XSYS Launches a Complete Guide of Best Practices in the Use of Washout Solvents For Consistent Plate Quality
Common quality issues associated with washout solvents in flexo plate making is the topic of a new technical paper by XSYS. The insightful guide which is entitled “XSYS WASHOUT SOLVENTS 101 – How can washout solvents contribute to consistent plate quality?” examines some of the often-heard myths surrounding the washout process and explains the adverse effects the incorrect use of washout solvents can have on the final print quality.
The guide highlights the importance of maintaining the right balance of components in the special type of solvent, such as XSYS nylosolv A, used in flexo plate making systems. If this part of the process is neglected, the effectiveness of the washout is compromised and numerous issues with the print quality can occur, including so-called rice-grain effect, register problems, or missing halftone dots. As well as providing solutions to some of these common problems, the new guide also explains the history of nylosolv, which was the first chlorine-free washout solvent on the market, and the science behind each of its components.
“We are always keen to share the vast pool of knowledge we have amassed here at XSYS to help our customers maximize productivity, guarantee high quality, and reduce plate waste,” said Simon Top, Product Manager nyloflex. “This new technical guide is another great example of how XSYS, as a leading supplier to the flexo industry, not only provides best-in-class solutions, but also delivers more value so our customers can produce brilliant results.
“As we conclude in WASHOUT SOLVENTS 101, not only does correctly adjusted washout solvent ensure that the best plate quality is produced, it also helps to increase equipment efficiency and longevity which will result in significant cost savings, higher productivity and more sustainable production,” said Stephan Reis, Global Strategic Marketing Director, in closing.
The XSYS WASHOUT SOLVENTS 101 guide is freely available in multiple languages and can be downloaded here.
Haitian Solutions for Every Application in Injection Moulding Segment
Haitian Huayuan India Pvt Ltd, celebrated, opening of new manufacturing unit at Kadi, Gujarat, under make in India project. The Unit is spread across 52,000 sq. meters of built-up area with State-of the-art-machine assembling unit to offer injection moulding machines.
We can offer you solutions for machine tonnages from 40 ton up to 8000 tons. Based on your application and product we can select right machine. We offer toggle machines from 86 ton – 3300 ton, two platen machine 450 ton – 6600 ton, All electric machines 40 ton – 8000 ton, two colour two component machines up to 1850 ton, hybrid machines with electric drive 360 ton – 3300 ton.
We have solutions for every application in Injection moulding segment.
Our In House Machine shop at Kadi, in an area of 20,000 sq. meters, adjacent to our mother plant. It’s a world class facility having Hexagon CMM machines, 19 numbers of VMC’s and HMC’s. Our Nigata HMC has 6 pallet changing with single set up. All our platens and Injection housing are in house machined for machines manufactured and suppled from our kadi unit.
Haitian believes in CRS activates and keenly participate towards development of few village schools.
Best wishes to all customers in the exhibition and please do visit our website and contact us. We shall be pleased to invite you to our plant at Kadi, Gujarat. Be our guest.
Stadler Shares Its Vision of the Recycling Industry and Strategic Priorities
STADLER, the globally active German company specialized in the planning, production and assembly of turnkey recycling and sorting plants, begins the new year ready to address the fast-growing demands of the recycling industry, which is evolving at an accelerating pace. The company’s strategic objectives for 2023 remain focused on anticipating the changing needs, developing solutions to address new requirements as they arise, consistently delivering added value for its customers.
“In 2022 the sense of urgency in addressing Climate Change and reducing greenhouse gas emissions has intensified to a new level,” explains Willi Stadler, CEO of the STADLER Group. “Greater environmental awareness is generating unprecedented pressure to reduce waste, recycle more, and move towards a closed-loop circular economy. We, at STADLER, believe we have the know-how and experience to support the recycling industry in addressing this challenge change with effective solutions.”
