From the Sector

Unter dem Motto »Get into the loop« trifft sich am 8. und 9. Februar 2023 beim Fraunhofer CCPE Summit erstmalig eine internationale Circular Economy Gemeinschaft unter der Leitung von UMSICHT-Institutsleiter Prof. Manfred Renner in München. Es ist der Startschuss für ein internationales Forum, das den Austausch von Lösungsideen und Innovationen für eine zirkuläre Kunststoffwirtschaft fördert. Sechs Fraunhofer-Institute widmen sich seit rund vier Jahre im Fraunhofer Cluster of Excellence Circular Plastics Economy CCPE der Frage, wie die Wertschöpfungskette von Kunststoff zirkulär gestaltet werden kann.

350 Millionen Tonnen Kunststoff werden weltweit in einem Jahr produziert. Damit dadurch nicht auch gleichzeitig 350 Millionen Tonnen Müll entstehen, kann eine Kreislaufwirtschaft diese Kunststoffe im Kreis führen und so Ressourcen und Umwelt schonen. Dieser Wandel zu einer zirkulären Kunststoffwirtschaft benötigt systemische, technische und soziale Innovationen. Zwei Tage lang stellen internationale Expertinnen und Experten sowie die Forschenden der sechs Mitgliedsinstitute im Munich Marriot Hotel in München dazu Strategien, Forschungsergebnisse und Umsetzungsprojekte vor. Das Ziel dabei: Den Wandel zu einer zirkulären Kunststoffwirtschaft mit Präsentation und internationalen Diskussionen beschleunigen.

AVK, the Federation of Reinforced Plastics, has once again awarded its Innovation Awards to a range of companies, institutes and their partners in 2022. Three innovative composites from each of the three categories Products & Applications, Processes & Methods and Research & Science were honoured during the JEC Forum for Germany, Austria and Switzerland in Augsburg at an award ceremony on 29 November 2022. A professional jury, composed of engineers, scientists and trade journalists, presented the awards for 2022 in three categories.

List of award winners in the three categories:
Products & Applications category
First place: LAMILUX Composites GmbH, Rehau, Germany: Lamilux Sunsation® – the new standard under the sun
Second place: Carbo-Link AG, Fehraltorf, Switzerland: CL RESTRAP – Reinforcement of concrete girders using flexible, prestressed CRP tapes
Third place: Borgers SE & Co. KGaA, Bocholt, Germany: blue label by Borgers ®

Innovative Processes & Methods category
First place: BaltiCo GmbH, Hohen Luckow, Germany: Rod laying technology as an additive manufacturing process
Second place: Schmidt & Heinzmann GmbH & Co. KG, Bruchsal, Germany: Pole Position, a positioning system for polarisation imaging
Third place: NETZSCH Process Intelligence GmbH, Selb, Germany: SensXPERT, process optimisation driven by material data to increase the efficiency of thermosets and fibre composites

Research & Science category
First place: Institute for Textile Machinery and High Performance Textiles at the Technical University of Dresden: Spherically curved fibre-reinforced plastic composite components made from near-net-shape fabrics
Second place: Leibniz-Institut für Verbundwerkstoffe GmbH, Kaiserslautern, Germany: HyKoPerm – a measurement system for an industry-specific characterisation of textile impregnation behaviour
Third place: Technical University of Munich, Chair of Carbon Composites: Manufacturing processes for a tension-strut-supported pressure vessel that can be adapted to suit a given space

The textile industry is the third largest consumer of plastics. While growth rates in the production of fibres and textiles are high, the circular economy has hardly become established in this segment. The EREMA Group is now intensifying development of recycling solutions for this application with their new fibres and textiles business unit. Currently, the focus is on PET fibre materials from fibre production and subsequent processing steps. Technologies for recycling mixed fibre textiles from textile collection sources are to follow in a follow-up project phase.

"With EREMA's VACUREMA® and INTAREMA® technology and PURE LOOP's ISEC evo technology, our company group already has an extensive range of machines for fibre and PET recycling applications. For ecologically and economically sound recycling, however, new technological solutions are needed to use the recycled fibres in higher-value end applications and to achieve a functioning circular economy," explains Wolfgang Hermann, Business Development Manager Application Fibres & Textiles, EREMA Group GmbH. The initial focus will be on PET, regarded as a key material for the production of synthetic fibres. The aim is to find recycling solutions that allow PET fibre materials to be prepared for reuse in PET fibre production processes. This is a significant step for the circular economy because PET fibres in textiles account for about two-thirds of the total volume of PET.

