The Processing Industry Closes the Recycling Loop 

Machine manufacturers and plant engineers of the processing sector focused on recycling at this year’s K trade fair. The numerous requirements for the recycling process are met with interesting and clever solutions.  

KUint_2016_12_Upcycling--From-Old-to-New-.pdf

2333111 SPE_Nachbericht K_Recycling_Adamy_EN

Extruder

Kunststoff-Aufbereitung

Dosierer

Compoundieren

Granulieren

Kunststoff-Recycling

Technyl Range Expanded with Heat-Resistant Polyamide 66 

With Technyl REDx, Solvay SA, Brussels, Belgium, has developed a polyamide 66 (PA66) with a "smart" self-reinforcing molecular structure. The heat-resistant material is claimed to be suitable for manufacturing highly demanding heat management systems, particularly in the automotive industry. It consists of a "smart" macromolecule, including patented self-reinforcement in the polymer chain that does not affect its molecular structure. This chemical configuration remains inactive during the injection molding of vehicle parts, and the material behaves like a free-flowing PA66. It is only at the elevated temperatures during vehicle use that the molecular structure is activated, leading to rapid crosslinking and increasing the mechanical properties well above their initial values, according to the manufacturer. 

The material can be processed at energy-saving mold temperatures of below 100 °C. According to the press release, aging tests for 3000 hours at 220 °C show a very high retention of properties and an increase in tensile strength of more than 50 % without affecting the elongation at break. 

2414773 TT_kurzbericht EN_Solvay

A small footprint, mobile on a rolling carriage, and just as suitable for industrial operation as for lab and test purposes: Dr. Boy GmbH & Co. KG, Neustadt-Fernthal, Germany, presented the Boy XXS with 63 kN clamping force at at K 2016. The new machine is now the smallest model in the manufacturer’s range. The energy-efficient servo drive of the electrical series is as much of a standard feature as the intuitive Procan Alpha machine control system. At 1.2 m width, 0.8 m depth and 1.3 m height (or 0.7 m without the optional carriage), the table-top machine is very compact. Weighing only 340 kg, the Boy XXS is also more lightweight for transportation than other machines. 

The new model does not use the piston plastication that is conventional for this machine size, but screw plastication operating on the "first-in, first-out" principle. For screw diameters from 8 to 18 mm, plastication volumes from 0.06 to 10.2 cm3 are possible. The platens are especially optimized for the micro-molds of many standards manufacturers. The diagonal configuration of the two tie-bars provides easy access to the plastication unit, mold space and ejector. 

Boy also presented its LR 5 handling system at the K show in Düsseldorf, Germany. An intuitive operating concept takes care of the control of the robot’s three linear axes, and the movements of the gripper hand. The synchronization of the workflows of the injection molding machine and handling unit is integrated in the graphic sequence programming of the machine control system. The handling, which is conceived for the machine sizes Boy 35 E to 100 E is equipped with German-manufactured drive technology throughout. With its modular design, individual models with different travel distances are available. The rotational and pivotable gripper hand of the LR 5 is designed for a handling weight of up to 5 kg. 

2436712 TT_kurzbericht EN_Boy

Combining the Best of Two  Polymer Worlds 

Thermoformable Acrylic Resin Systems for Large-Scale Production  

Thermosets offer high mechanical performance and, thanks to their low initial viscosity, permit the efficient series manufacture of composite parts by resin transfer molding. The main advantage of thermoplastics is that they can be thermoformed, welded and recycled. These advantages are now combined in a newly developed thermoplastic acrylic resin system, which offers new possibilities for the production of fiber-reinforced composites with short cycle times. 

Dr.-Ing. David Becker; Gilles Francois; Virginia Bozsak; Prof. Dr.-Ing. Peter Mitschang 

1 Hildebrandt, K.; Mack, J.: Becker, D.; Mitschang, P.; Medina, L.: Potentiale neuer Matrixpolymere für die FKV-Bauteilfertigung. Lightweight Design 7 (2013) 2, pp.14–21 

2 Arnold, M.; Franz, H.; Bobertag, M.; Glück, J.; Cojutti, M.; Wahl, M.; Mitschang, P.: Kapazitive Messtechnik – Zur RTM-Prozessüberwachung. Leichtbau-Technologien im Automobilbau, Lightweight Design 1 (2013) , pp. 50–55 

