picking flame retardants for polyamides new developments in lab

Transcription

December 2012
HOW TO HANDLE HIGH-TEMPERATURE PLASTICS
PICKING FLAME RETARDANTS FOR POLYAMIDES
NEW DEVELOPMENTS IN LAB COMPOUNDERS
GETTING TO GRIPS WITH GREEN CHEMISTRY
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contents
PAGE 13
05 Industry news
The latest compounding industry news including international acquisitions and
alliances, plus new investments and plant openings.
13 Compounding heats up
High-performance plastics present challenges to compounders as processing
PAGE 21
temperatures soar to 400˚C and beyond. Jennifer Markarian reports.
21 Picking flame retardants for polyamides
Pat Toensmeier speaks with resin producers and additives suppliers about recent
PAGE 33
developments in flame retardants for nylon compounds.
33 Lab compounders: small machines for big ideas
Mikell Knights reviews the latest laboratory extruders and kneaders for
developing new formulations and for small-scale production runs.
49 Inside the green revolution
PAGE 49
Dr Sally Humphreys reports from the first Green Polymer Chemistry conference
on progress in renewable and sustainable plastics technologies.
57 New products: polymers and additives
PAGE 57
63 New products: machinery and software
66 Compounder of the month: F&D Plastics
68 Dates for your diary
coming next issue
❙ Polymer foam technologies ❙ Pelletizers ❙ Dispersants and coupling agents
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December 2012 | COMPOUNDING WORLD
3
news
China XD commissions
new compounding lines
Owens
Corning
expands
China XD Plastics is adding
Harbin and will start to
taking its extruder count to 58
Owens Corning has started
new compounding lines at its
contribute to production in the
and increasing its total annual
up new furnaces at its glass
production facility in Harbin,
first quarter of 2013. The
capacity by 90,000 tonnes to
reinforcement manufactur-
China. The company says that
company says that the capacity
255,000 tonnes.
ing sites in Gous-Khroustal-
they will increase its total
expansion is backed up by
annual production capacity by
investments in R&D equipment
technical compounds for
135,000 tonnes to 390,000
to support new product
automotive applications. It says
tonnes.
development.
that its materials are used in
both sites has been more
China XD focuses on
ny, Russia, and in Tlaxcala,
Mexico.
Production capacity at
In December 2011, China
components for 23 automobile
than doubled and the new
installed at three newly built
XD added 20 new compounding
brands manufactured in China,
furnaces will be used to
plants within China XD’s
lines that came on stream in
including Audi, BMW, Toyota,
produce corrosion-resistant
Number 3 production base in
the first half of this year,
Buick, VW and Hafei.
Advantex glass. The new
The new lines are being
In its recently released third
Gous-Khroustalny furnace
quarter 2012 results, the
will produce roving and
company reported a 57.4%
wet-use chopped strands,
year-on-year increase in
while the extra capacity at
revenues, achieving US$163.3
Tlaxcala will be used for
million for the three months.
assembled roving and
The total volume shipped
dry-use chopped strands.
during the period was 61,589
Owens Corning has also
tonnes, while gross profit was
recently opened its new
US$40.4 million, representing
China Composites Center in
year-on-year increases of
Shanghai to provide local
China XD’s compounds are used by 23 car manufacturers in
57.7% and 50.9% respectively.
R&D support and expertise.
China, including BMW
❙ www.chinaxd.net
❙ www.ocvreinforcements.com
Songwon reveals one-pack plant location
Songwon Additive Technolo-
“This is a very important step
gies and Polysys Industries
for Songwon in the develop-
have announced plans to build
ment of our global OPS
an antioxidant OPS (one-pack
footprint following the acquisi-
systems) manufacturing plant
tion of Additive Technologies
in Kizad, Abu Dhabi. It will
Greiz and the capacity expan-
have an initial capacity of 7,000
sion which has already been
tonnes and is expected to be
implemented [in Germany]. The
completed in late 2013.
Middle East already represents
a key market for OPS and
The two companies are
polymer stabilizers and we
forming a new venture Polysys
Additive Technologies to
Left to right: Khalid Al Hamdan, MD of Pan Gulf; Maurizio Butti,
expect this position to grow
construct the facility. The
COO of Songwon; and Mohamed Al Muhairi, chairman of Polysys
significantly in the near future.”
Songwon Additive Technolo-
announcement follows the
formation of Songwon Additive
Company of Saudi Arabia and
Technologies, a joint venture
Polysys Industries of Abu
between Songwon of South
Dhabi for the manufacture and
Korea, Pan Gulf Holding
sale of Songnox OPS (see
www.compoundingworld.com Compounding World, Nov
2012: http://bit.ly/songwon).
Maurizio Butti, Songwon’s
chief operating officer, said:
gies also plans to build an OPS
plant in the USA, but has not yet
confirmed its location or timing.
❙ www.songwonind.com
December 2012 | compounding world
5
news
FBW adds two Coperion lines
FBW has installed two new
FBW has added two Coperion STS 35 extruders
that offered a good price-per-
Coperion STS 35 Advanced
to increase masterbatch production
formance ratio. We found that
twin-screw extruders at its
all these requirements were
compounding plant in
more than met by Coperion’s
Niederzier, Germany. They are
STS advanced series.”
being used to produce colour
Coperion’s STS extruders
and additive masterbatches in
are developed at the com-
small- and medium-sized
pany’s main production site in
batches from 25 to 300 kg.
Stuttgart, Germany, and are
The extruders are equipped
manufactured at its Chinese
with 35 mm diameter screws
factory in Nanjing. This, says
and feature Coperion’s new STS
the company, enables it to
Masterbatch die head, which
provide “a high-performance
can be quickly opened for rapid
compounding system at
cleaning. An easily exchange-
relatively low investment
able breaker plate permits
FBW’s managing director
selection: “Our aim was to
costs”.
filtering of the masterbatch
Gerd Cornils explains the
invest in two flexible, easy-to-
melt using insert screens.
reasons for the extruder
use masterbatch machines
❙ www.fbwgmbh.de
❙ www.coperion.com
Albemarle
invests in
FR plant
Masterbatch Verband,
Germany’s masterbatch
industry association, elected a
new board at its general
Albemarle has announced
meeting in Frankfurt on 23
plans to expand its
November. Erhard Naumann of
manufacturing operations
Lehmann & Voss was re-elect-
at Orangeburg, South
ed chairman, and he is joined
Carolina, USA. It is
on the board by Dr Martin
investing a total of US$65
Fabian of Lifocolor and Bernd
Masterbatch Verband’s new board (left to right): Erhard
million over five years at the
Schäfer of Deifel.
Naumann, Dr Martin Fabian and Bernd Schäfer
facility and expects to add
20 new jobs.
The expansion plans
The association is part of
the broader pigments
leading masterbatch makers in
chemicals legislation, in
organisation, Verband der
Germany.
particular regarding the
classification of pigments and
include a new plant for the
Mineralfarbenindustrie (VdMi).
production of the company’s
It has 19 member companies
discussed its members’
inconsistencies in information.
GreenCrest high-molecu-
and says that it represents the
concerns about REACH
❙ www.masterbatchverband.de
lar-weight polymeric flame
retardant. This is designed
to gradually replace
6
Masterbatch group elects board
At its general meeting it
Pantone picks Emerald as the colour of 2013
hexabromocyclododecane
Pantone has named Emerald as its “colour of the year” for 2013.
(HBCD) for use in extruded
It describes the colour – Pantone 17-1463 – as a “lively, radiant,
(XPS) and expanded (EPS)
lush green”. The company, which is a division of X-Rite and
polystyrene applications.
provides professional colour standards and forecasts, says that
Albemarle plans to
green is the colour of growth, renewal and prosperity. It adds that
commercialise the new
the prevalence of green has been steadily rising for several
technology in 2014.
seasons, especially in the fashion and couture markets.
❙ www.albemarle.com
❙ www.pantone.com
compounding world | December 2012
TIME
TO IMPROVE
YOUR IMPACT
RESISTANCE?
New Jetfine® optimizes the rigidity/impact
strength balance of exterior automotive parts
Polypropylene bumpers and fenders need to be tough to meet
increasingly stringent specifications in the automotive industry.
With their high aspect ratio and ultrafine grind, Jetfine® talcs:
• achieve very high impact resistance requirements for high-flow resins
• lower the CLTE for zero gap parts
• increase stiffness
• are compacted for easy handling
www.imerystalc.com
plasticstalc.americas@imerys.com
news
BASF starts up additive
blends plant in Bahrain
Foster to
expand
in Asia
BASF Plastic Additives has
Foster, the US-headquar-
begun production of customer
tered compounder special-
specific antioxidant blends
ising in medical and drug
(CSB) at its new plant in
delivery applications, is
Bahrain. It says that it is the
establishing an office in
largest facility of its kind
Belgaum, India to offer
worldwide.
technical service and
The new plant, which uses
product development
proprietary CSB technology,
support to customers in
will provide local supply and
Asia. The office will be
services to the fast growing
headed up by Amar
polymer market in the Middle
Nilajkar, who has a degree
East. Its production is in
Michael Heinz (far left) is joined by BASF colleagues and Bahrain
in polymer engineering
addition to BASF’s existing
officials at the opening ceremony for the CSB plant
from the University of
CSB manufacturing agreement
Massachusetts at Lowell,
with Astra Polymer in Saudi
board member Michael Heinz
the Middle East, while at the
and has been with the
Arabia, which was extended
said: “BASF’s investment in
same time setting standards
company for 10 years.
earlier this year.
this new site demonstrates our
with regard to quality, safety
steadfast commitment to
and employee training.”
increase in catheter device
support growing industries in
❙ www.basf.com
manufacturing in the Asia
Speaking at the plant’s
opening ceremony, executive
According to Foster, the
Pacific region has resulted
Evonik goes phthalate-free
in sales growth of nearly
300% for the company’s
medical polymer com-
tradename. Start-up of the
pounds. In addition, the
enter the phthalate-free and
phthalate-free plasticizer
new facility is scheduled for
pharmaceutical industry in
bio-based plasticizer market,
1,2-cyclohexane dicarboxylic
the second half of 2013 and the
India has shown a strong
and it is building a new 40,000
acid diisononyl ester, a
company says it will be
interest in Foster’s
tonnes/year production facility
chemistry which is already
followed by the launch of
expertise in blending active
at the Marl Chemical Park in
produced and sold by BASF
bio-based plasticizers.
pharmaceutical ingredients.
Germany.
under the Hexamoll DINCH
❙ www.evonik.com
❙ www.fostercomp.com
Evonik has announced plans to
The plant will produce the
APS Compounding exceeds production goals
APS Compounding, which started up in Romulus, Michigan, USA
just over a year ago, has produced its first 500,000 lbs (230
tonnes) of thermoplastic elastomer (TPE) compounds.
The company’s principal, Stephane Morin said: “We actually
exceeded our goal to reach the half million pound mark in the
first year”.
APS Compounding was established by the polymer distributor
Alliance Polymer & Services in 2011 and it operates two twinscrew compounding lines. The parent company distributes BASF
Elastollen TPUs and Polymax Maxelast SBC-based TPEs and it
wanted to add the ability to tailor custom grades.
❙ www.apscompounding.com
8
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news
CREATING TOMORROW’S SOLUTIONS
Above: Luxus has installed 12 new silos to increase storage
capacity at its Louth plant. Below: Luxus will use its new line to
develop formulations based on recycled and prime resins
Luxus expands
capabilities
UPGRADE
YOUR
PERFORMANCE!
Luxus has installed a new
compounding line for research
and development projects at its
plant in Louth, Lincolnshire, UK.
The line includes a Coperion
STS twin-screw extruder, a
Brabender loss-in-weight
feeding system and an
Automatik strand pelletizer.
Luxus produces thermo-
Terry Burton, technical
plastic compounds based on
Manager at Luxus, said: “Our
prime and recycled feedstocks
specialist interior automotive
at the site, which currently has
business in particular will
a production capacity of 30,000
benefit from the new line. Client
tonnes/year. Target markets
samples will be processed on
include the automotive, retail
the machine and then increased
logistics, wheelie bin and
to full-scale production in just a
construction sectors.
single rapid step”.
The new development line
Speaking about the
is part of the company’s new
selection of the Coperion
technical centre which is
extruder, Burton added: “We
scheduled to be fully opera-
were impressed with the
tional in February 2013. It will
overall quality of the machine,
be used to develop new
its flexibility and the support
formulations and optimise
that’s offered”.
existing grades based on PC,
Luxus has also recently
ABS, PC/ABS, PA, PP and PE.
taken delivery of 12 new 80 m3
In addition, it will assist with
silos at its Louth facility,
the recycling of increasingly
boosting storage capacity from
complex waste streams to
125 tonnes to 700 tonnes.
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High-temperature compounding | processing feature
The growing use of high-performance
polymers presents many challenges to
compounders as processing
temperatures soar to 400˚C and
beyond. Jennifer Markarian reports
Compounding
heats up
There is growing interest in very high performance
high melting points, such as those listed in Table 1, is
plastics, typically for the replacement of metals in ever
getting the extra heat into the polymer to melt and mix
more challenging applications. Polymers such as
it, and subsequently removing the heat to cool and
polyetheretherketone (PEEK), polyetherimide (PEI) and
pelletize the material.
polysulphone (PSU) are being specified in critical
Techniques to meet these challenges include using
components to withstand extreme conditions in the
high-wattage heaters, improved insulation, efficient
electronics, medical, automotive and chemical process-
cooling systems, and designs with good heat transfer. In
ing sectors, for example.
addition, temperature sensors must be designed to
Incorporating the required reinforcements, additives
and colorants into these high-temperature polymers
measure high-temperature ranges.
