MPW’s Material Thoughts

PVC liner saves city’s water tanks

A polyvinyl chloride (PVC) liner system, which is certified to NSF/ANSI Standard 61 for Drinking Water Systems, has been applied by the city of Ada, Oklahoma for its two potable water tanks. Utilizing an FDA-compliant material from thermoplastic compounder RTP Co.’s (Winona, MN) Sheet & Film Division, the city opted for a film that is radio frequency (RF) sealable for onsite installation. Fab-Seal Industrial Liners Inc., which made the film, undertook some RF sealing at its facility, laying out the necessary pieces like a large jigsaw puzzle, which was then reassembled together on site in Ada.

The 40-mil PVC liner system, which was custom made for the Ada tank, was 240-ft long by 240-ft wide, by 25-ft deep (73 by 73 by 7.5 m) with 144 boots for support columns. To put the size in perspective, RTP reports that the city of Ada’s eight tennis courts are located on the roof of the tanks. The liner uses a non-DEHP plasticizer to make it flexible for easier installation. RTP says one important advantage of its material is that it can be extruded rather than just calendared, since extruded films, while more expensive to produce, offer greater consistency in thickness and properties. The company also said a coating system would not have adequately compensated for cracking in the tank’s concrete, while the PVC liner has a 350% elongation factor, allowing it to flow into a crack area. The involved companies believe the savings offered by creating new liners for the tanks, instead of constructing wholly new tanks, could be financially attractive to other municipalities. RTP Co., Winona, MN, U.S.A.; +1-507-454-6900; www.rtpcolor.com.

Copolyester replaces PC in sports bottles

Cool Gear International Inc. (Plymouth, MA), a provider of patented, freezable sport and water bottles and food-storage containers, has opted for Eastman Chemical Co.’s (Kingsport, TN) Tritan copolyester in its new EZ FREEZE FREE premium product line of beverage bottles. Cool Gear says it choose Tritan on the basis of its clarity, dishwasher durability, and resistance to everyday use, as well as growing consumer and regulatory concerns over bisphenol A (BPA), a precursor material for alternative plastic polycarbonate (PC).

Cool Gear’s bottles utilize a freezable gel stick, which is attached to the cap of the bottles, and can be frozen prior to use. Once the cap is secured on the bottle, the gel acts as a makeshift ice cube, keeping beverages cooler longer. EZ Freeze had made products from PC but said in a release that growing consumer interest in a clear, durable material that was BPA-free led it to seek out a material alternative. Eastman says Tritan will resist crazing, cracking, or hazing from continual exposure to high heat and aggressive cleaning detergents, and it can be run in existing PC molds. This drop-in functionality was appealing to Cool Gear, which designs, manufactures, and distributes its housewares and seasonal products worldwide. Eastman introduced the Tritan material at last October’s K show in Düsseldorf, Germany (see original report from the show). Tritan’s heat resistance reaches 226°F, roughly 65°F higher than traditional copolyester materials. Eastman Chemical Co. (Kingsport, TN); +1-423-229-2000; www.eastman.com.

MPW’s Product Watch

Measuring/testing: Heat deflection testing unit minus silicone oil

The HDT Vicat 500 Aloxide testing unit from this manufacturer is billed as the answer for HDT/Vicat testing without the concerns that can be raised when using traditional equipment containing silicone-oil baths. Rather than silicone oil, a fine aluminum-oxide powder is fluidized with compressed air to form a circulating testing bath medium. An auto-air system regulates the airflow along with the bath temperature to ensure the proper level of fluidization and temperature uniformity throughout the bath. Oil-vapor emissions and oil-recycling problems therefore are eliminated. Also, with no silicone oil to contend with, testing can be completed at temperature ranges of up to 500°C. Email the company for a comparison study explaining further benefits of this new system. CEAST, Pianezza (Torino), Italy; [email protected]; www.ceast.com. In the U.S. contact sales manager Steve Knight in Charlotte, NC at +1-704-423-0042; [email protected].

Processing machinery: Be faster than the failure

An online diagnostic tool from this company is designed to help processors, and other manufacturers using highly stressed production machinery, to identify potential faults before they actually become downtime problems.

