Innovative Methods of Packaging - Thesisthesis.com.pk/edition/14Issue.pdf · MARK YOUR CALENDAR...

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Innovative Methods of Packaging

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Dear Readers,Welcome to the fourteenth edition of Polymer & Packaging International, Pakistan’s premier magazine on the allied sectors. In our quest to share the latest industrial trends and developments, in this quarter we have focused on coverage of one of the leading exhibitions of the world in China of which we were media partners. The exhibition not only had exhibitors and visitors from large corporations and businesses across the globe but the conference also shed light on new technological advancements and research-based developments unfolding in the industry.According to Pakistan Plastics Manufacturers Association (PPMA), the plastic industry has taken a lead in its strive for excellence. Today, it is known to be the fourth largest sector of imports, and contributes mostly to the local exchequer under different heads. The industry of plastics is flourishing with an average growth rate of 15% annually. The latest developments in polymer and packaging industry have also taken place during the last few years. On the other side, the economy of Pakistan is becoming stronger with each passing year, buoyed by private organizations and sector-related investment. The real GDP of Pakistan is also increasing at a steady rate, indicating more developments will take place in the near future.The consumption of plastics in Pakistan is still low as compared to other countries in South Asia but the demand is continuously increasing and this indicates that there is huge potential in this industry. Moreover, there has been an increase in the export of plastics due to new, innovative and robust technologies. Since maintaining quality remains the key factor in the industry today, synthetics in manufacturing of polymers can be the game changer. In highly dynamic and competitive environments, acquiring the latest technology along with re-engineering of business processes are pivotal for success and to stay abreast with international standards.The theme of this edition is focused on the extrusion process and flexible packaging trends in the polymer and packaging industry respectively. This issue would discuss significant developments and innovations that have made the plastic and packaging sector more vibrant. The concept of using environment-friendly products is becoming communal among societies, thus increasing the demand for flexible packaging.We hope that you will find this issue informative. We would also like to thank all our advertisers, subscribers and contributors for their continued support and appreciation. We assure them that we will keep bringing and updating them about the latest happenings of the industry.

Happy reading!

Our TeamManaging EditorS.H. [email protected]

Assistant Manager MarketingParas Ali [email protected]

Business CoordinatorM. Eijaz uddin [email protected]

Editorial AssistantKarishma [email protected]

Layout & VisualizationRehan A [email protected]

Published by:Thesis Publishing (Pvt) Ltd.

Address:Room No. 706, Business PlazaMumtaz Hassan Road, Karachi-74000, PakistanPhone: +92-21-3246-1722Website: www.thesis.com.pk

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polymerandpackaging.com 3

EDITOR’S NOTE


CONTENT

03 / EDITOR’S NOTE

05 / MARK YOUR CALENDAR

06 / BARE ESSENTIALS

08 / NEWS

11 / TECHNOLOGY UPDATE

12 / EVENT NEWS

14 / COMPANY IN FOCUS

17 / EXCLUSIVE COVERAGE

20 / INTERVIEW

22 / CASE STUDY

24 / COUNTRY IN FOCUS

26 / ARTICLE

06

11 14

17

2220

24


MARK YOUR CALENDAR

Omanplast 21-23, March 2017Muscat, Oman

Indoplas 7-10, September 2016Jakarta, Indonesia

Chinaplas16-19, May 2017Guangzhou, China

K 201619-26, October 2016Dusseldorf, Germany

Arabplast 8-10, January 2017Dubai, United Arab Emirates

Iftech Pakistan18-20, August 2016Lahore, Paksitan

Taipei Plas 12-16, August 2016Taipei, Taiwan

Gulfood Manufacturing7-9, November 2016DUBAI, UAE

PlastEurasia7-10, December 2016Istanbul, Turkey

Plasti&Pack 201618-20, August 2016Lahore, Paksitan


COUNTRY PACKAGING MACHINERY

PAPER & PAPER BOARD

MACHINERY

PLASTIC & RUBBER

MACHINERY

PLASTICMATERIAL

PRINTINGMACHINERY GRAND TOTAL

Saudi Arabia - - - $ 214,932,772 - $ 214,932,772

United Arab Emirates $ 19,564 $ 58,972 $ 1,428 $ 77,800,150 $ 681 $ 77,880,795

Qatar - - - $ 58,624,944 - $ 58,624,944

China $ 4,627,250 $ 1,138,801 $ 12,911,732 $ 35,069,844 $ 2,529,516 $ 56,277,143

India $ 1,968,063 $ 189,236 $ 1,398,601 $ 38,794,328 - $ 42,350,228

Thailand $ 471,918 $ 29,065 $ 5,750,488 $ 15,527,856 - $ 21,779,327

Korea $ 212,857 $ 206,554 $ 1,188,465 $ 16,597,524 $ 20 $ 18,205,420

Italy $ 12,377,187 $ 792,380 $ 3,134,523 $ 1,137,025 $ 79,521 $ 17,520,636

Taiwan $ 935,025 $ 43,854 $ 3,682,217 $ 5,557,241 $ 5,344,009 $ 15,562,347

Germany $ 4,154,540 $ 684,412 $ 849,084 $ 3,470,449 $ 684,335 $ 9,842,819

Singapore $ 63,797 $ 4,124 $ 318,026 $ 8,636,006 - $ 9,021,953

Belgium - $ 2,978 $ 3,060 $ 8,094,510 $ 4,183 $ 8,104,731

Japan $ 356,810 $ 110,531 $ 6,277,200 $ 1,009,866 $ 145,642 $ 7,900,049

Kuwait - $ 51 - $ 6,988,129 - $ 6,988,180

Canada $ 679 - $ 6,315,133 $ 29,287 - $ 6,345,099

BARE ESSENTIALS


Technology Inc. (Canada) has sold its 60th double bubble line in the world, and it is also the 10th supplied to the same customer in South America. “We are honored to be the chosen supplier to one of the leading producers of shrink bags in South America. We are one of the few equipment suppliers in the world who has successfully provided customers with the tools to process PVdC, Nylon and EVOH. We take customers’ wish-list, custom design equipment to their particular needs, and turn their wish-list into reality” Says Jim Stobie, Macro’s CEO.Macro is able to provide double bubble shrink film lines up to 11 layers and up to 900mm. Film thicknesses range from 20µ to 100µ. The double bubble line is also equipped with different annealing options depending on the applications to provide low shrink, medium shrink and high shrink options.

EXXONMOBIL INTRODUCES EXCEED™ XP PERFORMANCE POLYMERS FOR LIQUID AND FOOD PACKAGINGExxonMobil is expanding its comprehensive slate of polyethylene products with the introduction of Exceed™ XP performance polymers. Developed through advanced catalyst technology, process research, and application expertise, Exceed XP is specifically designed to provide extreme performance in a variety of liquid and food packaging film applications and to run at faster output rates on blown-film lines. With Exceed XP performance polymers, converters can fabricate improved liquid packaging films for demanding applications including bag-in-box bladders, pillow and stand-up pouches, and flexi-tank container liners. The toughness and flex-crack resistance of films made with Exceed XP help absorb the shock and mitigate the risk of pinholes caused by the repeated movement of products during production, handling and transportation. This, combined with the film’s sealing performance, can minimize leakage and product waste. Exceed XP also allows converters to produce food packaging films that withstand demanding environments like low temperatures or high-volume content packaging. The toughness and sealing performance of the films help producers and brand owners protect and preserve their food products, while minimizing waste, from production through consumption. Exceed XP performance polymers offer a range of options for bubble stability and ease of extrusion to deliver a combination of extreme performance with processability and improved output. Converters can cost-effectively tailor film solutions via linear polyethylene blends or downgauging. “The flexible food packaging market continues to drive toward more lightweight, yet stronger and more effective solutions,” said Deman. “Exceed XP can help meet these market needs by providing an outstanding combination of toughness, damage resistance and sealability. Downgauging levels of up to 30 percent can be achieved with better packaging performance, while helping to extend shelf life and product safety to protect and preserve food longer.” Exceed XP forms a part of ExxonMobil’s commitment to growth and innovation. With a strong foundation of global reliability, product consistency and technical support, ExxonMobil extends its Exceed™ and Enable™ slate of performance polyethylene products with Exceed XP – for when extreme performance matters.

NEWS

Macro Sells its 60th Double Bubble line in South America

Film and sheet extrusion machinery supplier Macro Engineering &

New 50kg cement sacks from BSW Machinery and Cherat Packaging trim weight by 20%New Halguard® 58625 Compound from Teknor Apex Costs Less than Premium HFFR Products while Meeting Stringent Requirements for General-Purpose Applications

Cherat Packaging Pakistan and BSW Machinery, the Vienna based subsidiary of Windmöller & Hölscher, have jointly introduced a polypropylene (PP) sack that weighs 65 g but holds 50 kg of cement. Woven PP sacks are used globally as flexible packaging for cement. The most commonly used PP sack holds 50 kg of cement and weighs more than 80 g which is an industry standard. However, the new sack weighs 15 g or 20% less.The reduced material consumption has a major impact on overall cost. Carbon footprint is also reduced as less PP to melt directly translates in less energy being used from polymerization to extrusion. As a measure of the success of this development, more than 50% of the cement factories in Pakistan have not only tested and approved the sack but are now using them commercially. The relationship between BSW and Cherat Cement is not news as this is the third line that Cherat Cement has acquired from them.

Pak Packages Pvt. Ltd. procure rotogravure cylinder manufacturing facility on turn keyPak Packages (Pvt.) Ltd have recently acquired cutting equipment from Heliograph

Holding Group on turn-key basis for its cylinder making project. According to market experts, not only is this a significant development but the state of the art machinery and equipment will serve multipurpose functions and may be a game-changer for the Pakistani pre-press market. The rotogravure cylinder manufacturing facility will be equipped with sophisticated machinery like the Daetwyler CFM series and Ohio Spectrum. Thanks to the high-degree of automation and increased efficiency of manufacturing lines, Pak Packages will be able to serve and fulfil the local demand of customers with high-quality standards and high printing press speeds in a more efficient and quality-oriented manner.The complete turn-key solution including OEM consumables has been sold by Daetwyler Graphics, Switzerland which is represented by the IR Group of Companies in Pakistan.


Technology Days 2016: Complex packaging applications

The “Packaging” versions of the hybrid and electric Allrounders of the Hidrive

and Alldrive series are ideally-suited for high-speed applications. We offer special features for the production of screw caps and thin-walled applications, including with in-mould labelling (IML). Thin-walled tubs produced in a cycle time of 1.65 seconds will be one of the highlights at the Technology Days,” says Andreas Reich, Senior Sales Manager Packaging at Arburg. His colleague from the Packaging Team, Reiner Schmid adds: “We use a mould with a variable number of cavities for the active further development of our machines in line with the requirements of the packaging sector, so that we can work with 2, 4 or 6 moulds. We will be demonstrating this on another exhibit.

Hybrid Hidrive machines in “Packaging” versionArburg offers “Packaging” (P) versions of the hybrid and electric high-performance Hidrive and Alldrive machine series. These efficient, high-speed machines provide high productivity as well as reduced energy consumption and are characterised by a well-balanced combination of distance between tie-bars, clamping force and opening stroke. Moreover, they provide fast, precise, energy-saving mould movements (through servo-electric toggle-type clamping units), high plasticising flow rate (through barrier screws and servo-electric dosage drives), dynamic position-regulated screws and effective injection volume flows.