Standard grades of PEEK, for example, require a
presents significant challenges to compounders.
minimum processing temperature of about 400°C
High-temperature compounding is more demanding in
(750°F), notes Richard Leibfried, market development
every aspect. It has implications for the extruder design
manager for Victrex Polymer Solutions. The company’s
and its materials of construction, as well as requiring
higher-temperature versions of PEEK (HT and ST
tighter process control, more precise pelletizing, careful
grades) require a minimum capacity of 430°C (800°F).
compound formulating, and a rigorous approach to
Leibfried recommends ceramic heating bands and notes
cleaning and maintenance.
that the insulation of bare metal helps dramatically.
Twin-screw extruders are generally used, and longer
Equipment design
length/diameter (L/D) ratios are typically employed to
The basic challenge of compounding polymers with very
enable adequate melting and mixing. Longer extruder
Table 1 - Typical melting points of high-performance polymers
Resin
Amorphous resin
glass transition temp (°C)
Crystalline resin
melting point (°C)
Polysulphone (PSU)
190
-
Polyetherimide (PEI)
215
-
Polyethersulphone (PES)
220
-
Polyphenylene sulphide (PPS)
-
285
High-temperature nylon (HTN) or polyphthalamide (PPA)
-
300-330 (depending on grade)
Polyetheretherketone (PEEK)
-
345
Liquid crystal polymer (LCP)
-
325-400 (depending on grade)
Source: Solvay Specialty Polymers
13
processing feature | High-temperature compounding
Entek says that
lengths also allow more flexibility in downstream
materials used
feeding and venting zones. Screws and dies must be
in extruder
parts need to
meet the high
designed to minimize dead-space, because any material
caught in a dead-spot will quickly degrade.
Materials of construction should also be considered.
temperature
If a process is run hotter than the tempering tempera-
requirements
ture of the metal, the metal could lose hardness, which
could result in premature wear, comments Craig
Benjamin, design engineer at Entek Extruders. The
process used to heat-treat or temper the metal must be
changed in order to adjust the temperature at which the
metal maintains hardness. Corrosion can also be
amplified at higher temperatures, and the corrosionresistance of extruder materials should be considered,
adds Benjamin.
KraussMaffei Berstorff makes twin-screw extruders
with heat-treated steel designed for processing up to
420°C (790°F), or with a special design that allows
processing up to 450°C (840°F). Barrel elements with a
special heating and cooling system provide direct and
intensive heat transfer or cooling, notes Dr Thomas
die head and sometimes additional heating of the die
Winkelmann, head of the processing department for
plate to achieve a common temperature distribution and
twin-screw extruders at the company.
permit stable material flow out of the die. In addition,
The extruder’s barrel housings are designed to
increase the heating performance in the barrel section
by using more heating cartridges and by reducing the
screw designs are chosen to add thermal energy by
optimizing shear stress without degradation.
Because processing windows are typically narrower
distance to the processing chamber. This barrel design
with higher-temperature processing, there is a finer
can deliver up to 50% more heating power compared to
line between melting and degradation. Screw designs
the standard version, which ensures that the required
are thus targeted for different materials and different
processing temperatures are reached quickly, reliably
grades to balance shear and dispersion for that
maintained and exactly controlled, says Winkelmann.
formulation. “Operators must be aware that different
In addition, the barrel sections and strand die heads
grades are set up differently,” notes Glenn Desio,
have insulating plates to limit heat losses and decrease
technology manager for crystalline polymers at Solvay
heating energy consumption. The optimized layout of
Specialty Polymers.
the cooling bores provides high-efficiency, counter-flow
Additives used in high-temperature formulations
cooling with standard injection of water. Using a strand
must be chosen to withstand the higher processing
pelletizing system requires high-power heating of the
temperatures. Matching colours can be challenging,
KraussMaffei
notes Desio, because the colours must be both stable
Berstorff has
during compounding and the right colour match at room
developed
temperature and the application’s use temperature.
barrel hous-
Colorants are generally limited to inorganic pigments,
ings that
adds Leibfried. There are few restrictions, however, on
significantly
inorganic fillers and fibres, and a wide range, including
increase
nano-fibres, are used. Kevlar and other aramid fibres
heating
can be temperature sensitive, so care must be taken
capacity
when using these, says Leibfried.
Pelletizing high-temperature polymers presents
challenges as well, plus extra care must be taken
because customers expect high pellet quality from
these high-value materials.
Strand pelletizers have been the traditional choice
for high-temperature resins. However, they typically
need more space for such applications because they
14
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This BKG
require a longer distance to cool down from a high
underwater
temperature. Cooling with a spray mist and an air belt
pelletizer has
is an alternative to a water bath that has been found to
and screen-changer assembly must be designed to
an insulated
work well in Entek’s processing lab, notes Dean Elliott,
operate at higher temperatures using insulation,
closed water
laboratory manager at Entek Extruders.
specially designed hydraulic cylinders, and cooling for
system to
Trained maintenance personnel are important
the die, which prevents die freezing.
In addition to die-plate design, the entire pelletizer
some parts.
handle high-
because thermal expansion during processing changes
temperatures
the gaps in the pelletizer, notes Desio. There is a narrow
pelletizer supplier Gala Industries, says that the
window of optimal temperature, knife-blade speed, and
company’s Heat Flux Die Plate technology combines
roll pressure needed to make good pellets, he adds.
surface-insulation methods and manufacturing
While strand systems are widely used, die-face
Mark Tate, technical manager for underwater
techniques to reduce or eliminate die-hole freezing, and
pelletizers can now also be used due to technology
can therefore be used to pelletize high-temperature
advances in die-plate design, and suppliers note an
polymers.
increased interest in underwater, die-face systems for
processing high-performance resins.
Pelletizing high-temperature resins using underwa-
He notes that another possible concern when using
underwater pelletizing for high-temperature compounds is the resulting hot process water; Gala uses
double-insulated tanks to ensure operator safety.
systems, says Ralf Simon, managing director at BKG, a
Today’s systems from Gala come standard with coil
supplier of underwater pelletizer systems. The
heaters, which are more energy efficient than earlier
die-plate must be designed to minimize heat loss and
cartridge-heater technology and have improved conduc-
maintain a good temperature distribution in the plate,
tivity of heat into the die. “We have seen 30-60%
and must be made of steel designed for higher
reduction in energy use, which is particularly a benefit
temperature use. Insulation can be used to keep heat in
when running higher temperatures,” says Tate.
▲
ter, die-face pelletizers requires specially designed
BKG demonstrates
the improved
temperature
distribution of a
die with thermal
insulation (right)
compared to one
without (left)
16
COMPOUNDING WORLD | December 2012
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Preventive maintenance is crucial for high-temperature processing because there is less tolerance in all
aspects of the process. Because the cycle from room
temperature to processing temperature is more
extreme, expansion and contraction of metal parts is
also more significant, and regular maintenance should
be done at shorter intervals.
This maintenance should include tightening barrel
bolts, checking alignment, and checking that elements
on the screw shaft are tight, says Entek’s Benjamin. If
gaps develop between the screw elements, polymer
could leak through onto the shaft, which would make
pulling the screw more difficult. “These are all maintenance items that processors should normally do, but
they may need to be done more frequently,” he
Above: Gala
says that
mechanical
seals require
less maintenance and
endure faster
speeds and
higher
temperatures
He adds that another technology that is
beneficial for high-temperature
processing is a mechanical seal to
prevent water from entering the
Right: Gala’s
Cleaning is also important. While
standard, commercial purge
compounds may not work well in
pelletizer motor. Compared to radial
high-temperature processes, a few
shaft or lip seals, mechanical seals
high-temperature purge com-
require less periodic maintenance
pounds are available. For example,
and better endure faster speeds and
higher temperatures, says Tate.
While everyone wants to minimize
downtime, it is particularly important to
Heat Flux Die
recommends.
reduce the polymer wasted during downtime
Sun Plastech’s Asaclean purging
compound comes in high-temperature grades. Asaclean SX is designed
to clean in the temperature range of
300-390°C (570-735°F). Asaclean PX is
when running expensive engineering resins, comments
designed to clean at temperatures up to 420°C (788°F)
Tate. He claims that Gala’s EAC (Electronically Ad-
with low levels of smoke and processing odour. Some
vanced Cutter) technology increases uptime and
use neat resin as a purging compound between
reduce or
reduces blade and die-face wear. The system incorpo-
different grades of that resin.
eliminate
rates automated blade advance, periodic blade
Plate is
designed to
die-hole
freezing
sharpening, and blade monitoring.
Underwater pelletizers have an advantage for
When making extreme colour changes, the most
effective technique is still to pull the screw and clean it,
says Solvay’s Desio. With PEEK in particular, adds
high-temperature resins with low viscosities that can
Berstorff’s Winkelmann, mechanical cleaning of screws
cause problems when trying to draw a strand. “The
and barrel borings is necessary.
temperature difference from the molten material to the
It takes special training and care to clean and
cooling water, which is at 80-90°C in these applications,
operate a high-temperature processing line. Not only is
creates a skin around the molten material, and
it hot, but there can be a fire risk because processing
low-viscosity materials are then easy to cut,” notes
can be close to the auto-ignition temperature of
BKG’s Simon.
materials. Operators must be comfortable working with
Underwater pelletizers are closed systems, which
high-temperature equipment and must take appropri-
can be an advantage compared to open, strand systems
ate precautions. Training and documentation of
for some materials in which evaporation of volatile
procedures are critical.
components may be an environmental risk. Underwater
systems also offer the general benefits of throughput,
Click on the links for more information:
automation, and a smaller footprint.
❙ www.asaclean.com
❙ www.bkg.de
❙ www.entekextruders.com
❙ www.gala-industries.com
❙ www.kraussmaffei.com
❙ www.solvayspecialtypolymers.com
❙ www.victrex.com
Underwater systems are broadly used with polyamides, and are increasingly used with PEEK, PPS, and
PSU, for example. Some grades of LCP have been run
successfully in small-scale and larger commercial
systems, but other grades of LCP remain a challenge,
note suppliers.
18
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Flame retardants | additives feature
Pat Toensmeier speaks with resin producers and additives suppliers
to find out the latest trends and technical
developments in flame retardants
for polyamide compounds
PH
OT
O:
A2
M
AC
1
AU
TO
M
OT
I
VE
BE
NC
HM
AR
KI
NG
Picking flame
retardants for
polyamides
Polyamides are widely used in high-volume markets
smoke and corrosion, have minimal effects on electrical
Invista supplies
such as the automotive, electrical, electronics, appliance
properties, maintain high-temperature stability and are
an FR grade of
and industrial sectors. Like all engineering thermoplas-
compatible with colours.
tics, polyamide (PA) formulations are continually
Torzen PA 66
Many companies are also looking at innovative
tweaked to enhance properties and performance for
co-flame retardant combinations, which along with the
changing applications and regulatory needs.
use of synergists such as boehmites (an aluminium oxide
One critical formulation area for PA is flame-retard-
benefit is that “flow is not as greatly affected” during
are working with FR suppliers on a range of additive
moulding, extrusion or compounding, explains Hanley.
temperatures and end-use environments also affects
cost. Almost all new FR grades are free of halogens and
FR chemistries. “There is a lot of work underway in
bromines, which are effective and economical, but for
non-halogenated chemistries, mostly for flame
regulatory and environmental reasons are being phased
retardants based on phosphorous or nitrogen-contain-
out of many applications.
ing materials,” says Richard Wenger, technical product
In their place, additive suppliers and resin producers
properties of PA formulations, including those that use
reinforced grades. Other considerations include FRs
that do not migrate during processing or use, have no
affect on part colour, and importantly, do not impede
processing or contribute to machine corrosion from
release of by-products.
Melamine compounds, alkylphosphinates, phosphorus
derivatives and metal hydroxide are among the leading
materials that are being specified in PA grades for flame
fuse box
Maintaining thermal stability in higher processing
ments while minimizing trade-offs in performance and
are seeking alternative FRs that do not affect the
508 relay and
hydroxide), achieve properties at lower loadings. The chief
ant (FR) additives. Resin producers and compounders
chemistries to meet shifting fire and toxicity require-
for this Peugeot
manager for the PA 6 business of DSM, which also
produces PA 46. “At elevated temperatures low-level
Densely packed
circuit boards
that use
high-heat
lead-free
soldering
demand
upgraded FRs
retardance, says Steve Hanley, product development
manager for engineering plastics at PA 6 producer BASF,
which also makes FRs. These chemistries are compliant
with international regulatory standards, yield low levels of
21
additives feature | Flame retardants
This micro
switch is
moulded using
BASF’s
breakdowns can occur that generate phosphoric acid
and other signatures. A lot of suppliers are working at
the molecular level or with additives to mitigate the
release of acidic by-products.”
Ultramid
A3U40G5 25%
glass-reinforced PA 66
Evaluating chemistries
In interviews, resin and additive producers discussed
materials that are gaining ground in FRs. Vikram Gopal,
technology and product marketing director at PA 66
resin and compounds producer Invista, focused on four.
Melamine cyanurate, versions of which contain
nitrogen, is good where requirements include a UL94
V-0 rating, comparative tracking index (CTI) above 500
volts, and coloured parts. Melamine cyanurate, Gopal
says, produces “intumescent and runaway effects” that
not surprisingly, corrosive smoke.
Other chemistries include three cited by BASF:
remove fuel from a fire. The material, which is also
melamine polyphosphate, which contains nitrogen;
economical, is generally limited to unreinforced resins.
nitrogen/phosphorous compounds; and magnesium
Aluminium diethylphosphinate, a metal phosphinate
used with synergists, is similar in performance to
hydroxide.
