CW March 2012

March 2012
thE latEst addItIvEs for pEt EuropEs MastErbatch lEadErs NEW trENds IN pEllEtIZErs NpE: What to sEE IN orlaNdo
IntroducIng
on the iPad and iPhone
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Having led the way with high-quality digital-only magazines for the global plastics industry, AMI is now also making its titles available free-ofcharge on the iPad and iPhone. The dedicated app for Compounding World magazine is now ready to download from Apples App Store on your mobile device, or from iTunes on your computer. Just search for AMI Plastics. Current and past copies are available free-of-charge and new issues will be added to the app as soon as theyre published. If you are using Apples latest iOS 5 operating system, then the magazines will appear in your Newsstand and new editions will be added automatically if you sign up for our free subscription. The Compounding World app is sponsored by Leistritz, a leading supplier of twin-screw extruders.
AndroId VErSIonS coMIng Soon: our technology partners are finalising apps for Android devices and these will be ready in the coming months watch this space for details.
CHECK OUT OUR OTHER FREE APPS: AMI has also launched free apps for its three other digital magazines Injection World, Pipe and Profile Extrusion and Film and Sheet Extrusion. Plus theres an additional AMI Conferences app featuring brochures for our forthcoming events. Simply search for AMI Plastics in the App Store or iTunes.
contents
04 Industry news
page 4
The latest industry news including Russian investments in nanocomposites, big deals in bioplastics, plus new owners for Maag and Citadel.
17 Europes leading masterbatch producers

AMI recently updated its report on Europes largest masterbatch makers. Carole Kluth reviews the leading players and recent industry changes.
page 17
25 New ways to promote the performance of PET

Lilli Sherman looks at new developments in additives designed to improve the appearance, recyclability, processing and performance of PET.
37 Cutting edge technology: advances in pelletizers

page 25
Jennifer Markarian examines innovations in strand and underwater pelletizers designed to improve this crucial step in the compounding process.
47 The compounders guide to NPE 2012

NPE is heading south to Florida this year. We preview the huge range of new compounding machinery, polymers and additives that will be on show in Orlando.
page 37
48 Compounding and recycling lines 54 Auxiliaries and components 58 Materials testing 62 Polymers and compounds 67 Additives 68 Colorants
page 47
72 Compounder of the month: Shantou Best 74 Dates for your diary
coming next issue

Anti-oxidants Materials handling Clarifiers Chinaplas and Plast previews Click here to make sure you get your copy
contact us
Applied Market Information Ltd AMI House, 45-47 Stokes Croft, Bristol, BS1 3QP, United Kingdom Tel:+44 (0)117 924 9442 Fax:+44 (0)117 989 2128 www.amiplastics.com Head of business publishing: Andy Beevers E-mail: abe@amiplastics.com Senior editor: Chris Smith E-mail: cs@amiplastics.com Contributing editor: Lilli Sherman E-mail: editorial@compoundingworld.com Designer: Nicola Crane Advertisement manager: Claire Bishop E-mail: claire@amimagazines.com Direct tel: +44 (0)20 8686 8139
Copyright Applied Market Information. No part may be reproduced without the prior written permission of the publisher.
www.compoundingworld.com March 2012 | compounding world
news
Huge pET recycling plant opens in california

carbonlite has opened its new bottle-to-bottle pET recycling plant in riverside, california, uSA. The company says that it is the largest such facility in the world and that it will recover more than 2 billion bottles per year. According to carbonlite, most pET bottles collected in california were previously exported to china for recycling into polyester fibre. it is working with customers such as pepsico and nestle waters to ensure that its bottle-grade rpET is reused in new beverage bottles. The company says that it plans to double the plants annual capacity to more than 4 billion bottles in mid-2013.
Ampacet moves and expands Europe HQ

Ampacet has moved into Huskys former factory in Luxembourg Ampacet has opened its new European headquarters in dudelange, luxembourg, including additional compounding capacity and a new innovation centre. The company is investing E25 million in the facility, which was previously used by Husky injection molding Systems. new high-capacity production equipment for black and white masterbatch is being installed at the site, increasing Ampacets European production capacity for these products by 60%. The building has room for further expansion, up to double this initial capacity. The American masterbatch groups headquarters for Europe, the middle East and Africa (EmEA) had previously been located in windhof, luxembourg, but did not include any production capacity. The companys new location is around 25 km away. The number of Ampacet employees in luxembourg is being increased from 75 to 125 because of the addition of production and innovation capabilities. The luxembourg government is supporting the move through a variety of financial measures. Ampacet says that luxembourg is an attractive location because of the access it provides to the European market. The Benelux region accounts for 23% of Europes total masterbatch production and is also a major consumer of such materials. Ampacet Europes consolidated turnover was E330 million in 2010. it has additional production sites in Belgium, italy, the uK, poland and russia.
www.carbonliterecycling.com
www.ampacet.com
roquette starts up new bioplastics unit

French starch processing group roquette has announced the start-up of a 25,000 tonnes/year plant to produce a new range of bioplastics. gaialene plastics are produced at the companys site at lestrem in northern France using a proprietary starch grafting technology. The Roquette has started to produce a new range of bioplastics at this plant in Lestrem, France
compounding world | march 2012
polymers are said to contain more than 50% renewable plant-based content and a 65% reduction in carbon footprint compared to pE. The company describes the resins as durable or semidurable. They are said to be suitable for injection moulding or extrusion and are characterised by good impact resistance, antistatic performance, a pleasant touch and easy colourability.
www.gaialene.com
www.compoundingworld.com
news
rusnano drives forward russian investments in nanocomposites

State-owned russian investment organisation rusnano has announced the commissioning of two new projects Metaclay and uralplastic-n as part of its plans to develop the countrys position in commercial nanotechnology. Metaclay, which is located at Karachev in western russia, has started production of a range of nanosilicates and nanosilicate polymer composites. The company has a production capacity of 14,800 tonnes/year of polymer nanocomposites, with plans underway to expand this to 50,000 tonnes/year by 2014. nanosilicate production will amount to 25,000 tonnes/year by 2014. rusnano has invested ruB1.1 billion (E28 million) into the venture, which is expected to realise sales of more than ruB5 billion (E129 Rusnano CEO Anatoly Chubais took part in the Metaclay factory opening million) a year, 80% of which will come from polymer nanocomposites. First applications are likely to include gas pipeline protection; gazproms Vniigaz research operation gave Metaclays anticorrosion products a positive approval. However, it is also targeting railway shock absorber, electrical and packaging markets. Meanwhile, uralplastic-n has been set up at Ekaterinburg in central russia to produce nanocomposite packaging films. The 21,000 tonnes/year plant is equipped with a 10-layer extrusion line, which is said to be the only one of its kind in russia. The nanocomposite film products are said to offer higher mechanical and barrier performance at reduced thickness compared to traditional films. uralplastic-n is a subsidiary of cJSc uralplastic, a major russian producer of pE film and foamed pp sheet for food, non-food and industrial packaging applications. cJSc uralplastic and rusnano have invested ruB2.5 billion (E64 million) in the project.
www.metaclay.com www.uralplastic.ru
dover corporation acquires the Maag group

dover corporation of the uSA has acquired the Maag group which includes the german pelletizer manufacturer, Automatik. The group was sold by clyde Blowers capital and cgS Management for uS$285 million. Maag, which is headquartered in Switzerland, also manufactures gear pumps and melt filtration systems. it will become part of dovers pump Solutions group (pSg). ueli Thuerig, who is cEo of
the Maag group, said: we have built a strong company through the years, and combining our expertise with pSgs global brands and market reach will be a welcome addition for our customers and suppliers. At Maag we look forward to the future benefits and synergies that this acquisition will bring. The Maag group was formed by the merger of Maag pump Systems and Automatik
in 2010 and has factories in Switzerland, germany, the uSA and china. it employs more than 500 people and had a turnover of approximately
E130 million in 2011.

Maag pump System was acquired by clyde Blowers capital of the uK from Textron in 2008, while Automatik was formed by a buyout from rieter in 2008 funded by cgS Management of Switzerland. Maag CEO Ueli Thuerig is looking forward to the future benefits of the acquisition
March 2012 | coMpounding world
www.maag.com www.pumpsg.com
news
lcA backs Vinyloop recycled compounds

recycled pVc from the Vinyloop process offers significant environmental benefits compared to virgin material according to a new life-cycle assessment study carried out by dEKrA on behalf of Vinyloop, which is part of Solvay. The study, which was carried out by the germanheadquartered organisation according to iSo standards, concluded that the energy demand for the recycled pVc is 46% lower while the global warming potential is cut by 39%. The Vinyloop process involves dissolution with a solvent to separate pVc from other materials and contamination. it is used at Solvays plant in Ferrara, italy, to produce recycled pVc compounds. These are used in a variety of applications, such as the internal layer of garden hoses and roofing membranes.
Huntsman gay acquires citadel from wind point

Huntsman gay global capital has acquired the compounding group citadel plastics from wind point partners for an undisclosed sum. citadels current management team will continue to lead the company. citadel was formed in 2007 when the wind point private equity firm purchased the thermoplastics compounder matrixx. Since then, it has acquired several more thermoset and thermoplastics compounders and added them to the group. They include Bmci, Fiberfil, Aclo, QTr and meridians Brazilian operations. Huntsman gay is a uS$1.1 billion private equity fund. it was co-founded by Jon Huntsman Sr., the chairman and founder of Huntsman, the specialty chemicals company. gary crittenden, managing director of Huntsman gay said: we really like citadels focus on highly engineered, custom compounds, and we have utmost admiration for mike Huff and the rest of the senior management team. we look forward to supporting citadels domestic and international growth through a variety of avenues, including strategic acquisitions.
www.citadelplastics.com www.hgequity.com
Farrel installs new mixer at SKZ

