio-BDO will increase the bio-based
content to up to 73%. Arnitel Eco is being used for a
number of soft touch applications in consumer
electronics, as well as for lms.
DuPonts Hytrel polyester-based product was one of
the rst TPEs on the market. It still continues to evolve
and nd new applications. A rather interesting one is
the exible backrest for an innovative ofce chair called
the DNA Ingo, designed by Colombian furniture
company MUMA and US design studio Curve ID. It is
made in Hytrel RS, which is 60% bio-based.
Alberto Mantilla, a partner at Curve
ID, says: We were looking for a very
specic material that few companies
could offer. We needed a range of
characteristics including strength
and exibility and we needed a
partner to work with us
collaboratively on an interna-
TPE tyre
delivers a
longer life
Injection moulder Mecaplast has extensive experience in the production
of wheels for the agricultural sector. With the support of API and mould
maker Tecnostamp, it recently developed the TPU GreenLifeTire as a
more sustainable alternative to tyres made in vulcanized rubber.
The TPU tyres are already being used in precision seeding equipment.
Depending on their size and position on the equipment, they serve to
press the seed into the ground and then afterwards to compress the soil
that is laid over the top. GreenLifeTires, which do not needed to be
inated, can be mounted on plastic or metal rims.
API, which supplies its Apilon 52 TPU for the application, says
the considerable and prolonged abrasion caused by the
ground causes conventional tyres to wear down
quickly. GreenLifeTires have higher abrasion
resistance, adhere less to the soil, have greater
resistance to notching and notch propagation, and
they weigh around 25-30% less.
Mecaplast offers to take back the tyres at the end of
their useful lives for recycling the material into new
products. It says versions made with a biodegradable
resin are in development.
www.apiplastic.com
Seeding machines with
GreenLife Tires in API TPE
API Mecaplast GreenLife Tire
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Left: Tablet covers are a
key application sector
for TPEs. This example
is produced in a
Multibase TPSiV grade
TPEs | Innovation
tional basis. We initially ap-
proached DuPont in Colombia
and later met with Rick Tobar,
DuPont development manager
in the US. This meant that Curve
ID had support in its New York
studio, while MUMA could liaise with
local contacts in Colombia.
We were looking for a thermo-resist-
ant elastomer that was both strong and
exible; one that would also maintain its
elastic properties during its lifetime. We wanted
back support that would mould to the users
individual lumbar requirements. And in addition to
this, we were looking for a renewably sourced material.
Hytrel RS exceeded our expectations, proving to be a
vital aesthetic and functional choice.
Juan Carlos Bedoya, MUMA CEO, explains the need
to differentiate the chair from the many existing mesh
products in the market: Since we wanted to compete in
the mesh market, the backrest should have a net
appearance, which meant we had to work with a
material that offered a good ow rate during the
injection moulding process, in order to copy the
geometry and dimensions of the product easily.
DuPont provided Curve ID with samples of materials
so that stress tests and prototyping could take place.
Curve ID designers worked with the DuPont team to
understand the parameters of Hytrel RS and how it
performed when tested against different patterns. The
aim was to nd the right geometry to satisfy both
aesthetic and ergonomic requirements, while making
the most of the materials capabilities. Test
results were shared with the DuPont team, who
then offered advice on the next steps in the
development of the backrest.
MUMA, DuPont and Curve ID also
explored how the material responded to
the original requirements in terms of its
behaviour and mechanical
properties. Thanks to the
experience and knowledge of
DuPont in computer simulation,
several different analyses were
completed that allowed MUMA to
understand the materials
performance during the injection and
post-injection process. The technical
collaboration from DuPont helped
MUMA overcome concerns it had,
enabling it to predict and
prepare for the result of the
nal production process.
Arkema recently extended its range of Pebax
RNew 90% bio-based polyether-block-amide
TPEs with Pebax RNew 80R53, a rigid grade
that it says goes beyond the limits of
thermoplastic elastomers. Intended
principally for ski boots, the new grade is 50%
more rigid than existing Pebax products already used
for alpine touring and cross-country ski boots.
All Pebax grades have high long-term UV
resistance and high performance under
extreme cold conditions. In addition, thanks
to its rigidity and outstanding processability,
Pebax Rnew 80R53 allows unequalled design
freedom for thinner and even more lightweight and
dynamic shoes, Arkema claims.
Thermoplastic polyurethanes (TPUs), now well into
their 60s, are among the oldest TPEs. COIM in Italy has
just launched a new range of TPUs based on renewable
resources, called Laripur RS. It says the range will
cover all traditional applications for TPUs. COIM was
unable to provide further details in time for Injection
Worlds publication deadline.
Lubrizol (which already has bio-based TPUs in its
Pearlthane ECO product line) has introduced aliphatic-
based Estane and Pearlthane TPUs to complement its
aromatic TPU portfolio (Pearlthane is the name
previously used by Merquinsa, which Lubrizol acquired
in 2011). Aliphatic TPUs show much better colour
stability than aromatic types when exposed to light.
Grades are intended for automotive, sports and
recreation, and portable electronics. Pablo Alegre,
Lubrizol Estane EMEAI marketing manager for
electronics, says the new materials exhibit faster
processing and good mechanical properties, while
providing good haptics, an excellent surface nish and
nice aesthetics.
Click on the links for more information:
S www.en-plast.com
S www.kraiburg-tpe.com
S www.rtpcompany.com
S www.exxonmobilchemical.com
S www.teknorapex.com
S www.softergroup.com
S www.glstpes.com
S www.multibase.com
S www.apiplastic.com
S www.dow.com/elastomers
S www.dsmep.com
S www.plastics.dupont.com
S www.arkema.com
S www.coimgroup.com
S www.lubrizol.com
Right: PolyOne
GLS is one of
many TPE
producers
looking hard at
the emerging
market for
wearable
electronic
devices
Below: MUMA
selected Hytrel
RS from DuPont
for the exible
back on its the
DNA Ingo ofce
chair
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The ENGEL duos exible concept has proven to be a great success over the
last 20 years. Now we have made the most efcient two-platen machine on the
market even better. For products with higher-than-usual cleanliness requirements,
this compact powerhouse is now available with a linear guidance system that is
clean, highly precise and energy efcient and with clamping forces from 350 to
700 tonnes.
Better because it is more ergonomic
The new, clear-cut design with its lower operating height and the new CC 300
control unit is an instant hit. If you do not want to compromise on anything be
it installation, maintenance or selection of injection unit size: The ENGEL duo is
the perfect choice. We have also made it easier to access the purging area and
we have reduced the nozzle center line by up to 225 mm.
There are just two things we have not changed: the machines reliability
and its variable modular system.
Cleaner and more ergonomic
ENGEL duo with a new design
ENGEL duo
ENGEL duo
ENGEL AUSTRIA GmbH | Ludwig-Engel-Strae 1 | A-4311 Schwertberg
Tel. +43 50 620-0 | Fax +43 50 620-3009 | packaging@engel.at | www.engelglobal.com
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conference preview | Injection World Molding Forum
The rst Injection
World Molding
Forum is set for
Philadelphia in June.
We preview some of
the presentations
lined up for this
exciting new injection
moulding conference
The rst Injection World Molding Forum takes place in
Philadelphia, PA, USA on 17-18 June. Organised by
Injection World magazine and Applied Market Informa-
tion (AMI), this exciting new event will explore many of
the themes and issues covered regularly in the pages of
this magazine, but in a face-to-face environment where
attendees can discuss and debate directly with our
assembled panel of expert speakers.
The full conference programme features 19 high-
level presentations by experts in their eld, including
senior business and technical representatives from
leading global machinery and materials companies, as
well as some top names from the US processing sector.
This article takes a look at what we have in store for
the rst day of the Injection World Molding Forum. We
will take a look at what the second day of the confer-
ence holds in the May edition.
Market update
The opening keynote session of the conference will
focus on some of the business issues facing the North
American moulding industry. It will open with a
presentation by Andrew Reynolds, research director at
AMI, who will look at the changing structure of the
injection moulding industry and detail successful
strategies for future business development. Reynolds,
one of the founders of AMI, has more than 30 years
experience in international plastics industry consulting.
Michael Araten, president and CEO of KNex brands,
will speak about the benets that accrue from reshor-
ing moulding work to the US. Reshoring is a key trend in
the US moulding industry at the present time and one
that Araten has a unique perspective on as the parent
of construction toy rm KNex and technical moulding
specialist The Rodon Group, KNex Brands is both a
customer and a moulder. Araten is an active campaign-
er for improving levels of innovation and global
competiveness in US manufacturing.
Jeffrey Sternberg is global automotive technology
director at DuPont. He will be speaking about the
changing requirements of the automotive industry as it
works to develop more fuel efcient and lower emission
vehicles. Sternberg, who is a chemist with more than 25
years of R&D experience behind him, will discuss how
these new goals will impact on polymer materials
innovation.
Lightweight solutions
Trexel president and CEO Steve Braig will develop the
lightweighting theme with a presentation looking at the
latest developments of the Mucell microcellular foam
moulding process in terms of weight reduction and part
Main image:
In-mould
assembly will
be one of the
topics up for
discussion at
the rst
Injection World
Molding Forum
Exploring the future of
injection moulding
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Injection World Molding Forum | conference preview
quality improvement. Braig has more than 20 years
plastics industry experience and is a member of the US
Manufacturing Council and the Coalition for Automotive
Lightweighting.
Wittmann Battenfeld regional sales manager
Thomas Betts will also be speaking about moulding
solutions for lightweight parts. He will look at physical
gas foam moulding, focusing on a new development
between the machine maker and German processor
Schaumform that uses cyclical mould temperature
control and a modied injection-compression moulding
technique to achieve premium surfaces.
Raj Shah, regional sales manager for KraussMaffei
Corp, completes the lightweighting session with a
presentation looking at the latest developments in
injection moulding of thermoplastic composite compo-
nents. KraussMaffei has been one of the key machinery
partners in a number of European projects in this area
and has worked closely with leading tooling system
developers such as Switzerlands Georg Kaufmann.
Advanced manufacturing
Competing in todays marketplace means not only
making better parts; it also means making them faster.
Stratasys solution sales manager Nadav Sella will
present the latest developments in the use of 3D
printing for high speed production of mould cavities. A
number of leading moulding companies including
Nypro and Germanys Robert Seuffer - have already
successfully used the technology to produce short
leadtime injection mould components in production-
intent materials.
Mark Moss, executive vice president for market and
product strategy at hot runner maker Synventive, will
discuss the use of advanced valve gate control to
regulate ow of polymer in the mould. This active gate
technique can improve surface quality and overcome
mould processing issues.
Integrating part assembly into the mould will be the
theme of Hansjrg Keusgens presentation. Keusgen,
who is head of sales and marketing at German mould-
maker Advaltech Foboha, will explain some of the latest
mould solutions and detail the potential productivity
gains available.
Kevin OHara, automotive business manager at
Macdermid Autotype, will focus on in mould decoration.
His presentation will look at the current state of the art
in the use of lm insert in-mould decorating (IMD) with
a focus on options for creating decorative surfaces with
textured effects.
Material developments
The rst day of the conference will be wrapped up with
a session looking at new material innovations. Solvay
Engineering Plastics global market director James
Mitchell will discuss the latest developments in
polyamides for high temperature applications. The
presentation will cover heat stabilisation, ow modica-
tion and ame retardant solutions that eliminate tool
fouling and corrosion. It will also review future applica-
tion trends for performance PA materials.
PolyOne Specialty Engineered Materials global
technology director Patricia Hubbard will close the day
with an examination of how the metal replacement
potential of advanced plastics is being extended to
include previously unattainable attributes such as
thermal and electrical conductivity. The chemist and
polymer scientist will discuss the performance and
potential applications for these new materials in the
injection moulding sector.
More information
In addition to the high-level conference sessions, the
Injection World Molding Forum also includes an exhibition
area where delegates will be able to network during all
refreshment breaks and the evening cocktail reception.
You can view the complete conference programme, and
get details of the special $300 discount for April bookings,
at the conference website: http://bit.ly/IWMF2014.
Alternatively, contact conference organiser Christine
Stelluti : Email: cas@amiplastics-na.com; Tel: +1 610
478 0800.
Speakers include (from left, top): Andrew
Reynolds, AMI; Michael Araten, KNex
Brands; Jeffrey Sternberg, DuPont; Steve
Braig, Trexel; Thomas Betts, Wittmann
Battenfeld; Raj Shah, KraussMaffei. From
left, lower row: Nadav Sella, Stratasys;
Mark Moss, Synventive; Hansjrg
Keusgen, Advaltech Foboha; Kevin
OHara, Macdermid Autotype; James
Mitchell, Solvay Engineering Plastics
and Patricia Hubbard, PolyOne.
Organized by:
Applied Market
Information LLC
Sponsored by:
Media supporters:
T H I N WA L L
PACKAGING 2014
International conference on lightweight plastic tubs, trays, jars,
containers and cups for food packaging
HEADLINE SPONSOR
May 20-21, 2014
The Westin Chicago North Shore,
Chicago, Illinois, USA
Images courtesy of: Inland Label and
Verstraete In Mould Labels
Amanda Schaeffer Conference Coordinator as@amiplastics-na.com Ph: +1 610 478 0800 Fx: +1 610 478 0900
Moving moulds part 4 | moulding masterclass
Moulding expert John Goff rounds off his tips on moving moulds
between machines with an explanation of how to use manufacturers
specications to ensure precise process replication
Moving moulds between different machines is a task
every moulder needs to deal with. Over the previous three
instalments (Part 1, Part 2 and Part 3) we considered
some of the basic considerations, then looked in detail at
the example of a moulder with two four-cavity tools for
production of a PP box and lid. We previously considered
the transfer of the box tool between two machines (A and
B), which had the same clamp force and screw size but
different injection unit classications, and saw that the
processing parameters could not be replicated. In this
nal instalment we will look at the lid moulding.
The basic injection unit specications for machines A
and B are shown in Figure 1. When we consider the
manufacture of the lid component using Machine B, the
inherently shorter melt ow length to ll the component
results in an injection time of 0.36 seconds to corre-
spond with the injection pressure of 118 bar hydraulic.
Converting the 118 bar hydraulic pressure into the
corresponding specic pressure value gives 1,588 bar.
The maximum available specic injection pressure
for Machine A is 2025 bar, meaning that the actual
pressure needed to produce the lid component is well
within its capability. To achieve the required 1,588 bar
specic pressure on Machine A, a hydraulic value of 141
bar must be selected.
So we can see that both Machine A and B are capable
of achieving the same quality standards and output
requirements for the lid component, whereas we had
previously determined that the box component could
only be produced on Machine B if we wished to avoid
quality and productivity issues.
Naturally, the process parameters selected for
Machine A will need to be referenced to the 1.196 : 1
ratio for the other hydraulic pressure settings, as
demonstrated above for the injection pressures.
Furthermore, the injection speed settings for both
Machine A and Machine B will require adjustment in
accordance with their corresponding available injection
rate values to achieve an identical ll time of 0.36s. The
plasticising rate will also need adjustment, as the rate
for Machine A is 32 g/s in PS and the corresponding rate
for Machine B is 52 g/s. The PP material used for the lid
and box components has a lower melt density than PS,
therefore, the actual plasticising rate for each machine
is reduced by approximately 14%. This means Machine
A has a reduced plasticising rate of 27.43g/s.
Knowing that the total shot weight for the four lid
components is 36.32g, with the derived cooling time of
3.6s and the screw recovery time of 2.8s, an equivalent
plasticising rate value of 12.97g/s is needed. Reviewing
the data for Machines A and B shows both can achieve
the required rate, even though there is a large disparity
between machines.
Returning to the scenario of our processor, we can
see the company has a dilemma. It has acquired two
perfectly good 2,100kN moulding machines, but only
one of them has the specication exibility required to
produce both the lid and box components.
We will now consider the consequences when the
same two mould tools are to be used in a moulding
machine of a completely different make but with the
same screw diameter. Machine C is a 2,000kN clamping
force machine with a 40mm diameter screw and barrel
assembly (the specication is detailed in Figure 1). The
attributes of Machine C will allow both the lid and box
components to be readily moulded to the desired visual,
Above:
Manufacturers
plasticising
system data
can be used to
accurately
replicate
process
settings on a
different
machine
Make use of
specications
moulding masterclass | Moving moulds part 4
atness and dimensional requirements.
The differences between Machines A & B (2,100kN)
and C (2,000kN) are quite apparent from the specica-
tion data. It is, therefore, important for the process
setter to have a good knowledge and understanding of
each machines attributes by having at least a hard copy
of the specications for reference prior to attempting to
transpose process settings derived in Machines A & B,
or before optimising moulding parameters to replicate
performance from both box and lid mould tools.
Naturally, the processing conditions selected for
Machine C will be somewhat different to those em-
ployed for either the box or lid mould tools in Machines
A and B due to the differences in shot capacity, screw
stroke, injection rate, injection pressure availability, and
hydraulic pump pressure. Another notable difference is
the L:D ratio of the 40 mm screw for Machine C
compared to the value for both
Machines A & B. Such a differ-
ence will affect both the melt
homogeneity and resultant melt
temperature.
Another scenario, might be to
consider a fourth machine of
different make or type possessing
a dissimilar screw diameter.
Certain process parameters will
be transferrable from Machines A
and B for example injection time,
holding pressure, holding pressure
time, screw surface speed
Figure 1: Key specication data for three moulding
machines, A, B and C
Machine A Machine B Machine C
Clamp capacity kN 2,100 2,100 2,000
Injection unit classication 430 600 750
Screw diameter mm 40 40 40
Screw geometry Standard Standard -
L/D ratio 20 20 25.2
Specic injection pressure bar 2,025 2,423 2,500
Maximum cylinder head volume cm
3
231 231 251
Maximum shot weight (PS) g 210 210 228
Maximum injection rate cm
3
/s 224 187 153
Plasticising rate (PS) g/s 52 32 39.4
Maximum screw stroke mm 184 184 -
Nozzle sealing force kN 80 80 50
Number of heating zones 4 4 5
Screw cylinder heating capacity kW 11.1 11.1 15.54
Source: Data from Sumitomo SHI Demag (Machine A: Systec 210/580-430;
Machine B: Systec 210/580-600) and KraussMaffei (Machine C: KM CX200-750)
Figure 2: A
process setting
chart bringing
together key
specication
data for all
machines in the
plant will help
achieve smooth
mould transfers
whereas others will have to be determined to accommo-
date the attributes of the specic plasticising unit.
Put simply, replication of the original processing
conditions will not reproduce base and lid components
to the previous quality and output rates. In certain
circumstances, for example where the screw diameter
is larger than that in either Machine A or B but provides
a comparable injection pressure, then an increase in
output rates can sometimes be achieved. More often
than not, however, the melt homogeneity and mainte-
nance of a consistent shot volume is necessary together
with other process parameter changes to ensure
comparability of performance.
Previous articles in this series have stressed the
importance of fully scoping original conditions so that
replication of component quality and cycle time can be
achieved and, as demonstrated above, this is particularly
important where different moulding machines and screw
diameters are involved. In conclusion, when moving a
mould tool from one machine to another regardless of
the make and type it is extremely important that full
details of the process are taken from the original
machine for replication. Generally the process setter will
not have to hand the required specication so, to enable
greater vision, a comprehensive chart showing the
important attributes of all machines in the workshop is
often derived (an example is shown in Figure 2).
About the author:
Moulding Masterclass series author John Goff is a
chartered engineer (CEng), Fellow of the Institute of
Materials, Mining and Metallurgy (FIMMM), and CEO of
injection moulding process consultancy and G&A
Moulding Technology (www.gandamoulding.co.uk), which
provides consultancy services on all aspects of process
setting, optimisation and control, including hot runner
technology, and developed and markets its own Pro-Op
process optimisation software tool. You can read the most
recent instalments in this series here, here and here.
ELASTO UK
t +44 161 244 9628
dex@elasto.co.uk www.hexpolTPE.com
AMI's Directory of Injection Moulders in the United Kingdom
48
CAHILL PLASTICSLtd.
Unit1,NorthMillsIndustrial Estate
FrogIsland
Leicester
LE35DH
Tel:01162628242
Email: sales@cahillplastics.co.uk
Website: www.cahillplastics.co.uk
ISO Registration: ISO 9001:2008
Contact: Mr. M. Cahill,Director
Moulder type: Custom, InHouse
Polymersprocessed: PS,SAN,ABS, LDPE,
HDPE,PP,PVC, POM,PA,PMMA, PC, PEEK,
PET,PBT,TPES
Marketsserved:Automotive, Telectron,
Leisure/Sport,Medical/Pharmaceutical,POS;
Engineering; Aerospace.
Servicesoffered: Tool Design, Tool
Manufacture, U/SWelding,High Frequency.,
PadPrinting,SilkScreenPrinting, Hot Foil
Stamping, Assembly,Insert Moulding,
Twin/Multi ShotMoulding
Number ofmachines: 11
Minimumlock: 25
Maximumlock: 400
CALEDONIAN PLASTICSLtd.
HolbrookRise
HolbrookIndustrial Estate
Sheffield
S20 3FG
Tel:01142478248 Fax: 01142510147
Email: jll@caledonianplastics.co.uk
Website: www.caledonianplastics.co.uk
Contact: Mr. J.J. Laing, Chairman
Moulder type: Custom, Proprietary Products
HDPE,PP,POM,PA,PC
Marketsserved:Automotive, Domestic
Appliances,Electrical,
Medical/Pharmaceutical,Household, Scalpel
Handles.
Servicesoffered: Clean Room,Assembly,
InsertMoulding
Number ofmachines:13
Minimumlock: 60
Maximumlock: 250
Minimumshot: 10
Maximumshot: 400
CALSONIC KANSEILLANELLI(CKLL)
Llethri Road
Llanelli
SA148HU
Tel:01554747000 Fax: 01554747135
Website: www.ckeurope.com
ISO Registration: TS16949
Contact: Mr. R. Williams,General Manager
Moulder type: InHouse
Polymersprocessed: PP, PA
Marketsserved:Automotive
Servicesoffered: Insert Moulding
Minimumlock: 110
Maximumlock: 1000
Minimumshot: 0
Maximumshot: 0
CALSONIC KANSEISUNDERLAND Ltd.
Pennywell Industrial Estate
Sunderland
SR4 9EW
Tel:01915644000 Fax: 01915644001
Website: www.ckeurope.com
ISO Registration: ISO 9002
Contact: Mr. J. Barnett,Operations Manager
Moulder type: Custom
Polymersprocessed: ABS,PP,PC, TPES,
PC/ABS; SMA.
Marketsserved:Automotive, Instrument
Panels;Interior Panels.
Servicesoffered: Hot Plate Welding, U/S
Welding,FrictionWelding,High Frequency;
Vibration.,Pad Printing,Painting,HotFoil
Stamping, Assembly
Minimumlock: 220
Maximumlock: 2300
Minimumshot: 0.100
Maximumshot: 5500
CAMERONPRICE Ltd.
Charlotte Road
Stirchley
Birmingham
B30 2BT
Tel:01214592121 Fax: 01214512303
Email: info@cameronprice.co.uk
Website: www.cameronprice.co.uk
ISO Registration: ISO 9002; 14001
Contact: Mr. A.J. Banks, Chairman
Moulder type: Custom, Proprietary Products,
InHouse
Polymersprocessed: PS,ABS, LDPE,LLDPE,
HDPE,PP,POM,PA,TPES,PU.
AMI's Directory of Injection Moulders in the United Kingdom
238
TYNE VALLEYPLASTICSLtd.
9EMarquis Court
Low Prudhoe Industrial Estate
Northumberland
NE426PJ
Tel:01661836938 Fax: 01661836939
Email: sales@tynevalleyplastics.co.uk
Website: www.tynevalleyplastics.co.uk
Contact: Mrs. G. Rice, ManagingDirector
Moulder type: Custom, Proprietary Products
LLDPE, HDPE,PP,PVC, POM, PA,PMMA,PC,
PPO,PET,PBT, PSU,TPES,EVA.
Marketsserved:Building,Domestic
Appliances,Electrical, Leisure/Sport,
Medical/Pharmaceutical,FlooringProducts;
Oil Industry.
Servicesoffered: Tool Design, HotFoil
Stamping, Assembly,Insert Moulding, CAD
PartDesign.
Minimumlock: 40
Maximumlock: 200
Minimumshot: 1
Maximumshot: 450
TYPERITE Ltd.
UpperDromore Road
Warrenpoint
Co. Down
BT34 3PN
Tel:02841772111 Fax: 02841752022
Email: info@typerite.com
Website: www.typerite.com
ISO Registration: ISO 9001:2008
Contact: Mr. G. Barlow,Managing Director
Moulder type: Custom, InHouse
Polymersprocessed: ABS,PP,POM, PA
Marketsserved:Business Machines, Printing
Consumables;TextileEquipment;Typewrite
Ribbons;Adapters.
Servicesoffered: U/SWelding,Assembly,
Machining
Minimumlock: 25
Maximumlock: 85
Minimumshot: 20
Maximumshot: 40
U.B.PLASTICS Ltd.
LittleBurtonWest
BurtononTrent
Staffordshire
DE141PP
Tel:01283565912 Fax: 01283541697
Email: sales@ubplastics.co.uk
Website: www.ubplastics.co.uk
ISO Registration: ISO9001:2000
Contact: Mr. R. Caswell,Managing Director
InHouse
Polymersprocessed: PS,LDPE,LLDPE,HDPE,
PP,PA
Marketsserved:DomesticAppliances,
Electrical,Horticultural/Agricultural,
Leisure/Sport,Caps andClosures,Thinwall
Containers for DairyPackaging,Brewery; Caps
for Beer kegs; Textiles; SecuritySeals;Filters;
SealingBungs.
Servicesoffered: Tool Design, PadPrinting,
InMouldLabelling/Decorating,HotFoil
Stamping, Assembly
Minimumlock: 35
Maximumlock: 300
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Maximumshot: 1250
UCPZELLER PLASTIK UK.
Salhouse Road
Sprowston
Norwich, Norfolk
NR7 9AL
Tel:01603894800 Fax: 01603407942
Website: www.gcs.com
ISO Registration: ISO 9002
Contact: Mr. D. Munro,Operations Director
InHouse
Polymersprocessed: PS,LDPE,LLDPE,HDPE,
PP
Marketsserved:Caps andClosures,CRC;
TamperEvidentClosures;Dispensing
Closures;Closures for
Medical/Pharmaceutical;Housewares&
Cosmetics/Toiletries Markets.
Servicesoffered: Tool Design, U/S Welding,
TopCoating.,Assembly, Wadding;Glueing.
Minimumlock: 80
Maximumlock: 400
Minimumshot: 5
Maximumshot: 50
www.ami-publishing.com
AMIs Directory
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IN THE UNITED KINGDOM
LOCATION AND PRODUCTION DETAILS OF 980 INJECTION MOULDING SITES
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Understanding colour | colour & masterbatch
Ron Beck, R&D
manager at
Americhem, looks at
how colour works,
how it is perceived,
and the implications
for specifying,
controlling and
measuring colour in
plastics
L
Beauty is in the eye of the beholder. And so is the
perception of colour.
By denition colour is what we see the physical
modication of light by an object as observed by the
human eye and interpreted by the brain. With all of
these variables at play, one thing is clear. Not all people
see, or feel, colour the same.
Polymer engineers have a unique challenge when
picking just the right colour that will broadly appeal to
their end users. Colour is a powerful tool that is proven
to affect mood, initiate action or even cause physiologi-
cal reactions. Through our eyes, our brains take in
information about colour and integrate it into a concept
or feeling. In fact, colour can be mood altering and has
been used as a therapeutic tool as far back as ancient
civilizations in Egypt, China and Greece.
Much goes into choosing just the right colour to
convey a message or feeling about a plastic product.
However, much more goes into how to actually achieve
that colour.
In this article, we will examine the physics of colour,
discuss the factors that dene appearance and take a
closer look at best practices in colour measurement
and polymer design.
Appearance is everything:
controlling colour in plastics
Figure 1: Three examples of light energy with their spectral power distribution: Illuminant A (Incandescent) has a colour temperature at
2,856 K; Illuminant D65 (Daylight) has a colour temperature at 6,500 K; and Illuminant F2 (Fluorescent) has a colour temperature at 4,200 K
colour & masterbatch | Understanding colour
Well begin by looking at the four elements of colour:
light, object, human eye (observer), and human brain.
Light: Light is a continuum of electromagnetic
energy and can be broken into two categories. The rst
is source, a device serving to illuminate, while the
second is illuminant, a theoretical source of visible
light with documented attributes that are used as a
basis for comparing colours. Illuminants can represent
average incandescent light, direct sunlight, daylight,
and more.
For example, Illuminant D65 is the standard daylight
illuminant that represents average illumination
conditions throughout the world. The D stands for
daylight and 65 is the temperature, which happens to be
6,500 degrees Kelvin. Illuminant D65, and its counter-
parts, are represented by a set of tables that can be
used to simulate conditions and to view objects, and
colour, in controlled lighting. Further, Illuminant F2
represents average illumination conditions for cool
white uorescent light (See Figure 1).
Object: Now, well move on to what objects do to
light. For starters, all objects interact with light in the
same ways:
G Specular reection refractive index, which is
responsible for gloss;
G Diffuse reection scattering of light, which is
responsible for opacity and hiding;
G Absorption of light mainly responsible for colour;
G Transmission how light passes through the object.
Every material reacts with light in these ways. But
its to what extent light reects, diffuses, absorbs and
transmits with the object that gives it its appearance.
Light absorption has a great impact on the colour of a
plastic object. For example, when a green pigment is
added to an object it will only reect the green colour and
all other colours are absorbed by the object (Figure 2).
Specular reection is to what extent the light
scatters. Imagine you have an object made of polypro-
pylene and an object made of polyester and you use the
exact same pigment in both. You will likely nd that the
two objects are completely different colours, despite
using the same pigment. This is because the two
materials have completely different refractive indexes.
Diffuse reection, on the other hand, dictates how an
object selectively absorbs (or hides) some colour. Start
with a white pigmented lm and gradually add colour.
For a while the lm will not change in appearance,
effectively absorbing the colour. The moment in which
the colour begins to be visible is known as the percola-
tion point.
For polymer engineers, this is an important moment.
Slight changes in the objects make-up or the pigment
can change the percolation point, creating a teeter-
totter effect when a product is produced. One time the
colour is there, the next time it isnt. This is caused by
the scattering of light.
Light absorption is what truly provides visible colour,
which is what is reected back from an object when it is
exposed to a light source therefore, the type of light
source directly impacts the appearance of the object.
Human Eye: Perception of colour is the result of an
extremely complex process. While we still do not fully
understand how it works, we do know that it involves
the interaction of three separate areas: the eye, the
optic nerves and the brain.
There are two kinds of light-sensitive cells in the eye
rods and cones. Rods control sensitivity to light and
are responsible for night vision. They are so sensitive
that during daylight they turn off. This is why you might
feel blind when you enter a movie theatre from a
brightly lit street. When the light level falls below their
overload threshold, they slowly regain their sensitivity, a
process that takes about 30 minutes to complete.
Where rods are colour blind, cones step in and are
responsible for distinguishing colour. Approximately 7
million cones are packed into the area of the retina
called the fovea. They are not nearly as sensitive to light
as rods, but are able to distinguish between colour
wavelengths.
Figure 2: When a green pigment is added to an object it will only reect the
green colour, while other colours are absorbed
Figure 3:
Colour
perception is
an extremely
complex
process
involving the
interaction of
the eye, optic
nerves and
brain
L
Understanding colour | colour & masterbatch
It is generally accepted that there are three types of
cone receptors with each responding to a different
range of wavelengths: one is sensitive to the blue region
of the visible spectrum, another is sensitive to wave-
lengths in the green region and the third responds to
wavelengths in the red region. Designers are familiar
with these colour spectrums as the RGB colour model,
which can be used to create an array of other colours.
Between the light sensing abilities of rods and the
colour distinguishing abilities of cones, the perception
of colour begins.
Human Brain: All visual data processing is done in
an area of the brain known as the visual cortex located
at the rear of the skull. Here, all of the signals coming
through the optic nerve bundle are sorted and organ-
ized. The rst thing it looks for are edges, or discernible
differences in colour or brightness. Once it has detected
edges, it organizes the edges into patterns. Then, it
searches its memory banks to see if any of these
patterns are identiable. This is how you can determine
if you are looking at a red apple or your Aunt Helen who
you havent seen in 15 years.
Unlike a shape, a colour cannot be dened. It has no
pattern with edges that can be catalogued and later rec-
ognized. While the brain has difculty remembering
precise colours, it is excellent at comparing colours. If
you examine two colours side-by-side, the brain can
easily tell whether they are identical. If they are not
identical, the brain again has a problem with accurately
quantifying the degree of the difference.
The brain analyses the signals it receives from the
eye, searches for edges, and then considers each
Figure 4: How
Many Colours Do
You See? Answer:
There are only
three colours
white, green and
pink. There seem
to be two different
shades of pink, but
they are really the
same. This shows
how surroundings
can greatly impact
appearance
colour & masterbatch | Understanding colour
individually. It is the brains ability to detect edges that
makes visual examinations of product designs so
valuable. Our optical system can discern specs, streaks
and blotches that no spectrophotometer could ever
detect. The spectrophotometer would simply average
the specs into the overall colour. It also allows us to
evaluate surface textures and recognizes specular
reections.
With all of these factors considered light, object,
the human eye and the human brain do all people see
colour the same? We most denitely do not. We all have
different spectral response curves even with normal
colour vision. Then there are also other factors, such as
individual colour deciencies and colour blindness that
make our perceptions of colour vast and unique
person-to-person.
What we see is not all about colour. Its all about
appearance. Colour, gloss, scattering, light sources,
surroundings and temperature all impact appearance.
For example, Figure 4 shows the impact of surrounding
colours.
For one to understand how the human observer sees
and evaluates colour, one must have a clear under-
standing of the light source, how the object modies
light, and how the human observer responds to light
and metamerism. The latter is a phenomenon in which
two objects have a given relationship under one set of
viewing conditions and a different relationship under
another. This happens because the two objects are
spectrally different. Preventing metamerism is
dependent on making sure the two examples have the
same spectral curve. Figures 5 and 6 illustrate and
explain metamerism.
Measuring colour
There are two ways to measure colour. One is by a visual
examination, relying on the human eye. The other is via
instruments and equipment.
Samples must be pre-qualied to: represent the
batch; be free from contamination; be in the same form
as the target; and be reproducible within acceptable
limits of repeatability. Then, a single sample is chosen
as the standard by which all others will be judged.
Visual examination: Because visual colour measure-
ment depends on consistent judgment, the observer
would need to provide repeatable judgments.
Examination by instrument: First and foremost, you
must understand the instrument, how it works and its
specications. Choose an instrument that gives you the
best mix of functions to meet your design needs:
G Spectral data, including absolute coordinates and
metamerism;
G Geometry;
G Precision and accuracy;
G Software, including the ability to complete the
necessary calculations, as well as the user interface;
It is also important to remember that no instrument
can replace the importance of the human eye. An
instrument may indicate a fractional difference in colour
that may not be discernible to the observer, so allow for
some margin of difference to avoid unnecessarily
scrapping an entire lot for a difference no one would
ever notice.
Possibilities are limitless
The colour match is only one component of product
design. The nal products end use creates a list of
attributes that must also be met to have a successful
product design. Depending on where the product will be
stored, factors that might need to be considered
include: bleach resistance, light stability, weathering
and chemical resistance, among others.
After all, what good is the right colour that provides
just the right feeling if the product itself fails to stand
up to its environment? With assistance from experts in
colour and product design, theres virtually no limit to
what designers can accomplish.
S www.americhem.com
Figure 6: Why metamerism happens
Figure 5: An example of metamerism
colour & masterbatch | Forecasting
Colour plays a key part in the
success of consumer products.
Leading colour suppliers aim
to predict the colours that will
excite consumers in their
annual forecasts. We take a
closer look
Colour is, at least in part, a
fashion business. Predicting
the colour palettes that will be
in vogue months ahead is
important for those developing
consumer-facing products.
Making those forecasts is a
task that typically falls to
colour suppliers, whose
specialist development teams
pull together information and
insight from across the creative
industries to put together their
ideas for the year ahead.
Colour has the power to
transcend and translate
cultural, political, religious and
social inuences. As a tool, it
has the power to communicate
emotions and stories as
succinctly as possible. And in
the world of plastics, colour acts
as the ideal marketing driver to
steer consumers purchasing
choices, says Judith van Vliet,
designer at Clariants Color-
Works Europe/IMEA.
The company released its
ninth annual ColorForward
analysis at the beginning of the
year, which aims to predict the
key trends for 2015 and to give
designers and manufacturers
a headstart in the colour
selection process.
The company says its
colour predictions are based
on researching societal trends
around the world. Experts
from major trend-watching
organisations and diverse
creative industries contribute
to the process, along with
Clariants own global network
of ColorWorks centres. The
colour palettes selected for
2015 are titled: Tune in Space
out; Live2Live; Redening
Eden; and Raw.
For more information visit:
http://bit.ly/CCF2015.
Polymer compounder
PolyOne also aims to provide
customers with insight into
future colour preferences with
its InVisiO Color Inspiration
2015 collection, which also
includes textural evaluation.
Color Inspiration 2015
provides an additional
dimension that helps facilitate
the creative process, says
Fernando Sanchez, director of
global marketing at PolyOne
Global Color and Additives. By
considering colour, effects and
material ideas early on,
designers can push past
boundaries toward a more
novel use of colour.
Each of the six InVisiO
colour palettes highlights an
inuential emerging trend, the
company says. It has labelled
its collection: Follow your Bliss;
Beyond Land and Sea; Luxury
Paradox; Future Antique;
Building Blocks; and New
Frontier. For more information
visit: http://bit.ly/1efBJuO.
Colour standards specialist
Pantone presents its latest
colour forecasts in its Pantone
View Home and Interiors 2015,
which it says will help
designers validate pre-con-
ceived colour choices as well
as providing new inspiration
and direction.
Consumer preferences,
behaviours and lifestyles are
constantly evolving, spawning
a desire for fresh colour
palettes in both home and
interior design, says Leatrice
Eiseman, executive director of
the companys Pantone Color
Institute.
The nine palettes Pantone
has assembled for 2015 are
named: Style-Setting;
Abstractions; Botanicum;
Zensations; Urban Jungle;
Tinted Medley; Past Traces;
Serendipity; and Spontaneity.
They are available as a plastic
standards set, which includes
a plastic chip cross-reference
for each of the 72 forecasted
colours in the collection. More
information is available here:
http://bit.ly/1dUe60k.
US-based masterbatch
supplier Plastics Color
Corporation published its rst
Color Report this year. It
identies two key colours for
2014 indigo-like Oceanana
and copper-like Copperico.
Our goal with the Color
Report is to help designers in
the initial concept stage so
they can develop the right
product in the right colour and
get it to the shelf faster, says
Tim Workman, PCC vice
president of business develop-
ment. We have extensive
information that can aid our
customers in getting the right
colours into their unique
market space quickly.
S www.clariant.com/colorworks
S www.invisiocolor.com
S www.pantone.com
S www.plasticscolor.com
Polyone InVisios 2015 Color Inspiration collection identies six
key colour palettes. These examples are from the Building
Blocks palette
Predicting a colourful future
US masterbatch producer PCCs rst colour forecast identies
two key colours for 2014
Visit our Team
at IMCD Plastics booth N1T65
Choose PRE-ELEC
carbon black concentrates for the most cost-effective product constructions.