Martin Klatt, head of plastic safety and regulatory
melamine cyanurate but uses solid-phase charring,
affairs at BASF, discussed these at AMI’s Fire Retard-
which minimizes fuel supply, for flame retardance.
ants in Plastics conference in Denver, CO, USA, last
Gopal notes, however, that the chemistry increases
summer. He indicated that like any additive, selection of
corrosion in processing equipment and lowers mechan-
FRs involves trade-offs. Magnesium hydroxide, for
ical properties compared with retardants such as red
example, has high thermal stability, good electrical
phosphorous and brominated polystyrene.
properties, low smoke density and colour neutrality in
Red phosphorous FRs meet UL94 V-0 standards and
CTI is in the range of 450-550 volts. The material uses
parts. But it requires relatively high loadings, is high in
density and affects mechanical properties.
Engine
charring and gas-phase scavenging (oxygen limitation).
components,
Red phosphorous is limited to black parts due to its
owing in part to the inherent flame-retardant properties
such as this
colour incompatibility, is difficult to process as a result
of the former. Nitrogen/phosphorous compounds, which
thermo-switch
of corrosiveness, and poses a safety risk from phos-
BASF supplies in 25% glass fibre-reinforced grades of
control module
phine emissions in processing.
its Ultramid PA 66, provide good toughness and
moulded using
While brominated materials are no longer specified
Some chemistries work better in PA 66 than in PA 6,
electrical properties, and have no colour issues, Klatt
Invista PA 66
in certain applications, they remain viable in parts
said, though trade-offs include high loadings and
for the Audi A7,
where they can still be used. Gopal says that FRs based
processability issues.
must resist
on brominated polystyrene and synergists are especially
increasingly
effective. The chemistry uses gas-phase radical
options. FRX Polymers developed phosphorous-based
high continu-
scavenging to minimize oxygen and reduces the
polymeric formulations for PA 6. Maggie Baumann,
ous-use
intensity of exothermic reactions. Trade-offs include a
marketing adviser, says the material, called Nofia, uses
temperatures
low CTI, high specific gravity, high smoke density and,
a catalyst and two monomers, bisphenol A and dimethyl
Suppliers also tout innovative chemistries as FR
Photo: A2Mac1 Automotive Benchmarking
phenyl phosphinate, to form under heat and pressure a
homopolymer of polyphosphinate. The homopolymer is
combined with diphenyl carbonate and building blocks
to produce a polymeric FR.
Nofia is used at loadings of 10-20%, or as a copolymer at loadings of 20-50%. “An end-user can replace a
copolymer with our material,” Baumann says.
Benefits include permanent flame retardance.
“Because it’s in polymeric form, there is no migration”
of component materials, she explains. Nofia grades are
processable – they have high melt flow and high melt
strength, and thus “can be extruded or injection
moulded without dramatically rebuilding a polymer.”
22
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Importantly, the grades deliver a UL90 V-0 fire rating in
thin-wall parts. Since it is based on phosphorous, the
material generates low smoke. It is transparent, and
has no toxic by-products, Baumann adds.
Photo: rhodia
Flame retardants | additives feature
When micro
circuit breakers
are moulded in
light colours it
Nyco, a producer of wollastonite mineral reinforce-
restricts the
ments, is offering the material as a way of extending
use of FR
properties of FRs. “I’m not sure if it would reduce the
additives to
need for a flame retardant, but could be feasible as a
colour-compat-
partial substitute,” says Gary Phillips, vice president of
ible chemistries
marketing and application development.
One reason is that wollastonite fibres have a high
melting point of 1,540°C. Phillips says that when the
fibres are silanated for resin compatibility, “a tight fibre/
resin matrix” develops, which extends FR properties
and increases structural strength. The company’s
Nyglos wollastonite fibres are acid scavengers that slow
polymer degradation in a fire. They can help achieve
UL94 V-0 ratings in some applications, he adds, and
meet UL94 V-1, 2 or 3 in others.
The fibres replace milled glass and 10-15% of
chopped glass in reinforced PA. When replacing milled
fibres are about one-third less expensive than most
conventional flame retardants, Phillips says.
A well-established technology for coupling agents
glass, they reportedly improve surface appearance in
could be an option for increasing loadings of FR
parts. Three grades are available: Nyglos 12 is 195
additives without affecting processing. Kenrich
microns long and 15 microns in diameter; Nyglos 8 is
Petrochemicals offers the titanates and zirconates it
156 microns long and 12 microns in diameter; and
supplies as coupling agents for use with conventional
Nyglos 4W is 63 microns long and 7 microns in diameter.
FRs, to increase their loading and performance.
Targets include under-the-hood electrical connec-
According to Kenrich president Salvatore Monte, the
tors. A high-temperature additive applied to the fibres
company’s Ken-React organometallic coupling agents
enhances thermal stability for such applications and
“proton coordinate to form 1.5-nanometer atomic
resists scorching during compounding. Nyco says that
monolayers on the flame retardant/filler particulate/fibre
the fibres recrystallize rapidly with chopped glass,
surface, as well as catalytically react with the polymer to
which improves cycle times.
change morphology and flow.” As a result, the monolay-
One benefit apart from their properties is price – the
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A nitrogen/phosphorous FR compound
business director for the fire resistance business unit of
was specified for this UL94 V-0
Rhodia, a resin producer (mostly PA 66) and compound-
generator cover moulded
er that is part of the Solvay Group. Mitchell highlights
by Bosch using PA 66
the difficulty of working with a wall thickness of 0.4 mm
from BASF
by saying that such a material is virtually film.
There is also the ongoing issue of reducing cycle
times, which raises performance questions. “Faster
cycle times demand faster crystallization capability [in
polyamide] while maintaining good dimensional
tolerance,” remarks Invista’s Gopal. FR additives must
be tailored for these changes as well.
Many of these challenges impact other applications.
In automotive, greater under-the-hood use of engineering PAs and higher underhood temperatures generated
by small, fuel-efficient engines raise performance
requirements of FRs. Similarly, the use of PA in
high-voltage components of electric and hybrid
vehicles, such as batteries, power electronics and other
retardant, ridding the matrix of water and air voids and
types of electric vehicle specialty equipment (EVSE),
creating a continuous phase”. This is said to dramatically
raises heat, mechanical and other performance
lower compound viscosity, thereby “reducing resin
requirements for additives.
demand for a given pigment-to-binder ratio.” The chief
BASF’s Dombrowski says that while automotive
benefit, Monte notes, is that more flame retardant can be
components have typically been rated at UL94 HB, “we
added without sacrificing processability.
will continue to see more applications requiring UL94
Monte states, for example, that “when 50% melamine
V-2 or V-0 flammability ratings due to the introduction
cyanurate is dispersed in mineral oil, the in-situ addition
of high-voltage components.” Additional concerns
of 0.7% Ken-React KR 238NF” reduced Brookfield
include the interaction of FR additives with UV stabiliz-
viscosity to 30,000 cps at 25°C from 1.6 million cps.
ers, since EVSE components such as vehicle chargers
have significant outdoor exposure.
Impact of product trends
Market trends influence additive formulations. Among
The green influence
the most significant are the downsizing and miniaturi-
Environmental considerations play an ongoing role in
zation of electrical and electronic devices. As parts
FR chemistry, as OEMs continue to move away from
become smaller, thinner and more densely packed in
halogens in formulations. Specifying a flame retardant
assemblies, FR additives must meet challenging fire
chemistry for PA is sometimes helped by the inherent
and smoke requirements, as well as resist arcing and
properties of the polymer. PA 66 has inherent UL94 V-2
short-term bursts of electromagnetic energy, maintain
performance, and is generally credited with outstanding
dielectric strength, and withstand high continuous-use
tensile strength at elevated temperature and good
temperatures and heat aging. Where higher-heat
processability, both of which aid in finding compatible
lead-free soldering is used for regulatory reasons in
FRs and facilitating product development. Some resin
circuit boards and other applications, FR additives must
producers are tweaking PA 6 formulations to improve
maintain properties without decomposing.
mechanical properties such as modulus, bringing the
“Like everything else in the electronics industry,
form factor is becoming smaller,” says LeeAnn
Dombrowski, electrical and electronics market segment
broadens additive selection.
Importantly, regulation of FR additives is becoming a
manager at BASF. “As a result, FR additives have to be
global standard. OEMs and other manufacturers don’t
even more effective than before, as flame resistance
need to worry about complying with different regulatory
has to perform the same but with thinner cross
rules when specifying FRs. “Flame retardants is the
sections. Materials for connectors in the appliance
only fully global business in engineering polymers,”
segment are now looking at glow wire certifications at
says Rhodia’s Mitchell. “The regulatory standards in
0.4 mm thickness versus 0.75 mm previously.”
China are as high as in Europe and elsewhere. A lot of
This is the new normal for many electrical and
electronic parts, affirms James Mitchell, global
26
stiffness of grades near that of PA 66, which also
what’s produced in one country is shipped around the
world. There is no need to reinvent the wheel when it
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helping to improve FR properties and processability.
Work is also underway to reduce moisture uptake and
increase the dimensional stability of FRs. These properties are important in thin-wall electrical parts used in
humid environments. An example is the new Technyl
XA1426, which is extending PA use by reducing moisture
uptake 40% in a 30% glass-reinforced UL94 V-0 grade.
BASF recently added Ultramid A3U40 G5, a 25%
glass-filled PA 66, which achieves a V-0 rating at 0.4
mm wall thickness and is glow wire-certified. Developed for household appliances, connectors, low-voltage
switchgear and railway applications, it has high flow,
can be fabricated in complex shapes, and exhibits low
smoke toxicity and density.
Also new is Ultramid B3U30G6, a 30% glass-filled PA
Clariant has
comes to flame retardant additive use in products.”
6 for similar applications and miniature circuit break-
doubled Exolit
“Green is reality,” Mitchell adds, noting that
ers, which are popular in Europe. It has high modulus
FR capacity at
European initiatives such as RoHS (restrictions on
(similar to PA 66), is compatible with light colours, and
its Hürth-
hazardous substances) and other standards are
achieves UL94 V-2 at 0.8 mm.
Knapsack plant
enforced in much of the world.
to meet
One coming trend will be development of FR
Invista formally launched an FR portfolio in October
at Fakuma in Germany. Based on its proprietary Torzen
burgeoning
additives for recycled PA resins. Mitchell and others
Marathon process technology, the materials reportedly
demand for
report that customers are asking about reclaim as a
provide 30°C higher continuous-use temperature than
non-halogenat-
matter of sustainability, and Rhodia and other resin
conventional PA 66 resins and 40-50% greater flow.
ed products
producers say they are working with formulations that
DSM recently launched Stanyl grades SC50 and
incorporate some recycled PA. But there are challeng-
MC50. Target markets include integrated and miniature
es. One is getting FRs certified for use with recyclate;
electronics. Both are glass-reinforced. Grade SC50 has
another is assuring the integrity of reclaimed resins.
a UL94 V-0 rating, and MC50 is UL94 V-2. The materials
“We can source recycled materials,” Mitchell remarks,
have high-flow properties, thin-wall strength, and meet
“but contaminants and UL certification are problems.”
glow wire ignition temperature requirements.
Suppliers are commercializing FRs that meet
On the additives front, Clariant has been investing to
demands for improved performance, stability and
meet the fast growing demand for its Exolit OP non-
processability. Following are representative examples,
halogenated organo-phosphorous flame retardants
all non-halogenated.
which are used in PA formulations. In October, the
Rhodia is working on polymer technologies that
company opened a second production line for the additive
significantly reduce FR loadings to enhance processing
at its plant at Hürth-Knapsack near Cologne in Germany.
and mechanical performance of PAs. One example is
The new line doubles the site’s total capacity for FRs
the new Technyl alloy AT20 V25, based on red phospho-
based on DEPAL (diethyl phosphinic acid aluminium
rus, which substantially reduces FR concentration while
salt). The company says that the expansion was driven by
Applications for Exolit OP include switches, plugs,
PC fans, and structural and housing components.
Smartphones, washing machines and airplane parts are
among the wide range of products that contain the
product.
More information
AMI’s Fire Retardants In Plastics conference is being
held in Denver, Colorado, USA on 13-14 June 2013.
The programme features speakers from Sony, BASF,
FRX Polymers and many more. For details, visit
http://bit.ly/FRP2013, or contact Kelly Cressman:
+1 610 478 0800, kc@amiplastics-na.com.
Target markets
the growing demand for halogen-free flame retardants in
Click on the links for more information:
for Clariant’s
the electronics and electrical engineering market.
❙ www.basf.com
❙ www.dsm.com
❙ www.invista.com
❙ www.frxpolymers.com
❙ www.nycominerals.com
❙ www.4kenrich.com
❙ www.rhodia.com
❙ www.clariant.com
Exolit OP FR
“The environmental and safety awareness of our
include the
customers has increased considerably, resulting in
electronics and
growing demand for our non-halogenated flame
electrical
retardants,” says Michael Grosskopf, head of Clariant’s
engineering
additives business unit. “Key customers are indicating
sectors
that their requirements will see further strong increases in the years ahead.”
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Lab compounders | machinery feature
Mikell Knights
reviews the latest
developments in
lab-scale extruders
and kneaders for
carrying out research
work, formulation
development,
customer trials
and small-scale
production
Small machines for big ideas
Laboratory compounders continue to proliferate, from
co-kneaders. It now features new PLC controls, new
bench-top models with outputs measured in grams of
wiring and a new touch-screen interface all mounted
material through to stand-alone units that can be used
integral to the machine base making a completely
for small production runs.
self-contained system, says Michael Lazorchak, global
Machinery makers are responding to demands for
quicker machine changeovers and wider processing
product manager for mixing systems at B&P.