The new system, called Profoxy, maintains constant watch over parameters such as revolutions/speed and power consumption after it is linked to a machine’s controller. Comparing these numbers with benchmark data or past figures can help processors see a problem coming and plan for necessary maintenance. The data from Profoxy can be seen on a PC, or be sent via email or SMS to a processor. The system can be installed on older machinery as well as new equipment. To now the firm is only serving German-speaking markets, however. Kröhnert Infotecs GmbH, Karlsruhe, Germany; +49 721-8601-8011; www.ki-contact.de

Plant management: Updated ERP system adds processor feedback

This firm’s latest version, EnterpriseIQ version (7.4.1.20), of its EnterpriseIQ enterprise resource planning (ERP) software includes 400 enhancements to the established software, most prompted by current customer feedback. According to the firm, this new version helps processors get leaner and stay more agile across their total supply chain. Customers receive free upgrades with installation, and update documentation is included. Updates in the new version include expanded EFT payment features, such as directory destinations; integrated CallerID functionality between telephony and customer resource management (CRM); merger of duplicated records in CRM that allows duplicate records to be combined using a wizard format; production cost calculations by Lot Number, in addition to existing item number, manufacturing number, sales order number, and production order number; and more. IQMS, Paso Robles, CA; +1 805-227-1122; www.iqms.com

Blowmolding: Wilmington delivers SB line

Wilmington Machinery (Wilmington, NC) has delivered a 50-cavity, 6-layer high-density polyethylene (HDPE) coextrusion system from its line of SB (small bottle) turnkey systems launched at the last NPE. Capable of throughputs topping 2000 lb/hr and 18,000 bottles per hour depending upon the size, the SB was delivered with multiple sets of molds and bottle conveying. The machine has 1.5 tons of clamp force and can run bottles from 250 to 500 ml. Jeff Newman, VP sales and marketing for Wilmington, says the SB addresses many processing issues associated with consistency of neck-to-neck or neck-to-tail dimensions on other wheel, shuttle, and reciprocating blowmolding machinery. The SB is a rotary-style blowmolding machine that uses a single-parison single-cavity process to produce single-serve multilayer containers from 80 to 500 ml, which can serve applications in dairy, juice, food, and liquid yogurt. Newman estimates cycle times as low as 6 seconds, and the system’s electric drives can generate annual energy savings of $35,000 to $75,000.

Composites: Fuel efficiency concerns propel glass mat demand

With fuel efficiency concerns once again driving automotive design, interest in composite materials including glass mat thermoplastics (GMT) are rising to the forefront. According to a report from Lucintel, the global GMT market is expected to grow at an estimated 7% compound annual growth rate during the next five years, with the total global GMT material market forecast to eclipse $500 million. The highest growth will be in the lightweight/low-density reinforced thermoplastics, while traditional GMT materials, typically constructed of glass fiber and polypropylene, are expected to see moderate growth. For more information on the 260-page research report entitled Global GMT Market 2008-2013: Trend, Forecast, and Opportunity Analysis, contact Sean Lofgren, Lucintel director of business development, at [email protected].

Packaging: Child resistance and dispensing promote closure growth

U.S. demand for caps and closures will increase 4.9% annually to $9.6 billion by 2012, representing over 276 billion units, according to a new report from The Freedonia Group, a Cleveland-based industry research firm. Gains will be bolstered by the popularity of value-added designs such as child-resistant and dispensing closures, with the latter offering increased convenience and controlled product release in numerous applications. Gains will be supported by the growth of closure-intensive plastic packaging at the expense of closureless containers like metal cans. Advances will be limited by competition from packaging formats that do not use closures, such as stand-up pouches and blister packs. The increasing use of peelable lidding rather than rigid lids in single-serving cups will also restrict expansion.

Plastic caps and closures are by far the largest industry segment and will expand at an above-average annual rate of 5.4% through 2012, benefiting from the ongoing supplanting of metal and glass containers by plastic in food and beverage applications. In addition, technological improvements have enabled certain plastic closures to replace metal closures on glass food containers. Representing 37% of the total market value, the beverage industry will continue to offer good prospects for caps and closures based on continued growth in the bottled water market, the increasing proliferation of single-serve drinks in plastic bottles, and heightened use of higher-value dispensing closures that enhance convenience and on-the-go consumption. The pharmaceutical market will see the fastest gains of all markets, reflecting the shift to an older demographic.