PA6, PE-HD, PP, PS based concentrates can be diluted even up to 60% and still obtain surface
resistance values less than 10E7 Ohm.
Please contact Premix sales team for specic product information.
colour & masterbatch | Update
Datacolor raises the limit
In latest handheld range
Clariant adopts project route
Colour management systems
specialist Datacolor has
introduced the Datacolor 45
family of high performance
hand-held spectrophotom-
eters for QA and colour
communication applications.
The Datacolor 45 instru-
ments provide uniform
circumferential illumination
that is claimed to ensure high
levels of repeatability, even
when used on textured
surfaces. Key features
include a low-prole
measuring head and
live-navigation based
colour user interface, while
all versions in the range are
offered with the companys
Datacolor Tools colour QC
software. Other features
include a Bluetooth interface
for software communication
and USB support for peripher-
als such as keyboards and
barcode scanners.
The new range includes
three models. The Datacolor
45G version provides simulta-
neous control of colour
appearance and gloss, even on
textured surfaces. It offers a
built-in 60 gloss meter and is
intended for colour measure-
ment of hard items such as
plastics and painted items for
consumer electronic or large
appliances.
The 45G CT version is
claimed to be the rst portable
45/0 spectrophotometer to
offer close tolerance control of
both colour and gloss, making
it possible to achieve consist-
ent digital communication of
standards. It is said to be ideal
for measurement of hard
surface automotive interior
parts or for use as a reference
instrument in the laboratory.
The 45S model is intended
for plastics applications where
colour appearance needs to be
controlled but the workow
requires other than 60
o
gloss.
It does not include a
glossmeter.
S http://www.datacolor.com/45
S Eckarts latest line of
special effect pigments
includes the Energysafe
products for production of
solar reective plastics.
Energysafe grades are
designed to reduce heat
build-up in plastics products
exposed to the sun and can
be used in polyolens, PVC,
styrenics and a range of
engineering plastics.
www.eckart.net
S Merck has extended its
range of special effect
pigments for plastics used in
outdoor applications. Its
silver-white pigment Iriodin
119 WAT product, for
example, is thermally stable
up to 800C and offers
extreme resistance to
yellowing. Target applications
include outdoor furniture and
automotive interiors.
www.merck-pm.com
in brief
Clariant Masterbatches
recently opened its rst project
house a 2m facility located
at Pogliano in Italy intended to
develop innovative master-
batch products and solutions
primarily for the functional
packaging sector.
The 400m
2
facility is
intended to bring together
specic sector expertise to
identify and focus on emerging
technologies and advanced
concepts that can be applied in
areas such as food and
beverage, personal care and
household goods. It will be
fully integrated into Clariant
Masterbatches recently
opened Innovation Centre at
Frankfurt in Germany.
The Project House is our
Masterbatches divisions
brand-new approach to
innovation, says Hans
Bohnen, Head of Clariants
Business Unit Masterbatches.
We recognise that Clariant
needs to reach beyond its
current portfolio in order to
create maximum value and
address the signicant unmet
customer and market needs
that exist.
Clariant offers a broad
range of colouring solutions
for the packaging sector.
Among its most recent
introductions for this market is
the HiFormer range of
integrated liquid colour and
additive masterbatches, which
are claimed to offer a number
of advantages to packaging
and consumer goods produc-
ers. These include highly
reproducible and vibrant
colour in both translucent and
transparent products and fast
colour change.
The company says it is
currently planning the
establishment of a second
Project House. Located outside
of Europe, it will focus on
non-packaging applications.
S www.clariant.com
Lehmann&Voss is to
distribute the EverGlide MB,
EverGlide SG and DynaSil FR
range of additive master-
batches from US-based
Polymer Dynamics within
the EU and Switzerland.
EverGlide MB acts as an
internal and external
lubricant. EverGlide SG acts
as a processing aid for
more demanding poplymers
such as PPS or PEEK.
DynaSil FR acts as a re
retardant synergist in
polymers such as PE, PP,
PA, PBT and PVC.
S www.lehvoss.com
L&V extends
portfolio
Update | colour & masterbatch
BMS and Gerhardi focus
on visual effects in PC
S PolyOne subsidiary Colorant
Chromatics has introduced a
range of colour masterbatch-
es for high-performance
applications in polysulfone
(PSU), polyethersulfone (PES)
and polyphenylsulfone
(PPSU). The range includes
10 standard colours and is
targeted at demanding
applications in markets
including aerospace,
automotive, telecommunica-
tions and healthcare. The
masterbatches are heavy
metal-free and use state-of-
the-art pigment dispersion
techniques to promote
consistent colouring and
improve homogenisation.
www.colorant-chromatics.com
in brief
Bayer MaterialScience worked
together with German
processor Gerhardi Kunst-
offtechnik to develop a
decorative mould concept that
allows designers to evaluate
special textural and visual
effects available from its
Makrolon and Bayblend
PC-based polymers.
This near-series mould
can be used to replicate the
most common surface design
techniques and thus produce a
wide array of variants without
further processing steps, says
Dirk Kieslich, head of process
development at Gerhardi.
These include matt and
high-gloss structures,
attractive shades with deep
lustre and also coated,
lm-decorated and metallized
surfaces.
S www.materialscience.bayer.com
More than 45 years
experience of customer adapted
thermoplastic compounds

