News from the Scottish Plastics and Rubber Association

2002

Newsletter Contents 2002

March 2002 Page International Rubber Study Group meeting in Glasgow 2 Battenfeld lecture on Plastics Micromoulding 4 Understanding an Industrial Energy Survey 5 Plade Fabricate Success 6 Workforce Development Plan on Skills Needs 6 Schools Project to assist teaching of polymers in schools 7 SPRA Corporate Members Forum 7 French student on development project with Safeglass 7 June 2002 SPRA Seminar: Improving Profitability in the Global Market 8 SPRA Dinner Dance 2002 9 Ticona Roadshow: Engineering Thermoplastics and Applications 9 Profitable Programmes to Boost Your Business 10 Les Rose receives Outstanding Service Award from Institute of Materials 11 SPRA Polymer Course for Fife School Teachers 11 SPRA sponsorship for Polymer Study Tour 2002 12 SPRA Annual General Meeting 2002 12 SPRA Corporate Membership 13 September 2002 Polymer Study Tour 2002: residential course for teachers 14 Conducting Polymers for Electrical and Optoelectronic Applications 15 Sustainable Waste Management conference report 16 Waste minimisation meeting report 17 Community Recycling Network seminar 18 December 2002 Krauss Maffei sponsor SPRA meeting: Innovation in Plastics Processing 21 Rapid Prototyping Technology 22 Waste Electrical and Electronic Equipment (WEEE) Directive workshop 23 Polycarbonate Recyclate 24 Formation of Impact Laboratories in Grangemouth 25 Report from SPRA Academic Liaison Officer 25 SPRA party visits Interplas 2002 26 Network meeting: Threat of Overseas Competition 26 Faraday Plastics Partnership: R&D Funding Road Map 27 MSc (with Distinction) from Plastics Moulding Technology course 28 Student placements sought for Polymer Engineering students 29

News from the Scottish Plastics and Rubber

Association

March 2002

Features in this issue: International Rubber Forum Micromoulding Energy Surveys Plade Fabricate Success Skills Needs Schools Projects

Corporate Members Forum French Connection

IINTERNATIONAL RUBBER FORUMNTERNATIONAL RUBBER FORUM In early February the International Rubber Study Group (IRSG), an international, governmental body, held their 103rd Meeting in the Moat House Hotel in Glasgow. The Meeting, postponed from October 2001 when the planned venue was Bahrain, took place in colder and damper weather but delegates, from a wide spectrum of countries, still enjoyed the cultural aspects of a Scottish venue amid a week of committee meetings and a two-day International Forum.

Much of the first day of the Forum was taken up with speakers attempting to interpret the complex statistics of rubber consumption, production and pricing, looking in particular for an explanation of the recent fall in prices of natural rubber (NR) and trying to forecast the trends over the next few years. The steady growth in rubber consumption was halted in 2001 but the forecasts are that consumption will increase over the next 5 years and prices will edge upwards. Howard Evans, Secretary General of the Association of the International Rubber Trade, attributed the recent drop in NR prices to a number of factors, including local currency exchange weaknesses in the Far East. One significant factor is the reduction in rubber content in vehicles, from 35 kg per car in 1975 to 22 kg / car now, largely due to more efficient use of rubber in tyres and other components.

For the first time annual consumption of synthetic rubber per capita has been dropping (9.5 kg per capita in 1990 to 6.5 kg in 2000). However, due to increasing population and increasing vehicle numbers, the overall trend in rubber consumption and production continues to increase. In many regions synthetic rubber plants are operating at only 60% capacity.

INTERNATIONAL RUBBER FORUM

Prof Noordermeer

Prof Noordermeer, Twente University, in the keynote speech, emphasised that the strong competitive position of NR ( maintaining 46% of rubber usage) although partly due to the relatively low price, is as much a result of the technical superiority of NR, particularly in its mechanical properties under dynamic conditions. He saw several threats to the current strong position of NR. Silica reinforced tyres, the so-called "green tyre" with reduced rolling resistance, function better with a blend of solution SBR and BR rather than with the traditional NR / emulsion SBR blends. Temperature limitations and ozone resistance preclude NR in some products. Synthetic rubber (SR) still has technical advantages for certain products but usually has the edge in product quality consistency.

David Shaw, Editor of the European Rubber Journal, in his review of the rubber industry in Western Europe, identified the sudden drop in machinery orders in the last quarter of 2001 (after September11). The industry in W Europe is also suffering from high labour costs and high costs of factory space compared to other countries. Labour costs in Hungary are 68% of similar costs in Germany. Inevitably discussion turned to the problems of Firestone and Ford and the observation that the difficulties may have been minimised if the problem had been identified earlier and if communications had been better. In Sri Lanka, producing a modest 87000 tpa of NR from 159000 hectare, a novel approach has been taken in adopting a Cluster Management Model. The USAID and various governmental bodies have joined with the NR producers and the rubber industry to develop a system that promotes self-interest and enhances global competitiveness through industrial interdependence. So far the collaborative venture and pooling of facilities have been very encouraging. Sri Lanka can improve output of NR by increasing tapping frequency but it does have the advantage of being to able to charge premium (up to 15%) prices for its main output of crepe rubber. The second day started with a session devoted to tyres, by far the main consumer of rubber. 2000 was a record year for tyre production but the mild winter led to low sales of winter tyres in Northern Europe and hence had a knock on effect on production in 2001. The international trade in tyres has increased significantly with the rationalisation of manufacturing plants and the move to lower labour cost centres. This is particularly true in the EU with 170 million tyres being exported by EU countries of which 140 million were to other EU countries.

Claude Bétizeau from Michelin France gave an excellent presentation on the use of natural rubber in tyres. Citing examples from 200g bicycle tyres to 5.5 tonne mine vehicle tyres, the latter containing 1 tonne of natural rubber equivalent to 20 years production from 10 rubber trees. He described the many factors that have to be balanced in the design of a tyre and the changes that have evolved in recent years. The key properties of natural rubber compared to synthetics lead to the conclusion that

Michelin would use more NR if the variability in Mooney viscosity and the problems of impurities could be resolved. In the discussion that followed the fact that silica fillers, as used for low rolling resistance, require silane coupling agents and these apparently do not work with NR, was identified as yet another reason for the reduction in demand for natural rubber. NR appeals to environmentalists because of its renewable source but recently extensive use of timber from the rubber tree has enhanced NR's "green" image. The use of rubber trees for sequestration of C02 and the importance of carbon banks in the future was emphasised. A total of 8 million hectares of rubber plantations in the world sequestrates 1 billion tonnes of carbon each year. Natural rubber plantations are but a small part of the total world forest which at 3.4 billion hectares represents 26% of the land area. The international trade in carbon emissions, the way that various governments have set about meeting their commitments to the original Kyoto Protocol, has resulted in a new market trading "permits to pollute", i.e. those industries that cannot reduce their CO2 emissions by the required x% in y time simply buy "credits" from those companies/organisations/countries that have. Potentially the rubber plantations should be able to benefit from this. However there are problem of cost associated with registration and monitoring.

The final session was a panel lead discussion on rubber wood as an ecofriendly source of tropical timber. As rubber trees are taken out and replaced after 20 years of latex production they provide around 3.4 million m3 of rubber wood per year. To date almost all of this has been used as fuel wood for drying and smoking rubber, domestic cooking, lime kilns, bakeries, etc. The drive for more long term uses and hence retention of the captured carbon has lead to successful use of rubberwood in furniture as well as for fibre in MDF. Rubber wood itself is problematical, because of its high sugar content it needs to be cut and processed within 3 days. Guthrie Symington (origins in East India Company) have installed chemical pressure treatment and kiln drying facilities in Malaysia and are now producing nursery furniture locally from rubberwood.