Plastics additives: Chemson acquired

Chemson Polymer-Additive AG (Chemson; Arnoldstein, Austria; www.chemson.com), the world’s leading supplier of additives for PVC, has been acquired by private equity company Buy_Out Central Europe II Beteiligungs-Invest AG (Buy_Out CE II). The purchase awaits approval from regulatory agencies. The seller was Switzerland’s Leman Capital, also an equity investor. Financial details were not released.

Chemson has 665 employees and production locations in Austria, Germany, England, Brazil, Australia, the U.S.A., and China, and has a turnover of euro 261 million in the 2006/7 fiscal year. Its market share is about 30-35%. Austrian newspapers speculate the purchase price was between euro 50-80 million, and Buy_Out officials did not deny this price range was accurate.

Kurt Stiassny, chairman of Buy_Out, said his group intends to expand Chemson’s presence, especially in Eastern Europe and Asia. In the first phase, Buy_Out acquires 100% of the company shares; in the second phase, the company’s management will participate proportionally. In parallel, Buy_Out will then invite Austrian financial investors to co-finance as partners, but it will retain the majority stake in the company.

Late last year Chemson announced it was expanding its capacity of calcium/zinc one-pack stabilizers at its Philadelphia site in the U.S., responding to what it said was growing demand for these there. Tin stabilizers remain the standard for PVC in North America. Elsewhere, Ca/Zn or other non-lead alternatives are steadily replacing lead stabilizers.

Rapid technologies: Consortium creates Direct Manufacturing Research Center

Aircraft manufacturer Boeing, rapid prototyping/manufacturing machinery and materials developer EOS (Electro Optical Systems, Krailling, Germany), chemicals and plastics supplier Evonik Industries (Düsseldorf, Germany) and rapid prototype tooling and parts manufacturer MCP HEK Tooling (Luebeck, Germany) have formed a Direct Manufacturing Research Center (DMRC) with the University of Paderborn (Germany).

The DMRC is scheduled to open in fall 2008. The firms have promised to contribute euro 2 million over the next five years, with the University contributing euro 600,000. German government funding could double the total contributed by the partners and University.

“Direct manufacturing offers the potential of significantly reducing parts production costs, as well as enhancing the ability to fabricate more complex and more functional component parts,” said Jeff DeGrange, chairman of the board of the DMRC consortium and senior manager of direct digital manufacturing at Boeing Phantom Works, Boeing’s advanced research and development organization. Direct manufacturing technology automatically builds up parts in layers, based on computer-aided design (CAD) data, with a laser used to melt material applied in layers. The process sees extensive use in prototype manufacturing but as yet little use for manufacturing commercial quantities.

The partners will contribute in a joint effort. Boeing defines production process and system requirements from an aerospace standpoint. Evonik Industries produces polymer-based standard materials as well as material solutions tailored for direct manufacturing. EOS and MCP HEK Tooling will provide their expertise in the development of laser sinter and laser melting systems for metals and polyamides.

Moldmaking: Joint Venture buys Ideal tool

Injection mold manufacturer Joint Venture Tool & Mold (Meadville, PA) has acquired competitor and neighbor Ideal Tool Co. Inc. (also Meadville). Ideal Tool will become an operating subsidiary of Joint Venture and be re-named Ideal Tool & Plastics, Inc. “This acquisition is an excellent fit. It enhances our capabilities, enables us to provide solutions and products that answer our customers’ demands for best-in-class quality, innovation and consistency,” said Richard Moroco, CEO of Joint Venture. The former president of Ideal Tool, Donald Smith, will remain as director of operations and maintain an equity stake in the company.

Profile extrusion: Greek processor added new lines from BEX

Plastic profile and pipe processor Elitherm S.A. (Salonika, Greece; www.elitherm.com) has acquired three new lines from Battenfeld Extrusionstechnik (BEX; Bad Oeynhausen, Germany; www.bex.battenfeld.com). The three new lines will double Elitherm’s capacity and make it one of the largest profile manufacturers in Greece.