High-performance electric Allrounder AlldriveAn electric Allrounder 820 A with a clamping force of 4,000 kN and a size 2100 electric injection unit will be used to produce flip-top closures at the Technology Days 2016. A 16-cavity mould from Ermo will be used. The moulded parts will be closed directly in the mould. The cycle time is approx. 14 seconds and the PP closures weigh 7.5 grams each.

BASF opens regional platform for design activities in Shanghai

BASF is connecting with designers in Asia Pacific at a new regional platform

for design activities, located in Shanghai. designfabrik® helps designers in Asia Pacific realize their concepts by bridging

the gaps between creative ideas and the possibilities of various materials. At the same facility, BASF is also hosting design-related activities for coatings solutions, care chemicals, construction chemicals, pigments and leather chemicals. The hub provides advanced solutions for multiple industries including automotive, cosmetics, building and consumer goods. The new platform is located at the BASF Innovation Campus Asia Pacific (Shanghai), the company’s largest research and development (R&D) site in the region and the global headquarters of Advanced Materials & Systems Research. At designfabrik, customers’ designers and design consultants collaborate with BASF in-house designers and engineers. BASF design experts focus on appearance, color, surface and function, while BASF engineers provide assistance in the development of component design adapted to plastics. “At designfabrik we will assist designers in the various phases of product develop¬ment and to help them realize even the most daring ideas,” said Andy Postlethwaite, Senior Vice President, Performance Materials Asia Pacific.

Krauss-Maffei Corporation in the US: The 50th Anniversary of a Success StoryKrauss-Maffei Corporation, the US subsidiary of the KraussMaffei Group with headquarters in Florence, Kentucky, celebrated its 50th anniversary on May 18 and 19 with more than 400 customers. The company has grown continuously since it

was founded in 1966 and has established itself as a leading provider of machinery for plastics and rubber processing in the North American market. It currently represents the three brands: KraussMaffei, KraussMaffei Berstorff and Netstal. Following a very successful financial year in 2015, Krauss-Maffei Corporation expects further growth in 2016.The event showcased a wide range of trendsetting applications with live demonstrations of injection molding, extrusion and reaction process machinery, including a Netstal injection compression molding cell and the new ZE 65 Blue Power twin screw extruder. The Open House also featured 50 table top displays highlighting additional technology and service offerings from partners, as well as over 20 educational technical paper presentations covering the latest productivity enhancements for customers.

Complete screw and barrel package for retrofit on standard injection molding machines is specially designed to process LSR

Xaloy® LSR Package from Nordson Includes All Components for Controlled

Mixing and Metering of Liquid Thermoset Rubber Ingredients and Resistance to Corrosion or Wear.Nordson Corporation has developed a complete injection-unit package for liquid

silicone rubber (LSR) molding that meets the special mixing and metering requirements of low-viscosity thermoset ingredients and can be readily retrofitted on standard injection molding machines. The company introduced the package at Chinaplas 2016. The Xaloy® LSR Package includes a specially designed screw, barrel, seal, valve, and nozzle, along with other components where needed, such as a feed-pipe adapter. Nordson recommends the package for manufacturers of seals, gaskets, cushioning pads, medical devices, infant feeding items, ruggedized electronic devices, and such kitchenware as baking pans and spatulas. As a specialist in the engineering and manufacture of injection-unit components, Nordson can develop customized packages to meet specific customer requirements, according to Mark Colella, global product manager for the Xaloy brand.


Solvay Announces New Application Testing Laboratory in Shanghai to Support Technyl® Customers’ Growth in AsiaSolvay Engineering Plastics, a world leader in polyamide-based performance materials, announced the creation of a dedicated part testing laboratory in Shanghai, China, to support the growth of its customers in the Asia region. Starting end of this year, this first Application Performance Testing (APT®) center outside Europe aims at accelerating the development and validation of Technyl® applications for automotive, consumer and electrical markets.“Our decision to create a dedicated facility in Shanghai will greatly enhance our ability to respond to our Chinese and Asian customers, thereby offering an optimum service to tiers and OEMs active in the region,” states Peter Browning, General Manager for Solvay Engineering Plastics. “This significant investment complements our state-of-the-art capabilities in Europe, enabling Solvay’s team to closely support Asian customers, who represent more than 40 percent of our business activity, in optimizing the use of Technyl® materials”. APT® Technyl® Validation is an advanced high quality and flexible service which offers a wide scope of part testing to meet the most demanding industry standards. Most of Solvay’s bench tests are developed and customized in close collaboration with OEMs and major Tier 1 suppliers. The company’s APT laboratory located at the Technyl® Innovation Center (Lyon, France) includes an array of equipment to address metal replacement, thermal management and fluid barrier application parts testing. This notably includes coolant (glycol) and oil circulation, hydraulic testing for structural applications, oil separation, air pulsation (up to 230°C), vibration testing for temperatures ranging from -35°C to +180°C, etc. Solvay’s new part testing laboratory in Shanghai will initially be equipped with installations dedicated to metal replacement applications. Progressively, the facility will be equipped with additional apparatus for testing thermal management and fluid barrier applications. APT® Technyl® Validation is part of the comprehensive and advanced service offer from Solvay Engineering Plastics, which also includes unique CAE simulation capabilities with MMI Technyl® Design and 3D printing with Sinterline® Technyl® Prototyping.

Cosmo Films collaborates with HP Inc. as an HP Indigo Pack Ready Film Supplier

Cosmo Films, a leading manufacturer of specialty BOPP films, announces

that it has been approved by HP Inc. as an HP Indigo Pack Ready film supplier for the revolutionary HP Indigo Pack Ready ecosystem.HP Indigo Pack Ready is a set of post print converting solutions developed, patented and

NEWS

qualified by HP. It is designed to maximize the value of Indigo digital print for labels and packaging.The first solution, Pack Ready Lamination, provides “zero cure time” lamination while instantly creating a strong bond between HP Indigo digitally printed substrate and Pack Ready laminate film, enabling digital converters to print, laminate and pack on demand for immediate time to market.The Pack Ready films from Cosmo ensure a high lamination bond strength and helps to maximise the environmental score card of digital printing, since the lamination process does not involve any solvents. Speaking on the development, Mr Sandeep Dutta, President of Cosmo US operations, said “Our association with HP goes back a long way when we developed the HP Indigo HPI DP label film, suitable for digitally printed labels. Our strength as the global leader in thermal lamination films, our global distribution reach and our focus on customised innovation helped us to be brought on board as a supplier for this landmark innovation.”

GDXL new plant expects to commence operation in late 2016

Guang Dong Xing Lian Precise Machinery Co., Ltd. (GDXL), being a leading

engineering partner and service provider in the PET packaging industry, expects to have its new factory operational in late 2016.To meet the increasing global competition of high-end PET mold products and the need for research and development of new production technology, GDXL has decided to expand its R&D and production scale by investing a new plant in Sanshan, Foshan, China. Thanks to

the state-of-the-art manufacturing equipment and an automated storage warehousing system, GDXL’s production capacity can be doubled in 3 years with manufacturing precision improved to within 5 μm. Delivery time can be shorten by one-third.GDXL has been dedicating itself into the R&D and supply of PET blow mold, preform mold and closure mold since its establishment in 1993. It also provides optimization and project retrofit conversion solutions to PET containers. Currently, its annual production capacity is 15,000 cavities for blow mold, 10,000 cavities for preform mold and 3,000 cavities for closure mold respectively.GDXL’s products have been sold to over 40 countries and regions including China, USA, Japan, Europe, Australia, Russia, South Africa, Pakistan, Iran, Malaysia, Singapore, Indonesia, Vietnam, Thailand, the Philippines, etc. The brand has been well recognized in the PET packaging industry. In particular, GDXL has been technically certified by the Coca-Cola Company and the PepsiCo Inc. as its qualified mold suppliers in China since 1999 and 2005 respectively. It has also been granted one of the worldwide R&D suppliers for PET bottle by Coca-Cola Atlanta in 2007.

ELIX Polymers wins “Frost & Sullivan New Product Innovation Award” for ECO ABS-NF

New natural fibre reinforced compound cuts customer carbon footprints without

sacrificing processability and performance.An innovative natural fibre-reinforced ABS developed by ELIX Polymers has picked up the 2016 Frost & Sullivan New Product Innovation Award. ELIX ECO ABS-NF was specifically designed to fulfil some of

the most demanding requirements of the automotive industry, and offers mechanical properties that are equal to or better than traditional glass fibre reinforced ABS. Explaining the reasons for the award, Frost & Sullivan said it praises the ability of ELIX Polymers to rise to the challenge of creating a natural fibre-reinforced compound that matches the characteristic properties of glass fibre composites. It is said that “this is likely to steer OEM willingness to adopt ELIX ABS-NF in a number of GF applications, thereby enhancing their environmental footprint (without compromising on mechanical properties)”.


TECHNOLOGY UPDATE

Innovations by SABIC to minimize food wastage, reduce weight, and lower carbon footprint of packaging materialsToday, an estimated one-third of food produced for human consumption is lost or wasted, equivalent to 1.3 billion tons of food every year, according to the Save Food report by the Food & Agriculture Organization of the United Nations. Even in the most developed supply chain systems such as those in Europe, 4% of transported goods are damaged in some shape or form due to low pallet stability. A growing consumer focus on convenience and sustainability will also drive continuous changes and innovation in packaging. With tomorrow’s resource challenges, packaging has a crucial role to play, particularly in helping to reduce waste in the global food supply and in protecting goods for consumers while complying with ever more stringent regulations that are put in place to increase food safety and to secure safe packaging. Today’s fast-paced lifestyles also are driving demand for pre-packed food, and for hot filling and microwave use. At the same time, consumer expectations are spurring brands to create packaging that is distinctively shaped, highly transparent, hygienic, easy to open, and with excellent graphics. These challenges need to be met while lowering weight and cost by reducing cycle times, down gauging and increasing the share of reusable packages to minimize waste and lower the environmental impact of everything we produce. On its stand at the K 2016 plastics trade fair in Düsseldorf, Germany, this October 19-26, SABIC will be showcasing several new products and technologies that help to address these specific market needs. With a strong focus on sustainability and an underlying theme of “Chemistry that Matters™,” SABIC will highlight a number of packaging solutions that address the challenges of the packaging industry, including:

REDUCING LOSS AND INCREASING EFFICIENCYSABIC’s multilayer and polymer blend technologies may help manufacturers to reduce transport losses, optimize protection of goods, and maximize pallet stability by increasing the holding force of collation shrink and stretch films used to protect food packaging, while also making those films stronger.The unique combination of SABIC polyolefin building blocks also continuously may enable improvements in efficiency

during production. They may offer higher tensile strength and higher toughness to optimize the wrapping process, by reducing film breakage and improving stretch film consistency of quality. SABIC technology may also reduce the environmental impact of packaging by enabling down gauging that can reduce thicknesses by up to 20% compared to current film concepts. Thinner products reduce plastic consumption and allow for higher processing speeds.