In this development work, the EREMA Group can build on existing know-how. Proven recycling technologies have been combined with a new IV optimiser. "This extends the residence time of the PET melt, which is particularly necessary in fibre recycling to efficiently remove spinning oils. Our recycling process also increases the IV value of the PET melt after extrusion back to the specific level that is essential for production of the fibre," explains Hermann. Waste PET fibre from production processes can therefore be further processed into rPET filament fibre, carpet yarn and staple fibre.

Fibre test centre with plant to test customers' materials
In order to accelerate development work, EREMA opened its own fibre test centre a few months ago, where a cross-company team is working on recycling solutions for fibre-to-fibre applications.

• Monomaterial solution contains renewably-sourced polypropylene from the Bornewables™ portfolio of circular polyolefins
• Trexel employs its proprietary MuCell® technology to deliver a range of lightweighting benefits
• EverMinds™ in action: reuse and design for recycling are focus of value chain collaboration

Borealis and Trexel, an expert in foaming injection and blow moulded parts, announce that they have co-developed a new plastic bottle based on a grade from the Bornewables™ portfolio of polyolefins made using renewable feedstocks derived 100% from waste and residue streams. The lightweight bottle – which will be showcased at the Borealis stand at the K 2022 (from 19 to 26 October 2022 in Düsseldorf) – is reusable and fully recyclable. It boasts a significantly lower overall CO₂ footprint because it is composed of renewably-sourced feedstock and produced in the foaming process.

The Bornewables™ portfolio of circular polyolefins helps reduce the carbon footprint while offering material performance equal to virgin polymers. Using Bornewables grades allows for design freedom and colour flexibility, and helps retain a premium look and feel. The grades – which are commercially available in Europe – help conserve natural resources because they are derived solely from waste and residue streams, for example from used cooking oil. Reusing waste already in circulation instead of fossil fuel-based feedstocks enhances the sustainability of applications made using the Bornewables grades.

The reusable new bottle developed by Borealis and Trexel retains its value over many life cycles thanks to the use of Trexel’s proprietary technology in tandem with Bornewables grades; as a material solution, the new bottle minimises the use of valuable raw materials. Moreover, converters consume less energy in the production process when using the MuCell® technology. The bottle thus helps close the loop on plastics circularity by way of design for recycling, the use of renewable feedstocks, and excellent material performance across multiple life cycles.

As a sub-exhibitor of Oerlikon, BB Engineering will present its product range in the fields of extrusion, mixing and filtration as well as PET recycling with the VacuFil and VarioFil R+ systems at the K show 2022.

BB Engineering has been focusing its development work increasingly on recycling technologies for several years. In addition to extruders, filters and mixers that are suitable for both recycling processes and the processing of recyclate, BB Engineering offers a complete PET recycling plant called VacuFil.

With VacuFil, BB Engineering has developed an innovative PET LSP recycling process. The process combines gentle large-scale filtration and targeted IV regulation for consistently outstanding rPET melt quality. Thus, much more than simple "downcycling" is possible with VacuFil. VacuFil processes a wide range of input materials - post-production and post-consumer. The patented key component Visco+ vacuum filter removes volatile impurities quickly and reliably. VacuFil is a modular system that can be designed for different recycling applications. Simple granulation is possible, but also direct feeding into further processing, e.g. in the synthetic fiber spinning mill. BBE offers VacuFil in combination with its own VarioFil compact spinning plant to produce polyester yarn.

At the K show 2022, visitors can experience the VacuFil Visco+ recycling technology in operation with a connected VarioFil spinning plant and see live how recycling yarn is produced from PET waste.

With over 60 participants from Europe and Turkey, the first SMCCreate Design Conference took place in Antwerp from 28-29 June. The conference was jointly organised by AVK – Federation of Reinforced Plastics and the European Allicance for SMC BMC. The topics covered the wide spectrum of SMC and BMC manufacturing, from design to sustainability solutions. 16 speakers from different European countries showed what is important in component manufacturing and design, and which solutions the companies offer in regard to materials, performance and much more.

After an overview of the general market developments and how the economic requirements affect component manufacturing, the focus was on the possibilities to enable sustainable design with SMC/BMC. In the second conference section „part design“, the topics of design and modelling, design with structural analysis and flow simulation, standards, and best class solutions as well as surface modification were presented.

