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Kunststoffe international, Half a Million More Parts
Mold cleaning is a challenge with a very small, 0.8 g light injection-molded part. The use of an efficient dry ice cleaning system not only increases product quality, but also reduces cleaning time, increasing both equipment availability and production capacity. Diehl Stiftung & Co. KG (see box p. 48) manufactures punched parts and approximately 850 t of fiber-reinforced high-temperature-resistant plastics such as PPS, PBT, PEI, PPA and PA into complex multifunctional parts at the plant in Telto...

Kunststoffe international, Polymer Materials
... place on land – via global air pollution – in remote regions such as the High Alps, the Tibetan Highlands, and on Greenland ice. Plastics: A Material with History Biogenic polymer materials (poms) such as amber, natural rubber, Asian lacquer, Chinese silk, paper and paper pulp, composite materials such as leather, horn and tortoiseshell, but also gelatine glue, casein- and egg white-treated painting grounds, shellac, linoleum, and the chemically modified biogenic polymer materials have an age-...

Kunststoffe international, 2005-11-21, A Home Game for the Italian Plastics Industry: Rendezvous in Milan
...ocessing PE-LD, PE-LLD, PE-MD and metallocenes (Fig.5). Energy consumption is relatively low since alternating current motors are used for the screw drives, and infra-red lamps for the barrel heaters. Primplast will be operating a shuttle service from the exhibition grounds to its company show and back. BG Plast, Marnate, will be displaying two new single-screw extruders, the inexpensive TM 50-25, and the THM 60-33, which is accessorised to meet the highest demands. An extrusion line for produc...

Kunststoffe international, 2005-11-21, Demand Continues to Rise: Polystyrene (PS)
Trend Report Commodity Plastics Polystyrene (PS) Demand Continues to Rise. Polystyrene still ranks among the quantitatively most important thermoplastics and after PE, PP and PVC is invariably in fourth place. Pushed by price pressure and price volatility, there is some movement on the polystyrene market, and the industry continues to consolidate. In addition product and procedure innovations will have high value nevertheless. Hans-Dieter Schwaben Consumption of PS in Europe decreased somewh...

Kunststoffe international, 2005-11-21, Development History of Plastics: Growth through Changing Times
...ere sealed with natural asphalt. Also from Arabia came certain tree resins, which could be shaped under heat and reached Europe as “gum arabic”. In Eastern Europe, people have known how to process amber, a fossil resin, since the end of the ice age. It was used to make spearheads and jewellery as well as cultural artefacts. Its disadvantages are low weathering resistance and high flammability, which gave the material its original name of “firestone”. The craft of amber processing continued on a...

Kunststoffe international, 2005-11-21, Exhibition Preview: North American and Canadian Products at K 2004
...in North America. The direct-drive models feature two coupled high-torque servo motors that are connected directly to the ballscrew spindles, eliminating belts and reduction gears. The belt-driven versions have been updated with new drives and a choice of injection units. Two-platens Propagate Demag will roll out its new Titan series hydromechanical two-platen line, which will ultimately range from 11000kN to 40000kN, with the 30000-kN size coming out in mid-2005 and the 40000kN model in 2006. ...

Kunststoffe international, 2005-11-21, General-purpose Plastics: Appearance Ever More Important
...5% of packaging (PE-LD/-LLD 34%, PE-HD/-MD 18%, PP 24%). The construction sector continues to be dominated by PVC (46%), with this figure set to rise. In the automotive sector, the biggest share is held by PP at 27%. In line with the rise in the price of raw materials, the market will have to expect further considerable price increases in general-purpose plastics. Demand is still growing, however, and a series of new polyolefin facilities are planned or already under construction. Company Polic...

Kunststoffe international, 2005-11-21, Good is Not Enough: From Initial Idea to Successful Product
...9;s X-Box shows that this kind of industry focussing and customer proximity can also stimulate innovation. Only because it was informed in good time of the planned development was BASF able to support Microsoft as a partner in the choice of materials and design of the game console. Today, we supply our Terluran ABS plastic in consistent quality to all X-Box production sites throughout the world. Sharing the Task of Tracking down Trends This example also shows that marketing units recognise the...