REDUCING FOOD WASTESABIC’s flexible packaging solutions already significantly contribute to minimizing food waste. The dedicated SABIC® PE/PP resins are essential in building advanced, multilayer barrier film concepts that provide longer shelf life of fresh and chilled food, cheese and meat. The corresponding reduction in food waste has a significant positive impact on the total life-cycle analysis of a flexible packaging system.

LIGHTERWEIGHT PACKAGING Reducing packaging weight remains key and is facilitated by using SABIC’s solutions in flexible pouches for both food and non-food applications. Leveraging the extended SABIC® PE/PP portfolio in pouches may enable further improvements in stiffness, sealing performance and retortability. The new SABIC® PP FLOWPACT Product Family, especially the very high MFI grades, are formulated to help our customers for thin-wall food packaging applications where a good balance of high stiffness and high flow is required:• Enabling down gauging, thereby reducing

packaging waste

• High flow and fast crystallization generates shorter cycle times, thus lowering production costs

NEW SABIC® LDPE film grade, is a new product from SABIC for manufacturing very thin-gauge packaging.• Offers excellent draw-down ability, running

stable at a film thickness as low as 12 μm, using less raw material and enabling higher production line speed

• Typically used in both mono and coex films and is available as a certified renewable grade

• Provides full compliance with stringent food-contact regulations for a broad range of applications with both fatty and non-fatty foods

SAFER PACKAGINGNEW SABIC® LDPE film grade, is a new product from SABIC for manufacturing very thin-gauge packaging.• Introduction of new product stabilizers in

advanced LLDPE resins • Introduction of phthalate-free PP solutions,

co-developed with international companies in the UAE and Europe

• Unique additive-free LDPE product family (with no migration into food)

Advanced 5-layer barrier film structures are another new product from SABIC for applications in meat packaging by using blown film technology. The use of high-purity SABIC® LLDPE 218BE and LDPE resins was crucial to achieve improved draw ability and cleaner operations, with fewer deposits.

Continue...


EVENT NEWS

MAINTAINING WATER PURITY WITH SABIC® HDPE CC860V GRADE FOR CAPS & CLOSURES FOR STILL WATER• Rated highly amongst available grades, it

is now being used by leading OEM brand owners

• Provides excellent organoleptic properties that are important in preserving taste and odor

• Complies with new food-contact directives regarding product safety and purity

SABIC’s new range of PP copolymer cast films may offer extra protection with high puncture and tear resistance, excellent sealability, eye-catching optics, and compliance with food regulations.

SUSTAINABILITYSABIC is proud to be the first chemicals company to offer both renewable polyethylene (PE) and polypropylene (PP) resins that are based on renewable feedstock sources. SABIC’s ISCC Plus-accredited renewable polyolefins help our customers meet increased regulatory demands. Unlike other products on the market, these new materials from SABIC are created using waste fats and oils and they use feedstock that is not in direct competition with the food chain. From sourcing to final production, SABIC’s renewable PE and PP require 84% less fossil fuel to manufacture than fossil-based polyolefins, and are fully recyclable. This enables SABIC, and our stakeholders, to reduce our collective carbon footprint and to save fossil feedstocks for future generations.

SUPERIOR PERFORMANCE – POLYETHYLENE WITH THE NEXLENE™ PROCESS TECHNOLOGYSABIC produces its new C8 mPE, POP and POE products using NEXLENE™ technology – a cutting-edge technology that combines a solution process and a proprietary metallocene catalyst. The packaging industry will benefit from this new SABIC product family with state-of-the-art molecular design – Bimodal Solution Process with Octene co-monomer – for the manufacture of flexible (food) packaging and wrapping materials that deliver high performance properties such as:• Outstanding processability: may enhance

bubble stability, lower motor load and extrusion pressure

• Superior mechanical performance: may improve tear resistance, excellent puncture and dart impact resistance and tensile strength

• Outstanding sealing property: may lower sealing initiation temperature (SIT) that enables faster packaging speed

• Excellent optics with high clarity and very low haze

• Superb hygienic properties with low extractables and outstanding organoleptics

SABIC will be participating in K 2016 in Düsseldorf, from 19 to 26 October 2016, at Stand D42 in Hall 6. For more information, please go to www.sabic.com/Kshow.

Brückner Maschinenbau-Technological innovations for the K 2016Intelligent Line Management: Simplified line operation and higher line availabilityContinually increasing speed and output with ever shorter delivery times and growing demand for quality make running a film stretching line a highly complex business. Film producers and their operating personnel stand before increasing challenges when it comes to guaranteeing a stable and efficient production with the highest quality film. This is where Brückner’s “Intelligent Line Management” (ILM) comes in. This is an

Soma – Five presses sold at drupa, new sale negotiationsCZECH REPUBLIC • Soma reported on a very successful drupa 2016 with more than

1,500 visitors coming to see demonstrations of the new Optima 2 flexographic printing press. It was officially launched at the show, and the demos showed wide-web production running the Arun plate mounting system developed in cooperation with the press maker, Allstein.The company sold five presses at the show and hosted several customers at its Soma Globe Technology & Training centre for printing trials after the show. The company said it is now working on final negotiations with them as well as on a number of enquiries for ongoing projects. The company also said the Optima 2 is available for printing trials in Lanskroun.

integrated solution which smooth the way for Brückner’s customers’ “Smart Production” and “Industry 4.0”. The focus lies here on a new way of operating lines, putting the emphasis on the process view as opposed to the usual machine view. This new operating concept is supported by an increasing amount of assistant systems.Along with the “Energy Monitor” which is already used to monitor energy consumption at all line components, Brückner has developed new tools and assistant systems for inline measurements and to directly influence important film values such as temperature, haze, molecular orienteering angle or also density and porosity. For film production this brings a variety of advantages:• Simplified line operation with significantly

fewer process parameters to adjust and intuitive user guidance

• Transparency and traceability of production data

• Targeted inline control of film properties for a consistently high film quality

• Increased line availability through shorter reaction time in case of malfunctions

• Efficiency, productivity and flexibility through assistant systems such as “fast product change” (key word: Just-in-time-delivery) or “energy monitor”

Film producers found it easier to produce the highest film quality all over the world, independent of surroundings, time, climate and weather conditions.

ENGEL is showcasing a comprehensive range of inject 4.0 productsThe aim of Industrie 4.0 is a smart factory. With the help of the networking and integration of production systems, the systematic exploitation of machines, process and production data and the use of decentralised, intelligent assistance systems,

the manufacturing processes in a smart factory continuously optimise themselves, making it possible to react very flexibly to the ever more quickly changing requirements. The result is greater efficiency, productivity, machine availability and quality. ENGEL is making it possible to actually experience the smart factory at K 2016. For all three areas of the smart factory – smart machine, smart production and smart service – ENGEL already has solutions within the range today to support processors to enable their processes to tackle the new challenges. Industry 4.0 is nothing new for ENGEL – it has been current practice in many areas for a long time, and ENGEL is continuously further-developing its inject 4.0 programme. At ENGEL, experience meets innovation.


Leading experts from across the supply chain to participate at AMI’s Polyolefin Additives 2016 ConferenceThe 9th edition of AMI’s international Polyolefin Additives Conference will take place at the Imperial Riding School Renaissance Hotel, Vienna, Austria from 13-15 September 2016.Polyolefins lead the global plastics markets in terms of production volumes and the diversity of their applications. For example, polyethylene pipes are gaining share in construction, agricultural films are transforming crop yields in arid regions, polyolefin packaging is preserving foodstuffs and minimising waste, while the use of polypropylene as a metal replacement is reducing weight in automotive manufacturing. The different properties of polyethylene and polypropylene materials are obtained by careful selection of resin, additives and processing methods. AMI’s Polyolefin Additives 2016 brings together industry experts to debate the optimal resins, additives and compounds for a wide range of

end uses from packaging films to automotive components.The two-day conference programme will commence with an exploration of market trends from a range of perspectives. Session 2 will focus on packaging performance requirements, with DOW presenting the practical aspects for flexible packaging converters and Turkish rigid sheet producer FARMAMAK discussing how to meet demands for PE and PP sheet. Sessions 3 and 4 will cover additives innovations and tailoring polyolefin properties, featuring a presentation from BOREALIS on the mechanical and crystallisation behaviour of talc-filled recycled polyolefin.Day two will begin with a session on stabilization, with BASF and ASAHI KASEI both exploring automotive applications. Session 6 moves on to enhancing film properties, where companies such as EQUATE and PAALSGARD will present solutions for increased performance. The conference will close with a session on flame retardants, with ENSCL-UMET looking at sustainability and Fraunhofer LBF discussing recent developments. The 2016 programme will also feature other leading additives and polyolefin suppliers, masterbatch producers and testing & research institutes, who together will offer the audience a true overview of the additives industry as it stands today and where it is heading for the years to come.

Reliability key for integrated petrochemicals logistics, say speakers at GPCA Supply Chain Conference Reliability in supply chain and logistics is a crucial value that the GCC petrochemical industry must adopt, said speakers at the 8th GPCA Supply Chain Conference, hosted in Dubai by the Gulf Petrochemicals and Chemicals Association (GPCA). “As an industry, we will continue to grow, but we need the infrastructure to expand as this is critical to competitiveness,” said Mohammad Husain, President and CEO, EQUATE, and Chairman of the GPCA’s Supply Chain Committee. “We often think of reliability in terms of operational questions - is the plant reliable? Is it producing the right quantity at the right time? But infrastructure that helps get petrochemicals to its customers is also critical to our operations. We need to think of reliability in every aspect of our operations, including in our supply chain.”As an export-oriented industry, the GCC petrochemical producers traded 70.3 million tons of product in 2015, according to GPCA research. Products like plastics and fertilizers were transported to customers in 166 countries worldwide, rendering the petrochemicals supply chain as one of the longest and most complex in the world. Critical elements of supply chain reliability include connectivity through technological advancement and human capital, according to Husain. While the World Bank’s most recent Logistics Performance Index has found that GCC countries are amongst the top 35% performers globally, challenges remain. Along with the emerging infrastructure and human capital shortfalls, port congestion and customs procedures are obstacles in the development of a dynamic logistics industry within the Arabian Gulf. However, government support for the petrochemicals industry, and its associated support sectors, represents a once-in-a-lifetime opportunity for development, according to the GPCA. The 8th GPCA Supply Chain Conference featured 22 speakers from the region’s petrochemicals industry, logistics providers, management consultancies and academia.

Sama Introducing Packing Machines Multi Line Series Bakery EquipmentsThe SAMA Company is involved in providing packaging machines and product processing systems. The company has a substantial reputation for not only manufacturing high quality Machines and

Processing Systems but also delivering reliability, service and excellent value for money. SAMA is participating at the upcoming Plasti & Pack and IFTECH 2016 in Lahore, Pakistan. Bakery equipments will be displayed in the event which includes sound making machines, laddo making machine, halwa making machine, samosa making machine, bakery ovens and much more. Multi line series for pillow pack is a state of art technology for industry to safe land, electrical consumption, human resources in less time double the production will also be introduced during the event.