A rather newer field was highlighted on Day 2 with Carbon SMC, discussing mobility and automotive applications. These included the integration of multiple material technologies, not forgetting the possibility of implementing green deal strategies here too. The advantages of SMC in automotive components for electrification were explained in more detail. The conference concluded with a sporty presentation on the development of a carbon SMC rear frame for a downhill mountain bike.

With the goal of making recycling of lightweight, high-volume fiber and flake recyclate much more economical and, in some cases even possible, Coperion has developed a new version of its ZS-B side feeder. Using the innovative ZS-B MEGAfeed, plastic recyclate with a bulk density under 200 kg/m³, long considered intake-limited and thus not worth recycling, can be reliably fed in large quantities into Coperion’s ZSK twin screw extruder and be concurrently recycled and compounded.

The ZS-B side feeder’s novel design makes it possible to feed very high rates of fiber and flakes, such as PA, PE, PET, and PP. As a result, the ZSK twin screw extruder’s high capacity can be fully exploited when the ZS-B MEGAfeed is used. Very high throughputs in both mechanical and chemical recycling of post-industrial and post-consumer waste are achieved.

Increased Throughput in Numbers
With a ZSK 58 Mc18 twin screw extruder, the throughput increase and thus the potential of the new ZS-B MEGAfeed becomes very clear. When recycling PA fibers with a bulk density of ~40-50 kg/m3, throughputs of 70 kg/h were previously achieved using conventional equipment. When the PA fibers were fed into the ZSK extruder using the ZS-B MEGAfeed, throughputs increased about fourteenfold to 1,000 kg/h. Similar results were achieved recycling carbon fibers with a bulk density of ~50-70 kg/m3; in this case, throughputs increased from 50 kg/h to 2,500 kg/h using the ZS-B MEGAfeed. When recycling PCR (Post-Consumer Recycled) flakes, throughputs increased from 50 kg/h to 700 kg/h, and from 80 kg/h to 1,300 kg/h with multilayer film flakes.

Key to Economical Recycling of A Wide Variety of Plastics
Plastics previously considered not recyclable are becoming a valuable raw material using the new Coperion ZS-B MEGAfeed. For example, PCR flakes or recyclate from carbon fiber-reinforced plastics can now be fed into the ZSK extruder at high feed rates and recycled economically.

In the case of mechanical upcycling, upstream processes necessary for compounding, such as compacting, melting and agglomeration, are completely eliminated using the ZS-B MEGAfeed technology. In this recycling process, flakes and fibers can be fed directly into the ZSK extruder, where they are melted, compounded, devolatilized, and filtered in a single step. In so doing, both investment costs and energy consumption drop. The production process becomes significantly more efficient. Moreover, the thermal product stress is reduced and recyclate quality increases.

Even when recycling PET, the feed rate is no longer a limiting factor. With the ZS-B MEGAfeed, PET flakes and fibers can be fed into the ZSK twin screw extruder in large quantities with no pre-drying or crystallizing, where they can be processed with the highest degree of profitability.

The ZS-B MEGAfeed can also feed large quantities of post-consumer waste, adding appreciable value to the chemical recycling process with the ZSKs. ZSK throughput rates are very high with the ZS-B MEGAfeed. Preheating of the recyclate via mechanical energy input of the twin screws thus becomes even more economical for further processing in the reactor.

Existing Coperion extruders can be retrofitted with ZS-B MEGAfeed technology to greatly expand their spectrum of applications and increase their throughput rates.

The Reifenhäuser Group will be represented with four booths at the world's leading trade fair for plastics processing, K 2022, from October 19 to 26. Under this year's Reifenhäuser motto "The Time is Now", the extrusion specialists will show producers of films and nonwovens solutions for the three major topics of the industry: sustainability, digitalization and productivity.

The main booth showcases the Reifenhäuser Blown Film, Cast Sheet Coating and Reicofil business units. With the help of machine exhibits, visual presentations and concrete solutions for end products, visitors will learn, among other things, how they can manufacture fully recyclable products economically, process recyclates safely, increase their output and network the entire production without becoming dependent on systems, specialists or manufacturers. To ensure smooth production even after purchase, Reifenhäuser Service shows how customers can get the best out of their Reifenhäuser products and increase their productivity with rework solutions, modifications, training programs and digital services.