3 Hümbert, M.; Becker, D.; Mitschang, P.; Andres, M.; Liebana, F.: Fusion Bonding of Thermoplastic Composites and Metals. JEC Composites Magazine, No 103 (2016), pp. 71–73 

4 Neitzel, M., Mitschang, P., Breuer, U.: Handbuch Verbundwerkstoffe: Werkstoffe, Verarbeitung, Anwendung. Carl Hanser Verlag GmbH Co KG (2014) 

KUint_2016_12_Combining-the-Best-of-Two--Polymer-Worlds.pdf

2028874 MGV_KK_IVW Kaiserslautern_Becker_EN

Thermoplaste

Harze

Verbundwerkstoffe / Werkstoffverbunde

Trends in Ultrasonic, Laser, Infrared, High Frequency Welding and in Lightweight Design 

This year again, visitors to the K 2016 trade show were presented with a wide range of solutions from joining technologies. Irrespective of the process, the trend is towards flexibility. Once again, the focus was on digitization and automation of the joining processes. 

KUint_2016_12_Quality-Welding.pdf

2272929 SPE_Nachbericht K_Fügetechnik_Facklam_EN

Verbindungstechnik

Ultraschallschweißen

Laserschweißen

Schraubtechnik

With Sigmasoft Virtual Molding, F. & G. Hachtel Manufactures Accurate Parts from the First Shot  

"Think of it like this: the clip is bent when it leaves the machine, and you can see it straightening as it cools", states Georg Schlöser. "And that is how we calculated it", he adds satisfied, since he analyzed the required shrinkage allowance with Sigmasoft, so that the mold could deliver dimensionally true parts from the first shot.  

Dr.-Ing. Silke Allert; Vanessa Schwittay, B.Sc. 

KUint_2016_12_Getting-Warpage-under-Control-.pdf

2315236 MGV_CD_Sigma_Schwittay_EN

Spritzgießsimulation

Spritzgießwerkzeuge

Spritzgießen

Temperiertechnik

Qualitätssicherung

Polyurethane World Becoming  More Sustainable 

Ecological as well as Economical Requirements as Targets 

That polyurethane can make a valuable contribution to the current trends of resource efficiency, lightweight design, sustainability and recycling that are prevalent in every industrial sector is demonstrated by the PU industry in the form of new solutions for increasingly demanding economical and ecological challenges. In this way, PU as a reactive material is confirming its great potential to be a long-term alternative to existing materials, and this not only because of its versatility. 

Florian Kessler, M.Sc.; Daniel Schneider, M.Sc. 

KUint_2016_12_Polyurethane-World-Becoming--More-Sustainable.pdf

2318807 SPE_Nachbericht K_PUR_Kessler_EN

Polyurethan

Faserverarbeitung

Schäumen / Reaktive Verarbeitung

Resin Transfer Molding

PUR-Schäummaschinen

Kunststoff-Rohre

Advances and Developments in Thermoplastic Polymers at K 2016 

Current materials and material concepts are reflecting what the plastics processing industry needs: complete solutions for significantly lighter vehicles, better materials for extreme application conditions across all industry sectors, a wider product range, and more additively manufactured plastics. 

KUint_2016_12_Megatrends-Drive-Material-Innovations.pdf

2320402 SPE_Nachbericht K_Werkstoffe_Warkotsch_EN

Kunststoff Werkstoffe

Polyamide

Polypropylen

Verbände, Institutionen, Messen

Injection Molding 4.0 – Visionary and Tried-and-Tested Solutions 

Industry 4.0 Comes to Injection Molding and True Innovations at K 2016 

Every three years, the showcase of plastics technology, the K fair, takes place, where one can deduce the current state of the industry. What is occupying the experts today, and what will still be flourishing in the future? The following article describes some of the development paths and trends. At the end of the day, there is a lot of tried-and-tested technology that is being continually refined and improved. There were also some innovative and visionary applications to be seen. 

KUint_2016_12_Injection-Molding-4-0--Visionary-and-Tried-and-Tested-Solutions.pdf

2329307 SPE_Nachbericht K_Spritzgießen_Jaroschek_EN

Automatisierungstechnik

Instandhaltung

Polyethylenterephthalat

Spritzgießmaschinen

Mehrfarben-Spritzgießmaschinen

Normalien und Heißkanaltechnik

Spritzgieß-Sonderverfahren

Mehrkomponenten-Spritzgießen

Spritzprägen

Folientechnik (IMD, IML, FIM, u.a.)