Ola Hugoson, CEO
Polykemi AB | Box 14, SE- 271 21 Ystad, SWEDEN | Phone: +46(0)411-170 30
Telefax: +46(0)411-167 30 | E-mail: polykemi@polykemi.se | www.polykemi.com
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RECOMMENDED READING
43
Applications | electrical & electronic
The market for LED luminaires is expected to climb to
reach a value of $25bn by 2023, according to US
consultancy Lux Research, around 10 times its 2013
size. And thats good news for plastics and plastic
processors, which are likely to play a key role in
meeting the cost reduction requirements of the
industry.
In its latest LED state-of-the-market report, the
consultancy predicted the secondary optics market
alone (secondary optics are used external to the LED
package to improve directional management of the
light) is likely to amount to a value of $6.9bn by 2023.
Tertiary optics, xtures and enclosures will provide
further plastics opportunities.
LED technology is the growth driver of the entire
lighting market, says Wolfgang Dehen, CEO of Osram
Licht, one of the worlds leading lighting companies.
The companys opto semiconductors division (which
produces LED components for applications including
lighting) posted sales of more than 1bn last year, up by
more than 10% on its 2012 performance.
Osrams latest LED development is the Superstar
Classic A lamp, which is designed as a drop-in energy-
saving replacement for traditional incandescent bulbs.
It is claimed to be the rst of its type to be manufac-
tured in Germany the company says production in
local markets is a key part of its strategy for LED
lighting for the future.
The new lamp uses Sabics Lexan LUX-G polycarbon-
ate. According to the resin maker, the LUX-G grades
have been developed to meet the extended heat ageing
requirements of the LED sector, which with typical
lifetimes of up to 50,000 hours last up to 50 times
longer than todays incandescent designs. The resins,
which were launched by Sabic last year, are said to
offer much improved colour stability and transparency
over standard PC grades.
In the lighting industry, our customers are looking
for solutions that address heat management, so that
LED bulbs can last longer. Equally important is the
transmission of light and the use of materials that are
compliant with the latest regulations for toxicity and
ame retardancy, says Venugopal Koka, director,
electrical industrial and lighting marketing for SABICs
Innovative Plastics business.
LUX resins are also being used by US-based Switch
Lighting to produce the globe for its Inna LED
incandescent lamp replacement. The company is
using an optimised injection-blow moulding
technique to produce the part to avoid the
production of a dark hot spot on the top of the lamp.
Russian company AtomSvet is using Makrolon
PC from Bayer MaterialScience to produce the
housings and lenses for a range of LED luminaires for
use in industrial and commercial environments, which
are exposed to dusty and damp environments where
temperatures can uctuate widely.
The company is using Makrolon LED2245 PC for the
Main image:
LED technology
is driving the
lighting
market,
according
to Osram
Bright future for LEDs
The fast-growing market
for energy-efcient LED
lighting presents real
opportunities for
polymer producers and
injection moulders.
Chris Smith reviews
the latest applications
www.injectionworld.com April 2014 | INJECTION WORLD
Below:
BMS helped
US-based
Kenall develop
the optics for
its TopDek
parking lot
lights
electrical & electronic | Applications
protective covers and integrated lenses,
which it selected for its high transpar-
ency and low light loss. Dimen-
sional accuracy is also a key
requirement, as the lens has to
align precisely with the
LEDs on the circuit
board module for
optimum illumination
efciency. This is especially
important in applications such
as greenhouse lighting, where the
LED package must be protected from
moisture penetration.
Bayer Material Science says the high impact
resistance of the Makrolon resin is also a benet in
industrial applications in Russia, where industrial lights
used in external applications must be able to withstand
events such as vandalism at low ambient temperatures.
US lighting company Kenall opted for Makrolon for
production of secondary and tertiary optical components
in its latest range of LED luminaires developed for use in
parking garages and high bay storage and warehousing
applications. The company also provided mould lling
analysis and technical support in developing a solution
that optimised light output and transmission.
Bayers materials, in combination with intelligent
design, efcient power electronics and state-of-the art
LED sources, allow us to boast product efcacies that are
among the highest in the market, says Nathan Heiking,
advanced lighting product manager at Kenall Lighting.
The company is using the Bayer MaterialScience
resins in its TekDek TD17 surface-mounted design,
which features sealed optics and a textured anti-glare
lens, and its pole-mounted TopDek designs.
Makrolon PC is also being used by US-based
TerraLux in its Line-voltage Linear LED Engine, an
integrated assembly of one or more LED modules, an
LED driver and heat sink, designed for application in a
range of LED lighting xtures. The company currently
produces the modules in three sizes - all share the
same 42mm by 28mm cross section but lengths range
from 100mm to 200mm.
TerraLux is using a medium viscosity grade of
Makrolon FR7087 formulated for easy release from
the mould. The grade is also ame retardant (rated
UL94 5VA at 3.0mm) and UV stabilised. Using Bayers
plastic gave us the design freedom necessary to create
one of the rst truly integrated LED linear light engines
that offers an IP-65 rating, is UL-listed for retrot
solutions and offers in-eld durability all while
maintaining maximum light output and efciency, says
TerraLux senior mechanical engineer Brett Pardikes.
DSM Engineering Plastics has developed a special
grade of its Stanyl ForTii high performance polyamide
4T for LED applications. The material is being used by
an undisclosed manufacturer of interconnects to
produce an integrated LED array holder, which is
designed to simplify the LED installation process by
using compression contacts in place of soldering.
Requirements for the array holder components
include the ability to withstand reow soldering
temperatures of up to 305C under load, resistance to
cracking during assembly, and high whiteness as the
reectivity of the array holder contributes to the overall
light output of the system. According to DSM, the Stanyl
ForTii grade outperforms the LCP resin originally
considered for the components. Benets include
reduced cracking during assembly and the ability to
process on a mould originally designed for LCP.
DSM offers a portfolio of polymer for LED applica-
tions. Its most recent introduction is Stanyl For Tii LED
LX, a mineral lled and halogen-free ame retarded
grade offering high reectivity and the ability to process
in high cavitation mould tools. The company also
markets thermally conductive Stanyl TC grades, which
can be used in place of cast aluminium to achieve
claimed system cost savings of up to 40%.
Click on the links for more information:
www.luxresearchinc.com
www.sabic.com
www.materialscience.bayer.com
www.dsmep.com
l Lux Research energy electronics analyst Pallavi
Madakasira will be speaking about the future outlook
for LED lighting and discussing material, cost and
supply chain issues at the Injection World Molding
Forum, which takes place in Philadelphia, PA, USA, on
17-18 June 2014. Find out more about the event here
http://bit.ly/IWMF2014
Above: Russias
AtomSvet is
using Makrolon
PC from BMS in
its latest
industrial light-
ing products
Right: DSMs
Stanyl ForTii is
being used in
LED array
holders in
place of LCP
* + 19% German VAT
16-18 June 2014
Hotel Nikko
Dsseldorf, Germany
International conference on markets and technology options for the end of life plastics
Sponsored by: Media supporter: Organised by:
Applied Market
Information Ltd.
SPECIAL OFFER: Save 100* if you register before 9th May 2014
END OF LI FE
PL A STI CS 2014
Images courtesy of: EXPRA
Rocio Martinez Conference Organiser rmm@amiplastics.com Ph: +44 117 924 9442 Fax: +44(0)117 311 1534
electrical & electronic | Update
US-based Miniature Precision Compo-
nents (MPC) is using a glass and mineral
reinforced grade of Akulon Ultraow PA6
from DSM Engineering Plastics to mould
covers used on hybrid electric car
engines.
Akulon Ultraow is claimed to provide
up to 80% improvement in ow com-
pared to standard PA6 grades used for
engine covers. Shorter injection and
holding times and faster crystallisation
performance can enable cycle time
reductions of up to 40%, according to
DSM, while the improved ow allows
wall thickness reductions of up to 20%.
MPC is using Akulon Ultraow
K-FHGM24 for its covers, a grade with
10% glass bre reinforcement and 20%
mineral ller. Mould lling simulations
showed the polymer would produce
parts with low warpage
www.dsmep.com
Barkley develops IMIW
Nano-diamond handles the heat
UK-based Barkley
Plastics has developed an
in-mould injection
welding (IMIW) technol-
ogy for production of a
range of fully-encapsu-
lated electronic devices
such as RFIDs.
Developed with the
assistance of UK-based
Warwick Manufacturing
Group (WMG) and
Austrian machinery
maker Wittmann Battenfeld,
the single-step production
system involves the moulding
of two shell components which
can then be assembled around
an electronic chip or insert
prior to overmoulding to create
a permanent hermetic seal.
Barkley Plastics developed
its own sliding core tooling for
the IMIW process. Wittmann
Battenfeld helped with design
of the production cell automa-
tion, including insertion of the
electronics and demoulding of
nished parts, as well as
special injection machine
programming. WMG
provided support for
determining weld
integrity, which can be
determined in the mould
using a pressure
transducer system.
Barkley Plastics has
trialled the technology
with a number or
polymers, including PC,
PC/ABS, PA, PPSU and in
unlled and glass-reinforced
grades and all have passed
required tests with ying
colours according to the
companys technical director
Maurice Cassidy.
www.barkley.co.uk
www.wittmann-group.com
MPC covers up with Akulon
Finnish company Carbodeon
claims to be able to increase
the conductivity of thermally-
conductive polymers by a
further 25% without negatively
affecting electrical properties
using an additive based on
nano-scale diamond.
The improvement is said to
achieved through incorporation
of a thermal ller system
based on boron nitride and the
companys proprietary
uDiamond additive. It claims
that replacing 45 wt% of boron
nitride thermal ller in a PA66
reference material with 44.9
wt% of boron nitride and just
0.1 wt% of its uDiamond
additive resulted in a 25%
thermal conductivity gain.
The performance improve-
ments achieved by this ller
are derived from the extremely
high thermal conductivity of
diamond, at around 2000 W/
mK, says Carbodeon chief
technology ofcer Vesa
Myllymki.
www.carbodeon.com
US-based Advanced Sensor
Technologies has switched
from polyetherimide (PEI)
to Radel polyphenylsulfone
(PPSU) resin from Solvay
Specialty Polymers for
production of its high-per-
formance industrial sensor
housings.
According to the
company, PPSU provides
improved chemical
resistance, mechanical
strength and thermal
performance for the
housings, which are used in
harsh operating conditions
such as chemical manufac-
turing and food and dairy
production.
Radel PPSU offers a
higher heat deection
temperature than PEI,
allowing the company to
offer a service temperature
of 135C. It performs better
in high-pressure environ-
ments and provides better
resistance to acids, alkali
and organic chemicals, the
company says.
www.solvay.com
PEI used
in sensor
housings
24-26 June 2014
Andels Hotel,
Berlin, Germany
M
M A S T E R B A T C H
2 0 1 4
Connecting with downstream customers
Media supporter: Organised by:
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30
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3D-PLASTIC HANS KINTRA GmbH
Einruhrstr. 92
41199 Mnchengladbach l l l l l
Contact: Herr H. Kintra, Geschftsfhrer
A & T KUNSTSTOFF GmbH
Wittenburger Str. 1
19209 Renzow l l l l l l l l l l l l l l l l l l l
Contact: Herr G. Augustin, Kaufm. Geschftsfhrer
A-FORM AG
Gewerbegebiet Nord 7
09456 Mildenau l l l l l l l l l l l l l l l l l
Contact: Herr P. Parczyk, Vorstand
A-Z AUSRSTUNG UND ZUBEHR GmbH & Co. KG
Ruhrall 1/3
45525 Hattingen l l l l l l l l
Contact: Herr O. Venschott, Geschftsfhrer
A. FOLLMANN GmbH
Lindenstr. 14
54518 Niersbach-Greverath l l l
Contact: Herr A. Follmann, Geschftsfhrer
A. KAYSER AUTOMOTIVE SYSTEMS GmbH
Hullerser Landstr. 43
37574 Einbeck l l l l l l l l l l
Contact: Herr H. Borth, Geschftsfhrer
A. RSLER GmbH
Wiesenauel 40
51491 Overath l l l l l l l l l l l l l l l l l l l l l l l l
Contact: Herr G. Rsler, Inhaber
A. U. K. MLLER GmbH & Co. KG
Dresdner Strasse 162
40595 Dsseldorf l l l l l l
Contact: Prof. Dr. D. Riedel, Geschftsfhrer
ABEL GmbH & Co. KG
Gewerbegebiet Ihne 7
58540 Meinerzhagen l l l l l l l l l l
Contact: Herr R. Abel, Geschftsfhrer
ACCUMA DEUTSCHLAND GmbH
Drausendorfer Str. 1
02763 Zittau l l l l
Contact: Herr A. Rberg, Verkauf
ACLA-WERKE GmbH
Frankfurter Str. 142-190
51065 Kln l l l l l
Contact: Herr G. Kiefer, Geschftsleiter
31
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3D-PLASTIC HANS KINTRA GmbH
Tel: 02166 43033 - Fax: 02166 41051 l l l l l ISO 9001 65 - 220 25 - 100 14 l
Email: info@3d-plastic.de
Website: www.3d-plastic.de
A & T KUNSTSTOFF GmbH
Tel: 038874 23434 - Fax: 038874 23323 l l l l l l l l 1 - 2400 35 - 420 6 l
Email: info@at-kunststoff.de
Website: www.at-kunststoff.de
A-FORM AG
Tel: 03733 55 09 0 - Fax: 03733 55 09 20 l l l l ISO 9001 0 - 9000 0 - 650 10 l
Email: info@a-form.de
Website: www.a-form.de
A-Z AUSRSTUNG UND ZUBEHR GmbH & Co. KG
Tel: 02324 92020 - Fax: 02324 920299 l l l l l ISO 9001; 16949 1 - 1500 50 - 500 15 l l l
Email: info@az-hattingen.de
Website: www.az-hattingen.de
A. FOLLMANN GmbH
Tel: 06508 476 - Fax: 06508 596 20 - 980 50 - 350 17 l
Email: kontakt@afo-online.de
Website: www.afo-online.de
A. KAYSER AUTOMOTIVE SYSTEMS GmbH
Tel: 05561 7902 0 - Fax: 05561 7902 2090 l l l l l l l l ISO 9001; 14001;
16949
3 - 500 40 - 360 100 l l l
Email: info@kayser-automotive.com -
Website: www.kayser-automotive.com
A. RSLER GmbH
Tel: 02206 2369 - Fax: 02206 4023 l l l 0.1 - 220 0 - 180 12 l
Email: info@a-roesler.de - Website: www.a-roesler.de
A. U. K. MLLER GmbH & Co. KG
Tel: 0211 7391 0 - Fax: 0211 7391 281 ISO 9001 l
Email: info@akmueller.de
Website: www.akmueller.de
ABEL GmbH & Co. KG
Tel: 02358 315 - Fax: 02358 8541 l l ISO 9001 0.5 - 200 22 - 100 15 l
Email: info@abel-pllastic.de
Website: www.abel-plastic.de
ACCUMA DEUTSCHLAND GmbH
Tel: 03583 5166 0 - Fax: 03583 5166 22 ISO 9001 23 l
Email: info@accuma.de
Website: www.accuma.de
ACLA-WERKE GmbH
Tel: 0221 69998 0 - Fax: 0221 697121 l l l l ISO 9001 1 - 250 15 - 250 15 l l
Email: info@acla-werke.de
Website: www.acla-werke.de
D
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8
AMIs database:
THE INJECTION MOULDING INDUSTRY
IN GERMANY
Germany is without a doubt the powerhouse of the European injection
moulding industry. In depth knowledge of this industry can be yours with
AMIs new comprehensive guides and database.
Services & machinery
Addresses, contacts,
polymers & markets
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details
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market, number of machines, etc.
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edition edition
88
AMIs Verzeichnis
DIE DEUTSCHE
SPRITZGUSSINDUSTRIE
Band 1: Norddeutschland