For a fuller report contact Charlie Geddes

c.geddes@blueyonder.co.uk

International Rubber Study Group

Tel: +44 (0) 208 903 7727 Fax: +44 (0) 208 903 2848 www.rubberstudy.com

MICROMOULDING

At the Stirling Management Centre on Tuesday 19 February an audience of 34 braved the wet conditions and were rewarded with a fascinating presentation by Peter Manser, Battenfeld UK, on the developments in micromoulding. Using the definition of micromoulding as components weighing less than 1 mg, Peter explained how the injection moulding machine had to be completely rethought to cope. A granular feed is plasticised using a 14 mm screw , fed through a shut-off valve to a dosing cylinder. From the dosing cylinder the melt is fed to the injection cylinder and into the mould at ram speeds of 760 mm/s.

Peter Manser

There is no sprue system but runners are typically 0.5 mm thick. To assist venting, full mould closing/clamping is left until injection starts. Mould units are generally of the rotary platen design to accommodate automated unloading and part handling, which includes 100% optical inspection with a camera system and storage oriented packaging. The manufacturing cell operates in clean room conditions. To meet the demands of stroke precision (1 mg is equivalent to 0.07 mm using a 4 mm piston) the machine is servo-electrical. Injection is by a cam system with switch over times of 20 ms while the clamp system uses a ball screw drive, giving dry cycle times of 1.8 s and overall cycle times of 2 to 5

seconds.

Tools are largely produced by conventional methods except that there are no guide pillars on the bolsters but registration guides on the cavity inserts which sit in the bolsters with O-ring seals. Laser machining and lithography processes (UV, X-ray or Synchrotron radiation) are used for fine cavity detail Peter illustrated the talk with numerous examples of mouldings from watch gears to medical implants.

Comparison of conventional and micromoulded runners

2-impression mould for medical part

Watch gear (0.0008 g)

. Capital outlay is high (up to £150k) and tools can be expensive but the low material usage makes the process insensitive to material cost and suitable for exotic materials. The Battenfeld Microsystem has been used for two-shot moulding and also for moulding metals and ceramics. Discussion centred on problems with material instability due to long residence times, tool design, computer simulation and future trends to nanometre dimensions. Alastair Pettigrew, an ENT specialist from Stirling, generated much interest when he described his aim of producing mouldings of bones from the ear, to be used in training aids for ear surgeons.

Alastair Pettigrew

Peter Manser tel: 01494 450 911

manser.p@vuk.battenfeld.com www.battenfeld.com

ENERGY SURVEYS

If you consider that your company is unconcerned about its energy bill and is content to pay its current level of Climate Change Levy (CCL), you need read no further. For companies that would like to reduce their energy costs and the CCL, the latest publication from the Energy Efficiency Best Practice Programme is essential reading. "Undertaking an Industrial Energy Survey", Good Practice Guide 316, provides the methodology and advice for companies to undertake their own internal energy assessments.

A matrix approach, applying a standard checklist to each area of a factory, can quickly identify where energy is being wasted. The checklist is divided into Services ( lighting, ventilation, space heating, compressed air etc), Processing (motors, steam systems, mixing, drying, forming, cooling, heat recovery etc) and Others (material handling, transport, catering, building fabric). In the Guide each checklist item is allocated a page covering "Things to Look for", "Tricks and Tips", "Potential Opportunities" and "Further Information" (in the form of a list of relevant publications). As and example, under Motors, "Things to Look for" includes oversized motors, hot and noisy gearboxes, worn or slack V-belts, worn bearings and unnecessary running. "Survey tips and tricks" include: pay attention to largest, long running and noisiest motors first; ways of estimating power consumption from

simple formulae; thermal imaging to detect hot-spots. "Opportunities" highlight : time switching; variable speed motors; stop-start control; soft start motors; smaller motors; new design drive belts. The Guide even suggests how to construct a report with the use of proforma. In the Workshops, held to publicise the Guide, advice is given on how to analyse energy usage from plots of weekly energy consumption against production output or other relevant drivers. Establishing a performance characteristic line from the plots allows monitoring of deviations between actual and expected consumption week by week. Anomalies show up best using cusum charts and resources can then be applied to diagnose and rectify the problem.

During the Workshop useful advice was given on when to bring in energy consultants, what to look for in a consultant and, more importantly, how to obtain grants to cover all or part of the cost. Advice is free for SMEs on the Energy Hotline 0800 585 794. Under Action Energy, Site Energy Assessments, involving up to 10 days of a consultant's time, are also free of charge for annual energy spends over £50000. Specific Measures Assessments, focussed on important needs, are fully funded for the first 2 days and 50% subsidised beyond that. The Scottish Energy Efficiency Office has launched an interest-free loan scheme, specifically for SMEs, for energy saving projects. Loans between £5000 and £25000 are repaid over a 5 year period.

Energy Efficiency Best Practice Programme

Action Energy Loan Action Scotland tel:

0800 092 9002

www.energy-efficiency.gov.uk www.energy-efficiency.gov.uk E-mail: loanactionscotland@glasleac.co.uk

PLADE FABRICATE SUCCESS

The moulding sector in Scotland has suffered badly in the last year although there are signs that the slump in the electronics industry is bottoming out. In other sectors of the plastics industry, companies are competing successfully on a global scale.

PLADE, an independent business founded over 30 years ago in Barrhead, has continually adapted to capitalise on new opportunities. Originally established to fabricate small components such as ducting in PVC-u, PP and GRP, Plade followed the route of scale and were soon producing large GRP structures up to 4 m diameter, 17 m long. Exporting large GRP structures proved to be economically unattractive and the company made the decision in the mid 1970s to

switch to producing wet benches for the blossoming semi-conductor business. This required new expertise in CAD and electronics and investment in clean room facilities. In the late 1980s Plade introduced their 6 sigma software control system and more cabinets were being fitted with robots. Today Plade export cabinets for a range of industries to all corners of the globe and they have received several awards for their enterprise.

Gregor Egan, Director, attributes the company's success to the willingness of a loyal workforce to adapt to new technologies and to recruitment of staff with high technology backgrounds to anticipate the opportunities and demands of customers. In recent months Gregor has taken particular satisfaction in securing a large order in the home town of their major USA competitor. Other plastics companies can take heart and perhaps learn from Plade's continuing success.

PLADE Tel : +44 (0) 141 881 8241

E.mail: plade@plade.com www.plade.com

SKILLS NEEDS

Polymer NTO, in partnership with the SPRA, have been awarded a contract from the Scottish Executive to produce a Workforce Development Plan for the polymer industry in Scotland. The project will examine skills needs relevant to industry's short term and long term plans.

Hugh Smith, SPRA President, is pleased that the Scottish Executive has recognised the importance of the polymer sector to the national economy. He comments, "Despite the recent difficulties for our industry, our sector has a major part to play in Scotland's future economic performance and consequent job creation. If we are to be successful, we must address the key issues of competitiveness, changes in the market place, and our future skills requirements".

Bill Erskine, Operations Manager at Polymer NTO confirms that investment in training by Scottish companies has held up well during the manufacturing downturn. He states that the Workforce Development Plan must reflect employer needs and asks for their support in carrying out the project. The finalised report is intended to be the basis for future investment in training provision and evidence to support grant applications from employers to help implement their training plans.

The Workforce Development Plan will be presented at a half-day seminar "Maintaining Profitability in the Global Market" on Tuesday 30 April at the Westerwood Hotel, Cumbernauld.