Hybrid-Spritzgießen (Metall / Kunststoff)

Montagetechnik

Oberflächentechnik

Optische Mess- und Prüftechnik

Machines from Wittmann Battenfeld Process a Water-Soluble Plastic in Mass Production 

Polyvinyl alcohol offers the outstanding attribute of solubility in water with simultaneous high resistance to most contact chemicals. The plastic has been little known until recently, primarily because it could only be processed into film, but manufacturing injection-molded parts from it was not possible. This changed with the solutions discovered by the Austro-Polish injection molding company Buzek Plastic, which developed in several evolutionary steps a mass production technology for making water-soluble, multi-chamber laundry detergent containers.  

KUint_2016_12_A-Material-Similar-to-Wallpaper-Paste.pdf

2325160 MGV_CD_Wittmann Battenfeld_Bauer_EN

Bildverarbeitung, Machine Vision

Industrie 4.0

Polyvinylalkohol

High-Performance Combined with Esthetics 

Arburg Breaks into the Large Machine Range 

One of the eye catchers at K 2016 was the Allrounder 1120 H hybrid injection molding machine in a new design and with a new control system. With the high-performance machine, Arburg GmbH + Co. KG, Lossburg, Germany, has significantly expanded the upper range of its portfolio. "The new machine size, with a 6500 kN toggle clamping unit is the result of a systematic expansion of our product portfolio," says Heinz Gaub, Managing Director Technology & Engineering at Arburg. The machine is claimed to combine the speed and precision of an electrical clamping unit with the power and dynamics of the hydraulic injection unit. It is also stated that the cast components are all bionically optimized so that the weight reduction can be achieved without losses in mechanical characteristics. According to Gaub, the dry running time is 2.4 s and the maximum opening stroke is 1050 mm. 

Besides the modern color scheme and contours, the sophisticated design is principally characterized by more features and better ergonomics. The practical extras that facilitate the set-up and work routines of the large machine include retractable steps to the clamping unit, service doors for the supply systems and integrated LED light strips indicating the operating status. 

The new Gestica control unit has a look and feel similar to smart mobile devices, including a glass front, a high-resolution full HD screen as well as industrial multitouch technology and one-click ergonomic hardware keys. The swivel operating panel is also height adjustable. The Gestica includes all the advantages of the former Selogica control system, but is easier and more intuitive to use. For example, the new "Easyslider" element allows precise control of movements during set-up, with a variable-color LED display. The speed is varied by swiping over a bar at the edge of the screen. The records of the Gestica and Selogica control systems are fully compatible, with no change in the hierarchical structural and graphical programming system. 

The exhibit demonstrated its effectiveness as part of an innovative turnkey solution. The folding step ladder that was molded in a family mold comprising eight separate parts and subsequently assembled in the cycle proved to be a highly sought-after product. It had been designed to suit the new Allrounder, especially for the K show by the Design Tech agency, which was also involved in the development of the machine. 

2436579 TT_kurzbericht EN_Arburg

A growing number of new generation blow molding units are interconnected and smart. In addition, interested parties are asking for a flexible and modular design. 

KUint_2016_12_Quality-Control-Included.pdf

2359880 SPE_Nachbericht K_Blasformen_Schäfer_EN

Blasformwerkzeuge

Extrusionsblasformen

New Insulation Materials and Research Projects Combine Functionality and Aesthetics  

60 years after the invention of the external thermal insulation composite system, insulation on building façades remains a crucial building block for boosting energy efficiency and improving the carbon footprint. Aside from the energy requirements, design aspects are also increasingly being incorporated into planning. 

