ISSN 2053-7174

January 2014

CREATING FOAMED POLYMERS

NEW ADDITIVES DEVELOPMENTS

COMPOUNDING WORLD FORUM

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www.compoundingworld.com January 2014 | COMPOUNDING WORLD 3

05 Industry news The latest compounding industry news including international acquisitions and

alliances, plus new investments and plant openings.

13 Expanding foam opportunities Jennifer Markarian reviews new developments in foaming agents, including the

latest technologies, applications and regulatory issues.

23 Polyfi l takes a fresh approach to foaming polypropylene

Polyfi l is using Vistamaxx as a masterbatch carrier material to create new

possibilities for foamed polypropylene sheet and thermoformed parts.

27 Stay sharp! Pelletizer makers maintain their cutting edge

Peter Mapleston reports on how the manufacturers of pelletizing systems are

developing their machine designs and expanding their service networks.

43 Compounding World Forum makes successful debut

The fi rst Compounding World Forum took place in Philadelphia in December.

Jennifer Markarian reports from the event.

51 2013 review: all about additives We report from Düsseldorf on a wide variety of new polymer additives that were

introduced at the K 2013 exhibition.

64 Compounder of the month: Sirmax

66 Dates for your diary

coming next issue� Thermally-conductive compounds � Materials handling � Additives for polyolefi ns

� Click here to make sure you get your copy

contents

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Applied Market Information LtdAMI House, 45-47 Stokes Croft, Bristol, BS1 3QP, United KingdomTel:+44 (0)117 924 9442Fax:+44 (0)117 989 2128www.amiplastics.com

contact usHead of business publishing: Andy Beevers E-mail: abe@amiplastics.comSenior editor: Chris Smith E-mail: cs@amiplastics.comContributing editor: Jennifer Markarian E-mail: editorial@compoundingworld.comDesigner: Nicola CraneAdvertisement manager: Claire Bishop E-mail: claire@amimagazines.com Direct tel: +44 (0)20 8686 8139

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www.compoundingworld.com January 2014 | compounding world 5

news

Plastics Color Corporation

(PCC), the US headquartered

masterbatch maker and

compounder, has announced

plans to significantly expand

production capacity at its

Calumet City, Illinois manufac-

turing facility.

It will add 40,000 ft2 (3,700

m2) to the building and at least

one multi-function compound-

ing line, which it expects to be

operational by late 2014. PCC’s

corporate operations manager,

Wes Woldt said that the new

line will increase capacity at

the site by 40%. The company

plans to add seven to ten new

personnel at the plant,

including an operations

manager.

PCC plans further expansions in late February.

PCC president Doug

Borgsdorf said: “We’ve been

running three shifts at Cal City

since March. Due to a rapid

expansion in our black

production business, we’ve

recently gone to a seven-day-

a-week schedule to meet

customer demand, increasing

our capacity by 18% this

December.”

The company says that its

corporate strategy is to grow

its black capacity in Illinois,

while its facilities in North

Carolina, California and China

focus on liquid colours, colour

concentrates and specialty

solutions. The latter include

new antimicrobials, flame

The plant’s management is

preparing an RFQ for new

extrusion equipment and says

that it plans to select suppliers

Clariant has launched its

annual ColorForward analysis

of colour trends for plastics. It

is the company’s ninth such

guide and predicts colour

trends for 2015.

The analysis is designed to

provide designers and

retardants and anti-counter-

feiting products.

PCC recently added two

new extruders at its Asheboro

facility in North Carolina, and it

is stepping up production in

China and California as well.

Additionally, new liquid colour

production equipment has

been ordered for the Asheboro

facility.

“Our business is growing in

every area as we continually

find ways to solve our custom-

ers’ challenges,” said Borgs-

dorf. “We are also exploring

several opportunities in Latin

America, with a partnership or

acquisition in Brazil at the top

of our list.”

❙ www.plasticscolor.com

manufacturers with a head-

start in the colour selection

process. “In the world of

plastics, colour acts as the

ideal marketing driver to steer

consumers’ purchasing

choices for the future,” said

Judith van Vliet, designer at

ColorWorks Europe/IMEA.

The colour predictions are

based on research of the most

influential societal trends

around the world. Experts

from major trend-watching

organisations and diverse

creative industries contribute

to the process, along with

Clariant’s own ColorWorks

centres around the world.

The palettes they have

selected for 2015 are inspired

by four societal trends that are

expected to have the most

influential global impact in the

near future. These palettes are

entitled ‘Tune in space out’,

‘Live2Live’, ‘Redefining Eden’,

and ‘Raw’. For more informa-

tion visit:

❙ http://bit.ly/CCF2015

Clariant reveals ColorForward 2015 colour forecasts for plastics

Clariant’s newColorForward2015 packpredictscolour trendsfor next year

PCC’s Doug Borgsdorf:

“Our business is growing in

every area”

Epsan, the Turkish

polyamide compounder,

has opened a new office in

Dortmund, Germany to

support its sales in the

country. The facility will be

managed by Adrian

Kaminski, who has

previously held manage-

ment positions at Invista

and Ter Hell.

“The new office shows

our commitment to grow

our business in the

automotive Industry and

Germany through direct

communication, technical

support and sales,” said

Arda Efe, Epsan’s global

sales manager.

❙ www.epsan.com.tr

Epsan opens German sales office

compounding world | January 2014 www.compoundingworld.com6

news

Schulman acquires Prime ColorantsA. Schulman has purchased

Prime Colorants, a producer of

colour and additive master-

batches based in Franklin,

Tennessee, USA, for US$15.1

million.

Prime provides pelletized

colour concentrates and dry

powder colour expertise to

customers in the automotive

and construction markets. It

also provides an entry point for

Schulman in the liquid colour

market. The company employs

around 50 people and expects

2013 revenues to be approxi-

mately US$12 million.

Joseph Gingo, Schulman’s

chairman, president and CEO,

said: “This latest acquisition is

part of our ongoing strategy to

grow our custom colour

capabilities in the United

States, as well as further

transform our US operations

from commodity products to a

business focused on niche

products and services. Colour

remains an area of opportunity

for us in the United States, and

the acquisition of Prime will

enable us to serve customers

better by offering colour

expertise in an area of the

country where we were not

previously located”.

The deal follows Schul-

man’s 2013 acquisitions of

Perrite and Network Polymers.

“Our strong balance sheet and

solid cash flow generation

continue to position the

company well to pursue its

acquisition strategy,” said

Gingo, adding: “We will remain

aggressive in pursuing this

strategy as well as the many

opportunities we are seeing

globally for bolt-on acquisi-

tions.”

❙ www.aschulman.com

Solvay is selling its Benvic

PVC compounding opera-

tions in Europe to OpenGate

Capital. In a separate deal,

Solvay has announced that

it is also selling its majority

stake in the South Ameri-

can PVC producer Solvay

Indupa to Braskem.

OpenGate’s acquisition

of Benvic, which operates

PVC compounding plants in

France, Italy and Spain, is

expected to be completed in

the first half of 2014. Benvic

employs more than 200

people and has annual

revenues of US$220 million.

OpenGate is investing

heavily in Europe’s PVC

supply chain. It acquired

Profialis, a European

supplier of extruded PVC

window and door profiles,

from the Tessenderlo Group

in January 2013. Last

month, OpenGate together

with Alain de Krassny

received approval for their

joint bid to take over Kem

One, the French PVC

production business that

was acquired from Arkema

by Klesch Group in July 2012

(see page 8).

In addition to the Benvic

deal, Solvay is selling its

70.59% stake in Solvay

Indupa, South America’s

second largest PVC

producer, to Braskem.

Solvay Indupa operates two

production sites in Argen-

tina and Brazil and had net

sales of approximately E542

million in 2012.

❙ www.solvay.com

Solvay isselling PVC businesses

Müller Kunststoffe is adding a

new TPE production line at its

plant in Lichtenfels, Germany.

The 4,800 tonnes/year line is

expected to come on stream in

the first quarter of 2014.

The company is part of the

Hexpol TPE group, which also

includes the Elasto businesses

in Sweden, the UK and China.

Its new investment will take

the group’s total capacity to

more than 65,000 tonnes/year.

Müller’s new line be used to

produce Lifoflex and Dryflex

TPE compounds. These

include halogen-free flame

retardant, conductive and food

contact grades, as well as

adhesion products for

multi-component applications,

plus compounds offering

improved compression set

performance.

In addition to the new

production line, Müller is

constructing a new 600 m2

building to expand its technical

centre at Lichtenfels. This will

be used for the development of

customised thermoplastic

elastomers including TPS,

TPO, TPU and polymer blends.

Construction is expected to be

completed by September 2014.

Georg Ender, managing

director at Müller Kunststoffe

said: “The production expan-

sion and investment in

technical resources is a result

of our growth over recent

years and will ensure contin-

ued fast and responsive

customer support, as well as

the development of new

polymer combinations and

compounds.”

❙ www.hexpoltpe.com

Müller to add new TPE capacity

Müller Kunststoffe is increasing TPE compounding capacity and

expanding its technical centre

compounding world | January 2014 www.compoundingworld.com8

news

Kem One, the former

Arkema PVC business, has

been acquired jointly by

OpenGate Capital and Alain

de Krassny. Europe’s

second largest producer of

PVC had been placed into

administration in March

2013 following its acquis-

tion from Arkema by the

Klesch Group in July 2012.

Under the terms of the

takeover, the OpenGate and

Alain de Krassny partner-

ship has also secured an

option to acquire Kem One’s

complementary down-

stream business, which

includes Alphacan and is

known as Kem One

Innovative Vinyls (KOIV).

This produces vinyl

compounds, pipes and

profiles with capacities of

170,000, 35,000 and 45,000

tonnes/year respectively.

Kem One (excluding

KOIV) operates six produc-

tion plants in France and

one in Spain. It has a

capacity of 900,000 tonnes/

year of PVC and 660,000

tonnes/year of caustic soda.

The company employs more

than 1,300 people and has

annual revenues close to

E800 million.

OpenGate, the global

private buyout firm, is

actively investing in the

European PVC supply chain

(see page 6).

Alain de Krassny is a

veteran of the European

chemicals industry and

president of Donau Chemie.

❙ www.kemone.com

Kem One gains new owners

Chemtura has filed a lawsuit

seeking to overturn modifica-

tions to California’s fire safety

standard. The supplier of

brominated flame retardants

says that the amended rules

and a new ‘smoulder-only’ test

weaken fire safety standards

for upholstered furniture and

represent a significant risk to

consumers

Representatives said that

the lawsuit is necessary to

obtain a judicial review of the

revised rules. “The revised rules

require furniture makers to

pass only a cigarette ‘smoulder

test,’ and eliminates a vital

requirement – required by the

law mandating the Bureau to

establish fire safety standards

– that all filling material used in

upholstered furniture pass an

Chemtura fights changes to fire safety standard

‘open-flame’ test to replicate a

candle, match or lighter flame,”

said Anne Noonan, senior vice

president for industrial

engineered products at

Chemtura.

For background information

on the changes to the fire

standard, see the report in last

month’s Compounding World (http://bit.ly/CWDec). For

Chemtura’s full statement

regarding the lawsuit, visit:

❙ http://bit.ly/FRlawsuit

Veka adds PVC recycling lineVeka Recycling has invested

almost E1.2 million in a new

compounding line at its UK site

located at Swanscombe in

Kent. The facility closes the

recycling loop by taking

post-industrial or post-con-

sumer window frame material

and producing high-quality

recyclate suitable for a wide

range of new PVC extruded

products.

Tony Cattini, managing

director of Veka Recycling, said

that the investment in UK

capacity will help to meet

continuing demand for

recycled content in new

products with associated

economic and environmental

benefits.

Veka Recycling is an

accredited Recovinyl recycler

and part of the Veka group, the

world’s largest extruder of PVC

profiles for windows and

doors. The group also runs

PVC recycling operations in

France and Germany.

❙ www.veka-recycling.co.uk

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compounding world | January 2014 www.compoundingworld.com10

news

Ford picks natural fibresFord Motor Company has

specified a cellulose-rein-

forced polypropylene com-

pound for interior components

in its latest Lincoln MKX

crossover vehicle. The natural

fibre composite is supplied by

Weyerhaeuser and is being

used in the floor console

armrest substrate, a structural

component located within the

centre console armrest.

Cellulose-reinforced

polypropylene has been used

on Ford prototype vehicles in

Dow has announced that it

is ending the production of

impact modifiers at

Grangemouth in Scotland. It

is closing the former Rohm

and Haas plant that

manufactures Paraloid

methyl-methacrylate

butadiene styrene (MBS)

based additives for PVC and

engineering plastics.

Dow took control of the

plant in 2009 as part of its

acquisition of Rohm and

Haas. It then invested in the

facility in 2011, increasing

its capacity by 10,000

tonnes/year and upgrading

its technology.

In a statement, Dow said

that the planned closure is

“the consequence of

ongoing economic uncer-

tainty, which has resulted in

a significant deterioration of

demand”. It added: “When

coupled with increases in

manufacturing costs,

competition, fluctuating raw

material and energy prices,

the facility has been

operating in an increasingly

challenging environment”.

Dow put its global

Plastics Additives business

up for sale in March 2013,

but was reported to have

shelved the planned sell-off

in September after bids fell

short of expectations.

Dow continues to

manufacture Paraloid

additives at other produc-

tion sites in the USA,

France, Turkey and

Singapore.

❙ www.dow.com

Dow to close MBS plant in Scotland

the past, but its use on the Lin-

coln MKX is its first commer-

cial application. The part is

being manufactured by

Johnson Controls for the 2014

model.

The tree-harvested natural

fibres are used in place of

traditional glass fibre rein-

forcements, and are claimed to

reduce weight and improve

sustainability. Ford says that

the weight saving in the

component is roughly 6%.