SCHOOLS PROJECTS

The SPRA Council has allocated part of the income from Corporate Membership fees to support the teaching of polymer materials and processes in schools. Last year the SPRA sponsored a teacher (Norman Easton, Craft Design & Technology, Deans Community High School, Livingston) on the Polymer Study Tour, a four day residential course held at Napier University and other Centres in the UK. In 2002 the SPRA will be repeating this sponsorship and encourage companies to do likewise (at a cost of as little as £600). The SPRA is initiating a pilot scheme in Fife Schools. Funding is being provided for 10 Technical teachers to become Schools Affiliates of the Institute of Material. The SPRA is organising a one-day course in Glenrothes in May for teachers of Design and Technology. As well as presentations on polymer materials and processes the day will include visits to 4 companies in the area. Also in the pipeline are plans to produce teaching kits containing mouldings with background details of the design and manufacture of the components

CORPORATE MEMBERS FORUM

At the Corporate Members Forum on 4 March, 2002, discussions centred on the Skills Needs Survey for Scotland and the need for companies to assume greater leadership in the establishment of the Sector Skills Councils to replace the National Training Organisations (NTO). The UK Government is aiming to reduce the number of sector bodies responsible for training and education but a bid is being prepared for the polymer industry sector. There is a possibility that the polymer sector may be subsumed into a larger body such as a Manufacturing Sector Skills Council, with some loss of the identity enjoyed by the polymer industry over the last 40 years. Hugh Smith reported on a meeting, representing SPRA as an Affiliate Member of the BPF, with Mr John Whittingdale, Conservative spokesman on Trade and Industry, at which a range of topics (including Climate Change Levy) was discussed. The meeting was advised to pay more attention to draft European Directives before they became law. The Forum also discussed a variety of initiatives aimed at teaching polymers in schools and at the same time inmproving the industry's image. Plans were agreed to make the Employers Learning Network stronger and more vibrant. The SPRA is delighted to announce that the following organisations have become Corporate Members of the Scottish Plastics and Rubber Association:

Balmoral Tanks Ltd New Medical Technology Ltd Sulzer Vascutek Ltd

Each company receives a Certificate and now has its own web page on this website, with appropriate contact details and weblinks to its own web site.

FRENCH CONNECTION

Audrey Gimon, SPRA prizewinner in 1998 for BEng Hons Polymer Engineering at Napier University, Edinburgh returned to Scotland in summer 2000 to work on a development project with Safeglass (Europe) Limited, East Kilbride as part of her continuing studies at Engineering School in France. Here she is seen carrying out compounding trials at Thermo Prism

News from the

Scottish Plastics and Rubber Association

June 2002

Schools Projects SPRA AGM 2002 Corporate Members

Features in this issue: SPRA Seminar Dinner Dance Engineering Thermoplastics Boosting Businesses Outstanding Service

Hugh Smith (SPRA President), introducing the half-day seminar "Improving Profitability in the Global Market" on 30 April 2002 in the Westerwood Hotel in Cumberanuld, saw the seminar as an opportunity to review the factors that make a company successful. The 3 sessions, Skills, Technology, Management Practices were designed to survey the present situation and included case studies of successful initiatives. Without belittling the importance of technological skills and Modern Apprenticeships Hugh felt that other factors, such as marketing and design skills were equally important to a company's future.

Hugh Smith (centre) and part of Seminar audience

PROGRAMME Session 1 SKILLS Session 2 TECHNOLOGY Session 3 MANAGEMENT PRACTICES

Value of workforce skills in competitiveness

Scottish Skills Survey

Understanding and exploiting technology Benchmarking Survey: UK Plastics Industry 2001 Exploiting market opportunities Six Sigma Plus at Honeywell

Michael Cross Bill Erskine Charlie Geddes Adrian Marks Richard Walton Chris Sturgess Patrick Shannon

(Consultant) (Polymer NTO) (SPRA) (Steve Orr Ltd) (Faraday Plastics Partnership) (Denroy Plastics Ltd) (Honeywell)

For details of the individual presentations click here

SEMINAR: "Improving Profitability in the Global Market"

SPRA DINNER DANCE 2002

Top Table ( l to r) Peter Davis (BPF), Hugh Smith, Mrs Smith, Les Rose (SPRA), Mrs Rose, Stuart Coull

Over 250 SPRA members and guests, from all parts of the UK, put the troubles in the industry behind them to enjoy the 2002 SPRA Dinner Dance in the Hilton Hotel in Glasgow on 15 March. Hugh Smith had his top table guests, Peter Davis (BPF), Mr and Mrs John Rainey (Denroy) and Mr and Mrs Les Rose (BP) piped in before SPRA members toasted their guests and the company enjoyed the meal, with its traditional Scottish flavour. After-dinner entertainment was provided by Stuart Coull, the main speaker for the evening.

Steven Love being presented with the SPRA prize by Hugh Smith

Prizes were presented to two students from Napier University, Steven Love (BSc Applied Chemistry) and Youjil Yahya (BEng Polymer Engineering). Steven had worked for Brand Rex in his placement year. Youjil had returned to complete his studies in France but one of his colleagues collected the award on his behalf. To round off a great evening the dance floor was just as crowded as in previous years.

ENGINEERING THERMOPLASTICS ROADSHOW

Anyone turning up on 24 April at Cumbernauld for the Ticona Roadshow, expecting a DJ, loud music and bright lights may have been disappointed but those who did were treated to a quickfire series of slick presentations from a team of 6 from Ticona UK. As well as covering the latest materials and e-business offered by Ticona, the main part of the evening was aimed at how designers should go about selecting materials.

Team of presenters from Ticona UK

A series of case studies illustrated a methodical approach, based on establishing a realistic design specification, comparing appropriate materials using property databases and applying techniques like spidergraphs to finalise selection.

Medical products case studies included an inhaler ( components in PBT and POM) and a needle free injector ("Topas" cyclo-olefin copolymer [COC] selected for its transparency, toughness, chemical resistance and sterilisibility).

Inhaler components

A costing case study illustrated the need to consider moulding conditions ( clamp force and cycle time) as well as material prices when comparing materials for a particular application. The team even indulged in role playing to demonstrate the interaction between supplier and customer in solving problems related to component design and mould design. Redesign of a water recirculation pump in 40% glass filled PPS had resulted in warping and the measures taken to meet the design specification were outlined. The buffet meal, provided by Ticona, allowed discussion to continue among the presenters and the audience of 30.

Ticona UK Tel: 01952 213 400 www.ticona.com

PROFITABLE PROGRAMMES TO BOOST YOUR BUSINESSES

At the March meeting in the Science Centre (Sensation) in Dundee, Douglas Mundie outlined the objectives and operation of Technology Ventures Scotland (TVS) and Doug Houliston (Napier University) explained the operation of the TCS programmes.

Douglas Mundie

Technology Ventures Scotland, funded by Scottish Enterprise and the Scottish Higher Education Funding Ccouncil (SHEFC), has a strategic role to encourage the overall investment in technological Research & Development in Scotland and to accelerate the commercialisation of Scotland's science and technology base, to meet Scotland's economic and social needs. TVS does not deliver projects but acts as a catalyst and facilitator for change. It is business focussed, particularly for SMEs in the manufacturing sector, and is working hard to raise awareness of opportunities. The TVS website attempts to create an on-line community for SMEs, with details of projects and events.

Doug Houliston, Napier University explained the purpose and operation of TCS programmes. High quality graduates are recruited to work on technology transfer projects in a company for 2 years but are paid and supervised by a University. The University supervisor has weekly contact with the graduate and appraisal meetings with the company every month. In addition the Associate has to present a progress report to a Local Management Committee every 4 months. Over 2 years, the budget of almost £80k comes from a Government grant of around £50k and a contribution from an SME company of just under £30k. From past experience, the TCS programme has resulted in the creation of new jobs and increased profits for companies and higher degrees for the graduates.

