“Quality control has always been important to us. But we were not really aware at the beginning that we could also ensure a considerable process optimisation by means of the OP5. At first, the measuring device delivered results that seemed irreal to us. This was solely due to the fact that even several daily laboratory measurements could not adequately reflect the dynamic changes in production. These variations only became visible through the short measuring interval of the automated OP5 online measurement. The continuous quality control with the use of the OP5 allows us to optimise the production process at any time and at the same time to finally classify our batch material. The advantages such as the fully automated measurement, the considerable time savings through the reduction of transition times and the high reproducibility through the OCS equipment, in comparison to the manual ISO1133 measurement, contribute to an effective process optimisation and reduction.“ David Cerra González, Quality Coordinator at Transformadora de Etileno A.I.E. (TDE), Spain Plastics are produced in countless variants today. The most common is polyethylene. Modern processes mean that there are also different variations of this material today. Low-density polyethylene, or LDPE, produced using a high-pressure process, is one of them. Transformadora de Etileno A.I.E. (TDE) has three plants for the production of low density polyethylene (LDPE) in Spain. The annual capacity of LDPE is approximately 160,000 t/year. TDE focuses on continuous quality control and assurance in the ongoing production process in order to detect and optimise dynamic production fluctuations at an early stage and in a relatively short sequence. For this reason, two OP5 measuring systems are already in use in two of three production lines. Various deviations in production have an impact on viscosity and can therefore be monitored by online viscosity measurement using OP5. The continuous measurement of the Melt Index (MI) of polymer samples also allows a final classification of the batch material.
Save time and reduce costs. Due to the continuous measurement, real-time results can be visualised in 5 to 10 minutes via the touch panel with a data trend in 24/7 operation. This leads to considerable time savings compared to a manual ISO 1133 measurement. The permanent data logging makes it possible to intervene significantly in the production process and save costs. High reproducibility through OP-MFR measurement. The OP5 MFR measurement is a method carried out by means of exact control of the melt flow in combination with a high-precision and self developed melt pressure measurement. This method achieves a typical reproducibility of +/- 1 % in comparison to the manual ISO 1133 measurement with +/- 5-10 % deviation. Are you interested in a detailed performance description in a 1-to-1 conversation with our experts? Then please feel free to contact us.

www.ocsgmbh.com

Guill announces the introduction of a new version of its popular 800 series, known as 800 Series Hybrid. In some extrusion applications that utilize crossheads and inlines, layers of the exact same material are applied multiple times, using a single die. This method is used to reduce the propensity for errors caused by gels breaking through a thin wall, weld lines, inconsistent wall thickness, plus material and process variations. Additional errors include difficult-to-process materials and demanding applications where there is zero fault tolerance.

Seeking to design the next generation multi-layer die to overcome these challenges, the engineers at Guill looked for a way to incorporate this technology into an updated version of the 800 Series. This led to the creation of the 800 Series Hybrid. The inherent benefits of the 800 Series are retained, including compact design, low residence time and a common deflector bore that eliminates tolerance stack up. The challenge was to create a hybrid design that incorporates the benefits of layer overlapping, while reducing unnecessary complexity and making the technology more cost-affordable for customers. This was achieved by overlapping layers in each semi-deflector, using a single cone. The highly efficient design of the 800 Series Hybrid reduces cost and size, as opposed to other methods of overlapping layers. Essential benefits of the 800 Series Hybrid include eliminating weld lines in materials through patented overlapping technology, producing a more consistent finished product; reduced sensitivity to changes in viscosity; reduced sensitivity to changes in line speed; myriad material and multi-layer application possibilities; works in all tubing and jacketing applications with a wide range of materials; low residence time; compact design and a low tolerance stack-up error factor, all resulting in improved concentricity. The 800 Series Hybrid extrusion tool greatly reduces stagnation, because overlapping layers are more inherently balanced than single layers and also because each semi-deflector is “tuned to flush.” Conventional deflectors must simultaneously achieve a balance between flushing, balancing and eliminating the weld line. There is less difference between the slowest moving material and the fastest moving material in the deflector channels, thus making the viscosity more consistent in the deflector.