Kunststoffe international, 2005-11-21, High-performance Applications: Trends in Packaging Technology
Injection Moulding Trends in Packaging Technology High-performance Applications. Consumption of plastic packaging as well as the demand for high-quality packaging articles is climbing inexorably. Their manufacturers can only survive this price war by maximising all savings potentials, especially as regards materials consumption. This is where machine technology comes in. Marc Tesche Hans Steupert No sector offers such large continuous sales growth as that of injection moulded packaging article...

Kunststoffe international, 2005-11-21, Influencing Product Properties: Additive Masterbatches for Foam Film
...ed with improved haptic characteristics, thermal and acoustical insulating properties or even damping behaviour. In summary, foamed film offers the following benefits: - reduced raw material usage, - lower weight, - insulating characteristics (e.g., ice cream containers and coolers), - mechanical and acoustical damping, - low moisture permeability and water absorption, - increased wall stiffness for the same amount of material and - good temperature resistance (PP and PET). Chemical Foaming Wit...

Kunststoffe international, 2005-11-21, Plastic, the All-purpose Material: Function in Form
...), rowers and yachters have been competing under the name “Team Kunststoff”. This year’s main event for Team Kunststoff’s national canoe-slalom squad was the world championship held at the end of July at Augsburg’s Olympic course, the “Ice Canal”. The team won 1 gold, 3 silver and 2 bronze medals. At the victory celebrations, the new world champions and the 2nd and 3rd place runners up in the individual events were presented for the first time with an official championship trophy. This took the ...

Kunststoffe international, 2005-11-21, Polymer Design and Modification: Polypropylene (PP)
...1954 and initial production in 1957. Overall consumption of polypropylene in Western Europe amounted to 7800kt in the year 2003 (polyolefine total: 19000kt, thermoplastics total: 39000kt). This represents an increase of 12% since the year 2000, noticeably higher than the average growth rate of just under 8% for commodity thermoplastics. In Europe and North America, the per-capita consumption of PP is 20kg per person and will grow to 25kg per person by 2010. Worldwide market growth is about 6% ...

Kunststoffe international, 2005-11-21, Polypropylene (PP)
...roducts minimise stress whitening, resulting in a perfect product fit for household items and low-temperature food packaging. Typical target applications include thin-walled containers with a high aesthetic appeal, such as for ice-cream (Fig. 2). Thin-walled means a higher MFR – and the trend towards increasingly high flowability is also particularly evident in injection moulding grades for packaging. For thin-wall packaging (TWP), it is essential to maintain the level of impact strength, which ...

Kunststoffe international, 2005-11-21, Polystyrene (PS)
...the aspect that to achieve a competitive cost position investments in world scale new installations with capacities greater than 120000 tonnes per year are necessary. Increasingly in recent years polystyrene tended to lose its traditionally slight price premium compared to other standard plastics. The commodity character of polystyrene is expressed also in strongly fluctuating market prices that have led to extreme situations again and again such as unexpected consumption highs and lows because ...

Kunststoffe international, 2005-11-21, Possibilities with Plastics: Sports Applications
...ants above all the high impact strength pays for itself well. Thus Makrolon flats withstood a shot test of over 400km/h without breaking or splintering – a characteristic that is very important e.g. for using polycarbonates in visors for ice hockey helmets since the hard rubber disks reach speeds up to 160km/h in hockey shots. Using a special coating polycarbonate lenses can also be made scratch-proof. For instance for ski goggles special UV absorbers guarantee that eyes are protected from stron...

Kunststoffe international, 2005-11-21, Product Marketing: Global Trends in Packaging Design
...ation? Then you should give it the opportunity to explain itself and to sell itself. A case example: Nirvana Natural is a shampoo line from England. As the product name implies, it is a product with completely natural ingredients sold in the upper price bracket. It is marketed on the select, prestige track. Close your eyes and try to picture the product just described. What does the bottle look like, or the logo? What could these natural ingredients be and how are they presented? It is not a dif...

