DarWIN research project accelerates multi-manufacturer machine learning

The Fraunhofer spin-off plus 10  has been conducting application-oriented research together with the South German Plastic Center SKZ . As part of their DarWIN research project, new AI-based process optimisation tools have been developed specifically targeting injection moulding machines. Sumitomo (SHI) Demag was selected to perform the final series of comprehensive research tests.

A beacon for automated machine learning in the future, the ambitious project has focused on developing continuous learning models that deliver higher moulding quality in shorter cycle times, around the clock. To accomplish this overarching strategy and facilitate autonomous reactions to individual production situations, the research team has captured valuable deep learning from different machinery manufacturers.

An R&D program instigated in the mid-2020s, developments accelerated at speed in 2021 with a series of machine learning tests facilitated by the Fraunhofer spin-off plus10 and the SKZ plastics centre. Labelled the DarWIN research project, this AI program focused specifically on gathering detailed and transferrable processing behaviours from multiple models of injection moulding machines using high-frequency machine data.

Through the transferability of pre-trained machine learning models, the DarWIN project proves that individual machines from different manufacturers have the capability to learn from each other. In reality, this now means that individual behavioural models of a specific machine don’t have to be completely re-learned every time. Instead they can be adapted to the machine and product application through minor automated adjustments.

This ability to adapt to the prevailing conditions, for example raw material characteristics and ambient conditions, provides robust evidence that processing patterns and behavioural models are transferable to machines of similar size and technology, regardless of the manufacturer.

AI tests performed on Sumitomo (SHI) Demag machines

Most recently, plus10 and the SKZ performed a series of thorough AI pilot tests on Sumitomo (SHI) Demag machines. Thanks to the high-frequency machine connectivity, Sumitomo (SHI) Demag machines provide the ideal platform to put the plus10 algorithms through their paces.

Offering real-time communication in the millisecond range, the company’s advanced machine controllers are ‘AI-ready’. This universally compatible digital interface allows for seamless communication across all machinery assets. Additionally, it facilitates easy implementation of continuous learning AI-based optimisation tools. Accomplishing optimal productivity at all times and allowing for further advances in interface design, continuous learning and AI-based software developments.

By providing this real test environment, Sumitomo (SHI) Demag continues to demonstrate how the company is proactively addressing the innovations coming down the line, delivering intelligent automation and actively shaping the future of injection moulding.

Supporting sustainable plastics production

The test simulation results further underpin the strong industry emphasis placed on sustainable plastics processing. Specifically, the plus10 technology allows for stable processing of sensitive and heterogeneous materials, such as thermoplastic post-consumer recyclables and fast-curing elastomers. Thus supporting all the efficiency and defining characteristics of a fully circular plastics processing economy.  

The research project ‘DarWIN’ was funded by the Federal Ministry of Education and Research (BMBF funding code 01IS20066). Concluding on 31 December 2021, the results are currently being processed and incorporated into the plus10 software. Plans are in place to publish the detailed insight at the end of 2022. Additional activities and live demonstrations of the development results will be shared at specialist events, including the “Digital Injection Moulding Meeting” to be hosted at the SKZ in Würzburg.

https://www.sumitomo-shi-demag.eu/

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 REHAU brings the latest zero-joint edgebands, RAUTAKANTEX Pro

REHAU’s engineering progress towards enhanced living

REHAU, the global leader in polymer-based solutions is elated to bring a range of edgebands that promises to give a true zero joint finish look to furniture. Furniture edgebands has come a long way, from plain white ones in the 1960s to glossy mirror-finished ones in 1990s and over the years, REHAU has adopted these transitions seamlessly, simultaneously they are innovating designs and developing cutting-edge technology. Today, the brand is known for manufacturing edgebands that gives translucent and 3D looks to furniture, upping the niche level of homes.

The RAUKANTEX edgebands range has been developed for all commonly-used processing methods for a true zero joint finish. It has undergone many transformations in its time, and the latest RAUKANTEX zero joint edgebands has now transformed it into state -of-the -art  furniture edging

REHAU Zero-joint Edgeband has a pre-applied, co-extruded polymer functional layer replacing the traditional glue, allowing for a much superior and seamless joint between the edgeband and the board. With REHAU presenting 1000+ color options, the edgebands aesthetically blends with all kind of furniture, enhancing home interiors and creating a style statement. The zero-joint edgebands offers maximum chemical resistance of PP and also promises longevity being scratch-resistant.