Farrel has formed a continuous compounding r&d partnership with SKZ, the german plastics centre. it is installing a cp125 continuous mixer at the SKZs lab in wurzburg. The cp125 is particularly suitable for the compounding of polyolefins with high loadings of mineral fillers, and for the production of additive and colour masterbatches. it can also be used for polymerelastomer blends. SKZ will use the Farrel continuous mixer for compounding R&D
www.vinyloop.com
www.farrel.com www.skz.de
compounding world app attracts 1,000 users

more than 1,000 people around the world have downloaded the the current top five users. we have been very pleased with the initial reaction to all five of our new apps, said Andy Beevers, head of business publishing at Ami. So far weve had a total of more than 5,200 downloads, with compounding world accounting for over 1,100 of these. The figures continue to grow on a daily basis. plus we expect lots more interest when we demonstrate and promote the apps on our booth at npE next month, and when we launch the Android versions soon afterwards. The compounding world app is sponsored by leistritz and is available free-of-charge along with past and current issues of the magazine. Search for Ami plastics in the App Store or click here for more details.
compounding world magazine

app for the ipad and iphone in the first few months since its launch. The uSA is the leading country for downloads, with china, germany, Thailand and the uK making up the rest of

www.amimagazines.com
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news
BioAmber signs big bio-based deals

Bio-based chemicals company BioAmber has secured uS$10 million of new funding from lanxess and announced a new technology development deal with bioplastics maker natureworks. lanxess and BioAmber a leading producer of renewablysourced succinic acid have already worked together in the development of a range of phthalate-free plasticizer products that will be launched by lanxess later this year. This new investment is intended to underpin that introduction, according to lanxess. The move give lanxess a minority shareholding in BioAmber and a seat on the board of directors for Jorge nugueira, who heads the lanxess Functional chemicals unit that makes phthalate-free plasticizers. minnesota, uS-based BioAmber currently manufactures succinic acid by fermentation at a 3,000 tonnes/year plant in pomacle, France, but it is planning to construct a new 17,000 tonnes/year unit on the lanxess park at Sarnia in BioAmber will build a new bio-succinic acid plant at Lanxesss Sarnia site in Canada canada. This is expected to commence production in 2013. BioAmber has also set up a new joint venture with uSbased natureworks Amberworks that aims to develop a new range of bioplastics based on the combination of natureworks plA and BioAmbers pBS (polybutylene succinate) technologies. within the agreement, natureworks will commercialise a new line of ingeo products based on BioAmbers plA/pBS compounding expertise. Target applications include food service products.
www.bio-amber.com www.lanxess.com www.natureworksllc.com
Baerlocher sets up in Turkey

Baerlocher has established a new company in Turkey to supply its additives to the countrys pVc window profile and pipe markets. located in istanbul, the new subsidiary is called Baerlocher Kimya and it is managed by mustafa Ataman and Bekir Ergn who are the managing and technical directors respectively. Baerlocher says that it will continue to work with its existing distributor dolunay Kimya to supply the other pVc markets in Turkey.
Brazil buys four mrS extruders

gneuss has supplied four of its multi rotation System (mrS) extruders to two companies in Brazil for pET recycling applications. The customers are unnafibras Textil and nova pack Embalagens. unnafibras Textil is a leading recycler of pET fibres and has purchased three machines, two for the production of textile fibres and one for bottle-to-bottle recycling. The two fibre lines have a total capacity of 1,500 kg/h, while the bottle grade line can produce 2,000 kg/h. nova pack has invested in an mrS line to extrude pET sheets using 100% recycled material. The companys managing director ivanor luis Arioli said that they selected the gneuss system for its competitive costs and the high transparency of the rpET film. The mrS extruder uses eight screws to increase the devolatilizing and decontamination performance compared to conventional extruders (see this issues npE preview for more details). Nova Packs Ivanor Luis Arioli (centre) with Gneusss Andres Grunewald (left) and Daniel Gneuss (right)
www.baerlocher.com

www.gneuss.com
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news
news in brief
Auserpolimeri of Italy has
appointed William Barnet & Son as distributor for its Compoline impact modifiers and compatibilizers. The agreement covers sales to the engineering plastics market in the US, India, China, Korea, Taiwan and Hong Kong. One of the three new ICMA lines is being installed at the So.f.ter plant in Forli, Italy
So.f.ter adds new ICMA lines

So.f.ter is expanding its engineering plastics capacity by 30,000 tonnes/year with the purchase of three new corotating twin-screw extrusion lines from ICMA San Giorgio. They are being installed at its plants in Forli and Ferrara in Italy, plus its Silao facility in Mexico. The wear-resistant lines will be used for producing filled and reinforced grades of PP and PA for applications in the automotive and household appliance markets. So.f.ters plant in Ferrara is the former P-Group business which it rescued from bankruptcy in 2011. The relaunch of the Ferrara plant allows us to participate, as a supplier, in a very positive initiative that helps keep our country a centre of technological excellence, said ICMAs managing director Giorgio Colombo. This investment confirms the intention of So.f.ter management to maintain Italy as a privileged product platform for the European markets, said Stefano Zocca, So.f.ters managing director, adding: Mexico is becoming the basis for our expansion towards the NAFTA countries. From there you can easily supply companies located in the United States or Canada, and it is also possible to collaborate with corporations that have relocated to Mexico and are looking for local partners with European levels of technology and quality.
www.auserpolimeri.it www.barnet.com PolyOne has opened an

expanded Innovation Center at its site in Suwanee, Georgia, USA. It includes twin-screw extrusion capacity for quicker solutions turnaround, a comprehensive design library covering colours and special effects, plus new equipment to expand capabilities in film extrusion, thermoforming, blow moulding and injection moulding.
www.polyone.com The European Chemicals

Agency (ECHA) has published more than 3 million REACH submission records covering 90,000 chemical substances online. The Public Classification and Labelling Inventory can be accessed at http://bit.ly/ECHAlist.
www.softerspa.com www.icmasg.it
EPI joins UAEs list of oxo suppliers

Canadas EPI Environmental Products is the latest supplier of oxo-degradable additives to gain approval to provide materials for the production of plastics carrier bags supplied within the United Arab Emirates (UAE). The UAE Ministry of Water and Environment announced early last year that it plans to introduce a ban on the use of non-degradable plastics bags and packaging products from the beginning of 2013. The legislation stipulates that such
items must use an oxodegradable additive that complies with ESMA (Emirates Authority for Standardisation and Metrology) standard 5009:2009. ESMA has approved and accredited EPIs TDPA oxodegradable additive for use in the production of plastic bags and packaging. The organisation has previously approved the d2w additive range from UK-based Symphony Environmental, the Reverte additives from Wells
Plastics, also from the UK, and Bin Halal Enterprises for the oxo-degradable additives developed by Willow Ridge Plastics in the US. According to ESMA, around 95% of the polyethylene plastic bags used in the UAE are produced locally. It adds that compliance with the regulation will be enforced through a combination of testing of imported products and inspections of local manufacturing operations.
www.echa.europa.eu PSI-Polymer Systems, the

US supplier of polymer filtration equipment and gear pumps, is opening a new European subsidiary in Talheim, Germany, to serve all EU countries. It will be headed up by Manfred Wege, who is a former managing director of Dynisco Europe.
www.epi-global.com
www.psi-polymersystems.com
March 2012 | compounding world 11
news
metabolix comes under scrutiny over bioplastics joint venture

uS-based law firm Hagens Berman Sobol Shapiro has filed a class-action lawsuit against bioplastics technology company metabolix in the uS district court of massachusetts, claiming it misled investors by not disclosing that its mirel bioplastic was not commercially viable. mirel was being manufactured by Telles, a joint venture between metabolix and Archer daniels midland (Adm). Adm withdrew from the venture in december of last year saying returns were too uncertain (compounding world, January 2012, page 8). Hagens Berman is appealing for company insiders to come forward with information passed between the JV partners about the actual and projected financial performance of the operation. meanwhile, in its endof-year results statement, metabolix said it had agreed terms with its former partner Adm covering the wind down of Telles, under which it will pay around uS$3 million for certain rights and assets, including pilot plant, compounding ingredients and more than 5 million pounds (2,270 tonnes) of pHA stock. The company said this stock will be used to supply customers until it is able to secure an alternative manufacturing partner. metabolix generated revenues of uS$1.4 million for 2011 and posted a net loss on its business of uS$38.8 million. The company said it will also recognise around uS$38 million in deferred revenues in the first quarter of 2012 as a result of the Telles termination. However, metabolix raised Metabolix says that it has more than 2,000 tonnes of Mirel PHA in stock uS$49.3 million from stock offerings during last year, leaving it with cash and investments totalling more than uS$78 million. The company says that it expects cash usage for 2012 to be around uS$24 million. we w see a robust and growing global market for bioplastics and remain confident that we are well positioned to serve customers and develop high value applications for our pHA biopolymers, said richard Eno, president and cEo of metabolix
www.hbsslaw.com www.metabolix.com www.adm.com
lifocolor expands in poland

lifocolor Farben, the germanheadquartered masterbatch maker, is investing E2 million to add new capacity at its lifocolor Farbplast subsidiary in Bydgoszcz, poland. compounding capacity is being increased to 1,000 tonnes/year, while the production and warehouse area is being expanded to 3,000 m2, three times its current size. The expansion, which is designed for batch sizes from 5 kg to 5 tonnes, is scheduled for completion in September 2012. lifocolor Farbplast has been producing masterbatch in Bydgoszcz for more than 15 years and the plant employs approximately 20 people. lifocolor Farben also has plants in germany, the czech republic and France. it produces colour and additive masterbatches as well as small quantities of engineering plastics compounds.
BYK adds to app for additives