edition
88
8
AMIs Guide to the Injection Moulding Industry in
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edition edition
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edition
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AMIs Guide to the Injection Moulding Industry in
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N
E
W

2
0
1
3
Natural gas has claimed its place in the automotive
industry as a cost efective fuel with a low carbon
footprint. Countries with major natural gas reserves are
increasingly capitalizing on the advantages of using
these resources, which is estimated to drive the growth of
natural gas use by close to % in the coming years.
Compressed Natural Gas (CNG) reduces CO
emissions by %
compared to current solutions in petrol or diesel. Further reduction
of CO
emissions can be achieved using lightweight solutions, such

as full composite Type IV tanks. Liners made from polyamide Akulon

Fuel Lock further reduce the impact on climate change compared to
other plastic liners by reducing the permeation of methane which is
a potent greenhouse gas. Permeation of methane is undesirable for
tank installations in passenger vehicles, making an efective barrier
of utmost importance not only for the wellbeing and the comfort of
the people but also for the safeguard of the environment.
Akulon Fuel Lock enables the safe use of lightweight composite
tanks with an extremely low permeation level.
A focus on reducing weight
Steel tanks have the advantage of preventing methane permeation,
however they add signifcant weight to the vehicle with detrimental
consequences on fuel economy. The European Union recently
adopted a set of mandatory emission reduction targets for new
cars. Passenger cars need to comply with a maximum CO
emission
of g/km, which is a reduction of % over the rate
(sources: European Commission Regulation Proposal July and
International Council on Clean Transportation July ).

The challenge is clear: How can we efectively use CNG as a low
carbon emission fuel while avoiding the CO
penalty that would

result from the additional weight of traditional steel tanks?
The solution is ofered by Type IV tanks that enable the use of
CNG as a fuel while reducing weight.
Akulon
Fuel Lock.
Lightweight, low permeation
polyamide for CNG tanks.
225
200
175
150
125
100
75
50
750 1000 1250 1500 1750 2000
C
0
2

e
m
i
s
s
i
o
n

[
]
k
m
]
mass of vehicIe [k]
2006
2009
2020 (taret)
A traditional L steel tank weighs around kg, while a composite
Type IV tank can weigh as little as kg. Every kg of vehicle
weight reduction reduces CO
emissions by g/ km, helping

manufacturers to avoid the per vehicle penalty.
Low permeation to reduce methane emissions
But weight reduction is only part of the solution. Indeed, while
lightweight composite Type IV tanks contribute to a better fuel
economy compared to steel, they carry the risk of methane
permeation. Since methane is a greenhouse gas (GHG) with times
higher Global Warming Potential (GWP) than CO
, its emission to air

constitute an extra burden on climate change. Permeation of this
gas represents a concern not only for the wellbeing and the comfort
of the passengers but also for the environment. Type IV tanks
need a liner made from an efective barrier material to prevent the
permeation of this greenhouse gas. Akulon Fuel Lock provides a liner
material that reduces methane emissions by a factor of at least
compared to conventionally used HDPE, enabling the use of Type IV
tanks inside passenger cars. The assessment of the environmental
impact of a CNG tank over its entire life cycle from manufacturing to
end of life, including its use in the vehicle for years or , km
shows that moving from a steel Type I tank to a Type IV tank with
an HDPE-based liner of mm wall thickness would decrease the total
global warming potential of only less than %, due to HDPEs poor
performance as a methane barrier.
On the contrary, lining the tank with Akulon Fuel Lock (.mm wall
thickness) would reduce GHG emissions up to more than %
compared to steel. In addition, the potential reduction in wall
thickness can increase tank volume by as much as .L for a L
tank, signifcantly extending the range.
Akulon Fuel Lock proves to be the most efective barrier, empowering
the automotive industry to make full use of CNG as a future fuel for
vehicles with lightweight construction and decreased impact on the
environment.
Safety is always a primary concern
Akulon Fuel Lock is a successful liner material because of the
balance it strikes between low-temperature performance (down
to -C) and low permeation, all while maintaining good
processability. Tank temperatures drop to -C during the fast-
flling process, causing shrinkage in the liner. At the same time, the
pressure increases rapidly, resulting in fast expansion of the liner.
Akulon Fuel Lock is designed to handle the required elongation
at low temperature, while also meeting the required impact
performance during drop tests to comply with ECE R. The material
successfully passes the pressure cycle test at -C with >,
cycles and withstands extreme fast-flling at -C. Akulon Fuel
Locks high-temperature performance exceeds HDPE in dimensional
stability (sofening/creep), ensuring leak tight tanks at high
temperatures in cars of up to C.