On its commitment toward a more sustainable nature, REHAU has always used ecologically friendly polymers, with RAUKANTEX pro, REHAU is reducing the need for adhesives and cleaning agents during the entire procedure. REHAU also uses ABS and PP materials that are ecological and harmless to human health. The brand is regularly launching various initiatives in its production pipeline to reach the ultimate goal of carbon neutrality.

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A new graphene nanotube product for thermoplastics allows automakers to increase cost efficiency

• OCSiAl has launched a new graphene nanotube concentrate for PA, filled PPS, ABS, TPU, and PC.
• The new product provides targeted conductivity in thermoplastics produced by injection molding at working loadings starting from 0.1 wt.% of nanotubes in the final system.
•  This approach allows makers to optimize the painting process and reduce the final production cost.

Painting of exterior automotive parts, such as fenders, bumpers, tanks flaps, grilles, mirror housing, exterior trims, and rear quarter panels, is complicated by the necessity of separate operation lines for metallic and polymer components, as plastics are insulative, which makes in-line electrostatic spray painting impossible. This leads to additional expenses and slows down the whole painting process.

To overcome this, manufacturers of automotive parts should wisely choose temperature-stable thermoplastic grades and modify these systems with electrically conductive additives. The most widespread is carbon black. However, because of their high working dosage required, car end parts with additives demonstrate worsened mechanical properties and processing challenges.

OCSiAl, the world’s largest manufacturer of single-wall carbon nanotubes, also known as graphene nanotubes, has launched the new easy-to-use TUBALL MATRIX 822 graphene nanotube concentrate specifically designed for PA, filled PPS, ABS, TPU, and PC compounds for injection molding. Introducing these nanotubes creates a permanent and homogeneous electrical conductivity without “hot spots” in the range of 10^5–10^9 Ω·cm, while retaining the original key mechanical properties, such as durability and strength, and minimally impacting the host polymer matrix. Furthermore, a low working dosage of 0.1-0.3 wt.% of graphene nanotubes demonstrates only a limited effect on rheological properties and processability.

Graphene nanotube concentrate now enables in-line e-painting of plastic exterior parts together with metal components using electrophoresis, where previously, separate production lines were required. Manufacturers of polymer injection molded parts for automotive, industrial, construction, mining, and other applications now have opportunity to reduce production costs and the number of rejected final parts without changing standard operating processes by using high-performance graphene nanotubes.

“The new product will also be valuable for improving automotive safety and tracking systems: graphene nanotubes allow makers to produce high-quality electrically conductive thermoplastic products without compromises in terms of overall product mechanical performance or durability,” said Vladimir Kravchenko, Development and Support Leader for Thermosets, OCSiAl Group. “We already see demand from manufacturers of fuel system parts including quick connectors, fuel pumps, valves, filter housings, EV-battery caps, and other car components.”

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Arkema to increase its global Pebax elastomers production capacity by 25%

Arkema announces a 25% increase in its global Pebax  elastomer production capacity by investing in Serquigny in France. This investment will notably enable increased production of the bio-circular Pebax  Rnew and traditional Pebax  ranges.

This new capacity will produce a variety of highly specialized grades to meet growing demand in numerous demanding applications thanks to the lightweight, flexibility and excellent energy return of these materials. These properties are particularly appreciated in sports equipment, such as soles for running shoes, ski boots or technical textile, in consumer goods such as smartphones and flexible screens, as well as in other markets such as medical equipment.

Derived from renewable castor seeds, Pebax  Rnew advanced bio-circular materials offer a sustainable solution to our customers who are increasingly driven by sustainability and social responsibility. Compared to other elastomers on the market, these materials have a carbon footprint that is up to 50% lower and can be fully recycled. In addition, this investment, which is scheduled to come on stream mid-2023, will lower the water consumption of the site by 25% thanks to process optimization.