Meeting the changing demands of a growing recycling industry
A variety of factors, from public awareness about environmental issues to legislation such as the EU Green Deal, are driving the changes in the recycling industry. The European Commission has submitted a proposal for new regulations aiming at achieving three key objectives: preventing packaging waste, establishing high-quality recycling loops, and creating a well-functioning market for secondary raw materials through the requirement of a minimum recycled content for some types of plastic packaging. Another factor of change is China’s ban on imports of polluted plastics, which is contributing to the soaring demand for sorting and recycling plants in Europe – in particular plants capable of sorting plastics into the different polymers.
The recycling industry is consequently growing fast and requiring an increasing degree of specialization. STADLER is at the forefront of this evolution, detecting new requirements and providing solutions. Two projects completed in 2022 are a perfect illustration of how the company is constantly breaking new ground: the first and most advanced fully automatic light packaging sorting plant in Eitting, Germany, and Europe’s first fully automatic textile sorting plant in Malmö, Sweden.
The pursuit of minimizing waste by recycling as much as possible has also put the spotlight on chemical recycling. In 2022, it capitalized the attention of the chemical and mineral oil industries looking for effective solutions for plastics that are difficult to recycle. “At STADLER we detected this emerging demand early on, and today we offer upstream equipment that sorts and prepares the plastics for the chemical process,” says Willi Stadler. “This is an important step forward, as chemical recycling companies break down the plastic into gas, convert it into oil, which is then transformed into virgin plastic. This means closing the loop of a circular economy for materials that until recently would have been discarded as waste.”
STADLER is constantly searching for new ways of supporting the recycling industry in its evolution. This includes participation in research initiatives such as the EnEWA project, which aims to unlock the untapped potential of obtaining recyclable paper from residual,commercial and plastic waste, for which it received the European Paper Recycling Council Award 2021/22 in the “Innovative Technologies and Research & Development” category.
Digitalization plays an increasingly significant role and STADLER is fully on board, as Willi Stadler explains: “This is a priority for STADLER, in all areas of our business – in our operations and, most importantly, in the sorting plants we design with data collection of incoming and outgoing recyclables and predictive maintenance. We will continue to invest significantly in this area.”
Meet an increasingly global demand for recycling plants
The demand for recycling is spreading across the world, and STADLER has expanded its activities in Latin America and in the United States to meet this need. In 2022 it completed the latest in a series of MSW sorting facilities in Brazil. The company also opened a new sales and service office in Mexico City, where it has already built a number of plants, including two large-scale facilities. Its subsidiary in the United States had a breakthrough in 2022 and is now supplying systems across the country. STADLER is investing in increasing its capacity at its production facilities in Germany and Slovenia in order to meet the growing demands of its historical and new markets.
Sustainability is in STADLER’s DNA
“STADLER is all about sustainability, starting from our very business model: as a specialist in waste sorting systems for the waste disposal and recycling industry, we provide an important infrastructure for the development of a circular economy. Effective waste sorting is the basic prerequisite for efficient recycling,” says Willi Stadler. “What’s more, with every recyclable material sorting plant we build, thousands of tons of CO 2 are saved. Just to give an example, a household waste sorting plant that treats 100,000 tons of input material per year saves about 100,000 tons of CO 2 equivalents.” In 2022, STADLER’s achievements in sustainability have been recognized with the Sustainability Today Industry Excellence Award.
STADLER is also focused on sustainability in its operations: “We are a medium-sized family business with 230 years of history, and we have been acting sustainably on our own initiative. As a member of the UN Global Compact, we are committed to sustainability and to the ten principles of sustainable business for the benefit of all people, today and in the future.” The company has adopted a modern energy management concept and is currently focusing on energy saving and self-sufficiency. For example, in 2023 it plans to extend its 88 kWp photovoltaic system with an additional 750 kWp.
The company’s sustainability extends to corporate governance and financial sustainability. It reinvests annual surpluses and ensures a high equity ratio, so that it is able to overcome economically unfavorable situations and protect its partnerships with customers, employees, suppliers and the local community. “Through our sustainable approach, we create an environment that fosters a high sense of purpose in our employees, who feel invested in the company,” says Willi Stadler. “At the same time, we are able to support our business partners in difficult times such as we are experiencing.”