Doug Houliston

www.technologyscotland.org

Douglas Mundie

01383 427 330

info@technologyscotland.org

TCS

www.tcscentre.co.uk

0131 455 5106

tcs@napier.ac.uk

OUTSTANDING SERVICE

The SPRA is delighted to announce that the Institute of Materials Award for Outstanding Service has been bestowed upon Les Rose, a popular and long serving member of the SPRA Council. Les, a research scientist at BP Chemicals in Grangemouth since 1985, has served the interests of professional members in the field of plastics and rubber in Scotland for the last 14 years. In the Plastics and Rubber Institute (Scottish Section) he held the posts of Vice-Chairman, Chairman and Hon Secretary. After the formation of the Institute of Materials, in 1993, he became Hon Secretary to the newly formed Scottish Plastics and Rubber Association until 1997.

Les Rose (left) is presented with the Institute of Materials

Award for Outstanding Service by Hugh Smith (SPRA President) at the SPRA AGM in Napier University

Since then he has continued to be an active member of the SPRA Council, with responsibility for social events such as the prestigious Annual Dinner Dance and has helped organize seminars. Les has been conscientious in all these roles and has had an excellent attendance record at Committee / Council meetings over the last 14 years.

SCHOOLS PROJECTS

FIFE SCHOOLS COURSE

In line with the SPRA commitment to supporting the teaching of polymers in schools, a one-day course "Polymer Technology (Materials and Manufacturing Processes" was presented to 10 Design and Technology teachers from Fife schools at Glenrothes College on 15 May,

As well as covering the basics of polymeric materials and a range of processes in the classroom, the teachers were then able to see the processes in practice during short visits to three companies adjacent to the College campus, Brand-Rex (wire and cable), Labone (injection moulding) and Spraymasters (painting and printing). The tutors, Charlie and Sheena Geddes, were pleased with the positive feedback from the teachers, who would welcome further support from the industry in the form of company visits, advice on design and manufacture, plastics materials and examples of products. The SPRA expresses its thanks to Ed Beck (Brand-Rex), Andy Stanley (Labone) and Derek Connor (Spraymasters) for their guided tours. It is hoped that other SPRA Corporate Members can provide the same level of support for similar courses in other geographical areas.

POLYMER STUDY TOUR

The SPRA is sponsoring two teachers on the Polymer Study Tour, a residential course for science, technical, design and technology teachers, to be held at Napier University, 23 - 26 June: Dave McKay, Arran High School, Isle of Arran and Andrew Miller, Milne's High School, Fochabers, Morayshire Companies can sponsor teachers from their local schools on the Polymer Study Tour for as little as £600

For details contact:

Wendi Beamson Polymer NTO 01952 407545 wendib@polymernto.org.uk

Colin Hindle Napier University 0131 455 2622 C.Hindle@napier.ac.uk

SPRA ANNUAL GENERAL MEETING 2002

Officers' reports at the Annual General Meeting on 9 May at Napier University, Edinburgh were generally upbeat, reflecting a healthy year for the Scottish Plastics and Rubber Asociation. Membership continues to increase, Corporate Membership (introduced in 2001) is progressing, the financial situation is sound, attendance at a varied programme of meetings has been good, the Newsletter and website continue to keep members and non-members informed and the SPRA has been involved in a number of collaborative ventures on behalf of the members.

Affiliate Membership of the British Plastics Federation has opened up new opportunities for Corporate Member companies and the SPRA is now represented on the Board of the Plastics and Rubber Division of the Institute of Materials and on the advisory board for the Faraday Plastics Partnership. The SPRA has collaborated with the Polymer NTO in establishing an Employers Learning Network, undertaking a survey of Skills Needs for the Polymer Processing Industry in Scotland and mounting a successful seminar in April on "Improving Profitability in the Global Market. The next step is to ensure that the SPRA's voice is heard in the process to establish the new Sector Skills Council for the UK polymer industry. The last 12 months have seen some major downturns for the polymer sector in Scotland with the disappearance of some companies but other parts of the sector have been performing well. As a result of the adverse trading conditions, numbers were down at the otherwise successful annual SPRA Dinner Dance in March. The uptake of academic courses for polymers remains low in Scotland and this should be of concern to the industry for its future. In his President's Report, Hugh Smith warned the industry:

We must recognise however that to participate in decision making or to have any real influence on policy we will need to demonstrate that SPRA is truly representative of the Scottish Polymer Industry. To achieve this it may be necessary to develop a twin track approach serving the needs of both our individual members and the commercial interests of a greatly expanded Corporate Membership.

Companies can help the SPRA to achieve this by signing up as a Corporate Member now.

CORPORATE MEMBERSHIP

With the impending introduction of Sector Skills Councils, which will be led and managed by employers (News March 2002 and Seminar Report), it is increasingly important that the Scottish Polymer Industry has a strong voice to play its part in influencing the mechanism for addressing skills needs. SPRA Corporate Members are likely to provide the necessary Executive Forum for the proposed SSC while the Employers Learning Network will act as the discussion group to raise issues.

It is vital that companies have representation in both these groups. If your company has not already signed up then act now.

Each company receives a Certificate and now has its own web page on this website, with appropriate contact details and weblinks to its own web site. For further details of the benefits of Corporate Membership see Corporate Membership or contact Sheena Geddes, Membership Secretary

News from the

Scottish Plastics and Rubber Association

September 2002

Features in this issue: Polymer Study Tour 2002 Conducting Polymers Sustainable Waste Management Waste Minimisation Community Recycling

POLYMER STUDY TOUR 2002

31 teachers from all over the UK gathered at Napier University in Edinburgh for the annual Polymer Study Tour from 23 - 26 June 2002. The action packed 4 days started off on the Sunday afternoon with a presentation on the Plastics Industry by David Oxley, followed by Careers in the Polymer Industry by Samantha Rye (Polymer NTO). After dinner the programme continued with the Rocket Car Race, as 8 teams of secondary school teachers used their combined skills in Science, Design and Technology to design and build a race vehicle from a 2 litre PET bottle, a few injection moulded plastic wheels, drinking straws and vacuum formings. The winner "Purple Whippet" made a very fast out and back run in just 87 seconds, with just one stop to refill the car using the bicycle pump.

Monday morning was taken up with lectures and demonstrations on the structure, properties and applications of polymers and then the delegates were let loose in the laboratories. They stretched, bent and smashed samples of polymers in the mechanical testing laboratory. In the polymer workshop they: compounded their own rubber mix and moulded it into coasters; extruded; injection moulded; vacuum formed and RF welded plastics. A great time was had by all and they did not go away empty handed. That evening was the SPRA technical meeting which provided an opportunity for the teachers to meet with a range of SPRA members from the industry.

Colin Hindle, organiser of the Polymer Study Tour, addressing the teachers

The lecture on Conducting Polymers for Electronic and Electro-Optical Applications by Prof Janos Hajto (Napier University) provided a thought provoking insight into the huge conductivity range of currently available polymer materials and their applications and potential uses in displays. Tuesday was devoted to visits to local industry with minibuses being used to ferry the members around the various companies. First on the tour was a visit to Carron Phoenix where Hugh Dennis gave an introduction to the company including its history as well as a description of the manufacturing process. This was followed by guided tours of the composite acrylic sink

manufacturing facility. En-route to Livingston for lunch at SAMC, the party seemed to get a little lost and somehow ended up at the Falkirk Wheel (well worth a return visit sometime). The afternoon was filled with visits to Bausch & Lomb to see injection moulding and contact lens manufacture, and Formould High Pressure Plastics to view vacuum and pressure forming. The course dinner that evening was held at the Craighouse Campus of Napier University, with Alan Griffiths, the well known Plastician, speaking on behalf of the Worshipful Company of Horners, the main supporters of the Polymer Study Tours.