The model, which features a 30 mm extruder with
flexibility. In addition, they are developing lab machines
reciprocating kneader technology, is now offered in a
that are capable of handling sensitive bio-based resins,
light-duty version with 300 screw rpm and able to
higher additive loadings, or very expensive medical or
process 3-15 kg/h of HFFR (halogen-free, flame-retard-
pharmaceutical grade materials.
ant compounds); a standard 450 rpm version handles
Over the following eight pages, we review the latest
5-30 kg/h; and a heavy duty 600 rpm version is designed
lab compounder developments from B&P, Brabender,
for 10-50 kg/h. The three versions are being offered on
Buss, Coperion, Entek, Feddem, KraussMaffei Berstorff,
every model in the line, allowing for systems to be
Leistritz, Randcastle, Steer and Thermo Fisher.
cost-effective and yet custom-engineered to the
B&P Process Equipment has upgraded the controls
of its TriVolution-60 Tri-Kneader pilot demonstration
process.
B&P is planning to build its first TriVolution 30
line located at its technology centre. The 30 mm
Tri-Kneader for a customer, and will build a second unit
laboratory scale Tri-Kneader has also been commer-
for its technology centre as a demonstration model. The
cialized and B&P now offers the model in three output
company is also planning to create a bench-top
versions.
TriVolution Tri-Kneader.
The line is designed to process 80% of jobs typically
The Tri-Kneader provides three axial oscillations of
run on a twin-screw extruder, and all of the formula-
the shaft for each revolution, instead of the single
tions that can be handled by traditional reciprocating
stroke per revolution used in traditional kneaders. It
33
machinery feature | Lab compounders
screw configuration adjusted accordingly.
This method can be used to change the unit to 30:1
or 20:1 L/D. Metering or venting ports are located at
10D, 20D and 30D, with side feeding capability at 12D
and 22D.
The TSE 20/40 is offered with a 7.5 hp motor and 600
rpm screw speed, or with a 16 hp, 1,200 rpm drive. The
latter is said to process throughputs from as little at
250 g/h up to 20 kg/h depending on material.
Brabender is also developing a lower-cost bench-top
version of its KETSE 12/36 twin-screw mini-compounder, slated for release during the second quarter of 2013.
The standalone KETSE 12/36 features a 12 mm
B&P’s Tri-
features a single screw with its mixing flights interact-
diameter screw with 36D processing length and a 3.2
Kneader
ing with stationary pins on the barrel wall to provide the
hp, 600 rpm drive. Van Allen says this unit has an
provides three
required mixing interface. In traditional designs, there
updated control system that is more user-friendly and
axial oscilla-
are three or four flights providing mixing interfaces
allows for better tracking of motor load. A removable
tions of the
each time the screw rotates. B&P says that the
barrel liner is also an option.
shaft for each
Tri-Kneader can have a maximum of 12 flights interfac-
❙ www.brabender.com
revolution,
ing six times to provide up to 72 pin/flight interfaces in a
instead of the
single revolution, thus improving mixing levels.
single stroke
Lazorchak presented a paper at AMI’s ‘Minerals in
Buss has been busy this year introducing its latest MX
30 four-flight laboratory kneader at trade shows around
used in
Compounding’ conference last month in Atlanta, GA,
the world, including Wire in Germany, NPE in the USA,
traditional
USA, that illustrated the TriVolution Tri-Kneader’s
Chinaplas in China and Plast in Italy. The company
kneaders
ability to compound mineral formulations with greater
reports high levels of interest from compounders and
efficiency and control, as well as handling loadings
took orders for its first production series.
greater than 60%.
❙ www.bpprocess.com
Featuring a 30 mm diameter screw, the MX 30 is the
smallest machine in the MX range and according to
Buss is the first laboratory kneader to feature four
Brabender now offers removable barrel liners for its
flight technology. It has a maximum screw speed of 800
TSE lab-scale twin-screw extruders. This development
rpm and is rated for outputs of 5 to 25 kg/h. The
brings much shorter machine downtime and changeo-
maximum processing temperature is 280oC.
ver times, says Kevin Van Allen, vice president sales
and marketing for the company’s US chemical division.
The barrel liner, now available for its TSE 20/40 lab
compounder, reduces changeover time from two hours
to about 15 minutes. Screw swap out takes about 15
minutes, Van Allen says, adding; “Processors
Brabender is
adding
removable
barrel liners
for its TSE
lab-scale
extruders to
speed up
changeovers
and shear-sensitive polymers and for the production of
compounds with high loadings of reinforcing
materials and other fillers. It is equipped with
a discharge extruder, a pelletizer and a
running colour concentrates will find it tremen-
user-friendly control system,
dously shortens downtime.”
offering the same process
The TSE 20/40 is a
stand-alone co-rotating
unit with a segmented screw
and clamshell barrel. The
versatility as larger models in
the MX Series.
Buss says that processing
parameters obtained with the MX
standard design is a 20 mm
30 can be reliably scaled-up and
diameter screw and 40:1 L/D.
applied to larger MX kneaders
Users that require shorter
because of the lab machine’s high
barrel and screw lengths can
conveying stability and linear
sheath the first 10D of the
output-to-speed ratio. In addition
screw with a special blank
to being used as a laboratory
sleeve. The material feed device
34
Like the larger machines of the MX Series, the MX 30
is particularly suitable for the compounding of heat-
extruder for formulation and
is attached on a downstream
product development, the MX
port on the barrel and the
30 is also suitable for custom-
Buss’s new MX 30 has been
nents. “Plug and play” features help to make installa-
generating interest
tion and start-up swift, says the company.
at exhibitions
The ZSK 18 can process batches as small as 200 g
during 2012
up to throughput rates of 40 kg/hr. “It has a specific
torque of 11.3, and with its screw diameter, could be
used as a pilot production unit when you have a very
specialized product program,” says Bernd
Ormanns, business segment manager, engineering
plastics.
He adds that the ZSK 26, 32 and 34 (a high volume
version of the 32) provide enough throughput to be used
as pilot lines if a processor has a production line facing
a difficulty. Users can achieve throughput rates up to
140 kg/h depending on the formulation.
Coperion also offers a special GMP version of the
ZSK 18 Megalab for pharmacutical compounding
applications. It is completely clad in stainless steel and
is equipped with leak-proof cooling water couplings.
❙ www.coperion.com
Entek says that its entry into twin-screw extruders for
er trials and for small-scale production of a wide range
laboratory tasks, the E 27 Max, allows users to test out
of compounds.
recipes and determine if they can actually process a
❙ www.busscorp.com
formula. “Compounders are willing to try out more
expensive materials and new, complex formulations
Coperion says its ZSK Megalab line is aimed at users
because they feel the smaller machines deliver more
looking for quick changeovers and production-machine
reliable results,” says Dean Elliott, Entek’s laboratory
features in a unit that works mostly in a laboratory. Its
manager.
newest model, the ZSK Megalab 18, joins the existing
26 mm and 32 mm models in the line.
The ZSK 18 Megalab is developed especially for
Coperion’s ZSK
“Processors are pushing the envelope regarding how
much pigment, or how much additive can be used, and
they are using small volumes of more expensive
processing small batch sizes while offering features
materials for medical, military, and pharmaceutical appli-
similar to production units for scalability. It features 18
cations,” Elliott adds. “If they can produce a stable
mm parallel co-rotating intermeshing screws with a
formula it will transfer to a larger production machine.”
1.55 OD/ID screw ratio. The screw geometry
Customers are also using Entek’s lab compounders to
features feeding, mixing and kneading elements
investigate biomaterials and soluble polymers, says John
18 Megalab is
similar to those used on full-scale
Effmann, the company’s director of sales and marketing.
supplied on a
production models.
mobile base
frame,
Each barrel and screw
The E 27 Max is the smallest model in Entek’s
six-model E Max line. The unit features a 27 mm
section is 4D. The barrel has
diameter screw with 1.47 OD/ID ratio, and a choice of
incorporating
an improved heating and water
three motors and three screw speeds: 15 hp for 400
all the major
cooling system for temperature
components
control to +/- 1 C. Coperion offers
o
the Megalab models with a standard
length of 40D standard, with
options to extend the unit up to
60D. A quick-release design
1200 rpm.
The parallel, co-rotating
intermeshing twin-screw unit is
designed with a segmented barrel,
with each barrel segment 4D in
with two retaining bolts allows
length. The unit is offered in lengths
for easy removal of the screws
from 28D -52D. It can compound PE
and die-head.
The compact unit is supplied
on a mobile base frame which
incorporates all the major compo36
rpm; 20 hp for 600 rpm; and 40 hp for
pellets with colour, additives and fillers
at a rate from 20-45 kg/h with a standard
20 hp, 600 rpm drive.
Entek is developing new feed elements
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Lab compounders | machinery feature
to 150 kg/h, depending on the material
Entek’s E 27
formulation. For example, Feddem
Max is being
says that the 26 MTS can process 50%
used to develop
glass-filled PA 66 at rates of 100 kg/h,
high-cost
45% glass-filled PET at 90 kg/h, and
resins and
POM at 80 kg/h.
bioplastics
The company highlights the
versatility of the MTS line and its
ability to process a wide range of
formulations without changing the
screw configuration. “This is a
primary philosophy of the company, that a processor
Feddem has
can handle a wide variety of different compound grades
entered the
and new mixing elements that will better handle low
and recipes with one screw design, without having to
lab-scale
bulk density materials. Elliott says the new kneading
open the machine or change the screw,” says Dieter
market with
block mixing element, called the Ultimate Kneader, will
Gross, Feddem’s managing director.
improve dispersion while lowering energy consumption.
❙ www.entek-mfg.com
“With this machine we have focused on the typical
masterbatch producer or compounder with a wide
product portfolio that processes two or three formula-
Feddem extended its Multi-Task Standard (MTS) series
tions on a machine every day and
of intermeshing, co-rotating twin-screw compounders
requires changeover times as
with the launch of its smallest model at this year’s
short as possible,” he adds.
Fakuma show in Germany.
Feddem offers a multi-
The FED 26 MTS unit is designed for lab-scale to
tasking screw design for a
pilot production, and shares many design features with
wide variety of different
the four larger units in the series. The new unit has a
technical compounds, and
26.6 mm screw diameter with a 1.55 OD/ID ratio and
a different multi-tasking
typical barrel lengths of 32, 42 or 52D. The extruder can
screw design for a wide
achieve processing temperatures up to 400oC, and has
variety of different
drive power of 28 KW and screw speeds up to 1200 rpm.
masterbatches.
The unit can be used for small batch processing for
The MTS line employs
material development, processing just 1 to 3 kg of
specially designed melting
material if required. Throughput rates range from 10 up
and mixing elements on its
the FED 26
MTS machine
KraussMaffei
standard screw that eliminate the requirement for a
Berstorff’s new
kneading block. The allows for processing of a wide
KMD 35-26/L
can be used to
develop recipes
for PVC pipe,
profile or sheet
variety of materials with one screw design.
Compared to a classic kneading block based
configuration, there is much less shear with Feddem’s
screw design and more mixing is used to heat up the
material. “We use more heating energy than shear
energy; there are more mixing elements in a given L/D
versus a conventional twin-screw compounder,”
explains Gross. He claims that the combination of
lower shear and extended mixing zones delivers a
better resultant mix, and can also help to retain
longer glass fibre lengths in reinforced compounds.
According to Gross, “more than 90% of the
formulations and recipes developed for compound
extrusion can be processed without kneading blocks,
and that includes masterbatch production from a
premix.” He concedes that some recipes, such as
calcium carbonate filled PP or PE, require kneading
down of the production process that creates premium
blocks and Feddem does supply equipment for such
quality end product without producing large numbers of
applications.
rejects. “The behaviour and flow is similar to what
❙ www.feddem.com
occurs on a larger production machine,” Mack says.
KraussMaffei Berstorff recently launched a new
and sheet extrusion, and it is suitable for all commercially
counter-rotating twin-screw lab extruder for proces-
available hard and soft PVC mixtures. The new model can
sors looking to reformulate their PVC recipes for the
produce profiles and sheets at 15-40 kg/h, and pipe at
production of pipe, profile or sheet products. Its new
30-70 kg/h. “Counter-rotating units are not modular like
KMD 35-26/L is said to be the smallest extruder of its
our co-rotating units; you cannot adjust screw geometry
type on the market, and features 35 mm screws and
by pulling off an element then adding an extra mixing
machine lengths of 26 or 32D.
element. There is no splined shaft and everything is rigid
Different screw geometries are offered for pipe, profile
“The model is ideal for processors looking to find out
for maximum strength,” Mack says.
Leistritz says
how to save on stabilizer, or to adjust the amount of
that its Nano 16
filler without compromising material strength,” says
and barrel air cooling, and features several transduc-
has the lowest
Martin Mack, vice president, research and development,
ers mounted on the barrel. The unit is a low-speed,
free volume
in the extrusion division of KraussMaffei Berstorff in
high-torque and high-pressure system, delivering screw
available of any
Florence, Kentucky, USA. Processors benefit from
speeds from 50- 80 rpm and pressure from 500 to 5000
twin-screw
enormous cost savings when they can test the formula-
psi. The unit uses KraussMaffei Berstorff’s C5 control
extruder
tion on a small scale, and this machine provides a scale
system.
The unit is designed with internal screw tempering
❙ www.berstorff.com
Leistritz offers a range of lab-scale machines from the
Nano-16 for processing tiny volumes of pharmaceutical
materials, through to the ZSE 27 Maxx capable of
delivering more than 300 kg/h. It also has a lab extruder
that can be switched from co-rotating to counter-rotating operation.