“We are very excited to commit to an expansion in our Pebax  elastomers capacity” said Erwoan Pezron, Senior Vice-President of Arkema’s High Performance Polymers Business Line. “The Serquigny plant has a long proven legacy in the production of these advanced materials, and we are delighted to add this new capacity to support our customers’ growing demand for high-performance sustainable materials. We will also continue to produce many of these materials at our Birdsboro plant in Pennsylvania”.

https://www.arkema.com/

Preconfigured Feeders Offer Plastics Industry A Powerful and Efficient Feeding Solution Coperion K-Tron Announces All-New ProRate PLUS Feeder Line

ProRate feeders are highly standardized and include a variety of design features to optimize performance and ease of use. Simple access for cleaning and maintenance, even within a cluster, is provided thanks to a patent-pending rail system called “ProClean Rail”.

ProClean Rail makes it possible to retract the base unit toward the rear of the feeder and rotate it for access to the feeding section and screw element. This allows for maintenance and cleaning of the feeding unit while keeping the feeder in position.

In addition, the bellows and screw use the latest magnet technology for simple but robust mounting. The magnet connections allow these parts to be released without tools while at the same time providing the required holding force for optimal and safe operation. Thanks to the high level of standardization of the feeders, the number of spare parts required for the emergency stock is minimal. Many parts are identical for all three models and can be used as exchange parts for all devices.

ProRate PLUS feeders are suitable for use in hazardous locations rated NEC Class II, Div. 2, Group F & G and ATEX 3D/3D (outside/inside).

Accurate weight measurement and reliable control modules for efficient operation. All ProRate PLUS feeders are equipped with P-SFT load cells, featuring reliable Smart Force Transducer weighing technology. They operate under compression and provide accurate, stable, and reliable digital weight measurement under a broad range of operating conditions.

The load cells supply a direct digital weighing signal and the onboard microcontroller ensures excellent repeatability and stability. P-SFT load cells have a high tolerance to vibration and electrical
noise. They feature built-in over and underload protection.

Each feeder comes equipped with its own pre-wired ProRate PLUS PCM control module. The PCM is mounted to the feeder stand, with adjustable height positioning. Each PCM is pre-tested in Coperion K-Tron’s manufacturing facility prior to shipping. There are two models of PCM to choose from: a basic motor control unit (PCM-MD) or an advanced version with an integrated user interface and line control functionality (PCM-KD). Within a group of up to eight feeders, one feeder must be equipped with the PCM-KD while the PCM-MD is sufficient for the others.

The PCM-KD comes with all the software the ProRate PLUS feeder will need for continuous applications and supports all three feeder models. The connection between weigh feeders, operator interface and smart I/O is via an industrial network. All motor setup, diagnostics, and operator interface functions are integrated into the PCM-KD user interface. The PCM-KD is equipped with a host communication port (Ethernet IP or Profinet).

A variety of service offerings to keep processes running smoothly

Coperion K-Tron’s dedication to customer satisfaction has also led to the creation of a unique new portfolio of service offerings for the launch of this product line. A variety of Start-up and Service Packages are available for ProRate PLUS feeders to ensure each customer can get exactly the level of service they need. Coperion K-Tron also offers quick and easy remote services for ProRate PLUS.

From an online portal to 24-hour phone support and even remote start-up assistance, trained service technicians are available to keep systems running around the globe. In all, the brand new ProRate PLUS feeder line offers a simple, robust and reliable solution for feeding a variety of free-flowing bulk materials in plastics processing applications.

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Game-changing recycling plant to be built in Melbourne’s west  

Belgium: TotalEnergies increases its production of high- performance polymers for specialty markets

TotalEnergies Polymer plant in Feluy, Belgium, announced the startup of a new production of high-performance polymers with the commissioning of a new reactor in its polypropylene unit.

Through this investment, TotalEnergies strengthens its leading position on the high value- added polymers market. The Company is therefore increasing its production of grades that meet the highest quality standards and technical requirements of specialty markets, including medical and automotive.

Thanks to their many properties, such as lightweight, impermeability or resistance, plastics have become an integral part of our daily lives. In the automotive sector for example, the use of polymers as replacement for metal contributes to reducing the overall weight of vehicles, thereby allowing reductions in CO2 emissions by as much as 10%. In the medical sector, polymers also play a crucial role in the supply of medicines, particularly by ensuring their protection and packaging.

Valérie Goff, Senior Vice President, Polymers at TotalEnergies, stated: “The commissioning of this new reactor in Feluy will enable us to meet the growing demand from our customers, including the automotive and medical specialty markets, for ever more efficient polymers that contribute to reducing the carbon footprint of end-use applications.”