The use of Cellulose

Reinforced Polypropylene is

relatively small in the current

project, but has the potential

to play a bigger role in the

future, explained Ellen Lee,

plastics research technical

expert for Ford. “If we transfer

its use to larger parts, it could

really benefit the vehicle

weight, which benefits fuel

economy,” she said. “Cellulose

has good reinforcement, so we

looked at fibreglass-reinforced

materials for this project.”

❙ www.lincoln.com

Lincoln’s latest MKX features a structural interior part made from cellulose-reinforced PP

Concentrates conference is setto attract a record audienceAMI’s Thermoplastic Concen-

trates 2014 conference, which

takes place this month in Coral

Springs, Florida, USA, is set

for a record attendance of

senior industry experts who

will meet to discuss both

technical and commercial

factors impacting on the

industry’s development.

The quality of discussion is

guaranteed by the fact that

more than 70% of the North

American masterbatch

industry by value will be in

attendance, representing more

than US$2.8 billion in sales

terms. The audience will also

include a significant number of

large concentrate producers

from Asia and Latin America.

A number of leading

customers for concentrates

will also be in attendance,

including the Rank Group,

which is giving a presentation

at the conference on its

current and future product

needs. The company spends

more than US$125 million on

masterbatches each year, so

this review is certain to prompt

a high level of discussion and

debate.

The Thermoplastics

Concentrates conference takes

place on 28-30 January. For

more details, visit:

❙ http://bit.ly/Conc2014

TemplateT H E R M O P L A S T I C CONCENTRATES 2014

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An international marketing, business, and technical conference for the thermoplastic concentrate industry

January 28-30, 2014Ft. Lauderdale Marriott Coral Springs Golf Resort,

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Stephanie Berchem – Conference Coordinator sb@amiplastics-na.com Ph: +1 610 478 0800 Fx: +1 610 478 0900

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www.compoundingworld.com January 2014 | COMPOUNDING WORLD 13

Foaming agents | addivites feature

Jennifer Markarian reviews new developments in foaming agents, including the latest technologies,

applications and regulatory issues

Lightweighting with polymer foams offers the appeal of

cost savings and enhanced sustainability, which is

helping to drive growth in a variety of markets, such as

food and consumer packaging and automotive applica-

tions. Microcellular foams produced using gas injection

and special equipment have been advancing and gaining

attention, but foamed parts made with chemical

foaming agents continue to make up the majority of the

market. Other additives, such as nucleating agents, also

play an important role in these processes.

Regulatory scrutiny is a reality for chemical foaming

agents, as it is for several other polymer additives. The

most commonly used chemical foaming agent,

azodicarbonamide (ADCA or AZO), was listed on the

European Union’s Substances of Very High Concern

(SVHC) candidate list under the REACH directive in

December 2012. ADCA was placed on a draft list of

prioritization (a preliminary step before potential

authorization) in June 2013. Public comment on the

draft closed in September, and some expect that ECHA

will propose that ADCA be considered for authorization.

An ADCA Task Force, which now includes over 50

companies, was established in 2013 by German

company Tramaco and Hebron (the European affi liate of

Otsuka Chemical) to support ADCA under REACH. The

task force worked to raise interest and advocate for

ADCA during the public comment period. This was

challenging because ADCA has been pushed through

the prioritization process more quickly than any other

substance to date, says Cornelia Tietz, project manager

and authorization expert at ReachCentrum, which

manages the task force. ADCA was already restricted in

food contact articles in the EU. While further restric-

tions on use in the EU have not yet been decided, some

have been looking for replacements, but have not

identifi ed good alternatives for all applications.

This situation opens doors for CFA development,

suggests Ned LeMaster, technical manager at Bergen

International. “Take, for example cross-linked foams,”

he says. “They are traditionally made with an AZO-type

chemical foaming agent. Endothermics generally do not

lend themselves to cross-linking due to their broader

decomposition reactions and lower gas yields. This is an

opportunity for new technology.”

“Manufacturers of foamed products try to deempha-

size foam technologies that are viewed in any way as

toxic, for concerns both real and imagined,” comments

Expanding foam opportunities

compounding world | January 2014 www.compoundingworld.com14

addivites feature | Foaming agents

Peter Schroeck, president and CEO of Reedy Interna-

tional. This includes, for example, processes that affect

air quality or climate change, such as ozone-depleting

blowing agents, including HCFCs. Another concern is

that by-products of chemical foaming agents may

be lingering in finished goods, although manufacturers

say that residual levels are minimal.

Maximizing the use of endothermic, carbon dioxide-

based foaming agents to displace AZO-foams will be a

prime goal for many industries, predicts Schroeck. “One

particular challenge for endothermic agents has been

centred around the compounding and eventual activa-

tion temperature of the CFAs within a compound.

Typical AZO foaming agents achieve their full expansion

a full 30–40 °C later than endothermic foaming agents,

allowing the foaming agent to be compounded easily

without prematurely activating it. Endothermic foams

historically have been a little trickier because the

window between compounding temperatures and foam

activation temperatures was so narrow.”

To solve this problem, Reedy introduced Safoam

HT-25, HT-45, and HT powder, which are FDA-grade

endothermic foams with a decomposition curve

designed to match that of AZO foams by reaching full

expansion at temperatures in the range of 200–210°C.

“This will open new windows for compounders of

chemical foaming agents,” says Schroeck.

Reedy also recently introduced the Saftec RB line

that includes products to improve melt strength in PE

and PP and improve chain entanglement in polyesters

and nylon, which enhances the performance of foaming

agents. These additives are designed for post-consum-

er recyclers to improve the performance of reclaimed

materials, but are also useful for improving virgin PET

and nylon for foaming and non-foaming applications.

Bergen International has developed a new product

line of exothermic foaming agents designed for foamed

pipe and profile extrusions, including products for ABS

ColorMatrix is

targeting its

Excelite liquid

foaming agent

at PVC

construction

applications

and PVC cellular-core pipe. The new additives are

claimed to offer several advantages over the bench-

mark for this industry. They include increased line

speeds, lighter profiles, finer and more consistent cell

structures, and lower let-down ratios.

The ABS grade, for example, demonstrated 2-4%

line speed improvements over the leading competitor in

that application, reports LeMaster. The ABS additive

was introduced in mid-2012, and the PVC additive was

introduced in 2013.

Bergen has also launched a line of endothermic/

exothermic blend foaming agents for foamed profile

extrusion. These products have improved throughput

and lower let-down ratios. One product, introduced in

2013, demonstrated reduced scrap through improved

processing stability in plastic lumber applications.

ColorMatrix, a subsidiary of PolyOne, has introduced

new grades of its Excelite liquid foaming agent designed

for PVC construction applications, such as decking,

panels and partitions, profiles and mouldings, and trim

and siding.

The liquid carrier’s good dispersion properties

promote quicker and more consistent incorporation and

foaming compared to solid foaming agents. The even

distribution of active foaming agents is claimed to

create a small, consistent cell structure in the vinyl

sheet or profile. A finer cell structure results in

mechanical property and structural integrity advan-

tages, such as enhanced screw and nail pull properties

and surface hardness.

With a consistent cell structure, it is also less likely

that weak spots will be formed in the sheet or profile,

explains Bjoern Klaas, director of new product develop-

ment and operations at ColorMatrix. He says that even

at densities as low as 0.45g/cm³, mechanical properties

can be achieved that are comparable to, and often

better than, higher density vinyl sheet foamed with

solids at similar or even higher addition rates.

s

compounding world | January 2014 www.compoundingworld.com16

addivites feature | Foaming agents

The liquid foaming agent can be metered directly at

the extruder feed throat, which allows more accurate

dosing. Liquid feeding also eases changeover for PVC

sheet because the dosing rate can be changed as the

sheet thickness is increased or decreased over a range

from 1 to 35 mm, as compared to a solid additive that

would necessitate separate dry blend formulations for

different sheet thicknesses.

ColorMatrix offers zinc-free Excelite formulations.

While the additive does contain AZO, the liquid formula-

tion helps minimize the risk of inhalation compared to

powders during handling and storage. “We are following

the SVHC situation closely and ColorMatrix is an active

participant, working closely with trade associations and

suppliers, in providing data to ECHA on its safe use,”

says Klaas. “Our researchers and technical teams are

constantly exploring new formulations. We are actively

testing new formulations that meet chemical legislation

criteria, but more importantly, provide the same or

improved levels of performance and value to our

customers.”

Other additives can enhance foaming. ColorMatrix

offers a ready-to-use lubricant and nucleating agent

formulation that is specifically tailored to enhance the

performance of Excelite for vinyl sheet. Next-genera-

tion, high-molecular weight process aids, when used

intelligently with certain liquid foaming technologies,

can potentially yield significant consistency, perfor-

mance and cost saving benefits for vinyl converters by

enhancing cellular structure, says Klaas.

Arkema’s Kynar Foam concentrate, introduced last

year for foaming polyvinylidene fluoride (PVDF) resins,

enables the formation of consistent, closed-cell foam

structures. These result in more predictable properties

and better overall chemical exposure properties, says

the company.

The foaming system, which is added at the extrusion

line in the same way as a colour concentrate, was

initially targeted at wire and cable applications and it

has grown in this market. “Wire and cable users like the

easier strippability and greater flexibility that foam

gives, and manufacturers like the lower weight and the

fact that approximately 30% less material is used,”

notes Dave Seiler, Americas business manager and

global advisor for fluoropolymers at Arkema.

At AMI’s Polymer Foam 2013 conference in Hamburg,

Germany, Arkema presented the use of the PVDF foam

concentrate in continuous, extruded pipe applications.

Arkema has also run commercial trials in film, sheet,

and rod applications.

Improvements in PLA foamingFoamed polymers generally have a positive impact on

sustainability measures because they reduce material

use and reduce end-product weight, which can translate

to fuel savings in transportation. Although these benefits

give foams a positive image, expanded polystyrene (EPS)

foam used in disposable packaging and cups has been

given a negative image by environmental groups who say

it takes up too much space in landfills.

Although EPS is not expected to disappear, compa-

nies have been evaluating alternatives. Potential

candidates have been polypropylene (PP) and PET, but

each has its own disadvantages, notes Bergen Interna-

tional’s LeMaster. “PP, for example, does not have

anywhere near the thermal properties of PS, which

makes it difficult to use as a replacement for disposable

hot container application,” he explains. “Reprocessing

issues and cost have been obstacles for foamed PET.

Roadblocks such as these have slowed the development

of a replacement for foamed PS, but it is anticipated

that the efforts will continue.”

Biobased materials such as polylactic acid (PLA) are

an obvious choice for development as an EPS replace-

ment and are just beginning to find commercial use here

and in other foamed applications. One significant hurdle

has been the poor melt strength of PLA, which makes

production of closed cell, low-density foams difficult.

Chain-extending, melt-enhancing additives can be

used to help stabilize foams. Although these additives

increase melt strength, they also substantially increase

the stiffness and viscosity of the polymer melt, bringing

the undesired effects of increasing die pressure and

torque on extrusion equipment, notes Dr Adam Pawlo-

ski, technical director of Interfacial Solutions (IFS),

which provides R&D services to the plastics industry.

IFS recently demonstrated a novel reactive extrusion

process that imparts hyperbranching along the backbone

of compostable or biobased thermoplastics to improve

melt strength as well as reduce die pressure and torque.

“The structures of hyperbranched polymers like PLA

differ from chain-extended polymers because the

Arkema’s

Kynar Foam

concentrate for

PVDF can be

used in wire

and cable

applications

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compounding world | January 2014 www.compoundingworld.com18

addivites feature | Foaming agents

branching reactions occur randomly along the backbone

of the polymer and are not limited to chain ends,”

explains Pawloski. “The high frequency of branching

sites produces many random branches of different sizes

generating a unique polymer structure. Effectively, the

shear viscosity of hyperbranched PLA is the same as

virgin, linear PLA, making it an easily processed

material, but with key improvements in melt rheology.”

In addition, hyperbranched PLA has the ability to

strain harden under elongation, which helps lock in the

cellular structure of foam and therefore reduce cell

collapse. Although both chain-extended polymers and

hyperbranched polymers are branched, IFS found no

evidence for strain hardening in the chain-extended

polymers.

“The ability of hyperbranched polymers to strain

harden is great for foaming applications,” says Pawlo-

ski. “Compared to using chain extended materials, a

processor should make a better foam with reduced die

pressure and torque on processing equipment when

using hyperbranched PLA”.

IFS Engineered Plastic Compounds, the compound-

ing associate of IFS, offers DeTerra biobased polymers,

based on this hyperbranching chemistry, for extrusion,

moulding, and foaming applications, including flame

retardant grades and grades incorporating post-indus-

trial or post-consumer recycled material.

Synbra Technology offers a different solution for

foaming PLA, in which foaming takes place in the solid

state at temperatures less than 100°C. Because the

material is not molten during foaming, there are no

issues with melt strength, explains Jürgen de Jong,

senior product developer at Synbra.

The company’s polymerization process for its

Synterra PLA was developed with Corbion Purac and

Sulzer Chemtech, and the company’s manufacturing

plant started up in 2011. The grade of Synterra PLA

used for foaming is optimized by varying the ratio

between L- and D-lactide in the PLA to control crystal-

linity. “If more than 10-15% D-lactide is used, the PLA

will be amorphous and too heat sensitive to be used for

foaming. If too little D-lactide is used, the polymer

crystallizes too fast to be foamed,” notes de Jong.

Synbra’s BioFoam Expandable PLA is positioned as an

alternative to EPS and is being moulded into a wide

variety of products, from planting trays to surfboards.

BioFoam is also used in insulation and received the Dutch

Construction award in 2011 when it was introduced.

At AMI’s Polymer Foam 2013 conference, de Jong

explained that to produce BioBeads for BioFoam,

Synterra PLA is compounded and, using EPS prefoamer

equipment, impregnated with a physical foaming agent,

carbon dioxide (CO2). The prefoamed pearls are made

with densities of 15 g/litre for loose bead or 30 g/litre

for further processing into moulded parts.