Elitherm, which extrudes pipe for the heating and air conditioning markets and also is a custom profile extruder, was founded in 1987, has expanded steadily since then. Most recently in 2004 it acquired two pipe extrusion lines from BEX, one to manufacture PEX pipes and another to produce PB and PP-R pipes, as well as two profile extrusion lines, one winBEX for window profiles and one miniBEX for small, custom extrusions. In 2005 Elitherm acquired another two extrusion lines from BEX.

Plastics supply: Sabic adding pharma PE grades in Europe

Plastics supplier Sabic Europe, based in Sittard, the Netherlands and part of Sabic (Riyadh, Saudi Arabia; www.sabic.com), this month began offering a new family of polyethylene grades for the European pharmaceutical packaging market. The new family includes seven new LDPE and two HDPE grades. Grades are available for extruded film, injection molded and blowmolded pharmaceutical packaging applications.

Rolf Scherrenberg, technical marketing manager LD/LLDPE, Sabic Europe, commented, “The long-term availability commitment of these grades from a major polyolefins supplier such as Sabic will enable customers to have security of supply and to avoid complex, time-consuming approval procedures and processes.”

Auxiliary equipment: Werner Koch receives honorary doctorate

Werner Koch, CEO and owner of Ispringen, Germany-based Werner Koch Maschinentechnik GmbH, manufacturer of mixers, dosing units, conveyors, dryers and related auxiliary equipment, was awarded an honorary doctorate in June from the Academy of Education at the Saint Petersburg (Russia) State Polytechnic University. Koch was awarded the title Doctor of Science in appreciation of the cooperation he supports between his company and the university. As in previous years, this year too Koch is offering a number of Saint Petersburg students the opportunity of a 10-day placement in Germany; this summer seven students pursuing a course in machine construction for plastics technology have taken up his invitation and are at the German company.

Global Plastics Bulletin Board

Polylactic acid (PLA) resin maker, NatureWorks LLC (Minnetonka, MN) will host the Innovation Takes Root 2008 technical conference (link), from Sept. 16-18 in Las Vegas at the Planet Hollywood Resort & Casino. Keynote speakers include Larry Wendling, VP R&D at 3M; Ron Pernick, co-author The Clean Tech Revolution; and Masatoshi Matsuda, senior staff engineer, Toyota Motor Corp.

The Education Committee for the NPE2009 international plastics exposition is now accepting abstracts for presentations in a new educational program, called the Business of Plastics, to be offered at NPE2009 (June 22-26, 2009; Chicago, IL; McCormick Place). The Business of Plastics program will address such topics as marketing, human capital management, finance, environmental issues, regulation, global economic trends, and other matters of strategic importance to plastics business management. Conference papers, learning labs, panel discussions, and other formats are possible. Abstracts proposing a topic and format can be submitted after July 21 when a special page for posting them goes online at http://www.npe.org/, including more information on the Business of Plastics program and submission guidelines. Information is also available from SPI by contacting Felecia Marsh at [email protected] or 1-202-974-5285.

The Sustainable Packaging Coalition will host the PAC National Conference 2008 at the Fairmont Le Chateau Frontenac, in Quebec City from Sept. 12-14 (link). Anne Johnson, SPC president, will deliver the keynote address, with presentations from Molson Canada, Canadian Packaging Magazine, the Packaging Machinery Manufacturers Institute, and more.

Intertech Pira is organizing a Biopolymers Symposium 2008 (link) for Oct. 6-8, 2008, to be held at the Embassy Suites O’Hare, in Rosemont, IL. In addition to four pre-conference workshops, the event will offer 44 presentations over two days, including talks by the Environmental Protection Agency, Nextek, and Brooks Sports.

Briefs

MacNeil Polymers Inc. (Cheektowaga, NY) was honored as the 2008 Business Matchmaker and featured in Buffalo Business First Magazine for its work to offer reclamation and recycling of most types of polymeric materials. MacNeil Polymers accepts post-industrial resins from compounding, injection molding, blowmolding, extrusion and thermoforming, offering customers grinding, sorting, contaminant removal, component disassembly, and material repackaging.