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https://modernplasticsindia.com/

TPEs make work outs easier and fun

Going to the gym is not only a recreational past time for adults but also a path for them to achieve their health and fitness goals. The desire to stay fit and healthy has never been more relevant than now. In addition, with the latest, innovative gym equipment and cable motion technology, fitness enthusiasts are able to expand their exercise possibilities to build balance, strength and power.

Furthermore, today’s gym equipment has evolved and it is no longer bulky but instead compact, to allow for space savings, and far more aesthetic. To achieve ergonomics and cost effectiveness in gym equipment, manufacturers are turning to TPE compounds.

KRAIBURG TPE, a global TPE manufacturer of a wide range of thermoplastic elastomer products and custom solutions for multiple industries, offers custom-engineered TPE compounds that are durable, flexible, and allow for wear and tear and chemical resistance. Thus, the compounds are suitable for gym equipment applications such treadmills, skipping ropes, weight training deep stations, upright bikes, etc.

VS/AD/HM series: keeping fit with TPEs

KRAIBURG TPE’s VS/AD/HM series of compounds can be used in gym equipment applications. The compounds are known for their chemical resistance as well as resistance to abrasion and scratches, which makes the
compounds ideal for gym equipment applications where the surface is in constant contact with human sweat and strenuous physical activities.

This series of TPE compounds offers a consistent colourability, allowing for the possibility of more attractive equipment. Also, the TPE compounds render a soft, velvety surface feel to products, making them suitable for handles and grip applications in equipment. The excellent adhesion property to nylon, PA6 and PA12, as well as other polar thermoplastics like PC, ABS, ASA and SAN, allow for flexibility in product development.

Other possible applications where the VS/AD/HM series can be used include fitness ab wheels, bicycle cushion covers, buttons, etc. EC series: aesthetic features in gym equipment KRAIBURG TPE’s EC series of compounds is an electric conductivity series with low resistivity, which is a fundamental property of a material that measures how strongly it resists electric current.

This holds the EC compounds in good stead for potential applications in gym simulation vests, required for stimulating the muscles, for work-outs and bodybuilding. The use of weight vests as a tool for fitness has increased significantly, especially in the tactical fitness industry, with weighted calisthenics, speed and agility, and other weighted running workouts.

Another attribute of the EC series is that it has a soft, non-sticky haptic surface, which provides comfort to the user when wearing the vest. Furthermore, it is halogen-free, for safety in applications, and has good
adhesion to polypropylene (PP) resin, allowing for a wide variety of applications.

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New Customizable PET Solution Maintains Carbonation in Beverages, Energy Drinks

Ring Container Technologies, a leader in the plastic container manufacturing industry, today announced it has developed a customizable PET solution for maintaining carbonation in beverages and energy drinks.  

Energy shots and beverages with BarrierGuard Enhance technology are customizable into unique shapes, creating on-shelf brand differentiation for smaller size carbonated PET bottles.

“Enhance is break-through bottle technology allowing beverage and energy drink manufacturers to re-imagine their carbonated drink space and brands,” said Tim Ferrel, Vice President of Business Development at Ring. “After a successful launch of BarrierGuard  OxygenSmart  and other technology solutions, we look forward to expanding this market and continuing to exceed our clients’ expectations.”

Traditionally, smaller PET packages have been difficult to carbonate and maintain carbonation, due to the volume and surface area. However, Enhance uses technology that enables carbonation in a PET bottle and preserves it for the duration of the product’s shelf life. Enhance beverage bottles are also resealable for consumers to enjoy later.

Enhance can leverage Ring’s APASS  guidance to design an optimal e-commerce solution for carbonated beverages and energy drinks to avoid costly Amazon handling fees. In addition, Enhance bottles are shatter proof and dent resistant, compared to metal cans that may dent during transportation, causing increased retail rejection and inventory cost.

“Enhance bottle technology can integrate the use of post-consumer recycled (PCR) materials to help meet recycled content goals of new state and federal legislation,” said Paul Kelley, Vice President of Product Development at Ring. “Enhance is another great example of how Ring’s technology portfolio continues to grow with an eye on both the environment and consumer packaging advances.”

https://www.ringcontainer.com/

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