wksb Zeitschrift für Wärmeschutz, Kälteschutz, Schallschutz, Brandschutz; 65/2011 and 66/2011 

http://www.energiesparaktion.de/ downloads/Kacheln/Energieeinsparung/Geschichte_Daemmung.pdf 

https://de.wikipedia.org/wiki/Fritz_Stastny 

http://www.hildundk.de/publikationen/sto_news_2015.pdf 

http://www.hildundk.de/project/ sanierung-abgeordnetenhaus- ismaningerstrasse/2/ 

http://www.hildundk.de/project/ forschungsprojekt-wdvs-modulation/2/ 

http://www.smarthoch3.de/demonstratoren/ 

KUint_2016_12_The-Envelope-Is-Important-.pdf

2360263 Werk_FG_IBK_Pfahl_EN

Produkt- / Formteildesign

High Quality Interior Components at Low Unit Cost 

DecoJect Process Combines In-Mold Graining with Injection Molding 

Decorative films are increasingly replacing painting in order to flexibly combine a high quality surface finish of the vehicle interior with small batch sizes and low unit costs. With DecoJect, systems integrator Engel presented the next development step in collaboration with partner companies at K 2016: the combination of injection molding with in-mold graining in a highly-automated roll-to-roll process. The film solution makes it easier to harmonize the vehicle interior when using different base materials. 

Dipl.-Ing. Wolfgang Kienzl; Dipl.-Ing. Michael Fischer MBA; Prof. Dr.-Ing. Georg Steinbichler; Steffen Plinke; Dipl.-Ing. Markus Kralicek 

KUint_2016_12_High-Quality-Interior-Components-at-Low-Unit-Cost.pdf

2368784 MGV_CD_Engel_Steinbichler_EN

Industrieroboter

An Eye for Details to Improve Efficiency 

The selection of extrusion products at the K 2016 trade fair ranged from new equipment concepts over flexible tool systems to software for equipment networking and process monitoring. 

KUint_2016_12_Greater-Extrusion-Flexibility-.pdf

2378599 SPE_Nachbericht K_Extrusion_Burgfeld_EN

Blasfolienextrusion

Extrusion

Werkstoffprüfung

First 100% Biodegradable Performance Shoe 

adidas has partnered with AMSilk for the first premium innovation footwear made using silk biopolymers. The adidas Futurecraft Biofabric prototype shoe features an upper made from 100% Biosteel fiber, a nature-based and completely biodegradable high-performance fiber, developed by the German biotech company AMSilk. 

The material offers a unique combination of properties that are crucial in performance, such as being 15% lighter in weight than conventional synthetic fibers as having the potential to be the strongest fully natural material available. In addition, Biosteel fiber also provides a far more sustainable offering, with it being 100% biodegradable in a fully natural process. This continues adidas’ journey of sustainable innovation – from a starting point of virgin plastics, to recycled plastics, to its <a href="https://www.kunststoffe.de/en/news/overview/artikel/2271647">partnership with Parley for the Oceans</a> and now a totally new frontier of investing in solutions that leverage science and nature as an integral part of innovation.

The shoe was unveiled at the renowned Biofabricate Conference in New York as adidas and AMSilk announce a partnership that will explore the use of Biosteel fiber in performance products on a larger scale. James Carnes , Vice President of Strategy Creation at adidas, said: "This concept represents premium innovation. By using Biosteel fiber in our products, we have achieved an unrivalled level of sustainability. We are moving beyond closed loop and into an infinite loop – or even no loop at all. This is a pioneering stride forward beyond sustainability into a new territory of bionic innovation.” Jens Klein , CEO of AMSilk, said: “The sports shoes which have been developed together with adidas are the first products worldwide with a high-performance material made of nature-identical silk biopolymers. With this development we are setting new standards regarding the functionality of renewable textiles.”

AMSilk GmbH is the world’s first industrial supplier of synthetic silk biopolymers and has its headquarters in Planegg near Munich, Germany. Sustainably produced using a patented biotechnological process, AMSilk high-performance biopolymers have the unique functional properties of the natural product they are based on. The organic high-performance material can be used in multiple ways, including in medical or technical products as well as cosmetic ingredients. 

2445945 Z_TT_Product_Futurecraft Biofabric_Adidas

Biokunststoffe

Six years after the initial launch of the ZSK Mc 18 twin screw extruder, which is characterized by its specific torque of 18 Nm/cm³, Coperion GmbH, Stuttgart, Germany, presents a revised compact version that has undergone a range of improvements designed to further simplify handling. The new compact version of the twin screw extruder is equipped with quick-release clamps for the simple, quick replacement of the feed hopper as well as the user-friendly CSpro control system.