Covestro and Lanxess Cooperate to Produce More Sustainable Raw Materials With Reduced Co₂ Footprint
Companies agree production of key basic chemicals
Covestro uses electricity with certificates of origin from hydropower for electrolysis in North Rhine-Westphalia
Cooperation reduces CO₂ emissions by up to 120,000 tons per year
Chemical companies Covestro and LANXESS are cooperating in the energy-intensive production of basic chemicals at their Lower Rhine sites in Germany and make them more climate friendly. LANXESS procures chlorine, caustic soda and hydrogen from the ISCC PLUS-certified sites of Covestro in Leverkusen and Krefeld-Uerdingen. With immediate effect, Covestro is manufacturing around one-third of the volume of products it supplies to LANXESS using energy from hydropower based on guarantees of origin.
“Covestro is pursuing the goal of completely converting its production to electricity from renewable sources on its path to operational climate neutrality in 2035,” says Dr. Klaus Schäfer, Chief Technology Officer of Covestro. “A particular focus is on the energy-intensive production of basic raw materials. In cooperation with LANXESS, we use energy in our electrolysis plants in North Rhine-Westphalia on a pro-rata basis, which enables us to reduce our reported emissions by up to 120,000 metric tons of CO₂ per year.”
“The joint project with Covestro is an important building block in making our entire value chain climate-neutral. By sourcing raw materials for these products with a significantly reduced carbon footprint, we will be able to reduce our reported indirect emissions by up to 120,000 metric tons of CO₂ equivalents per year,” says Dr. Hubert Fink, member of the LANXESS Board of Management. With its Net Zero Value Chain Initiative, the specialty chemicals group plans to eliminate Scope 3 emissions within its upstream and downstream supply chain by 2050. This includes indirect emissions, particularly from purchased raw materials, but also in logistics or disposal. For Scope 1 and 2 emissions, the company aims to be climate neutral as early as 2040. “With this program, we are taking the next step towards a climate-neutral product portfolio and also supporting our customers, who are increasingly looking for sustainable solutions,” says Fink.
Chlorine, caustic soda and hydrogen are basic building blocks for many products in the chemical industry. However, their production is very energy-intensive. LANXESS uses the raw materials supplied by Covestro, for example, for products that are then used in the food and agricultural industries. Covestro produces the three basic raw materials at its North Rhine-Westphalian sites in Leverkusen, Krefeld-Uerdingen and Dormagen. Both the former have already been certified to the internationally recognized ISCC PLUS standard for the production of the strategic raw material chlorine, while this is also planned for Dormagen in the near future. The correct allocation of the electricity to the products is ensured via this certification and the use of the renewable energy is proven by the invalidation of certificates of origin at the Federal Environment Agency.
Covestro is also actively involved in various projects to build a hydrogen economy that uses mainly or exclusively green hydrogen as an energy carrier. Among other things, the company is supporting, in cooperation with Hydrogenious LOHC Technologies, to build the world’s largest plant for storing renewable hydrogen in liquid organic carriers in Dormagen, Germany.
Teamwork during production monitoring in the electrolysis hall.
With regard to its energy supply, Covestro focuses on power purchase agreements (PPAs) for renewable energy or high-level certificates. Only recently, the company signed PPAs with Chinese supplier CGN New Energy on wind and solar power that will cover around 30 percent of the electricity needs of its important production site in Shanghai. Under another, utility Ørsted will supply offshore wind energy starting in 2025, which is expected to meet 10 percent of the electricity needs of Covestro’s sites in Germany. ENGIE, Belgium’s largest renewable energy producer, will provide onshore wind energy to meet 45 percent of the electricity demand of Covestro’s Antwerp production site in Belgium.