BYK-chemie has updated its Additive-guide app for the ipad and iphone. The free app now has improved search functions, plus the ability to store favourite products and send documents via e-mail. The app is in german and English and can be used online or offline. Click here to find out more, or search for BYK additiveguide in the App Store.
www.lifocolor.com
12 compounding world | march 2012
www.byk.com
news
rTp acquires clariants conductive compounds

rTp company has acquired clariants electrically conductive compounds business including technology and equipment. A compounding line based on a Banbury mixer will be transferred from clariants plant in Ahrensburg, germany, to rTps site in ladenburg, which is also in germany and was opened in April 2011. clariant explained that this technology no longer belongs to its core business. The two companies said that they will work to ensure a seamless transfer with no disruption for established customers. Jean Sirois, rTps European managing director, told us into new markets including wire and cable, film extrusion, sheet and construction products. Sirois added: we intend to continue the current business, and with our extensive conductive compound experience, we expect to be able to offer current customers expanded access to more conductive solutions. we also intend to take these products from clariant to our businesses in the Americas and Asia.. clariant said that its existing agreement with Bayer materialScience covering the production of compounds and masterbatches based on its Baytube carbon nanotubes is not included in the deal with rTp company.
polyplast licenses Thermylene

Asahi Kasei plastics north America has licensed polyplast compound werk of germany to manufacture and distribute its Thermylene brand of chemically-coupled glassreinforced pps in Europe. Thermylene pp products are said to provide improved tensile strength, creep resistance, toughness and elevated temperature performance, making them a cost effective alternative to pA and lFTs. licensing Thermylene to polyplast makes our products available globally, said John moyer, president of Asahi Kasei plastics. compound and masterbatch maker polyplast, part of the polyplast muller group, has three facilities in germany at Eilenberg, Straelen and Bingen am rhein. it has a production capacity of around 48,000 tonnes/year.
www.rtpcompany.com
compounding world: There is unique technology in the clariant business with regards to formulation and process, which we will retain. it is a nice complement to our conductive business, extending our product line. we can now use our expertise in resins such as pS, pp, TpEs and pVc, taking
RTP currently supplies conductive compounds for applications such as these connectors made by Konnectors Unlimited
www.asahikaseiplastics.com www.polyplast.com
radco to market Aura uV protection for pc

uS-based radco infusion Technologies has secured an exclusive licence from Bayer materialScience to market the german firms novel Aura polycarbonate uV stabilisation technology worldwide. The Aura technology uses infusion techniques to incorporate uV stabilisers into the surface of pc parts, where
14
the need for uV protection is greatest. The uV stabilisers penetrate up to 7 mil (175 microns into the surface), according to radco, and because infusion takes place at lower temperatures than compounding it is possible to use thermally sensitive additives. The process is said to be
particularly effective for the protection of components such as lenses and outdoor lighting fixtures. it is also said to be cost effective and environmentally acceptable. its a breakthrough for lighting manufacturers, since it helps overcome the issue of yellowing after extended uV exposure, said Kevin dunay,
market segment leader electrical and electronic polycarbonates for Bayer materialScience in the uS. The company says the first commercial application will be introduced this year a lens for an outdoor light injection moulded in its lEd2643 grade of makrolon.
www.radcoinfusion.com
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European masterbatch makers | markets feature
AMI recently updated its report on the size, strategy and performance of Europes largest masterbatch makers. Carole Kluth reviews the leading players and recent industry changes
Examining Europes leading masterbatch producers

Europes masterbatch industry has been through a dramatic period of upheaval since 2006 when AMI produced the previous edition of its report on the
Corporate performance and ownership among masterbatch producers. The severe impact of the global financial crisis of 2008 has been compounded by underlying slower growth for masterbatch because of the increasing maturity of the business. This changing business environment has had a profound effect on companies and their strategies, with some players cutting back activity and closing plants, while others have sought wider or new markets to sustain or grow the size of their business. The difficult economic environment has also been characterised by variable financial performances in the industry with weaker players seeing margins eroded and their survival threatened, while others have used the opportunity of smaller order size and just-in-time delivery to actually improve their profits. Despite this underlying upheaval, superficially there appears to have been relatively little change in industry structure with the market still led by A. Schulman, followed by Clariant as the second largest and Ampacet now occupying the number three position. This standing applies both in terms of the volume and the value of their respective masterbatch businesses. However, all three companies have been engaged in a process of strategic realignment in recent years, prompted by the combination of slower growth, reduced margins and the impact of the global financial crisis. For A. Schulman this has resulted in a number of strategic acquisitions in order to shift its focus onto more speciality areas and specific colour-matched products, as well streamlining some of its existing operations.
Historically Schulman was largely known in the masterbatch world for supplying its Polybatch products to the film extrusion industry. The acquisition of Delta Plast of Sweden in 2007 gave the group an enhanced position in the specific colour-matched market targeting the moulding industry. Its subsequent acquisition of ICO in 2009 extended its activities in
March 2012 | COMPOunDIng wOrlD 17
markets feature | European masterbatch makers
products with 14 plants in Europe, the most extensive network of any player in the region. it has reached this position through a combination of acquisition and investment. ampacet europe, which Ami ranks as the third
other companies 37%
largest supplier of masterbatch in Europe in terms of

a schulman europe clairant masterbatches ampacet europe polyone corporation cabot plastics International polyplast mller plastika Kritis hubron (International) tosaf compounds Kunststof Kemi
volume and value, has also been pursuing a strategy to develop more speciality and specific colour-matched grades of masterbatch. These complement the volume black and white polyolefin grades it supplies to film and blow moulding accounts. it is currently expanding capacity for colour masterbatch at its Busto garolfo site in italy and also has plans to build a new plant in Europe for black and white masterbatch. Fundamentally the size of these three leading masterbatch businesses in Europe has not altered significantly in the past five years with the focus being on portfolio changes and cost savings to improve cash flow and margins. up-to-date financials are not available for the Ampacet corporation, but filed accounts for Ampacet italia showed a 25% increase in turnover for 2010 to E60 million and an improving profit margin of nearly 7% compared with 6% the year before. Similar improvements have been reported by Schulman and clariant in more recent accounts. Schulman, whose financial year runs to 31 August, saw a 38% increase in sales to nearly uS$2.2 billion for the 2011 financial year, thanks in part to the impact of acquisitions, including the incorporation of ico for the full year. The increase in turnover was also driven by higher average selling prices as well as improved volumes. masterbatch sales accounted for 40% of this globally and were 30% higher on the previous year. clariant reported fourth quarter 2011 sales for its masterbatch division down 10% compared with Q4 2010. Strong growth in middle East and growth in Asia/pacific and north America could not fully compensate for very weak demand in Europe in general and from Southern Europe in particular. For the full year, sales were just over cHF1.1 billion, down slightly on the previous year, mainly because of the strength of the Swiss franc. in local currency terms the business grew by 2%. clariants strategy for its masterbatch business is to focus on opportunities in personal care and medical packaging and on growth in emerging markets. other companies featured in Amis report have also been refocusing operations on core skills and cutting back peripheral activities and streamlining their product range. For example Viba, BASF, cabot, polyone and Ferro have all shifted their market involvement in masterbatch in recent years through a combination of acquisitions,
top 10 masterbatcch producers

source: amI consulting 2012
rotational moulding markets around the world. This year, its purchase of the French colour masterbatch company Elian gives it further capabilities in supplying small-lot specific-colours for the injection and blow moulding sector. The group is also clearly looking to expand its specific-colour masterbatch business globally with other recent acquisitions including mccann color in the uSA and mash industria in Brazil, both added in 2010. in 2012 a new plant will come on stream in india. in Europe it has also been streamlining and reorganising some of its existing plants. its plant in givet, France is now the main site for manufacturing the full range of Schulmans masterbatches with some production having been transferred here from Belgium and the uK. in the uK, the companys crumlin plant in South wales has been reorganised to produce smaller colour lots and speciality compounds for the local market. clariant has also been engaged in a worldwide restructuring and reorganisation of its operations which it started in 2008. when completed by the end of 2013, its project clariant will have led to the closure of 14 sites and an additional downsizing of six more worldwide. within Europe this resulted in the closure of its plant in wigan, uK in 2010 and in Huningue, France in 2011 with production transferred to other sites. like Schulman, clariant was traditionally known as a supplier to a specific industry segment, in this case the fibre market. However, over the years it has built a position as a supplier of a full range of masterbatch
EuropEs Top 10 masTErbaTch producErs (basEd on 2010 proucTion volumEs)

source: ami consulting
closures and concentration on key strategic markets. polyone ranks fourth in Amis listing of masterbatch producers, although it recently significantly increased its position in the supply of colorants for the plastics industry through its acquisition of colormatrix with its liquid colours business. it reported a 4% increase in revenues for the fourth quarter of 2011, despite generally difficult trading conditions, and full-year revenues increased 9% to uS$2.9 billion, compared to uS$2.6 billion in the prior year. polyones European masterbatch business probably accounts for only around 10% of this. The company has been investing in new equipment with new lines installed in Belgium, France and Hungary in 2010, but it has also been streamlining some of its operations, shutting down a plant in denmark and transferring production to Sweden. cabot, Europes largest producer for black masterbatch, has significantly rationalised its production in the region over the past five years, closing facilities in the uK and italy as it pursues a strategy to expand its black business in the faster growing markets of the middle East and Asia. output in Europe is nearly half what it was when Ami last surveyed the leading producers. basF has also been rationalising its European production sites, resulting in the closure of plants in Spain (in 2010) and the netherlands (2011) with production transferred to its cologne site. viba of italy has also been focussing on improving efficiencies for its network of plants in Europe, resulting in the closure of a plant in Hungary in 2009. Ferro has also closed most of its European masterbatch facilities in recent years to concentrate production in Spain. The result has achieved a smaller, more focused operation supplying primarily to the moulding and film extrusion markets. As these companies have altered and rationalised their product ranges, so opportunities have opened up for other players in the market. independent black masterbatch producers in particular have enjoyed strong growth as cabot has strategically withdrawn
from some segments. The main winners from this development have been hubron in the uK and polyplast mller in germany. other companies that have enjoyed good growth through the downturn, thanks largely to an expansion of their geographic sales include Tosaf and plastika Kritis. The latter has proved a success story, despite the weak state of the greek economy, thanks to its strong export sales and its plants in Eastern Europe and Turkey. israeli owned Tosaf compounds has grown through a combination of acquisitions such as its purchase of impact colours in the uK, and investment in new plants and equipment. regardless of the strategy adopted, the challenge for industry players has been to develop successful corporate development within a volatile cyclical economic climate. it is clear that recent years have seen an increase in the pressures affecting the industry. Volatility in the demand pattern from customers has led to shorter delivery time schedules and smaller order sizes. Although this has led to better margins, in the context of volatile raw materials pricing and availability it makes pricing and planning a huge challenge to management. The rising cost of pigments, additives and polymers is also leading to significant shifts away from traditional colour solutions and a questioning of the value, or necessity, of masterbatch in some areas putting further strains on masterbatch producers. Finally there has also been a continuation of the trend whereby many customers have the desire to have a European or even global supply strategy which offers both opportunities and threats as masterbatch producers look to wider geographical markets. given the challenging economic forecasts for the Euro zone it is likely that the shift in strategy that Ami has observed in its new report will continue for most masterbatch producers into the medium term future. However, it should not be forgotten that new investwww.compoundingworld.com
ments are also continuing, especially from the more focussed and well positioned suppliers within Europe and especially in Central and Eastern Europe. While access to capital will be a significant challenge to the industry going forward, it will be interesting to see the extent to which equity groups and cash rich
%$7& 0$67(5

