issue 04/2023

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Exclusive report from the Kunststoffe editorial team: recyclate processing, digitalization and a smart energy system.

Compounding system from Buss: the co-kneader Compeo 88–18 F with a screw diameter of 88 mm has a throughput range of up to 850 kg/h.

16:9

Exclusive report from the Kunststoffe editorial team: recyclate processing, digitalization and a smart energy system. 

Hardware and Software Solutions for Extrusion

Messe K-Kunststoffmesse

Schröder, Susanne

Energieeffizienz

Materialhandling

Extrusionsanlagen

Digitalisierung

Compoundieren

Perspectives for the Future

This year, the world’s leading trade show K has succeeded in presenting practical solutions for greater resource efficiency on a broad front. A first foray through the trade show grounds.

K 2022 gave numerous practical examples showing visitors how recyclates can be reliably processed with digital aids.

State-of-the-Art Injection Molding Solutions for Greater Resource Efficiency.

State-of-the-Art Injection Molding Solutions at K 2022

Spritzgießen

Doriat, Clemens, Dr.

Solar / PV

Schaumspritzgießen

Temperiertechnik

Mehrkomponenten-Spritzgießen

Condition Monitoring / Prozessüberwachung

Spritzgießwerkzeuge

Biokunststoffe

Handling, Handhabungstechnik

Elastomer-Spritzgießen

Oberflächentechnik

Industrie 4.0 für die Kunststoffverarbeitung

Spritzgießmaschinen

Kunststoff-Rezyklat

Silikonkautschuk

Kreislaufwirtschaft

It Can Be Done!

Bio-Fed’s booth will be dedicated to the topic of bioplastics in all their facets, and will be run jointly with Akro-Plastic, AF-Color and parent company K. D. Feddersen.

Bio-Fed‘s K trade fair presentation is dedicated to the topic of bioplastics in all its facets.

Compound

Kunststoffe, biobasiert

Polyethylen

Kunststoff Werkstoffe

Polypropylen

Kunststoffe, bioabbaubar

Organic – both Inside and Outside

Fraunhofer ICT has analyzed stripping agent-assisted and extractive extrusion processes.

Pilot plant for extractive extrusion at Fraunhofer ICT in Pfinztal, Germany.

Bereitstellung von Rezyklaten mit reduzierten Emissionen: Schleppmittelunterstützes Stripping und extraktives Extrusionsverfahren

Providing Recyclates with Reduced Emissions

Kunststoff-Recycling

Physical Recycling of Plastics

Compounder Mocom will focus chiefly on technical compounds for WiFi and radar applications as well as on fuel cell and battery technology.

Applications for the light-transmitting PC compounds with metallic effect include illuminated trim.

Elektromobilität

Compoundeure

Compound Innovations for Trade Show Debut

At K, Radici will present the Renycle product family. These engineering compounds have a variable proportion of mechanically recycled PA obtained from PIR and PCR.

Reducing weight and ensuring safety are the aims of compounds developed by Radici specifically for electromobility.

Polyamide

Technische Kunststoffe

More Comprehensive  Life Cycle Analysis

How the direct compounding opens up new potential to reduce CO2 footprint – also for smaller components thanks to a further development from KraussMaffei.

DCIM technology enables injection molding and compounding in a single heating process.

Efficiency Meets Sustainability: Systematically Reduce Costs and CO<sub>2</sub> Emissions

Extruder

Cost-Effective Direct Compounding for Medium-Sized Components

Kraiburg TPE’s latest thermoplastic elastomer (TPE) has been specially developed for consumer and industry applications and contains up to 40 % post-consumer recyclate (PCR). In accordance with standard ISO 14021, the manufacturer recycles materials that end consumers from households and the industry can no longer use for their intended purpose.

The latest solution from Kraiburg TPE makes a post-consumer recycling proportion of 40 % possible. The TPE is partly made from household waste. 

Thermoplastische Elastomere

TPE with a Post-Consumer Recycling Proportion of 40 Percent

In the second part of the series the digitalization applied in injection molding was presented with examples. The quality of the granulates used, produced in the upstream compounding process, is an important influencing factor via the viscosity. Can consistent granulate quality be achieved through the use of digitalization in compounding? Does comprehensive data recording bring with it further use cases, and what special attention must be paid to a continuous process? The Eastern Switzerland University of Applied Sciences presents the first results of internal projects.

Alex Ramsauer (left) and Prof. Daniel Schwendemann from IWK take a critical look at the data analysis.