Kunststoffe international, 2005-11-21, Production Cell Offers Complete Solution
...ry short cycle time is the production of thin-wall plastic containers in which the decoration is produced by injection moulding. Success in selling packaged food is dependent to a very large extent on an attractive packaging. Yoghurt, butter and ice cream packed in lightweight stable tubs (title picture and Fig.1) need an eye-catching, commercially appealing print on the lid and/or container to attract consumers’ attention and to describe the contents. This is where the In-Mould Labelling (IML) ...

Kunststoffe international, 2005-12-07, Pipe Extrusion: The 36D Process Concept Opens up New Potential
...ave hardly changed in recent years. A uniform material quality depends on higher and pulsation-free throughput, thermal and materially homogeneous melt, controlled shear deformation and melt temperature; other benefits are low specific investment (price/throughput ratio) and operating costs, and a large processing bandwidth (PE80, PE100, PP-H/B/R, PB, PE-LD) [1]. New features are the requirements for low melt temperatures to avoid sagging at large dimensions, and to minimise the cooling length, ...

Kunststoffe international, 2006-04-04, Market Launch: Foamed Liquid Silicone Opens New Doors
...sti-mate at the present time. Due to the high heat stability of silicones, they are, for example, ideal for seals and gaskets in the automotive segment (Fig.1). Other high-potential appli-cations include household articles like baking trays (Fig.2), ice cube containers and com-ponents for electrical household appliances. The weight reduction attainable with the foaming process in combination with the outstanding properties of LSR also make the product attractive for applications that were former...

Kunststoffe international, 2007-08-14, Output under Pressure
...ticles from the solids channel into the melt channel is known from extrusion blow molding, and is supposed to reduce the melt temperature slightly due to the internal cooling caused by the solids in the melt channel. However, the so-called "ice cube effect", as shown in Figure 5, can also lead to problems, because to a great extent, the colder melt particles in the gap are only deformed elastically, and can then hardly be sheared adequately behind the barrier gap. As a result, inhomogene...

Kunststoffe international, 2007-08-14, Tiny Tubes with a Huge Impact
...R 350 million in research, development and customer orientated projects in 2006. Nanotechnology is also an important development platform at Bayer MaterialScience. High hopes are pinned on carbon nanotubes (CNT). With this focus Bayer Technology Services and Bayer MaterialScience were able to develop a new synthesis process. It is based upon chemical vapor deposition (CVD) in which a catalytic decomposition of a hydrocarbon takes place. Entering Large Scale Production Previous production proce...

Kunststoffe international, 2007-09-19, Mastering Demanding Challenges
...ylene and polyethylene, the cost of raw materials accounts for over 80 % of the total cost and is of considerable importance when it comes to pricing. In general, efforts concentrate on products where improved product properties and a better price/performance ratio play a role. This strategy is based on continual improvements in efficiency and innovation, on the development of growth prospects and on strengthening plastics as energy-efficient materials. Basell is not appearing at the K 2007 as a...

Kunststoffe international, 2007-10-21, Polymethylmethacrylate (PMMA)
...of Evonik Industries in Russia, investments are made mainly to optimize production facilities. The Raw Material Supply The market situation for raw materials continues to be difficult. The costs of PMMA production are subject to how the prices for certain petrochemical products develop. This refers to products used for acetone, being an intermediate product for MMA, as well as MMA (methylmethacrylate) itself. Since 2003, the costs of acetone and MMA have increased by 50 %. Even the prices char...

Kunststoffe international, 2007-12-17, Application Optimized Materials
...he same level of Charpy impact strength (unnotched) that was delivered by the base PA66 (Fig. 2). On top of this the newly developed material has advantages in the notched Charpy impact strength. Particularly in the front area with its stone and ice particle hazards the better notched impact strength is a sensible improvement. It can be seen from Figure 3 that the lack of CaCl resistance of the standard PA66 can be classified as a predominantly optical problem, since the mechanical properties of...

Kunststoffe international, 2008-01-15, Elastomer Industry Has Understood
...Fair Report K 2007) The elastomer industry has become ever more heavily dependent on automotive manufacture (approx. 68 % of elastomer products are processed in this sector). Increasing raw material and energy costs associated with spiraling oil prices and growing price pressure due to cheap imports from Asia and Eastern Europe have severely shrunk margins despite continually rising sales. The European, and in particular the German, elastomer industry can only defend its position through techn...

