From the Sector

The Aachen Center for Integrative Lightweight Production (AZL) of RWTH Aachen University is installing a new ENGEL injection molding system in its technical center. Engel Deutschland GmbH – in cooperation with the ENGEL Centre for Lightweight Composite Technologies in Austria – will install the 2-component injection molding system with turning plate and 17,000 kN clamping force in 2019. This machine setup is the basis for further developments of efficient inline-combination technologies using different kinds of polymer performance materials.

The ENGEL injection molding system will enable innovative combinations of already established fiber-reinforced plastics (FRP) processes and the development of new individual processes. The focus is on increasing resource efficiency in lightweight production. With the new equipment, new research and development initiatives can explore the more efficient use of materials, which are eventually the key to the mass production of lightweight components. The research will address multi-material systems, continuous processes, process chains as well as self-optimizing processes.

Dr.-Ing. Michael Emonts, Managing Director of the Aachen Center for Integrative Lightweight Production (AZL) is looking forward to realizing new innovative lightweight production process with the new injection molding system: “This new injection molding system offers us as specialists for lightweight production technology in cooperation with the injection molding experts of the Institute of Plastics Processing – the IKV – the opportunity to establish hybrid processes for industrial lightweight applications. The system will expand our existing machinery in the AZL Technical Center and will be available as an important platform for lightweight production research at RWTH Aachen University.”

Being a Partner of the AZL, ENGEL has already been working closely with the AZL for many years as a Partner Company of the AZL Partner Network. Dr. Stefan Engleder, CEO of the ENGEL Group, emphasizes the importance of close collaboration with technical universities and especially with the AZL: “The AZL provides great conditions for industry-related research activities in the field of lightweight composites as it is characterized by a strong interdisciplinary approach. It benefits from the great infrastructure and the collaboration with well-known institutes of the RTWH Aachen University. ENGEL is looking forward to working together with the AZL on developing efficient lightweight composite mass production processes.”

In addition to the numerous composite and lightweight equipment at the RWTH Aachen Campus, the AZL Technical Center comprises large-scale equipment for the development of processes for lightweight production, such as a composite press from Schuler Pressen GmbH with 18,000 kN clamping force.

The global antimicrobial market is big business. Demand is strong due to increasing public awareness about contamination and infections, and by consumers’ desire for protective solutions. At Cinte Techtexil China 2018, taking place Sept. 4-6 in Shanghai, SANITIZED (China) Ltd. will be showcasing on Booth D25, Hall N1, its long-lasting Sanitized® Swiss antimicrobial protection for flexible polymer applications.

In recent years, regulatory developments have limited the available types of biocides that can be used to protect polymers and textiles from bacterial and fungal growth. For example, the biocide OBPA was widely used to protect PVC and other plastics from such issues in the past, but the European Union blocked OBPA from sale in January 2013, prompting producers to seek other options. Commonly used alternatives such as DCOIT, BBIT, zinc pyrithione or IBPC have their own limitations, related to their use in various flexible polymer applications.

Outdoor applications in particular have seen an increase in performance requirements –– especially as regards antimicrobial effectiveness after exposure to water and ultraviolet light. Such additives also should not contribute to yellowing after UV exposure, but the available alternatives often fall short in this regard. And antimicrobial additives need to be able to meet the requirements for heat stability during the application process, while also avoiding initial discoloration and demonstrating compatibility with other additives in the formulation.

SANITIZED AG has developed a solution that addresses all these issues. Sanitized® PL 14-32 offers highly effective, long-lasting antimicrobial protection for flexible polymer applications. Besides thermal stability and compatibility with most formulations, Sanitized PL 14-32 provides high UV resistance and no yellowing after UV exposure, as well as good water resistance. It protects the target material against the unwanted effects of microbes such as bacteria, mold, mildew, yeast, pink stain and algae – all of which can destroy material, while also causing unsightly stains, cross contamination, odor development and biofilm formation. The product has been proven to deliver thermal and color stability, and efficient antimicrobial protection in several formulations. Further, it is supported under the EU`s Biocidal Products Regulation (BPR), and the U.S. Environmental Protection Agency has approved its active substances.

• Additives, pigments and masterbatches for transportation, packaging, textiles & fibers
• Support to “future-proof” medical applications
• Contributing towards more sustainable engineering plastics

Clariant, a world leader in specialty chemicals, turns the spotlight on its increasing on-the-ground support and innovation focus for North America’s four key plastics application segments at NPE 2018 Booth S18155.

Clariant is pushing forward with plans for growth in the region by advancing R&D competencies, and increasing its manufacturing footprint and technical capabilities across its 50+ sites, 3 R&D and 6 technical innovation centers. Clariant’s innovations for the plastics industry include advanced additives, masterbatches and pigments which support the packaging sector in engaging consumers via differentiated, convenient solutions. At NPE, it will also highlight solutions for enhancing and protecting healthcare products, as well as its contribution to stronger and colorful textiles and fibers for everything from e-mobility to industrial applications.