addi Innovations for ng value
About the author

Carole Kluth is a senior project manager with AMI.
More information
Corporate performance and ownership among masterbatch producers - a review of Europes 50 leading players is available now from Applied Market Information price E455/380/$590. For further information or to order a copy contact Rgine Futter at AMI Publishing: rf@amiplastics.com. AMI Consulting has also recently published a detailed market report on the European thermoplastic masterbatch industry. Further information is available from Andrew Reynolds at AMI Consulting: apr@amiplastics.com. AMIs European Masterbatch conference will be held on 19-21 June at the Imperial Riding School Hotel, Vienna, Austria. Further information is available from Sabine Prack at AMI Conferences: sp@amiplastics.com. Details of all AMIs products and services related to the global masterbatch industry can also be found on our website: www.amiplastics.com
companies will increase their activity in the

+
sector. It is already notable that these financial institutions play an increasingly strong role in the plastics processing industry where they are participating in a process of reshaping the industry and its relationships. So far there have been only limited acquisitions by these groups in the masterbatch industry but it is anticipated that within the next few years a number of equity groups will establish
y 25th Anniversar
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significant holdings in the sector. Once this has occurred relationships and strategies are likely to change further leading to greater financial rigour and less innovation.
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On the positive side the process will further accelerate the necessary restructuring of the industry.
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Additives for PET | materials feature
new ways to promote the performance of PET
The rapid growth in PET resin consumption over recent decades has driven the development of a healthy PET additives sector. This is focused on developing and producing the vital ingredients for colouring and improving the performance of the polymer to meet the stringent demands of the packaging industry and other end-use markets. Further opportunities have been created by the recent rapid expansion in the use of recycled PET (RPET) and the accompanying requirements for additives that help to make these reclaimed materials process, perform and look like virgin resin. PET continues to take market share from HDPE in the bottle market, scoring successes in beauty, personal care and home-care packaging applications. The increasing emphasis on sustainability is a key contributing factor, with PET creating opportunities for downgauging and the use of higher recycled contents. Morgan Gibbs, director of technical service and development at Ampacet, notes that more and more companies are looking to increase the RPET content in their products. While the post-consumer recycled (PCR) content for HDPE packaging is typically no higher than 25-28%, there are PET applications, such as water
Lilli Sherman looks at new developments in additives designed to improve the appearance, recyclability, processing and performance of PET resins
bottles, where 100% RPET is now being used. Gibbs adds that Ampacet has a developmental product that addresses the loss of intrinsic viscosity that is associated with RPET. The new additive is now being field tested and the results look promising. Another key advantage of PET is the design flexibility it provides for the developers of new packaging products. Ampacets strategic business manager for moulding, Doug Brownfield explains: PET allows the design of bottles with various unique twists and shapes, and it also offers more dynamic shelf appeal due to its inherent glossy nature. Ampacets Formula X LiquidMetal colour technology can be used to extend this
March 2012 | CoMPounDinG WoRLD 25
Ampacets Formula X LiquidMetal technology creates packaging with a glossy metallic look
materials feature | Additives for pET
Reducing friction
1.0 0.9 0.8 0.7 0.6 0.5 0.4 0.3 0.2 0.1 0.0
Initial 24 Hours 1 Week
Another area of focus for additive r&d teams is Blank PET PET + 0.5% 703840
60% reduction in friction
addressing pETs inherently high friction (coF>0.6). This can lead to a range of processing problems, including: poor line speeds during filling and labelling; an increased tendency to scratch and mark; poor packing density of parts in a box; and increased noise. These problems cost producers money, which has now generated great interest in methods to reduce pET friction, says Ampacets Brownfield.
This performance is also seen in PET-G
The company has recently added an innovative slip additive to its FormulaX range of additive masterbatches. Ampacets FormulaX pET Slip 703840 is said to significantly reduce surface friction in a range of pET applications it is particularly aimed at bottles, but can also be used in sheet and film. The additive has been foodcontact approved in both Europe and north America. Ampacets pET Slip is normally added to the resin via masterbatch at low use levels ranging from 0.5% to
Ampacets FormulaX PET Slip 703840 reduces surface friction in a range of PET applications
appeal, creating packaging with a glossy metallic look more usually associated with car exteriors. meanwhile, marketing director for global colour and additives at PolyOne, Fernando Sanchez, highlights several key trends. These include the development of foamed pET technologies to improve the lightweighting of bottles, plus the introduction of additive technologies designed to extend the shelf life of the product. Sanchez also mentions the use of oxygen barrier additives both active and passive to broaden the range of food and drink that can be packaged in pET. chris Kerscher, north American marketing manager at A. Schulman, highlights further opportunities in extruded pET. His company has focused its developAmpacets DeNestur masterbatch helps the separation of thermoformed trays ment efforts on additive masterbatches that enhance the processing, performance and appearance of such materials, ranging from sheet extrusion to biaxiallyoriented film, adding, polybatch masterbatches for biaxially-oriented pET are manufactured to higher technical standards for performance at thin gauge and under demanding processing conditions.
1.0%. According to Brownfield, pET Slip is designed as an internal lubricant alternative to the external workhorse industry standard lubri/Stat. while this product reportedly does a good job, it involves a secondary spray process which requires extra cost and equipment and can be affected by dust and dirt. FormulaX pET Slip is claimed to improve quality, reduce waste, and save money. Several users have reported getting significant improvements in downstream handling as the product enables improved filling, conveying and label sleeving of bottles. The additive works by migrating to the surface of the pET the migration is fast so that it provides instant mould release properties. it has been shown to have long-lasting friction reduction in that it continues to work in the finished bottles. According to company data, it reduces surface friction by up to 60% and reduces mould release force by up to 40%. moreover, it increases packing density by up to 25%. like the rest of Ampacets FormulaX product line, pET Slip is offered in pET micropellets which offer some advantages over products in liquid or wax carriers. gibbs explains: These micropellets allow you to get a letdown as low as 0.1%, so we can easily compete with liquid and wax carrier products while at the same time eliminating screw slippage and housekeeping problems associated with the latter. He also adds that the companys micropellet technology complements the use of micro-feeders that have surfaced in the industry over the last few years. Ampacet has also introduced an additive masterbatch that eases the separation of thermoformed or injection moulded products such as trays or cups. called denestur, it can be used in pET, pE and pp,
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materials feature | Additives for pET
aldehydes and other transformation products when processing prime and recycled pET resins. webster explains: Thermoplastic polyester will thermally degrade at processing temperatures typically used to process the resin into a fabricated article. recycled pET degrades faster during the same process. in all cases, breakdown products like acetaldehyde (ethanol) are generated in the resin that affect taste and odour and are regulated by rEAcH and EpA. A 95% drop in aldehydes has been demonstrated with the addition of 0.1% celban 150m and processing temperature of 280oc with a residence time of 5 minutes. other performance attributes include the control of melt rheology, molecular weight and discoloration or yellowing. The additive also provides high thermal stability and high solubility without adverse effect on haze or opacity. Another product from the companies is celban 800S, which deals with the residual acid formed from vinyl polymers in pET. webster says that the recycling of pET Sukanos XRPET additive masterbatch enhances RPET film and sheet imparting an easy-glide, anti-static, non-stick surface for faster line speeds and reduced waste. The company claims friction reductions of up to 70% which leads to a 25-50% reduction in the force required for mould release and de-nesting. A. Schulman has also been working on surface properties and has launched a new de-nesting additive masterbatch that is said to be ideal for rigid stacked thermoformed pET containers. Based on a proprietary blend of ingredients, polybatch pT-dn 105 is available in both a pET and a pETg carrier. Stabilization Technologies has worked with the custom additives concentrates manufacturer and compounder Phoenix Plastics to expand their line of internal and external lubricants with a thermally-stable and extremely polar low-melting lubricant, called phenalube. it has been used for the dispersion of organic and inorganic pigments in pET textile fibres. Joe webster, the president of Stabilization Technologies, says that the additives chemistry is new and unique to polar condensation polymers such as pET and nylon. due to its high polarity and compatibility in polar resins, it has been shown to significantly aid in the dispersion of colorants. End-use levels are 0.2%-0.3% for the blow moulding of pET and rpET. resins from bottle-grade