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Circular Economy Forum at K 2022 from 19 to 26 October in Düsseldorf

Circular Economy Forum at K 2022 from 19 to 26 October in Düsseldorf

VDMA and 13 member companies to present the latest technologies for the circular economy in the plastics industry at K 2022

This year will once again see a Circular Economy Forum held at K in Düsseldorf, The World’s No. 1 Trade Fair for Plastics & Rubber, from 19 to 26 October 2022. On the outdoor premises between Halls 10 and 16, the VDMA (German Engineering Federation) as organiser and 13 of its member companies will demonstrate the pivotal importance of technology in the implementation of the circular economy in the plastics industry. The participating companies are all represented at the Circular Economy Forum in addition to their stands in the exhibition halls. Arburg, Coperion, Engel, Erema, Kurtz-Ersa, Lindner, R-Cycle, Vecoplan are taking part with own pavilions while Battenfeld Cincinnati, Leonhard Kurz, Plasmatreat, Sumitomo (SHI) Demag and Wittmann Battenfeld will exhibit at the joint stand of the Forum. With machines running visitors can see how plastic waste is converted into high-quality regranulates or how recyclates are processed into attractive, highly functional and recyclable products by means of various processing methods.

The Circular Economy Forum picks up on all three guiding topics of K 2022 – Circular Economy – Climate Protection – Digitalisation. Because high tech is also required to optimise manufacturing processes and make them ever more efficient – as another measure besides the recycling of plastic products to save CO2. Both approaches are not conceivable without digitalisation. It is, for instance, the enabler for digital product passports and globally applicable traceability standards. The linking of all components in the production line is considered the prerequisite for optimising processes. On the topic of data exchange between machines the VDMA has initiated a showcase that makes the live data of integrated machines visible on the basis of OPC UA, at the VDMA Dome and also retrievable by smartphone.

The VDMA Dome at the centre of the Forum will once again this time serve as an information point and meeting place. But it will also provide an overview of important technology-relevant process steps in the plastic circular economy. By means of “The Machine” installation nearly 40 companies with over 50 submissions will present their technology highlights for the Circular Economy. Technologies range from sorting, shredding, washing and regranulating, or material handling to the most important converting processes (injection moulding, extrusion, blow moulding, foaming and additive manufacturing) not forgetting downstream process steps such as ultrasonic welding, surface treatment or thermoforming.

 

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K trade fair shows solutions for a circular climate-neutral plastics industry

K trade fair shows solutions for a circular climate-neutral plastics industry

 

Special show Plastics shape the future brings together experts on the key issues of the future

At K trade fair, which is starting now, everything revolves around the transformation of the plastics industry into a circular, climate-neutral and resilient branch of industry. Under the three hot topics “Climate Protection – Circular Economy – Digitalisation”, globally leading companies, representatives of cutting-edge technology and renowned research institutes will show what changes industry and science are driving forward to make the plastics industry more resource-efficient and greenhouse gas neutral. The industry already has the key technologies needed for this at hand. In times of multiple crises, however, it is becoming clear that the path to transformation is stonier than was thought just a few months ago. The effects of climate change, dramatically increased energy and gas prices and interrupted supply chains pose major challenges for industry and society. It is questionable, for example, how quickly a secure and sufficient supply of electricity and heat from renewable energies can be achieved – also to reduce dependence on fossil raw materials.

 

Ingemar Bühler, Managing Director of PlasticsEurope Deutschland e.V., the association of plastics producers and trade associations, says: “The current challenges have one thing in common: they require a clear compass and determination. To overcome them, we need the consistent implementation of innovative industrial solutions and business models now and in the coming years, for example, to quickly achieve significant progress in the circular economy. We also need the right policy framework now to help strengthen the economy, sustainably secure our prosperity and our future, while advancing climate action.”