Akulon Fuel Lock: A drop-in replacement
Akulon Fuel Lock exhibits extremely high parison stability in the
blow molding process. The parison stability allows to move towards
a very narrow wall thickness distribution of . . mm for a
m long parison of kilograms. The material can be processed on
blow molding equipment suitable for HDPE with a L/D ratio of .
In addition, cycle times can be reduced by to % over HDPE.
Direct inline re-use of up to % scrap has no efect on the parison
stability or material performance. Akulon Fuel Lock is also available
for injection molding and extrusion, giving you the freedom to design
in virtually any confguration, and the ability to produce tanks for
heavy-duty vehicles. In addition, DSM ofers both design and on-site
technical support so you get the maximum return on your investment.
A proven track record
Akulon Fuel Lock enables safe use of lightweight composite tanks
with an extremely low permeation level. The Akulon Fuel Lock
portfolio consists of a number of impact modifed, high barrier,
polyamide material grades for injection molding, blow molding and
extrusion. These commercially available materials have been tested
and used in this feld of applications for several years without any
accidents or issues. Akulon Fuel Lock is used in tanks that comply
with ECE R.
1hermaI roerties
250
200
150
100
50
0
R0P AkuIon fueI Lock
t
e
m
e
r
a
t
u
r
e

[
C
]
125
86
125
225
132
180
CIobaI warmin PotentiaI (CwP) of a ChC tank over
its entire Iife cycIe
900
800
700
600
500
400
300
200
100
0
5teeI R0P AkuIon
k

C
0
2

e
q
u
i
v
a
I
e
n
t
s
nd of Iife
Methane ermeation
1ransort emissions
Manufacture
1meIt 1softeninQ0.45[Ma] vICA1
DSM Engineering Plastics
For further information, please see:
www.dsm.com or contact:
Europe
el ` /6 /7 7`796
lnloLurope.LLl_dsm.com
Americas
el Suu ``` /``7
lnlo/mericas.LLl_dsm.com
Asia Pacific
el S6 ` 6/ SSS
lnlo/sia.LLl_dsm.com
DSM
All information, advice and/or samples (information) are provided by or on behalf of DSM Engineering Plastic on an as is basis, without any further warranties
as to the accuracy, usefulness, correctness or completeness thereof. Use or disclosure of or reliance on such information shall be for your own sole risk, account
and responsibility and you will indemnify and hold DSM Engineering Plastics and its affiliates harmless from and against any and all damages or claims from third
parties in respect of your receipt, use or disclosure of or reliance on the information.
The disclosure of information shall not be construed as granting you a license or any other intellectual property rights relating to such information. The obtaining of
such license or rights shall be subject to separate negotiations.
.
Environmental information and methodological background
Life Cycle Thinking
At DSM, sustainability lies at the heart of our business. Thats
why we focus on how our products and processes efect people,
proft and the planet in their entire life cycle. We contribute to a
brighter living with innovative solutions that create more value
with less environmental impact.
The ecological benefts can be created at any stage of the
product life cycle, from raw material through manufacturing and
use to potential re-use and end-of-life disposal. To measure
these benefts we use the Life Cycle Assessment methodology.
Cradle to Gate Eco Footprint of Akulon Fuel Lock
The cradle to gate eco footprint values for kg of Akulon Fuel
Lock in fve impact categories are provided in the table below.
They can be used to assess the environmental impact of Akulon
Fuel Lock in footprinting studies further down the value-chain.
Life Cycle Assessment (LCA) and Footprinting
DSM has a well-established LCA competence center. We
routinely apply ISO series standards for LCA and The
Greenhouse Gas Protocol for Carbon Footprinting.
The Global Warming Potential (GWP) - or Carbon Footprint,
expressed as CO equivalents was calculated using the
Intergovernmental Panel on Climate Change method (IPCC
GWP a).
The Eco Footprint was calculated using the methods prescribed
by the International EPD
system. Details can be found at

http://www.gednet.org.
For data on the raw materials processes background
information from EcoInvent Database v. from the Swiss
Centre for Life Cycle Inventories was used.
Eco footprint, cradle to gate of Akulon Fuel Lock
Impact category Unit Value
Global warming (GWP) kg CO
eq .
Ozone layer depletion (ODP) g CFC- eq
Photochemical oxidation g C
eq .
Acidifcation g SO
eq
Eutrophication g PO
-
eq .
Trends and technical developments in the international
roong and geomembrane liner industry
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Chinaplas 2014 | show preview
Chinaplas is back in Shanghai for
2014. Injection World takes a look at
what will be on show at this years
biggest plastics exhibition
L
The Chinaplas show returns to Shanghai for 2014, with
the doors opening on the event on 23 April. The largest
plastics industry trade show of this year, more than
100,000 people are expected to pass through the
turnstiles of the Shanghai New International Expo
Centre before the show closes on 26 April, according to
organiser Adsale Exhibition Services. It says more than
2,900 companies will exhibit at this years show - the
28
th
- taking up a total of 220,000m
2
of oor space.
China has not escaped the impact of the global
downturn, but in its case has seen slower rather than
negative growth. Government gures put GDP growth
for 2013 at 7.7%, the same as 2012, and its economists
forecast a 2014 performance of between 7 and 8%. Big
efforts are underway to refocus economic growth on
domestic consumption rather than exports. And this,
together with rising labour costs, is seeing a general
upgrading of manufacturing technology in all industries,
including plastics.
Many companies understand that using low-end
technology to operate cannot sustain their development.
Technological and management breakthrough, quality
upgrade and following government policies like energy
saving, high efciency and environmental protection are
the best solutions, says Adsale chairman Stanley Chu.
Chinese plastics processors are turning their
attention to high growth industries and increasingly to
the automated high technology manufacturing solutions
used in Europe and the US, examples of which will be
seen throughout the Chinaplas show. Over the next
seven pages, we take a look at what will be on show in
Shanghai.
Arburg
S www.arburg.com
German injection machine maker Arburg sees the
Chinaplas show as critical for its global development.
With their strong growth rates, the markets in
China and Asia are very important for us. We are,
therefore, active at the local level here and have
signicantly improved customer support with our
distribution warehouse near Shanghai, which we
opened in 2013, says Arburg managing director of
sales Helmut Heinson, who says the company is
now able to offer faster delivery of machines and
automation to the region.
Arburgs product display will
focus on high performance
automated manufacturing,
which will be demonstrated in
the form of a high speed IML
packaging system and electron-
ics overmoulding application.
Spotlight falls on Shanghai
Left: Arburg
will show high
speed IML
moulding on a
hybrid Hidrive
machine
show preview | Chinaplas 2014
Assembled around an Allrounder 57H Hidrive hybrid
machine in packaging specication, the IML cell will
produce four decorated tubs in a 4s cycle. The 180 tonne
machine will be equipped with an IML system from
French automation and in-mould labelling specialists
Sepro Robotique and Machines Pags. The 4-cavity
mould is from Swiss manufacturer Kebo and labels
from Verstraete of Belgium.
Hotmelt overmoulding of electronic components will
be demonstrated on an Allrounder 275V vertical
machine. Hotmelt adhesives provide excellent adhesion
to electronic components while the low melt viscosity
minimises risk of damage, says Arburg.
The machine will feature a special 35mm screw
optimised for hotmelt processing. It will produce an
LED carrier comprising an LED circuit board insert and
two connector cables on a cycle time of 110s using a
1+1 cavity mould and a manual loading process.
Borouge
www.borealisgroup.com
Polyolens specialist Borouge will introduce its
BorPure MB5568 multimodal HDPE grade for light-
weight PCO1881 short-neck closure production at the
show.
The new polymer, which was launched in Europe by
Borouge sister company Borealis in the rst quarter of
this year, is said to offer the ability to further down-
gauge closure designs without compromising on ESCR
or organoleptics. ESCR performance is said to be 50%
improved on the previous BorPure MB 6561 grade.
The multimodal BorPure MB5568 grade is also easy
to process in thin wall closure applications. The
polymer has a ow equal to that of benchmark
monomodal MFR 2 HDPE, according to the company.
Cost reduction in bottle production is a key factor in
competitiveness for the beverage industry and lowering
the volume of material used in caps is a focus element
of that initiative, says Russell Tew, Borealis marketing
manager advanced packaging and bre.
Dr Boy
www.dr-boy.de
German machinery maker Dr Boy will show two
moulding machines in Shanghai, including an XS model
equipped with its own integrated sprue picker.
With a 10 tonne clamp, the XS is the smallest
machine from Dr Boy and occupies just 0.74m
2
of
oorspace. Its size 14 plasticising unit can be equipped
with 12, 14 or 16mm diameter screws and can deliver
shot volumes from 0.1cm3 to 8.0cm
3
.
The machine at the show will be tted with a pneu-
matically-operated spruepicker that ts within the safety
gate. As we demonstrated during K 2013, we also offer
complex automation equipment for our Boy injection
moulding machines as per customer requirements. We
are now able to respond even better to customer
requirements through the addition of these devices,
says Dr Boy export manager Wolfgang Schmidt.
The company will also show a Boy 35E machine. All
E-Series machines ordered with a 24 mm diameter
screw diameter and larger can now be tted with the
EconPlast system that was launched at K2013. This is
claimed to deliver an energy saving of 50 % during the
melting phase, along with more precise and faster
barrel heating and shorter startup and heating times.
Clariant
www.clariant.com
A key exhibit on the Clariant stand will be its recently
introduced HiFormer range of liquid colorant master-
batches.
The new liquid masterbatches are said to be
especially applicable for packaging and consumer
goods manufacturers, providing vibrant colours in both
Below:
Dr Boy will
demonstrate
its integrated
automation
options
Right: Borouge
launches its
latest cap-
grade HDPE at
Chinaplas
translucent and transparent polymers, good reproduc-
ibility and fast colour change. The colorants are highly
concentrated and supported by customised dosing and
handling equipment.
Clariant will also be promoting its ColorFoward 2015
guide - which forecasts global trend-setting colours and
colour palettes and will highlight its new Addworks
polymer additive branding.
Elasto
www.hexpoltpe.com
TPE producer Elasto, which has been manufacturing at
Foshan in China since the beginning of last year, will be
showing a number of applications using its Dryex SBS
and SEBS products.
The company says toys and baby care applications
will be a particular focus of this years exhibits. It says it
is seeing good growth in this sector in China, with many
manufacturers selecting its Dryex products for the
pleasing haptics and easy processing. It will also show
TPE adhesion grades for use on PA, ABS/PC and PS
substrates, crystal clear and low compression set
grades, and conductive and anti-static products for the
electronics sector.
Engel
www.engelglobal.com
Austrian headquartered Engel will be showing
integrated manufacturing cells covering all the
major market sectors, from automotive through to
packaging.
For the automotive sector, the company will
demonstrate a 900 tonne Duo machine producing
oil sumps using the FoamMelt technology it
develops with Trexel. This foaming technology
reduces part weight, improves stability and eliminates
sinking. The process is automated using an Engel Viper
20 linear robot.
Automation is increasingly becoming an integrative
process that enables extremely economical production
processes and guarantees a constant high level of
product quality, says Gero Willmeroth, sales and
service manager at ENGEL Machinery Shanghai. The
demand for automated system solutions continues to
increase in Asia.
Other exhibits include an all-electric tiebar-less
e-motion 30 TL machine, which will be running at the
show producing mobile phone lenses in an 8-cavity
mould using an Engel Viper 6 robot. An e-motion 400/160
machine will be producing 500ml IML food containers on
a 2-cavity mould supplied by Glaroform of Switzerland.
IML automation is supplied by Swiss specialist Beck
Automation and the labels y Viappiani of Italy.
For the medical sector, Engel will show a Victory
1350/300 machine making petri dishes on a 4+4-cavity
mould supplied by Plastisud of France. Parts are
removed in pairs fully automatically, tted together,
stacked and prepared for packaging in an automation
solution by Hekuma of Germany.
The company will also show its new CC300 control
system. This includes an extra-large 21-inch touch
screen panel and new single-button selection system to
provide simple control of all machine and robot
movements. The control unit of the manufacturing cell
has long since become an important factor in efcien-
cy, says Willmeroth. With our new CC 300 we can
support our clients in maximising the full potential of
integrated system solutions while increasing process
safety at the same time, even when the level of
qualications of the employees are low.
Ferromatik Milacron
www.ferromatik.com
Exhibiting on the Milacron stand, Ferromatik Milacron
will present a 160 tonne high performance hybrid
moulding machine from its modular F-Series line.
F-Series machines cover the range from 50-600 tonnes
Left: These
precision
mobile phone
lenses will be
moulded on a
tiebar-less
all-electric
Engel TL30
Below:
Ferromatik
demonstrates
2.7s cycle
moulding on a
160 tonne
F-Series
machine
and are designed to allow the customer to select the drive
conguration that best suits the application. Plasticising
and mould movement is electric on all models; ejector
and injection movements can be specied electric,
hydraulic or accumulator-backed hydraulic.
The F-160 model at Chinaplas will be tted with an
AP series injection unit with 40mm screw that com-
bines electric plasticising with hydraulic injection. The
machine will be producing 110mm diameter PP lids
weighing 7g on a 2.7s cycle time. The machine will be
equipped with a hot runner system from Milacron group
company Mold-Masters.
The F-Series machine will be running alongside 30
tonne and 350 tonne examples from Milacrons Elektron
all-electric moulding machine range. Both machines
will be supplied from the companys Chinese plant
at Jiangyin.
Frigel
S www.frigel.com
Italian cooling equipment producer Frigel will be
showing its new Microgel 3RC prototype portable chiller
and temperature controller.
According to the company, this new system incorpo-
rates a number of energy-saving features and rede-
signed internal circuitry that improves accuracy and
reduces operating costs. It also incorporates an
improved self-diagnostics function and can be con-
trolled either by its integral touch screen or via a
wireless web connection.
The company will also show its Ecodry 3DK closed
loop dry cooling system, which uses Frigels own
adiabatic technology to reduce water and energy use by
up to 95% compared to a typical evaporative cooling
tower solution.
Huntsman
S www.huntsman.com/tpu
Huntsman will launch two new injection moulding
grade TPUs at the show, targeting applications in
sporting footwear.
The introductions come just weeks after the
company ofcially inaugurated its new TPU
production plant near Shanghai. China is the
biggest market for TPU and we have an exciting
few years ahead of us. We have a new state-of-
the art production plant at our disposal and a robust R&D
programme in motion that will see new solutions for core
markets coming through steadily, says Huntsman global
business development manager Stephane Peysson.
Avalon 95 ABU is a UV protected high performance
polyester-based TPU offering very good abrasion
resistance and good ex performance. The material is
also claimed to process on short cycle times. Avalon 95
AHT is a high transparency polyester TPU offering good
UV stability and aimed at applications such as logo
windows and other see-through footwear parts.
Husky
S www.husky.ca
Husky injection Molding Systems presentation in
Shanghai will focus on its hot runner and controller
product line.
Among the technologies to be demonstrated on its
stand are the Ultra SideGate hot runner, Ultra nozzles,
and the latest developments in synchronized stem control
applications. The company will also display the most
recent expansions of its Altanium temperature controller
product line, including the already available Altanium
Delta and a preview of the upcoming Altanium Matrix2.
KraussMaffei
S www.kraussmaffei.com
German injection moulding machine maker KraussMaf-
fei, which has just doubled the size of its Chinese
production plant at Haiyan, will demonstrate cube-
mould production of three part closures on its stand at
Chinaplas.
The 200 tonne CXW 200-380/180 SpinForm moulding
machine will produce the fully assembled three-part
push-pull closures on a cycle time of 6.4s using TIM
mould technology from German company Zahoransky.
In the mould on the swivel platen machine, the basic
Right: Frigel
displays its
Ecodry
closed-loop
cooling
technology
Below:
KraussMaffei
will be making
three-part
closures using
an in-mould
assembly
mould from
Zahoransky
Companies included:
Injection moulders
Blow moulders
Rotational moulders
PE flm extruders
Sheet extruders
Cable extruders
Pipe extruders
Profle extruders
Tube and hose extruders
Compounders and
masterbatch producers

By the end of 2013, total
polymer demand in Hungary
is set to reach 784,000, seeing
an increase of 6.7% on the
previous year and Hungarys
highest demand to date.
4th edition
AMIs Directory
PLASTICS PROCESSORS
IN HUNGARY
LOCATION & PRODUCTION DETAILS OF 440 PLASTICS PROCESSING PLANTS
LOCATION & PRODUCTION DETAILS OF PLASTICS PROCESSING PLANTS
PLASTICS PROCESSORS
IN HUNGARY
AMIs Directory
4th edition
LOCATION & PRODUCTION DETAILS OF PLASTICS PROCESSING PLANTS
PLASTICS PROCESSORS
INHUNGARY
AMIs Directory
4th edition
Book:
205/245/$320

AMIs Directory of Plastics Processors in Hungary Blow moulders
81
MEDICAL PRODUCT SZVETKEZET
Type: Custom
Polymers processed: LDPE, HDPE, PP, PVC,
PET
Markets served: Food/Drink, House Chemicals,
Medical/Pharma, Bottles for Automotive Industry
(For Fuel).
Size: Under 1 litre, 1 to 5 litres, 5 to 25 litres.
Services offered: Tool Design, Tool Manufacture,
Assembly, Filling, Pad Printing, Silk Screen Printing
Polymer throughput: Less than 500 tonnes per
annum
MEPLA MANYAG S FMIPARI KFT.
Type: Custom
Polymers processed: LDPE, HDPE, PP, PET
Milk Bottles; Water Bottles; Washing Liquid Bottles.
Size: Under 1 litre, 1 to 5 litres.
Services offered: Assembly, Pad Printing
Numbers of colours: 1
annum
METALCAR KFT.
Type: Custom, In House
Polymers processed: LDPE, HDPE
Markets served: Toys
Services offered: Pad Printing
annum
MIKROPAKK KFT. -BUDAPEST-
Type: Custom
Polymers processed: LDPE, HDPE
Markets served: Cosmetics/Toiletries,
Medical/Pharma, Non-Packaging Technical Parts
(excluding Automotive Parts)
Size: Under 1 litre.
Product Development, Assembly, Silk Screen
Printing, Design
annum
MOTOPLAST KFT.
Type: Proprietary Products
Polymers processed: HDPE
Markets served: Toys, Ride on Three Wheels
Motorcycles (The Wheels).
Product Development, Assembly, Silk Screen
Printing, Design
Numbers of colours: 11
annum

NEW-MKER MANYAGFELDOLGOZ
KFT.
Type: Custom
Polymers processed: LDPE, HDPE, PP
Horticulture/Agriculture.
annum
PACCOR HUNGARY ALMAND KFT.
Type: Custom
Polymers processed: LDPE, HDPE, PP, PET,
PETG
Markets served: Cosmetics/Toiletries, Food/Drink,
House Chemicals, Industrial Chemicals(including
IBCs and Big Drums), Medical/Pharma
Services offered: Product Development
Polymer throughput: Between 1001 and 2500
tonnes per annum
PACCOR HUNGARY EFFEKT KFT.
Type: Custom
Polymers processed: HDPE, PP
Markets served: Auto Fuel Tanks, Food/Drink,
Industrial Chemicals(including IBCs and Big
Drums), Non-Packaging Technical Parts (excluding
Automotive Parts), Jerrycans; Flasks; Hospital
Waste Containers; Barrels.
Size: 1 to 5 litres, 5 to 25 litres, 25 to 220 litres.
Services offered: Assembly, Labeling
Polymer throughput: Between 2501 and 5000
tonnes per annum
PET HUNGARY KFT.
Type: Custom
Polymers processed: PET, APET
Medical/Pharma, Body Builder Drink Bottles.
Polymer throughput: No polymer consumption
available
PET STAR KFT.
Type: Custom
Polymers processed: PET, CPET
Markets served: Cosmetics/Toiletries, House
Chemicals
available
PET-EXPRESSZ KFT.
Type: Custom
Polymers processed: PET
Markets served: Food/Drink, House Chemicals
available

Polymers, products & machinery
Gold database:
460/ 550/$715
Address Listing AMIs Directory of Plastics Processors in Hungary
36
GYURIK MANYAG KFT.
Egres u. 11.
2624 Szokolya
Tel: 27 585 010
Fax: 27 375 038
E-mail: info@gyurik.hu
Website: www.gyurik.hu
Contact: Mr. Gy. Gyurik, Managing Director

Parent company: Privately Owned
ISO registration: ISO 9002.