waste typically requires the careful removal of other plastics and crossover contamination from metals that can adversely affect its molecular weight, melt rheology and colour matching capabilities. one of the biggest problems is crossover contamination from vinyl plastics. during hightemperature processing of pET at 260oc and higher, the presence of vinyl will result in de-hydrochlorination and form hydrochloric acid which attacks the ester linkages of polyester. Attempts over the years to add classical acid acceptors (acid buffers) used in polyolefins have failed as they also attack the polyester due to their intrinsic basicity, webster explains. developed to serve as a selective polyester acid inhibitor for vinyl contamination, celban 800S will not interact with the polyester and maintains the clarity of the resin. The product has been shown to be very selective for acidic chloride, and will also address bromides and hypochlorites that attack polyesters. Enduse levels are typically 0.1-0.2%. Sukano has also been focusing on enhancing the properties of recycled pET. its X-rpET additive masterbatch has been specifically developed to enhance the functionality, processability, and appearance of recycled pET mono- and co-extruded film. included in the new X-rpET series are: a foaming masterbatch for reducing packaging weight; a melt enhancer that is said to ensure uniform cell structure, thus improving mechanical performance and processability; a special colour masterbatch designed to enhance opacity and appearance; and, a slip/antiblock masterbatch that provides easy processing and
As good as new
Stabilization Technologies and phoenix plastics have also developed two new additives aimed at optimizing recycled pET performance. celban 150m is an aldehyde inhibitor, sold as a concentrate in amorphous thermoplastic polyester, that was specifically developed to control the formation of
enhanced de-nesting of thermoformed parts.
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materials feature | Additives for PET
resins surface aesthetics. For example, A. Schulman has been working on products that enable designers to impart a more natural matte or synthetic paper effect to PET. Polybatch PT-DUL 3040 extends the companys DUL line of matte additive concentrates to biaxially oriented PET. Through controlled light-scattering, PT-DUL 3040 increases haze and lowers gloss of traditional PET films. Product performance can be tailored to offer dramatic visual impact or subtle translucency. The product is targeted at industrial and packaging applications such as release films, labels, and snack foods. The companys Papermatch additive concentrates are designed to impart the look and texture of paper to PET film. They can be used in a variety of applications ranging from printed point-of-purchase displays and Ampacets BlueEdge additive controls colour issues in packaging made from RPET Ampacet developed its BlueEdge colour correction additive for RPET bottles and sheet. It is said to significantly reduce or eliminate colour issues that can occur in recycled materials. stationery, to food and industrial packaging. Kerscher says: We see buying behaviour and consumer moods shifting to a softer more natural aesthetic. The DUL and Papermatch concentrates offer designers visual alternatives while maintaining the functional performance of traditional PET packaging. Steve Tattum is global market manager at ColorMatrix, which was recently acquired by PolyOne. He
Looking good
With so much PET being used in packaging products, there is a strong focus on enhancing and modifying the
Additives for PET | materials feature
highlights the advantages offered by the companys advanced liquid colour and additives dispersions technology. For many applications, manufacturers have a choice of liquid or masterbatch to improve clarity, reduce energy consumption or provide UV or oxygen barriers. Depending on the application, liquid additives can offer significant benefits, such as processing advantages and accurate metering that enables precise, effective and consistent dosing to improve production efficiencies. Tattum adds that liquid colour can also mean lower addition rates and direct colour addition, which helps to minimize inventory and waste levels. Recent developments from ColorMatrix that are designed to improve the appearance of PET bottles include its Optica organic resin toners. These provide colour control and haze reduction, as well as improved processing. In 2008, Ampacet was among the first suppliers to launch a UV absorber concentrate designed to eliminate the typical yellow hue of UV-stabilized PET. Ampacets CrystalClear 603192-PT contains a proprietary additive which has no inherent colour. Also, it is a more efficient UVA, so less than half as much additive is required, versus earlier industry products. Several other key players in this arena now offer similar products. Amber PET is a recent addition to the Ampacets FormulaX line. It is specifically designed for pharmaA. Schulman has developed products that give PET a matte look
ceutical containers and can be used at low levels typically around 1%. The company can offer customized grades in a variety of amber shades to meet transmission requirements in accordance with USP 671.
recognized by both the European PET Bottle Platform (EPBP) and the Association of Plastics Recyclers (APR) as having no negative impact on recyclability. Shelf life can be adjusted and controlled according to specific applications up to and beyond 24 months, if required. Clariant Masterbatches is established in this market with its CESA-absorb masterbatches designed to offer long-lasting barrier to oxygen and carbon dioxide in PET bottles. They contain a combination of ingredients that remains stable during handling and processing and avoids the need for a nitrogen blanket, which is often required when using other oxygen absorbers. Another way of extending the shelf-life of food and drink contained in PET packaging is to use UVstabilizers to protect light-sensitive products. For example, Americhem offers its nDuramax customizable, high-performance UV stabilizer concentrates for PET flexible and rigid packaging, designed to both extend the contents shelf-life and enhance package colour consistency.
Shelf-life extension
Although PET is widely used for food and drink packaging, its limited barrier properties can restrict its use with perishable products. As a result, work is focusing on ways to improve the barrier performance without compromising other important properties, such as transparency. options include active barriers, such as an oxygen scavengers that react with oxygen it enters into the bottle, or passive ColorMatrix highlights the advantages that liquid colours can bring to certain PET bottle applications barriers that provide a protective layer in the bottle to prevent the penetration of oxygen or carbon dioxide. PolyOnes Sanchez says: we see more development underway targeted toward optimising active technologies. For example, introducing oxygen scavengers into bottles creates a haze effect, which translates to reduced transparency. He notes that development efforts are focusing on oxygen scavenger technologies that enhance the transparency of the bottle. ColorMatrix is active in the oxygen scavenging market with its novel Hyguard technology for PET packaging. It has a triggering mechanism that initiates oxygen-scavenging activity without any loss of activity between the blow moulding step and bottle filling, as can occur with other scavengers. It is said to provide excellent clarity and full recyclability. It is the first oxygen scavenging technology to be Ampacets Amber PET masterbatch for pharmaceutical containers meets USP 671 requirements
Absorbing stories
BASF recently launched its new Tinuvin 1600 that is said to represent a major milestone in UV absorber technology. It is specifically designed to provide longlasting protection of thin-layer applications for exterior uses, allowing transparent thermoplastic sheets, films and fibres to retain their mechanical properties, colour, and transparency for extended periods of time. Belonging to the chemical class of triazines, the additive exhibits very low volatility, excellent thermal stability and good substrate compatibility in various polymers, which reportedly enables very easy processing. It has been shown to impart far superior durability than
32
ComPoUnDIng woRlD | march 2012
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Krntner Montanindustrie (KMI) is a world leading mining and processing company dealing with MicaceousIronOxide(MIOX) KMI uses unique processing technologies for micronization of highaspectratiominerals KMIsproductrangeincludes
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completely compatible with regrind, ensuring lowenergy, high-quality colouring. With more and more colorants in the recycle stream, SmartHeat offers improved aesthetic qualities, minimizing haze that can be detrimental on the quality of recyclate. A new nucleating agent for PET and PBT developed by Adeka is said to improve crystallization temperature and mechanical performance significantly, even in the Reference (no UVA) State-of-the-art UVA Tinuvin 1600
0 10000 20000 30000
Clarity (%)
presence of glass fibres. Food-contact approvals are currently pending, according to Peter Goman, vice president of sales & marketing for Amfine Chemicals, Adekas North American subsidiary. ADK STAB NA-05 is recommended for films and fibres and reportedly can be used to dramatically increase preform productivity, especially in hot-fill bottle applications. Last year, PolyOne introduced OnCap CRT, a process-optimization additive that is designed to work with all types of resins, including PET. It is said to improve energy efficiency and throughput in extrusion and injection moulding. It boasts cycle-time reductions of 30% or more, and is also said to improve consistency, dimensional stability, and appearance. Click on the links for more information:
Xenon exposure (ASTM G 155) (Hours) BASFs Tinuvin 1600 extends the durability of products under intense exposure to UV light traditional UV absorbers of other chromophore classes. According to BASF, Tinuvin 1600 extends the durability and life expectancy of products under intense exposure to UV light for up to 20 years. It is recommended for: biaxially-oriented PET films for photovoltaics, window films, displays, protective films and other long-term applications; PET and PA fibres; and a range of applications in other polymers such as PC, PMMA, SAN and ASA.