Experts from science, industry, non-governmental organisations and politics will inform and discuss how this can be achieved on seven theme days at the K Special Show in Hall 6. The central dialogue forum at K will focus on the three main themes of the fair, which will be examined from economic, social and ecological perspectives. The focus will be on resilient value chains, Industry 4.0, a CO2-neutral industry and the decisive levers for more circularity in plastics.

 

Economic situation of plastics producers

The plastics producing industry in Germany is facing one of the greatest challenges in its existence due to Russia’s war of aggression in Ukraine. The Europe-wide shortage of energy resulting from the Russian aggression and the resulting high electricity and raw material prices meet with serious problems in the supply chains that have already existed since the Corona pandemic. As a result, production at plastics producers fell by 3.2 per cent in the year to August. More and more of these companies are also having problems passing on the increased costs of energy, raw materials and logistics to customers.

 

The demand for plastics is not only declining in Germany. In China, the government’s rigid zero-covid policy and the crisis in the real estate market are leading to a significant slowdown in economic growth. In the USA, high inflation and rising interest rates are dampening the mood to buy and invest. A clear easing of the situation is not in sight. Therefore, targeted and effective political measures and their prompt implementation are now necessary to secure the competitiveness of the German and European locations of the plastics producing industry.

 

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K in Düsseldorf – 70 Years of the World’s No. 1 Trade Fair for the Plastics and Rubber Industry

K in Düsseldorf – 70 Years of the World’s No. 1 Trade Fair for the Plastics and Rubber Industry

Over 3,000 companies from 60 nations to present innovations for the efficient and responsible handling of plastics

 

Hot Topics K 2022: Circular Economy – Climate Protection – Digitalisation

 K in Düsseldorf will celebrate its 70th anniversary this year! Its USP is the thematic leadership as the No.1 Trade Fair for Plastics and Rubber. With 3,037 exhibitors offering the widest range of innovations along the entire value chain, K 2022 will provide a complete overview of where the sector is headed. K 2022 will occupy all 18 exhibition halls as well as large outdoor areas. The ranges on display will include machinery and equipment, raw materials and auxiliaries as well as semi-finished and technical parts and reinforced plastics products.

 

K 2022: 3,037 exhibitors from 60 countries

The exhibitors will represent 60 countries. with strong participation from Europe, particularly from Germany, Italy, Austria, Turkey, the Netherlands, Switzerland and France as well as from the USA. K will clearly reflect the changes on the world market: the number of companies from Asia has remained at a constant high level for several years. Especially China, Taiwan, India, South Korea and Japan will make an impressive appearance – and this despite the current difficult conditions in these countries due to quarantine regulations in their own countries when returning from overseas or major delays in issuing visas.

 

The German plastics and rubber industry will be represented with 871 exhibitors on 66,940 square metres (about 38% of the space).

 

Erhard Wienkamp, Managing Director of Messe Düsseldorf, looks forward to K with anticipation: “K 2022 is our first major trade fair since the pandemic. With 179,000 sqm of net exhibition area our fairgrounds is completely booked.” And Wienkamp adds: “Not only is K in Düsseldorf the performance barometer of the industry and its global marketplace for innovations but also sets sustainable economic impulses. Especially after the pandemic-induced changes and in a difficult global economic climate it will provide orientation.”

 

Commenting on the situation in the global plastics and rubber industry, Ulrich Reifenhäuser, Chairman of the exhibitors’ advisory board at K 2022, said: “Polymer materials are indispensable and omnipresent in nearly all sectors of our living environment today. In 2021, global plastics production reached approximately 390,7 m tonnes; in Germany alone, 21 m tonnes were produced in 2021. However, the entire industry faces a variety of challenges such as supply chain issues and exploding energy prices. The need for personal exchange on a global level at K 2022 is enormous, all the more as the plastics industry is undergoing a transformation process towards a circular economy.”

 

Plastics production

390.7 million tonnes of plastic were produced worldwide in 2021, 352.3 million tonnes of which were derived from fossil raw materials, 32.5 million tonnes from recycled plastic, and 5.9 million tonnes from bio-based plastics. According to analyses conducted by the International Rubber Study Group (IRSG), almost more than 29,88 million tonnes of rubber were manufactured and consumed within the same time period. Asia is now responsible for more than 50% of all global plastics production. Rubber production is also traditionally dominated by Asia.