The mechanical properties of BioFoam are currently

slightly less than those of standard EPS at the same

density, and the company is working on gaining a better

understanding this property development. De Jong

explains, “Because the PLA crystallizes in the foaming

process (as required to get shape stability at tempera-

tures above the glass transition), fusion of the foamed

pearls becomes critical, which is reflected by the

mechanical properties.”

In his presentation, de Jong showed that BioFoam is

completely biodegradable; compared to cellulose, the

degradation of BioFoam begins more slowly, but after

60 days there is no difference. BioFoam is registered as

a compostable material under DIN EN 13432-2000-12.

BioFoam also has “Cradle to Cradle” (C2C) certification,

which indicates that it meets this eco-label’s sustain-

ability criteria in material health and reutilization, water

and energy utilization, and social responsibility. The C2C

label has been useful in selling BioFoam both inside

and outside of Europe, comments de Jong.

In October 2013, Synbra announced that it is

collaborating on the launch of the world’s first 100%

biodegradable and 99% biobased surfboard foam. Its

partner in the project is Tecniq, a California-based

company focused on developing environmentally

conscious products. The brandname for the new

surfboard foam technology is Bióm and manufacturing

is scheduled to start in the Netherlands in the third

quarter of 2014. There are also plans to add US

production shortly afterwards.

Companies are

looking at

alternatives to

EPS for

disposable

packaging

applications

s

compounding world | January 2014 www.compoundingworld.com20

addivites feature | Foaming agents

Graphite additives for foam insulationFoamed materials are commonly used as insulation. Dr.

Volker Altstädt, professor in the department of Polymer

Engineering at the University of Bayreuth in Germany,

has been examining the influence of carbon-based

additives on foamed material characteristics that affect

thermal conductivity in extruded polystyrene (XPS)

insulative foam materials. He presented his findings in

a presentation at AMI’s Polymer Foams 2013 conference

in November.

One of the variables affecting thermal conductivity is

infrared radiation. Various carbon-based particles,

including activated carbon, carbon nanofibre, and

expanded graphite, are used as heterogeneous foam

nucleating agents in XPS. These carbon-based particles

can also act as infrared absorbers, although they have a

more significant effect at temperatures greater than

50°C. Foams nucleated with graphite-based particles

improve thermal insulation because of their nucleation

efficiency, as well as their infrared absorption and

reflection capacities, Altstädt demonstrated in his

presentation.

Thermal conductivity of extruded foams also

depends on foam density and cell size. Cell nucleators

can produce low-density foams with smaller cell sizes,

which results in lower thermal conductivity and

therefore better insulation. Thermally reduced graphite

oxide (TRGO) and carbon nanotubes (CNT) produce

smaller cell sizes with greater homogeneity than talc,

and TRGO seemed more effective than CNT. “Particles

of TRGO in the cell walls and struts exert a physical

barrier force that suppresses the growth of big cells

and reduces cell coalescence,” said Altstädt.

Another characteristic of foam is its expansion ratio;

the optimal foam expansion ratio is dictated primarily

by the end-use of the foam. Expansion ratio is affected

by many variables, including processing parameters

and additive parameters, such as particle aspect ratio,

surface area and additive dispersion. In his presenta-

tion, Altstädt compared the influence of talc, CNT, and

TRGO on radial expansion, which is the ratio of the

diameter of the extruded foam to the diameter of the

die. He concluded that the physical barrier force exerted

by TRGO platelets on the cell walls results in a low

expansion ratio. His presentation concluded that TRGO

is a promising, multi-functional nanofiller.

More informationThe papers from the Polymer Foam 2013 conference

can be purchased at http://bit.ly/Foam2013. AMI’s next

Polymer Foams conference takes place on 4-6

November in Cologne, Germany. For more information

about attending, exhibiting or speaking at this event,

please contact Kat Langner: kl@amiplastics.com.

Tel: +44 117 311 1511.

❙ www.amiconferences.com

Click on the links for more information:

❙ www.arkema.com ❙ www.bergeninternational.com ❙ www.biomblanks.com ❙ www.ifsengineeredplasticcompounds.com ❙ www.interfacialsolutions.com ❙ www.polymer-engineering.de (Bayreuth Uni)❙ www.polyone.com ❙ www.purac.com ❙ www.reachcentrum.eu ❙ www.reedyintl.com❙ www.synbra-technology.nl

Synbra and

Tecniq are

planning to

scale up

production of

biobased foam

blanks for

surfboards

A Biom

biodegradable

foam blank is

prepared

during the

surfboard

manufacturing

process

ENTEK_DeanElliot_CW_A4_051812_x1a.indd 1 5/18/12 11:55 AM

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www.compoundingworld.com January 2014 | compounding world 23

Polymer foaming | case study

Masterbatch producer Polyfil developed its new Ecocell

VM1 foaming agent to optimise the production of

lightweight foamed polypropylene sheet. The patented

additive concentrate is designed to create strong, light

and flexible parts. In addition, it can speed up production

times and reduce the energy used during manufacturing.

Polyfil operates a compounding facility in New

Jersey, USA, specialising in functional additive master-

batches. The company paid particular attention to the

specification of the carrier material for its Ecocell VM1

chemical foaming agent (CFA), selecting Vistamaxx

6102 propylene-based elastomer (PBE) from ExxonMo-

bil to give the required improvements in processing and

performance.

Manufacturers of thermoformed products are

striving to reduce weight, while speeding up throughput

and lowering production costs and energy usage.

Replacing standard PP sheet with foamed PP sheet can

help achieve these goals. Making foamed sheet,

however, can be a complex process to get right.

The level of foaming must be carefully controlled and

some additives can alter the properties of the resin. For

example, mechanical strength can be reduced or part

rigidity increased. Vistamaxx can help overcome these

issues.

Based on tests performed by Polyfil, foamed PP

sheets that use its Ecocell VM1 CFA with Vistamaxx can

produce lighter, stronger and more flexible thermofor-

med products compared to those made using Polyfil’s

previous foaming masterbatches based on other carrier

materials. The inherent elastomeric properties of

Vistamaxx PBE help the final part to retain flexibility, by

reducing the tendency towards rigidity caused by

additives like talc or calcium carbonate.

In addition, Vistamaxx can help to decrease thermo-

forming temperatures, saving energy during part manu-

facture. Plus it can increase the retention of foam

content during thermoforming, reducing part weight

and raw material use.

“Ecocell has been well received in the marketplace,”

says Russ Bradley, foams market development

manager at Polyfil. “There’s a great deal of interest in

thermoforming, and using Vistamaxx PBE as a carrier

resin with the foaming agent provides benefits that will

help open doors to that market.”

For example, using Ecocell in PP foamed sheeting

has been found to deliver two main advantages in

thermoformed microwaveable bowl applications. The

incorporation of Vistamaxx PBE reduces cycle times and

also decreases thermoforming oven temperatures by as

Polyfil takes a freshapproach to foamingpolypropylene

Polyfil is using Vistamaxx as a masterbatch carrier material to create

new possibilities for foamed polypropylene sheet and thermoformed parts

Polyfil uses

ExxonMobil’s

Vistamaxx as

the carrier

material for its

Ecocell VM1

foaming agent

masterbatch

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Polymer foaming | case study

much as 200˚F (93˚C), leading to a 25% reduction in

energy usage.

Thermoforming deep-draw bowls can cause PP

foamed sheet cells to open up, but using Ecocell with

Vistamaxx PBE helps to prevent this because the cells

are small. Usually, the thermoforming process removes

around 8% of the cells from the foam. Using Vistamaxx

PBE in the foaming agent not only prevents this loss, but

actually boosts foam content by around 10%. The

outcome is a product that can be 30% lighter and may

use 25% less polymer than a foamed PP sheet that does

not use Vistamaxx PBE with the foaming agent.

Using Ecocell with Vistamaxx PBE for the PP foamed

sheeting also improved the touch and feel of the bowls,

while improving the coeffi cient of friction. This can be a

crucial factor when handling a bowl that is fi lled with

hot, microwaved food.

“We see excellent improvements when we add

1.5%-3.5% Vistamaxx PBE as a carrier resin,” says

Renee Lapierre, Polyfi l’s foams technology manager

(the quoted percentage is the loading in the fi nished

product). “Vistamaxx PBE has been successfully

integrated into processing and production. Once the

process is dialled in, it is easy to

replicate,” he adds.

In addition to offering benefi ts to customers,

Vistamaxx also improves the masterbatch production

process. It can be compounded at lower temperatures

than other polymer carriers, such as low density

polyethylene and polyethylene copolymers. This makes

it well suited to incorporating specialty additives that

are shear- or heat-sensitive.

� www.polyfi lcorp.com� www.exxonmobilchemical.com

process is dialled in, it is easy to

replicate,” he adds.

In addition to offering benefi ts to customers,

Vistamaxx also improves the masterbatch production

process. It can be compounded at lower temperatures Foamed PP

sheet can

increase

throughput

while reducing

production

costs

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www.compoundingworld.com January 2014 | COMPOUNDING WORLD 27

Pelletizers | machinery feature

Peter Mapleston reports on how the manufacturers ofpelletizing systems are developing their machine designs and

expanding their service networks to meet the evolvingneeds of the global compounding industry

Suppliers of strand- and underwater pelletizers make a

point of keeping their designs up to date with the latest

trends in compound formulations. So whether you are

processing really sticky high melt-fl ow polymers, or

long fi bre reinforced compounds with reinforcement

levels up around 80%, there is a product for you.

Whatever type of pelletizer you choose, it is essential

to maintain its condition, particularly with respect to its

blades. Many equipment suppliers have been extending

their sharpening and refurbishment services, especially

in emerging markets.

Read on for an update on what is happening in the

world of pelletizing.

Strand pelletizersCoperion Pelletizing Technology unveiled its new HD

(Heavy Duty) Series strand pelletizers at K 2013. They

are said to be ideal for processing engineering plastics

with high fi ller and reinforcement content. The two new

models have been specially developed for use with

Coperion’s ZSK Mc18 twin-screw extruders. The SP 500

HD handles throughput rates up to 5,000 kg/hour while

the SP 700 HD is designed for up to 6,300 kg/hour.

Strand pelletizers for reinforced plastics are

subjected to extremely high stress, since the materials

are very abrasive, rigid and tough, Coperion notes. In

addition, high throughput requirements demand high

draw-in speed and a large number of strands. The HD

pelletizers have an abrasion-resistant feed opening and

feed mechanism. The rotor runs in bearings on both

sides and is entirely free from play, thus ensuring

constant knife clearance, says the company.

Depending on the actual application, the rotor knives

are made of hardened tool steel, special PM steel or

tungsten carbide. Control of the pelletizer is said to be

easy to integrate into the control and visualization

system of the ZSK Mc18 extruder.

“In view of the high draw-in speeds of between 40

and 120 m/minute and strands numbering between 125

and 150, manual feed of the strands has more or less

reached its capacity limits,” Coperion says. Therefore,

the new pelletizers can be equipped with an automatic

strand feed system that automatically guides the

strands via a water slide and a conveyor belt into the

pelletizer’s feed mechanism.

Labtech Engineering of Thailand manufactures its

new Sidecut pelletizers under worldwide license rights

from Hoshipla of Japan. Labtech claims that they

represent a new concept for the strand pelletizing of

thermoplastics. The pelletizer uses a fan-shaped

cutting wheel that cuts the strands sideways with a

scissors action.

Labtech says that the machine can be used to

Stay sharp! Pelletizer producers maintaintheir cutting edge

Coperion’s

HD strand

pelletizers are

designed to

handle high

loadings of

fi llers and

reinforcements

COMPOUNDING WORLD | January 2014 www.compoundingworld.com28

machinery feature | Pelletizers

pelletize practically any type of

thermoplastic resin, even

materials that cannot be

pelletized using conventional

machines. It cites fl exible PVC

and thermoplastic elastomers

with Shore A hardness values as

low as 5. At the other end of the

scale, because of the gentle shear

cut action, highly-fi lled and brittle

strands can be pelletized without

causing dust and shattering of

the pellets. “Anything that can

be cut with scissors can be

cut with this pelletizer,” says

Daniel Gorander, export sales and

marketing manager.

The Sidecut can produce very long

pellets of up to 50 mm lengths, which

is very useful for fi bre reinforced engi-

neering plastics, Gorander notes. A

special version produces micropellets

with diameters as low as 0.3 mm.

Reduction Engineering Scheer is

responding to demands from the industry for

more up-time and higher production output,

says product manager Tom Kernstock. This means

adopting new metallurgies that provide longer-lasting

parts, and developing improved designs for ease of

maintenance.

The company has just launched a redesigned line of

high-speed pultrusion strand pelletizers that it says

incorporate an extensive range of enhancements. The

system has been developed for fully wetted strand lines

and it is intended to help compounders of long-fi bre

reinforced materials handle increased line speeds while

reducing maintenance requirements.

The LFT Pultrusion Pelletizer has a rotational

cutting speed of 1,200 rpm, twice that of previous

models, allowing for higher linear velocity. “Our

next-generation design was developed in response to

customer demand for a faster, more

productive precision cutter that also offers

easy cleaning,” says Kern-

stock. He adds that the new

pelletizers are not only

faster, but also deliver the

strand control that is neces-

sary for pellet accuracy and

quality.

Models are available in

eccentric and push/pull

designs. The eccentric

model adjusts the rotor to

the bed knife while the

push/pull model adjusts

the bed knife support to the

rotor. The eccentric model

has a redesigned ring gear

adjustment which allows for

precision adjustment and

easier accessibility. Meanwhile, the rotor on the push/

pull version features a load isolator mechanism which

reduces shear load away from the rotor bearing and

allows for cooler operation.

Both models are mounted on a new slide rail

system. The feed rolls and the table are easily movable

for simplifi ed cleaning and maintenance. A new dust

cover attachment is also available.

Another key improvement is the mounting of the

adjustable gap cylinder on a stainless steel cover for

easy adjustability. A position-locking lift arm connects

the cylinder to the upper feed roll. Both models boast a

cutting gap adjustment down to 12 microns.