Borealis Borcycle C Chemical Recycling Provides Circular Solutions for Crosslinked Polyethylene for the Wire & Cable and Infrastructure Sectors
Pyrolysis process keeps difficult-to-recycle crosslinked polyethylene like XLPE and PE-X in the circular loop
Chemically recycled grades in the Borcycle C portfolio are ISCC PLUS certified according to the mass balance methodology
EverMinds approach provides innovative and viable solutions to recycling challenges in the Wire & Cable and Infrastructure industries
Borealis announces the capability to use its proprietary Borcycle C chemical recycling process to recycle crosslinked polyethylene (PE) types such as XLPE and PE-X into recycled polyethylene. Thanks to its suitability for high performance applications, the recycled PE obtained in the pyrolysis process can replace virgin PE in the manufacture of XLPE and PE-X for use in the Wire & Cable and Infrastructure industries, respectively. Using ISCC PLUS (International Sustainability and Carbon Certification) certified grades in the Borcycle C portfolio enables customers to capitalise on circular solutions while at the same time maintaining high application quality and industry standards.
A sustainable solution to overcome the challenges in recycling XLPE and PE-X
For cable networks, XLPE offers cost effectiveness and flexibility in installation. When used as insulation in low voltage electrical cables, XLPE boasts a better overall life-cycle impact than alternative materials: less of this lighter-weight material is required to provide top cable system performance. PE-X is deployed in a wide range of advanced polyolefin plumbing and heating pipes, and is particularly suited for coping with demanding environments. Compared to conventional materials, the inherent properties of crosslinked PE-X offer distinct benefits, including exceptional toughness, chemical resistance and durability at high temperatures. Up until recently, however, it was difficult to recycle XLPE or PE-X in such a way as to obtain the virgin-like PE required for these high-performance applications.
By drawing on its polymers expertise and recycling know-how, Borealis can now offer its customers a circular solution for crosslinked PE. In a series of tests conducted by Borealis, XLPE and PE-X plastic waste were pre-treated and fed into the Borcycle C chemical recycling process. This chemically-recycled material was analysed and determined to be suitable for use as cracker feedstock in the production of new ethylene in the manufacture of virgin-grade XLPE and PE-X.
The proprietary and evolving recycling technology Borcycle C transforms plastic waste streams into value-added products. These chemical recycling solutions complement mechanical recycling by turning difficult-to-recycle plastics – like crosslinked polyethylene – into virgin-level grade materials with the highest safety and performance characteristics.
Grades in the Borcycle C portfolio of circular polyolefins are ISCC PLUS certified according to the third-party mass balance methodology. This allows the customer to track and quantify the effective circular feedstock used at each step in the manufacturing process. When customers choose grades from the Borcycle C portfolio, they are replacing fossil fuel-based feedstock with an identical volume of circular feedstock without incurring extra switching costs, and – most importantly – while maintaining the same high application quality.
“True to our EverMinds mindset, we’re proud to provide a long sought-after solution for XLPE recycling. Having pioneered the development of advanced insulation and jacketing systems, we are now making them more circular as well,” says Bart Verheule, Borealis Global Commercial Director Energy. “As Borealis Energy celebrates its 60th year as a reliable and trusted partner to our customers and value chain partners, we intend to keep re-inventing essentials for sustainable living in both the Wire & Cable and Infrastructure sectors.”
University of North Carolina Wilmington Expands Polystyrene Recycling with Support from Foam Recycling Coalition
The University of North Carolina Wilmington’s demand for recycling services has markedly increased since the start of its recycling program in 1989. What began with a five-person operation has expanded to include collections, hauling, and processing capabilities with an on-campus hand-sorting material recovery facility and drop-off center (The Depot). Now, with the help of the Foam Recycling Coalition, the university will expand its polystyrene foam recycling capabilities to meet increased volumes.