Improved processing
Productivity is incredibly important for high-volume packaging applications, so it is no surprise to find that additives suppliers have also been focusing on products that improve the processing of PET. ColorMatrixs SmartHeat additive is designed to provide controllable reheat in blow moulding, without affecting the colour or clarity of the bottle. It can be incorporated in any standard ColorMatrix colour, facilitating controlled and consistent blowing performance. The reheat agent is added during preform production at the same time as the colorant. In the blowing process, heat is distributed more evenly through the preform with SmartHeat. This is said to result in increased heat uptake speed, as well as more even heat transfer through the body of the preform. To stand out from the crowd, PET bottles are now ColorMatrixs SmartHeat additive is added during preform production at the same time as the colorant
34
www.ampacet.com www.polyone.com www.aschulman.com www.stabilization-technologies.com www.phoenixplastics.com www.sukano.com www.colormatrix.com www.clariant.com www.americhem.com www.basf.com www.adk.co.jp/en
being created in more and more varied shapes and sizes, says Tattum. These new designs can be difficult to produce before the preform begins to set. A greater degree of control, as offered by SmartHeat, can widen the process window for thicker or difficult-to-blow parts. He also points out that controlling heat can generate measurable savings in energy usage, resulting in cost savings and a reduced carbon footprint. SmartHeat is
compounding world | March 2012
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Pelletizers | machinery feature
Cutting edge technology
Pelletizing systems play a critical role in compounding and masterbatch production processes, influencing product quality, line efficiencies and product changeover times. Such equipment includes both strand pelletizers in which cooled strands of polymer are cut into cylindrical pellets and hot-cut or die-face pelletizers in which molten polymer is cut at the die into spherical pellets and then cooled. The pelletizers job is to produce uniformly shaped pellets efficiently, with minimal downtime for cleaning and maintenance. Suppliers have been working hard to meet customer demands for pelletizers that are even more efficient, trouble-free and cost-effective, as well as responding to growing requirements for shorter production runs and more frequent changeovers. Here we look at some of their latest developments.
Jennifer Markarian examines the latest developments in strand and underwater pelletizers designed to improve the efficiency of this crucial step in the compounding process
Strand pelletizers
Strand pelletizers are commonly used in compounding, especially with smaller machines. Conventional systems produce throughputs up to a maximum of around 12,500 kg/h, while automatic lines can deliver up to around 20,000 kg/h. They are suitable for frequent product changes and place very limited stress on the polymer melt. Horst Mueller, manager of IP, technical standards and documentation at Automatik Plastics Machinery, part of the Maag Group, comments that the trend to smaller lots and reduced inventories in compounding plants makes equipment flexibility an important feature. He notes that compounders want easy cleaning and minimal material waste on changeovers. At the same time, they want to reduce costs and energy consumption. Automatik offers its Easy Change Cutting Head for its Primo Plus series of dry-cut strand pelletizers to meet these needs. The spare cutting head, which costs considerably less than an entire pelletizer, increases equipment availability for frequent changeovers, explains Mueller. The head can be changed in about 15 Automatik offers its Primo Plus with the Easy Change Cutting Head for quick changeovers
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March 2012 | CoMPoundInG world
machinery feature | pelletizers
The new model is easy to clean, with tool-less, removable in-feed and discharge chutes, and minimized pellet hold-up points, which is critical for compounders performing frequent changeovers. Another new feature is a single, large, pneumatic cylinder with an upper feed roll that remains parallel with the bottom roll. This design produces a greater uniform pulling force when processing varying diameter strands, resulting in less waste. The Bullet Series comes in three models with 2-, 4-, and 6-inch cutting widths. Bay Plastics Machinery (Bpm) executive vice president, Jason Forgash, notes that customers are running smaller lots sizes with more frequent changeovers at the same time that the need for contamination control is increasing. weve made improvements to turnaround BKGs new water filtration system for underwater pelletizers separates particles under 70 microns minutes so that cleaning, maintenance, and configuration changes can be done off-line, potentially eliminating the need for a stand-by pelletizer. The hot-air knife is another device offered by Automatik to improve the productivity of strand pelletizers. The hot-air knife is mounted to the die head and it removes melt residue from both the die holes and the extruded strands, preventing contamination and minimizing production disruptions. Reduction Engineering Scheer recently introduced its Bullet Series strand pelletizer, which the company says maximizes efficiency for 24/7 operation in both laboratory and small-volume production. The new design combines the cutting performance of the reduction Engineering model 304 pelletizer with innovative features of the E-Series pelletizer acquired with Scheer pelletizing machinery. times for our pelletizers by striving to eliminate pellet hang-up areas, and by engineering the pelletizer so the operator can open everything up in the cleaning process and get to anywhere a pellet can touch, says Forgash. Even the discharge chute, which in the past was often not even included in the cleaning procedure, is removable for easy cleanout. Bpm strand pelletizers are designed so operators can remove necessary pieces without tools, and have safety switches so that the machine will not run if all pieces are not back in place. Forgash also sees a growing trend towards automating the strand pelletizing system through the use of waterslide systems, in which the strands fall into an angled trough and are fed to the pelletizer. The automated system eliminates the need for manual restringing of dropped strands, which increases productivity and reduces scrap. Bpm also sees demand for its small waterslide line, which was designed for running difficult, low-viscosity materials or for small volume runs at low rates - 600 lbs/hr (270 kg/h) or less. Knowing that it is more difficult to justify automating a small line, Bpm designed the machine to keep the cost reasonable. Bpm is working now with extruder system oEms to further integrate the extruder with Bpms pelletizing system controls. The companys digital pellet length control (dplc) software adjusts the feed roll and rotor motors based on the input pellet length. currently the operator adjusts feed roll speed to maintain desired pellet length if the extrusion line speed changes. Further
38 compounding world | march 2012 www.compoundingworld.com
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estimated that they account for around 20-25% of secondary pelletizing or compounding applications, but this market share is increasing. BKG Bruckmann & Kreyenborg Granuliertechnik, which specializes in underwater die-face pelletizers, conducted a global market study last year and found that such pelletizers have taken market share from strand pelletizing systems over the past decade. The technology is proven in nearly any polymer pelletizing application, says ralf Simon, managing director at BKg, who notes that it has long been used in high-volume polyolefin production, but is now also used in high-volume production of polyamides and pET. while in the past, rates were limited, BKg pelletizers Galas patentpending Flux Die Plate provides several advantages for temperaturesensitive materials integration with the extruder will adjust the feed roll speed automatically, maintaining pellet length without operator input. compounding systems supplier Coperion recently entered the strand pelletizer market by acquiring a majority stake in Pell-Tec Pelletizing Technology, based in niedernberg, germany. pell-Tec produces strand pelletizing systems up to 6000 kg/hr. coperion and pell-Tec have been successfully working together for a number of years, and coperion has now taken the next step, said Thomas Kehl, a member of the executive board of coperion, who noted that coperion plans to extend the companys range of strand pelletizers across all output requirements. today can run up to 35 tonnes per hour of pET on one cutter, says Simon. underwater die-face pelletizers are now also common for glass-filled polymer systems. over the years, BKg has improved its wear protection systems for the pelletizer blades, water box, and especially the centrifugal dryer, which runs at high rpm and is subject to potential wear from abrasive fillers. Benefits of die-face pelletizer technology include automation, low maintenance, small footprint, and an enclosed system for dust control, notes Simon. BKg introduced a new water filtration system in 2010, which Simon says is now a proven technology with over 50 systems in operation. Highlyfilled compounds, which may contain up to 70% calcium carbonate, titanium dioxide, or carbon black, can create high dust levels in the process water coming out of the centrifugal dryer, resulting in problems at the process water
Die-face pelletizers
in an underwater die-face pelletizer, the molten polymer is fed through a die plate and cut by a knife blade in a water-flooded cavity; the pellets are then sepaAutomatiks Duro belt dryer is designed for abrasive compounds and can be used with underwater pelletizers
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rated from the cooling water and dried, typically with a centrifugal dryer. The process provides consistent product quality and can handle a wide range of melt flows, viscosities and filler content. underwater pelletizing systems can be used for higher throughput rates and they are the dominant technology for the primary pelletizing of virgin polymers, such as in polyolefin production. it is
Pelletizing & Pulverizing Technology