 

According to Plastics Europe, 21 million tonnes of plastic were produced in Germany in 2021. The turnover of plastics producers totalled 31 billion euros. German plastics processing achieved revenues of 69.4 billion euros in 2021. Rubber processors were able to show revenues of 9.95 billion euros.

 

When it comes to the application area of plastics in Europe, the packaging sector holds the largest share with around 39 percent, construction follows in second place with 21 percent, and the automotive sector is in third place with almost 9 percent. (Source: Plastics Europe, figures from 2021)

 

Production of machinery for plastics and rubber

The current situation of machinery and equipment suppliers, the largest exhibitor group at K, is as follows: The production value of plastics and rubber machinery reached a volume of 38.6 billion euros worldwide in 2021 (2020: 34.2 billion euros). In terms of production value, the largest single nation in plastics and rubber machinery manufacturing in 2021 was China with a 35 percent share, followed by Germany with 19.6 percent and Italy with 7.1 percent. In terms of world trade, German mechanical engineering, with a share of world exports of 22 percent, ranks directly behind the new export champion China with 23.9 percent, Japan with 9.1 and Italy with 8.6 percent. The demand for processing machinery and equipment is present in all important sales markets and will continue to grow.

 

Manufacturers from Germany closed the year 2021 with a production value of 7.55 billion euros for core machinery and thus 7.6 percent above the values of the previous year.

 

The Hot Topics of K 2022

At the last edition of K three years ago, exhibitors already unanimously emphasised the need for operational and closed cycles along the complete material chain. Never before had the industry been so unanimous in addressing an issue and working so cohesively on solutions for environmental compatibility, resource conservation and waste reduction. This development has accelerated since then. K 2022 will provide impressive proof that this industry assumes responsibility and that plastics will in future be part of the solution rather than a problem. And this is precisely why the three hot topics of K 2022 will be Circular Economy, Climate Protection and Digitalisation.

 

Without plastics, careful management of the world climate will not be possible. Plastics are enablers for lightweight construction, e-mobility, the use of wind and solar energy. And here the Circular Economy is of vital importance, while digitalisation is an indispensable enabler for transparency and resource efficiency. All three hot topics will also be highlighted in the Specials at K 2022.

 

The Specials of K 2022

Official special show Plastics shape the future

The special show “Plastics shape the future” in Hall 6 will demonstrate how crucial plastics are for a sustainable future. It will show which fascinating developments are already taking place today and that the visions for tomorrow are just on their way to becoming reality. Seven focus days will be held – with discussions on innovative technologies, impulse lectures, entertaining demonstrations of lighthouse projects and exciting experimental shows. The special show will also address economic, ecological and socio-political aspects and present solutions to problems the plastics industry has to deal with. The special show will be a project of the German plastics industry under the auspices of PlasticsEurope Deutschland e. V. and Messe Düsseldorf.

 

Circular Economy Forum

A Circular Economy Forum will again be held at K this year. In the outdoor area between Halls 10 and 16, the VDMA (German Engineering Federation) as organiser and 13 of its member companies will demonstrate the pivotal importance of technology in the implementation of circular economy in the plastics industry. With machines running, visitors can see how plastic waste is converted into high-quality regranulates or how recyclates are processed into attractive, highly functional and recyclable products through various processing methods.

 

Start-up Zone

The Start-Up Zone will celebrate its premiere at this year’s K. Start-ups are young, creative, flexible and particularly stand out with their innovative solutions. So what better fit for K 2022, The World’s No. 1 Trade Fair for Plastics & Rubber, than to offer a dedicated presentation area to newcomers specialised in the development of innovative products and solutions revolving around plastics and rubber? And this is precisely what K 2022 will be doing with the new Start-up Zone in Hall 8b of the Düsseldorf Exhibition Centre at K from 19 to 26 October 2022. Eleven companies will participate in the Start-up Zone.