The Nano-16 was primarily developed for the
pharmaceutical industry, where a low volume machine
is needed for early stage development. “Processors had
grams of new material available to them, and with other
conventional lab units, a feeder could not reach a steady
state (for accurate testing) with less than 200 g,” says
Charlie Martin, president and general manager at
40
BUSS KNEADER TECHNOLOGY
quantec ® 96 EV-10C
Cutting-Edge Compounding Technology
MX and quantec ® BUSS Kneader Series
BUSS innovative 4-flight screw technology sets new benchmarks in the economical
processing of temperature and shear sensitive plastics such as PVC and high grade
cable compounds:
>
2.5 times higher throughputs
>
Enhanced mixing quality and dispersion
>
Energy savings up to 25%
Buss AG
Hohenrainstrasse 10
4133 Pratteln
Switzerland
Phone +41 61 825 66 00
Fax +41 61 825 68 58
info@busscorp.com
www.busscorp.com
would be best processed on a co- or counter-rotating
extruder when scaled up to full production.
❙ www.leistritz.com
Randcastle says that compounding with a
single rotor or single screw featuring its
spiral-fluted extensional mixer (SFEM)
technology delivers high levels of product
mixing for smaller volumes of material. The
company offers the SFEM technology on its
expanded line of micro-batch mixers, and the
mixing elements can be scaled up for use on its
single-screw extruder.
“Initially one would think that it impossible to get
material elongation using one shaft until there is the
realization that there are two forces at work on the
material; pressure flow and drag flow,” says RandcasRandcastle’s
American Leistritz Extruder. The Nano-16 can process
batch mixer
batch sizes of 50 g or smaller, and the polymer
uses the
compounding industry is starting to take notice of the
around the screw in a helical manner, Randcastle
company’s
model for high-value formulation developments.
instead splits a certain section of the rotor into two
tle’s president Keith Luker.
Rather than designing screw flights that wrap
SFEM technol-
The unit integrates a twin-screw extruder with a
design halves. Each half of the rotor at that section
ogy to deliver
unique micro-plunger feeder that simulates a continu-
features a melt channel with drag flows similar in
very high
ous extrusion process for batch samples from 20 g to
depth, pitch and length, but designed to move material
levels of
100 g. The 16 mm diameter screw has the lowest free
in a direction exactly opposite to the melt channel
mixing
volume available for a twin-screw extruder, claims the
design on the other half.
company.
Grooves at each end of this special section allow
The micro-feeder plunger delivers material to the
pressure flow and drag flow forces to create elongation
feed barrel for precision feeding at extremely low rates,
and mixing. Material washes over the geometry in the
and it can meter materials in virtually any form,
section, creating flow that is dominantly elongational,
including powders, micro-pellets, pastes, slurries, and
says Luker.
granules.
At the other end of the lab scale, Leistritz’s ZSE 27
A paper delivered at the SPE Antec 2011 conference
by Dow Chemical and Randcastle showed that the use
of SFEM elements can deliver better mixing than a
1.66 OD/ID configuration. The company reports that
twin-screw. Luker says that the SFEM elements mixed
customers are achieving throughputs of more than 300
eight times better than the twin-screw, and 1,000 times
kg/h with the machine which bridges the gap between
better than a conventional single-screw extruder.
lab and production models. For example, Innovative
❙ www.randcastle.com
▲
Maxx has 28.3 mm diameter screws with a high-volume
Polymer Compounds (IPC) of Ireland is using a ZSE 27
Maxx for the production of compounds for medical
Steer’s new
applications in its Class 100,000
OMicron 10
clean room, as reported in last
model can
month’s Compounding World.
process
The processing units of the
high-end
ZSE 27 Maxx are interchangeable
polymers in
with the company’s Micro 27 GL/GG
batch sizes as
modular twin-screw extruder which
small as 15 g
can operate in both co-rotation and
counter-rotation modes. The
operating mode is selected using a
switch in the gearbox. Leistritz says
that this is a unique feature that allows
users to decide whether a formulation
42
blends, shear-sensitive materials, fibre-grade polyester
or PE masterbatches. Three sizes are offered – the
Omega 20, 25 and 30 – featuring 1.71 OD/ID, 1,200 rpm
screw speed and throughputs ranging from 5 -100 kg/h.
The OmegaLab is offered with special screw
configurations for handling a range of renewable resins,
reinforcements and fillers. For example, Steer was
awarded a contract in North America to develop and
commercialize a manufacturing process for a product
compounded from chicken feathers and PP. Proprietary
mixing elements help the OmegaLab line to achieve the
required mixing, while avoiding excessive shear levels,
says Roden.
“You cannot put too much energy in a biopolymer too
fast so you need the machine length to gently heat it.
Thermo Fisher
Steer has introduced a second model into its OMicron
Some think a long residence time burns the material,
Scientific’s
line of laboratory twin-screw extruders designed to
but it is really about the amount of energy put into the
Process 11 is
process special, high-end polymers in batch sizes as
mix,” says Janit Panchal, who is taking over the
the company’s
small as 15 g. The new OMicron 10 has a screw
technology manager role at Steer America as Roden is
smallest
diameter of 10 mm and joins the existing 12 mm model.
transferring to Steer India in Bangalore to focus on new
twin-screw
It has a 1.55 OD/ID ratio and throughputs range from
equipment development.
co-rotating
0.15 to 1 kg/hr. The machine is typically supplied with an
extruder
L/D ratio of 30-36.
The fourth of Steer’s lab lines is the Mega series,
designed to handle more conventional polymer blends
Steer’s OMicron models are offered with a clamshell
and colour compounds, as well as short fibre reinforced
design that allows processors to stop the process, open
thermoplastics. Three models are offered - the Mega20/
the machine and immediately inspect what is happening
Lab, Mega25/Lab and Mega 32 – featuring 1.55 OD/ID
to the material at any point in the process. Traditional
and throughputs from 5 to 100 kg/h.
segmented barrel designs are also offered for process-
❙ www.steerworld.com
ing materials under high pressures or for running
liquids.
The OMicron line employs special screw geometry
Process 11, a new bench-top twin-screw co-rotating
created by the company to improve material processing
extruder for small-scale experiments. It has 11 mm
at low volumes. For example, Steer’s proprietary
diameter segmented screws and can deliver through-
‘shovel’ elements, which assist the processing of
puts from 20 to 2,500 g/h.
difficult-to-feed density materials with low bulk
The space-saving unit, which is the smallest from
densities, are available for its laboratory machines as
the company, has a user-friendly touch screen with
well as its production lines.
integrated feeder control, and all electronics reside in
Quick change features with this model allow the user
the extruder housing. A removable top barrel half
to go from operation to screw removal in a matter of
allows users to stop and inspect material along the
seconds, says Robert Roden, technology manager at
screw shaft and enables them to modify the screw
Steer America. The company plans to add this ease of
design with individual screw elements in order to
accessibility and ease of cleaning technology to the
optimize the process. The removable barrel also
other lab lines.
simplifies screw and barrel cleaning, and offers optional
The Omicron is the smallest of Steer’s four lines of
laboratory extruders. The AlphaLab series comes in two
barrel designs to suit the application.
Atmospheric venting ports are standard with an
models with 18 or 20 mm diameter screws, a 1.46 OD/
option to add a vacuum stack. Due to the small
ID ratio, 1,200 rpm screw speed, and throughputs from
dimensions of the unit, top feeders are used in place of
5-40 kg/h. They are designed for processing specialty
side feeding. Split feeding from a secondary or tertiary
polymers, alloys and blends, mineral-filled polymers,
feeding port is possible.
additive- and colour-masterbatches and flame retardant compounds.
Steer also offers its OmegaLab series, designed for
applications such as automotive compounds, polymer
44
Thermo Fisher Scientific recently introduced its
Process results and conditions generated from the
Process 11 can be successfully scaled up to Thermo
Fisher Scientific’s 16 mm and 24 mm lines.
❙ www.thermoscientific.com/mc
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23-25 April 2013
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The Good
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as process scrap, or less
commonly post-consumer
waste (Typically this source of
material is handled by specialist
recycling companies).
This process takes place in a
device called a grinder, in which
the plastic components are fed in
through the throat of the grinder
and then pass into a chamber that
typically contains rotating knifes
which mechanically cut the plastic
component dimensions to a size
small enough to pass through a
screen. This regrind may then be: 1. Fed directly back into the
manufacturing process
on a continuous basis
2. Fed directly back into the
manufacturing process
on a batch basis
3. Used in another manufacturing
process such as a component
for a compounded material
containing the regrind
(and other ingredients).
Given that thermoplastics are by
definition capable of being heated
and re-shaped many times the use
of regrind would appear to be an
obvious solution to achieve greater
rates of operational efficiency
through the use of process scrap
and/or reject components.
However care must be taken to
ensure that the use of regrind does
not significantly impact on either
processing and/or the performance
of the product being manufactured
and in order to determine the
possibility to use regrind the following
factors must be considered: -
Degradation
Thermoplastic raw materials
are inherently unstable at
processing temperatures. The
extent of degradation will
be dependent upon: • Type of polymer
• The use of stabilsers
• Thermal history (Time spent at
processing temperature)
• Presence of other materials
such as pigments and fillers
In the case of ‘closed loop’
type recycling operations it is
worth considering the addition
of additional staibisers during
the manufacturing process.
The degree of degradation when
processing a standard MFR 4
PPHP by injection moulding and
subsequent granulation is depicted
in the graph where the melt
flow (an approximate measure
of degradation) is increased
by 13% after two cycles.
advertorial
PP Processing Degradation
4.6
MFR g/10min
4.4
4.2
4
3.8
3.6
0
1
2
Pass Number
Contamination
As most plastics are incompatible
great care should be taken
not to mix material types.
It is therefore essential that no
purgings, or scrap product resulting
from material changes are recycled
and it is vital that machinery is
thoroughly cleaned between
material types. Other sources
of contamination include: • Oil
• Dirt / Rubbish
Dust
The mechanical abrasion that
constitutes the regrind process tends
to result in dust. Ideally this should
be removed and disposed of. In
the case of some polymers dust
will significantly affect the physical
properties of the end product.
Fibre Fillers
The mechanical abrasion that
takes place in the regrind
process dramatically affects the
physical properties of plastics
that contain glass, carbon or
other fiber reinforcement.
• Masterbatch
All contaminated material should
be eliminated from any recycling
process and disposed of. Failure to
do so will result in the contamination
of more material and further scrap.
In addition to reducing the
length of the fibers, any chemical
coupling agent (size) will also be
affected, and since the fibres
depend upon their interface with
the plastic that surrounds them the
grinding process can dramatically
reduce physical properties.
Plastribution is the UK’s leading distributor of plastics raw materials,
delivering reliability, know-how and true business partnership to
the world’s best polymer suppliers and our UK customers.
In the event that you require further information about the
shrinkage of polymers, please do not hesitate to contact a
member of the Plastribution team for further information by
emailing sales@plastribution.co.uk or phone 0845 3454560
© Plastribution Limited. All rights reserved. 2012
Food and
Medical Applications
In both these cases special
consideration should be given
to the use of regrind. Normally
in medical applications regrind
is not used. In the case of food
packaging careful evaluation
must be undertaken to ensure that
compliance with required standards
are maintained as well as overall
suitability for any given application.
It is strongly advised that if there is
any cause for concern about the
use of regrind then further advice
should be sought from the material
supplier. Where it is not desirable
to use regrind the scrap can be
sold to specialists companies
who will recycle the waste.
GREEN POLYMER
CHEMISTRY 2013
International conference on manufacturing conventional plastics
from sustainable sources
CLICK
HERE FOR
DETAILS
19-21 March 2013
Maritim Hotel,
Cologne, Germany
* + 19% German VAT
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Green polymer chemistry | conference report
PHOTO: UNICA
The first Green Polymer Chemistry conference provided
a fascinating insight into efforts to develop renewable and
sustainable polymers. AMI’s Dr Sally Humphreys reports
Inside the green revolution
Opinions may differ on whether the world has yet
harvested from trees rather than from seeds, which is
Ford is using
reached the point of peak oil production, but most agree
the case for other vegetable oils.
12% soy-based
oil prices will continue to rise and alternatives will have
Hickingbottom said the agricultural industry is
polyols
to be found in the future to fossil-based fuels and
already seeing a “battle for acres” emerging on a global
in its US
chemical feedstocks. Renewable and sustainable
scale. This began in 2002 along with the drive to use
seating
sourcing for plastics is one key area of development and
bioethanol/biofuel, which has increased demand on
foams
AMI’s Green Polymer Chemistry conference, which took
arable land to grow the required feedstocks. By 2010,
place in Cologne earlier this year, brought experts from
the area of land under cultivation had expanded
agriculture, chemical engineering, biotechnology and the
worldwide by 70m hectares. But biofuels are not the
polymer industry together with sustainability managers
only demand driver. The rise in per capita income
from major consumer brand owners and the automotive
across Asia means that consumers are eating more
industry to discuss all aspects of this challenging sector.
meat, creating a corresponding increase in demand
LMC International’s senior research economist Dr
Sarah Hickingbottom presented an analysis of the
for animal feed.
Bio-based plastics and other fine chemicals
global agricultural feedstocks market at the event. Her
are now also being produced from
data showed that worldwide, corn wheat and cassava
agricultural feedstocks and the
production amounted to 1.7bn metric tonnes in 2010/11,
challenge is to find sources that are
and sugarcane and sugar beet totalled 160m tonnes
sustainable in this global marketplace
(the leading sugar producer is Brazil). On the vegetable
both financially and environmentally.
oil side, palm predominates at 48m tonnes (85% grown
Hickingbottom said more land is
in Malaysia and Indonesia). Palm oil is unique in being
certainly available for cultivation in areas
49
conference report | Green polymer chemistry
by approximately 14.3m tonnes.