The new pelletizer has a push distance between the

nip point and the cutting point of less than 9 cm,

compared to over 15 cm for previous models. The

reduced distance minimizes the uncontrolled strand

zone and ensures enhanced quality.

Five models are available, with cutting widths

ranging from 30.5 to 81 cm, and there is also a labora-

tory model for one or two strands.

The company designed an entirely new cutter for the

process, rather than basing the design on a traditional

strand cutter. On compounding lines making reinforced

compounds with chopped glass, speed is not a problem

in pelletizer design, but LFTs, being much harder, are

tougher to cut, with the result that vibrations are

higher, Kernstock says. More attention has to be paid to

minimizing these vibrations to prevent metal-to-metal

Reduction

Engineering

Scheer is

targeting

long-fi bre

applications

with its LFT

pultrusion

pelletizer

Labtech’s

Sidecut

pelletizer uses

a scissor-type

cutting action

to handle a

wide range of

materials

Your #1 Source for Plastic Processing Equipment

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With over 100 years of combined experience

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Reduction Engineering Scheer, Inc. is the

leading Plastics Processing Equipment

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much more. Call us today and we will meet

your individual need for plastic processing.

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Corporate Headquarters235 Progress Blvd.Kent, Ohio 44240 USAPhone: 1-330-677-2225Toll Free: 1-800-844-2927Fax: 1-330-677-4048Salesoh@reductionengineering.comwww.reductionengineering.com

New Strand & Underwater Pelletizers

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Pelletizers | machinery feature

contact, since the cutting gap is around six times less.

“We have to take steps to make the equipment more

robust.”

Reduction Engineering has a history dating back to

the late 80s of producing pelletizers for making LFTs. In

the early days, output rates of under 10 m/minute were

typical, says Kernstock. Today, for fully wetted com-

pounds, it’s closer to 100. “As compounders developed

their processes, we followed suit,” he says.

Automatik Plastics Machinery has launched its

largest single-side-mounted dry-cut strand pelletizer,

the Primo 200E with a cutting width of 200 mm. Pellet

dimensions can be quickly changed by means of an

optional automatic pellet length adjuster, while a

second drive motor for the feed mechanism has an

integrated speed control. When processing abrasive

products and at high production temperatures, the

Primo 200E can be equipped with a separately driven,

highly wear-resistant metal feed roll instead of the

standard elastomer feed roll.

The feed geometry is designed without major

defl ections, so the plastic strands are not subjected to

pre-tensioning prior to cutting. This means that even

highly-fi lled masterbatches can be pelletized in high

qualities, with hardly any longs or dust.

Underwater pelletizersGala says its new Efl ex underwater pelletizing system

derives its name from its two main features: effi ciency

and fl exibility. It is designed to accommodate relatively

Automatik’s

Primo 200E

strand

pelletizer has

an extended

cutting width of

200 mm

Your #1 Source for Plastic Processing Equipment

STUTTGART, GERMANY • CHAPECO, BRAZIL • SHANGHAI, CHINA

Pelletizer Rebuilds

Before

After

With over 100 years of combined experience

and manufacturing capabilities worldwide,

Reduction Engineering Scheer, Inc. is the

leading Plastics Processing Equipment

Manufacturer. We meet the plastic industries

need for complete Strand & Underwater

Pelletizing Systems, rebuilt equipment and

dies. Also, located in our Headquarters in

Kent Ohio, is the largest operation for service

work in the United States. Service work we

succeed in is, pelletizer rotors, feed-rolls, dies,

complete pelletizer machine rebuilds, and

much more. Call us today and we will meet

your individual need for plastic processing.

Strand Conveyor Stainless Steel Water Bath

Pelletizer Rotor Service Work

Strand Air Knife

New & Rebuilt Dies

Corporate Headquarters235 Progress Blvd.Kent, Ohio 44240 USAPhone: 1-330-677-2225Toll Free: 1-800-844-2927Fax: 1-330-677-4048Salesoh@reductionengineering.comwww.reductionengineering.com

New Strand & Underwater Pelletizers

Sharpening Service Die & Equipment Rebuilds OEM Spare Parts

Processing EquipmentProcessing EquipmentProcessing EquipmentProcessing EquipmentProcessing EquipmentProcessing EquipmentProcessing EquipmentProcessing EquipmentProcessing EquipmentProcessing EquipmentProcessing EquipmentProcessing EquipmentProcessing Equipment

T200 Series Pelletizer

CLICK HERE TO GET IN TOUCH

COMPOUNDING WORLD | January 2014 www.compoundingworld.com32

machinery feature | Pelletizers

small production quantities and/or frequent material

changes. Gala-Europe managing director Michael Eloo

says that the Efl ex system can be cleaned and/or

prepared for the next job within minutes.

Various fi ltration systems are available. “Depending

on the selected option, it will in most cases no longer be

necessary to replace the process water, even in case of

drastic changes of product or colour,” says Eloo. “This

not only saves valuable resources and cleaning time but

also eliminates the need to reheat the fresh process

water, which again saves energy costs.”

Gala’s EAC (Electronically Adjustable Cutter)

advanced pelletizer features automated blade advance,

periodical blade grinding during the pellet production,

and blade monitoring. Eloo says that on previous

models, automation was implemented with pneumatic

or hydraulic actuation controlled by valve positions and

PLC controlled blade advance. “While the overall

function was always ensured, the complexity of the

parts working hand in hand could be considered a

downside,” he says. While failures were rare, related

troubleshooting meant that the maintenance staff had

several potential paths to check.

To remedy this, Gala integrated the stepper motor

advance into its MAP (Manually Adjustable Pelletizer)

base machine, and eliminated several components from

the A5-PAC pneumatically adjusted cutter, Gala’s

previous state-of-the-art pelletizer with full automation.

This not only reduced the complexity but also signifi -

cantly improved the precision of the overall machine

concept. The EAC also actively retracts the blade off the

die plate surface to minimize the direct contact of these

tools during the process. This results in a signifi cant

reduction of wear on both the die face and the blades.

The EAC pelletizer comes with a mechanical seal as

a standard. It is available in all of the Gala pelletizer

sizes, and Gala pelletizers of any model and size can be

upgraded to the EAC version. As with the previous

models, a blade position indication is available as an

option.

Eloo says EAC pelletizers show “a marked reduction”

of blade and die plate wear in direct comparison with

other pelletizing equipment. “In some applications, the

blade life was more than doubled while the die plates

lasted many months longer than before, even in

extremely abrasive applications.”

Nordson BKG has introduced an innovative water

fi ltration design for its underwater pelletizers that uses

substantially less energy than previous systems and

reduces the release of heat to the workplace. The new

Optigon system is rated at using only 1,440 kW per year

(measured at 8,000 hours), compared with 44,000 kW

and 98,480 kW for the company’s Optiline and Polyline

systems, respectively.

Insulation on BKG’s optional water systems helps to

conserve energy and prevent its release to the environ-

ment. It also serves as touch-protection for workers.

Die plate rims are provided with thermal insulation,

which ensures a uniform temperature profi le in the fl ow

channels and retention of heat in the die plate. The

energy saving potential in comparison with conventional

die plates is said to be about 30%.

Motors used in the company’s pelletizing systems

already achieve the IE2 classifi cation for energy

effi ciency (a ranking of “High Effi ciency”). Nordson BKG

intends to increase energy effi ciency to the IE3 classifi -

cation (“Premium Effi ciency”) in the near future.

Italian pelletizer supplier Filtec recently appointed

ADG Solutions as its exclusive distributor in North

America. ADG Solutions president Sandy Guthrie says

his company will supply Filtec products and parts as

Gala’s Efl ex

underwater

pelletizing

system is

optimised to

handle

frequent

material

changes

Nordson BKG’s Optigon water fi ltration system makes a major contribution to energy effi ciency

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INNOVATION CUSTOMIZEDPUMP, PELLETIZING & FILTRATION SYSTEMS

well as providing technical support and engineering

services. Its initial offering is the GRO water ring

pelletizer, which is available in models with output

capabilities from 40 to 5,000 kg/hour.

“In comparison with other water-ring systems, the

Filtec GRO pelletizer exhibits a longer working life and

entails less downtime for job changeovers and mainte-

nance,” Guthrie claims. “Its one-piece design, with fully

integrated cutting chamber, water system, and dryer,

eliminates complications like extra piping and water

overflows.” He adds that wear to the die face and blades

is reduced thanks to a blade-holding mechanism that

allows the blades to “float,” accommodating surface

variations in the die face.

Econ developed its EUP 10 underwater pelletizing

system for laboratory applications – it can produce

around 1-35 kg/hour of pellets. “The principle is the

same as for our bigger machines, there are just fewer

features installed,” says Magdalena Deisl in sales and

marketing.

When started, the melt flow is directed downwards

by the polymer diverter valve. Once a constant melt flow

is given, the stream is redirected and the die plate is

rinsed with melt. As soon as the melt is continuously

emerging from each hole, the stream is once again

directed downwards. The die plate is cleaned and the

pelletizer housing is fixed to the pelletizing head.

Afterwards, the melt is directed to the pelletizing head

with the die plate installed, and the emerging melt

strands are pelletized under water. The machine can be

used for all thermoplastic materials. It incorporates

Econ’s patented thermal insulation technology to

prevent “freezing” of the die holes.

At your servicePelletizers are by nature robust pieces of equipment,

and tend to last decades. As output rates of compound-

ing extruders have continued to rise, pelletizer makers

have found it useful to design retrofit packages to

enable their existing installed equipment to keep pace

with upstream units.

Davis-Standard says that its pelletizer debottleneck-

ing retrofit technology has proven very successful,

enabling substantial output increases while keeping

equipment footprint unaltered. Charles Crumb,

Filtec’s GRO

water ring

pelletizer is

designed to

provide a long

working life

compounding world | January 2014 www.compoundingworld.com36

machinery feature | Pelletizers

business group manager for extrusion pelletizing

systems, says that improved model designs can

increase throughput by up to 25% at low cost, enabling

short payback times. A new die plate design and a

conversion kit can nearly double the knife assembly life

on existing pelletizers.

“The latest pelletizer die plate design can increase

product throughput rate proportional to an increase

number or size of the die plate orifice holes,” Crumb

says. “This technology also improves cutting face

longevity, internal heat media distribution, and allows

ease of cleaning.”

In addition, the design enables greater process

flexibility for a broad melt viscosity processing range

without a die change. The technology was developed to

support existing markets, de-bottlenecking projects and

improved scrap recovery as well as new markets such

as bio-based resins, Crumb says.

Automatik makes more than 800 new cutting rotors

for strand pelletizers a year at its own factory, as well

as refurbishing and sharpening almost 4,000 at its six

sharpening centres in Brazil, Germany, China, Malaysia,

Taiwan and the USA. The sharpening service is provided

for all common rotor types on the market, including

those from other manufacturers. A rotor can be

sharpened as many as 15 times, depending on the

degree of wear and the rotor type.

The type of steel used for the rotor knife has an

important influence on cutting performance and should

be selected in line with the plastic being processed,

says Thomas Willemsen, director of Automatik’s

Aftersales BU.

Available options range from martensitic chrome

steel, through powder metallurgy steels and tungsten

carbide steels, to a special ceramic material. The tooth

profile of the rotor is a further key factor influencing the

cost-effective operation of a pelletizing system. Automa-

tik has a range of 15 different profiles, and new geom-

Soredi goes underwater with AutomatikItalian compounder Soredi has grown

over the past 30 years from a small,

family-run operation to a major

producer with an annual capacity of

over 16,000 tonnes. It produces

compounds based on 15 different

thermoplastics, including 23 grades of

its Niplene polypropylene-based

products.

Soredi has traditionally used

dry-cut pelletizing systems, but in the

last few years it has started using

underwater pelletizing, which its

equipment supplier Automatik

Plastics Machinery says is more

effective for its particular require-

ments.

“We became familiar with the

Automatik dry-cut pelletizer technol-

ogy when we formed our company,

and in 2009 we were introduced to the

underwater cutting system,” says

Soredi’s general manager Giorgio

Ghidini. “After watching the Sphero

100 machine in action, we found that

there was less wear to the equipment,

it offered greater flexibility during

production when we needed to change the

colour of the granules, the granules

produced were of a perfect spherical size

and there was a reduction in the amount

of dust that was created during the

cutting process.”

Automatik says the Sphero 100

features a “unique knife-head design

and optimized water-flow conditions

within the cutting chamber that

combine to ensure the production of

perfectly spherical pellets that are

ideally suited for further processing.”

It can handle up to 8,600 kg/hour of

material.

Highlight features include

optimized melt-flow channels that

reduce the residence time and

increase product quality; the absence

of an internal adapter that results in a

reduction of energy consumption; and

a bolted-through diverter valve that

connects directly to the valve plate,

eliminating the build-up of polymer

deposits

“We are extremely satisfied with

the performance of the Sphero 100

cutting system and also Automatik’s

Duro 2000 belt dryer,” says Ghidini.

“More importantly, our clients are

very satisfied to receive the type of

granules that we are now producing,

which flow very easily during their

production processes.”

❙ www.soredi.it❙ www.maag.com

Automatik’s Sphero pelletizer boasts a

special knife-head design and optimized

water-flow patterns

The Instant Expert: Plastics, Processing and PropertiesGoodship, 2010€100.00 or £82.50 or $125.00

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Visit www.pidbooks.com for hundreds of recent titles, easy online ordering,

special offers and clearance bargains!Order online or by telephone, fax or email. Contact Matt Wherlock,

Tel: +44 (0)117 924 9442 Fax: +44 (0)117 9892128 email: mjw@amiplastics.comAll prices are correct at the time of publication but may be subject to change.

Please check the Plastics Information Direct website for current prices and shipping charges.