Processes operated: Injection moulding.

HAJR KFT.
Tarnyi J. u. 14.
4030 Debrecen
Tel: 052 471 874
Fax: 052 471 874
E-mail: hajrakft@freemail.hu
Website: www.hajraKFT.hu
Contact: Mr. J. Szab, Managing Director


Processes operated: PE film extrusion.

HA-NO PLASZT KFT.
Orion u. 14.
1214 Budapest
Tel: 12 761 911
Fax: 12 761 911
E-mail: hanoplast@mail.datanet.hu
Contact: Mr. Z. Hamvas, Managing Director


Processes operated: Injection moulding, Blow
moulding, Tube and Hose extrusion.

HRSHEGYI LSZL
Apponyi t 16.
7084 Pincehely
Tel: 074 406 005
Fax: 074 406 005
E-mail: harshegyila@citromail.hu
Contact: Mr. L. Hrshegyi, Owner


Processes operated: Blow moulding.

HD - ROTATECH KFT.
Ipari Park
Bnki Dont t 7528/5 HRSZ
2373 Dabas
Tel: 52 514 010
Fax: 52 514 011
E-mail: hd-rotatech@hd-rotatech.hu
Website: www.hd-rotatech.hu


Processes operated: Rotational moulding.

HEMBACH KFT.
Szabadsg t 41.
8154 Polgrdi
Tel: 022 366 261
Fax: 022 576 025
E-mail: hembach@t-online.hu
Website: www.hembach.hu
Contact: Mrs. Z. Hembach, Managing Director

Parent company: Privately Owned.
ISO registration: ISO 9001; 14001.

Processes operated: PE film extrusion.

HENKEL MAGYARORSZG KFT.
Vsrtr 2.
5516 Krsladny
Tel: 066 474 666
Fax: 066 474 996
E-mail: name.surname@henkel.com
Website: www.henkel.hu
Contact: Mrs. A. Ujhelyin Mojzsis, Managing
Director

Parent company: Henkel Group, Germany

Processes operated: Blow moulding.

HE-PA HUNGARY PLAST KFT.
Jzsef Attila u. 80.
8284 Nemesgulcs
Tel: 87 433 322
Fax: 87 433 389
Website: www.hepahungary.hu
Contact: Mr. A. Rehberg, Managing Director


Processes operated: Injection moulding.

Addresses & contacts
Available
as a fully
searchable
database
Full addresses and numbers of all
manufacturing plants
Managerial contacts
Polymers processed
Markets served/products manufactured
Machinery information
Which information is shown:
For more information contact us on sales@amiplastics.com or Tel: +44 (0) 117 9249442
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details
closure body is made in parting line one and the valve
and lid in parting line two. A 90 rotation of the cube
mould takes the parts to an assembly position.
KraussMaffei says this arrangement is simpler than
traditional cube mould systems and is more exible in
production. If the application changes, it claims the
machine can be quickly retrotted thanks to the cantile-
vered spin unit and easy-to-replace cavity plates. In
particular, this type of exible production concept is
specially tailored to the requirements of manufacturers of
packaging and medical technology products in Asia, says
Frank Peters, vice president of sales at KraussMaffei.
The machine at Chinaplas will be equipped with the
companys BluePower servomotor and actuator, which
uses electric drives on the sliding table and spin unit to
save energy while also providing parallel movement.
MHT
www.mht-ag.de
MHT Mold & Hotrunner Technology will be showing its
extended range of upgrade sets for operators of Husky
HyPET preform injection moulding machines.
The company can now supply upgrade sets for
HyPET 120 and 225 machines, as well as the 300, 400,
500 and GL600 models. It claims its upgrades allow
producers to lift output by up to 50% without the need
for major machine modications, which it says it
achieves by tightening up cavity spacing to allow an
additional row of cavities on each side of the mould.
The upgrades, which are available for maximum
water thread diameters up to 30/25, also include MHTs
own three-stage post mould cooling unit.
Moss
www.moss.it
Moss will demonstrate its MO 3062 entry-level four-
colour rotary dry offset printer for decorating the at
face of plastic closures.
The MO 3062 can print 1,250 parts each minute.
Features include orientation into the loading device,
automatic loading onto the continuously rotating
cap-holder wheel, removal of dust and static charge,
ame treatment, printing and UV-curing, camera
inspection, and counting into boxes.
Motan-Colortronic
www.motan-colortronic.com
New from Motan Colortronic for the Chinaplas show is
the Ultrabend 95, a gravimetric dosing and blending
unit designed for medical applications.
The company, which has operated its own Chinese
production and service subsidiary Taicang Motan-Color-
tronic Machinery since 2006, will be showing its full range
of plastics ancillary equipment at the Chinaplas show,
including compressed air and dry air dryers, conveying
systems and material distribution control systems.
Nordson Xaloy
www.nordsonpolymerprocessing.com
Nordson Xaloy will be showing its new SmartHeat
system for heating injection barrels and nozzles.
The SmartHeat system replaces traditional heater
bands with a two-layer plasma-sprayed metallized
ceramic coating which sandwiches a nichrome wire wrap
and is fully enclosed in a thermal insulation cover. It is
claimed to offer faster response and more uniform
temperature distribution than traditional systems,
together with a 30-60% improvement in energy efciency.
According to Xaloy, the system is also more durable
than electrical heater bands, eliminating the need for
heater maintenance and replacement.
Piovan
www.piovan.com
Italian ancillaries maker Piovan will show its EasyCool
chiller range in Shanghai, focusing on the performance
and energy saving features.
EasyCool chillers are available in air cooled (CA) and
water cooled (WA) versions and in cooling capacities
from 50 to 280kW. The units use scroll compressors
mounted in tandem to allow cost effective operation at
partial loadings, which the company says is 95% of the
time for most processing applications. The evaporator
Right: Somos
mobile drying
equipment will
be shown by
ProTec
www.amiplastics.com
Messe Duesseldorf,
8-14th May, 2014
Visit the AMI Stand EN/A02
on the ground oor of the
North Entrance (Eingang Nord)
- Browse and Buy from our range of Packaging
related Market Reports and Directories including:
AMIs 2014 Directory: PE Film Extruders in Europe
AMIs 2014 Directory: Sheet Extruders in Europe
- Over 80 Packaging and Plastics-related Technical
Books on display to buy
- Subscribe free of charge to our Film & Sheet
and Injection World digital magazines
For more information e-mail Matt Wherlock
(Stand Manager) mjw@amiplastics.com
and condenser are also designed to provide very high
heat transfer rates.
ProTec Polymer Processing
www.sp-protec.com
Materials handling specialist ProTec Polymer Process-
ing will head up its offering for injection moulders with
its Somos T/TF eco range of mobile dryers, which are
claimed to provide energy efcient operation beside the
processing machine.
The range caters for material throughputs of around
3 up to 100 kg/h and drying temperatures of between 60
and 140C at a dew point temperature of -35C. Hopper
sizes range from 30 to 300 litres, allowing units to be
selected to match the material consumption of the
processing machine.
The dryers are offered in two variants: TF versions
are supplied with an integrated conveying system for
feeding the machine, T versions have no conveyor.
Radici Group
www.radicigroup.com
Italys Radici Group will be presenting its latest
specialty grades of polyamide, including its Radilon
enhanced heat resistance HHR and Xtreme grades,
Radistrong PA6 and PA6,6 long bre reinforced metal
replacement products and Radilon DT PA6,12 and
Radilon D PA6,10 long bre reinforced grades.
Radici has manufactured PA, PBT, TPEs and POM at
its plant at Suzhou in China since 2006 and plans to
install a new line this year that will increase annual
capacity by 5,000 tonnes.
Above:
Precision POM
racks moulded
by Sumitomo
Demag
www.amiplastics.com
Messe Duesseldorf,
8-14th May, 2014
Visit the AMI Stand EN/A02
on the ground oor of the
North Entrance (Eingang Nord)
- Browse and Buy from our range of Packaging
related Market Reports and Directories including:
AMIs 2014 Directory: PE Film Extruders in Europe
AMIs 2014 Directory: Sheet Extruders in Europe
- Over 80 Packaging and Plastics-related Technical
Books on display to buy
- Subscribe free of charge to our Film & Sheet
and Injection World digital magazines
For more information e-mail Matt Wherlock
(Stand Manager) mjw@amiplastics.com
s
Chinaplas 2014
Dates: 23-26 April 2014
Venue: Shanghai New International Expo Centre,
Pudong, Shanghai, China
Hours: 09:30-17:30
Ticket prices: One-day pass RMB30;
Four-day pass RMB50
Organiser: Adsale Exhibition Services
Website: www.chinaplasonline.com
Schottli
www.schoettli.com
Swiss mould maker Schttli, the latest addition to the
Husky Injection Molding Systems business, will be
promoting its solutions for special medical and
specialty closure applicatons.
Asia Pacic is a growing market, particularly for
medical moulds, and we are looking forward to the
opportunity to connect with our customers in this
region and demonstrate the combined capabili-
ties of Schttli and Husky, says Thomas
Anderegg, President of the Schttli Group.
Exhibits include Schttlis latest mould
technologies for medical parts such as
syringes, infusion/transfusion products, diagnostic
systems and feminine care items. The company will
also display Huskys EASYcube mould technology for
multi-material closure production.
Sumitomo Demag
www.sumitomo-shi-demag.eu
The centrepiece of the Sumitomo SHI Demag display at
Chinaplas will be an El-Exis SP packaging machine pro-
ducing 1.2g screw caps on a 96-cavity mould on a 1.8s
production cycle.
The El-Exis SP 420-3000 machine will be running a
96-cavity hot runner mould and will be equipped with a
25:1 L/D ratio barrier screw with a special backow
barrier designed to improve reproducibility. The company
says the fast cycle time results in part from the activeAd-
just system within the hybrid machines NC5 controller,
which allows movement of all axes to be optimised to
achieve the shortest possible process times.
The company will also be running a hydraulic Systec
120-200 C machine at the show producing medical rack
components in POM on a 16-cavity mould by Kebo of
Switzerland. The machine is tted with a servo pump
system to reduce energy consumption and runs a 12s
cycle. Part removal is achieved using a Success 11 robot
by Sepro of France and a quality inspection system by
US-based Avalon Vision Systems completes the package.
Sumitomo Demag manufactures Systec C series
machines for the Asian region at its Demag Plastics
Machinery unit at Ningbo in China. Last year it an-
nounced it is expanding capacity at the Ningbo plant,
aiming to take annual production from 650 to around
1,000 machines by 2015.
Wittmann Battenfeld
www.wittmann-group.com
Wittmann Battenfeld will be showing three machines on
its stand two all-electric Power Series models and a
hydraulic HM ServoPower type together with a range
of ancillary and automation units.
A 240 tonne EcoPower machine will be producing a
structural foam part with a high quality surface nish
using a technology developed with German company
Schaumform. This uses Wittman Battenfelds Cellmould
physical foaming technique, BF-Mold variotherm mould
temperature control and Hi-Q mould position control.
The company will also be demonstrating a MicroPo-
wer machine producing a medical lter with an
80-micron mesh on a two-cavity mould with three-
platen injection. The 1.1mg component is intended for
use in micro pumps and inhalers.
A 110 tonne HM ServoPower machine will be
producing a medical insulin pen component in PP on a
48-cavity mould supplied by Hasco.
The companys automation display includes W808,
W818 and W818TS robots (the latter with a telescopic
axis) as well as long stroke W828 robots. All the units
on display will have been manufactured at Wittmanns
plant at Kunshan in China.
Ancillary items on display include a Drymax Aton
F30 segmented wheel dryer, Tempro C90, C120 and
C140 temperature controllers, MAS granulators and
Minor 2, Junior 2 Compact and Junior 3 screenless
beside the press granulators. A number of Feedmax
loaders and Dosimax and Gravimax blending units
complete the line-up.
Wittmanns automation
display includes its
W808 beam robot
Tel: +44 (0)117 924 9442 Fax: +44 (0)117 9892128 email: mjw@amiplastics.com
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Bangladesh

167
Demand for thermoplastics in Bangladesh 2011-2013

% change
Units: 000 Tonnes 2011 2012 2013
1
2011-2012 2012-2013
LL/LDPE 67 74 80 10.0% 8.4%
HDPE 49 50 52 3.5% 3.2%
PP 41 44 49 9.1% 9.2%
PVC 32 34 35 4.4% 3.9%
GP-HI PS 11 12 13 5.3% 6.3%
EPS 5 6 6 1.9% 3.6%
PET 41 47 53 15.6% 12.2%
Sub-total commodity 246 266 286 8.3% 7.5%
ABS/ SAN 1 1 1 12.8% 11.4%
PBT 0 0 0 22.2% 15.2%
PA 2 2 2 15.1% 9.6%
PC 3 3 3 7.1% 6.7%
Acetals 0 0 0 10.0% 9.1%
PMMA 0 0 0 7.1% 6.7%
Sub-total engineering 6 6 7 10.9% 8.7%
TOTAL POLYMER DEMAND 252 273 293 8.4% 7.5%
1
Forecast
END USE APPLICATIONS FOR THERMOPLASTICS IN BANGLADESH 2013
Included in this report:
All commodity and engineering thermoplastics
Analyses trends from 2007 up to 2017
Gives forecast through to 2017
Covers all Indian subcontinent countries
Provides analysis by processing sectors
Includes statistical data of country demand
LL/LDPE