Kunststoffe international, 2008-02-29, Design and Lighting Technology
...e CO2 debate. Daytime Running Lights: Driving with lights on during the day (Fig.4) provides enhanced safety, since the ability to be seen by other motorists, especially under unfavorable color and contrast conditions in traffic, is improved noticeably. In the Scandinavian countries, among others, daytime running lights are mandatory for all automobiles – here, because of the twilight conditions that are so very frequent. Use of daytime running lights is becoming more common around the world. In...

Kunststoffe international, 2008-06-16, We're Moving towards Specialties
...mportant are innovations for the future success of a company? Gudrun Klein, who is responsible for materials and applications at Kunststoffe, discusses these and other current topics in an exclusive interview with Dr. Willy Hoven-Nievelstein, Group Vice President of Engineering Plastics Europe at BASF SE. Gudrun Klein Kunststoffe: Which polymer segments and sites in Europe are you responsible for? Hoven-Nievelstein: The Performance Polymers Division of BASF looks after the engineering plastics...

Kunststoffe international, 2008-08-14, Planting without Shards
...ss surfaces) who will answer in the affirmative, but the injection molding experts, too. These breakproof and frost-resistant polypropylene planters are up to a meter in height. Customers in garden centers have the choice of different rectangular, round, semi-circular and pillar-like shapes, plus half a dozen smart colors, which would be an embellishment to any rural terrace and almost any sophisticated city apartment. Since these designer items have to be injected via a long flow path from ...

Kunststoffe international, 2008-09-23, Noise Abatement through Use of a Foam-Filled Ballast Layer
... for the purpose of applying the system. The liquid polyurethane system was injected directly into the voids between the ballast rocks by means of a mixing head. Simply foam filling the ballast in the load-bearing region around the railroad ties sufficed to achieve the desired objectives of increased service life and noise reduction. The polyurethane system cured within a short period of time and the stretch of track was able to accommodate traffic once again. In the summer of 2007, a 300-meterl...

Kunststoffe international, 2008-10-17, Polyoxymethylene (Polyacetals, POM)
...ile industry with approx. 40%. Tied for second place are the electrical/electronics branch as well as general industry at 15%, closely followed by the consumer goods industry with 13% (Fig. 2). In Asia, the leading field of consumption is office equipment and electrical/electronics – the largest producers of office machines and home appliances have their headquarters there, but the automobile branch is catching up. On the Market since 1956 DuPont put the first polyoxymethylene und...

Kunststoffe international, 2008-10-17, Polystyrene Rigid Foam (EPS, XPS)
...n the last two years (2006/07), EPS consumption has increased above average – driven by the rapidly growing Asian market. For the coming five years, a somewhat more modest growth of on average 4% p. a. is predicted (Fig. 1). Prices for EPS have fallen by a good 20% in view of the existing surplus capacities in the 2nd half of 2007. Since the beginning of 2008, manufacturers have attempted to raise the price level again; this is essential to obtain adequate margins in the f...

Kunststoffe international, 2009-01-26, Polyurethane Systems in Rail Traffic
...used by the high-speed Shinkansen train. The manufacturer of the PU railroad ties, Sekisui Chemical Co. Ltd., Tokyo, assumes that ties made of the material Eslon Neo Lumber FFU (FFU stands for fiber-reinforced foamed urethane) have a service life of at least 50 years. The projected time in place thus exceeds that associated with conventional rail construction by more than a factor of three. The extended maintenance cycles also mean corresponding cost savings for rail network operators. A...

Kunststoffe international, 2009-10-14, Focus on High-Tech
...resence of a catalyst (Fig. 2). Alongside the carbon nanotubes hydrogen is formed which is disposed of via a burner system, thereby also producing energy. Patented Catalytic Chemical Vapor Deposition (CCVD) technology is used and the specific choice of catalysts is decisive. It is the catalysts that, in addition to the precisely defined process parameters, are responsible for the consistently high product quality. Baytubes are free from amorphous carbon. For standard grades the MWNT content is m...