 

Science Campus

Firmly established at K is the Science Campus. This year, everything will revolve around the direct dialogue between research and industry. There will be 25 exhibitors with exciting innovations and research results for the plastics and rubber industry. Among them will be renowned universities, colleges and scientific institutes, such as various Fraunhofer Institutes, the Technical University of Dresden, Tomas Bata University Zlin, Czech Republic and Wageningen University & Research, Netherlands.

 

Plastics Business Breakfasts

The Bio Plastics Business Breakfasts will be held in form of are three mini-conferences from 20 to 21 October, each from 8 a.m. to 12.30 p.m., with different focus topics concerning bioplastics.

 

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Ingemar Bühler Managing Director General PlasticsEurope Deutschland e. V. Regional Director Central Europe, PlasticsEurope

Ingemar Bühler Managing Director General PlasticsEurope Deutschland e. V. Regional Director Central Europe, PlasticsEurope

Ingemar Bühler joined PlasticsEurope Deutschland e. V. and serves as Managing Director and Regional Director Central Europe. Ingemar was born in Leverkusen in May 1981. He earned a master’s degree in international politics at the University of Erlangen. In addition, he earned a global business diploma and several executive certificates in the area of strategy development and negotiation at the University of Oxford’s Said Business School and at the LSE. During his studies he also worked at several renowned think tanks, including the Friedrich-Ebert-Stiftung, SWP, SNV, Chatham House and the foreign office. Ingemar is fluent in German, English, French
and Spanish.

Ingemar joined the corporate world in 2009 and worked first as a project manager and executive management support at Bayer AG HQ, prior to leading its newly established international advocacy team. In 2014 he moved to Bayer’s agricultural business division as head of strategy, executive and financial communications. From 2016 to 2019 he was executive management support and chief of staff of the global public affairs team, before taking over responsibility as head of public affairs & sustainability in Germany with additional responsibilities for EU affairs.

Ingemar is married and father of two daughters.

 

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Borealis and Bockatech Showcase Next-Generation Plastic Foaming Technology for More Sustainable Yet Cost-Saving Thin Wall and Reusable Packaging

Borealis and Bockatech Showcase Next-Generation Plastic Foaming Technology for More Sustainable Yet Cost-Saving Thin Wall and Reusable Packaging

  • Winning combination of Borealis polypropylene and Bockatech Eco Core injection moulding technology produces lightweight reusables and packaging for the thin wall market at reduced cost
  • Even greater sustainability gains made possible thanks to Eco Core platform’s compatibility with grades from the Bornewables, Borcycle C and Borcycle M portfolios
  • Development in line with Ever Minds initiatives promoting design for reuse, recycling, and eco-efficiency for wiser use of resources

Borealis and Bockatech, inventor and licensor of the innovative Eco Core manufacturing technology, are showcasing lightweight and ultra-lightweight reusable cups made of Borealis polypropylene (PP) using the patented Eco Core plastic foaming technology. These robust and fully recyclable cups represent the many thin wall and reusable packaging applications that can be developed using Borealis PP resins and the next-generation Eco Core foaming technology. True to the Ever Minds ambition to accelerate circularity, Borealis and Bockatech are easing the transition for converters and brand owners by providing high-performance, sustainable packaging solutions that can be produced using existing equipment and processes, yet at low cost.

Today’s ultra-lightweight cups made using Borealis PP and the EcoCore technology platform for sustainable packaging are even lighter than many conventional single-use paper cups. Yet they boast good insulation properties, with twice the thermal barrier of PP cups with solid walls of the same weight. Durable EcoCore mouldings can be microwave and dishwasher-safe. Because they are made solely of PP, they are easy to recycle once they have reached end of life after hundreds of use cycles.