Colin Hindle, teachers and Alan Griffiths (left) at the Course Dinner

POLYMER STUDY TOUR 2002

The final day was again at Napier University's Merchiston Site and started with a session on Plastics Identification and demonstrations of Freelight displays. This was followed by a series of excellent presentations by: Colin Williamson on the History of Plastics; John Sale on Plastics and the Environment; John Wilcox on the IoM Industrial Affiliates Scheme.

On behalf of all the teachers I would like to thank the Worshipful Company of Horners and all the other sponsors (including of course the SPRA) for their generous financial support of this years Polymer Study Tour. I would also like to thank the companies and individuals that gave so willingly of their time in accommodating the industrial visits. The feedback so far has been very positive and I already have a few ideas of how we can improve and I am looking forward to an even better tour next year.

Colin Hindle

(SPRA Academic Liaison Officer and Organiser/Tutor of the Polymer Study Tour)

0131 455 2622 C.Hindle@napier.ac.uk

CONDUCTING POLYMERS FOR ELECTRONICS AND OPTO-ELECTRONICS APPLICATIONS

SPRA members were joined by teachers from the Polymer Study Tour on Monday 24 June for a talk by Prof Janos Hajto of Napier University on the exciting developments involving polymers in the fields of electronics and opto-electronics. Most polymers are excellent insulators but electrical conductivity can be increased towards semi-conductivity and even metal conductivity by a variety of techniques.

Conjugated chain structures can be produced by controlled synthesis (polyacetylene, polyananline) or by pyrolysis of conventional polymers such as polyacrylonitrile. Conductivity can be further enhanced by adding dopants (either inorganic or metallic) to match doped silicon or even metals and graphite. A second approach is to produce conventional polymers filled to a high level with metal particles, leading to conductive adhesives capable of replacing lead solders. Janos demonstrated how these electroactive polymer systems can be used to create p-n diodes, p-n-p transistors and p-n light emitting diodes (PLEDs). The PLEDs have the potential to produce full-colour, all-polymer display systems in the form of flexible panels.

Finally, Janos fascinated the audience with a demonstration of display systems pioneered by Freelight Systems, a spin-off company arising from research work carried out by Prof Hajto and Colin Hindle at Napier University. The principle is to produce transparent polymers containing fluorescent dyes, in a variety of geometrical forms including fibres, so that ambient light is collected and emitted in a narrow band as a form of amplification.

The unique features of Freelight displays are:

no electrical power system very high efficiency full colour range operates outdoors in sunlight display sizes from mobile phones to sports stadia high volume, low cost manufacture.

Prof Janos Hajto, School of Engineering Napier University, Edinburgh

0131 455 2288

www.napierengineering.org.uk

j.hajto@napier.ac.uk

SUSTAINABLE WASTE MANAGEMENT

At the Sustainable Waste Management Conference in Aberdeen on 7 June, the recurring theme was implementation of the maxim advocated by SEPA: REDUCE - REUSE - RECYCLE. Under the heading of "recycle" there is a growing acceptance of the role of composting and energy-from-waste, the former seen as the answer to impending legislation, restricting the amount of organic waste sent to landfill. This has also opened up an opportunity for biodegradable plastics. Mater-Bi from Novamont in Italy is thermoplastic material, suitable for conversion into film, mouldings and foam. It consists mainly of starch (from corn, wheat or potatoes) modified by a linear polyester and vegetable oil to achieve the desired mechanical properties and processability and is 100% biodegradable. It is argued that Mater-Bi is an environmentally friendly option compared to traditional thermoplastics in packaging but it is expensive and there is much debate in the literature about life cycle analysis data and impact on the environment.

Polargruppen of Norway and Bio Bags (Scotland) showed that bags from Mater-Bi are not only 100% compostable but their high water vapour permeability has the potential to reduce the water content of kitchen food waste by up to 20%, thereby saving on collection fuel charges.

The aeration also helps to reduce smells. Caledonian Industries demonstrated a packaging foam produced from

Mater-Bi, which is completely water soluble and biodegradable.

The Biobags have played their part in Stavanger in Norway, where, in only 3 years, the treatment of domestic waste has been transformed, vastly reducing landfill and increasing composting and energy recovery. The landfill reduction target for 2010 has already been achieved. Materials recovery is split into 13 streams, with high recovery rates for paper, glass and metals (all over 50%) but only 14% for plastics packaging.

Waste treatment in Stavanger, Norway, in 2000 and 2003

Similar targets have been achieved in Italy, using a scheme based on separation at source in the home. To ensure correct separation the council insists that all waste streams must be in transparent plastic bags. Area Waste Plans being published across Scotland do not anticipate reaching the waste management targets as quickly as Norway and Italy but several campaigns are being mounted to make the general public more aware. Despite many examples of waste minimisation in packaging, Municipal Solid Waste is estimated to increase at a rate of 1.5% per annum. A 3 year project in a small community (50 households) in rural Aberdeenshire, showed that, after introduction to composting and waste separation, residual waste reduced in the first year but levelled out thereafter.

The conference also heard how business and commerce in the North East has responded to waste minimisation policies but, at this stage there appear to be no plans to integrate industrial waste with municipal waste.

Novamont Polargruppen BioBags (Scotland) Caledonian Industries

www.novamont.com www.polargruppen.com www.biobags.co.uk www.caledonian-group.co.uk

WASTE MINIMISATION

At a meeting on Waste Minimisation, on 25 July at Agilent Technologies in S Queensferry, organised by the Business and Environment Network, Jane Richardson of Electronics Scotland explained the raft of legislation, due to be implemented over the next few years, that will have a direct effect on the electronics industry.

In the Waste Electrical and Electronic Equipment (WEEE) legislation, to come into force in January 2004, the producer is responsible for meeting the recovery and re-use targets (90% and 75% respectively for domestic appliances). A producer is defined as a manufacturer that sells, or resells, under its own brand name. The electronics industry still has to clarify a number of issues: investment necessary to comply with legislation; interpretation of legislation; increased expertise; increasing awareness on compliance issues. In addition to the WEEE legislation, manufacturers should be aware of the European Waste Catalogue which identifies 20 categories of waste and covers restrictions relating to hazardous waste. Moves to lead-free solders could cause some problems in recycling smelters with options such as tin/antimony solders. Flame retarders in printed circuit boards are also likely to cause problems. Concern was expressed by recyclers at the meeting that, at the moment, there is insufficient interest or attention given to recycling plastics from electrical and electronics equipment.

Business & Environment Network (Scotland)

0131 477 7000 BEN@ecce.org www.business-environment-network.org.uk

Electronics Scotland

0131 550 3774 jane@electronics-scotland.com www.electronics-scotland.com

COMMUNITY RECYCLING

At the Community Recycling Network Seminar on 9 August in Dundee, a series of speakers, representing different materials in the waste stream, outlined current positions on recycling and how community groups could benefit from contributing to waste management systems. The paper industry in the UK is suffering from lack of investment in paper recycling (no PRN funding being available for non-packaging paper waste). It is easier to export waste paper for recycling (even to China) and the UK is not fully utilising the "polluter pays" principle. Smith Anderson in Fife have pioneered a recycling system for office waste paper, offering complete security during collection, shredding, de-inking and repulping. Aluminium, steel and glass recycling systems are well organised and make full use of PRN money. Publicity and education are strong, prices for sorted waste are stable and community groups can participate in a

variety of schemes.

When it comes to recycling plastics from the domestic waste stream, only bottles have proved commercially viable. Stuart Foster (RECOUP) attributed the success of plastic bottle recycling schemes to the facts that they constitute a significant proportion (40%) of plastics in domestic waste, the bottles are reasonably clean and there are just two main types of plastics (PET and HDPE) to be segregated. Collection schemes for plastics bottles are on the increase throughout the UK and the cost of generating PET recyclate is significantly lower than virgin prices. Manual sorting is still a substantial cost but machines are now available for automated segregation, including sorting by colour.