Kunststoffe international, 2010-07-22, Big Breakthrough for PPS Composites
...eading edge. ?:What was the next significant step? Offringa: The next big milestone is certainly the A380, currently the biggest passenger aircraft. It consists of about 25 percent composites. And the proportion should be twice that for the next aircraft generation. For example, the A350, with over 50 percent of its total weight of fiber composites, will probably take off for the first time in 2011. The Boeing 787 Dreamliner, too, which completed its maiden flight in 2009, is half made of compos...

Kunststoffe international, 2010-08-19, End of the Ice Age
Standing in front of the impressive backof the Glarus Alps, Bernhard Merki points with his outstretched arm towards the ice covering high above Näfels with its dull gloss even in the light of the June sunshine. “That is the Vrenelisgärtli,” says the CEO of Netstal-Maschinen AG. “For many years now the glacier has regularly melted completely or almost completely in the summer.” This observation on the incipient climate change is a subject for discussion among the natural scientists. But the spars...

Kunststoffe international, 2010-08-19, Rising Temperature? We are Getting Back to Normal
Michael Hehl on individual pain thresholds, trends in process engineering, control as the first violin in production – and doing without luxuries Kunststoffe: Mr. Hehl, two years ago, sales of your group were almost twice as large. However, you have survived the crisis year 2009 without layoffs. How close did you come to the threshold of pain? Hehl: A relative decline in sales of 46 percent within two years is a relative thing when you consider that the record year 2007 was exceptional. Your que...

Kunststoffe international, 2011-09-23, Efficiency as Far as the Eye Can See
... for insulin pens in one operation using a three-cavity mold (Zahoransky Formenbau GmbH, Freiburg, Germany) without the need to bond the needles retroactively into the prefabricated needle holder, as was done before. Thin walled covers for an ice cream container are produced in two-component injection molding by in-mold labeling. An all-electric Engel e-motion 740H310W/180 T combi is used for this. Hall A5, booth 5204 KraussMaffei High Performance in the Smallest Space KraussMaffei Technologies ...

Kunststoffe international, 2012-09-17, Efficiency Meets Process Integration
...his time as a clean-room model. All the manufacturing cells are equipped by Engel with a robot of the viper and easix series, and developed and manufactured conveyor belts. ► Hall A5, booth 5204 Sumitomo (SHI) Demag Twice Decorated A novel combination of IML and IMD, combining decoration and function in the high-segment, is presented by Sumitomo (SHI) Demag Plastics Machinery GmbH, Schwaig, Germany. The process reduces the production of displays with integrated operating elements or switches to ...

Kunststoffe international, 2012-10-15, LED Lighting Technology in Vogue
...sults from the amorphous structure and is superior to that of semicrystalline materials. The Bayblend, Makrolon and Apec ranges contain tailored products for injection molding components that must cope with various maximum service temperatures. A new material is being developed that targets metallized reflectors which must remain dimensionally stable, even in extreme temperature changes. Material grades are now available that have low coefficients of linear thermal expansion (CLTE). They can be ...

Kunststoffe international, 2012-11-26, Untapped Potential in Gas-Assisted Injection Molding
...d. To successfully employ CO2- GAIM, processors must observe a few important process details. These concern choosing the right injector, and avoiding changes in the cross-section of the supply line from the GAIM installation to the injector. The choice of injector is important for ensuring that gas-assisted injection proceeds smoothly and that discharge is guaranteed [5]. True, this is also the case for nitrogen but, because CO2 has a much higher density at a given pressure, it takes longer to r...

Kunststoffe international, 2013-08-19, From Dream to Value
...d Thomas, explaining what the motto of K2013 stands for. “Few people are fascinated today by watching the clouds from above. A person using an airplane wants to cover a large distance as quickly as possible. This way of traveling has its price, though, causing high fuel consumption and noise. Today, man dreams of unlimited flying without fuels or noise. These wishes are generating ideas of how this dream might become a reality.” Swiss designer Bertrand Piccard is one example of this, being fasci...