Deepak Parikh, president of region North America, Clariant comments: “Clariant’s product innovation for the US and wider North American plastics industry embraces the region’s fastest growing end-use areas of automotive and construction. It also addresses the impact of trends driven by changing consumer lifestyle preferences and market regulations on other important segments such as packaging and healthcare.”

Transportation
Clariant brings color and protection to support the increasing use of engineering plastics and high temperture resins in automotive interiors, exteriors and under-the-hood. Halogen-free Exolit® OP 1400 provides outstanding flame retardancy to polyamide parts, enhances safety with UL 94 V0 performance down to 0.4 mm and enables the molding of complex parts with no mold deposits and blooming. Exolit OP 1400 has been awarded the Clariant EcoTain®label for outstanding sustainability and performance. At the same time, Clariant offers low-halogen controlled high-performance PV Fast® pigmentswith excellent migration and weather fastness properties to meet the high requirements of today’s transportation and automotive industry. Easy processing Renol® compounds and masterbatches for engineering and high temperature resins provide heat and light stability, and flame retardancy, while maintaining critical flow properties in parts like SMT connectors. Importantly, they are available as small lots which enables customers to purchase only what they require and contribute to a reduction in their carbon footprint.

Packaging
As US packaging manufacturers explore more consumer-friendly, lighterweight and appealing solutions, Clariant is on hand to support their functionality, sustainability-related and color desires. Clariant Pigments has an innovative cooperation with Konica Minolta and matchmycolor to enable fast, precise and efficient color matching of HDPE products, using select organic PV Fast and Graphtol® pigments that comply with FDA regulations. The ColorWorks®center in Chicago is dedicated to US brand managers and designers with teams of color design experts to create color formulations faster than ever before for bottles, caps, closures and films.

According to market reports, plastic pouches are gaining share from traditional pack types in packaged food and are mainstream in home care. To support smoother and more environmentally-compatible processing especially for film applications, Clariant offers an FDA-compliant, vegetable-based powder amide wax, Licolub® FA 1, which acts as a slip and anti-block agent. It is suitable for polyolefins and PVC.

Textiles & Fiber
At NPE 2018, Clariant puts the focus on strong and colorful textiles, carpets and industrial fibers. New AddWorks® TFB 117 offers a number of benefits to help stabilize and smoothen fiber production processes, protect color, and improve heat stability and mechanical properties of fibers. AddWorks TFB 117 ensures smooth spinnability with less filaments breakage, even at low processing temperatures and at high speed spinning up to 5,500 m/min. Clariant also offers a broad range of colorants for polypropylene, polyester, polyamide and acrylic fibers, featuring migration fastness, chemical stability, light- and weather-fastness.

Healthcare
Clariant supports risk control and regulatory compliance for medical polymer and pharmaceutical packaging solutions. Its Mevopur® color and performance masterbatches and compounds include a USP Class 6 line of compliant products and multiple global ISO, 87, 88, and 661.1 certifications ahead of the market deadline. Clariant also offers selected FDA-compliant organic pigments and polymer soluble dyes that meet purity migration fastness as well as toxicological properties for medical devices and pharmaceutical packaging.

Exhibitors from eight countries have already confirmed to participate in the fair’s European Zone. They join an expected 500-plus total exhibitors from around the world. The 2018 edition of this biennial fair takes place from 4 – 6 September in halls N1 – N3 of the Shanghai New International Expo Centre.

While China retains its edge in terms of technical textiles and nonwovens production capabilities, in the eyes of Chinese buyers, European suppliers are still the leaders when it comes to technology and innovation. This was widely reported by European exhibitors at the previous edition in 2016 of Asia’s leading biennial trade event for the industry: Cinte Techtextil China.

“In the Chinese market, buyers want good quality products, so overseas companies, and products with recognised quality certifications, have a lot of potential,” Ms Ping Chen, General Manager of IBENA Shanghai Technical Textiles commented. “As a leading German company in the industry, our products are welcomed by many buyers at this fair. It is also important to be in the German Pavilion as this signals to buyers that we have quality products, and it attracts more attention.” Swiss firm Sanitized AG had the same experience. “As a Swiss company in the European Zone I believe it’s an advantage, as some local buyers have more confidence towards imported products,” Mr Steven Liu, Sales Manager said.

Other exhibitors commented on the long-term trends in the Chinese market. “There’s a definite shift to more high-quality machinery in China that isn’t affected by what’s happening in the overall economy. Moreover, there are opportunities for overseas suppliers as there is still a gap between us and what Chinese companies produce,” Dr Joachim Binnig, Vice President, Head of Development & Technology, Autefa Solutions Germany GmbH explained.