Eco Core produces durable, monomaterial moulding walls with a composite skin-foam-skin structure in only seconds, and at low cost. When using the innovative technology and Borealis PP in combination, converters and brand owners benefit from:

  • Up to 50% less plastic used in production when compared to solid wall mouldings;
  • Improved recyclability of moulding and injection moulded labels (IML) thanks to monomaterial PP;
  • Suitability for existing injection moulding machines, ancillary equipment, and processes;
  • Shorter cycle times of 5 to 7 seconds;
  • Design freedom for shapes, colours, transparency, high-precision details as well as for decorative elements such as in-mould labelling.

“With our partner Bockatech we’ve made unique progress in making thin wall and reusable packaging even more sustainable. The compatibility of the EcoCore platform with a variety of PP resins enhances its appeal to our customers,” says Peter Voortmans, Borealis Global Commercial Director Consumer Products. “Our Bornewables portfolio of circular polyolefins, and our transformational Borcycle C family of chemically-recycled grades can be used as drop-in solutions for food and non-food. In addition to that, Borcycle M our portfolio of mechanically recycled grades enables production of non-food applications. All three solutions can further lower the carbon footprint of thin wall packaging whilst maintaining high performance – with this we re-invent essentials for sustainable living.”

“At K 2022 we’re excited to be able to show how value chain collaboration is making reuse and eco-efficiency more affordable for consumers and brands,” says Chris Bocking, Bockatech Founder and Chief Strategy Officer. “We’re also looking forward to demonstrating what EcoCore can do with a broad range of more sustainable reusable and thin wall applications, including bowls for to-go food service, pots for foods such as noodles as well as soups, pails and even aerosol caps.”

 

Eco Core has a wide range of reusable as well thin wall packaging uses and creates mouldings with skin-foam-skin walls in seconds.

K 2022 will take place from 19 to 26 October 2022 in Düsseldorf, Germany.

We invite you to “Innovate Collaborate Accelerate” together with us by visiting Borealis and Borouge in Hall 6 at Stand A43. Freshly-brewed coffee will be served in two sizes by baristas in reusable lightweight cups made using Borealis PP, as well as Bockatech EcoCore technology and our partners’ expertise.

The ultra-lightweight (430 ml) cups featured at the Borealis and Borouge stand at the K 2022 weigh just 14 g and are produced in around five seconds using an Arburg electric Injection Moulding Machine (IMM) with a Roboplas robot and Trexel MuCell physical gas along with a chemical foaming agent (CFA). In addition to this, a live demonstration will run at the Trexel stand, Hall 13 Stand B46 during the K Fair. The lightweight (250 ml) cups weigh around 15 g and are made by Paccor using CFA alone. Both cup types have durable insulated 2 mm skin-foam-skin walls and are moulded using an optimised Borealis PP resin blend with dishwasher-proof, PP in-mould labels from MCC Verstraete that feature HolyGrail 2.0 digital watermarking.

 

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Cooperations for Creative and Sustainable Solutions

Cooperations for Creative and Sustainable Solutions

Innovation in a complex world comes from collaboration

Knowledge grows faster than companies. And it is through the exchange of knowledge and the contribution of different perspectives that the best ideas are born. When you think about this, it becomes clear that companies need to cooperate to develop solutions to the challenges of our time faster and more effectively. Covestro offers its own “ecosystem” for collaborations and thus a wide range of connecting points for working with partners.

Manifold collaborations for innovative smart poles
In addition to material properties and functionality, the focus is increasingly on design options. A current example of this is a smart pole designed for future mobility and smart cities – an intelligent pole with multiple functions that Covestro is presenting at the K 2022 plastics trade fair.

Smart poles must demonstrate stable performance even in harsh outdoor environments, while meeting high requirements for modern urban design, functionality and, not least, sustainable development trends. In addition to its own expertise and many years of experience, as well as a portfolio of suitable polycarbonate plastics and blends, Covestro therefore relies above all on intensive collaboration with technology and innovation partners in the development of such concepts, which include suppliers, customers, OEMs, start-ups, designers and universities.