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Tel: 03733 55 09 0 - Fax: 03733 55 09 20� � � � ISO 9001 0 - 9000 0 - 650 10 �

Email: info@a-form.deWebsite: www.a-form.de

A-Z AUSRÜSTUNG UND ZUBEHÖR GmbH & Co. KG

Tel: 02324 92020 - Fax: 02324 920299� � � � � ISO 9001; 16949 1 - 1500 50 - 500 15 � ��

Email: info@az-hattingen.deWebsite: www.az-hattingen.de

A. FOLLMANN GmbH

Tel: 06508 476 - Fax: 06508 59620 - 980 50 - 350 17 �

Email: kontakt@afo-online.deWebsite: www.afo-online.de

A. KAYSER AUTOMOTIVE SYSTEMS GmbH

Tel: 05561 7902 0 - Fax: 05561 7902 2090� � � � � � � � ISO 9001; 14001;16949

3 - 500 40 - 360 100 � ��

Email: info@kayser-automotive.com -Website: www.kayser-automotive.com

A. RÖSLER GmbH

Tel: 02206 2369 - Fax: 02206 4023� � � 0.1 - 220 0 - 180 12 �

Email: info@a-roesler.de - Website: www.a-roesler.de

A. U. K. MÜLLER GmbH & Co. KG

Tel: 0211 7391 0 - Fax: 0211 7391 281ISO 9001 �

Email: info@akmueller.deWebsite: www.akmueller.de

ABEL GmbH & Co. KG

Tel: 02358 315 - Fax: 02358 8541� � ISO 9001 0.5 - 200 22 - 100 15 �

Email: info@abel-pllastic.deWebsite: www.abel-plastic.de

ACCUMA DEUTSCHLAND GmbH

Tel: 03583 5166 0 - Fax: 03583 5166 22ISO 9001 23 �

Email: info@accuma.deWebsite: www.accuma.de

ACLA-WERKE GmbH

Tel: 0221 69998 0 - Fax: 0221 697121� � � � ISO 9001 1 - 250 15 - 250 15 ��

Email: info@acla-werke.deWebsite: www.acla-werke.de

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THE INJECTION MOULDING INDUSTRY IN GERMANY Germany is without a doubt the powerhouse of the European injection moulding industry. In depth knowledge of this industry can be yours with AMI’s new comprehensive guides and database.

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Services & machinery

Addresses, contacts, polymers & markets

8Click here for more details

CD database functions include:• Search and select records by name, country, polymer, market, number of machines, etc.

• Export addresses and contacts to an excel spreadsheet

www.ami-publishing.com

Applied Market Information Ltd.6 Pritchard StreetBristol, BS2 8RHUnited Kingdom

Tel: +44 (0) 117 924 9442 email: sales@amiplastics.com Fax: +44 (0) 117 989 2128 www.amiplastics.com

editionedition 88AMI’s VerzeichnisDIE DEUTSCHE SPRITZGUSSINDUSTRIE Band 1: Norddeutschland

edition 888

AMI’s Guide to the Injection Moulding Industry inGermany Volume 1: North Germany

Applied Market Information Ltd.6 Pritchard StreetBristol, BS2 8RHUnited Kingdom

Tel: +44 (0) 117 924 9442 email: sales@amiplastics.com Fax: +44 (0) 117 989 2128 www.amiplastics.com

editionedition 88AMI’s VerzeichnisDIE DEUTSCHE SPRITZGUSSINDUSTRIE Band 2: Süddeutschland

edition 888

AMI’s Guide to the Injection Moulding Industry inGermany Volume 2: South Germany

A. KAYSER AUTOMOTIVE SYSTEMS GmbHHullerser Landstr. 4337574 Einbeck � � � � � � � � � �� � � � � � � � � �� � � � � � � � � �� � � � � � � � � �� � � � � � � � � �

Contact: Herr H. Borth, Geschäftsführer

A. RÖSLER GmbHWiesenauel 4051491 Overath � � � � � � � � � � � � � � � � � � � � � � � �� � � � � � � � � � � � � � � � � � � � � � � �� � � � � � � � � � � � � � � � � � � � � � � �� � � � � � � � � � � � � � � � � � � � � � � �� � � � � � � � � � � � � � � � � � � � � � � �

Contact: Herr G. Rösler, Inhaber

A. U. K. MÜLLER GmbH & Co. KGDresdner Strasse 16240595 DüsseldorfContact:

ABEL GmbH & Co. KG

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Learn all about...

2280 injection

moulders which

process over 2 million

tonnes of polymers

and operate over

55,000 machines.

CD database format:

The data from the two books is also combined into one fully searchable database

Book format:

The data is available in two seperate books,Volume 1 North Germany & Volume 2 South Germany

info@kayser-automotive.com -Website: www.kayser-automotive.com

A. RÖSLER GmbH

Tel: 02206 2369 - Fax: 02206 4023�

Email: info@a-roesler.de - Website: www.a-roesler.de

A. U. K. MÜLLER GmbH & Co. KG

Tel: 0211 7391 0 - Fax: 0211 7391 281�

Email: info@akmueller.deWebsite: www.akmueller.de

ABEL GmbH & Co. KG

Tel: 02358 315 - Fax: 02358 8541�

Email: info@abel-pllastic.deWebsite: www.abel-plastic.de

ACCUMA DEUTSCHLAND GmbH

Tel: 03583 5166 0 - Fax: 03583 5166 22�

Email: info@accuma.deWebsite: www.accuma.de

ACLA-WERKE GmbH

Tel: 0221 69998 0 - Fax: 0221 697121��

Email: info@acla-werke.deWebsite: www.acla-werke.de

Available as a fully

searchable database

NEW 2013

Pelletizers | machinery feature

etries have been developed specially for softer plastics.

The importance of specifying the right cutting

components is highlighted in case studies provided by

Willemsen. For example, one compounder was unhappy

with the durability of a rotor after it changed the TiO2

content in a compound from 1% to as much as 8%.

Following consultations with Automatik, the compound-

er installed a new rotor and cutting blade

tailored to the new formulation. This

enabled the service life of the rotor to

be quadrupled, delivering a substantial

reduction in production costs.

Another customer was helped to

significantly improve pellet quality in the

processing of a TPU with a Shore A

hardness below 75 by replacing the rotor

and installing a new cutting blade tailored

specially to its material. Originally, the

pelletizer was producing more than 30%

skewed cuts and approximately 5% overlong

pellets. After the upgrade, skewed cuts were

down to just 2 or 3% and overlong pellets were

occurring only sporadically.

Producers of strand pelletizers are challenged with

the task of designing machinery that is versatile enough

to handle materials ranging from extremely high melt

flow resins through to 70-80% filled long glass fibre

reinforced pultruded products, says Jim Forgash, vice

Econ’s EUP 10

makes its

underwater

pelletizing

technology

available for

lab-scale

operations

Moscow, 28.01.-31.01.2014Hall Forum, stand FA49Underwater pelletizing systems.

www.bkg.de | +49.251.26501.0

machinery feature | Pelletizers

president sales at Bay Plastics Machinery. He says that

the company has traditionally focused on markets in

North and South America, but more recently it has

added a new emphasis on supporting markets through-

out Asia. Ongoing sales growth has led to recent facility

expansions, with BPM nearly doubling its manufactur-

ing fl oor space.

“This increased capacity and in-house engineering

has led to a signifi cant growth in the support of spare

parts for any and all brands of pelletizers throughout

the world,” says Forgash. He also puts growth down to a

surge in demand from markets such as recycling,

pultrusion and micro-pelletizing for which BPM offers

a variety of specialized products.

Reduction Engineering Scheer recently announced a

signifi cant expansion of its sales and service operations

in the Far East. The company has doubled the size of its

China operation in Shanghai and established a new

sales and service centre in Tainan, Taiwan, to support

its customer base in Thailand, Malaysia, Singapore,

Indonesia, and Vietnam. It has constructed a new 600

m2 production area and renovated 200 m2 of an existing

facility for offi ce space. The expansion comes in

response to strong demand for pelletizing machines in

the region, according to Paul Merich, Asia-Pacifi c sales

director for Reduction Engineering Scheer.

The company produces replacement pelletizer blades

for its own equipment and for other OEMs. It has

grinding operations in the US, Germany, in China, as

well as in Taiwan. Half of the company’s sharpening

business is for third party equipment – in fact, its origins

were in sharpening, before buying pelletizing equipment

businesses, fi rst from Conair, and later from Scheer.

Click on the links for more information:

� www.coperion.com � www.labtechengineering.com � www.reductionengineering.com � www.maag.com (Automatik)� www.gala-industries.com � www.bkg.de� www.fi ltec.it � www.adgs.net � www.econ.eu � www.davis-standard.com � www.bayplasticsmachinery.com

Davis-Standard

offers retrofi t

die plate

designs that

boost through-

puts and

reduce knife

wear

DON’T MISS A SINGLE ISSUE OF

CLICK HERE TO SUBSCRIBE NOW

DON’T MISS A SINGLE ISSUE OF

Available on the web and as Apple iOS and Android Apps for tablets and smartphones, Injection World magazine is 100% focused on the technology of injection moulding. And it is available free.

Companies included:• Injection moulders• Blow moulders• Rotational moulders• PE fi lm extruders• Sheet extruders• Cable extruders• Pipe extruders• Profi le extruders• Tube and hose extruders• Compounders and

masterbatch producers

By the end of 2013, total polymer demand in Hungary is set to reach 784,000, seeing

an increase of 6.7% on the previous year and Hungary’s

highest demand to date.

www.ami-publishing.com

4th editionAMI’s Directory

PLASTICS PROCESSORS IN HUNGARY

LOCATION & PRODUCTION DETAILS OF 440 PLASTICS PROCESSING PLANTS

LOCATION & PRODUCTION DETAILS OF PLASTICS PROCESSING PLANTS

PLASTICS PROCESSORS IN HUNGARY

AMI’s Directory

4th edition

LOCATION & PRODUCTION DETAILS OF PLASTICS PROCESSING PLANTS

PLASTICS PROCESSORS IN HUNGARY

AMI’s Directory

4th edition

Book:£205/€245/$320

AMI’s Directory of Plastics Processors in Hungary Blow moulders

81

MEDICAL PRODUCT SZÖVETKEZET Type: Custom Polymers processed: LDPE, HDPE, PP, PVC, PETMarkets served: Food/Drink, House Chemicals, Medical/Pharma, Bottles for Automotive Industry (For Fuel). Size: Under 1 litre, 1 to 5 litres, 5 to 25 litres. Services offered: Tool Design, Tool Manufacture, Assembly, Filling, Pad Printing, Silk Screen Printing Polymer throughput: Less than 500 tonnes per annum

MEPLA MŰANYAG ÉS FÉMIPARI KFT. Type: Custom Polymers processed: LDPE, HDPE, PP, PET Markets served: Food/Drink, House Chemicals, Milk Bottles; Water Bottles; Washing Liquid Bottles. Size: Under 1 litre, 1 to 5 litres. Services offered: Assembly, Pad Printing Numbers of colours: 1Polymer throughput: Less than 500 tonnes per annum

METALCAR KFT. Type: Custom, In House Polymers processed: LDPE, HDPE Markets served: Toys Size: Under 1 litre, 1 to 5 litres. Services offered: Pad Printing Polymer throughput: Less than 500 tonnes per annum

MIKROPAKK KFT. -BUDAPEST- Type: Custom Polymers processed: LDPE, HDPE Markets served: Cosmetics/Toiletries,Medical/Pharma, Non-Packaging Technical Parts (excluding Automotive Parts) Size: Under 1 litre. Services offered: Tool Design, Tool Manufacture, Product Development, Assembly, Silk Screen Printing, Design Polymer throughput: Less than 500 tonnes per annum

MOTOPLAST KFT. Type: Proprietary Products Polymers processed: HDPE Markets served: Toys, Ride on Three Wheels Motorcycles (The Wheels). Services offered: Tool Design, Tool Manufacture, Product Development, Assembly, Silk Screen Printing, Design Numbers of colours: 11Polymer throughput: Less than 500 tonnes per annum

NEW-MŰKER MŰANYAGFELDOLGOZÓ KFT. Type: Custom Polymers processed: LDPE, HDPE, PP Markets served: Food/Drink, House Chemicals, Horticulture/Agriculture. Size: Under 1 litre, 1 to 5 litres. Polymer throughput: Less than 500 tonnes per annum

PACCOR HUNGARY ALMAND KFT. Type: Custom Polymers processed: LDPE, HDPE, PP, PET, PETGMarkets served: Cosmetics/Toiletries, Food/Drink, House Chemicals, Industrial Chemicals(including IBCs and Big Drums), Medical/Pharma Size: Under 1 litre, 1 to 5 litres. Services offered: Product Development Polymer throughput: Between 1001 and 2500 tonnes per annum

PACCOR HUNGARY EFFEKT KFT. Type: Custom Polymers processed: HDPE, PP Markets served: Auto Fuel Tanks, Food/Drink, Industrial Chemicals(including IBCs and Big Drums), Non-Packaging Technical Parts (excluding Automotive Parts), Jerrycans; Flasks; Hospital Waste Containers; Barrels. Size: 1 to 5 litres, 5 to 25 litres, 25 to 220 litres. Services offered: Assembly, Labeling Polymer throughput: Between 2501 and 5000 tonnes per annum

PET HUNGARY KFT. Type: Custom Polymers processed: PET, APET Markets served: Food/Drink, House Chemicals, Medical/Pharma, Body Builder Drink Bottles. Size: Under 1 litre, 1 to 5 litres. Polymer throughput: No polymer consumption available

PET STAR KFT. Type: Custom Polymers processed: PET, CPET Markets served: Cosmetics/Toiletries, House Chemicals Size: Under 1 litre, 1 to 5 litres. Polymer throughput: No polymer consumption available

PET-EXPRESSZ KFT. Type: Custom Polymers processed: PETMarkets served: Food/Drink, House Chemicals Size: Under 1 litre, 1 to 5 litres. Polymer throughput: No polymer consumption available

MEDICAL PRODUCT SZÖVETKEZETCustom

Polymers processed: LDPE, HDPE, PP, PVC,

Markets served: Food/Drink, House Chemicals, Medical/Pharma, Bottles for Automotive Industry

Under 1 litre, 1 to 5 litres, 5 to 25 litres. Services offered: Tool Design, Tool Manufacture, Assembly, Filling, Pad Printing, Silk Screen Printing Polymer throughput: Less than 500 tonnes per

Polymers, products & machinery

Gold database: £460/ €550/$715

LOCATION & PRODUCTION DETAILS OF PLASTICS PROCESSING PLANTS

Polymers processed: PET

MEPLA MŰANYAG ÉS FÉMIPARI KFT.Custom

Polymers processed: Markets served: Milk Bottles; Water Bottles

Under 1 litre, 1 to 5 litres. Services offered: Numbers of coloursPolymer throughput:

METALCAR KFT.Custom, In House

Polymers processed: Markets served:

Under 1 litre, 1 to 5 litres. Services offered: Polymer throughput:

MIKROPAKK KFT. -BUDAPEST-Custom

Polymers processed: Markets served: Medical/Pharma, Non-Packaging Technical Parts (excluding Auto

Under 1 litre. Services offered: Product Development, Assembly, Silk Screen Printing, Design Polymer throughput:

MOTOPLAST KFT.Proprietary Products

Polymers processed: Markets served: Motorcycles (The Wheels). Services offered: Product Development, Assembly, Silk Screen Printing, Design Numbers of coloursPolymer throughput:

Polymers processed:

Markets served: Medical/Pharma, Bottles (For Fuel).