Company Name: IR GroupEstablished in: 2015Founded by: Imran Rehman

Technical Services:1. Mechatronics Support2. TechnicalSupportfromCertified

Engineers3. Technicaltrainingonshop-floorby

Foreign Technical Engineers4. Turnkey solutions

Areas of expertise: 1. Plastics Printing Packaging2. Lamination Adhesives3. CalciumCarbonateandfillers4. Anti-microbial additives for plastics5. Recycling and Solvent Recovery

Solutions6. Environmental Friendly Additives for

degradable plastics

Projects: 1. Turnkey solutions for Gravure cylinders2. Turnkey solutions for solvent less, solvent

based and water based machinery and equipment

3. Electrostatic print assist systems4. Anilox rollers and sleeves5. Cleaning Solutions6. Solvent recovery and recycling projects

Core Competencies:1. In depth knowledge about Prepress –

Press – Postpress2. 20+ years of experience in Flexible

Packaging3. Technical team for full on–site support4. Professional attitude and high-level of

motivation to work with 1st class brands

Target for next 10 years:IR Group’s target is to become a market leader in the field of plastics printing,consumables, spares and machinery for the flexiblepackagingindustryinPakistan.

IR Group of Companies, established in 2015 has two strategic business units, which offer a full range of consumables, spares and machinery for the Plastic, Printing & Packaging Industry in Pakistan.1. Cloud Packaging Pvt. Ltd.2. Alpha Solutions Pvt. Ltd.The group is a founding member of German Pakistan Chamber of Commerce and Industries (GPCCI), Plastic Manufacturers Association (PPMA), Flexible Packaging Association of Converters of Pakistan) , Pakistan (FLEXPAC). Cloud Packaging serves the Plastics, Printing & Converting Industry with consumables, machines and after-sales services. Cloud Packaging provides a professional platform for 1st-Class European manufacturers and solution providers with an aim to be one-stop solution to the Flexible Packaging Industry. Alpha Solutions focused on selling Woven Polypropylene Sacks & Polyethylene Products. Alpha Solutions merged with IR Group in the Year 2015. The company started to represent top manufacturers from Pakistan for Woven Polypropylene Sacks, Polyethylene Products with a unique concept of Marketing House expanding its product range covering Flexible Plastic Printing and Packaging Business. IR Group always emphasis on the quality of service. For that reason, the group created a team of certified engineers to run its technical support department and to manage after sales services which is one of the core functions of the company. To serve their clients more comprehensively, the group offers technical trainings on shop floor in supervision of foreign technical engineers. The group is specialized into provide turnkey solutions, particularly for gravure cylinders, solvent less, solvent base, water base lamination machinery and equipment. IR Group provides solutions for plastic printing, lamination adhesives, calcium carbonate and fillers, anti-microbial additives for plastics and other special additives. The group represents many renowned brands from Germany, Italy, Switzerland, UK, Sweden, USA, Czech Republic, Norway, Spain and Taiwan.

Leading Source for 1st Class Flexible

Supplies

COMPANY IN FOCUS


THE GLOBAL MARKET FOR PP COMPOUNDSAMI, an authoritative report from industry consultants, AMI Consulting, published recently quantifies and analyses the global market the polypropylene compounds.The study segments the market into NAFTA, Latin America, Europe, Asia and Middle East/Africa, by product family and by application. Within the automotive segment which is the largest market for PP Compounds, applications are split into interiors, exteriors and underhood.The report quantifies in detail PP Compound demand by OEM as well as providing an analysis of the industry’s supply structure and up-to-date information on the world’s largest producers of PP Compound. The report examines the rate of structural change in the industry which has seen few mergers and acquisitions in the last year but plenty of investment in new capacity as PP Compounders seek to keep pace with growing local demand and internationalise their businesses. Recent investors Borealis/Borouge, GS Caltex, Kingfa, LyondellBasell, Mitsui, SABIC and Washington Penn. The largest independent PP Compounders are Washington Penn and Kingfa. The former had a particularly strong 2015 whereas the latter is establishing plants in both North America and Europe in 2016.In 2015 the global market grew by 4% suppressed by weak automotive production globally. Asia now accounts for 46% of global demand compared with 28% in Europe and 26% in the Americas.The report is updated annually to ensure that current information is available in support of the strategic decisions that are required of participants to ensure they keep abreast of developments within this fast changing industry.AMI Consulting has published a number of multi-client studies in the field of PP Compounds including a report in 2016 called the European Market for PP Compounds and a report in 2014 called the Global Market for LFT (long fiber) PP Compounds.

The BOBST DarkNight® process produces high barrier metallized films through defect reduction and web-handling optimization.

LOSS OF BARRIER PERFORMANCE DUE TO DEFECTS IS A COMMON PROBLEMDefects on metallized films lead to a drastic deterioration of barrier properties and poor visuals known in the industry as “Starry Night”. Reduced water vapour and oxygen barrier in turn translate in to a reduction in shelf life of food products.

BOBST DARKNIGHT® FOR HIGHER BARRIER METALLIZED FILMIn order to meet the increasingly demanding standards in the flexible packaging industry for barrier applications and products with longer shelf life, BOBST has developed DarkNight®, a unique and innovative process to produce High Barrier metallized films through its K5000 and K4000 vacuum metallizing platforms. Traditionally, thin Aluminium foils are used as a barrier in laminate structures to protect products from moisture and oxygen permeation, UV light radiation and aroma/mineral oils migration but leading brand owners now want to reduce their Aluminium foil consumption in order to reduce packaging costs but also need a more consistent quality in their supply chain of metallized films.

High Barrier Metallized Films and Elimination of Starry Night Defects with BOBST DarkNight®

As BOBST is known in the industry as a process specialist, it was a natural step to use this know-how to develop an innovative solution which is a major step forward in the journey to full Aluminium foil replacement.

COST-EFFECTIVE SOLUTIONBOBST DarkNight® is the smarter way to achieve high barrier metallized films at a lower cost; a major cost advantage arises from the fact that it eliminates the need to use high Optical Density (OD) deposition levels (>3.0 OD) in order to achieve high OTR & WVTR barrier values; as is usually required for high barrier applications.

SUPERIOR PACKAGING PROTECTION The BOBST DarkNight® process works in conjunction with BOBST Hawkeye (which comes as standard) which along with the Optimised Web-Handling System provides a new approach to defect reduction which enables the production of higher barrier films. Enhanced barrier performance means superior packaging protection properties (permeation resistance) resulting in increased shelf life for food products; in addition the effective light barrier properties which BOBST DarkNight® provides protects products which are particularly sensitive to UV rays.

Figure 1: The global market for PP Compounds

INDUSTRY ANALYSIS


Despite general beliefs that the slumping economy would bring harshness and challenges to the industry, CHINAPLAS 2016, having closed on April 28, achieved remarkable results beyond all expectations. Both exhibitors and visitors were engaged fully at the fairground amid an active and dynamic business atmosphere. With infinite business opportunities, the 30th CHINAPLAS demonstrated a promising future for the industry. CHINAPLAS will keep on moving forward to achieve another milestone.CHINAPLAS, Asia’s No.1 and world’s No.2 plastics & rubber trade fair, was held from April 25 to 28, 2016 at Shanghai, PR China. The number of visitors amounted to 148,575 in four days, setting a new record since its debut in 1983. The second show day saw the peak of visiting numbers at a headcount of 54,823. Compared to the show held at Shanghai in 2014, the number of visitors this year increased by 13.96%; and compared to 2015 in Guangzhou, the increase is 15.84%. As CHINAPLAS is well-recognized by the plastics & rubber industries as well as their downstream sectors globally, and the gradual improvement of the living standards of many developing countries keeps stimulating the demand for consumer goods and packaging, the number of overseas visitors this year reached 39,454, setting a record that represents 26.55% of the total. The ten regions topping the chart are Korea, India, Taiwan, Japan, Indonesia, Vietnam, Iran, Thailand, Hong Kong, and Malaysia, among over 160 countries and regions.Apart from the significant growth in the number of visitors, CHINAPLAS 2016 also achieved record heights in the show scale in terms of exhibition area and number of exhibitors. The show covered an exhibition area of over 240,000 sq. metres with a participation of 3,335 exhibitors from 39 countries and regions, of which 35% were overseas exhibitors and 14% joined CHINAPLAS for the first time.Mr. Stanley CHU, Chairman of Adsale Exhibition Services Ltd., organizer of CHINAPLAS, said, “We were very happy to witness the 30th CHINAPLAS

making historical breakthroughs in terms of exhibition area and quantity of exhibitors and visitors. At CHINAPLAS, exhibitors and visitors engaged themselves in business discussions and negotiations, whereas all concurrent events won full-house audience. Making its debut as a platform only for introducing and importing overseas machinery and materials to China, CHINAPLAS has grown into an excellent must-visit show for technology sourcing and exchange among industry professionals and buyers from all over the world. Right timing, geographical advantage and strong support from partners have contributed to the success of CHINAPLAS. The implementation of “Re-industrialization” in the West and the “Made in China 2025” project has urged the manufacturing enterprises to conduct business transformation and technology upgrade. The rise of Asian emerging countries and the shift of the global center of economic gravity eastwards put CHINAPLAS under the spotlight; thanks to our partners, exhibitors, buyers and the whole Adsale team, whose staunch support and effort make CHINAPLAS 2016 a complete success.” According to the team leader of CHINAPLAS, Ms. Ada LEUNG, General Manager of Adsale, who cudgels her brains to introduce innovative elements to the show every year so as to keep the loyal visitors feeling fresh and excited each year, CHINAPLAS 2016 has evoked an overwhelming response. The feedback from both exhibitors and visitors were very positive and encouraging. The exhibitors are generally satisfied with the visitor quality and their participation results. Most of them agreed that the participation of CHINAPLAS 2016 exceeded expectations as the visitor profiles are getting more international, and so is the trade fair itself.Mr. Stephan GREIF, CEO of Demag Plastics Machinery (Ningbo) Co., Ltd., expressed that CHINAPLAS 2016 made him proud for several reasons: The number and level of interested customers were as high as the waves in a tsunami. The company has never met so many customers from the Middle East, India, South East Asia, Russia before in the show, and there were customers from China,

Europe and the States as well. Customers demonstrated an astonishingly high level of interest and technical knowledge. On the other hand, the technology standard of the machinery, automation solutions and other equipment exhibited is comparable to those in Europe, and it has been a pleasure for them to find that CHINAPLAS had become on a par with K Show in Germany in terms of organization, safety and visitor behavior.In addition, CHINAPLAS also received encouraging feedbacks from the end-users of different industries. With one accord, they discovered many innovative, automated and green solutions to help their companies make a breakthrough.“I have visited CHINAPLAS at least 10 times, and I was very happy to see the integrated solutions in the Automation Technology Zone,” reflected Mr. Xiaosheng WU, Engineering Manager of Memtech International Ltd. – Nantong Memtech Technology Co., Ltd. “The production of automotive interior demonstrated by Demag in hall E7 impressed me very much. The fibers embedded within the mold, meanwhile far infrared preheating, injection molding and after treatment processes were displayed together this year while in the past, these were presented separately. The integration brought me some new ideas, and I believe it would become the future trend. By visiting CHINAPLAS, you can benefit more than you see.”Mr. Jianjun CHEN, R&D Manager of Shanghai POVOS Enterprise (Group) Co., Ltd. – a wholly owned subsidiary of Phillip, a wholly owned subsidiary of Phillip, said that his visiting experience was better than he had expected. “It broadened my knowledge in the field of materials. I found some high strength and high temperature resistant materials, PBS materials, food grade materials, etc., which are widely applied in a lot of components and parts. These technologies are useful to our product development.”Next CHINAPLAS will be held on May 16-19, 2017 at China Import and Export Fair Complex, Pazhou, Guangzhou, PR China.