All Ford cars produced in the US currently use a
minimum of 12% soy content polyol, with the aim to
increase this to 25%. One problem faced by car makers
with regard to renewable materials is the large number of
cars produced, currently 4.8m a year, which means any
“green” option must be available in considerable quantity.
In the case of soy, the United Soybean Board was keen to
find a use for the oil, which is effectively an unavoidable
side-product of bean production for animal feed.
Braskem has exploited Brazil’s position as the
world’s number one producer of sugar cane to position
itself as the leading producer of bio-based polyethylene
and polypropylene. The polymer producer has current
GLOBAL PRODUCTION OF AGRICULTURAL FEEDSTOCKS 2000-2011
(CALCULATED IN EQUIVALENT ETHANOL LITRES)
Source: LMC International
annual production capacities for its “green” polymers of
200,000 tonnes and 30,000 tonnes respectively.
The company’s commercial director for renewable
materials Fabio Magalhães Carneiro said 86.5 tonnes of
around the Black Sea, South America and South East
sugar cane is required to produce 7200 litres of ethanol,
Asia if conversion proves cost-effective.
which yields three tonnes of polyethylene. That means ap-
Brand owners and retailers have studied sustainable
sourcing extensively. Unilever’s global director of
sustainable sourcing development Dr Jan Kees Vis has
proximately 65,000 hectares of sugarcane is required to
meet its 200,000 tonne PE production capacity at present.
Data from the country’s sugar cane industry
been involved in projects including the Sustainable
association UNICA shows Brazil currently farms more
Palm Oil roundtable and said the company’s aim is to
than 7.5m hectares of sugar cane, around 2% of its
double its size “while reducing our environmental
available arable land. Braskem’s current PE production
impact”. Unilever’s plans include a
commitment to source 100% of its
agricultural raw materials
sustainably. At present, palm oil
is the top material at 1.4m
would require less than 1% of total production.
Competition between food and feedstocks is one of
the challenges faced by developers of bio-based
chemicals and plastics. One way of tackling the problem
is to develop technologies capable of producing
tonnes annual consumption,
chemical raw materials from non-food cellulose. There
primarily for surfactants, then
have been several technology breakthroughs in the past
paper, soy and sugar, followed
few years in these so-called second generation
by other oils.
technologies.
Unilever has put together a
Italy’s M&G Group built a pilot plant in 2009 using its
Sustainable Agriculture Code
and wants to use products
with certification, such as
Rainforest Alliance and Fair Trade. But
BASF is
there are many other issues, such as the need to
working with
ensure the security of food supplies. Vis said brand
blends of PCC
owners such as Unilever will in future be asking
derived from
questions of suppliers about the sustainability, not just
CO2 and starch
renewable sourcing, of new products.
based PHB as
The automotive industry is also pushing forward in
an ABS
the sustainability arena. Ford Motor Company’s Maira
replacement
Magnani, who is a reseach engineer within the car
maker’s Advanced Materials & Processes group at its
research centre at Aachen in Germany, detailed some of
the firm’s notable new developments in renewable
sourcing, including the use of a soy polyol-based
polyurethane foam which cut carbon dioxide emissions
50
GLOBAL AVAILABILITY OF LIGNOCELLULOSIC
FEEDSTOCKS BY MAIN TYPE AND REGION
Source: Süd Chemie, UN Food and Agriculture Organisation
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production of monomers for plastics such as PE and
PET. According to Professor Andre Koltermann, group
vice president of Süd Chemie’s corporate R&D unit,
global biomass production amounts to between 120 and
165bn tonnes a year. Asia’s rice growing industry is the
biggest potential source, contributing around 750m
tonnes of rice straw a year.
Koltermann said the SunLiquid process can produce
one tonne of ethanol from four tonnes of straw, which is
the typical straw yield from one hectare of farmed
ENVIRONMENTAL BENEFITS OF PEF AGAINST PET (NON-RENEWABLE
ENERGY AND GREENHOUSE GAS EMISSIONS)
Source: Avantium, Copernicus Institute at Utrecht University
wheat. The process is energy neutral and almost carbon
neutral, offering an approximate 95% reduction in
greenhouse gas emissions compared to ethanol
produced by petrochemical means. It has been running
Proesa technology, which generates C5 and C6 sugars
a 1,000 tonne/year demonstration plant since the
in a continuous process from bio-mass cellulose. Chief
beginning of this year.
technology officer Dario Giordano said the plant has
to be the largest global producer of biobutanol at more
many enzymes and 15 types of biomass feedstock have
than 7m gallons last year, is also moving into lignocel-
been tested. It is now building a new demonstration unit
lulose technology. The company’s director of interna-
at Crescentino in Italy that will have capacity to make
tional development Charlie Liu said it has developed a
40,000 tonnes of cellulosic ethanol and will generate 15
process to produce a bio-based PA5 monomer. The
MW of power from lignin by-products.
monomer is based on lysine converted via decarboxyla-
Meanwhile, the VTT Technical Research Centre of
tion to pentamethylenediamine, which can be combined
Finland has examined the feedstock potential of the
with a biobased di-acid to produce a variety of PA5,X
country’s forests, where growth is expected to rise by
polymers including PA5,10, PA5,6, and PA5,4.
25% over the next five years due to the effects of global
Braskem’s
China-based Cathay Industrial Biotech, which claims
now been in operation for 400 days continuously and
Indian company Petron Scientech has developed an
warming. VTT’s Professor Ali Harlin, industrial biomate-
ethanol to ethylene technology with a claimed conver-
rials research programme leader, said it has piloted
sion rate of near 100% and close to 99% ethylene
manufacture of ethanol from lignocellulose with
selectivity. Wim van der Zande, director of the com-
paper-making partner UPM. Biomethane can also be
pany’s Netherlands-based operations, said the process
‘green’ HDPE
used in the olefin supply chain by conversion of
is highly endothermic so heat recovery is built into its
unit in Brazil
methanol to olefins (MTO) and VTT has also experiment-
reactors.
has a capacity
of 200,000
tonnes,
ed with wood oils and the manufacture of LDPE from
tall oil.
German company Süd-Chemie has partnered with
Petron Scientech has also supplied technology to
companies such as Oswal in India to maximise its use of
sugar cane – the sugar is sold, bagasse is sent to fuel
equivalent to
Sabic in the development of the SunLiquid process,
power stations, and the molasses used to make
65,000 Hectares
which takes lignocelluose feedstocks and converts
industrial ethanol. Greencol Taiwan (a JV between
them to second generation sugars or ethanol for use in
CMFC and Toyota Tshuho) has also taken the Indian
of sugar cane
company’s technology to produce mono ethylene glycol
(MEG) monomer for bio-PET production at a new
100,000 tonne plant due to start up this year.
Production of bio-based MEG is already commercial
– Coca-Cola being the most prominent user in its
PlantBottle polymers. However, a fully bio-based PET
requires the development of a commercial route for the
purified terephthalic acid (PTA) component. One solution
to this challenge could be Avantium’s development of
PEF from furan dicarboxylic acid (FDCA) synthesised by
dehydration and oxidation from carbohydrates. According
to new business development director Dirk den Ouden,
FDCA produced using its YXY Technology could act as a
drop-in replacement for PTA to produce polyethylene
52
WOOD-PLASTIC
COMPOSITES 2013
The international business conference & exhibition for
the wood-plastic composites industry
HEADLINE SPONSOR
25-27 February 2013
Austria Trend Savoyen Hotel, Vienna, Austria
Images courtesy of: battenfeld-cincinnati Austria GmbH, Beologic, TimberTech and Trex Company
SPECIAL OFFER: Save €200 if you register before 25th January 2013
Organised by:
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Also sponsored by:
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Maud Lassara – Conference Organiser ml@amiplastics.com Ph: +44 117 924 9442 Fax: +44(0)117 311 1534
Above left:
furanoate (PEF). It could also be used as a feedstock in
Bayer Material-
production of polyurethanes and polyamides.
Science’s PCC
Avantium’s partners include Teijin, Coca-Cola,
which is a precursor for polyamide 66.
There is also a great deal of interest in technologies
to synthesise polymers from carbon dioxide. Several
from CO2 plant
Solvay, Rhodia and Danone. The PEF-based material is
at Leverkusen.
said to have been successfully tested on commercial
polypropylene carbonate from CO2, including BASF and
Above right:
blow moulding, fibre and film lines and is claimed to
Bayer MaterialScience in Europe, Novomer in the USA,
Development of
provide a higher gas barrier than PET. A pilot PEF plant
SK Innovation in Korea, and Mengxi in China.
bio-based
is being constructed at Chemelot in the Netherlands
polyols in
with an annual capacity of 40 tonnes.
Ford’s US
laboratory
Work underway at the Leibniz Institute for Catalysis
companies worldwide are involved in the production of
BASF is motivated by low monomer costs, reducing
CO2 emissions trading and the abundant feedstock
from power plants. It is testing the polypropylene
is focused on the development of catalysts for produc-
carbonate materials in several applications, including
tion of monomers from vegetable oils. Institute group
using it in blends with PLA as an ABS replacement in
leader Angela Köckritz said the German vegetable oil
electrical appliances, in agricultural films and in paper
market comprises 5.16m tonnes of rape seed oil and
coatings. BASF research chemist Dr Anna Brym said
50,000 tonnes of sunflower oil, with imports of sunflow-
one issue that must be dealt with is the low activity of
er, linseed, soybean oil (from USA), castor oil (from
catalysts, as well as the need to remove the catalyst
India), palm and coconut oil (from Malaysia and
after polymerisation.
Indonesia).
These vegetable oils can be used in the synthesis of
Bayer MaterialScience has generated polyetherpolycarbonate polyols from CO2 for use in polyurethane.
polyurethane, polyester, polyamide, polyacrylate and
The CO2 supply is scrubbed at the coal-fired power
epoxy resin, said Köckritz. Emery Oleochemicals has
plant where it is captured from the flue gases and then
achieved ozonolysis of oleic acid, which can be used in
reacted with propylene oxide. It has taken the company
polyamide 6,9. Evonik has chemical pathways for the
time to reduce the by-products and improve catalyst use
production of ricinoleic acid to give polyamide 10,10 and
towards its “dream production” target level but some
6,10. Arkema has a polyamide 11 produced from
slab stock foam has been produced and tested, said Dr
11-undecanoic acid from castor oil. BASF has made a
Christoph Gürtler, head of the company’s new catalytic
polyamide 6,10 and a variety of polyols from sources
processes competence centre.
such as castor oil.
Royal DSM is producing a polyamide 4,10, thermo-
The first Green Polymer Chemistry conference provided
from bio-sources. Director of sustainability Frederic
a unique opportunity for agro-economic and bio-based
Petit said DSM is also a partner in the Biosuccinium
polymer experts to gather and debate the key issues
project with Roquette, which intends to produce
around this novel technology. The second event, Green
succinic acid using a yeast-based process.
Polymer Chemistry 2013, will be held in Cologne,
The two companies hope to begin large scale
54
Green Polymer Chemistry 2013
plastic copolyester and unsaturated polyester resin
Germany from 19-21 March 2013. For more information
production in a 10,000 tonne/year unit in Italy this year.
or to book your place contact Rebecca Utteridge:
Plans are also in hand to make bio-based adipic acid,
rju@amiplastics.com or visit www.bit.ly/Green2013
The international conference and exhibition for the plastic cable industry
HEADLINE SPONSOR
5-7 March 2013
Maritim Hotel, Cologne,
Germany
Images courtesy of: Albemarle Martinswerk and LyondellBasell
* + 19% German VAT
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Polymers and additives | products
biomaterials
Consortium tests almond shell masterbatch
Spanish researchers plan to
develop masterbatches
containing almond shells
AIJU – Spain’s toy research institute – is
and furniture, say the researchers.
Partners in the three-year project, which is
co-ordinating a project that aims to
develop masterbatches using
funded by the Spanish Life+ programme,
agricultural waste products, such
include masterbatch maker IQAP, toy manufac-
as almond shells, together with
turer Injusa, and injection moulder Perez Cerda
biodegradable polymer carriers.
Plastics. The first meeting took place in October.
Target applications include toys
❙ www.aiju.info
masterbatch
Americhem launches black
nigrosine masterbatches
Colour and additive systems
supplier Americhem has a
new line of highly concen-
pigments
Cappelle
targets
technical
polymers
trated low-aniline nigrosine
Belgium-based Cappelle
black masterbatches, which
Pigments has introduced a
are available in PA 6 and 6,6
new bismuth vanadate
carriers at concentrations up
pigment – Lysopac Yellow
to 40%. Compared to carbon
6619B – intended for use in
black, the new products are
technical polymer com-
said to provide a deeper
pounds up to 300°C.
black, higher gloss and
The 6619B pigment offers
minimal stress whitening.
Due to their minimal
a green-yellow shade
Target applications include under-the-hood components
impact on physical properties
providing high light fastness
as well as the thermal
and suitability for use with
introduced ePVC – a precol-
performance. The com-
stability required for
glass reinforced polyamides,
oured capstock compound for
pounds also reduce moisture
polymers such as PA and PC.