This starts with product design: designs by students from Sweden’s Umeå Design Institute were used to create the 5G small cell in the upper part of the smart pole. As part of a pilot project with this institute and Deutsche Telekom, Covestro investigated how a 5G network infrastructure could be implemented inan urban environment while taking aesthetic aspects into account. Polycarbonates are ideally suited for CMF (color, material, finish) design and enable interference-free transmission of high-frequency radio signals even in harsh weather conditions. To investigate the influence of material and CMF design under different conditions, Covestro operates state-of-the-art test facilities for a wide range of frequencies up to 50 GHz at its Asia-Pacific Innovation Center in Shanghai.

Together with the Umeå Design Institute, design concepts for electric charging stations for different usage scenarios have also been developed, one of which is the charging station design built into the base of the smart pole. Finally, as part of the modern urban landscape, the design of the smart pole must fit into the architectural and cultural context of the city in which it is installed. In addition to durability, the main focus here is on the weather resistance, flame retardancy, diverse light integration options and design freedom of the polycarbonates.

Circularity requires special partnerships
The value of such collaborations becomes even clearer when the complexity of the challenges increases: A circular world often requires the involvement of all partners along a value chain – industrial designers, raw material suppliers, plastics manufacturers, customers, disposers and recyclers. Only when all stakeholders are involved and work closely together can products be developed that can be recycled cleanly, reliably and affordably so that new products can be made from them.

Covestro works with partners from industry and science at all stages of a product cycle to find solutions for a more sustainable future. The exchange takes place with both established companies and start-ups. Covestro will be showcasing the results of these collaborations at the K 2022 plastics trade fair.

 

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Aptar Food + Beverage Receives RecyClass Approval for its SimpliCycle Valve as Fully Recyclable in the Polypropylene Recycling Stream

Aptar Food + Beverage Receives RecyClass Approval for its SimpliCycle Valve as Fully Recyclable in the Polypropylene Recycling Stream

In addition to the Association for Plastic Recyclers (APR) recognition in North America in 2021, SimpliCycle is now recognized by RecyClass in Europe as fully compatible in the PET, HDPE, and PP recycling streams

Aptar Food + Beverage, a global leader in consumer product dispensing and active material science solutions, today reported that it has received approval for its SimpliCycle TPE-S valve from RecyClass as fully compatible with polypropylene (PP), polyethylene (PET), and high-density polyethylene (HDPE) recycling streams. RecyClass is a non-profit, cross-industry initiative facilitating the transition toward a circular plastic economy. The organization published Design for Recycling Guidelines and conducts evaluations of a variety of products in partnership with independent laboratories to assess the product’s ability to be recycled. Aptar’s SimpliCycle valve previously received European PET Bottle Platform (EPBP) Endorsement for full compatibility with RecyClass Guidelines for PET stream, and now has also received full compatibility approval for recyclability in PP and HDPE streams. This achievement provides food and beverage brands with validation that Aptar closures featuring SimpliCycle valves not only offer more hygienic and controlled product dispensing for consumers, but also contribute toward their sustainability commitments by enabling full packaging recyclability. Aptar’s SimpliCycle valves will be commercially available globally at the end of 2022.

“In addition to Critical Guidance Recognition from the Association of Plastic Recyclers (APR) in North America,” said Shyam Kotak, General Manager of Aptar’s Elastomeric Flow Control business, “we now have those same approvals from the leading European organization for evaluating plastic recyclability. The Design for Recyclability Guidelines for these two important organizations have been increasingly adopted around the globe. These approvals are evidence of Aptar’s continued dedication to bringing more sustainable products to market in collaboration with our customers to enable them to meet their sustainability goals. This is good news for brands, fillers, recyclers and consumers, all of whom are looking for plastic packaging to be more in line with a circular economy.” Aptar is a member of RecyClass and active in its technical committees.