30th CHINAPLAS expanding on adversityVisitor count grows by double digits

EXCLUSIVE COVERAGE


EXCLUSIVE COVERAGE

WINTEC unveils two exhibits at Chinaplas 2016

Premiere for all-electric e-winBy focusing on productivity, quality and energy efficiency, WINTEC – based in the Chinese city of Changzhou is improving the performance of injection moulding machines for standard applications for the Asian market with an attractive price-performance ratio. At Chinaplas 2016, which took place in Shanghai from April 25th to 28th, the branch of Austria’s ENGEL Group for the first time presented one of the new all-electric e-win series alongside a large t-win machine.

E-win: cost effective from the startLeading industry professionals and experts from around the world came together in Cologne for the first BOPET Film conference, organised by specialist plastics industry consultancy AMI.The conference provided a unique networking opportunity and a highly effective forum to meet and discussed the latest developments, opportunities and challenges in the evolving BOPET industry in which technological advances are becoming increasingly important. The diverse programme opened with a market overview session including an overview of global BOPET market trends by AMI Consulting and a presentation on global economic and M&A trends from Ernst & Young. Delegates heard about novel material developments from Wells Plastics, A. Schulman Plastics and FRX Polymers. C.A. Bishop Consulting discussed how substrate quality can affect barrier performance. The programme also featured trend setting technology developments to help enhance film performance and improve process efficiency and sustainability from Aquafil Engineering, Nordson Corporation, Kampf Schneid- und Wickeltechnik, Softal Corona & Plasma and Greycon.

Shazil Pakistan increases production capacity of High Grade PET FlakesShazil Pakistan (Pvt) Ltd, the country’s leading Plastic /PET Bottle Flakes processing and recycling company recently announced the expansion of production of hot washed PET Bottle Flakes. With the addition of two lines that are now operational, the company has increased their production capacity to 50,000 tons of High Grade PET Flakes per year.Speaking at a ceremony, Director of Shanzil Pakistan Mr. Azeem Shariq reiterated the company had come into existence in

1999 with an aim to spread awareness in the country about the advantages of recycling. Besides this, the project had also intended to emphasize the importance of clean environment and related issues of environmental compliance which the country is currently facing. He said that after 15 years of being in operation, the company had fully matured and is now providing strong countrywide collection, transport and sorting system under one roof. Mr. Azeem Shariq also added that this “rich experience would not only continue to be beneficial for the company but would serve of value to customers around the world who will get high grade material at competitive prices”.With certifications from Environment Protection Agency of Pakistan (EPA) and Chinese AQSIQ, Shazil Pakistan (Pvt) Ltd is the only ZERO WASTE Recycling Company in the country and is actively engaged in manufacturing Pet Bottle Flakes, LLDPE Recycled Granules, PP Recycled Granules, PVC Recycled Resin, Wood Charcoal. Other than taking pride in being “Asia’s leading Plastic/PET Bottle Flakes Processing and Recycling Company,” it aspires to be a world leader in PET Bottle Flakes business. Shazil Pakistan (Pvt) Ltd was also the only company from Pakistan to display its products at the recently concluded highly coveted ChinaPlas 2016 held in Shanghai.

Clariant, a world leader in specialty chemicals, offered Chinaplas 2016 visitors insight into the Value for People its local focus is bringing to the region – from product innovations centered on the specific needs of its plastics processors and product developers, to new on-the-ground investments to progress Clariant’s commitment to becoming a China Insider.Clariant’s tailored support for Greater China and South East Asia’s plastics and related market segments was reflected at Chinaplas in its new products, extensive portfolios,

Clariant at Chinaplas 2016: emphasis on local tailored support for Greater China and South East Asia

and pioneering concepts and solutions from its Additives, Masterbatches and Pigments Business Units. All are aimed at addressing the trend in the region for high quality, high performance and safe use for consumers – both domestic and worldwide - and a move towards more sustainable production.Featured highlights for the plastics industry at this year’s event focused on the major regional manufacturing segment E&E, as well as packaging, automotive and general plastics applications.


Sipa’s mould refurbishing and conversion services in China are an important element of its complete PET preform and bottle mould offering. They provide customers with the option of having some components replaced by new ones in order to improve preform quality (refurbishment), or having the mould converted to produce a completely new (and quite often lighter) design of preform. The advantage of mould conversion over buying a brand new mould lies in the lower capital investment involved. The existing mould is reused, and return of investment is faster. Customers can choose which is best for them by having a mould audit carried out by Sipa experts in the field. The state of wear of mould components can be assessed in their own plant, and different options on refurbishing or conversion can then be proposed. The mould refurbishing and conversion services complement Sipa’s extensive in-house capability to develop and produce brand new high performance moulds and hot runners in-house. The hot half of each Sipa mould requires maintenance only after five million cycles, and it is possible to maintain

The moulds refurbishing and conversion service in China

components such as piston, flange O-rings and pin valves without opening the whole mould. The company’s range of solutions benefits from Sipa’s special focus on reducing energy consumption. With better distribution flow and a higher water temperature (14-15°C instead of 8°C), water consumption is minimized and performance in terms of condensation reduction is improved.The smooth, polished, rounded profiles on Sipa hot runners reduce stress on material, resulting in better preform quality and a reduced acetaldehyde (AA) level. Mould systems also exhibit enhanced cooling performance, resulting in high quality preforms, maximum productivity and reduced production costs. Sipa’s service centre in Hangzhou, China, complements two others in Italy (Vittorio Veneto, the company’s headquarters) and the USA (Atlanta). It has been in operation since 2004. Having started out as a support operation for existing customers in China that Sipa had previously handled directly from Italy, the Hangzhou operation has rapidly expanded its portfolio. Recently enlarged production capacity in Hangzhou means that Sipa can now produce 300 cavities a month for blow moulding and 800 cavities for injection moulding. With mould plate manufacturing as well, a 144-cavity cold half can be created in six weeks. Sipa continues to add new machines every year, and has a strong focus on lean manufacturing to improve efficiency and reduce lead time.

that enhance performance and processing in transparent polycarbonate (PC), polyamide (PA) and polyoxymethylene (POM) compounds, and improve surface quality in automotive interior parts. The company is also launched Dow Corning®MB25-035 Masterbatch, an advanced new material designed for reducing friction in form-fill-seal (FFS) packaging applications. Dow Corning’s additive technologies greatly improve the surface properties and processing performance of PA compounds. For instance, Dow Corning® 31-441 Additive is a solid silicone polymer that excels at delivering high slip performance at lower loadings than polytetrafluorethylene (PTFE), so mechanical properties are maintained. It offers excellent antiscratch properties and improves extrusion efficiency by decreasing screw torque. Key applications include automotive parts, industrial gears and bearings, and moving parts in appliances and peripherals.

Dow Corning Showcases Newest Performance-Enhancing Silicones, Launches New Masterbatch, Delivered Four Presentations at ChinaplasDow Corning, a global leader in silicones, silicon-based technology and innovation, that showcased at Chinaplas 2016 advances in its rapidly expanding portfolio of materials for the plastics industry. These include several recently introduced silicone-based additives Pipe extrusion lines: A

success story for China - made in ChinaAt Chinaplas in Shanghai, KraussMaffei Berstorff presented a single-screw extruder in the 30D Series (KME 60 – 30 B/R) with newly developed screw geometry. This extruder is produced in China specially to meet the requirements of the local market for PP-R processing. On the occasion of Chinaplas KraussMaffei Berstorff opened the plant of the KraussMaffei Group in Haiyan on April 26, 2016. Customers and interested parties saw a live demonstration of the production of twin-strand PP-R pipes (diameter between 20 and 40 mm).

Twin-strand technology – produced locally with German engineering – to reduce unit wage costs “Economical production, high outputs and perfect end product quality have also long been standard requirements in the mechanical engineering and system construction industry in China,” emphasized Michael Hofhus, Vice President Extrusion at KraussMaffei Berstorff in China. “As a competent system supplier, we have been satisfying precisely these needs of our customers through our product portfolio in the Performance Series from our plant in Haiyan for several years. On a highly competitive local market processors focus on both quality and lower unit wage costs,” said Hofhus.

Expansion of the market position thanks to the successful Performance Series “In the last few years we have placed complete lines up to a diameter of 1200 mm on the market. However, we are not only very successful as a system supplier for complete lines, but also in business with individual machines,” added Hofhus. “With our single-screw extruder model KME 60-30 B/R from the Performance Series, we offer processors a suitable machine concept, especially in regard to locally used materials,” said Hofhus. The 30D Series, an extension of the single-screw series that has been used successfully for many years, is perfectly designed to process local PP-R material thanks to its revised screw concept.


Being one of the leading companies of plastics extrusion, Reifenhäuser is known to be successful machinery manufacturer in Germany for more than a century. The company has stood up for innovative technology in plastics extrusion, for its expertise, continuity, progress, and reliability. With the Group’s technologies and a highly skilled workforce of over 1500 employees, the Reifenhäuser Group enables customers to produce blown films, cast films, sheets, nonwovens, monofilaments and strapping tapes of the highest quality. We recently had the privilege of meeting Mr. Ralf Pampus, Director Strategic Sales and Managing Director - Reifenhauser at the sidelines of Chinaplas this year. Here is what he had to share

Q. What are the new trends that are shaping the industry and how do you predict the future?

A. One new trend that we see worldwide is the film quality demand which is increasing. For example; the customers’ new demands are related to flatness of the films because after the extrusion process the film gets often printed and laminated and therefor the customer can have significant benefits in higher printing speeds with flatter film. Another trend is that the technological demand also increases very fast; we need to work on high technological applications. The industry is demanding more high-tech equipment which can enhance the production process. For example; components that have automated systems make the process more efficient are mostly preferred by the customers.

Q. Being a company in business since 1911, maintaining quality of products must have been one of the areas where you excel. In a nutshell, how do you ensure that high standards are maintained in your operations?

A. We have a big corporate quality team that continuously measure the quality of our products. We also have certain

quality checks during the production processes to ensure the quality standards are maintained. We have a special service team that check and monitors the whole process at each step from manufacturing to finished goods. However, when it makes sense, interdisciplinary teams from all sites operate in a Reifenhäuser Corporate Procurement Network (RCPN) to bundle demands and create synergies. We also offer our customers comprehensive services to support them in achieving a long-lasting successful production. We ensure that the lines are working reliably to produce the best quality in the most efficient and profitable manner even after many years of operations.

Q. As the company claims that it operates the world’s largest R&D center for plastic extrusion lines. What kind of research is conducted and how important it is for market penetration?

A. Today fast technology and continuous research are the most important factors for our organization. We are spending a major portion of our earnings on the research lab. We can only be successful as a German machine supplier and get higher sales when we have the best technology. We have to conduct researches on our operations every now and then. We have installed 10 extrusion lines in our lab on which we continuously develop new components or even products with our clients. We have a privilege in providing high technology to our clients as compared to all our regional competitors. This helps in meeting the demands of our customers or event customers’ customer more effectively.