UNCW received a $9,627 grant from the Foodservice Packaging Institute’s Foam Recycling Coalition (FRC) to purchase four containers to collect the increased volume of polystyrene foam. It will add a second densifier, donated to the university, that will double the capacity to process foam, including packing blocks, coolers, peanuts, foodservice containers, egg crates and meat trays.
“99% of all foam collected at UNCW comes from off-campus via drop-off at either our MRF or The Depot. As well as receiving material from the public, we partner with local businesses to process their foam,” said Feletia Lee, chief sustainability officer with UNCW Business Services. “UNCW is looking to expand our relationships with the city and county to target foam in their operations.”
“The University of North Carolina Wilmington is making strides to meet demand and create a circular economy with over 95% of materials processed on campus being sent to vendors in North Carolina. The Foam Recycling Coalition is proud to support the university’s efforts to divert more foam polystyrene from landfills,” said Natha Dempsey, president of the Foodservice Packaging Institute, which oversees FRC.
The grant is made possible through contributions to FRC, which focuses exclusively on increased recycling of post-consumer foam polystyrene. Its members include Americas Styrenics; Chick-fil-A; CKF Inc.; Dart Container Corp.; Dolco; Dyne-A-Pak; Genpak; INEOS Styrolution America LLC; Lifoam Industries, LLC; Pactiv Evergreen; and Republic Plastics.
UNCW is the 27th grant recipient to receive this funding since 2015. Over 8 million additional residents in the U.S. and Canada can recycle foam polystyrene as a result of FRC grants. Visit www.RecycleFoam.org to learn more about foam recycling, read about previous recipients or apply for a grant.
Hansgrohe Selected INEOS Styrolution’s Sustainable Novodur ECO for Their Chrome Plated Sanitary Fittings
Novodur: INEOS Styrolution’s specialty ABS1
Novodur P2MC: special injection moulding grade suitable for electroplating
Novodur ECO P2MC B50: plug-in grade with 50% bio-attributed contribution
Novodur ECO B50: product carbon footprint savings of up to 71%
INEOS Styrolution, the global leader in styrenics, has today announced that Hansgrohe, a leading global manufacturer of sanitary fittings and fixtures has selected the company’s sustainable Novodur ECO solutions for their next generation products.
Hansgrohe is one of the world’s largest producers of shower heads, hand-held showers and taps/ faucets. As part of their challenge to reduce the company’s ecological footprint, the company decided to look at the materials used for the production of their sanitary fittings. They selected INEOS Styrolution’s Novodur ECO P2MC B50 for two reasons: Firstly, Hansgrohe’s high quality standards were not to be compromised and secondly, adjustments to production had to be minimal.
INEOS Styrolution’s bio-attributed Novodur grades fulfill these demands: The products offer identical properties as the conventional material – including surface quality, impact strength, high flowability and, in the case of Novodur ECO P2MC B50, suitability for electroplating. The material is also a plug-in solution not requiring any changes to the production setup. At the same time, Novodur ECO B50 grades offer product carbon footprint (PCF) savings of up to 71%2.
Frank Semling, Chief Operating Officer at Hansgrohe SE, said: “We are extremely pleased that the transition to the new sustainable Novodur ECO P2MC B50 was very swift and completely hassle-free.”
He continues: “We are excited to be the first INEOS Styrolution customer in our industry to change to the new bio-attributed material. We encourage more companies in all industries to make the switch to sustainable materials to jointly improve our CO2 footprint and achieve the goals defined in the Paris Agreement.”
Dr. Eike Jahnke, Vice President Specialties EMEA at INEOS Styrolution said: “We consider Hansgrohe to be a pioneer in many ways. They led the way to the design bathroom of the 21st century, and at the same time, they are committed to sustainable management and responsible business practices. We will continue to develop sustainable styrenics ECO solutions for entrepreneurs like Hansgrohe. We are committed to deliver premium performance at reduced ecological footprint.”
“Thanks to the unchanged properties of INEOS Styrolution’s bio-attributed ABS Novodur ECO P2MC B50 compared to the previously used material, we are now switching quickly, which makes our internal processes easier”, said Matthias Stunder, Plastic Technology International Lead at Hansgrohe.