SimpliCycle Recyclable Valve – Sustainability and High-Performance
Aptar has been the industry leader in providing flow control dispensing solutions for more than 25 years. Its award-winning SimpliCycle recyclable valve is driving sustainability to the forefront of packaging innovation. Made from a low-density material, if used in a closure on a PET botte, when collected with the bottle in the PET recycling stream, the valve floats in the recycling tanks, allowing it to be easily separated from the PET flakes and then recycled right along with the polyolefin’s streams. If used in a closure on a PP bottle, when collected with the bottle, the closure goes directly into the PP recycling stream and is fully compatible as now approved by RecyClass.

When assembled into an Aptar closure, the SimpliCycle valve provides a fully recyclable and high-performance solution for use with either PET, PP or HDPE containers. SimpliCycle was recently honored to be awarded the best CSR/Sustainability initiative in 2021 by World Food Innovation Awards and in 2022 received the prestigious 2022 WorldStar Global Packaging Award for packaging innovation as well as the 2022 AmeriStar Award in the Sustainable Packaging category.

“Aptar will be at Pack Expo in Chicago October 23-26 to showcase our newest closures designed for recycling, such as our tethered beverage sports closures and lightweight and linerless food closures featuring our SimpliCycle valve. We are also showcasing food grade rPP provided by Pure Cycle,” said Kotak.

 

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Covestro Simulations Help Optimize Polyurethane Foaming Processes

Covestro Simulations Help Optimize Polyurethane Foaming Processes

Example instrument panel: shorten development cycles, reduce complexity and costs

The heart of automotive development – the design phase – is becoming increasingly digital. Automotive manufacturers and direct suppliers in particular often ask for digital verification for specific components, from instrument panels to interior trim. The focus is on simulation calculations that shorten development cycles, reduce complexity and costs, and mitigate risks. Covestro has worked intensively on the simulation of the polyurethane (PU) foaming process and has developed material models and state-of-the-art calculation methods for this purpose, as well as building up powerful computing capacities. To this end, the company will present its current developments at the world’s largest plastics trade show, K 2022 in Düsseldorf.

Product and process design is heavily dependent on the engineer’s experience with customers. Trial and error in setting up the final process is time consuming and costly. That is why simulations have played an important role in the planning of new products for quite some time. In car interiors, however, it has long been a question not only of simulating structure and form, but of creating a digital twin of the possible manufacturing process. To this end, those involved are relying on the science of materials modeling to simulate the foaming process.

This can be explained using the example of an instrument panel. In this application, semi-rigid PU foams based on Bayfill have become well established, as they enable the economical and reliable production of components with complex contours. In addition, the foams provide a pleasant feel and noise insulation.

“Thanks to Covestro’s digital twin for Bayfill foams, suppliers and automotive manufacturers receive detailed information about the processing behavior of the material as early as the design phase, before real experiments or trials are necessary,” says Dagmar Ulbrich, Head of Automotive Systems R&D at Covestro. “This helps identify potential challenges early on, when product and tooling changes can still be made at low cost.”

Polyurethane foams can meet the requirements for instrument panels and other interior parts well, but the foam must be processed within a specific process window. Simulated foaming based on Covestro’s material models helps to optimally adjust the process window.

 

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Ground-Breaking Ceremony for New Manufacturing Facility of Nu-Vu Conair Pvt. Ltd.

Ground-Breaking Ceremony for New Manufacturing Facility of Nu-Vu Conair Pvt. Ltd.

Nu-Vu Conair Pvt. Ltd., one of the leading manufacturers of Plastic Auxiliary Equipment in India organized a ground-breaking ceremony for its new manufacturing facility in Ahmedabad (Gujarat). The ceremony took place on 27th Sep and the event was graced by Mr. Filippo Zuppichin (CEO, Piovan Group), Mr. Kirk Winstead (CEO, IPEG Inc), Mr. Davide Cappellini (CTO, Piovan Group) and the Indian Management Team of Nu-Vu Conair.

Ground-Breaking Ceremony for New Manufacturing Facility of Nu-Vu Conair Pvt. Ltd.