Aladdin automated plastic bottle sorting machine (4 - 6 tonne per hour) from MSS Inc

There is still reluctance in some local authorities to introduce plastic bottle recycling, the main reason given as "insufficient funding" although this may change when the Area Waste Plans for Scotland are implemented.

Geoff Wright, from a not-for-profit organisation with the intriguing name of Urban Mines, called for a shift of thinking from considering waste as a problem to viewing it as a resource and a means of job creation. He revealed plans for a Sustainable Growth Park, which will have road rail and canal links, a civic waste recycling unit with properly designed parking bays, a Waste Materials Recycling Facility (MRF) and units for companies recycling waste streams into

products. Jim Baird of Remade (Scotland) sees a role for consortia (initially of local authorities but later extending to the private/community sectors) to take advantage of economies of scale, to give better and more stable prices, to reduce negotiating time and strengthen partnerships. There would of course be obligations for tonnages, spot prices would be sacrificed and there would be less local decision making. There would have to be investment in collection and a stable supply of quality recyclate would have to be established.

Recycling Advisory Group for Scotland (RAGS)

Tel: 0131 226 6666 E-mail: info@rags.org.uk Website: www.rags.org.uk

RECOUP: Stuart Foster Tel: 01733 390 021

E-mail: stuart.foster@recoup.org Website: www.recoup.org

Urban Mines Tel: 01274 699 406 E-mail: james.horn@urbanmines.org.uk Website: www.urbanmines.org.uk

Remade Scotland Tel: 0141 582 0450 E-mail: remade@gcal.ac.uk Website: www.remade.org.uk

News from the

Scottish Plastics and Rubber Association

December 2002

Features in this issue: Innovations in Processing Rapid Prototyping Waste Electrical Equipment Polycarbonate Recyclate Impact Laboratories Academic Report

Interplas 2002 Overseas Competition R&D Funding Roadmap Congratulations Student Placements

INNOVATIONS IN PLASTICS PROCESSING

The SPRA meeting, "Innovations in Plastics Processing", sponsored by Krauss-Maffei UK, a founder Corporate Member, provided a varied programme, covering

polyurethane processing, electric injection moulding machines, multicomponent moulding and hot runner valve gates.

Gary Coleman (Krauss Maffei) outlined recent developments in reaction processing, with specific reference to mixing heads for long fibre reinforced reaction injection moulding (RRIM) and clear coat moulding (CCM) in which a substrate is sandwiched between a clear PU coating, the main applications being automotive interiors.

Reaction Injection Moulding (RIM)

mixing head with glass roving cutting unit

Andrew Armstrong (Krauss Maffei) covered electric injection moulding machines and multicomponent moulding. The ELTEC series continues the characteristic 2-platen KM configuration. The opening/closing cycle is controlled by 2-thread ball spindles, which also act as tie-bars, operated by a chain drive, which makes the clamp unit ideal for clean room moulding. Final clamping is achieved using a small volume hydraulic ram. Two DC motors power the injection unit. One motor controls injection while both motors are engaged for plasticisation, back pressure being achieved by slowing down the injection motor. The main advantages of the ELTEC range compared to hydraulic machines are: greater precision and repeatability, lower energy consumption, lower noise levels, less cooling water and clean room operation.

Eltec: electric injection moulding machine

Electric machines are expected to grow to 50% of the market in 10 years time The current capital cost premium of 25% over comparable hydraulic machines is expected to narrow with further developments in electric motors and control systems. Krauss Maffei have been involved in multicomponent moulding

machines for almost 40 years. Current models, with up to four components, are available in a range of configurations using conventional units. Most recent development has occurred in the mould area. Non-rotating mould design uses slide retraction, core-back movement and transfer from cavity to cavity. Rotating index designs have a central shaft protruding through the back of the moving platen, capable of rotating +/- 180o, to index mouldings on cores from one cavity to the second, for overmoulding with the second material. A swivel plate turntable has been developed to give multi component stack mould capability which can greatly increase the output of components in comparison to a standard rotating method. The swivel plate is integrated into the machine bed on a vertical axis with the injection units positioned at either end of the clamp unit. This method of moulding can increase the volume output for a given size of machine whilst maintaining an optimum clamp force. i.e using as small a machine as possible – no or limited tool size constraints. Typical applications include hard/soft effects for aesthetic appeal, mechanical hinges, optical lenses and built in seals.

Indexing mould design for 2-component moulding

2-component moulding

Jim Scales (Thermoplay UK) explained the increasing use of valve gates with hot runner systems to give cleaner gates on closures and medical products, faster filling with large shot weights, elimination of drool in foam moulding and reduced gate expansion with TPEs. In large mouldings sequential control of valve gates is used to control filling and minimise flow lines and weld lines.

Krauss Maffei (UK) Ltd tel: 01925 644 100 www.kraussmaffei.co.uk

gary.coleman@kraussmaffei.co.uk andrew.armstrong@kraussmaffei.co.uk

Thermoplay UK Ltd tel: 01268 415 805 www.thermoplay.co.uk

thermoplay@thermoplay.co.uk

RAPID PROTOTYPING TECHNOLOGIES

At the November meeting at SAMC in Livingston, Charles Thompson, from Arrk Product Development Group Ltd, the largest prototyping bureau in the world, reviewed the latest developments in helping companies get their products to the market more quickly.

Stereolithography (SLA) gives epoxide models direct from CAD solid model files using a laser technique with x-y control to cure successive layers of resin in a bath. In Selective Laser Sintering (SLS) a laser fuses layers of thermoplastic powder (Arrk use polystyrene or glass-filled nylon) to produce a more robust model but it is less repeatable than SLA and accuracy is not as good.

SLA model

Fused Deposition Modelling (FDM) uses molten filaments of extruded thermoplastics (usually ABS, polycarbonate or wax) to build up models with reasonable accuracy but it is a slower process. In (LOM) Laminated Object Modelling the laser fuses together layers of paper or thermoplastics sheets. Tolerances are poorer than SLA and SLS, detail is less and the models are subject to warpage. Desk Top Modellers, essentially 3-D printers, use starch or plaster based materials. With recent developments in CNC machining, direct machining of models, in a variety of materials, to give high accuracy and repeatability, is becoming more competitive, although there are limitations in geometry.

SLS model

Vacuum Casting

For multiple prototypes, Arrk use Vacuum Casting in polyurethane resins, from a silicone rubber mould of a master produced by any of the primary techniques. However production is slow and labour intensive, with only 4-5 castings per day. For large prototypes Arrk use Reaction Injection Moulding (RIM).

To produce metal prototypes, Arrk can offer Express Casting (8-10 days), a vacuum casting process using a sacrificial SLS master in polystyrene, Quick Casting (3 weeks), based on the lost wax process from a hollow SLA master and Rapid Plaster Moulding(3-4 weeks), based on conventional pattern-making techniques, via SLA or SLS models, rubber moulds and dental plaster. For the production of Rapid Tooling (for rapid prototypes or as a bridge to production tooling) Arrk prefer to work with aluminium which is capable of good detailed finishes and is capable of over 100,000 shots. Cast tools using CAD derived models followed by sintering and metal impregnation, are less robust and give problems of porosity and cracking. Aluminium tools can be produced in 3-6 weeks compared to 5-9 weeks for conventional steel tooling.