Kunststoffe international, 2015-02-28, Icy Foaming
A new method for foam extrusion combines the advantages of physical and chemical blowing agents. Solid carbon dioxide (dry ice) pressed into pellets is used as blowing agent that is added via the extruder hopper. The foaming method, which is simple to retrofit, provides a good entry-level solution to foam extrusion. Parameter (fixed)UnitValueGranule temperature°C65Dry ice diametermm7Nucleating agent contentwt. % MB0.5Temperature feed zone°C50Temperature melt zone°C170Die temperature°C127Paramete...

Kunststoffe international, 2015-10-12, Sustainably Produced Foam Mattresses
...nto the atmosphere every year. Most experts, including the World Climate Council, are convinced that these emissions reinforce the natural greenhouse effect, so causing long-term changes in global climatic conditions – higher temperatures, melting ice, rising sea levels. Top priority is therefore being given to preventing carbon dioxide emissions – particularly by expanding the use of renewable energy, reducing energy consumption, and increasing energy efficiency. Another way is also gaining imp...

Kunststoffe international, 2016-02-17, Gas Injection Molding with Carbon Dioxide
...w injection solution, developed by Linde in collaboration with Maximator, has reduced the cycle time for a refrigerator handle by 36 %. Based in Sinsheim, Germany, mid-sized German company Engel Formenbau und Spritzguss GmbH operates in a global, price-driven market. "For us, as a comparatively small company, innovation is the key success factor in such a competitive environment," says Dietmar Engel, Managing Director, when asked about the company’s market strategy. In addition to conventional ...

Kunststoffe international, 2016-02-17, Mold Surfaces as a Quality Determinant
Due to today’s high quality industry standards, cleanliness is an important factor and thus, injection mold cleaning is one of the most important prerequisites to yield high product quality. Through the use of dry ice, the Hans Geiger Spritzgießtechnik GmbH was able to increase not only its quality but also its overall productivity. The quality and added value of a product is always a result of several, perfectly interconnecting, individual steps. This is only one of the reasons why the Geiger...

Kunststoffe international, 2016-11-30, Icecold to Higher Quality and Productivity
Tool and mold cleaning is a quality and cost critical production step in the plastics industry. Dry ice enables effective yet gentle cleaning of fine cavities without disassembling or removal of the tools. Molds and dies, for example used at injection molding and extrusion, are today often cleaned with chemicals and mechanical auxiliaries such as brushes or abrasive paper. This takes time, because the tools need to cool down, have to be removed from the machine, expanded, cleaned, and must be re...

Kunststoffe international, 2017-07-19, On the Ball
...nters were already available for flat or cylindrical objects such as bottles and cans, but round objects could only be printed using round screen or pad printing techniques or laminated with films – tried and tested methods which are standard practice for high volumes, but unsuitable for small volumes and individual items: Setup times were too high, production and drying times too long, handling and logistics uneconomical and the production of films, templates and printing plates too expensive. ...

Kunststoffe international, 2017-08-21, High Performance without High Weight
... become increasingly popular, new challenges for the equipment have emerged. A person on tour far away from mountain stations needs particularly light but extremely strong and reliable material, which enables him/her to traverse rock edges and ice ledges or climb a scree slope. Simultaneously, full control of the skis must always be ensured during the descent. Various manufacturers of touring boots and special ski boots solve this difficulty by using Grilamid L 20A HL NZ, which offers outstandin...

Kunststoffe international, 2017-09-20, Dry Ice Shower for Complex Components
Coating companies, who paint interior and exterior parts made of plastic for the automotive industry, have to meet high quality and efficiency requirements. To equip a paint line for surface treatment with a fully automated dry ice blasting unit, including a robot and dry ice granulate production, can increase the profitability. Autotest Iggingen GmbH now has a fully automated blasting system for cleaning with dry ice, supplementary to the classic wash system. Managing director Oliver Bolk expl...

Kunststoffe international, 2018-05-15, All a Question of Strategy
... the entire group of companies. This is where the threads for the development and production of technical plastic parts come together. The automotive supplier sees itself well positioned not only with its own product portfolio, but also with the choice of strategic partners. How this works is demonstrated by the example of a component for the BMW X2. Windshields, water cowls, liquid and expansion tanks, air intake systems and system components for the interior air conditioning – such a product p...