Innovative Degassing and Decontamination Technologies for Demanding Recycling Applications
Gneuss Extrusion Technology
New OMNI Recycling Machines for closed loop recycling of PET, PS and polyolefin post-consumer reclaim
Gneuss’ MRS Extrusion Technology has proven itself as an alternative for the reprocessing of contaminated materials like polyester, polystyrene, polypropylene or polyethylenes. In combination with the highly efficient Gneuss Rotary Filtration Systems and optimized vacuum technology, customizable recycling lines tailor-made for a specific material can be engineered. Several Letters of Non Objection (LNOs) from the FDA, EFSA conformity and local approvals in Latin America confirm the decontamination efficiency of the technology.
OMNI Recycling Machine for post-consumer fiber or thermoform reclaim
Gneuss will show its latest machinery innovations for today’s and tomorrow’s recycling needs with the new OMNI Recycling Machines.
The OMNImax Recycling Machine processes industrial and post-consumer waste from all kinds of polymers and in all forms and shapes. It includes a 3C Rotary Feeder, an
MRSjump extruder, a fully automatic melt filtration system RSFgenius and an online viscometer VIS.
3C Rotary Feeder
The newly developed 3C Rotary Feeder makes it possible to use low bulk density materials without any external processing steps. A conveyor belt feeds shredded reclaim material into the hopper, where a fast-rotating disc with knives cuts, compacts and pre-conditions the material. The knives add energy into the material and start the heating and degassing process before the material is automatically fed into the MRSjump extruder.
MRSjump
The MRS extruder is based on conventional single screw technology but is equipped with a multiple screw section for devolatilization. It enables very efficient and gentle decontamination of PET, whilst achieving the requirements for direct food contact standards. The MRS extruder permits the processing of R-PET directly into high quality end products such as packaging sheet, strapping tape or filaments without pre-drying by using a simple and rugged vacuum system. This is achieved by means of its unique and patented processing section. The Multi Rotation Section is a drum containing multiple satellite single screws, driven by a ring gear and pinion transmission.
The satellite screws rotate in the opposite direction to the main screw. This disproportionately increases the surface exchange of the polymer melt. A large opening for venting, exposing the full length of the satellite screws, is completely under vacuum. This provides excellent and unrestricted access to the polymer melt, the surface of which is constantly replaced at an extremely high rate by the action of the satellite screws in the multiple screw section. The surface area – and the surface area exchange rate – available for devolatilization are far greater than in other extrusion systems. As the thermal and mechanical stress on the polymer melt is minimized, PET processed on the MRS extruder has excellent optical and mechanical properties.
The new MRSjump has a longer, modified version of the Multi Rotation Section, which ensures both a longer residence time of the material and more surface area exchange under vacuum. The longer Multi Rotation Section, coupled with a powerful vacuum system operating at 1 mbar, can be used to boost the viscosity of R-PET and to hold it at a stable level in spite of variations in the input material. Therefore, there is no need for any liquid phase (LSP) or solid state polymerization (SSP). With the stabilization and/or increase of the intrinsic viscosity in the extrusion process, the MRSjump is especially well suited to recycling e.g. PET film waste or fiber reclaim – applications for which direct recycling with one single extrusion step was previously impossible due to low intrinsic viscosity or variable input viscosities. In combination with Gneuss’ Rotary Filtration Technology, a high melt purity is guaranteed. Quality assurance can be provided with an online viscometer VIS for measuring melt viscosity.
As demand for PET bottle flakes outpaces supply and processors are looking for alternative feedstock (e.g. to fullfil recycled content mandates) the MRSjump offers an excellent solution for PET thermoform, film or fiber recycling, while the newly developed MRS cutter compactor makes it possible to use low bulk density materials.