www.guill.com

• Create truly unique yarn designs: with up to 6 colors from a large predefined color range and infinite combinations of twisting & air entanglement
• Endlessly recyclable yarn solution – available in both standard PA6 and 75% recycled content EqoCycle PA6 yarn
• Efficient and flexible – all colors in stock to shorten lead-time; customized lot sizes

B.I.G. Yarns brings inspirational design freedom to high-end loop-pile contract and automotive carpets with the unveiling of ColorMind. The innovative yarn technology is B.I.G. Yarns’ first venture into a two steps yarn collection, offering a unique solution for creating multi-color PA6 yarns for any carpet design. Available from mid-June 2021 in both standard and EqoCycle 75% recycled content yarn, designers are invited to work closely with B.I.G. Yarns experts to realize the designs they have always wanted. Combinations of variable levels of twisting and air entanglement, using up to 6 colors at once, elevate design possibilities beyond current limitations. The ColorMind color bank features predefined colors, always in stock, meaning short lead times. Manufacturers can also benefit from customized lot sizes and bobbin length, creating even more flexibility and design freedom.To preview a taster of the potential directions opened up for loop-pile carpets, B.I.G. Yarns has used the technology to achieve its own “Optica” dot effect and “Illusion” wave effect as inspiration for customers’ design explorations.“ColorMind offers never-seen yarn diversity to support a new level of design sophistication in high-end carpet segments. We’re very proud and excited to enter into two steps yarns with a solution offering something truly special, the result of intensive dedication from our design and development teams,” comments Emmanuel Colchen, General Manager, B.I.G. Yarns. “ColorMind combines our strengths in delivering high-performance, more sustainable yarns to fit the evolving demands of these segments, underpinned by our expertise in color sequencing and color mixing. We’re looking forward to exciting collaborations and innovative, eye-catching designs for future loop-pile carpets.”
ColorMind PA6 yarns are based on a unique Solution Dyed Nylon yarn and are suitable for Class 33 certification (heavy commercial use). The EqoCycle yarn version is mainly based on post-industrial waste and supports contract and automotive carpet manufacturers with a drop-in circular solution to reduce the ecological footprint of their end carpets.

www.colormindyarns.com.

HST Maschinenbau GmbH, which has been part of the Krones Group since 2014, can draw upon decades of experience in developing and manufacturing high-pressure homogenizers and piston pumps. These products complement Krones’ process technology portfolio with a key process step for producing milk, milk-based drinks, dairy products, juices, and other foods at all the needed throughput ranges.And now, the HLI series has been added to complement the proven HL range. These new 55 to 90-kW systems can process up to 13,000 liters per hour at 200 bar. At launch time, three models are available: HLI55, HLI75, and HLI90, all in the same configurations as the HL series and including an option that fulfils the European Union’s ATEX (Equipment for potentially explosive atmospheres) Directives. Additional models for the lower output range to 45 kW are currently in development. The systems in the new series each consist of a three-piston high-pressure pump with a homogenizer valve at the outlet.

Lower energy and media consumptionThe “I” in HLI stands for “integrated” and underscores the design changes implemented in the new series. A compactly dimensioned drive design eliminates the need for additional units or coolants, which makes for a substantial reduction in operating costs for media and electrical power during production. For example, it cuts consumption of cooling water for the pistons by more than 30 percent compared with conventional piston lubrication. Excellent product quality, lower homogenizing pressureThe homogenizer valve has a crucial impact on product quality – and, by way of the homogenizing pressure, on the energy input required. The homogenizer valve on the HLI series can be perfectly matched to the required physical stability of UHT dairy products, vegan beverages, desserts, and fruit drinks. As a result, shelf lives of up to twelve months can be achieved without compromising the product’s flavor. Optimized flow conditions make it possible to obtain the same product quality at a lower homogenizing pressure. Of course, all areas that come into contact with the product are made in accordance with the latest hygiene requirements.The HLI series can be configured for either aseptic or non-aseptic processing. The aseptic models of HST homogenizers use proven technology that entails a series of sterile barriers and can be equipped with high-grade temperature and flow metering capabilities on request. Particularly suited for the production of UHT diary products and desserts as well as milk-based drinks, vegan beverages, and fruit juices: the new HLI series high-pressure homogenizers from HST.krones.com