Strand Pelletizing
l Precision grinding of cutting rotors l Maintenance, Repair and Refurbishment of cutting rotor assemblies l New cutting rotors in several materials and designs, bed knives etc.
Under Water Pelletizing

l Re-sharpening of UWP knives and Surface grinding of die-plates l Repair and Refurbishment of die-plates l New die-plates and UWP knives
Pulverizing
l Precision grinding of discs and segments l New discs and segments in different materials and designs l Special wear resistant coatings
Rue Jean Koch 4 B-4800 Lambermont Belgium Phone: +32 8731 0906 E-Mail: pelletizing@bks.be Internet: www.bks.be
contact
BKS Belgium
BKS Malaysia
No.12, Jalan High Tech 5 Kawasan Perindustrian High Tech 43500 Semenyih, Malaysia Phone: +60 3 87 23 36 29 E-Mail: sorna@bks.com.my Internet: www.bks.com.my
How to stay sharp

BKS re-sharpens knives for strand and die-face pelletizers at its plants in Belgium and malaysia. it also regrinds die plates and offers repair services. it has looked at the optimisation of cutting performance in strand pelletizing systems and provides the following advice. Factors that can be controlled by the compounder include strand temperature. Strand temperatures should be as high as possible to reduce the risk of breakages, but they should be low enough to ensure that pellets do not stick together after cutting. BKS highlights the importance of having a homogenous temperature across the cross-section of the strand prior to pelletizing. it says that if the stand is cool on the outside, but still hot or even liquid on the inside, then it increases the risk of creating dust and fines and it will reduce the lifetime of cutting tools. clearly the number of cuts also influences knife longevity, as does the diameter of the strand. optimal distribution of the strands along the cutting width helps to extend cutting tool lifetimes. corrosion of cutting tools can be caused by the compound formulation or contaminated cooling water, while wear rates will be increased by abrasive ingredients in the material being processed. cutting gap adjustment also plays an important role the smaller the gap between the rotor and the bed knife, the BKS carries out precision grinding to re-sharpen cutting rotors better the cutting quality and the longevity of the cutting tools. in addition, the geometry of the rotor knife is a crucial factor, with the helix, rake and relief angle all having a strong influence on cutting performance. The materials used for the cutting tools also play a critical part in resisting wear and corrosion. options for bed-knife materials include tungsten carbide, ceramics, Stellite or diamond. The choice for rotor knife materials extends to tool and stainless steels, tungsten carbide, Stellite and materials made using powder metallurgy. The re-sharpening of cutting tools has a direct influence on the performance and longevity of pelletizers and requires knowhow to maintain optimised geometries. Similarly, the thorough maintenance of the bearings is vital to ensure the concentricity of the rotor which has a direct impact on the cutting gap.
www.bks.be
pump, heat exchanger blockages, or dust in the final product. Simon says that while traditional water filtration systems for underwater pelletizers have difficulty filtering these high contamination levels, BKgs optigon line efficiently filters particles under 70 microns. The system detects the level of contamination in the filter and automatically rotates and cleans the filter elements. BKg suggests using a continuously operated band filter. Automatiks duro belt dryer is an alternative solution for abrasive compounds that might cause wear in traditional impact or centrifugal dryers, as well as for brittle or chalky compounds that might produce excessive dust. Automatik, which supplies both strand and underwater pelletizing equipment, has successfully introduced to the market this relatively new type of patented pellet dryer for underwater pelletizers. in this system, most of the water is removed in a pre-dewatering chute and the pellets are dried by suction at high air speed as they move along a perforated conveyor belt.
This technology is low maintenance and reduces energy consumption, notes mueller. The patent-pending Flux die plate from underwater pelletizer supplier Gala Industries uses special insulation and manufacturing techniques that provide several advantages for temperature-sensitive materials. The technology reduces pressure drop across the extrusion land by 40-50% and reduces power consumption by 70%, says John roberts, global sales market manager at gala. The die plate allows a broader window of operation because it is less sensitive to rate fluctuation and upstream pressure requirements. gala has also developed a patent-pending rotary clamp design with a safety locking feature. This clamp offers simple, single-handed operation for opening and closing the clamp, while also providing an additional level of safety for the operators. Davis-Standards Black Clawson Converting Machinery division produces underwater, water-ring and air-ring pelletizing systems under its pelletor
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Brought to you by Applied Market Information, the leading provider of market intelligence and conferences for the global plastics processing industries. For more information, contact our advertisement manager, Claire Bishop. E-mail: claire@amimagazines.com Tel: +44 20 8686 8139 www.amimagazines.com
updATEd MEdIA pACks wITh Our 2012 FEATurEs lIsTs
nEw
machinery feature | Pelletizers
that today micro-pellets are primarily used in rotational and slush moulding as an alternative to powders, but new applications can be expected in the future. Coperion, which specializes in large underwater pelletizers, has introduced a next-generation pelletizer knife design used for polyolefin resin production. Since metals with higher abrasion resistance also tend to be more brittle and prone to breakage, Coperions new composite design uses a more flexible steel to hold a highly abrasion-resistant cutting edge, explains Klaus Kapfer, general manager for the polyolefin extrusion systems business unit. The composite knife can replace monobloc, solid knives or bimetal, claw knives, and has several advantages. The blade optimizes the pressure applied to the die plate for good cutting with the flexibility to counteract knife breakage. A new shaft design promotes pelletizer water circulation, so that pellet flow is Black Clawsons X model series can increase throughput by up to 25% in a given machine size brand. The company recently expanded its X model series, which features extra die plate orifices that can increase throughput by up to 25% in a given machine size. They are available for both new machines and for retrofitting to existing equipment. Retrofitting with the X model offers a quick payback time and uses the same equipment footprint, notes Charles Crumb, business group manager for extrusion pelletizing systems at Davis-Standard. The company also offers simple component upgrades that can improve the life of parts such as seals, bearings, knives, and die plates, thus reducing maintenance downtime and increasing the time the pelletizer is operating. High on-stream factors are key for pelletizer efficiency, says Crumb. He adds that the Pelletors die plate heating system gives it a very high on-stream factor due to its unique ability to sit idle without Coperions new composite knife technology is designed for underwater pelletizers used in polyolefin production die-hole freezing during feed material flow interruptions such as extruder feed bridging or maintenance issues. Davis-Standard developers are working on a new die plate design, to be available later this year, which increases die-face lifetime as well as throughput. Another project in development is a micro-pelletizing die designed to produce pellets around 1-1.5 mm. The new die will cover the grey area from the upper end of micro-pellets to the lower end of regular pellets, explains Crumb. He adds Click on the links for more information: not obstructed even with a high number of knives on the rotor. This new design also optimizes the transition between the shaft and the blade, avoiding dead spaces between the knife and knife rotor in which pellets can stick, which has shown significant advantages for handling sticky or rubber-like polymers, notes Kapfer. Pelletizer supplier Econ explains that underwater pelletizers with its thermally-insulated and wearresistant die plate design help optimize production efficiency by eliminating hole freezing, in which the molten polymer cools and solidifies inside the die-plate holes. Insulated plates can handle a wide throughput range, such as occurs at start-up, without freezing. Econs insulated die plates are made of a new Ceconid material and have minimal energy losses to the process water. This reduces heating requirements says the company, adding that the Ceconid die plates also lead to longer blade service life.
www.maag.com (Automatik) www.reductionengineering.com www.bayplasticsmachinery.com www.coperion.com www.pell-tec.de www.bkg.de www.gala-industries.com www.bc-egan.com (David Standard / Black Clawson) www.econ.eu
44
ComPounDIng woRlD | march 2012
Hall West, Section E, booth no. 7271
World
! e r e i Prem
Just a screen changer ?

f b est backflush performance f l owest backflush waste f l ow operating costs & quick ROI
BEST TECHNOLOGY INSIDE !

www.kreyenborg-group.com
FIRE RETARDANTS IN PLASTICS 2012

Trends and technical developments in the international flame retardant industry
June 14-15, 2012

Images courtesy of: Clariant, GBH International, and Fire Testing Technology
Grand Hyatt Denver, Denver, Colorado, USA
SPECIAL OFFER: Save $190 if you register before April 27, 2012
Organized by: Applied Market Information LLC Sponsored by: Media supporter:
Marissa Hann Conference Coordinator mh@amiplastics-na.com Ph: +1 610 478 0800 Fx: +1 610 478 0900
NPE 2012
| exhibition preview
The compounders guide to NPE 2012
NPE, the major North American plastics industry exhibition, moves from Chicago to Orlando for the first time this year. The shows organiser, the SPI plastics industry trade association is billing NPE 2012 as a new beginning for the exhibition which was launched in 1946 and has been running in Chicago since 1971. Relocating to the Orange County Convention Center in Orlando is intended to make the event more affordable for both exhibitors and visitors alike the spiralling cost of showing at Chicagos McCormick Center had been flagged up by many NPE exhibitors over recent years. The organisers can take one thing for certain for NPE 2012 the economic backdrop will be a whole lot more optimistic than at the previous event. NPE 2009 took place at pretty much the deepest point in the US downturn. Economic gloom combined with international travel restrictions in place in the wake of the H1N1 flu pandemic pushed attendance down by around 30% on 2006. But US manufacturing is looking fairly confident right now, buoyed by an upbeat automotive industry and lower than expected inflation and unemployment figures. NPE 2012 officially runs from 1-5 April, although visitors should note that the exhibition itself is only open from 2-5 April. Sunday 1 April is being billed as Super Sunday with a range of social, networking and
NPE is heading south to Florida this year. We preview the huge range of new compounding machinery, polymers and additives that will be on show in Orlando
educational events running throughout the day. More than 1,830 companies had taken around 84,000 m2 of booth space by the end of February with more bookings expected this month. Visitor registrations are also up on the 2009 figures they are predicted to exceed 50,000 and could approach 60,000, according to the events organisers. While NPE has now been eclipsed in size by Chinaplas and arguably PlastIndia too, it remains a crucial event on the global plastics industry calendar. It is second only to Germanys K exhibition for the number of new product launches that are made by exhibitors during the event. That is why we are devoting 16 pages
March 2012 | COMPOUNdING WORld 47
Orlandos Orange County Convention Center is the new home for NPE
exhibition preview |
NPE 2012
of this special issue to our NPE 2012 preview. It is also why we will be exhibiting at the show ourselves and reporting from directly the event. You can meet the AMI Magazines team on the Applied Market Information booth, 63000 in South Hall. Full details of the exhibition including registration, travel and accommodation information, plus listings of the wide range of accompanying conferences, seminars and social events can be found at the events website:
exceed 20%, causing substantial reductions in extruder throughput. The new PLC control automatically adjusts the timing of the reciprocating ram which stuffs material into the screw. Changes are made in accordance with variations in extrusion drive amperage caused by changes in material bulk density. Since the ram cycle governs the rate at which material is fed into the extruder, the controller ensures that production will continue at the maximum level without the need for operator intervention.
www.npe.org
Over the following 16 pages we preview a large number of new products that will be launched at NPE. Our focus is on developements that are relevant to the compounding industry and they are listed alphabetically by company under the following sections: Compounding & recycling lines Auxiliaries & components Materials testing Polymers & compounds Additives Colorants Page 48 Page 54 Page 58 Page 62 Page 67 Page 68
Booth: 4855 www.adgs.net

Apex Engineering builds modular compounding lines based around equipment that can be chosen by the customer. It integrates the selected extruder, feeders, pelletizer and control system. The company says that the lines can be compounding material within 15-20 days of delivery to the site. It adds that they resemble a normal process line, rather than a boxy sea crate frame, and can be integrated into a traditional factory or warehouse type building. State-of-the-art control software is included, specifically tailored for the plant interfaces. Allen Bradley control platforms are used unless the customer has an alternative preference. A compounding control center (CCC) accompanies the process module and wiring is minimized using ethernet, remote I/O and intelligent MCC. Apex says that its approach means that project schedules are simplified and shortened by 25-30% with off-site construction resulting in a comparable reduction in project costs. The finished module can be easily disconnected and shipped anywhere in the world.
Compounding & recycling lines

ADG Solutions, which is the exclusive North American distributor of Davis Standard reclaim and compounding equipment, will be demonstrating a new PLC control for Apex Engineerings modular compounding lines save time and money the companys ram stuffer extruder at NPE. The controller increases efficiency and productivity for the recyclers of low bulk density polymer scrap such as films, fibres and thermoformed sheet. Bulk density variations in light feedstocks can
Booth: 61006 www.apex-engineering.com

B&P Process Equipment will be demonstrating its innovative Trivolution tri-kneader technology for the first time at a major exhibition. The company has built an interactive display model so that visitors can see the inner workings of the ground-breaking reciprocating kneader. The model consists of a three-zone process barrel with the middle zone open to expose a clear process section that provides a view into the heart of the process. The interaction between stationary pins in the barrel wall and the flights that rise from the rotating and reciprocating screw shaft will clearly demonstrate the folding, orientation, compression, shearing and decompression stages offered by this technology. The feed and discharge ends of the display model will include touch-screen interfaces where visitors will
48
COMPOuNdINg wOrLd | March 2012
NPE 2012
be able to explore the various process layouts, machine features and functions. These include feeding, degassing, temperature control as well as maintenance and R&D benefits designed into the machine. B&P says that the Trivolution is ideal for compounding sensitive additives and fillers into a high-heat polymer matrix, or for achieving excellent dispersion in fractional melt compounds. It can also be used to impart great mechanical energy into difficult to compound formulations.
Booth: 2108 www.bpprocess.com