Charles Thompson (Arrk) [left] in discussion with Mike Barker (Napier Univ ) [3rd left] and Kevin Steele (RDM Centre) [right]

Arrk Product Development Group Ltd

Tel: 01642 769930 E-mail: projects@arrkeurope.com Website: www.arrkeurope.com

WASTE ELECTRICAL AND ELECTRONIC EQUIPMENT DIRECTIVE

At the WEEE Seminar/Workshop in Glasgow on 01 November, organised by SEPA, almost 100 representatives of a broad cross-section of public and private organisations agreed with the aims and rationale for targeting Waste Electrical and Electronic Equipment and accepted the concept of Producer Responsibility in making the Directive work but a number of grey areas emerged. Legislation is expected in its final form in March 2003, giving member states 18 months to implement the Directive. Some ambitious targets have been set, 80% recovery and 75% recycling.

Aims of the WEEE directive:

1. to minimise waste from end-of-life electrical and electronic equipment

2.

to set measures for re-use, recycling and other forms of recovery of brown and white goods electronic and electrical end-of-life equipment

3.

to minimise the risks and impacts associated with using hazardous substances in the production, treatment and disposal of equipment

Much of the debate at the Seminar centred on methods of waste collection and systems for funding and monitoring the process. Most favoured a collection system based on bring-back schemes operated by retailers rather than by local authorities. It is understood that retailers oppose this because they claim they are not qualified to handle hazardous waste. A key point from the Directive is that equipment should be collected with minimum damage. A deposit/refund system is a possible alternative. There was minimal support for a scheme similar to the complex PRN (Packaging Waste Recovery Notes) devised for recovery and recycling of packaging waste. It is claimed that PRNs do not provide an incentive for collecting waste and do not appear to be contributing to the funding of the required infrastructure to facilitate recycling. The most likely alternative is an advance disposal/recovery fee imposed at the point of sale and made visible to the consumer. Grey areas still requiring more thought include responsibility for historical waste and for orphan products, where the original producer is no longer in business.

One of the aims in Scotland is to deal with the waste locally. Several recovery/recycling firms are in place, and appropriately licensed, to deal with electrical and electronics waste. At the moment these companies are operating well under capacity and recycling only 4% of the waste. In two years time that figure will have to rise towards 80%. At that stage recyclers will be handling up to 10000 tonnes per annum of plastics arising from WEEE. The question being asked is "How does the plastics processing sector intend responding to this challenge?" This is in line with the changing attitude to waste as a resource rather than as a problem. Waste management should be seen as an opportunity for innovation and job creation. For example, the implementation of WEEE Directive is aimed at encouraging designers to be more sensitive to environmental issues through innovative design solutions.

Could the range of plastics used in electrical and electronic equipment be narrowed to minimise segregation problems? Could products be designed for easier disassembly and re-use of components? Would standardisation of components help?

In the workshops there was a special plea to consider plastics waste. If the industry is unable or unwilling to increase the use of recyclate then alternative means of disposal must be considered, eg feedstock recycling by pyrolysis or energy from waste. Automated segregation technology is expensive but may hold the key for producing recyclate of an acceptable specification.

The SEPA maxim "No option but change" could be equally applied to the plastics processing sector's attitude towards accepting recycled plastics from post-consumer waste. As well as the 10000 tpa arising from WEEE, SEPA are estimating up to 450000 tpa of plastics waste being collected in Scotland by Local Authorities under the new Area Waste Plans.

For details of the WEEE legislation, visit: www.letsrecycle.com

POLYCARBONATE RECYCLATE

The SPRA technical meeting programme for 2002-2003 opened on 24 September with a presentation from John Gardiner, Sytek Polymers, co-sponsored by Hardie Polymers, entitled Costdown Solutions with Engineering Polymers. Sytek, technical compounders, can offer costdown opportunities with industrial and recycled grades of polycarbonate and PC/ABS. Polycarbonate that is off-specification for colour can be re-coloured to suit the customer, with significant cost savings compared to the prime equivalent.

John also outlined the changes that will come into effect in 2005 as a result of the WEEE Directive. Polycarbonate and PC/ABS, recovered from electrical and electronic equipment, is being compounded by Sytek to appropriate technical specification (strength, impact, colour, processability), again with considerable cost saving. Even now Sytek can offer long term supply of quantities from 25 kg to full truck loads of prime, off-spec and recycled material. Colour matches can be prepared in 5 days and production samples (25 kg) in 10 working days.

Fergus Hardie with Hardie Polymers team members, Sue Woodcock and Isobel Ferguson

John Gardiner (Sytek Polymers) in discussion with Mike Barker (Napier University)

Sytek Polymers Ltd

Tel: 01453 751 555 E-mail: sales@polycarbonate.co.uk Website: www.polycarbonate.co.uk

Hardie Polymers Ltd

Tel: 0141 942 3330 E-mail: sales@hardie-polymers.co.uk Website: www.hardie-polymers.co.uk

IMPACT LABORATORIES

The newly formed Impact Laboratories in Grangemouth, a spin out business established on 1st October 2002 by 5 former BP Chemicals staff, aims to provide specialist testing and consultancy services in material, pipe and container testing for product certification and industry approval.

The Container Testing Laboratory is accredited to ISO 17025 for testing plastic drums, jerry cans and composite containers. The Pipe Testing Laboratory handles hydrostatic pressure testing of pipe (50 - 180 mm dia) to ISO 1167 between temperatures of 20oC and 95oC. The Material Testing Laboratory provides a routine test facility covering tensile/flexural behaviour, impact fracture, slow crack growth, fatigue and creep. Impact Laboratories also has access to, and experience in, microscopy, spectroscopy, calorimetry and rheology.

Managing Director, Les Rose (l) with the Impact Laboratories team Les Rose, Managing Director, predicted "We intend offering a

consultancy service calling on an in-depth understanding of material product development gained from a wide experience on foams, wire and cable, film, pipe, container and oriented structures. Our aim is to shortcut your time to market for product development."

Impact Laboratories Limited, PO Box 21, Bo'ness Road, Grangemouth, FK3 9XH

Tel: 01324 489 182 Fax: 01324 489 633

info@impact-labs.com www.impact-labs.com

ACADEMIC LIAISON OFFICER REPORT

Against a background of increasing interest in engineering courses at Napier University, enrolments for the BEng Polymer Engineering programme remain steady but low. The programme is quite international with students from India and Finland joining those from France and Scotland. From Easter 2003 the 3rd year students will be looking for 6 month placements in industry, hopefully with a significant number going into companies in Scotland. This year also sees a significant change to the teaching of materials and manufacturing on a wide range of engineering and design programmes at Napier University, all sharing common modules in years 2 & 3 ( 50% polymer content). When these students go out on industrial placement around Easter time, they will be ready and able to make a real contribution to any company with an interest in plastics or rubber. With a total of about 90 students on each module, the continued provision of polymer materials and processing at Napier University is assured. The summer period has seen very significant changes to the Polymer Processing Workshop with the installation of the new Davis-Standard pipe and profile extrusion line and also the installation of a Bekum extrusion blow moulding machine and Brabender Plasticorder, both generously provided by BP when Applied Technology moved to Belgium. In order to accommodate these new and newer pieces of equipment there has been a clear out of older equipment. The Banbury BR internal mixer and one of the 2-roll mills were victims of this purge. A basic rubber compounding and moulding capability has been retained with one 2-roll mill and compression presses.

The BSc Applied Chemistry programme, with its specialism in polymer science and technology, is now in the final stages of what has been a very full and useful life. Interest in the part-time courses, HNC Polymer Technology and MSc Plastics Moulding Technology, has foundered because of lack of company support and these two course have not run in the last two years. It is still hoped that the MSc Plastics Moulding Technology can be revived in October 2003 and there is growing interest in it from the EU, India, China, and the Far East. The picture at other UK centres is even more depressing with the pace of downsizing and closure of polymer departments increasing. At a local level, the HNC Injection Moulding course at Bell College has no first year students this session. If this course closes there will be no provision in polymers at Certificate or Higher Certificate level in academic centres in Scotland for the first time for half a century. The earlier "use it, or lose it!" message seems to have fallen on deaf ears.