• Fourth live broadcast: versatile Internet TV, with input from turnkey experts
• Live link: exclusive insights into Arburg assembly and machine commissioning
• Best practice: Hauff relies on cube technology

• The impact of the global coronavirus epidemic is still too prevalent
• The safety of visitors and employees is highest priority
• We look forward to the 2022 Technology Days

Arburg is cancelling the Technology Days event it was planning to hold between 7 and 12 June 2021. Consultations with official bodies and due consideration of the ramifications of the global coronavirus epidemic that are still clearly evident prompted the decision that was taken last Friday. The so-called ‘Federal Emergency Brake’ applied by the German government has a decisive influence on this situation.
“We regret this cancellation hugely but we are compelled to take this step due to prevailing parameters”, explains Juliane Hehl, the Managing Partner responsible for Marketing at Arburg. “Up until the final moment, we were hoping, and were genuinely working flat out, to enable these Technology Days to take place in the form, at long last, of a physical trade fair”, states the shareholder with reference to all the planning and efforts invested over the last few months. Our Technology Days are a brand in their own right, as well as being the largest in-house event in the entire World of Plastics – so we really did do everything conceivable to facilitate, at long last, a personal and physical event experience for our customers.
The safety of visitors and employees The postponement of the traditional timing of this event from March to June, the extension from four to six days, a Covid-compliant invitation and visitor management system, a meticulously planned hygiene and testing concept – with all of these measures, the safety of visitors and employees was always at the forefront of our deliberations.
Eager anticipation of the 2022 Technology Days “As unfortunate as things are at present: We stand by our view that the whole world is looking forward to getting back to normal events and trade fairs”, states Juliane Hehl. The Technology Days could have acted as a beacon for an entire sector, so it was entirely right and proper for us to have made every attempt to organise and hold the event. “We therefore extend an even warmer invitation to the World of Plastics to visit our Technology Days here in Lossburg in March 2022!”
arburg.com

Destination circular economy: Starlinger’s new backflush filter allows manufacturers of woven bags made of polypropylene tapes to use a proportion of recycled polypropylene of 50% and more in the tape extrusion process.

In times where buzzwords like sustainable packaging and closed packaging cycles are on everyone’s lips, Starlinger & Co. GmbH is now able to provide another solution to the plastic packaging industry that will ensure greater sustainability. “With our SPB filter, we are offering tried and tested technology that enables woven bag manufacturers to use recycled material for bag production without compromising on quality and cost-effectiveness. As such, you get exactly the same specifications and properties with recycled input material as with tapes made from 100% virgin material,” explains Hermann Adrigan, Head of Sales at Starlinger. Especially when it comes to packaging made of tape fabric, which is characterised by its high strength properties, high-quality tapes are the most important requirement. The tear-resistant sacks are filled with up to 50 kg of contents – in the case of big bags, the fabric even has to sustain two to three tonnes of weight. When using recycled material, the Starlinger SPB filter ensures excellent melt filtration for the high tape quality required. “This enables fabric bag manufacturers to work even more sustainably and at the same time meet a criterion that is becoming increasingly important in the packaging market: the amount of recycled content in the product,” says Adrigan.