Americhem says the new
the decking and exterior
penetration into exterior
It is said to be easy to
masterbatches are likely to
profile market.
profiles, reducing risk of rot.
disperse in the polymer.
find applications in sectors
According to the company,
The ePVC compounds
Also new is Lysopac
such as under-the-hood
the ePVC capstock compound
have undergone extensive
Yellow 6618B. Providing
automotive parts. They can
provides improved strength
weather testing. They can
thermal resistance to 230°C,
also be combined with
and weathering resistance
also be used with Amer-
the grade provides improved
carbon black where high UV
along with better colour
ichem’s nGrain simulated
reflow in powder coating
stability is required.
retention, scratch and mar
woodgrain effect.
applications.
resistance and impact
❙ www.americhem.com
❙ www.cappelle.be
Americhem has also
pvc plasticizers
Galata extends Drapex plasticizer range
Galata Chemicals has added
Intended for use in white
200˚C grade is said to provide
the plasticizer is pitched at
applications requiring the
Drapex Alpha 200C to its family
and clear PVC formulations or
improved extraction resist-
of natural oil-based primary
applications requiring high
ance, reduced VOCs and better
performance of trimellitates.
plasticisers.
levels of performance, the
processing. The company says
❙ www.galatachemicals.com
www.compoundingworld.com December 2012 | compounding world
57
products | Polymers and additives
functional fillers
Modified mineral filler can
raise thermal performance
The latest additions to the
pvc additives
Bio-based
modifiers
for PVC
functional filler product line
Bio-based polymers devel-
from Quarzwerke subsidiary
oper Metabolix has introduced
Mineral Engineers allow
a series of polyhydroxyal-
users to modify thermal
kanoate (PHA) copolymers
conductivity and optical
that it says could be used as
performance.
modifiers in rigid and flexible
PVC formulations.
The company has
developed a range of
the copolymers can be used
modified mineral fillers
based on a naturally-occur-
A new thermally conductive filler from Mineral Engineers can
as low extractable plasticiz-
ring alumina-silicate
assist heat dissipation in electronic devices
ers or as processing aids to
prevent excessive shear
designed to impart thermal
conductivity in polymer
ing electrical insulation. It says
illumination and release a
heating. Certain copolymer
compounds when used at
the fillers are engineered to
strong glow in darkness.
grades have also been found
moderate to high volume
minimise any negative impact
fractions. The mineral filler
on both mechanical perfor-
luminance of more than 20
is processed to particle sizes
mance and processing and it is
mcd/m2 after 60 minutes,
Metabolix worked with
between 5 and 30 microns,
applying for patents on the
making them suitable for
AlphaGary to validate the
then coated using a special
new materials.
applications such as road
materials. AlphaGary is
Silglow fillers provide a
to act as impact modifiers in
transparent formulations.
markings, warning signs and
beginning to test the
is Silglow, a modified fused
guide lighting. The materials
polymeric PHA modifiers in
the new fillers are likely to
silica that is anorganically
are characterised by a
some current high-value
find applications in the
treated to provide glow-in-the-
density of 2.2 g/cm3,
applications.
electronics sector where
dark performance. According
hardness of 6.5 mohs and are
increasing energy density
to the company, the materials
available in grain sizes from
the first production samples
requires more effective heat
are charged when exposed to
0.1 to 5.0 mm.
early next year.
dissipation without sacrific-
natural daylight or artificial
❙ www.hpfminerals.com
❙ www.metabolix.com
surface treatment.
Mineral Engineers says
Also new from the company
Metabolix hopes to ship
pvc plasticizers
PolyOne lifts bio-content for reFlex 300
Target applications for
PolyOne has introduced reFlex
reFlex 300 include
300, a 99% bio-based plasti-
healthcare tubing
cizer that is claimed to provide
99% bio-based under the
according to Rob Rosenau,
a one-for-one replacement for
USDA BioPreferred pro-
president of PolyOne
general purpose phthalate
gramme. It is said to be
Performance Products and
plasticizers in flexible PVC
suitable for a range of
Solutions.
applications.
applications, including
It is the second product in
The new grade is certified
demand for renewable
technology for plasticizers,”
“Our reFlex 300 bioplasti-
healthcare tubing and
cizer enables customers to
the company’s newly-intro-
connectors, electrical plugs
expand their offerings with
duced reFlex range, which is
and insulators, gaskets, seals,
differentiated alternatives
the result of a development
flooring and toys.
that heed consumer calls for
alliance between PolyOne and
agricultural products group
58
Archer Daniels Midland (ADM).
“We continue to see
increased marketplace
eco-conscious solutions.”
❙ www.polyone.com
PVC Formulation 2013
Market trends and technical developments in PVC additives and compounding
CLICK HERE
FOR DETAILS
12-14 March 2013
Hilton Hotel, Düsseldorf,
Germany
Image courtesy of: Chemson press photo
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products | Polymers and additives
reinforcements
AGY develops high modulus S-glass
impact performance
US-based glass reinforce-
applications that would have
ment maker AGY has
previously required more
introduced a new high-mod-
costly alternatives. “It brings a
ulus glass fibre and extended
new level of tensile modulus to
its range of sizings for
the arena of glass fibre without
compounds or allow glass
thermoplastic composite
losing any of the unique
content to be reduced to
applications.
properties that glass brings as
make weight savings without
a component of composites
sacrificing performance, says
Modular Direct Melt (MDM)
such as electrical and thermal
the company.
manufacturing method and a
insulation, and high impact
proprietary S-glass formula-
absorption and low coloration
combined with our S-2 Glass
tion, the new S-3 UHM glass
of the resin system,” he says.
technologies, to open up new
Developed using AGY’s
fibre provides a tensile
AGY is producing glass
fibre with a tensile
modulus of
99 GPa
compared with traditional
chopped products. This could
result in higher performance
“We expect these sizings,
applications in the automo-
The introduction of the new
tive, aerospace and industrial
modulus of 99 GPa, which the
glass follows an updating of
company says is a 40%
the AGY sizing options, with a
improvement over traditional
number of new sizing systems
E-glass products.
being made available to
have been evaluated on a
on directly sized rovings or as
improve compatibility with a
range of fibres from low
chopped fibre in lengths from
dent Drew Walker, the new
range of engineering thermo-
diameter E-glass to S-2 types
3.2 mm (0.125 inch) to 6.4
grade will allow material
plastics, including PA 6 and
and are claimed to provide
mm (0.25 inch).
formulators to use glass in
6,6, PA 11, PA 12, PBT, PC, PEI,
improved mechanical and
❙ www.agy.com
According to AGY presi-
PEKK and PEEK.
The new sizings are said to
conductive compounds
markets,” says Walker.
The sizings are available
masterbatch
RTP meets ATEX pump challenge PCC goes
US compounder RTP Company
AOD air-operated diaphragm
markets and end-users have
has developed a special
pump, which is manufactured
their own more demanding
electrically conductive version
in RTP’s Series 100 PP.
specifications. One of these
of its 100 Series glass-rein-
While the pump meets the
customers asked for a
forced PP for an all-polymer
requirements of the interna-
special design using
diaphragm pump that meets
tional ATEX Directive for use in
conductive polymers.
the most stringent require-
potentially explosive require-
ments for use in potentially
explosive environments.
direct with
PLA blue
pigment
Plastics Color Corporation
Working in partnership
(PCC) is now marketing its
ments, All-Flo sales and
with All-Flo and its injection
SoluPLAs TN 920259 blue
marketing manager Paul
moulding partner – Ohio-
tint masterbatch, originally
based Royal Plastics – RTP
developed for Ingeo PLA
All-Flo, a well-established
developed an RTP 100
producer NatureWorks,
supplier of polymer-based
Series compound using a
directly as a new addition to
pumps for applications
carbon powder additive.
its SoluPLAs family of PLA
The pump is produced by
McGarry says certain national
enhancers.
such as mining where the
“Not only did RTP
light weight and improved
Company provide a conduc-
corrosion and wear
tive material that had the
colour concentrate, the
resistance is a major
properties and met the
SoluPLAs product line
Aside from the TN 920259
benefit over metallic
requirements, it had the
includes additives for
alternatives. One of its
same processability and
modifying the clarity, UV
most popular models for
worked with our existing
protection and acoustics of
mining applications is the
moulds,” says McGarry.
bio-based PLA resins.
All-Flo It 1 inch (25 mm)
❙ www.rtpcompany.com
❙ www.plasticscolor.com
60
This month’s free
brochure downloads
Simply click on the brochure cover or link to download a PDF of the full publication
AGC: Fluon MPC compounds
This eight-page brochure
from AGC Chemicals covers
the company’s Fluon MPC
melt processable
fluoropolymer compounds,
which are used to pigment
and enhance ECTFE, ETFE,
FEP, MFA, PFA and PVDF.
➤ Click here to download
Nyco: engineered reinforcements
v
Wo l l a s t o n i t e : E n g i n e e r e d R e i n f o r c e m e n t s f o r
Polymer Applications
A Specialty Mineral That Provides
Excellent Balance in Stiffness and Impact
Plastribution: know-how
www.plastribution.co.uk
Issue 03 October 2012
the magazine
More efficient LEDs
0845 34 54 560
In this issue
Don’t be left in the dark, turn to page 24 and find out more.
The Olympic torch – Momentum
13
Joining the App revolution
14
Recycle with industry know-how
16
Nylon replaces metal in cars
32
In the third edition of
Plastribution’s know-how
magazine you can find out
more about the newest
additions to the company’s
product portfolio , including
the latest resin options for
LED applications.
Steer: EPZ screw elements
This brochure from Nyco
covers the company’s
Wollastonite engineered
reinforcements for polymer
applications. The specialty
mineral provides excellent
balance in stiffness and
impact, plus Class A surface
appearance.
This 20-page brochure from
Steer Engineering features
its wide range of screw
elements including many
innovative designs
developed by the company. It
also covers replacement
barrels and shafts.
• IMPROvEd MEChANICAl PROPERTIES • IMPROvEd MElT STRENGTh
• lOWER dENSITY – ThIN WAll COMPOSITES • ClASS A SURFACE APPEARANCE
• CONdUCTIvE MOdIFIEd
Pl ASTICS
Imerys: Jetfine talcs
Jetfine® talcs
for high performance polypropylene
and engineering thermoplastics
• Unique ultrafine milling technology
This eight-page technical
brochure from Imerys Talc
covers the company’s
Jetfine talcs for highperformance polypropylene
and engineering
thermoplastics compounds.
It includes property
comparisons for different
formulations.
Poly.ERP: case study
This 16-page case study
from Kirchhoff
Datensysteme examines the
development of its Poly.ERP
customised ERP system for
compounders and how it
was successfully
implemented at Polymer
Chemie.
• Improved TPO and ETP impact strength at very low temperatures
• Excellent dimensional stability
• Reduced part thickness
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
M
M A S T E R B AT C H
A S I A 2 013
New opportunities and expanding markets
CLICK
HERE FOR
DETAILS
18-20 March 2013
Marina Bay Sands Hotel,
Singapore
Images courtesy of: Automatik Plastics Machinery, ExxonMobil Chemical
SPECIAL OFFER: Save USD300 if you register before 15th February 2013
Organised
Organised
by: by:
Applied
Applied
Market
Market
Information
Information
Ltd.Ltd.
Sponsored by:
Media supporter:
Adele Brown – Senior Conference Organiser ab@amiplastics.com Ph: +44(0)117 924 9442 Fax: +44(0)117 311 1534
Machinery and software | products
extruders
Battenfeld-Cincinnati to demonstrate
wood-plastic composite capabilities
Battenfeld-Cincinnati will
Battenfeld-Cincinnati’s fiberEX 114 is
operation worldwide covering
demonstrate its latest WPC
particularly suitable for the extrusion
outputs from 20 to 1,000
processing technology for
of solid WPC profiles
kg/h. The fiberEX 114
solid decking profiles during
extruder is the second model
AMI’s 9th Wood Plastics
in a new range of high-per-
Composites conference in
formance WPC extruders,
Vienna, Austria, in February.
joining the recently introduced fiberEX 135 model.
The company will be
running its new fiberEX 114
Both are claimed to provide
parallel twin-screw extruder
optimal process stability
– a high output WPC
along with maximum
production unit that the
production outputs and
degassing performance.
company says is well suited
for the extrusion of solid
emerging trends, originally
diagonal cuts and does not
AMI’s Wood Plastics
WPC decking profiles.
developing in Germany but
require injection-moulded
Composites conference
now gaining market share
finishing caps. The reduced
takes place in Vienna on
across Europe.
surface area also minimises
25-27 February.
Demand for WPC products
is growing at around 20-25%
a year in Europe, says
Compared to traditional
Battenfeld-Cincinnati. Solid
hollow profiles, solid decking
decking profile is one of the
offers the ability to accept
For more information,
water absorption.
Battenfeld-Cincinnati has
more than 250 WPC lines in
visit http://bit.ly/WPC2013.
❙ www.battenfeld-cincinnati.com
instrumentation
Dynisco performs better under pressure
Vertex models are the first
design is the sensor tip
Dynisco has added two new
that offers accuracy to within
pressure transducers to its
±0.5% over pressures ranging
Dynisco units to offer direct
arrangement, which
range – the Echo series
from 0-1,500 psi or 0-10,000
pressure measurement.
incorporates a single highly
targets general purpose
psi. They feature stainless steel
Eliminating the typical
robust diaphragm manufac-
extrusion monitoring applica-
construction on all surfaces in
mechanical pressure transfer
tured from high corrosion
tions, while the Vertex units
contact with the melt, while the
systems or liquid fill media
resistant Inconel 718 steel
deliver the additional perfor-
diaphragm is coated with
means improved precision and
and finished with a DyMax
mance required for more
titanium aluminium nitride for
longer service life, according
diamond-hard protective
demanding markets such as
additional durability, enabling
to the company. The absence
coating. This new construc-
the medical sector.
Dynisco to offer a two-year
of any liquids also eliminates
tion also includes an
warranty.
leakage risk.
improved sensor wall
Echo sensors use a proven
sensor design
Key to the new Vertex
structure with improved
ability to handle side
Dynisco’s Vertex models offer direct
pressure measurement
for demanding
applications
stresses.