Coperion has completely overhauled its ZS-EG side devolatilization. It now offers clearly improved features for fast and neat assembly and disassembly. The new design of the ZSK's connection barrel has been optimized for quick changing and allows all four mounting bolts to be simultaneously undone in a circular movement. What's more, the screw shafts can be completely loosened, cleaned, or changed in only a few moves. Cleaning and maintenance times are sharply reduced as a result. The new ZS-EG is fitted with radial shaft sealing rings. As a result, the lantern area remains visible. They additionally permit nitrogen purging in an explosive environment. Thanks to the new seals, there is no longer a vacuum in the gear lanterns, and the service life of the gear-side shaft seal is considerably greater. 

Coperion brought its patented feed enhancement technology (FET) for ZSK twin screw extruders to market some time ago, for a significantly enhanced feed performance when processing powdered bulk material. The technology involves equipping the feeding zone with a porous, gas permeable wall section, to which a vacuum is applied externally. Intermediate particle air is then sucked out of the powdered bulk material through this wall section. This compacting of the bulk material reliably improves the material intake capacity in the feeding section by a factor of two to three. The flow rate increases substantially while the compound quality remains high. Since its market launch, Coperion has successfully used the FET technology for the feeding zone of the ZSK twin screw extruder as well as for the ZS-B twin screw side feeder. It has been integrated into new machines and has also been retrofitted into existing compounding plants in close consultation with Coperion's process engineers. 

The ZSK 58 Mc 18 extruder that will be showcased at the K trade show is designed for all demanding compounding tasks. It is equipped with the user-friendly CSpro medium control system, which Coperion has been using in its ZSK high performance extruders since 2010. The control system comes with high-grade, standardized and pre-tested software, is fitted with the latest Siemens SPS-Generation S7-1500, and is connected via ProfiNet to the CPU (central processing unit) with compact ET200SP peripheral modules. Integration and data exchange in superordinated networks (ERP) takes place via the standardized OPC-DA and OPC-UA protocols. The control system is rounded off with additional complex software functions such as recipe management, order and material management, analysis of downtimes and the evaluation of historical values.

The CSpro medium enables the condition of the plant to be easily visualized via a web browser in the network with support for display of this information on smartphones and tablets. CSpro medium is ideally suited to the requirements of Industry 4.0. 

2415175 Z_TT_Product_ZSK Mc18 twin screw extruder_Coperion

At K 2016 in Düsseldorf, Netstal, Näfels, Switzerland, presentedaXos 8, the latest version of its innovative control technology, for the first time. The new version offers many new features and functions of aXos 8 that result in advantages for users in daily operation. They also offer complete flexibility with regard to process programming by application specialists. 

With a new and intuitive user interface in the form of a fold-out dashboard, access to the relevant process parameters and machine settings is simplified significantly, and the already outstanding aXos user experience is improved further. With a new component management and improved reference curves, the performance potential of Netstal injection molding machines is fully utilized. aXos 8 guarantees simple handling for daily operation while simultaneously providing expert users with the complete flexibility to develop sophisticated and complex applications. 

A redesigned user interface with individually customizable header for the display of the most important cycle information is a key new feature of aXos 8. "For the graphical illustration of expanded process data, the header can be expanded and turn into a full-screen dashboard. The directly adjustable parameters are displayed via separate tiles in a digital dashboard, which can be custom-arranged by users," said Adrian Marti , Netstal's head of controller development. In each case, the pre-set and actual values are displayed. Process data over time can be illustrated via progression charts. A color-coded status display of the individual tiles allows an optimal overview of current process information.

The newly designed component manager offers a graphical overview of the entire injection molding system and allows the easy and direct access to all installed components. The new display combines the pages for command and component parameterization. The processor can now select his preferred method of accessing the parameterization – either via the component manager or the context menu of the graphical process editor. 

The option of superimposing reference curves in the graphical display of the command parameterization significantly facilitates the monitoring of process parameters. The chronological sequence of each actual value can be saved as a reference. Saved reference curves can be superimposed and hidden individually. All reference curves are automatically saved in the data record. 

2334036 Z_TT_Product_aXos 8 machine controller_Netstal

Steuern, Regeln

New Composite Tube Manufacturing Process 

North Thin Ply Technology (NTPT), Renens, Switzerland, has launched a unique new composite tube manufacturing process. The patent pending process effects a unique fibre placement capability that has enabled the first real major technological development in golf shaft manufacturing since the mass adoption of graphite golf shafts in the 1980s. 