OMNIboost Recycling Machine including polyreactor JUMP
The OMNIboost Recycling Machine with an polyreactor JUMP processes PET waste, whether form from industry or postconsumer, directly into high-quality products. The integrated JUMP can lift the IV value of a PET melt up to 0.95 dl/g.
In the JUMP the polymer passes over several slow turning elements which create a polymer film, the surface of which is constantly renewed. The reactor vessel is kept under vacuum, through which volatile substances are reliably removed. By regulating the residence time in the reactor, the vacuum, the fill level and the speed of rotation of the agitating devices, the polycondensation reaction can be altered to achieve the required product properties. The JUMP is a robust and reliable liquid state polycondensation system (LSP) and a compact, quick and efficient alternative to conventional solid state systems (SSP). It enables direct reintroduction of the polymer into the production process without the need to remelt the PET.
OMNIboost Recycling Machine with JUMP polyreactor, MRS Extrusion System, Rotary Filtration Systems and 3C Rotary Feeder.
Gneuss Filtration Technology
Tailor-made retrofits of pressure- and process-constant Rotary Filtration Systems
The continuous Rotary Filtration Systems are characterized by a filter disk on which the screen cavities are located in a ring pattern. Screens can be changed on the part of the filter disk that is not active in the melt channel, while the production process continues to run without any interruptions or disturbances.
Gneuss’ top model, the RSFgenius, operates with an integrated back-flushing system offering self-cleaning for very demanding applications and highest quality requirements. Screens can be automatically re-used up to 400 times and filtration finenesses below 10 microns/1200 mesh are available.
Retrofitting a fully-automatic RSFgenius to an existing extrusion line, whether in a pelletizing, sheet, fiber or pipe application, permits the use of more contaminated (and often cheaper) material and/or the use of finer screens. Every retrofit is tailor-made and usually without the need to move any existing equipment.
Patented Rotary Filtration System RSFgenius.
Gneuss Measurement Technology
Measuring Technology for Extrusion – Flexible, Fast, Safe, Digital
Gneuss provides flexible sensor solutions for pressure and temperature measurements, individually tailored to your application. Abrasion, corrosion, temperature, Gneuss offers the right solution for every challenge.
Gneuss delivers fast. Whether standard sensor or application-specific customized solution. The flexible manufacturing structure allows shortest delivery times.
Gneuss creates safety. In addition to standard-compliant pressure monitoring, Gneuss offers the necessary quality assurance of the measuring equipment.
Gneuss is digital. The latest generation of Gneuss sensors and pressure monitors communicates completely digitally. Integrated RFID chips for digital gauge monitoring are available for all sensor models.
How Bry-Air is Alleviating Cancer Risks With Energy-Efficient PET Drying
The Indian plastic industry is a major contributor to the country’s economy. Coming with a wide range of benefits, plastics find application across diverse industries for their sheer versatility and flexibility. Though it is lightweight, it is inherently highly resistant that is well complemented with high impact strength at the same time. As a result, from automobile to food packaging, healthcare, electrical & electronics, building & construction, wire & cable, etc. almost all industries are seeking plastics for various reasons.
Owing to the increasing utilization of plastic, between April – September 2022, the Indian plastic export stood at US $6.38 billion, and aims to increase the plastic export to reach US $25 billion by 2025. Also, the domestic consumption of plastics too is at its peak, rising year on year. It has grown by 23% and is expected to reach 22 million MT in 2022-23. Hence, it is important more than ever to manufacture plastics of the highest quality that conforms to industry standards for multiple reasons. Plastic processing is a complex process and the industry is continuously on the lookout for energy-efficient and cost-effective solutions. The inability to conduct efficient drying can lead to splash, silver streaking, voids, blisters, gas bubbles, haziness in the final product. Along with this, plastic can also lose its tensile strength and compromise the structure of the product. Similar, is the case in PET drying, a popular form of plastics and having high affinity towards moisture. Drying of PET is one of the most critical steps to ensure superior quality of moulded products.