Cereplast’s (Hawthorne, CA) renewable materials, which combine starches with corn-based polylactic acid (PLA) resin, now satisfy new federal procurement guidelines for biobased content, meaning they’re given preference by the U.S. General Services Administration (GSA), which is the purchasing agent that manages billions of dollars in federal agency procurement. By meeting the new guidelines, which were enacted June 13 by the United States Department of Agriculture, companies that use Cereplast Compostables materials can be listed on the USDA BioPreferred web site (link).

Fuwei Films (Holdings) Co. Limited (Beijing) has been selected as a co-author of the new national standards for BOPET (biaxially oriented polyethylene terephthalate) films in China. As a member of China Plastics Processing Industry Assn.’s BOPET Films Committee, Fuwei subsidiary, Fuwei Shandong will co-author the revision of the National Standard GB/T 16958-1997 Packaging BOPET, with the updated standards expected by the end of 2008.

Through a technology partnership, Spirex Corp. (Youngstown, OH) has added a KraussMaffei 320-1900 injection molding machine to its research lab and outfitted the press with its Twinshot System for multimaterial co-injection molding. Spirex says customers testing Twinshot parts will be able to achieve “production-grade product for accurate evaluations”, according to a press release. The KraussMaffei 320-1900 features a 60-mm screw with a length:diameter ratio of 26.6:1, and a maximum RPM of 195. The maximum shot weight is 700g or 24.7 oz, and its platens measure 41.73 by 43.11 inches. In addition to a 2.5-inch, 25:1 L/D Johnson Extruder, Spirex’s lab also features rheology and melt flow analysis; online optical dispersion testing; lab trials; and training programs.

Packaging manufacturer Superfos has developed a tool to calculate the carbon-dioxide emissions of packaging on the basis of the choice of raw material selected and energy consumption in production, transport, and disposal. Superfos, which makes cardboard and plastic-based products, says packaging accounts for only 10% of an average product’s total carbon-dioxide emissions.

Names in the News

Janet E. Mann has been named senior VP of marketing, technology, and commercial development for packaging and sheet and rollstock supplier Spartech Corp. (St. Louis, MO). Mann, who was most recently general manager, industrial chemicals at Archer Daniels Midland, will be based in Clayton, MO. Her previous plastics experience includes work with Chemtura, Dow Chemical, and Akzo Chemicals.

Valois S.A.S. (Le Neubourg, France), which designs, develops, and injection molds proprietary spray, aerosol, and dispensing systems for the pharmaceutical, perfumery and cosmetics markets, has named Alex Theodorakis as president Valois of America. He has been with the North American branch of the company since 1993, most recently working as director of manufacturing for Valois’s pharma and beauty and home divisions. Valois of American is based from a 133,000-sq-ft site in Congers, NY, which employs 130.

Gas-assist technology (GIT) provider Cinpres Gas Injection Ltd. (www.cinpres.com) has promoted its current international sales consultant, James Jenkinson, to the role of company sales director. “The focus of the new position will be significant sales growth in Germany, Eastern Europe, India, Brazil, China and the USA, to which James’ dynamism, enthusiasm, considerable sales experience and multi-lingual capabilities will be invaluable,” adds Jon Butler, Cinpres managing director. Jenkinson, who is fluent in English, French, German and speaks some Spanish, will work from the company’s headquarters in Middlewich, Cheshire, England.

DuPont Engineering Polymers’ website, Plastics.dupont.com, has been re-designed to meet the needs of “design engineers/molders/processors”, according to the company, while incorporating one, standard DuPont look and feel. The site now offers: multiple languages, improved search engine, a “Uses and Applications”, and a “Knowledge Center”, which has material selector tools, and a library of processing, design, and technical information.

Celebrating 10 years as an independent, publicly traded company is plastics and chemicals supplier Nova Chemicals (Calgary, AB), with CEO Jeffrey Lipton recognizing the occasion by ringing the closing bell at the New York Stock Exchange on July 2.