Under 1 litre, 1 to 5 litres, 5 to 25 litres. Services offered: Assembly, Filling, Pad Printing, Silk Screen Printing Polymer throughput:

Address Listing AMI’s Directory of Plastics Processors in Hungary

36

GYURIK MŰANYAG KFT. Egres u. 11. 2624 Szokolya Tel: 27 585 010 Fax: 27 375 038 E-mail: info@gyurik.hu Website: www.gyurik.hu Contact: Mr. Gy. Gyurik, Managing Director Parent company: Privately Owned ISO registration: ISO 9002. Processes operated: Injection moulding. HAJRÁ KFT. Tarányi J. u. 14. 4030 Debrecen Tel: 052 471 874 Fax: 052 471 874 E-mail: hajrakft@freemail.hu Website: www.hajraKFT.hu Contact: Mr. J. Szabó, Managing Director Parent company: Privately Owned Processes operated: PE film extrusion. HA-NO PLASZT KFT. Orion u. 14. 1214 Budapest Tel: 12 761 911 Fax: 12 761 911 E-mail: hanoplast@mail.datanet.hu Contact: Mr. Z. Hamvas, Managing Director Parent company: Privately Owned Processes operated: Injection moulding, Blow moulding, Tube and Hose extrusion. HÁRSHEGYI LÁSZLÓ Apponyi út 16. 7084 Pincehely Tel: 074 406 005 Fax: 074 406 005 E-mail: harshegyila@citromail.hu Contact: Mr. L. Hárshegyi, Owner Parent company: Privately Owned Processes operated: Blow moulding.

HD - ROTATECH KFT. Ipari Park Bánki Donát út 7528/5 HRSZ 2373 Dabas Tel: 52 514 010 Fax: 52 514 011 E-mail: hd-rotatech@hd-rotatech.hu Website: www.hd-rotatech.hu Parent company: Privately Owned Processes operated: Rotational moulding. HEMBACH KFT. Szabadság út 41. 8154 Polgárdi Tel: 022 366 261 Fax: 022 576 025 E-mail: hembach@t-online.hu Website: www.hembach.hu Contact: Mrs. Z. Hembach, Managing Director Parent company: Privately Owned. ISO registration: ISO 9001; 14001. Processes operated: PE film extrusion. HENKEL MAGYARORSZÁG KFT. Vásártér 2. 5516 Kőrösladány Tel: 066 474 666 Fax: 066 474 996 E-mail: name.surname@henkel.com Website: www.henkel.hu Contact: Mrs. A. Ujhelyiné Mojzsis, Managing Director Parent company: Henkel Group, Germany ISO registration: ISO 9001. Processes operated: Blow moulding. HE-PA HUNGARY PLAST KFT. József Attila u. 80. 8284 Nemesgulács Tel: 87 433 322 Fax: 87 433 389 Website: www.hepahungary.hu Contact: Mr. A. Rehberg, Managing Director Parent company: Privately Owned ISO registration: ISO 9001. Processes operated: Injection moulding.

Addresses & contacts

81

Services offered: Assembly, Labeling Polymer throughput: Between 2501 and 5000 tonnes per annum

PET HUNGARY KFT.Type: Custom Polymers processed: PET, APET Markets served: Food/Drink, House Chemicals, Medical/Pharma, Body Builder Drink Bottles. Size: Under 1 litre, 1 to 5 litres. Polymer throughput: No polymer consumption available

PET STAR KFT.Type: Custom Polymers processed: Markets served: Cosmetics/Toiletries, House Chemicals Size: Under 1 litre, 1 to 5 litres. Polymer throughput: available

PET-EXPRESSZ KFT.Type: Custom Polymers processed: Markets served: Food/Drink, House Chemicals Size: Under 1 litre, 1 to 5 litres. Polymer throughput: available

Available as a fully

searchable database

36

HÁRSHEGYI LÁSZLÓApponyi út 16. 7084 Pincehely Tel: 074 406 005 Fax: 074 406 005 E-mail: harshegyila@citromail.hu Contact: Mr. L. Hárshegyi, Owner

Parent company: Privately Owned

Processes operated: Blow moulding.

Processes operated

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

Parent company:ISO registration:

Processes operated

• Full addresses and numbers of all manufacturing plants

• Managerial contacts• Polymers processed• Markets served/products manufactured• Machinery information

Which information is shown:

For more information contact us on sales@amiplastics.com or Tel: +44 (0) 117 9249442

81

Click here for more details

www.compoundingworld.com January 2014 | COMPOUNDING WORLD 43

Compounding World Forum | event review

The fi rst Compounding World Forum took place in Philadelphia in

December. Jennifer Markarian reports from the event

More than 220 key players from throughout the

thermoplastics compounding industry gathered in

Philadelphia, PA, USA last month for the fi rst Com-

pounding World Forum.

Organised by AMI and Compounding World magazine,

the conference and exhibition attracted attendees from

across America and from further afi eld, including

representatives from Europe, Asia, The Middle East and

Africa. They heard expert presentations about the latest

trends and developments in market demand, business

strategies, materials technology and process optimisation.

Andy Beevers, publisher and editor of Compounding World, chaired the conference and gave the opening

presentation. He highlighted the critical role that

compounders play in bridging the gap between the

relatively small number of resin, additive and pigment

producers – a few hundred major players around the

world – and the huge number of plastics processors.

There are more than 200,000, of the latter, each with their

own requirements. Compounders help to tailor materials

to meet these needs, and also act as educators who teach

how plastics can provide value to an application.

OpportunitiesCompounders must understand the changing forces in

technology, regulations, the environment and the

marketplace and then must balance materials exper-

tise, design services and processing skill to serve the

market, explained Roger Avakian, vice-president of

scientifi c development at PolyOne. In commercializing

biobased compounds, for example, PolyOne recognized

a market shift to long-lasting, biobased materials and

identifi ed the need for durable, fl ame-retardant

biobased compounds. He also discussed 3D printing as

another emerging opportunity for compounders.

Medical compounding is an established and growing

opportunity for compounders willing to invest in this

highly regulated industry. Minimally invasive surgery

devices, such as catheters, are one high-growth area in

which materials and additives play an important

functional role. Larry Acquarulo, founder and CEO of

Foster Corporation, described fi llers that provide x-ray

visibility, surface modifi ers to optimize the critical

coeffi cient of friction, and nanoclays that can reinforce

thin-wall catheter tubes.

To operate in this medical market, “clean” com-

pounding must be performed under good-manufactur-

ing practice (GMP) standards. The entire manufacturing

space must use only materials that comply with

regulations to avoid cross contamination, explained

Paul Burke, vice-president of manufacturing at Teknor

Compounding World Forum makes successful debut

The Conference

World Forum

attracted an

international

audience of

more than 220

industry

professionals

compounding world | January 2014 www.compoundingworld.com44

event review | Compounding World Forum

Apex, which operates a clean compounding plant in

Vermont. A company must make an all-or-nothing

choice to create a clean-compounding facility, which

might mean saying “no” to a product with, for example,

heavy metals or flame retardants, he noted.

Although metals have been a long-time target for

plastic part suppliers, metal substitution still offers

“low-hanging fruit” opportunities for compounders in areas

such as appliances and automotive, explained Jeffrey

McCoy, manager of marketing and business development

at A. Schulman. He emphasized that using plastics is not

about making a one-to-one replacement for metal, but

developing a proposal for an alternative material that can

provide value through lightweighting, manufacturing

simplicity and reduced system cost. OEM engineers are not

always educated about plastics, and materials suppliers

need to go to them to provide technical education to the

engineering community, said McCoy.

In addition to being teachers, compounders need to be

diligent students of changing regulations. Jeffery

Keithline, an expert in food and drug law with Keller and

Heckman, described a host of regulations affecting

plastic compounds. These include the US Toxic Sub-

stance Control Act (TSCA) reform efforts, EU REACH

requirements, and US and EU food contact controls.

Although the US industry is not anxious to have addi-

tional regulations, centralized regulations at the federal

level would be preferable to inconsistent regulations that

differ by state, noted Keithline, who called on industry

members to stay active in regulatory discussions.

Additive technologiesA primary function of compounding is adding value to

plastics using additives to meet specific property

requirements. Anti-counterfeiting additive technology,

for example, includes a range of pigments and molecu-

lar tracers that must be increasingly sophisticated to

thwart counterfeiters, explained Stuart Swain, director

of sales and marketing at Chroma.

Antimicrobial additives have an important role to

play in helping address increasing concerns about

antibiotic resistance and the ongoing, high levels of

healthcare-associated infections. Cost is a significant

factor, and applications that have a functional need for

antimicrobials will have the most success, predicted

Lise Moloney, director of healthcare business develop-

ment at Sciessent.

Producing compounds with electrical conductivity

requires excellent dispersion and depends on many

variables, such as carbon black loading and type, the

polymer, and other additives in the formulation,

explained Christine Van Bellingen, product manager for

carbon black & graphite for polymers at Timcal. She

also demonstrated how graphite is used to make

compounds thermally conductive, and pointed out that

conductivity can differ strongly depending on whether it

is measured in-plane or through-plane.

Hexagonal boron nitrides are a cost-effective

additive for thermal conductivity, added Armin Kayser,

director of business development at ESK Ceramics, a

3M company. He described a new product with a larger

particle size that offers a more isotropic conductivity.

Martin Klatt, senior manager for flame retardancy

research at BASF, explained the different modes of

action by which flame retardants can act. Combinations

of phosphorous compounds and melamine salts

broaden the application of non-halogenated solutions

and will continue to be a development focus, he noted.

Jim Harper, applications development manager at

Imerys, reminded delegates that mica is a valuable

mineral for reinforcing polypropylene compounds.

Although it has been in the compounder’s toolbox for

some time, its advantages are not always well under-

stood. Mica is a platy, high aspect-ratio mineral that is

easily dispersible. Even at high loadings it has a low

effect on melt flow because the plates orient in the flow

direction, and it can be used in class-A surfaces.

Suppliers combine expertise in materials and

Stuart Swain of

Chroma

discussed how

to combat

counterfeit

products such

as this unsafe

cable (left)

Paul Burke of

Teknor Apex

discussed the

implementa-

tion of clean

compounding

at its Vermont

plant (above)

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Compounding World Forum | event review

processing with an understanding of design. Styron, for

example, worked closely with Renault to co-develop and

engineer a fully thermoplastic, mono-material lift-gate

for the French car maker’s new Clio, noted Anis Tebib,

marketing manager for Styron Automotive. Part design,

tool design, and optimal processing, all aided by

process simulation, were crucial for the success of

long-glass fibre reinforced polypropylene in the part.

Designers must understand how fibre content, the

fibre-matrix interface, and fibre orientation in the

moulded part affect properties. In one composite part,

for example, designers needed to gate in an unusual

location to allow the fibres to orient in line with the

stress and remove a vent that hindered the desired flow,

explained Raj Mathur, vice-president of technology and

business development at Plasticomp.

Optimizing the processThe Forum featured experts on extrusion technology to

share best practices in running a compounding process.

Finding the optimal degree of fill is one of the keys to

success. This optimum can be found by running a

simple experiment design with combinations of low,

medium, and high rpm and throughput, suggested Bert

Elliott, engineering manager at Leistritz.

Optimizing screw configuration is another way to

improve productivity. On the average line, there are

theoretically about 500 trillion permutations of potential

configurations, and a few of these will produce better

output and/or better properties, noted Adam Dreiblatt,

director of process technology at CPM Century

Extrusion. Simulation software is a good tool, especially

for comparison studies that can show relative changes

The sold-out

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Compounding

World Forum

featured more

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3858_Plastics_en_210x148+5.indd 1 05.11.13 10:05

compounding world | January 2014 www.compoundingworld.com48

event review | Compounding World Forum

fibre from Sonae Industria, is easier to process than

other natural fibres; it is surface-treated similarly to

sized glass fibre, explained Christophe Chambonnet,

global manager for Woodforce. Extrusion trials have

been carried out by ICMA San Giorgio using Woodforce

with the goal of increasing extrusion rates without

degrading the fibres. Silvano Zattra, ICMA’s export

sales director, explained that extrusion processing

simulation helped predict optimal conditions, such as

melt temperature to avoid burning the fibres.

Among all the complex, technical discussions,

Kimberly Williamson, corporate process manager for

Techmer PM, brought a fresh look at how using lean

manufacturing principles allowed the compounder to

improve sustainability in its facilities and save costs at the

same time. Bringing about behavioural changes in the

way employees functioned was key to significantly

reducing water and electricity consumption and the

amount of waste going to landfill. Employees shared in

the monetary savings from the new, sustainable prac-

tices, with the result that the entire company is engaged

in the commitment to reduce, reuse, and recycle.