The component specialists of the Reifenhäuser Extrusion Systems business unit will additionally present their portfolio at two other exhibition booths. Here, everything revolves around screws, barrels and extruders - and why, especially for processing recycled material, high-performance wear protection is essential for reliability and high economic efficiency. Reifenhäuser Extrusion Systems will also showcase its innovations for flat dies and coextrusion blocks and their coordinated interaction for maximum productivity.

In addition to its own booths, Reifenhäuser will also be present as a partner of the R-Cycle initiative as part of a joint pavilion on the open-air site in the so-called Circular Economy Forum. R-Cycle is a cooperation project of various technology companies and organizations along the entire life cycle of plastic packaging.

Aanother highlight for visitors to the Reifenhäuser trade fair booths is the opportunity to additionally participate in the in-house exhibition on October 20, 21 and 24 at the Reifenhäuser Technology Center.

• DOMOs neuer Service deckt das globale Produktportfolio von Werkstoffen für den Spritzguss ab.
• DOMO Engineered Materials ermöglicht den direkten Zugriff auf die stets aktuelle Materialdatenbank für Spritzgusssimulationen, sodass Kunden jederzeit die aktuellsten, umfangreichsten und validierten TECHNYL®-Werkstoffdaten einsehen können.
• Dieser neue Service für schnellere Projektentwicklungszeiten wird am 12. Mai 2022 freigeschaltet.

Bisher mussten Anwender, die die neuesten Datenbanken für Spritzgussanwendungen von den jeweiligen Anbietern erhalten wollten, auf ein Update der Simulationssoftware warten. Von der Verfügbarkeit neuer Materialien bis zur Aktualisierung der öffentlichen Datenbanken verging beträchtliche Zeit – mitunter mehr als ein Jahr. Darüber hinaus mussten sich Anwender regelmäßig an verschiedene Kontakte wenden, um von Materialanbietern Auskünfte über die neuesten verfügbaren Ressourcen einzuholen.

DOMO ermöglicht es seinen Kunden jetzt mit regelmäßigen Aktualisierungen der Datenbank für Autodesk Moldflow einen wertvollen neuen Service zu erhalten. Auf Anfrage werden auch Spritzgussmaterialdaten für andere Softwarelösungen (Moldex3D, CADmould usw.) von unserem Sales und Technical Manager zur Verfügung gestellt.

Da Kunden so stets die neuesten Materialdaten für Spritzgusssimulationen zur Hand haben, können sie Zeit und Mühe bei der Generierung der notwendigen Daten für ihre Projekte sparen. Diese validierten Messdaten für präzisere Simulationen ermöglicht den Kunden, ihre Entwicklungszeiten zu verkürzen und Produkte schneller auf den Markt zu bringen.

Darüber hinaus umfassen diese direkten Aktualisierungen auch neue Werkstoffe aus DOMOs Entwicklungspipeline sowie neue validierte Daten, die über die gewöhnliche Vorgehensweise von Spritzgussanwendungen hinausgehen und beispielsweise die Optimierung der Vorhersage von Faserausrichtungen erlauben.

The Spanish recycling company Anviplas has been involved in plastics recycling for more than 30 years, during which time it has built up extensive know-how that now benefits customers throughout Europe, in Africa and in Asia. Their cooperation with EREMA is almost as long. Since 1991, Anviplas has relied on the technology and service provided by the Austrian recycling machine manufacturer.

Employing 64 people, Anviplas recycles post-industrial and post-consumer plastic waste, especially HD and LD-PE as well as PP, to make recycled pellets in all colour variations. The production capacity is 1,800 tonnes per month. An EREMA type INTAREMA® 1716 TVEplus® recycling machine with screen changer is in operation at the site in Navarcles (Barcelona) for processing the PP material stream. This patented extruder system was developed for handling difficult-to-process materials, such as heavily printed films as well as very moist waste. This machine is characterised by its optimised 3-stage degassing system; firstly by preheating and predrying the material in the preconditioning unit, secondly because the screw design allows reverse degassing, and thirdly in the degassing zone of the extruder.

Anviplas customers manufacture a huge bandwidth of products made using their recycled pellets. They range from various film products, such as stretch, shrink, mulch and silage films, to irrigation, corrugated and high-pressure pipes, as well as containers such as tubs, bottles, barrels and crates.

In February 2022 the Repeats Group, a pan-European platform for LDPE recycling, and Anviplas announced, that Repeats has made an investment in the Spanish recycling company. For Repeats this investment in Anviplas represents an important step in building a pan-European plastics recycling platform.