Vertex accuracy is within
0.25% of full scale over the
standard pressure ranges of
1,500, 3,000, 5,000, 7,500 or
10,000 psi. A four-year
warranty is provided.
❙ www.dynisco.com
www.compoundingworld.com December 2012 | compounding world
63
products | Machinery and software
materials handling
Conair improves flake feeding
Conair has introduced two
through an oversized opening
avoid compaction in the feed
new developments for its
at the base to a horizontal
zone. According to Conair,
TrueBlend blending systems
auger that positively conveys it
this allows the flake to flow
to improve the handling of
to the mixing chamber.
easily through into the mixing
flake recyclate and other
Where high volume
chamber.
TrueBlend units are
mixers
Kreyenborg
upgrades
mixer at
Ponachem
Hamburg, Germany-based
difficult-to-feed regrind
throughputs have to be
materials.
accommodated, the company
available to handle through-
compounder Ponachem has
uses lift augers positioned at
puts of less than 23 kg/hour
slashed mixing times and
– like PET bottle scrap or
an angle in a corner of the
on the smallest TB45 unit to
reduced energy consumption
thicker film and sheet scrap
regrind bin (pictured). Instead
5,455 kg/hour on the largest
from its 20-year old silo
– has granules with
of forcing the material into the
TB3500 models. They can be
mixer system after Kreyen-
relatively large, flat surfaces
base of the bin, these lift it to
supplied with up to 12
borg upgraded its pipe auger
“Certain thin, flaky regrind
to an open mixing screw.
so they tend to pack
ingredient bins.
together and bridge in
l Conair has also
Kreyenborg Plant
conventional hoppers,”
introduced the new
Technology replaced the
says Conair’s blend
TrueFeed LQ liquid feeder
original pipe auger in the 20
product engineer Jeff
for handling liquid colours
m3 silo with an open mixing
and additives. The unit
Bickel.
screw incorporating a special
uses standard peristaltic
segment design. The result
two different approaches to
pump dosing but the liquid
was that Ponachem gained a
overcome feeding problems.
container is mounted on a
reduction in the required
For smaller throughput
load cell to provide real-time
mixing cycle for its plastic
quantities, the units can be
loss-in-weight dosing. Conair
regrind from 4 hours to just
fitted with side feeders with
claims the improved
20 minutes. Similar results
steeply angled sides that
accuracy can enable
can be achieved with any
help prevent regrind from
significant savings on costly
free-flowing material, says
hanging or bridging. The
colorants.
Kreyenborg.
material can then flow easily
❙ www.conairgroup.com
❙ www.kreyenborg.de
The TrueBlend range uses
software
Rowa completes its ERP integration
Germany’s Rowa Group says
speeds up the administration
that ‘blending’ only releases a
gain important data relating
the integration of its Infor
and management of the entire
batch for delivery when all
to the entire product history,
Blending Lab information and
testing process. The LIMS
tests have been completed and
such as the quality of the raw
Management System (LIMS)
system also allows test
fully documented”, says Wulf
material deliveries. We can
into its ERP system is now
compliance certificates to be
Hagemeister, technical
then assess this data and
complete, improving manage-
generated for every product
manager at Rowa Master-
integrate our findings into
ment of its quality systems.
delivery and incorporated into
batch.
production planning and
the LIMS system allows
customer-specific test profiles
the documents delivered to the
customer.
“LIMS records all control
“Because the system
makes all data for a product
control,” he says.
The LIMS ERP integration
centrally accessible and
project commenced in
- which may deviate in either
results on a product, customer
interlinked, we can conduct
September 2011, with the
test criteria or in threshold
and batch basis, and manages
statistical comparisons of the
roll-out scheduled to take
values - to be created,
them in a central database,
performance of different
12 months to complete.
recorded and recalled for
which the ERP accesses. This
product batches quickly and
subsequent testing. This
means, among other things,
comprehensively. We can thus
❙ www.rowa-masterbatch.de
❙ www.infor.com
64
Download the programmes for
these forthcoming conferences
Simply click on the brochure cover or link to download a PDF of the full publication
Polyethylene Films 2013
Companies attending the
previous Polyethylene Films
conference accounted for
more than 3 billion lbs of PE
resin usage. Don’t miss this
essential industry event
when it returns to Florida’s
Daytona Beach on 5-6
February 2013.
Polyethylene
Films 2013
Bottle image courtesy of:
ExxonMobil Chemical Company
The international marketing, business and technical conference for
the polyethylene film industry
HEADLINE SPONSORS
The Grass Yarn
& Tufters
Forum 2013
Trends and developments
heaDLIne sponsor
18-20 February 2013
Maritim Hotel, Cologne,
Germany
February 5-6, 2013
The Shores Resort & Spa,
Daytona Beach, Florida, USA
Images courtesy of: Bold text
for company name
speCIaL offer: Save €210* if you register before 18th January 2013
SPECIAL OFFER: Save $200 if you register before December 14, 2012
Organized by:
Applied Market
Information LLC
Media supporter:
Also sponsored by:
The Grass Yarn & Tufters
Forum is the international
conference covering trends
and developments in the
artificial grass market. The
seventh such event is being
held in Cologne, Germany
on 18-20 February and its
influential programme
includes FIFA.
* + 19% German VAT
Images courtesy of: Dow Chemical Company
Organised by:
Applied Market
Information Ltd.
Media supporter:
fax back to +44 (0) 117 311 1534
Pipeline Coating
International conference on pipeline protection, coating technology, materials and markets
18-20 February 2013
Austria Trend Hotel Savoyen,
Vienna, Austria
Images courtesy of: Bredero shaw and shawCor, Canusa systems and Wasco Coatings Group
sPECIAL OFFER: Save €110 if you register before 14th December 2012
Pipes in Infrastructure
AMI is holding the fifth
international Pipeline
Coating conference on 18-20
February in Vienna, Austria.
This event, which attracts a
large global audience,
covers the latest
developments in pipeline
protection and coating
technologies.
Sponsored by:
2013
Pipes in
I n f r a s t r u c t u re
Market trends, new products and technical developments in plastic pipes
for infrastructure applications
Images courtesy of: Wavin GmbH and Hobas Rohre GmbH
Pipeline Coating 2013
AMI is holding the Pipes in
Infrastructure 2013
conference in Düsseldorf,
Germany, on 9-11 April.
Check out the programme
which covers market trends
and technical developments
in plastic pipes for
infrastructure applications.
9-11 April 2013
Hotel Nikko, Düsseldorf
Germany
* + 19% German VAT
SPECIAL OFFER: Save €100* if you register before 8th March 2013
Organised by:
Applied Market
Information Ltd.
Media supporters:
Media supporter:
Organised by:
Applied Market
Information Ltd.
Fax back to +44 (0)117 311 1534
o +44 (0) 117 311 1534
o +44 (0)117 311 1534
Grass Yarn & Tufters Forum
Stretch & Shrink Film
STRETCH & SHRINK
FILM 2013
The business conference & exhibition for
the stretch & shrink film industry
10
th
ANNIVERSARY
CONFERENCE
The 10th anniversary
conference will be
a celebration of the
success of the stretch &
shrink film industry over
the past ten years
Plastic Closure Innovations
AMI’s 10th international
conference on Stretch &
Shrink Film will take place
in Berlin, Germany, on 16-18
April 2013. The programme
includes detailed market
analyses, plus the latest
materials, processing and
application developments.
PLASTIC CLOSURE
INNOVATIONS 2013
Trends and technical developments in the international closures industry
16-18 April 2013
23-25 April 2013
InterContinental Hotel,
Berlin, Germany
Maritim Hotel, Cologne, Germany
* + 19% German VAT
Sponsored by:
* + 19% German VAT
Hartley’s image and Vosene image courtesy of: GCS
SpECIAL OFFER: Save €150* if you register before 8th March 2013
Organised by:
Applied Market
Information Ltd.
The Plastic Closure
Innovations 2013 conference
takes place in Cologne,
Germany, on 23-25 April.
Download the impressive
programme that includes
speakers from leading
producers of caps and
closures as well as key end
users.
SPECIAL OFFER: Save €100* if you register before 22nd March 2013
Media supporter:
Fax back to +44 (0)117 311 1534
Organised by:
Applied Market
Information Ltd.
Sponsored by:
Media supporter:
To see our full line-up of more than 25 plastics industry events
over the next 12 months, please visit www.amiconferences.com
compounder of the month
F&D Plastics
Head office location:
Date founded:
CEO:
Ownership:
No. of employees:
Sales 2012:
Plant locations:
Production 2012:
Profile:
Product line:
Product strengths:
Leominster, Massachusetts, USA
1967
Jean Rosbury
Privately owned
92
US$20 million
Leominster, MA, USA, and St-Laurent, QC, Canada
5,000 tonnes
F&D Plastics is a family-owned business that started as a grinding firm and
began masterbatch production in 1993. In 2004, it invested in new extruders and
then expanded into Canada by acquiring CEK Colorplast in Lachine, Quebec. In
2008, Canadian production was relocated to a new facility in St-Laurent. During
2010, F&D increased capacity by 37%, installing four new lines. It is among the
50 largest masterbatch producers in North America. In addition to serving the
North and South American markets, it has a partner in Malaysia and is looking
at developing a sales network in the UK.
F&D Plastics produces white, black and colour pigments and masterbatches
based on polyolefins, as well as engineering polymers, recycled material
and biopolymers. Its strongest markets include housewares, lawn & garden,
hardware and medical. It does some toll compounding for select customers.
F&D focuses on service, price and technical support. It has invested more than
US$1.5 million over the past three years to be more competitive in these areas.
Forthcoming features
The next issues of Compounding World magazine will have special reports on the following subjects:
January
Polymer foam technologies
Pelletizers
Dispersants and coupling agents
February
Thermally-conductive compounds
Materials handling
Additives for polyolefins
Editorial submissions should be sent to Andy Beevers: abe@amiplastics.com
For information on advertising in these issues, please contact
Claire Bishop: claire@amimagazines.com Tel: +44 (0)20 8686 8139
Catch up on our recent
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Compounding World – Nov
The November issue of
Compounding World boasts
special features on clean
compounding for medical and
other demanding applications,
developments in carbon black,
the latest mixing technologies,
and new materials testing
equipment.
Compounding World – Oct
The October edition of
Compounding World contains
special features on reinforcing
fibres, titanium dioxide trends,
extruder alignment techniques,
melt filtration systems plus
Fakuma show highlights.
➤ Click here to view
Injection World - Nov/Dec
The November/December
edition of Injection World has
in-depth features on machine
setting procedures,
automotive applications,
machinery market trends,
renewable polymers, and hot
runner developments.
Pipe and Profile – Nov/Dec
This edition of Pipe and Profile
Extrusion is packed with
reports on wood-plastic
composites (WPCs), materials
handling systems, cross-linked
polyethylene (PEX) for pipe
applications, and PVC
plasticizers.
Injection World – October
Injections World’s October
issue is filled with features on
the latest trends in caps and
closures, advanced medical
device applications, moulding
multi-layer optical parts, plus
innovations in thin wall
packaging.
Film and Sheet – November
The November edition of Film
and Sheet Extrusion magazine
contains special features on
BOPP trends, multilayer
packaging, bioplastics research,
extruder innovations and
additives for polyolefins.
Take out your own FREE subscriptions to any of the magazines.
Click on the logos below to simply register on-line.
dates for your diary
Global exhibition guide
7-10 January
29 Jan - 1 Feb
ArabPlast, Dubai, UAE
www.arabplast.info
Interplastica, Moscow, Russia
www.interplastica.de
22-25 February GAIL Plastasia, Bangalore, India
www.plastasia2013.com
6-7 March
Plastec South, Orlando, FL, USA
www.plastecsouth.com
6-8 March
Plast Bulgaria, Sofia, Bulgaria
www.plast.bg
12-15 March Plastimagen, Mexico City, Mexico
www.plastimagen.com.mx
12-15 March
Pro-Plas Expo, Johannesburg, South Africa
www.proplasafrica.co.za
3-5 April
Plastex Uzbekistan, Tashkent, Uzbekistan
www.plastex.ite-uzbekistan.uz
3-6 April
Tiprex, Bangkok, Thailand
www.tiprex.com
10-11 April
PlastTeknik, Malmo, Sweden
www.easyfairs.com
10-12 April
Plastic Japan, Tokyo, Japan
www.plas.jp/en
7-10 May
PlastPol, Kielce, Poland
www.plastpol.com
14-16 May
Plast-Ex, Toronto, Canada
www.plast-ex.org
20-23 May
Chinaplas, Guangzhou, China
www.chinaplasonline.com
20-24 May
Feiplastic, Sao Paolo, Brazil
www.feiplastic.com.br
16-23 October
K 2013, Düsseldorf, Germany
www.k-online.de
AMI conferences
29-31 January
Thermoplastic Concentrates, Coral Springs, FL, USA
18-20 February
The Grass Yarn & Tufters Forum, Cologne, Germany
25-27 February
Wood-Plastic Composites, Vienna, Austria
5-7 March
12-14 March
PVC Formulation, Düsseldorf, Germany
18-20 March
Masterbatch Asia, Singapore
19-21 March
7-8 May
14-15 May
Polymers in Cables, Miami, FL, USA
14-16 May
Polymer Sourcing, Vienna, Austria
3-5 June
Masterbatch, Frankfurt, Germany
4-6 June
End of Life Plastics, Cologne, Germany
13-14 June
Cables, Cologne, Germany
Green Polymer Chemistry, Cologne, Germany
Bioplastics Compounding & Processing, Miami, FL, USA
For information on all
these events and other
conferences on film,
sheet, pipe and
packaging applications, see
www.amiplastics.com
Fire Retardants in Plastics, Denver, CO, USA
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picking flame retardants for polyamides new developments in lab

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