More informationThe complete proceedings for the Compounding World

Forum 2013 are now on sale. For details, go to

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The next Compounding World Forum will be held on

9-10 December in Philadelphia. The venue has been

switched to the Loews Hotel which provides extra space

for more exhibitors and more attendees.

For details on attending, exhibiting, sponsoring or

presenting at the Compounding World Forum 2014,

please contact Kelly Cressman, the conference coordi-

nator: kc@amiplastics-na.com, Tel: +1 610 478 0800.

Book your place by 9 May and save $500 on the full

delegate fee. For details of this special offer and lists of

compounders and exhibitors who took part in 2013, visit:

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The develop-

ment of the

groundbreaking

thermoplastics

tailgate for the

Renault Clio

was discussed

in detail

The use of

hexagonal

boron nitride in

conductive

compounds

was discussed

by Armin

Kayser of ESK

Woodforce and

ICMA San

Giorgio

discussed the

compounding

of wood fibres

in properties such as mixing quality.

Successfully feeding difficult materials, such as high

levels of low bulk-density powders, combines optimal

fill and screw configuration with proper feeder-system

layout and design. Having a short drop from the feeder

to the extruder is crucial, noted Paul Andersen, director

of process technology for Coperion. Having effective

venting and ensuring that powders are fed into the

screw are also important.

Turn-key compounding lines can integrate the

extruder, upstream dosing, and downstream functions,

or the package can include everything but the building

shell. Such lines can be built in modules, which

minimizes onsite work, can be quickly installed and pro-

vide the potential for easy relocation of the equipment,

explained Matt Sieverding, general manager of Krauss

Maffei Berstorff’s North American extrusion division.

Turn-key systems are advantageous for greenfield sites

in the developing world, but are also used in North

America, he noted.

Steps to sustainabilityBiobased polymers and natural fibres add an extra

challenge to the compounding process because of

temperature and moisture limitations and shear

sensitivity. Variable kneading blocks can be used to

provide a combination of dispersive and distributive

mixing, and fibres can be added downstream so that

they experience only distributive mixing, noted Dean

Elliott, lab manager for Entek Extruders.

Woodforce, a high-aspect ratio engineered wood

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www.compoundingworld.com January 2014 | COMPOUNDING WORLD 51

Additives | show review

Following on from our extensive previews and reviews

of the K 2013 exhibition, which took place in October in

Düsseldorf, Germany, we bring you our fi nal report on

the big show, focusing on new additives that were

launched at the event.

Over the following pages we look at the latest

developments in compatibilizers, impact modifi ers, PVC

plasticizers, stabilizers, pigments, cross-linking agents,

anti-counterfeiting technologies, masterbatches,

antimicrobials, processing aids, thermal management

products, antistatic additives, fl ame retardants and

laser-marking materials.

You can fi nd links to our previous coverage of the K

2013 exhibition, including machinery, materials and

business news, at the end of this story.

AkzoNobel introduced a new easy-to-use concen-

trate version of its vegetable-based Armostat antistatic

additive. Armostat 1800-XP75 is supplied as free-fl ow-

ing granules containing a 75% loading of the additive in

a PP carrier resin. The product is designed as an

alternative to the animal-based antistatic additives for

PP fi lm and rigid packaging applications.

� www.akzonobel.com/polymeradditives

Arkema showed a wide variety of its latest polymers

and additives in Düsseldorf. For example, the French

company has extended its ethylene acrylate copolymer

range with the addition of a Lotryl grade with a modifi ed

molecular structure that gives it excellent compatibility

with both polar and non-polar matrices. It can be used

in masterbatches for the improved dispersion of fi llers.

It can also be used as an impact modifi er or an

adhesion promoter in fl exible packaging.

Another recent development from Arkema is its

Lotader IM ethylene acrylate terpolymer for improving

the impact resistance of polyamides, including PA 6 and

PA 6,6. The new IM grade is said to retain the same

processability as existing Lotader products, while

offering further improvements in impact resistance.

Another new impact modifi er for engineering

plastics is Clearstrength E950, a high-performance

MBS core-shell product specifi cally designed for

polycarbonate applications, including glass-reinforced

grades and PC/polyester blends. For applications in PC/

ABS blends, Durastrength 480 is a new acrylic impact

modifi er that is effective at low temperatures. It also

maintains melt viscosity to facilitate injection moulding.

Arkema was also highlighting the use of Orevac

K 2013 review: all about additives

We report from Düsseldorf on new polymer additives that were

introduced at the K 2013 show

The K show is

still the best

hunting ground

for discovering

innovations in

polymers and

additives

COMPOUNDING WORLD | January 2014 www.compoundingworld.com52

show review | Additives

18340 as a coupling agent for cross-linked halogen-free

fl ame-retardant (HFFR) wire and cable compounds. The

new grade is said to provide optimised reactivity and

fl uidity to enable excellent processability of the HFFR

compounds, particularly for applications requiring good

mechanical properties plus chemical and abrasion

resistance at high temperatures.

For PVC applications, Arkema was promoting its

Durastrength impact modifi ers, including two new

products: D362 is a cost-effi cient composite acrylic

modifi er for profi les and siding, while 382 is a high-

performance grade that delivers very high impact

resistance, high surface gloss and strong plate-out

resistance for PVC profi le applications.

New processing aids for PVC include Plastistrength

564 and 559 (meth)acrylic additives for helping to

control fusion and melt elasticity. The former is for

window sills, wall panels and siding, while 559 is for

sheets and profi les that include CaZn stabilizers. Other

additions include Plastistrength 560 and 566 for

controlling PVC foam processes – 560 is for sheets,

while 566 is for pipes and profi les.

� www.arkema.com

Brüggemann Chemical introduced two new

Bruggolen colour-stable copper-based stabilizers that

are designed to enhance the performance of polyamides

in electrical and electronics applications. Bruggolen

H3376 and H3386 achieve comparative tracking index

(CTI) values of 600 V and 575 V respectively – polyamides

used in electrical and electronic (E&E) components

should have a CTI of at least 550 V to prevent short

circuiting and component defects caused by tracking.

The new stabilizers are also claimed to offer consid-

erably greater long-term protection against thermal and

oxidative degradation compared to antioxidants based on

amine, phenol or phosphorus derivatives.

It has long been known that polyamides can be

stabilized against thermal and oxidative degradation by

the addition of a mixture of copper salts (in particular

copper iodide) and halides (usually potassium bromide

or potassium iodide). However, this kind of stabilization

can have serious drawbacks, which is why it has rarely

been used for E&E products.

For instance, polyamides absorb approximately 3 %

water when in service, which results in stabilizers

based on copper salts being extracted due to their

water solubility. Once extracted, they reach the surface

of the component and form a fi lm resulting in defects

The heat ageing performance at 150°C of PA 6,6 stabilized with 0.3 % by

weight with a new Bruggolen copper stabilizer from Brüggemann (A),

compared with 0.6 % of an arylamine-based stabilizer package (B), 0.4 %

of a stabilizer package based on sterically hindered phenols with syner-

gists (C), and unstabilized PA 6,6 (D)

Eckart showed

Energysafe

solar refl ective

additives for a

wide range of

coloured

plastics

C

M

Y

CM

MY

CY

CMY

K

20130503弘煜-廣告稿.pdf 2 2013/5/21 上午 09:27:31

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Additives | show review

and blemishes or serious discolouration. This not only

makes polyamide articles unattractive, but the compo-

nent’s tracking resistance also drops signifi cantly.

The new Bruggolen copper stabilizers do not contain

any water-soluble salts and thus do not bloom or cause

any blemishes or defects on the surface of the article. In

addition, polyamides can be stabilized with smaller

quantities of the new stabilizers while offering improved

performance. This includes elevated protection against

thermo-oxidative degradation, even at temperatures in

excess of 150°C.

Both of the new Bruggolen stabilizers are colour-

stable and, unlike conventional salt-based copper

stabilizers, do not discolour after conditioning. They are

therefore particularly suitable for products which are

natural coloured or in light colour shades.

Available in powder and pellet form, the new copper

stabilizers are ideally suited to compounding polyam-

ides. Applications for polyamides in electrical engineer-

ing include insulating elements and housings for

circuit-breakers, contactors, transformers, electric

motors and printed circuit boards.

� www.brueggemann.com

Colorant Chromatics, a subsidiary of PolyOne,

introduced a new range of colour masterbatches for

high-performance applications in polysulfone (PSU),

polyethersulfone (PES) and polyphenylsulfone (PPSU).

The range includes 10 standard colours and provides

resistance to heat, fi re and oxidation. Target markets

include the aerospace, automotive, telecommunications

and healthcare sectors.

These colour concentrates are formulated without

Grafe has

developed an

antistatic

compound for

the production

of coloured

safety helmets

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CAP-2977-13_ANZ_CompoundingWorld_DEZ_2013_210x148mm_RZ.indd 1 03.12.13 13:49

compounding world | January 2014 www.compoundingworld.com56

show review | Additives

heavy metals and use state-of-the-art pigment

dispersion techniques to promote consistent colouring

and improve homogenization for more efficient

processing and reduced waste.

❙ www.colorant-chromatics.com

Dow Elastomers used the Düsseldorf show to

announce its new Intune polypropylene-based olefin

block copolymers. It describes these as compatibilizers

that enable the combination of non-polar and polar

polymers with PP. For example, they can be used to

combine PP with PE, EVOH, PA or polyolefin elastomers,

providing benefits from each material while minimizing

trade-offs in properties.

The company says that the new technology can be

used to produce unique blends and multi-layer

structures. It is targeting a wide range of markets,

including packaging, consumer durables, transporta-

tion, construction, hygiene and wire and cable. Samples

are already available and commercial production is

scheduled for early 2014.

❙ www.dow.com

DuPont introduced its Entira EP compatibilizers for

the high-value recycling of mixed polymers. The first

grades are ethylene-copolymers that are optimized for

recycling mixtures of PE and PP. In particular, the

compatibilizers are said to significantly improve

low-temperature toughness, even when used at low

concentrations of around 4%.

The company is currently developing further

formulations of compatibilizers for other mixed

materials. These include PE together with PA or EVOH,

which are typically used as barrier resins in polyolefin

based packaging products. Another area of interest is

PE-PET mixtures with PE as the dominant matrix.

DuPont says that compounding mixed polymers

together with Entira EP in a twin-screw extruder

provides recyclates in pellet form with excellent

mechanical and processing properties, even when there

are high degrees of contamination. It also claims that

the re-compounding process is more economical,

because using Entira EP significantly reduces the need

for melt filter cleaning operations.

❙ www.dupont.com

Eckart showed a range of new effect pigments at K

2013. These included new Energysafe products for the

production of solar reflective plastics. They are

designed to lower the heat build-up in plastics products

exposed to the sun, and therefore reduce surface

temperatures. The pigments can be used in polyolefins,

PVC, styrenics and a range of engineering plastics.

One example is Energysafe Graphite Black which

enables the production of solar reflective plastics in

very dark shades. The resulting plastics can reflect up

to 33% of the incident solar energy; by comparison

plastics pigmented with carbon black reflect less than

5%. Target applications include outdoor products, such

as garden furniture, and automotive components, such

as dashboards.

Eckart has also developed Energysafe Lignum Brown

for applications in wood-plastics composites (WPCs),

where Total Solar Reflectance (TSR) values of 20% can

be achieved. Other products in the range include:

Energysafe White for adjusting the brightness of light

shades; Energysafe Granite for high levels of near-

infrared reflectance; Energysafe Argentum for plastics

with a metallic look; Energysafe Henna for reddish

shades; and Energysafe Aurum Solar which exhibits a

golden yellow in full shade.

The company also showed Platalux, its new genera-

tion of effect pigments that use silver-coated pigments

based on glass. These combine an inherent sparkle with

a champagne coloured shade that creates pronounced

Huntsman is

testing its

Altiris infrared

reflecting

pigment in

greenhouse

applications

Grafe’s Blue

Wet master-

batch creates a

water effect in

plastics

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compounding world | January 2014 www.compoundingworld.com58

show review | Additives

glitter effects in pure colours or in combination with

transparent colour pigments and dyes.

❙ www.eckart.net

Evonik was promoting its new Elatur phthalate-free

and bio-based plasticizers for PVC. Production of these

new 1,2-cyclohexane dicarboxylic acid diisononyl

additives (a similar chemistry to BASF’s Hexamoll

DINCH) started in June 2013 at the Marl Chemical Park

in Germany.

The company was highlighting its Elatur CH grade, a

phthalate-free plasticizer that is particularly suitable

for sensitive PVC applications such as articles that

come into direct contact with the skin. It is currently

developing new grades including bio-based versions

Evonik also used K 2013 to introduce two new

additives for the cross-linking of polyethylene using the

Monosil process in the production of high-performance

cables. Dynasylan Silfin 201 and 202 are its first

products of this type that contain tin-free catalysts.

The standard catalyst for the Monosil process is the

tin-organic compound dibutyltin dilaurate (DBTDL).

However, there are health and environmental concerns

regarding tin, so Evonik decided to develop alternatives.

❙ www.evonik.com

Grafe used K 2013 to promote a wide range of its

latest additive and colour masterbatch products. For

example, it showed a new counterfeit protection

masterbatch for synthetic yarns and fibres. The

patent-pending technology uses a new combination of

chemical substances that can be detected by X-ray

fluorescence analysis.

The company also showed its latest development in

antimicrobial masterbatches which is based on additive

technology from Amistec in Austria. This protects

against pathogens such as MRSA, VRE and ESBL, but

allows the production of brightly coloured plastics

parts, something that can be limited by other antimicro-

bial technologies.

The German masterbatch maker and compounder

has also been focusing on developing new antistatic and

conductive materials, and it presented a range of such

applications. For example, it has developed a perma-

nently antistatic compound for coloured safety helmets.