Q. Industry 4.0 is one of the important topics these days. Can you tell us a bit about your Company’s strategy to meet future demands?

A. Yes, industry 4.0 is undoubtedly one of the important phenomenon and we are working to implement it for the last few years. We have already employed mathematicians who are working on algorithms and convert a lot of data into meaningful reports generated on the panels. These panels are connected with our blown film lines. When the data is compiled, we try to make a relationship between the machine settings and the film quality. By this, the quality of the film can be secured. We also measure performance of different parts of the machine and evaluate it on with production quality standards. Industry 4.0 will make our product lines more efficient and secure the quality of the produced film in the future.

Q. Depending on technologies is something that cannot be ignored. Currently, which technology and system is the Company using that set it apart in the industry?

A. We do have a competitive advantage on technology that differentiates us apart from our competitors. We have the biggest extrusion network in Germany. There are different companies at Reifenhäuser which are all involved in extrusion business for the interchange of technology. We at Reifenhäuser develop and manufacture all core components on our own. The company disposes of up-to-date machinery at its Troisdorf and Worms sites. All parts in contact with the melt or parts that influence some how the quality of the product, such as screws and barrels, dies and stretching unit are manufactured by specialists of Reifenhäuser and submitted to stringent quality control. We develop these parts much faster because of high-tech equipment. In the production processes, Reifenhäuser works on lean management methods to ensure fast and reliable production and delivery. We also rely on up-to-date IT solutions to ensure efficient cooperation. We use web-based platforms in addition to specialized ERP systems to facilitate the exchange of data, shorten processing times and reduce errors.

Q. Pakistan is one of the countries that your Company serves. How do you rate the potential of the industry/market and scope of doing business?

A. From the last 12 months, we see the Pakistan market with growing importance for the complete industry. The quality demand of the machines is very high. In the next few years, I expect the demand from Pakistan will further rise and it will not be limited to 4-5 manufacturers only. Pakistan has worldwide good connections and we also have clients whose headquarters are in Pakistan that are investing worldwide. In this regard, we look forward to have great business opportunities in the times to come.

Q. Anything you would like to recommend or share at the end?

A. Industry 4.0 is not only a hype, in the future the digitalization of production will have a major influence also on the plastic industry. This will make machine operations easier, controllable and efficient. Industry 4.0 will soon reach to Asian countries such as Pakistan and India. So, each one of us has to think about high technology applications and efficient systems which will be the need of industry in near future.

Exploring the Present – Shaping the FutureAn interview with Mr. Ralf Pampus, DirectorReifenhäuser Group

INTERVIEW


The world demand of BOPP film grew by an average of 6.1% per annum to reach an estimated 6.06 million tonnes in 2011. BOPP film producers have more than kept pace with demand growth and increased by 40% the size of production capacity since 2006. After a very busy year for sales of extrusion lines in 2010, decisions on new investment decisions have been delayed due to the state of the market.The Central and East Asian region (China, Japan, South Korea and Taiwan) is the world’s largest producer and consumer of BOPP films accounting for over half of global demand and capacity in 2011. The average world BOPP film ‘nameplate’ capacity utilization during 2011 was around just 70% with Chinese producers having a tough time building a profitable business and have many of the new lines installed in China in recent years have been running slow or not at all during 2011. The flexible packaging applications for BOPP film now account for 80% of world demand.PCI Films Consulting ‘conservative’ forecasts show world demand for BOPP films will continue to grow by an average of 6.6% per annum to reach 8.3 million tonnes by the end of 2016. The growth in Asian demand is expected to account for a vast majority of the predicted world growth over the next five years. The capacity additions announced and expected, will expand the world BOPP film industry by another third over the industry size in 2011, with China again leading industry investment.On the other side, according to AMI’s latest report on the global BOPP film industry claims that demand for BOPP film grew by 4% in 2015. With a focus on increasing production efficiencies, reducing waste and the development of value-added film, many companies enjoyed improved profitability in 2015. This led to another up lift in capacity announcements during the year, but this time led by new players and new markets. However, with potentially a further 37 new lines, adding another 1.5 million tonnes of capacity in the pipeline for the period 2016-2017 utilization rates are expected to remain at around 70-75%. The utilization rates are also being impacted by the trend to downgauge to produce thinner films and by the development of more speciality films.Source: PCI Films Consulting, AMI

ARTICLE

By the end of 2016, Reifenhäuser will have 5 running high end blown film lines in Pakistan with the total output of more than 10.000 tons of blown film per year. We consider it a big success, given the current state of packaging industry in Pakistan. Customers finally understood that investments in high quality, high output, reliable equipment bring higher profit and better market positions due to less stops, higher speeds, more automation and higher product quality.Reifenhäuser goal is to be preferred supplier when it comes to delivering the best technology, the best reliability, the best lifetime and manufactured product quality, which gives an edge to a blown film manufacturer in his markets and we see it globally. Market all over the globe tends to stratify into two layers – players saving money on capital investments and fighting hard for small margins and players investing in the top of the class equipment, these players tend to grow and we see them expanding all over the world.Some of the latest innovations from Reifenhäuser will be proudly presented at a K2016 show in Duesseldorf, Germany as proven solutions, both of which work at the top of a blown film tower. The Ultra Flat is an oscillating haul-off that serves to iron out the inherent bagginess of film at the top of the tower. It pulls the film tight, anneals it and locks in the results. It makes the film look prettier and flatter but more importantly the results show up when the processor uses that film in-house or sells it to a secondary market like a converter. The flatter film enables higher speeds on downstream equipment such as a printing press, bag machine or form-fill-seal system. If that sounds like a machine direction orientation (MDO) unit, it’s not, but Reifenhäuser also has one of those for the top of the tower. The Ultra Stretch follows the same idea as the Ultra Flat and adds more rollers and different drives to create an actual MDO unit atop the tower. A processor can do any stretching there, rather than on a separate MDO unit. Having this function on top of the tower obviously helps with floor space. It also lets the haul-off use the heat still in the film at that point. No oil heating system is needed, which means it’s cleaner, and it is more energy efficient than doing MDO off-line.The Reifenhäuser Group, based in Troisdorf near Cologne, Germany, is the world’s leading supplier of plastics extrusion lines, machines, and components. The group has the world’s largest company knowledge network for extrusion technology: Six business units with nine subsidiaries bundle highly specialized knowledge in design, process technology, automation systems, project planning, manufacturing, project management and logistics. As a whole, the group covers the largest range of extrusion technologies. Its companies offer systems for the production of films, sheets, nonwovens, monofilaments, and the relevant components. The company was founded in 1911 as a forge and is managed today for the third generation by brothers Bernd, Klaus and Ulrich Reifenhäuser.

Reifenhäuser, success in Pakistan

The Market Trends of BOPP Films


Instead of printed paper, a reverse printed BOPP film or a printed PET film can be applied. MSB 30 provides brand owners full latitude for their product design.“Vistamaxx performance polymers are key to the development of Treofan MSB 30 metallized BOPP film”, said Paul-René Clauss, sales developer, Vistamaxx performance polymers, ExxonMobil Chemical. “They enable the laminate structure to be simplified, while boosting sealing performance.”

SIMPLIFIED LAMINATE STRUCTUREThe application of MSB 30 allows the number of laminate components to be reduced from 3 layers to 2. The potential for cost savings for the entire laminate mostly depend on the PE sealant grade, which was previously used.

SEALING PROPERTIES BOOSTEDUsing Vistamaxx polymers in MSB 30 boosts its sealing properties.Market reference laminates offer a minimum seal strength of 5N/15 mm, which cannot be achieved with a standard BOPP film as the sealant. Treofan MSB 30-based laminate, however, offers a seal strength of about 8N/15 mm and even higher, if desired.Seal integrity (hermeticity) is also enhanced. SKYE tests indicate a much higher overpressure versus a standard BOPP film.Besides high seal strength and seal integrity, seal-through powder contamination is a key feature for powdered products. At pouch filling, powder particles within the seam area should be incorporated to ensure hermeticity. Standard BOPP films are limited in being able to fulfill this task.The following graph shows the seal strength of a MSB 30-based laminate versus a laminate with a standard BOPP film after contamination with corn starch. The jaw pressure was varied during the test.“Using Vistamaxx polymers to enhance the sealing properties of this BOPP film has made a significant difference and allows us to enter new markets,” said Detlef Hütt, Innovation Engineer, Treofan Germany GmbH & Co. KG.

BRAND OWNER TESTINGSeveral brand owners and converters have been running samples recently. Application tests of our film usually take 6-12 months to complete.

Standard metallized OPP-film vs. MSB 30, seam contamination by corn starch, various pressure; T=110°C

Treofan Germany GmbH & Co. KG, a leading global manufacturer of biaxially oriented polypropylene (BOPP) films, has developed a new 5-layer BOPP film using Vistamaxx™ performance polymers from ExxonMobil Chemical. Using Vistamaxx polymers in the heat sealable side of a new, metallized BOPP film simplifies the laminate structure, allows aluminum foil to be replaced and can reduce costs compared to market reference alternatives.

KEY ADVANTAGES• Simplified laminate structure as the usual

3-layer laminate can be converted into a 2-layer laminate

• Replaces aluminum foil and PE sealant, but provides brand owners full latitude for their product design

• Follows market trend to replace aluminum foil

• Enhanced sealing properties and seal integrity

• Lower costsTreofan was looking to develop a new BOPP film for the packaging of instant soups, but would also be well-suited for any other kind of dehydrated powdered product such as spice blends or instant sauces. Meeting the needs of brand owners is key to gaining a foothold in this market.

SEALING PERFORMANCE IS KEYFor a new film to be successful, it would need to achieve at least the equivalent seal strength, seal integrity (hermeticity) and seal-through powder contamination as the market reference. Treofan contacted ExxonMobil Chemical to learn more about the versatile capabilities of Vistamaxx polymers.On discovering that Vistamaxx polymers can be used to tailor BOPP film formulations to improve packaging sealing, optical properties and processing performance, development work started.Today laminates for soup pouches are usually comprised of a 7-9 μm aluminum foil and a sealant, made of PE, with a thickness of 10-30 μm. The PE sealant is either a blown film, adhesive laminated to aluminum foil or directly extrusion coated on the aluminum foil.Treofan developed a metallized BOPP film, Treofan MSB 30, using Vistamaxx™ performance polymers in the heat sealable side. MSB 30 replaces the aluminum foil and PE sealant. On the outside of a soup pouch, many brand owners prefer printed paper.

CASE STUDY


COUNTRY IN FOCUS

Germany – Europe’s Leading Plastics NationPlastics are an essential part of modern life. Increased living standards, growing environmental awareness, and sustainable development thinking are driving the demand for new and innovative material solutions. Plastics are everywhere, and often in the unlikeliest of places: in housing and construction, in wind turbines and solar panels, and even in state-of-the-art sporting apparel. As Europe’s largest producer of chemicals and plastics, Germany is Europe’s leading plastics industry. The country’s plastics industry includes polymer manufacturers, converters and machine manufacturers alike. And with sales of over EUR 90 billion, the domestic plastics industry counts as one of Germany’s most important industry sectors.