Mr Roger Zhang, Sales Manager for German firm J.H. Ziegler Nonwovens and New Materials commented: “Our products are mainly for high-end Chinese customers, such as BMW and Audi. The Chinese market has gradually matured, but the production capability for high-performance products which are energy efficient and eco-friendly is still developing, so there is a lot of space for overseas brands to develop here.”

European Zone highlights
This year’s European Zone will feature around 30 exhibitors from eight countries, including Austria, Belgium, the Czech Republic, France, Italy, the Netherlands, Sweden, Switzerland and the UK, while further exhibitors can be found in national pavilions from Belgium, the Czech Republic, Germany and Italy. Some of the exhibitor highlights in the European Zone include:

• Arkema (France): with brands including PMMA Altuglas, Rilsan, Pebax, Kynar PVDF and Bostik, they will present polymer resin for fibres and yarns, which apply to a wide range of applications, at the fair.
• Dakota Coating (Belgium): specialists in thermoplastic and thermosetting adhesives, their polymer products, based on polyethylene, polyolefin or mixtures, ethylene vinyl acetates, co-polyamides, polyurethanes and co-polyesters, are suitable for automotive, building, heat transfer and sound insulation uses.
• Lenzing Plastics (Austria): a new exhibitor at the fair, they are a leading manufacturer of polyolefin and fluoropolymer products, such as Thermoplast and PTFE products. One of their core competencies lies in the monoaxial stretching of films and filaments, and they offer special solutions in the fields of construction & insulation, medicine & hygiene, packaging and cables, as well as automotive and technical textiles. They will highlight their PROFILEN® PTFE product at the fair, and with its extreme durability and very smooth surface, it is highly valued in many niche applications in the technical and medical sectors.
• Protechnic (France): leading manufacturers of hot-melt adhesives and plastic printed films, they will showcase hot melt thermo-adhesive nets, webs and films at the fair.
• Trelleborg Coated Systems (Italy): another new exhibitor this edition, they produce high-performance, engineered coated fabrics. They offer a wide variety of substrates – from Kevlar® to silk – with a choice of weaving methods.

The market for the production of carpet yarn is increasingly evolving towards more demanding processes. However, beyond commodity products, standard plants can no longer fully exploit their advantages. From 20th to 22nd March 2018, Oerlikon Neumag will be presenting an economical alternative in Shanghai in hall W3, booth F03 at the Domotex asia/Chinafloor, the leading floor covering trade fair in the Asia-Pacific region: the BCF plant Sytec One with single-end technology.

If the requirements for the production of BCF yarns increase, for example, from recycled polyester or fine filaments, then this can also lead to higher breakage rates. Highly standardised production plants must then often strike compromises with regard to throughput, quality or cost-efficiency. In such cases, the Sytec One offers a good solution instead of the mostly three-end technology plants for standard processes.

Single-end technology with 98% productivity

This BCF plant works with only one yarn (end) per position, making it ideal for demanding production processes. The reason: when a yarn break occurs only one yarn tears, all other yarns continue to run. This not only simplifies troubleshooting, it also reduces the re-threading time. In addition, less waste is produced. As a result, the productivity of the Sytec One is still over 98% for ten breakages a day, while a plant with three-end technology only reaches around 92%.

Faster processes due to a straight yarn path

In addition, the absolutely straight yarn path of the Sytec One enables significantly higher process speeds of up to 15% in spinning and texturing processes compared to multi-end technologies. Higher total titers of up to 6,000 dtex can also be produced without any problems. The gentle yarn guidance also ensures minimum friction on the individual filaments. This means less yarn breaks and a more stable process.

Optimised key component: spinning pack

Last but not least, the engineers at Oerlikon Neumag have developed a new design for the spinning pack. This central component of every BCF machine significantly influences the yarn quality. The corresponding solution for the Sytec One optimises the polymer flow in the spin pack, thus reducing the polymer dwell time. This leads to shorter product and colour change times and increases the plant efficiency. In addition, the spinning packs were widened so that yarns with up to 500 filaments can now be produced.

The product mix is decisive

In view of these advantages, the single-end Sytec One is recommended for processes with high breakage rates, fine filaments, frequent colour changes or in general when demanding processes take up an increasing share in the business. "The product mix is decisive for the choice of technology," sums up Alfred Czaplinski, Sales Manager BCF at Oerlikon Neumag. "We are happy to advise on the optimal solution and offer both single-end and three-end plant technologies." 

Good business at the Domotex Hanover, Germany

In the run-up to the trade fair, the Domotex Hanover in mid-January was already proving to be a promising harbinger. With four lively trade fair days and contract conclusions in the lower double-digit million euro range, mainly from the European and Asian markets, the order intake for Oerlikon Neumag was very good.