Another antistatic product is its High Performance

Antistatic Agent (HPAS) which is designed for automo-

tive interior parts made from PP or PC/ASA. It helps to

prevent components from attracting dust and has been

shown to be effective for more than four years.

Grafe has also been working on a new flow-improver

for medical products. This is designed to overcome

streaking problems that can occur when moulded

plastic parts are over-moulded at the same tempera-

ture. The company says that its Flow-Improver can

reduce the processing temperature of the over-mould-

ing plastic by 40˚C to help overcome the issue.

In the colour masterbatch field, Grafe says that blue

and unusual effects will be taking centre stage in 2014.

Its Blue Wet product is designed to create the effect of a

plastic filled with water, while Starry Blue is said to

capture the appeal of the sky at night.

❙ www.grafe.com

Huntsman presented a new application for its Altiris

infrared reflecting pigment. As previously covered in

Compounding World magazine, this new TiO2 based

additive was initially aimed at PVC building applications,

such as siding and profiles. However, it is now being

tested in polyethylene greenhouse films to provide

improved growing conditions.

Recent lab and field testing in Turkey has shown

that 50 micron greenhouse film containing 1% Altiris

pigment successfully reflects infrared energy, resulting

in reduced temperatures inside the greenhouse. This

helps to keep relative humidity levels high and reduces

the loss of moisture from plants.

❙ www.huntsman.com

Merck used K 2013 to highlight its special effect

pigments for plastics used outdoors and exposed to the

sun. For example, its silver-white pigment Iriodin 119

WAT product was developed for such applications. It is

thermally stable up to 800˚C and extremely resistant to

yellowing. Target applications include outdoor furniture,

architectural products and automotive interiors.

The company was also showing its latest Iriotec

pigments. For example, Iriotec 9000 reflects heat and is

designed for outdoor applications such as blinds and

canopies. Aimed at laser-marking applications, Iriotec

8000 enables precise labelling of products, regardless

Perstorp’s

Pevalen

plasticizer can

be used in toys

and provides

outdoor

durability

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Forum 2014

December 9-10, 2014Loews Philadelphia Hotel,

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compounding world | January 2014 www.compoundingworld.com60

show review | Additives

The complete K storyThis materials review is the final instalment in our extensive coverage of

the K 2013 exhibition, which has focused on the product launches and

news stories that are most relevant to the compounding industry. For the

complete picture, click on the links to see our previous reports.

Materials preview part 1: http://bit.ly/Kmats

Materials preview part 2: http://bit.ly/Kmats2

Machinery preview: http://bit.ly/KMach

Compounders’ views on K: http://bit.ly/Kviews

Industry news from K 2013: http://bit.ly/K13news

Machinery review: http://bit.ly/KMach2

Other K 2013 product launches have been included in our recent

features on topics such as flame retardants, carbon black, mixers and

lab-scale compounders. The next K show will be on 12-26 October 2016.

of the type of polymer and colour being used.

❙ www.merck-pm.com

Perstorp was showing Pevalen, a non-phthalate PVC

plasticizer for sensitive applications. The polyolester

additive is claimed to be efficient and easy-to-process,

as well as exhibiting excellent UV stability for outdoor

durability. It also has low volatility, cutting out VOCs and

providing consistent properties.

Pre-marketing of the product has shown that it is

suitable for sensitive ‘close-to-consumer’ applications.

Target markets include vinyl flooring in hospitals,

schools and public buildings, plus automotive interiors,

toys, moulded parts and coated fabrics.

Perstorp is investing in scaling up Pevalen produc-

tion – it says that by 2015 it will be commercially

competitive with other high-volume plasticizers. It is

also planning to increase the bio-based content of the

additive.

❙ www.perstorp.com

Songwon used K 2013 as the launchpad for its new

Songxtend range of stabilization packages for poly-

olefins. Songxtend 1101 and 1102 are general purpose

products for polypropylene, protecting properties and

avoiding discolouration during high temperature

processing.

The Songxtend 2121, 2122 and 2123 packages are

specifically aimed at automotive applications and are

tailored to address fogging and odour issues in car

interiors. The different grades have different sulphur

levels: 212 reduces sulphur by 60% while still maintain-

ing high thermal stability; 2122 offers an optimised

cost/performance balance by reducing sulphur by 30%;

and 2123 is 100% sulphur free to minimise odours while

still retaining stabilisation performance.

❙ www.songwon.com

Sukano introduced new antimicrobial masterbatches

for long-lasting freshness control in polyester and

polyamide fibres. They are designed to bring permanent

protection against unpleasant odours in sportswear.

The products combine Sukano’s functional master-

batch experience with patented Pure technology from

the Swiss performance textiles company HeiQ. The

silver-based concentrates enable fibre manufacturers

to spin pre-dyed fibres with a permanent antimicrobial

effect that withstands wash cycles.

Sukano says that the antimicrobial masterbatch is

effective in low concentrations and provides the good

dispersion required for the production of low denier

microfilament fibres.

❙ www.sukano.com

Tosaf launched a new range of flame retardant

masterbatches for corrugated pipes that are used as

conduits for electrical cables in construction applica-

tions. Such conduits need to meet the European flame

retardant standard IEC 61386-1.

The company says that efficient and low-cost

chlorinated paraffins have traditionally been the

additives of choice for such applications. However,

these chemicals have come under pressure from the

REACH regulation, which has restricted the use of

short-chain chloroparaffins as they have been classified

as Substances of Very High Concern (SVHC). At the

same time, increasing numbers of pipe producers are

trying to make their products comply with the Low

Smoke Zero Halogen regulation (LS0H; IEC 607541).

In response to these issues, Tosaf has developed the

new masterbatch which uses no chlorinated additives

and meets the LS0H norm for standard pipes. In

addition, the company says that the high-efficiency

products reduce dosing requirements and present no

additional costs for the pipe producer.

❙ www.tosaf.com

Songwon has

developed its

new Songxtend

range of

stabilization

packages for

polyolefins

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Download the programmes for these forthcoming conferencesSimply click on the brochure cover or link to download a PDF of the full publication

To see our full line-up of more than 25 plastics industry eventsover the next 12 months, please visit www.amiconferences.com

The Masterbatch Asia conference will be celebrat-ing its 10th anniversary in style on 18-20 March 2014 in Bangkok, Thailand. Down-load the brochure for full details of the programme and booking information.

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AMI’s international confer-ence on lightweight plastic tubs, trays, jars, containers and cups for food packaging returns to Chicago, Illinois, USA, on 20-21 May 2014. Download the brochure to see the impressive line-up of speakers.

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AMI’s next international conference for the stretch and shrink industry is being held on 1-3 April 2014 in Cologne, Germany. This well established event attracts a large and infl uential audience. Find out more by downloading the brochure.

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The business conference & exhibition for the stretch & shrink film industry

1-3 April 2014Maritim Hotel,

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The Asia Pacifi c conference on markets and technology for fl exible barrier packag-ing is being held by AMI on 24-26 March 2014 in Bangkok, Thailand. Download the brochure to see the full programme and booking details.

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24-26 March 2014Swissôtel Nai Lert Park,

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Asia Pacific conference on markets and technology of flexible barrier packaging for retail and industrial applications

Specialty Packaging Films Asia 2014

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AMI will be holding its Polyethylene Films 2014 conference at Daytona Beach, Florida, USA on 11-13 February. This leading event attracts an infl uential audience: in 2013, the attendees were responsible for using over 3 billion lbs/yr of polyethylene!

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The international conference on pipeline protection, coating technology, materials and markets is being held on 24-26 February in Vienna, Austria. Download the programme to see the truly global selection of speakers.

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Erema: Recycling News

This 32-page magazine celebrates Erema’s 30th anniversary, and covers the launch of its new Intarema plastics recycling technology at K 2013. It also features interesting case studies from around the world.

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C.A. Picard: extruder technology

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RE Scheer: Bullet pelletizerMaguire: gravimetric blenders

This brochure from Reduction Engineering Scheer has full details of its Bullet range of strand pelletizers. These are designed to be easy and fast to clean and service, making them ideal for rapid changeovers.

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This interactive product guide covers Maguire’s full range of WSB gravimetric blenders. It explains how the blenders operate and includes technical specifi cations, key benefi ts, plus options and accessories.

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Timcal: carbon addtives

This 24-page technical brochure from Timcal covers the company’s carbon additives for polymer compounds, including its Ensaco conductive carbon blacks and its Timrex graphite and coke.

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Head offi ce location: Cittadella, Padua, Italy

Date founded: 1999

CEO: Massimo Pavin

Ownership: Privately owned

Number of employees: 170

Sales 2012: €142 million

Plant locations: Cittadella and Tombolo in Italy; Kutno in Poland; and Jundiaí in Brazil

Production 2012: 85,000 tonnes

Profi le: Sirmax was formed by the merger of Maxplast and Sirte in 1999 and it has grown to become one of Europe’s leading technical compounders. It operates two plants in Italy and opened a facility in Kutno, Poland in 2006. This has been gradually expanded, most recently with the installation of an 8,000 tonnes/year Coperion twin-screw extruder in October 2013, taking its total capacity to 40,000 tonnes/year. The company also opened a plant in Brazil last year and a second compounding line is expected to be installed during 2014.

Product line: PP compounds account for around 85% of Sirmax’s output, with the remainder including PA6/66, ABS, PC/ABS, POM, PBT and PPO materials. Sirmax is one of the leading independent suppliers to the large appliance market, which accounts for almost 75% of its output. The remaining volume is sold to the automotive, electrical and small appliance industries, including applications such as power washers and coffee makers.

Strengths: Innovation, fl exibility and logistics.

Sirmax

compounder of the month

Forthcoming featuresThe next issues of Compounding World magazine will have special reports on the following subjects:

FebruaryThermally-conductive compoundsMaterials handlingAdditives for polyolefi ns

MarchAdditives for PETTwin-screw extrudersNatural fi bres and fi llers

Editorial submissions should be sent to Andy Beevers: abe@amiplastics.com

For information on advertising in these issues, please contactClaire Bishop: claire@amimagazines.com Tel: +44 (0)20 8686 8139

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Compounding World – NovemberCompounding World’s November edition reviews some of the top compounding news to emerge from the K2013 show. It also takes a look at the latest innovations in carbon black and explores how to get the best from them, plus new developments in PVC compound production and useful advice on safe plant operation.

� Click here to view

Compounding World – DecemberThe December edition of Compounding World has a special focus on the latest regulatory and technical developments for fl ame retardants. Plus there are reports on lab compounders, electronics applications and European market trends.

� Click here to view

Pipeline Coating – NovemberThe November edition of Pipeline Coating examines global energy markets, internal fl ow coating for gas pipelines, a major refurbishment project in Iran, plus details of the Ethylene Pipeline South project.

� Click here to view

Compounding World – NovemberCompounding World’s November edition reviews some of the top compounding news to emerge from the K2013 show. It also takes a look at the latest innovations in carbon black and explores how to get the best from them, plus new developments in PVC compound production and useful advice on safe plant operation.

�

Film and Sheet – Nov/DecFilm and Sheet Extrusion’s

November/December edition has special features on K show

highlights, melt fi ltration technology, masterbatch

developments, new bag-making equipment, plus European

market trends.

� Click here to view

Injection World – Nov/DecInjection World’s November/December issue boasts special features on award-winning automotive applications, the latest engineering plastics, innovative hotrunners, and European market trends.

� Click here to view

Pipe and Profi le – Nov/DecThe November/December edition of Pipe and Profi le

Extrusion looks at the latest innovations in mixing

technology, explores new developments in WPCs, and

reviews the latest applications for PEX pipe. It also reviews

some of the new launches and introductions at K2013.

� Click here to view

Compounding World – December

retardants. Plus there are reports

dates for your diary

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21-23 January SwissPlastics,Lucerne,Switzerland www.swissplastics.ch

28-31 January Interplastica,Moscow,Russia www.interplastica.de

29 Jan - 1 Feb Samuplast,Pordenone,Italy www.samuplast.it

11-13 February PlastecWest,Anaheim,CA,USA www.plastecwest.com

17-20 February SaudiPlastics&Petrochem,Riyadh www.saudipp.com

4-6 March Plastics&RubberVietnam,HoChiMinh www.plasticsvietnam.com

11-13 March JECEurope,Paris,France www.jeccomposites.com

7-10 April PlastivisionArabia,Sharjah,UAE www.plastivision.ae

23-26 April Chinaplas,Shanghai,China www.chinaplasonline.com

8-14 May Interpack,Düsseldorf,Germany www.interpack.com

27-30 May Plastpol,Kielce,Poland www.targikielce.pl

16-19 June Argenplas,BuenosAires,Argentina www.argenplas.com.ar

18-19 June PDM&PRE,Telford,UK www.pdmevent.com

3-6 September Indoplas,Jakarta,Indonesia www.indoplas.com

29 Sept - 3 Oct Plastex,Brno,CzechRepublic www.bvv.cz/plastex-gb

30 Sept - 3 Oct Equiplast,Barcelona,Spain www.equiplast.com

14-18 October Fakuma,Friedrichshafen,Germany www.fakuma-messe.de

Global exhibition guide

AMI conferences 28-30 January ThermoplasticConcentrates,CoralSprings,FL,USA

18-20 February GrassYarn&TuftersForum,Barcelona,Spain

24-26 February PVCFormulation,Düsseldorf,Germany

11-13 March Cables,Cologne,Germany

18-20 March GreenPolymerChemistry,Cologne,Germany

18-20 March MasterbatchAsia,Bangkok,Thailand

12-14 May PolymerSourcing&Distribution,Hamburg,Germany

13-14 May FireRetardantsinPlastics,Denver,CO,USA

16-18 June EndOfLifePlastics,Düsseldorf,Germany

17-18 June PolymersinCables,Philadelphia,PA,USA

24-26 June Masterbatch,Berlin,Germany

28-30 October PolyolefinAdditives,Cologne,Germany

For information on allthese events and other

conferences on film,sheet, pipe and

packaging applications, see

www.amiplastics.com