The industry plays a major role in providing new and innovative products and solutions to a number of key industries including the automotive, mechanical engineering, packaging, electrical engineering, and construction sectors. Growth (carbon composites) and future (INDUSTRIE 4.0) market trends are also making themselves felt in the domestic plastics sector. Germany is setting the international standard as a plastics industry location, with the country’s leading-edge network of Chemical Parks and unique cluster concept providing industry actors with swift and easy access to all parts of the plastics industry value chain.

The Plastics Industry in GermanyContributed by GPCCI

The industry in numbersINTERNATIONAL MARKET DEMAND AND PRODUCTIONThe global plastics industry has recorded average annual growth of nine percent since 1950. In the past 30 years alone, international plastics production has grown by around 500 percent. World plastics production ramped up from 1.5 million tons in 1950 to almost 300 million tons in 2013. According to the PlasticsEurope Market Research Group (PEMRG), global plastics materials demand is forecast to grow 3.7 percent per annum for the period 2012 to 2017.

EUROPEAN MARKET DEMAND AND PRODUCTIONThe European plastics industry has generated total annual sales of over EUR 300 billion in the last three years. Europe


accounts for around 20 percent of global plastics production (50 million tons in 2013). To provide some context, China and the NAFTA trade bloc are responsible for 25 percent and 19 percent of global plastics production respectively.

With plastics demand of around 46 million tons per year, the European market belongs to the biggest markets in the world. The market is best characterized by a high level of demand for quality and performance which has proven attractive with international investors. Four European countries count among the top ten destinations for global plastics and rubber foreign direct investment (FDI), with Germany leading the way in the vanguard of European countries.

GERMAN MARKET DEMAND AND PRODUCTIONThe German plastics industry generates sales in the region of more than EUR 90 billion each year. The industry is made up of around 7,000 companies in total. These companies employ a workforce of about 375,000 people. The industry enjoys more than six percent share of domestic industrial production.

The German plastics production market, with 240 companies and 37,500 employees, generated sales of EUR 26.7 billion in 2013. Germany is home to more than 6,500 companies active in plastics processing. They can call upon a workforce of around 310,000 people. In 2013, plastics processing companies reached sales of around EUR 58 billion.

Germany’s plastics and rubber machinery companies are world leaders. In 2013, they employed a labor force of 27,500 people in more than 200 companies - generating sales of EUR 6.5 billion. According to the VDMA engineering industry association, sales are expected to increase to more than EUR 7 billion through to 2015. The growing domestic market is characterized by highquality requirements of the end consumer. Within Europe, Germany is the leading market, accounting for around 25 percent of plastics demand.

HOME MARKET EUROPE

More than 12 million tons of plastics produced in Germany found their way to export markets in 2013, with around 8.5 million tons of foreign plastics making the reverse journey into the country. With 72 percent of all exports, the European single market (EU-28) is the biggest recipient of German plastics, followed by the remaining countries in Europe (12 percent) and Asia (10 percent). All told, German plastics exports generated turnover of almost EUR 33 billion (equivalent to 3.6 percent of total German exports). Within the European single market, the main importers of German plastics are Italy, France, Poland, and the Netherlands. Germany is also one of the largest importers and processors of plastics materials - 87 percent of all plastics imported in 2013 came from EU-28 countries (91 percent across Europe).

Market applications and segmentsPlastics continue to play a defining role in finding innovative and forward-looking solutions to the way we live. Whether in the automotive sector, construction, packaging, or even in the field of health care products, the plastics industry is creating new and profitable business opportunities in numerous application markets. Carbon fiber-reinforced plastics (CFRP) application is virtually unlimited, ranging from lighter prostheses to faster canoes and more durable rebars (reinforcing bars). CFRPs are primarily deployed in the automotive, aerospace and wind energy sectors – areas where Germany has successfully positioned itself as a global leader

PACKAGINGMARKETWithin Europe, more than 50 percent of all goods are packaged in plastics. According to PlasticsEurope, major efficiencies achieved in plastics packaging mean that, by weight, plastics account for only 17 percent of all packaging. Packaging is the largest plastics application market segment, with 35 percent of total plastics processing finding its way into the packaging sector. According to the IK (“The Plastics Packaging Industry Association”), the industry sector in Germany had a production capacity of 4.3 million tons and sales of EUR 13.6 billion in 2013. The share of plastics packaging in the whole packaging market has been growing constantly in recent years and currently stands at 42.5 percent in production value terms. As such, plastics packaging is the best-selling material in the packaging market.

New technologies and improved processes are creating greater efficiencies which are making plastics packaging more attractive. Plastics also provide a ready solution to environmental challenges and ensure the safe and hygienic transportation of water, food, and other consumer goods in an increasingly urbanized world.

The family of bio-based plastics (“bioplastics”) is also gaining in terms of market attractiveness thanks to increased functionality factors.

OPPORTUNITIESMajor opportunities abound for companies active in the packaging sector. In 2013, over 19 million tons of packaging materials from glass, metals, paper, and plastics were produced. With 42.5 percent of the German packaging market by production value (paper 33.2 percent, glass 7.8 percent, and metals 16.6 percent), plastics enjoy a significant share of the packaging materials market. The food and beverage sector is a major application market. Increased demand is also forecast for packaging films, hollow bodies, closures, cups, and cans.


ARTICLE

New Sidel services aims to optimize performance across the lifecycle of the pet bottling lineTo lower the total cost of ownership (TCO) of invested equipment, it is essential for beverage producers to optimise productivity and performance across the entire lifecycle of their PET bottling lines. Sidel, the leading provider of production equipment and services for liquids in PET, has announced new services for effective maintenance to help reduce costly downtime and turn it into profitable uptime.

For beverage producers to optimise productivity, regular maintenance is required. When this is effectively carried out, it enables performance to be maintained or regained and even improved throughout the lifecycle of the equipment on the PET bottling line. This allows producers to reduce costs, maximise profitability and achieve the lowest total cost of ownership for their investment.

The cost benefits of proactive maintenanceBy adopting a preventive rather than reactive approach, equipment is monitored, allowing pre-planning of scheduled downtime to carry out all essential regular maintenance. Thereby the potential for long, costly and inconvenient shutdowns and loss of production are limited. It also helps to ensure that production schedules and targets are achieved, with regular health checks helping to extend the longevity of the line. As important as recognising the necessity of maintenance, is the choice of the type of maintenance undertaken and the provider chosen to carry it out. Sidel has introduced new dedicated maintenance services to reflect this importance.

Sidel’s three-phased approach to maintenanceThe reasons for intervention in any line’s production performance can often be put down to three different causes: the need for a producer simply to maintain the line performing with its current efficiency; the need to regain production capability in the case of a breakdown; and the wish to improve performance and/or productivity. Maintaining performance over any length of time generally requires the provision of service support such as diagnostic visits, spare parts supply, targeted skills training and regular, and efficient maintenance work. To regain performance in the event of a breakdown, effective action to fix the issue quickly is essential in restarting production.

This is either through well trained employees resolving the problem in-house or via the service provider. Improved performance can be achieved through options and upgrades that add value. As new technologies and solutions are developed by Sidel, these offer line improvement solutions that can significantly increase quality, flexibility and production performance on installed equipment. Another important factor in the effective maintenance of a bottling line, whether for emergencies or normal wear and tear, is the need for the timely provision of original spare parts, ideally designed, tested and certified by the same engineers who designed the machine. Sidel is therefore also aiming to encourage a more proactive approach to inventory management among its customers.

Comprehensive on-site and remote support The right equipment must be backed with the expertise and speed of response of a team that can offer a genuinely comprehensive support service. Sidel offers a combination

of knowledge and expertise along with ease of accessibility on a global basis.Sidel undertakes some 1,400 diagnostic visits a year to ensure a true understanding of its equipment currently operating in the market, developing customised maintenance services and sharing its expertise. The company has a global team providing 24/7 technical support on dedicated hotlines, along with instant emergency troubleshooting via remote access.Wherever on-site intervention is required, Sidel has more than 850 field service engineers in strategic geographic locations throughout the world locally available. In the event of any equipment failure, global field experts can be dispatched to provide hands-on assistance to quickly bring productivity back to target levels.Equally, training can also play a vital role in keeping a production line running smoothly. When employees are well instructed and able to carry out fast and efficient maintenance processes, they too can bring the line quickly back up to speed once the necessary work is fully completed.


Versatility of One Step Injection Stretch Blow MoldingBy Paul Atkin, Sales & Marketing Division - Nissei ASB Machine Co. Ltd.

In 1978, just as PET container molding was being introduced, Nissei ASB Machine Co., Ltd. of Japan was founded as an independent company specifically to develop and market one-step injection stretch blow machines.In the very early days of PET container molding, one-step and two-step machines were almost on a par in terms of output, mainly for simple designs for carbonated soft drinks. Later, as two-step molding became more common for molding simple, low value containers, the one-step molding method quickly established itself as being dramatically more versatile for a wide range of container shapes and alternative materials.

Figure 1 - ASB’s hugely versatile ASB-70DPH machine

One-Step VersatilityThe inherent versatility of the one-step process can be attributed to three fundamental differences between the one-step and two-step processes;1. The one-step preform is molded within the same machine as the

bottle is blown, so designers can optimize the preform design for the container rather than being locked into utilizing a limited range of stock preforms.

2. One-step preforms are held by the neck throughout the entire process so extreme neck designs and special orientations can easily be accommodated without consideration for transfer or unscrambling - and with no scuffing, this also offers vastly superior visual quality of the finished containers.

3. In a one-step machine, residual energy stored within the injection molded preform provides the heat required for blow molding so preform designs are fundamentally different. By manipulating this stored heat, the preform can be made to stretch in interesting and unusual ways.

Preform ConditioningThe ASB Series machines have a built-in advantage with the second of its four stations being designed for preform conditioning. Together with the inherent flexibility of the one-step process, this station provides unrivalled ability to customize the preform temperature before transfer to the blowing station.

Other one-step machine manufacturers attempt to modify the preform temperature directly in the injection mold, but this method lacks flexibility and is very sensitive to factory conditions.The ASB conditioning station has the ability to apply overall, partial or spot cooling or heating to the preform very consistently and precisely while using simple and cheap-to-modify mold parts for maximized flexibility. The conditioning station can also be used to apply reshaping to the preform prior to blow molding either to maximize the material properties or to apply specific forms.

Alternative Materials & The Non-Food MarketAlthough PET is still the mainstay of one-step molding for the food and beverage market, more than 20 different molding materials have all been successfully molded by ASB’s one-step process, including Polypropylene, Polyethylene, Styrene, Polycarbonate, Acrylic, Cyclic Olefin Copolymer, and Polyphenylsulfone to name just a few. With one-step molding’s flexibility in terms of both product design and moldable materials, the door is opened to a huge range of products in other market segments. In this selection we can see some lesser known one-step molded examples in various resins such as a pitcher, a drinking cup, a steering gaiter for a car and a lamp cover.