Colin Hindle SPRA Academic Liaison Officer

0131 455 2622 c.hindle@napier.ac.uk www.napier.ac.uk

INTERPLAS 2002

SPRA party arriving in Birmingham

25 intrepid travellers (9 SPRA members, 1 teacher and 15 students) set forth from Edinburgh at midnight on 30 September, on a coach normally reserved for the Scotland Rugby team, and arrived at the SECC in Birmingham at 6.30 am. Revived by some breakfast the marauding party started the long trek round the Interplas 2002 exhibition at 9.30. Regular Interplas visitors found the exhibition smaller than in previous years, with not much new to see. The machine hall did offer some excitement, with advances in automation, more electric injection moulding machines

and specialised techniques of multi-component moulding and micro-moulding. The ancillary processes and services exhibitors had some interesting techniques on display but there was not much to see on the materials suppliers stands. Scottish industry was represented by Balmoral Tanks, Silberline, and VTS Royalite while Albyn had a display on the BPF stand. Although exhibitors were disappointed by the attendance some claimed that the quality of the enquiries had improved. Mounting the coach at 6pm the SPRA party were still in good mood, comparing trophies, but fatigue quickly set in long before the coach reached Edinburgh. The parting comment from Colin Hindle, that he would see the students at his 9 am lecture, proved the final straw.

THREAT OF OVERSEAS COMPETITION

The main topic for discussion at the Scottish Polymer Employer Learning Network meeting at the Westerwood Hotel in Cumbernauld on 24 October 2002, was how companies are tackling the threat of overseas competition.

For companies, from diverse sectors of the plastics and rubber manufacturing industry, the main threats come from low cost production in China and Eastern Europe, greatly influenced by significantly lower labour costs. Companies shared similar approaches to minimising the threat by concentrating on efficiency savings, switching production of price sensitive components to Eastern Europe, turning to more added value products and playing on strengths of design, development and marketing.

Efficiencies All companies had made efforts to reduce manufacturing costs through:

decreasing labour content of operations by introducing more automation;

reducing head count (different shift patterns, flexible part-time labour);

introducing upskilling (operators responsible for maintenance);

energy efficiency initiatives;

waste minimisation.

However it was agreed that such efficiencies had limited effect on manufacturing costs and there is an increasing trend of price dominated contracts being awarded to China and Eastern Europe where labour costs are less than 50% of the Scottish equivalent, and as low as 10% in some cases. A number of OEMs are now using reverse auctions (on the Internet). In one case a contract was placed at 30% of the current price.

Manufacture in Eastern Europe

Several companies have set up sister plants in the Czech Republic, Romania and Greece to capitalise on the lower labour costs and nearness to market for customers that are also setting up plants there. Although the main attractions are the low labour costs and the shorter response times, there are still problems of lower quality, unfamiliarity with high volume production and failure to meet deadlines but many overseas competitors are on a fast learning curve. Plants remaining in Scotland are increasingly being used for specialised products, products that are less price sensitive and for developing new lines and processes.

Innovation Accepting that price sensitive commodities will transfer to Eastern Europe and China, several companies have redirected their company ethos to concentrate on innovation and added value operations. By concentrating on design, product development, process innovation, marketing and sales, Scottish companies can still be competitive in a wide range of market sectors. Closer links are being formed with design houses and universities to capitalise on opportunities from innovation. However it was suggested that knowledge of polymeric materials and associated manufacturing processes in UK design houses is dangerously low. It is also recognised that the slow down in education and training in recent years and the trend of downsizing has resulted in employees with extensive knowledge and skills not being replaced.

Teamwork Some companies have spent time analysing the company aims and mode of operation. Keeping the total workforce informed of the company situation can result in better teamwork and more effective use of all resources, towards the goals of efficiency and innovation. Continuing education, particularly of mature staff, has resulted in significant cost savings and improvements.

Assistance To achieve the necessary change in philosophy and operation, companies can resort to a number of initiatives through governmental and other sources. Scottish Enterprise has experience of retraining staff in the electronics sector. The Scottish Manufacturing Steering Group (Scottish Executive) has a list of 52 initiatives intended to support manufacturing in Scotland. A current survey asks companies to list the 3 key actions that could be taken by the Scottish Executive to improve the situation. The Scottish Polymer Technology Network can help companies to source funding for a range of projects to develop materials, processes and products. The TCS programme for graduates was highly recommended and the Faraday Plastics Partnership focuses on assistance for R&D for longer- term projects.

If you are interested in joining the Scottish Polymer Employers Learning Network contact: Hugh Smith: tel: 01569 763 296; Hugh.Smith@Albyn-Int.com Gill Doyle: tel 01592 630 123; GillDoyle@aol.com

R&D FUNDING ROADMAP

Faraday Plastics Partnership has produced a roadmap to guide companies through the complex process of identifying possible sources of funding, to help the company to be more competitive. A brief summary is provided here but more information can be provided by contacting Faraday

www.faraday-plastics.com/fundmap_a.htm

SMART AWARDS

LINK

TCS

CASE STUDENTSHIPS

PARTNERS IN INNOVATION

WRAP

LTCS

CARBON TRUST

Funding grants to develop pre-production prototype or new product/process. SMART Micro Project: 50% funding for individuals or very small companies SMART Feasibilty Study: 75% funding for small companies SMART Development Projects: 30% funding for SMEs

50% funding for joint research projects between industry and academia.

40 - 60% funding for the employment of a high quality graduate for 2 years on a specific challenging project in an SME.

Sponsoring of PhD students on specific industrially based projects

50% funding for collaborative research into construction technologies

Waste and Resources Action Programme: 50 -100% grant for projects aimed at reducing landfill

Landfill Tax Credit Scheme: funding for Environmental Bodies for projects relating to sustainable waste management

Funding for projects aimed at development of new and emerging low carbon technologies

CONGRATULATIONS

Congratulation to SPRA member, Eric Christison (ST Microelectronics, Edinburgh) who graduated from Napier University with an MSc (with Distinction) from the part-time programme in Plastics Moulding Technology. Eric was also the winner of the GE Plastics ABS and Demag Hamilton prizes, for an excellent project on the application of Moldflow software to predict birefringence in injection moulded lenses.

STUDENT PLACEMENTS

Students on the 3rd year of the BEng Hons Polymer Engineering programme at Napier University in Edinburgh seek industrial placements for 24 weeks starting from end of March 2003, or soon after.

Studies so far have covered all aspects of engineering with particular emphasis on polymer materials, design, and polymer processing. Students will return to Napier University in October 2003 for the final (Honours) year, including a significant individual project which could be carried out in collaboration with the placement company.

A number of the students are from other EU countries and hence are bilingual.

Please contact:

Colin Hindle, School of Engineering, Napier University, Merchiston Site, 10 Colinton Road, Edinburgh, EH10 5DT, Scotland.

Tel. 0131 455 2622 Fax. 0131 455 2264 Mobile 07714 337 523 E-mail: c.hindle@napier.ac.uk

OVERSEAS STUDENT

Ricardo Goncalves, a Polymer Engineering graduate from Universidade do Minho, Portugal, is requesting a placement in a polymer processing company in Scotland. The training period, to develop his professional ability and to improve his language skills, will be supported financially through the Leonardo da Vinci Programme for six months but he may be interested in a longer placement. Ricardo has had recent experience at Queen's University, Belfast where he completed a project on "Measurement of Friction in Polymer Processing". Any company interested in providing a training placement should contact Ricardo direct.

Ricardo Goncalves E-mail: rffvg@hotmail.com