31
rapidly and consistently through the period 2007 to 2012, averaging growth of nearly 10%
every year. Slower years were between 2010 and 2013 where the global recession,
extended monsoon season and the eurozone crisis slightly curtailed growth. Generally,
growth for LL/LDPE has been growing at 1.4 times that of the subcontinents GDP growth.
84% of the subcontinents demand is accounted for by India.
LDPE is produced in dedicated plants whereas LLDPE can be produced in swing plants
capable of producing both high density as well as linear grades. Swing plants in the region
have tended to favour LLDPE grades however the ability to swing between grades makes
calculating capacity problematic. All subcontinent LL/LDPE production comes from India.
Production has been consistently lower than local demand and hence the region has
become increasingly dependent on imports. In 2011 Indian imports were 625,000 tonnes but
this increased to over 785,000 tonnes in 2012 (50% of demand). To cope with fast growth in
demand there will be a number of new Indian plants coming on stream in 2013-2015. BCPL,
Reliance, GAIL and OPaL will be investing in HD/LLDPE swing plants whilst Reliance
Industries also plans a 400,000 tonnes/year LDPE plant as part of its USD12 billion capacity
investment programme. While capacity is expected to exceed regional demand by 2015
overall the subcontinent will continue to rely on imports although India is expected to become
a net exporter before 2016.
Table 2.1
SUPPLY/ DEMAND FOR LL/ LDPE IN THE INDIAN SUBCONTINENT 2007-2013
Units: 000 Tonnes 2007 2008 2009 2010 2011 2012 2013
1
Capacity 595 620 635 910 1,020 1,020 1,130
Production 479 501 534 750 878 856 915
Demand 1,203 1,356 1,491 1,628 1,752 1,908 2,078
% demand change 12.8% 9.9% 9.2% 7.6% 8.9% 8.9%
1
Forecast
Figure 2.1: CAPACITY AND DEMAND FOR LL/LDPE IN THE INDIAN SUBCONTINENT 2007-2013
What are the challenges
faced by the plastics industry
in the Indian sub-continent?
Data management | DFM
The early phase of the design for manufacturing
process is not only important in generating a good
component design that lends itself to effective produc-
tion. It also allows the engineering team to collect a
considerable volume of valuable information for the
next phase of the product development process - de-
signing and building the mould tools.
As part of the DFM process an analysis of the tool
setup will have been completed to determine what the
gating conditions will look like. And a mould lling study
will have indicated the appropriate venting require-
ments and show cooling times, distortion issues, clamp
force requirements, shear rates and other signicant
processing values. This data allows the engineering
team to make calculations on cycle time, part shrink-
age, injection moulding machine size requirements, and
mould tool dimensions. It is now vitally important that
these ndings, calculations and requirements for the
mould tools are collected in a structured way.
The best way to manage this data collection is in a
Tool Specication sheet. Such a document provides the
ideal means to bring together all the information
required for the subsequent mould production stages.
The Tool Specication will carry all of the essential
information required by the toolmaker to produce a
quote, as well as to design and build the mould.
A typical Tool Specication sheet will be structured
as follows:
Integrate
your DFM data
1) General part information
This area will contain information on the component
itself. This will include names, numbers, materials,
cycle time, shrinkage factor, and the like. The general
part information becomes even more useful if the 2D
part drawings are not available, which is not unusual at
the early stage of a project.
2) Mould tool information
This section of the Tool Specication will include
information on all mould tool-related areas. It will not
only specify the tool steels, hardening, coating and coat-
ing areas but will also show the number of cavities, the
number and type of sliders and lifters required, and the
tool layout to be used. Information on anticipated
hotrunner systems would be found here as well.
Figure 1 shows a schematic tool layout with gating
information. This ensures the tool designer has
everything on hand to start the design once the
component design is released for tooling. Figure 2
shows the specied areas of marking on the component
geometry, which most often will be overlooked at the
tool concept phase. This is because the position of
markings is typically considered at a later stage,
generally while 2D drawings are being created. The
problem that can often then arise is that, especially for
smaller components, there is not enough space
available to get datum stamps, material information or
The DFM process generates a great deal of valuable data. Andr
Eichhorn explains how to bring that valuable information
together in a structured fashion
DFM | Data management
the recycle symbol placed. Sometimes it is found that a
marking that is either embossed or recessed on the
component is located in the area of a lifter or slider-
movement - looking at the graphic would make the tool
designer aware of the positions and make sure that this
can be balanced this with ejector, slider or lifter
locations and even cooling lines.
Depending on the completeness of the 2D drawings,
other information on the surface structure of the
component can be added as well so that the tool
designer can also consider separate inserts to allow high
gloss or industrial polishing in certain areas of the tool.
And the most important page for security of lling of the
component would be one carrying the venting informa-
tion provided from the ow study, as shown in Figure 3.
3) Equipment Specication
This part of the Tool Specication brings together all
information related to the equipment required to
produce the part and any special considerations that
must be taken. For example, it will look at the type and
size of moulding machine to be used in production, as
well as the robotics required for part removal. Drying
equipment and mould or part cooling and other
temperature control technology can be specied at this
point as well.
Specic requirements for mould tool qualication
can also be laid down in this section, as well as data on
the number of sample parts to be delivered and/or
measured, at which place the tool needs to be validated,
and what acceptance criteria must be reached before
tool transfer into production is authorised.
4) Commercial Information
Most customers will also include some commercial
information as they will use the tool specication sheet
for the RFQ phase. All mould tool related deliverables
will be specied, such as the full set of drawings to be
delivered, sampling phases and the number of samples,
parts or production runs to be made.
The Tool Specication sheet can, in fact, be used for
a number of different tasks. However, looking at it from
a purely technical perspective, it is the perfect place to
bring together and organise all the data collected
during the DFM phase. The DFM records, mould lling
studies and other reports can be seen as working
documents - the Tool Specication sheet is a record
showing in one view all of the nal decisions made
during the DFM process.
About the author:
Andr Eichhorn is general manager of Germany-based
AST Technology. This is the latest instalment in a series
of articles in which he discusses how product manufac-
turing problems can be overcome at the outset of a
project by the intelligent application of Design for
Manufacturing techniques. You can read the most
recent articles in this series here, here, and here.
Figure 1: A schematic tool layout from an example Tool Specication sheet. Figure 2: Required tool marking indicated on the component
Figure 3:
Venting
information can
also be included
in the Tool
Specication
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The complete collection of articles published in Injection World Magazine
from 2009 to August 2013, brought together in a practical guide to
optimising and troubleshooting the whole injection moulding process
G Learn about controllable and consequential variables and understand the four steps to perfect
mouldings
G Explore screw properties, injection conditions, mould design, process control and much more
G Printed in colour, clearly illustrated, concise and clearly written for moulders at all levels
Order your copy now to perfect your moulding performance and products. Price: 60 / 50 / $75
Materials | product update
Grafe has developed a
range of carbon black lled
electrically conductive
polymers that meet Category
1 - 2 requirements for PAH
(polyaromatic hydrocarbon)
content laid down by GS
(Geprfte Sicherseit). PAHs
are produced by incomplete
combustion during produc-
tion of the carbon black and
are classied as harmful to
human health, says the
company. GS Category 2
requires a PAH content of
less than 10 mg/kg.
www.grafe.com
Lehvoss North America, a
subsidiary of Germanys
Lehmann & Voss, has
introduced Luvocom 8000, a
new series of PEEK com-
pounds intended for high
wear applications. The new
grade does not contain PTFE,
which generally decreases
the mechanical performance
of the compound, while
exceeding the tribological
performance of competing
products, the company
claims. Wear rates are said
to be up to three times lower
than industry-standard
PTFE-lubricated PEEK.
www.lehvoss.com
US PLA biopolymer maker
Natureworks worked with
Irish start-up 3Dom Filament
to develop a range of
laments for use in 3D
printing systems. The new
PLA laments carry the
Natureworks Ingeo brand
and include PLA blends in a
range of diameters and
colours.
www.natureworksllc.com
www.3domlaments.com
in brief
Norner stretches the life of PP
POLYPROPYLENE
Norwegian research institute
Norner has developed a
proprietary new technology
that extends service life of PP
in aggressive media.
The new formulations are
intended for the transporta-
more than 25 years at 70C.
Norner senior researcher
Harry ysd says the PP
technology is currently in the
implementation phase in a
chemical plant application.
www.norner.no
tion of hot water, warm
hydrocarbons or alkaline
liquids in PP-lined piping
systems. The company claims
good results have been
achieved in accelerated testing
indicating service lifetimes of
3D PRINTING
Stratasys targets living
hinges and snap-ts
The latest addition to the
Stratasys range of 3D printing
materials is Endur, designed
to simulate the properties of
PP and to allow production of
exible features such as living
ACETAL
The resin is said to provide
high strength and impact
resistance down to -40C and
is suitable for use with
conventional and high
ethanol content fuels. Users
also benet from a claimed
25% reduction in manufac-
turing time.
www.celanese.com
Celanese has developed a new
low permeation Hostaform
grade of POM for production of
injection moulded parts for
use in fuel tanks that must
comply with the latest SORE
(small off-road engine)
regulation in the US.
Traditionally, tanks for
SORE applications have been
Low permeation POM for fuel applications
hinges and snap-ts.
Suitable for use with the
companys Objet EdenV, Objet
Connex, Objet500 Connex3 and
Objet 30Pro printers, the
Endur material offers good
impact resistance, high
elongation at break and a
heat-deection temperature
up to 54C at 0.45MPa. It is
said to be suitable for a range
of form, t and assembly
applications, including
printing of living hinges and
snap-ts.
Beta eld trials showed
high user satisfaction with
Endur for models and
prototypes of polypropylene
parts, says Stratasys
product director for materi-
als and applications, Fred
Fischer.
www.stratasys.com
moulded in HDPE but this
cannot meet the new US EPA
and CARB regulations, the
company says. The Hostaform
S9364LPI grade, which is
described as a low permea-
tion, toughened hybrid POM, is
claimed to be able to meet the
requirements in a single-layer
construction.
product update | Applications
INDUSTRIAL
PA66 gas cylinder guard replaces steel
UK-based moulder Glazpart is using an
Akromid A3 PA6,6 compound from
Akro-Plastic to produce an innovative
injection moulded industrial gas cylinder
protection guard that replaces an existing
steel design.
This is an extremely demanding
application, says Akro-Plastic. Each
cylinder weighs 100kg and the guard must
withstand a 1.2m drop test onto a hard
surface at temperatures between -40C
and +65C.
Plastic guards have been used on
industrial gas cylinders weighing up to
50kg but this is said to be the rst
application on the
larger 100kg types. It
took two years to select
the material and
develop the component
design, which has been
compliance tested by
the Brussels-based
Apragaz certication
body.
The parts are manufactured in
Akromid A3 S1 Grey, a highly impact
modied PA6,6 grade produced at the
Akro-Plastic plant in Germany and
supplied in the UK by K D Feddersen.
The guards are tted
during cylinder testing.
Up to 300 are required
per shift, calling for up to
30,000 each year in the
UK. The steel guards
previously used were
produced in China and sup-
plied in batches, which lead
to occasional shortages.
Manufacturing in the UK is said to have
eliminated this problem.
www.akro-plastic.com
www.kdfeddersen.com
www.glazpart.com
ENGINEERING
human intervention at the
plant, which produces some
120m gears annually.
The company also uses
Engels quick mould change
system, which it has
combined with its own design
mould cart.
www.winzelergear.com
www.engelglobal.com
US-based technical moulder
Winzeler Gear has added a
further ve Engel e-Victory
machines to its highly
automated production facility
in Chicago in the US.
The new equipment (four 65
tonne e-Victory 200/65 and one
160 tonne e-Victory 740/160)
take the moulders machine
Winzeler gears up with ve Engel machines
if we had to rely on conven-
tional machine designs.
Winzeler uses a combina-
tion of linear and six-axis
robots to automate its
production systems, along with
automated box loading with
bar coding traceability. The
aim is to ensure consistency of
production and eliminate
AUTOMOTIVE
TPE secures automotive lines
Automotive systems supplier
Veritas has selected Hipex
thermoplastic elastomer from
Kraiburg TPE for production of
Kraiburg TPE worked with
Veritas to develop the clip,
providing advice at the design
stage through to volume
production. We are con-
vinced that HIPEX will
become a standard material
for use in the engine
compartment and transmis-
sion, says Dr Martin
Geissinger, product manager
at Kraiburg TPE.
www.kraiburg-tpe.com
two-component clips for
securing brake lines in the
engine compartment.
The Hipex material was
chosen for its ability to
withstand temperatures up to
150C and its resistance to
oils and greases. It is also
compatible with the
polyamide resin used for
the body of the clips (a
mechanical anchoring
technique is used).
park up to 39, more than half
tiebar-less Engel designs.
The Engel tie-bar-less
design provides us with the
ultimate exibility when
designing our automation,
says John Winzeler, president
of Winzeler Gear. The
moulding plant dynamics
would be changed completely
Piovan: Moving materials
Find out more about Piovans
options for materials
conveying in this brochure,
which explores the key
considerations to be made in
selection of a centralised
system. The 12-page
document discusses silos,
distribution units, pipework
and loaders.
Click here to download
EN
Customers. The core of our innovation
Feeding&Conveying
Drying
Dosing
Temperature Control
Refrigeration
Granulation
This months free
brochure downloads
Simply click on the brochure cover or link to download a PDF of the full publication
If you would like your brochure to be included on this page, please contact
Claire Bishop. claire
@
amimagazines.com. Tel: +44 (0)20 8686 8139
Arburg: Electric Allrounders
Arburgs electric Allrounder
machines deliver the
performance and precision
required for production of
complex parts. This 16-page
brochure details key machine
features and construction
details and identies some of
the major processing benets.
Polykemi: Custom compounds Maguire: gravimetric blenders
This six-page brochure
provides a brief introduction
to the Swedish Polykemi
Group. The publication details
the groups global production
sites and subsidiary
companies and explains what
makes its custom compounds
business different from its
competitors.
This interactive product
guide covers Maguires full
range of WSB gravimetric
blenders. It explains how the
blenders operate and
includes technical
specications, key benets,
plus options and
accessories.
Elasto: Dryex AM
The Dryex AM range of TPEs
from Elasto has been
formulated to meet the
demanding requirements for
automotive oor mat and
trunk liner production. This
four-page brochure details
the entire product family.

T
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R

A
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T
O
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O
T
I
V
E