As per the current practice, PET drying is carried out at 160°C temperature with -40° dew point for a residual time of 5-6 hours. Normally, the return air temperature from material drying hopper is 70°C to 80°C. Here, it is important to note that the return air coming out of the hopper needs to be cooled down to achieve a temperature below 45°C for entering the desiccant drying system (honeycomb rotor/ drum). In case the temperature is more than 45°C, it will impact the effectiveness of adsorption. Hence, a cooling coil is installed to compensate the heat. On the other hand, as the material requires a temperature of 160°C, there is a need to add extra energy to the dry air coming out of the desiccant system. This indicates a supply of added energy at both the levels.
Coming with extensive knowledge and continual R&D in desiccant dehumidification and adsorption technologies, Bry-Air Green DrySmart (GDS) delivers same performance of -40°C even at a incoming air temperature of 70°C. Meticulously designed to level up the ‘art of drying,’ it comes with waterless drying ability that is well complemented with honeycomb rotor technology to make it energy-efficient. In the process, it eliminates the use of a cooling coil required to reduce the temperature coming out of the chamber.
At the same time, the air leaving the desiccant rotor is substantially at a higher temperature than that of the air acquired through traditional drying, it requires less amount of energy to reach 160°C. A total of 40% of drying process energy is saved in the whole process.
If the Indian Plastics industry implements the above said desiccant drying process, we can cumulatively save around INR 40 lakh kW energy every year against the 22 lakh metric tons of PET being manufactured annually. This translates to a notional saving of approximately INR 3.2 crore annually for the Indian PET processing industry. Hence, it is the need of the hour that the industry incorporates a coherent PET drying process for ensuring process excellency and optimize manufacturing.
The other important reason for deploying this process is to minimize the formation of acetaldehyde. In the testing process of acetaldehyde in PET, 1 mg of chipped/ peeled PET is heated at 150°C for a duration of 15 minutes which triggers VOC gases and a attached unit of gas chromatography senses the level of acetaldehyde. This chemical is a potential health hazard with the ability to cause cancer. In many countries, maintaining acetaldehyde below the maximum permissible limit is followed very strictly.
If a cooling coil is added to the Bry-Air Green DrySmart (GDS) Dryer, it acts as a Super Dryer, delivers 12 times improved dry air by achieving -60°C dew point. Therefore, the GDS enables a PET processor to select either an energy efficient dryer or opt for a Super dryer and dry their PET at 135°C for a residual time of 3-3.5 hours only thereby reducing the formation of acetaldehyde.
As PET plastics are invariably used in both the primary and secondary packaging, mainly used for water bottles, aerated beverages, juices, liquor, PET aluminum lid cans, jars, trays, etc. installing Super Dryer can keep the level of acetaldehyde within safe limits, making it suitable for safe consumption. Hence, efficient PET drying is the way forward for a resilient product as well as the industry at the same time.
Constantia Flexibles Announces Joint Venture in India
Constantia Flexibles, a leading producer of flexible packaging worldwide, signed a joint venture (JV) agreement for its Indian business and operations with Premji Invest and SB Packagings. The combination will help Constantia Flexibles achieve its ambition to grow further and create value in the Indian market.
“I am very pleased to partner with SB Packagings and Premji Invest,” says Pim Vervaat, CEO of Constantia Flexibles. “I have the greatest respect for SB Packagings’ achievements and look forward to the joint venture, supported by Premji Invest, to grow the combined business profitably.”
The JV is pursuing organic as well as inorganic growth in higher added value market segments in India, continuing its strong growth trajectory in the hygiene segment whilst further developing the more sustainable mono-material EcoLam product range. With the new partners, Constantia Flexibles is able to strengthen its business in the region and various market segments. As SB Packagings is a leading player in the hygiene segment, the new partnership will help extend Constantia Flexibles’ portfolio.
The closing of the joint venture agreement is expected to be completed by the end of March, pending regulatory approvals. KPMG India acted as the exclusive financial advisor to Constantia Flexibles for the transaction.