Figure 2 - Molding possibilities are almost unlimited

Cosmetics & Thick BasesCosmetic PET containers are a special case where the customer is always requesting more weight and more thickness to provide the highest quality image and feel to their products.Molding very thick PET containers is a special challenge since the thick preform cools slowly leading to crystallization causing an unwanted hazy appearance. Traditionally this has been overcome by using specialized copolymer materials that are also very expensive. Now, ASB has developed a preform molding technique utilizing advanced cooling channel design together with injection mold parts that move as the cavity fills. The result is perfectly cooled preforms free of haze that can be blown into containers having the look and feel of premium glass. With this process, standard grades of PET


can be used but specialized copolymers and even Eastman’s Tritan Copolyester might also be used – in this market of premium products, resin costs take second place to quality.

Figure 3 - Premium quality cosmetic containers in PET

Body Forming During Blow MoldingPET’s stiffness is great for molding strong, lightweight simple shapes but creates difficulties whenever sharply blown details are required.Over many years ASB has developed this technique of using movable mold parts to easily enable sharp location points for handles, or deep pinch grip type handles or indeed any other insertion detail so that the finished container can be locked into a dispenser unit or could be fitted with a snap-on cap etc.

Ultra-Narrow Neck 2.5mm (patent pending)Very small PET containers are another area where one-step molding is the only practical molding choice. Another new molding technique from Nissei ASB allows the neck bore to go down to as low as 2.5mm. Once again their ASB Series conditioning station comes into play where it is used to completely re-shape and cool the preform prior to blow molding.

The FutureThe PET container molding industry is rapidly becoming more competitive and converters that wish to grow need to seek out high-margin niche markets where the advantages of one-step molding provide the best solutions and invest in the equipment capable of these innovative molding techniques.This is nothing new for ASB. As the world’s leading machine maker for nearly 40 years it has been the company’s philosophy to continually move the goalposts for flexibility and innovation one-step ahead of the competition.

Plastic Gives Paper the Sack!Heavy duty sacks are generally regarded as those that hold 25kg of product, although there are some exceptions. The year 2010 marked the point at which plastic sacks overtook paper sacks in terms of number of units, since then plastic’s share has grown to almost 55% and is forecast to rise to almost 60% by 2020. Sacks are a significant segment of polyethylene packaging in Europe, accounting for a little over 7% of total polyethylene film production. Why has there been such dramatic penetration of the total sack market at the expense of paper sacks in most of the end use sectors? The main reasons include the following: plastic sacks show improved ‘stackability’ which reduces storage space and transport cost as opposed to, for example, stand-up paper or woven sacks; they are lighter than their paper alternative and so can dramatically reduce the carbon footprint of the packaging; plastic sacks are 100% recyclable as opposed to paper sacks laminated with a plastic liner and they demonstrate 100% sealability giving rise to dust-free handling with no spillage or waste; additionally barrier properties can be built into the base film where required, e.g. to improve odour or moisture barrier. The plastic heavy duty sack sector has always made good use of newly developing raw materials: first butene linear resins, then the higher alpha olefins and, more recently, metallocenes to allow a continual process of product improvement and material downgauging. Major thickness reductions took place at the turn of the millennium then during the period 2006-2010, however further thickness reductions have continued to take place, but at a slower pace. LDPE remains the major polymer used in the production of heavy duty sacks at a little over 50%, followed by HDPE/MDPE, butene, octene then metallocene. Bimodal HDPE and metallocene resin show the highest growth rates, although from a much lower base.Advances in form-fill-seal (FFS) machinery will continue to create further opportunities for plastic industrial sacks to displace multi-wall paper sacks in their existing stronghold areas, such as powder products (e.g. cement), food and pet/animal feed. Although cement products account for almost one third of all sacks used in Europe, demand for cement plastic sacks is the smallest segment – as over 90% of cement products are packed in paper sacks rather than PE. Cement is normally hot filled at between 90° and 110°C which has made it extremely challenging for plastic film to compete with paper. Additionally, with cement being a very fine powder, it makes it very difficult to extract air from a plastic sack, while paper has sufficient permeability to permit de-aeration after filling. Finally, the cost of plastic sacks is slightly higher than that of paper sacks and, with cement being a relatively low cost item, it is difficult to justify expenditure in alternative wrapping equipment. However, the problems of packing fine powders using plastic have been largely overcome, so that technically there is no barrier to change. The largest end use markets for plastic sacks are chemicals and fertilisers, accounting for one-third of European demand, and horticultural products, accounting for 20% of demand. In the case of chemicals, often only a simple print is required for product identification; in the case of horticultural products and some fertilisers, high quality flexographic print up to 10 colours is the norm, in order to produce an eye-catching impression at point of sale of what is essentially a consumer-aimed market segment. Plastic sacks also hold a dominant position in sectors such as sand & aggregates and salt, at 90% plastics penetration – these end uses require only simple or no print. Food packing in plastic heavy duty sacks is a relatively fast-growing sector, driven by increasingly strict requirements on paper sacks in terms of food contact compliance and the risk of contamination by paper fibres.Source: AMI

ARTICLE


Food packaging industry is pulsating and highly competitive, with food manufacturers always on the look-out for packaging that can provide consumers with increased convenience as well as longer shelf life lower costs. The industry is aware that consumers want innovation and value uniqueness, and therefore the packaging industry must innovate regularly. Given the size and diversity of the food packaging industry, this brief overview can only touch a few of the major work the industry is performing worldwide.Most evident has been the switch from glass to plastics with the majority of beverages nowadays packed in polyethylene terephthalate (PET). It is just 40 years since the first PET bottle appeared in the market and its growth since then has been hugely successful. A 330 mL bottle weighs only 28 g, which is up to 86% less than an average equivalent glass bottle.A variety of bar code symbols that can be read by smartphones are appearing on packs. The QR (quick response) is the most common – it can launch exclusive content, update your Facebook status, download coupons, promotions and music and invite your friends to join you. Astra Polymers food approved range of additives, masterbatches and filler compounds are a perfect fit for food packaging companies seeking high-level solutions to meet the industries’ stringent processing, environmental, and toxicity requirements. We have formulation know-how to design color and additive products that fulfill Food & Drug Administration requirements for a variety of end-use applications. This includes high-clarity films, sealable trays, lids, containers, and caps. Our key processes in the food packaging market are injection molding, sheet extrusion, and blown film.

CAST & BLOWN FILMFrom simple mono-layer trash bags to complex co-extrusion packaging applications, Astra Polymers supply the cast and blown film industry with a variety of color and additive masterbatches. We design solutions for various resins used in film processing, including PP, PE, PET, In addition, we create and manufacture antifogs, polymer process aids, slips, clarifiers, and high-clarity antiblocks, as well as products to help increase the life of the contents inside the package.

SHEET EXTRUSIONAstra Polymers provides custom-formulated products for the sheet extrusion/thermoforming marketplace. We focus in color and additive concentrates for polymer systems including: polyolefins, styrenics, thermoplastic polyolefins, and selected engineering polymers. We aid formulate products that take into account critical specifications linked with food, medical, and industrial applications.

INJECTION MOLDINGMany of the customers are focused on improving cycle time and increasing quality to reduce scrap rates. So it’s important that Astra Polymers formulates and manufactures color and additive concentrates specifically designed for injection molding applications. Our team can create formulations that are based on the specific requirements of each individual application.Global market for masterbatch is projected to reach $11 billion by 2020, driven by rising demand for colorful plastics from end-use markets such as packaging, and consumer goods, among others. The masterbatch market in Saudi Arabia is projected to reach $167 million by 2020. Key innovations which Astra Polymers have initialized to benefit the market over the past few years, include anti-shrinkage masterbatch, flame-retardant masterbatches for PP pipes and PC sheets, anti-fog masterbatches for food packaging, anti-microbial and odor managing masterbatches, and masterbatches for biopolymer and biodegradable resins.

Astra Polymers –The Perfect Fit For High Level Innovative Food Packaging SolutionsBy Waqas Latif, Marketing Specialist - Astra Polymers


FAV Plastico (Pvt.) Ltd. is a firm with an understanding of the growing needs and requirements of the plastic industries of Pakistan and thrives in providing top quality masterbatch. FAV Plastico promises quality excellence in order to earn its vision of being one of the leading suppliers of masterbatches in Pakistan. As the leading manufacturer of color concentrates and additive masterbatches, we offer exceptional products and services. Our black, white, color and additive masterbatches meet the diverse appearance and functional demands placed on plastic products. We provide thousands of black and white masterbatches, including those having high pigment loadings, temperature resistance, UV resistance and electrical conductivity. We are producing additive masterbatch such as processing aid, UV stabilizer, light stabilizer, slip additive, anti-block and anti static, i.e, for preventing static charge in flexible packaging industry.Our broad palette of color concentrates encompasses all organic and inorganic pigments and those for pearlescent, metallic and other special effects. These are supported by our color team formed of multiple disciplines working together to create colors and effects that support our customer’s brand initiatives. ‘FAVOLENE’ is the brand name for FAV Plastico masterbatch, in which we are manufacturing color, white, black, additives and PET masterbatch. The firm offers an extensive portfolio of products and technical expertise as our R&D department works continuously on new developments and on innovated new products for valuable clients. We work to convert your ideas into reality.Providing services: • Analysis of Competitors products • Sampling & Color matching

• Technical information & quality certificates

• Technologist visits to the clients plant and provide technical support

• Provides assistance to run product in accordance with the customer’s requirement

• Consultancy: We are always with you and ever ready to provide good consultancy to our valuable and new clients such as Material selection, Machine and process selection, better process flow for maximum output, troubleshooting guidance during production etc.

Use of Masterbatch in Flexible Packaging ProductsThe flexible packaging industry is a large market with wide range of segments and products. The primary function of packaging materials is to protect the product from physical, chemical and microbiological deterioration.

Continuous change of people’s lifestyle persuades masterbatch and film manufacturers into innovation and developments of new concepts. Food packaging takes herein a major role as high demanding segment, often searching for exceptional properties.

Flexible packaging is produced either by blown, cast or orientation process. To fulfill all consumer needs, often primary packaging materials are converted by lamination, extrusion coating, etc. into a final product.

Flexible packaging became a key element for product differentiation by its appearance. The wide type of packaging materials in combination with all kind of printing

techniques allows the creation of a unique product. FAV Plastico masterbatch is used in almost every polymer/plastic product and process; we have highly experience techniques for application in single and multi-layer film process as well as in injection molding and blow molding, thermoforming, extrusion and in all other plastic and polymer processes.

We help our customers to make the best use of our masterbatches with our technical expertise. FAV Plastico manufacture’s masterbatch that can be formulated for non-oriented and oriented film applications to optimize the products and increase process performance. We develop and deliver masterbatch that increase the market value of film by enhancing its quality.

FAV Plastico masterbatch can be used in thousands of consumer packaging products, including food packaging such as frozen foods bags, snack and chips packaging, meat wrap, boil-in bags, and individual cheese slice wrappers, non-food flexible packaging include packaging for home and auto parts care wipes, paper product overwrap, garden and lawn products, electrical & electronics, cosmetic and personal hygiene items T-Shirt bag. Consumer package manufacturing choose FAV Plastico masterbatches for their flexible packaging needs because our innovative custom color and additive technologies have been known to influence consumer purchasing decisions.

FAV Plastico is your most reliable masterbatch supplier for flexible packaging.

Introducing Masterbatches for Flexible Packaging Products-FAV Plastico

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