M
A
T
S
Mold-Masters: IRIS coinjection
The IRIS system from
Mold-Masters combines ve
of the companys standard
mould technologies to enable
coinjection barrier moulding
processes to run on a
standard moulding machine.
This brochure explains how.
A WORLD CLASS COMPOUNDER
THE POLYKEMI GROUP
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product update | Machinery and equipment
ENERGY EFFICIENCY
Energy drives investment
decisions, says Demag
Injection machinery maker
Sumitomo SHI Demag says
that half of all the Systec
hydraulic machines it delivers
today are being specied by
customers with its energy-
saving ActiveDrive technology.
ActiveDrive technology is
claimed to reduce energy
consumption by up to 60%
compared to a standard
hydraulic system, depending
Sumitomo Demag
marketing manager Bernd
Trger says the rising cost of
power and a growing
emphasis on environmental-
ly-aware plant operation is
behind the growing demand
for the technology. Sustain-
ability is shifting increasingly
into focus during invest-
ment, he says.
www.sumitomo-shi-demag.eu
on the specic application. It
comprises a high dynamic
frequency-controlled servomo-
tor and constant pump and
control, which together allow
oil delivery to be matched to
demand during periods of
machine idling or partial load.
The ActiveDrive system can
be specied on Systec
machines with both hydraulic
and toggle clamping systems.
US-based Dynamic
Conveyor has added a new
vertical conveyor option to its
range of part handling
equipment. The new design,
which retains the established
DynaCon modular construc-
tion system, aims to meet
demands for more compact
production cells to allow
plant capacity to be maxim-
ised. The system can be
customised to any height and
is available in widths from
4-60 inches (100-1500mm).
www.dynamicconveyor.com
Eurotherm has launched a
new melt pressure indicator
and controller targeted at
plastics injection moulding
and extrusion applications.
The Piccolo P304i melt
pressure indicator and P304c
controller are compatible
with most industry standard
probes and use automatic
shunt calibration to simplify
new installations and
retrots. Other features
include PID control with
overshoot, auto-tuning and
fast acting alarm functions.
www.eurotherm.co.uk
Swedish automation
company WEMO has
developed its side-entry S
Design line of robots for fast
cycle moulding applications.
The high speed handling
units have been designed to
deliver high levels of
precision, efciency and
performance and are said to
be capable of working at
cycle times of less than 2.5s.
The units can be adapted to
work with a wide variety of
mould congurations.
www.wemo.se
in brief
MULTI-SHOT
The Boy 2C XS is an
auxiliary injection unit from
German machine maker Dr
Boy allowing a standard
single injection unit
injection moulding machine
to be converted to two-
component or multi-com-
ponent production.
The 2C XS unit provides a
plasticising volume of
76.4cm
3
and injection
pressures of up to 3,128 bar.
It is supplied as a package
complete with its own
integrated hydraulic drive
and the companys Procan
Alpha 2 control system.
The system can be used
with Dr Boy moulding
machines as well as
machines from other
manufacturers. The
company says it is simple to
integrate and easy to move
between machines.
www.dr-boy.de
Boy bolts on
a 2K option
DECORATION
heat effected zone, avoiding
damage to the substrate
material or distortion of the
marking, according to the
company.
The laser is driven by
Gravotech software that is
said to be intuitive and
efcient, allowing the user to
communicate easily with
external databases and to
quickly import codes, images
and logos.
www.technifor.com
New laser for plastic
marking operations
Gravotech group company
Technifor has added a new
laser to its product line-up
that, with a 532nm wavelength,
is said to be well suited to
marking of sensitive surfaces
such as plastics.
The TG400 green laser
provides a ne 30 micron beam
that delivers very high quality
marking denition, making it
suitable for reproduction of
small characters and data
codes. It also minimises the
Catch up on our recent
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Injection World Jan/Feb
The January/February edition
of Injection World is packed
with special features on
packaging technologies,
thermoplastic composites,
machine market trends,
production monitoring
software, and implementing
design for manufacturing.
Click here to view
Pipeline Coating February
The February edition of Pipeline
Coating examines the latest
global energy forecasts and
reviews prospects for pipeline
investment in North America.
Plus, a look at Shells Stones
deepwater FPSO project and
details of the rst NordStream
internal inspection.
Click here to view
Injection World March
Injection Worlds March issue is
overowing with information on
bioplastics, materials handling
systems, thin wall moulding,
and Indian market trends. Plus
there are useful tips on melt
preparation and weld lines.
Click here to view
Compounding World - April
The latest edition of Compounding
World includes an analysis of the
European compounding industry,
reviews the latest additive
applications and previews the
Chinaplas fair. Plus, an in-depth
look at activity in the vinyl LP
record industry.
Click here to view
Pipe and Prole Mar/Apr
The March/April edition of Pipe
and Prole extrusion looks at
the latest developments in pipe
grade polyolens and reviews
the titanium dioxide pigment
market. This issue also previews
the Chinaplas show and reports
on the latest Euromap
machinery statistics and
forecasts.
Click here to view
Film and Sheet - Jan/Feb
The latest issue of Film and
Sheet Extrusion looks at lm
recycling, including how
supercritical CO
2
is being used
in packaging recovery. Plus, the
latest bioplastics introductions
and a review of new renewable
ller materials sourced from
sea shells, paper and grain.
Click here to view
dates for your diary
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And dont forget to tell your colleagues, customers and suppliers
about the magazine. You can use the e-mail button above
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symbol in the browser) to help spread the word.
Global exhibition guide
23-26 April Chinaplas, Shanghai, China www.chinaplasonline.com
8-14 May Interpack, Dsseldorf, Germany www.interpack.com
13-16 May Ausplas, Sydney, Australia www.nationalmanufacturingweek.com.au
27-30 May Plastpol, Kielce, Poland www.targikielce.pl
10-12 June Plastec East, New York, NY, USA www.plasteceast.com
16-19 June Argenplas, Buenos Aires, Argentina www.argenplas.com.ar
17-20 June FIP Solution Plastique, Lyon, France www.f-i-p.com
18-19 June PDM & PRE, Telford, UK www.pdmevent.com
19-22 June Interplas Thailnd, Bangkok, Thailand www.interplasthailand.com
3-6 September Indoplas, Jakarta, Indonesia www.indoplas.com
29 Sept - 3 Oct Plastex, Brno, Czech Republic www.bvv.cz/plastex-gb
30 Sept - 2 Oct Interplas, Birmingham, UK www.britishplasticsshow.com
30 Sept - 3 Oct Equiplast, Barcelona, Spain www.equiplast.com
14-18 October Fakuma, Friedrichshafen, Germany www.fakuma-messe.de
28 Oct 1 Nov IPF, Makuhari Messe, Tokyo, Japan www.ipfjapan.jp/english
2-5 November Pack Expo, Chicago, IL, USA www.packexpointernational.com
18-21 November Plastimagen, Mexico City, Mexico www.plastimagen.com.mx
19-20 November Expoplast, Montreal, Canada www.expoplast.org
2015
10-13 January Arabplast, Dubai, UAE www.arabplast.info
5-10 February Plastindia, New Delhi, India www.plastindia.org
10-14 March Koplas, Seoul, South Korea www.koplas.com
AMI conferences
28-30 April Plastic Closure Innovations, Berlin, Germany
12-14 May Polymer Sourcing & Distribution, Hamburg, Germany
20-21 May Thin Wall Packaging USA, Chicago, IL, USA
16-18 June End of Life Plastics, Dusseldorf, Germany
17-18 June Injection World Molding Forum, Philadelphia, PA, USA
24-26 June Masterbatch 2014, Berlin, Germany
For information on all
these events and other
AMI conferences and
seminars, see
www.amiplastics.com
SPECIAL OFFER: Save $200 if you register before October 22, 2012
Media supporter:
December 1-2, 2012
The Hilton Atlanta,
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Please create the cover in a separate
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SPECIAL OFFER: Save $200 if you register before October 22, 2012
Media supporter:
December 1-2, 2012
The Hilton Atlanta,
Organized by:
Applied Market Information LLC & Injection World
June 17-18, 2014
Philadelphia, Pennsylvania, USA
Images courtesy of: Shutterstock
The international conference on business development and technology innovation in injection molding
Turn page for the full programme
SPECIAL APRIL OFFER: REGISTER by APRIL 30 to SAVE $300!

C O N F E R E N C E P R O G R A M
June 17-18, 2014
Hilton Philadelphia City Avenue, Philadelphia, PA, USA
Injection World magazine and AMI are pleased to invite you to join
top injection molding industry professionals at the Hilton Philadelphia
City Avenue in Philadelphia, PA, USA, on June 17-18, 2014 for the rst
Injection World Molding Forum.
This new conference features a high-level program assembled by the
editorial team of Injection World that will explore many of the themes
and issues covered regularly in the magazine in a live face-to-face
environment, allowing delegates to debate the key issues directly with
our assembled panel of expert speakers.
The Injection World Molding Forum will examine critical business
and market developments, and explore process technology and
material innovations. Its prime focus will be on exposing the new
technologies that will enable injection molders to develop the cost-
effective manufacturing solutions demanded by their customers. These
innovative technologies will be applicable to molders operating in
industries as diverse as automotive, electrical and electronic, housewares
and consumer goods.
Novel process innovations to be covered at the conference include
thermoplastic composites, 3D printing, conformal mold cooling, cyclical
mold temperature control, in-mold assembly, multi-component molding,
component lightweighting and production of optical quality parts.
On the material side, presentations will explore new metal replacement
options and high temperature polyamide developments.
Strategic business and production issues will also feature on the Injection
World Molding Forum agenda, with keynote presentations looking
at the changing structure of the North American molding industry,
analyzing the business case for reshoring, discussing regional
process technology trends and requirements, and identifying new
opportunities resulting from the evolving demands of the automotive and
electronics industries.
The Injection World Molding Forum is the place for the North American
molding industry to discover and discuss vital market and process
technology developments and to network with molding technology
experts at every level of the supply chain.
FIVE GOOD REASONS WHY YOU SHOULD ATTEND:
1. Hear leading experts explain the latest injection
molding innovations
2. Find out how new processing technologies will
improve your competiveness
3. Gain insight into the trends shaping the North
American molding business
4. Identify investment opportunities to secure high
value molding contracts
5. Network with key players from the North
American molding industry and supply chain
Tuesday, June 17, 2014
8:00 Registration and welcome coffee
9:00 Opening announcements
SESSION 1 MARKET UPDATE
9:10 The changing structure of the injection molding industry:
What drives successful strategies
Mr. Andrew Reynolds, Research Director,
APPLIED MARKET INFORMATION LLC, United States
9:40 End user viewpoint: The benets of reshoring manufacturing
Mr. Michael Araten, President and CEO,
KNEX BRANDS and THE RODON GROUP, United States
10:10 The road ahead: How changing automotive industry
requirements will drive innovation in plastic materials
Mr. Jeffrey Sternberg, Global Automotive Technology Director,
DUPONT, United States
10:40-11:10 Coffee break
SESSION 2 LIGHTWEIGHT SOLUTIONS
11:10 Microcellular injection molding: Enhancing design freedom
for complex lightweight plastic parts
Mr. Steve Braig, President and CEO,
TREXEL, INC., United States

11:40 Achieving premium quality surfaces and cell structures in
physical gas structural foam molding
Mr. Thomas Betts, Regional Sales Manager,
WITTMANN BATTENFELD INC., United States
12:10 The lightweight revolution: High volume, cost effective
injection molding of thermoplastic composite parts
Mr. Rajesh Shah, Regional Sales Manager,
KRAUSS MAFFEI CORP, United States
12:40-2:10 Lunch
SESSION 3 ADVANCED MANUFACTURING TECHNOLOGIES
2:10 3D printed molds: Speeding time to market
Mr. Nadav Sella, Solution Sales Manager,
STRATASYS, Israel
2:40 Active gate technology for hot runners: A higher level of
control for injection molding
Mr. Mark Moss, Executive Vice President
Market and Product Strategy,
SYNVENTIVE MOLDING SOLUTIONS, INC, United States
3:10 Assembling in the mold: Increasing production efciency
using innovative molding technologies
Dipl.-Ing. Hansjrg Keusgen, Head Sales and Marketing,
FOBOHA GmbH, Germany
4:10 Film insert molding and textured surfaces
Mr. Kevin OHara, Automotive Business Manager,
MACDERMID AUTOTYPE, United Kingdom
SESSION 4 MATERIAL DEVELOPMENTS
4:40 Extending the potential of polyamides:
Engineering solutions delivering enhanced high
temperature performance and moldability
Dr. James Mitchell, Global Market Director,
SOLVAY ENGINEERING PLASTICS, France

C O N F E R E N C E P R O G R A M
5:10 Challenging metals: Formulating performance plastics to
provide equivalent thermal and electrical performance
Ms. Patricia Hubbard, Global Technology Director, Specialty
Engineered Materials,
POLYONE, United States
5:40-7:15 Cocktail Reception
Wednesday, June 18, 2014
8:30 Welcome coffee
9:00 Opening announcements
SESSION 5 BUSINESS OPPORTUNITIES

9:10 Global and North American injection market developments:
Identifying technology trends and changing
molder requirements
Mr. Mark Sankovitch, President,
ENGEL MACHINERY, INC., United States

9:40 Future outlook for LED lighting: Material requirements, cost
and supply chain demands
Ms. Pallavi Madakasira, MS, M.Sc.,Analyst,
LUX RESEARCH, United States
SESSION 6 PROCESS INNOVATION

10:45 Integration of electro-mechanical functionality with
molded interconnects
Mr. Richard Macary, President,
SELECTCONNECT TECHNOLOGIES, United States
11:15 Top surface quality 'out of the mold' using induction
heating technology
Mr. Mathieu Boulanger, Business Development Director,
ROCTOOL INC., United States
11:45 Multi-component molding: Cost effective entry options to
multi-component and co-injection molding
Mr. Michael Feltes, Director Business Development IRIS and E-Multi,
MOLD-MASTERS, Germany
12:15-2:00 Lunch
2:00 Cold cure LSR injection molding: Enabling LSR overmolding
on thermally sensitive polymers such as PE and PP
Mr. Ryan Cutler, Operations Manager,
ELMET NORTH AMERICA, INC., United States
2:30 Innovative injection molding of optical parts: Mono- and
multi-layer solutions for production of short cycle
stress-free parts
Mr. Joachim Kragl, Director Advanced Molding Systems
and Processing,
ENGEL MACHINERY INC, United States
3:00 Conference wrap up and questions
3:30 Conference ends

AMI reserves the right to alter the program without notice.
The latest program including any new speakers or changes to schedules can
be viewed on our website www.amiplastics-na.com
CONFERENCE HOTLINE
Contact: Chrissy Stelluti, Conference Coordinator
Tel: +1 610 478 0800
Fax: +1 610 478 0900
Email: cas@amiplastics-na.com
Organized by:
APPLIED MARKET INFORMATION LLC
Applied Market Information LLC (AMI LLC) is the leading
supplier of plastics consultancy and information services to the
global plastics industry.
Based in Wyomissing, PA, AMI LLC supplies all of AMI European
directories and CDs and continues to develop a whole new
range of products for the North American market. Its range of
specialized services cover individual consulting services, multi-
client reports, conferences and publishing.
To nd out more about AMIs products, services and events,
visit our website at: www.amiplastics-na.com or call:
+1 610 478 0800 or email: consult@amiplastics-na.com
INJECTION WORLD MAGAZINE
Injection World is a monthly digital magazine published by AMI
that is specically written for injection molding companies,
product designers and mold makers. It is available free-of-
charge online and on the iPad, iPhone and Android-based
devices using our free apps.
www.injectionworld.com
Turn page for booking details
Special April offer
Register before April 30, 2014
and save $300
SPONSORSHIP AND EXHIBITION SPACE
AMI events are more than just arenas for listening and
networking. They also represent highly-targeted opportunities to
enhance your image and to promote your products and services
to an international audience. Running in conjunction with the
conference, the table top exhibition is an integral part of the
event, providing the ideal setting to increase your companys
exposure. As you are considering your involvement with this
conference, please keep in mind that many of our sponsorship
options include a table top exhibition space. There are several
different sponsorship options that you may consider. Please
contact the Conference Coordinator to discuss which opportunity
will provide you with the best ROI.
CONFERENCE DETAILS
DATE AND LOCATION:
June 17-18, 2014
4200 City Avenue
Philadelphia, PA 19131, USA
Tel: +1 215 879 4000
HOTEL ACCOMMODATION
The conference fee does not include lodging. We have negotiated a special rate
of $155 + tax per night for a single or double room at the Hilton Philadelphia City
Avenue. Please contact the hotels reservation department directly and be sure
to mention AMIs Injection World Molding Forum conference to qualify for the
special room rate. The hotel rate is guaranteed for a limited number of rooms so
do not delay in making your reservation for a room at the conference location.
REGISTRATION FEE
Register before April 30, 2014 for only $990. Thereafter, the fee will be $1290.
Registration includes all sessions, conference proceedings, the cocktail
reception, luncheons and break refreshments.
GROUP RATES
For companies wishing to register two or more delegates, group discounts are
available. Please contact the Conference Coordinator for more details.
SPONSOR THIS EVENT AND PROMOTE YOUR COMPANY
AMI events are more than just arenas for listening and networking. They also
represent highly targeted opportunities to enhance your image and promote
your products and services to an international audience.
Each event offers the following unique awareness building opportunities:
sponsorship of the cocktail reception, lunches, coffee breaks, and much more.
For further information, please contact the Conference Coordinator at
+1 610 478 0800.
EXHIBITION PACKAGE
This package includes an exhibition space in the conference room where we
will be hosting registration, the cocktail reception and coffee breaks, giving
exhibitors maximum exposure. It also includes 1 free delegate place. Exhibitors
may either use tables provided by the hotel or bring their own stand or display.
A limited number of tables are available and are assigned on a rst come, rst
serve basis. The cost of this package is $1990. Please note: When applicable,
exhibitors are responsible for any electricity and/or handling fees involved with
their booth. For further information, please contact the Conference Coordinator.
SOCIAL EVENTS
The social events organized for AMIs Injection World Molding Forum
conference will provide an ideal setting for delegates and speakers to mix
business with pleasure. On the rst evening, everyone is warmly invited to
attend the cocktail reception.
SUBSTITUTIONS / CANCELLATIONS
Delegates may be substituted at any time at no charge. We ask that you
provide ample notication of substitution in order that materials can be
prepared. Full refunds, less an administrative charge of $200 will only be made
on cancellations received prior to March 21, 2014. We regret that we cannot
make refunds on cancellations received after this date or for no-shows at the
conference. Please note that refunds cannot be made on table top bookings
or sponsorship packages.
FAX FORM TO: +1 610 478 0900
REGISTRATION FORM
Injection World Molding Forum 2014
June 17-18, 2014
Philadelphia, PA, USA
Company: __________________________________________
Address: ____________________________________________
____________________________________________________
Tel:______________________ Fax: _______________________
Company activity: ____________________________________
Delegate Details
If more than one delegate please photocopy form
Title: _____________First name:_________________________
Surname: ___________________________________________
Position: ____________________________________________
Email: ______________________________________________
Special dietary requirements: ___________________________
Payment Details
Please make payments in US Dollars ($)
q Delegate fee $990 ___________
(before March 21, 2014)
q Delegate fee $1290 ___________
(Thereafter)
q Exhibition package $1990 ___________
(includes exhibition space
and 1 delegate space)
Total: ___________
Method of Payment
Payment terms are NET 30
q By Check: In US Dollars ($), made payable to
Applied Market Information LLC
q Bank Transfer: Please call or email for banking
information. Note: You are responsible for any
bank charges involved with the transaction.
q Visa/Mastercard/Amex
My card number is:
Name of cardholder: ___________________________________
Expiration date: __________________ Security code:_________
Cardholders signature: _________________________________
Date: ________________________________________________
Invoice email (if different from above):______________________
Image courtesy of:
CONFERENCE HOTLINE
Ms. Christine Stelluti, Conference Manager
Applied Market Information LLC Tel: +1 610 478 0800
1210 Broadcasting Road, Suite #103, Fax: +1 610 478 0900
Wyomissing, PA 19610, USA Email: cas@amiplastics-na.com
Please make copies of this registration form for others to use or
download a PDF le copy of the brochure from our web site at
www.amiplastics-na.com
Click here for a PDF of the brochure

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