TPT Golf shafts are manufactured using NTPT's Thin Ply Technology lightweight prepreg plies in combination with the new manufacturing process. The result is a perfectly centered and near homogenous shaft giving golfers greater stability during their swing and a better feeling impact that imparts lower spin to the ball - resulting in higher yardage and a lower shot dispersion. The micro-structure of a thin ply laminate results in higher mechanical properties. Within a golf shaft, or any other tubular product, the use of thinner plies offers nearly unlimited options for fibre angles and fibre type combinations. NTPT's novel process ensures that each of the carbon plies are laid concentrically, resulting in a symmetrical shaft (or tube) with no spine, unlike the traditional table rolling production methods that have dominated the golf market until now. 

The process also enables a precise control over the ratio of longitudinal plies to off axis plies along the length of the shaft. The resulting uniformity of wall thickness and control of fibre alignment provides a smoothly changing flex profile exactly matching the specific design. 

NTPT's novel composite tube manufacturing process sees its first commercial application on the golf course but the overall potential of this innovative manufacturing technology is considerable. Automotive drive shafts, aircraft struts, windsurf masts, as well as other sports equipment shafts and frames are just a few example applications with the process being ideal for any tubular structures where weight, performance and cost are critical factors. 

2328378 Z_TT_Product_TPT Golf Shaft_North Thin Ply Technologies

Sabic, Sittard, Netherlands, introduces the next generation of LDPE foam grades that can reduce degassing time by 50%. The first product of a new generation of LDPE foam grades from Sabic has been designed to increase production efficiency at the foam manufacturer. The new Sabic LDPE “fast converting” foam grades reduce the time that semi-finished products need to be kept in storage, thanks to faster degassing of the blowing agent. They can therefore reduce the working capital of foam manufacturers drastically. 

Polymeric foams are widely used in areas that encompass building and construction, automotive, packaging, sports and leisure, and more. Trends in these industries are driven by consumers looking for solutions that are smarter, better and more sustainable, whilst at the same time reducing total costs. Foam and lightweight solutions are essential to respond to these trends: they enable a more efficient use of materials and energy and, at the same time, they can enhance properties. 

Sabic LDPE 2102FC is the first in a series of products that combine up to 50% savings in degassing time − reducing the foam manufacturer’s inventory − and an improvement in production efficiency of up to 5% through less production waste and better foam consistency. 

2333808 Z_TT_Product_Foam Grades_Sabic

Polyethylen

At K 2016 Royal DSM launched ForTii Ace next generation high performance polyamides. With this new polymer DSM is making a major move to substitution of die-cast metals and expensive high performance engineering thermoplastics like PEEK. 

Automotive OEMs are expected to take around 200 kg on average out of every car they make by 2025, in order to meet increasingly stringent CO 2 emission norms in major automotive markets around the world. DSM is convinced that ForTii Ace will have an important role in helping OEMs and their component and systems suppliers meet these CO 2 targets. Target applications include powertrain, transmission, chassis, and thermal management applications. At the same time, many industrial applications now incorporating die-cast designs will also benefit from the properties of ForTii Ace as a replacement material.

ForTii Ace has a glass transition temperature—the point at which amorphous areas of a material begin to lose their rigidity and hardness—of 160°C, which is significantly higher than other polyphthalamides (including existing ForTii grades) and at least 80°C higher than PA66. It also has higher resistance to various automotive oils and chemicals, even compared with PEEK. Most thermoplastics aimed at automotive die-cast metal replacement exhibit a significant drop in mechanical performance when operating at temperatures over 125°C, which is not the case for ForTii Ace, according to the manufacturer. With its high glass transition temperature and high crystallinity, the mechanical performance and the heat-aging performance of ForTii Ace are superior to rival polyphthalamides based on polyamides 6T, 9T and 10T. 

With their extreme chemical resistance as well as mechanical performance, some grades of ForTii Ace will even provide cost-effective alternatives to polyetheretherketone, PEEK, in selected applications. The ForTii Ace family will include grades with various types of fillers and reinforcements, including glass and carbon fibers at addition rates of up to 50%. 