Part 3 of the Series: Digitalization in Compounding

Every Unit Counts

Evonik is expanding its portfolio of polyamide 12 compounds for insulating electrical conductors with the product Vestamid LX9050 OR.

Busbars insulated with the new RAL 2003 signal orange colored material can be used at elevated operating temperatures up to 125 °C.

Additive

Improved Fire Protection for High-Voltage Batteries

With a newly developed process from Entex it was possible to compound an injection grade compound of PLA with a 50 % wood flour content.

The PLA compound with 50 % wood flour content was successfully produced on Entex’s planetary roller extruder

Compounding PLA Formulations with a 50 % Wood Flour Content, without Premixing

Kunststoff

Direct to Highly Filled Bioplastics

Compounder Mocom will be showcasing products made from 100  % post-consumer recycled materials (PCR) at the Fakuma.

Compounder Mocom will be showcasing products made from 100 % post-consumer recycled materials (PCR) at the Fakuma

Automotive

Messe Fakuma

Made Entirely from PCR

Lehvoss will be coming to Fakuma with compounds for lightweight construction applications, including those intended to serve as metal substitutes.

Lehvoss will be coming to Fakuma with compounds for lightweight construction applications

Faserverbundwerkstoffe

Replacing Metals with PPA Compounds

Based on interviews in industry, this article describes a common understanding of the most important use cases. The results capture the current direction in the plastics industry.

Part 1 of the Series: Use Cases Based on Strategic Priorities in Plastics Processing

Strategie und Organisation

Implementation of Industry 4.0 in Injection Molding and Compounding

The MRS multi-rotation system enables even the smallest particles to be homogeneously incorporated into polymer melts.

Evacuation in the MRS section: the MRS multi-rotation system removes from 3 to 250 l of water per hour from the polymer in less than 6 s

Cascade Extruder with Multiple Screw Devolatilization System for Compounding

Neither Shaken nor Stirred

To extend the range of polymer powders for selective laser sintering, Paderborn University in collaboration with the Maag Group has developed an extrusion line that can produce round particles with good flowability.

The extrusion line to manufacture powder for selective laser sintering of plastics is in the Paderborn University laboratory

Research Project to Manufacture Powder for Selective Laser Sintering of Plastics

Selektives Lasersintern von Kunststoff, Metall, Keramik

Additive Fertigung

Perfectly Round

Polymers distributor K. D. Feddersen will be presenting various new materials at the Fakuma trade-show which it will be sharing with other companies in the group.

M Vera bio-based compounds are also suitable for food contact

Wide Range of Materials at a Shared Booth

This time around, polymers distributor Albis will be focusing on sustainable products and will be presenting materials based on recycled products or renewable resources aimed at various industrial sectors.

Albis will be presenting materials based on recycled products or renewable resources

All Things Sustainable

Brüggemann and Grafe developed a color masterbatch for polyamides, which, even after 1000 hours’ service at 130 °C, still retain their warning effect without darkening.

Injection-molded and extruded polyamide components for E-mobility are typical applications for the color-stable and cost-effectively processable eOrange masterbatches jointly developed by Grafe and Brüggemann

Masterbatches

Orange Retains its Warning Effect

Bipolar plates are one of the key components of fuel cells and redox flow batteries. They consist of plastics compounds highly filled with electrically conductive materials. To save space, cut costs, and reduce weight, there is increasing demand for the production of thinner plates without compromising robustness and service life. This can be achieved using modified polymers. With a new technology, bipolar plate films based on these modified polymers can be processed as coils.

The modified polymers enable films to be processed  as coils

Modified Conductive Compounds Make It Possible to Manufacture Bipolar Plates from a Bipolar Film Coil

Brennstoffzelle

Brennstoffzellen

Folien

Ultrathin Bipolar Plates for Fuel Cells

The quality of final products can be increased by using measurement technology for monitoring production processes. Interest in it is increasing especially for compounding. There are various existing methods of non-destructive testing that can also be used inline in the manufacturing process. The different methods are suitable for different applications: an overview of the current capabilities and limitations of the various inline methods.

Fig. 2. Dependence of measurable ultrasonic amplitude (extinction coefficients) of filler content and the accompanying median size of chalk particles in plastics compounds: By using such databank-integrated calibration curves, both of these quality relevant features can be quantified inline by ultrasound

Inline Testing Methods for Monitoring Processes

Messtechnik

Mikrowellenmesstechnik

Kunststoffverarbeitung

Transparency in Compounding

Polymers can be protected against relevant microorganisms with a single antimicrobial product.

The antimicrobial protection of the new Sanitized product is permanently effective, even after weathering