50% and more of recycled content

In tape production, impurities and, in many cases, the range of different polymers in the recycled input material cause problems such as filter blockages or tape tears, which, in turn, reduce production efficiency. The SPB melt filter from Starlinger, on the other hand, achieves a high melt throughput with excellent cleaning capacity even in the case of more heavily contaminated input material. This way, a stable production process and high degree of efficiency are ensured.Thanks to the hydraulic backflushing function of the filter, the respective filter screen is backflushed and thus cleaned when a defined degree of contamination is reached. The backflush cycles are relatively short due to the high pressure build-up in the filter, and the extrusion process is not interrupted – an important criterion that saves material and time. Depending on the degree of contamination of the melt, the filter can achieve throughput rates of up to 720 kg/hour and allows for 50% and more of recyclate in tape production.

Know-how for a closed packaging cycle

“For optimum recyclate quality, our division Starlinger recycling technology offers recycling plants that are tailored to the specific needs of bag manufacturers,” adds Hermann Adrigan. “In principle, we at Starlinger combine the know-how and technology for “circular packaging” under one roof: From the manufacturing process and the packaging recycling process to reusing the recyclate for the same product. And our customers benefit from this. With our equipment, it is a lot easier for packaging manufacturers to use recycled material in the extrusion process because they can rely on the quality of the recycled pellets.” Design for Recycling is another important criterion for implementing a circular economy in the packaging sector. “In this respect, woven bags made of polypropylene are the perfect example,” says Adrigan. “They are a mono-material packaging consisting of 99% PP – even if they are coated. Considering this, it is obvious that the bags should be collected after usage and recycled. We want to promote and advance this process with our technologies.”

www.starlinger.com

MEAF Machines has added a PROMIX physical foaming installation to its in-house extruder test and demonstration line. As of mid-May this will allow customers to get hands-on experience with this material saving equipment while using their own polymer grades in the process. The potential savings from the PROMIX equipment come in addition to the benefits of the MEAF extruders, that are already among the best for energy efficiency and economy.

‘Physical foaming offer a significant material saving potentials for extrusion processes,’ says Roald de Bruijne, Sales Manager at MEAF. ‘PROMIX are setting new standards in the production of microcellular foam products with a very homogeneous cell structure and unprecedented process stability, while using eco-friendly CO2 and N2 blowing agents. Depending on the application, density reductions of 5 to more than 30 % can be achieved. The resulting material saving will not only benefit the plastic processors, but also their customers and the environment.’
‘When opting for a new type of raw material, material mixture or a new machine supplier, it is always helpful to be able run a test before deciding the best way forward,’ adds Roald. ‘It is like taking a test drive when you are looking to buy a new car. With MEAF’s new in-house test & demonstration line, we provide this capability to our customers. Our extrusion line has been designed and build to accommodate the latest technologies, such as physical foaming, and a wide variety of materials for our customers’ packaging needs, be it PET, PE, GPPS, PS, PP, PLA or biodegradable grades.’
For any sheet or film extrusion, the largest contribution to the production costs are by far raw materials, often surpassing 70 % of the total production expenses, usually followed by energy consumption. Therefor every manufacturer is looking to reduce its overall production costs by reducing the raw material expenses. One approach is to increase the amount of recycled material, regrind skeletal waste or bottle-flakes in the case of PET film extrusion, or the utilisation of filler components such as CaCO3. ‘To reduce the overall raw material costs further, even more needs to be done,’ explains Roald. ’This is where MEAF’s sheet extrusion line in combination with PROMIX physical foaming comes in. Not only will it typically reduce the cost of plastic raw material by 20% compared to conventional packaging, the overall weight reduction of 10 to 30% has further benefits, as some countries use this a basis for packaging taxes. In addition packaging can be made 100% recyclable, while also allowing the utilization of recycled raw material, also foamed.’ The micro foam process offers excellent rigidity, insulation and insensitivity to scratch marks, and results in the lowest energy consumption per kg in the industry. With the set up processors can work with multiple types of materials in one extruder, such as PP, PS, PET, PE, GPPS and PLA. Both foamed and non-foamed sheets can be produced on the same line, even allowing for multilayer A/B/A sheet, where the A-layer is a solid non-foamed layer, and the B-layer is of a foamed material.

https://www.meaf.com.