This will be the third greenfield facility of the company that will come up on the recently acquired 75,000 sq. ft. land adjacent to the current factory in Ahmedabad. Post this new plant which is expected to be completed in Dec-23, the overall manufacturing set-up will reach to more than 2,00,000 sq. ft. The new plant will help augment company’s manufacturing capabilities by almost 50% to meet growing demand as well as better serve the customers.

 

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ALPLA Starts Production at the New Plant in Lanseria Near Johannesburg

ALPLA Starts Production at the New Plant in Lanseria Near Johannesburg

New headquarters for Sub-Saharan Africa: 35,000 square metres for production, logistics, administration and training

In the presence of the South African Environment Minister, the ALPLA Group opened a state-of-the-art production site in Lanseria near Johannesburg. In the new headquarters for Sub-Saharan Africa, the internationally active plastic packaging specialist is merging five previous locations in South Africa under one roof. All ALPLA technologies, processes and materials are combined in the Lanseria plant and the first apprenticeship programme of ALPLA in Africa will start at the beginning of 2023.

35,000 square metres of covered production, administration and storage space, another 12,500 for future expansion, and 30,000 square metres of roof area equipped with solar panels: with the new plant in Lanseria, ALPLA is setting the course for further growth in Sub-Saharan Africa. After around two years of construction and relocation, the international packaging company celebrated the opening of the ultra-modern location on 12 October in the presence of the South African Minister of Forestry, Fisheries and the Environment Barbara Creecy, the Premier of the Gauteng province Panyaza Lesufi, Austrian Ambassador-Designate to South Africa Romana Königsbrun and many other high-ranking guests.

‘All of Sub-Saharan Africa is on the upswing, the markets have enormous potential. Our investment in South Africa is a clear commitment to the continent. In this way, we are increasing our competitiveness and guaranteeing the long-term regional supply of safe, affordable and sustainable packaging solutions,’ explains ALPLA CEO Philipp Lehner. ‘Here in Lanseria we concentrate our expertise, optimise production processes, use state-of-the-art equipment and create energy-efficient operations,’ adds Mike Resnicek, Managing Director Sub-Saharan Africa at ALPLA. The plant has one of the largest solar installations on a privately owned manufacturing building in South Africa.

Combined competencies and technologies
The new location in the industrial area north of Johannesburg combines and builds on the five previous plants in Harrismith, Denver, Isando, Kempton Park and Samrand. The departments, employees and machines were relocated step by step. Around 350 employees will start working in Lanseria and their number is subject to further growth. The new plant will produce bottles, closures and special packaging for the food, personal and home care, chemical, cleaning agent and pharmaceutical industries – a total of around 3.5 billion pieces per year.

ALPLA uses six different technologies, including injection and compression moulding, injection stretch blow moulding and extrusion blow moulding. In addition to international corporations, ALPLA also supplies smaller local companies with plastic packaging solutions. ‘The new plant with its modern equipment meets all international quality standards, is operated efficiently and increases flexibility. Our customers in the region will benefit from this service in the long term,’ says Javier Delgado, ALPLA Regional Managing Director Africa, Middle East and Turkey.

Success story apprenticeship
With the new plant in Lanseria, ALPLA is also promoting its own training of specialists and has established a dual education and apprenticeship programme. This dual system of practical and theoretical training based on the Austrian model is already in operation at the ALPLA locations in Germany, Mexico, India, Poland and China. From 2023, the first 12 South African apprentices are to begin their training in the plastics technology and machining technology trades in the ‘Future Corner’ training centre in Lanseria.

Independent personnel development is an important building block for the future of the company, as Resnicek emphasises: ‘Global know-how, ability to run on state-of-the-art equipment, innovative spirit, team spirit and problem-solving skills characterise our “Family of Pioneers”. We introduce young people, mainly from the Lanseria community, to the world of ALPLA and offer them the opportunity for professional and personal development. We look forward to the African and South African premiere of this successful model.’

 

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