Century Extrusion will launching a variety of new products in Orlando. It will be showing a CXE 133-mm 36L/D twin-screw extruder featuring an innovative oil monitoring system. The GearControl-Oil system monitors the condition of the gearbox by analysing its oil. It is designed to spot any damage in its very early stages to give operators the chance to carry out the required maintenance or repair before a serious and costly breakdown happens. The system can also determine the best time for the oil to be replaced, eliminating unnecessary changes. It monitors six different parameters and uses a speciallydeveloped algorithm to produce a simplified indication of the gearbox condition. Century will also be showing its new highperformance E-series extrusion strand die. Polymer flow within the die has been modelled and optimised to ensure uniform distribution to all the die-holes. In addition, a unique split-body construction enables quick changeover of the distribution manifold when required. The E-series strand die also boasts a new die-plate clamping system that eliminates loose bolts in the work area. Operator safety is enhanced because the dieplate is retained by a gib retention bar during change-overs. Other new developments from Century include a high-output CXE machine with a 177-mm screw diameter, plus a new RXT series extruder manufactured at the companys China-based Ruiya Extrusion factory. Entek Manufacturing will have two twin-screw extruders on display at NPE a 27-mm model for laboratory applications or small-lot compounding, plus a 103-mm largescale production machine. The latter features an all-new base design for easier access. It has a 52:1 L/D, a 300 rpm/600 hp motor plus a side feeder. The company will also be introducing improved Coperion will be promoting the enhanced capabilities of its latest co-rotating twin-screw extruder design,
the ZSK Mc18. It will be showing one of these machines with 45 mm diameter screws plus a ZS-EG twin-screw side devolatilization unit and the companys innovative Feed Enhancement Technology (FET) on a ZS-B side feeder unit. The ZSK Mc18 boasts a specific torque of 18 Nm/cm3 which is 30% higher than the ZSK Mc Plus, and it also achieves up to 30% greater throughput rates. A new ZSK 32 Mc18 machine has recently been commissioned for customer trials at the companys US facility in Ramsey, New Jersey. Coperion will also be showing its new HFS horizontal fluid-bed separator at NPE. The compact unit is claimed to offer superb fines separation performance over a wide variety of compounded products. It removes dust or misshaped pellets from the bulk materials prior to packaging or processing, therefore ensuring a high-quality end product. Centurys E-series
B&Ps Trivolution model will get its first public outing at NPE
extrusion die features optimised melt flow
Booth: 6463 www.coperion.com
Booth: 5585 www.centuryextrusion.com
control functions for its twin-screw extruders. Updates include: enhanced trend monitoring; remote access for
March 2012 | COMPOUNDING wORLD 49
npE 2012
Coperions new HFS separates the pellets from the fines
24/7 machine support via the internet or a phone line; an improved and expanded recipe/formula system; and remote storage of trended data on office servers. in addition, the Entek plus business unit will be showing several recent developments including: new twin-screw replacement technology featuring new concepts for screws and screw elements; gearbox and melt pump re-manufacturing capabilities; a new single-piece twin-screw design; and, the latest in-house lab developments including bioplastic and highly-filled resin processing capabilities.
Booth: 4691 www.entekextruders.com

Farrel Pomini will be showing its cp1000v compact processor which is ideal for the production of polyolefin compounds with high levels of mineral fillers, as well as making colour and additive masterbatches. A continuous mixer imparts the required amount of shear and energy into the material, while the pumping function is completed by the short l:d, hot-feed extruder located after the mixer. The mixer features three-piece rotors for easy removal without disturbing the bearing housings. Various rotor geometries are available to meet specific mixing tasks. Farrel will also be promoting its new state-of-the-art process laboratory & customer demonstration Facility in connecticut, uSA. The labs primary processing machine for customer demonstrations is a cp550 compact processor that can be configured with rotor geometries up to double the standard length, utilizing the lcm rotor. The cp550 is a production-sized machine from which scaling up is routinely done with confidence, according to Farrel. This 103-mm twin-screw will be the larger of two Entek machines on show Gamma Meccanica will be highlighting the latest developments for its plastics recycling lines. For example, its Tandem system features two extruders to
provide double filtration for handling materials with full print coverage, high levels of contamination, or more than 10% moisture content. The configuration, venting and filtration can be varied for each extruder depending on the application, but both machines feature the companys special degassing chamber. This delivers the highest exposure for the melt strands under vacuum, removing volatiles from the material and yielding a higher quality granule. The company is also launching a larger and very robust water ring (hot die face) pelletizer. The TdA 6.0 is a compact design for 7 and 8 extrusion lines and is capable of processing 4,000-6,000 lbs/ hour (1,800-2,700 kg/hour). it is designed to handle materials with a higher mFi and the self-aligning blade holder ensures uniform granules and reduced fines. in addition to being used with gamma meccanicas own lines, the pelletizer is also offered for applications with other makes of extruder.
Booth: 8644 www.gamma-meccanica.it

Gneuss will be showing a complete extrusion line with a multi rotation System mrS 130 extruder, a fullyautomatic rSFgenius 150 filtration system and a ViS online viscometer. The mrS extruder can process pET or plA without pre-drying. it features a drum containing eight satellite single screws. The barrels are approximately 30 % open and provide optimum exposure of the melt. Thanks to this design, the devolatilizing performance is 50 times greater than that of a conventional single screw extruder, according to gneuss. The comapny says that the mrS also offers excellent decontamination performance. it has received four letters of non objection from the uS FdA for the reprocessing of pET material for applications in the food industry. The latest letter allows producers to process up to 100 % pET bottle flake into FdA
Booth: 6445 www.farrel.com
50
POLYMERS
in
Photovoltaics 2012
International forum on markets, materials and manufacturing of photovoltaics
24-26 April 2012

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NPE 2012
KraussMaffei Berstorff will show a modular compounding line for simplified shipping
approved end products such as food containers. Gneuss will also be showing three of its rotary melt filtration systems SFXmagnus 90, RSFgenius 75 and RSF genius 200 in addition to the one fitted to the fitted to the MRS extruder.
Booth: 6685 www.gneuss.com

KraussMaffei Berstorff will be showing a compounding line based around a ZE 60 A UTX twin-screw extruder fitted with an EasyClean module. This design includes several individual components and improved features, which permit the cleaning time for product change to be reduced by up to 40%. The complete plant has a modular design with the line divided into practical units that have the dimensions of a sea container for simplified shipping. The modular structure considerably reduces assembly times at the customers site. It also ensures significant savings in total construction costs because additional steelwork is not usually required.
Booth: 1503 www.kraussmaffei.com
!compounding
& extrusion
!materials
handling
!service
!!The advance into a new performance dimension of compounding technology. The new
ZSK Mc18 twin screw extruder of Coperion, formerly Werner & Peiderer, is the most productive high performance ZSK of all time. With a specic torque of 18 Nm/cm3 it stands for considerable throughput increases with improved product quality and the widest processing window on the market to provide you with a unique technology advantage. Thats what we mean when we say condence through partnership. !!www.coperion.com
Visit at NPE 2012 Orlando, FL/USA, Apr 2-5, 2012 West Hall, Booth no. 6463
NPE 2012
Leistritz will be displaying a ZSE-50 MAXX twin-screw extruder configured for both reactive and direct extrusion with a screen changer, gear pump and flexlip sheeting die. This machine has a 400 hp motor and a 52/1 L/D process section with provision for vacuum venting, liquid injection and downstream side stuffer. It features a special modular barrel section design with high-wattage cartridge heaters and increased coolant flow to improve heat transfer. The 1.66 OD/ID screw set will be shown outside the machine. Also on display will be a Leistritz ZSE-40 MAXX with a new swing-gate strand die assembly. This facilitates a streamlined transition from the extruder to an oval breaker plate and then to a front-end die plate. Screens are accessed by swing bolts, which allow removal of the screen carrier plate for good cleaning access. A replaceable multi-strand die plate is integrated into the design. An area of the Leistritz booth will be dedicated to lab-scale twin-screw extruders. Three models will be displayed. The Nano-16 features a 1.2 OD/ID ratio and can process batches as small as 20-100 g. It will be joined by a ZSE-18 with an integrated side stuffer for the downstream addition of fillers and fibres. The third lab-line on display will be a Micro-27 modular twinscrew extruder that can operate in both co-rotation and counter-rotation modes. Leistritz will display a ZSE40 MAXX with a new swinggate strand die assembly
Booth: 5975 www.leistritz-extrusion.com
Intelligent Additive Solutions

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npE 2012
Auxiliaries & components

Air Products will be showcasing its polarFit ultra-fine grinding mill which provides a cost-effective way to reduce hard-to-grind materials to particle sizes that are smaller than those achieved with conventional impact mills. it generates consistent yields of particles between 45 and 240 microns, and in some cases as small as 10 microns. The mill is ideal for the cryogenic size reduction of a wide range of materials, including pigments, plastics, powder coatings, thermoplastic elastomers and waxes. it uses a combination of size reduction mechanisms, including impact, attrition and particle-particle collision. An easily adjustable grinding gap allows the production of particle sizes from ultra-fine to coarse.
while also enabling its capabilities to be extended to as many as 500 loaders and pumps. meanwhile, the entry level FlX system which can be set up with as few as eight loaders can now be expanded up to 128 loaders and 40 pumps. The controlworks plant-wide ancillary equipment monitoring system has also been redesigned on a new platform, which the company says will also make it easier to adapt the system to individual requirements.
Booth: 3643 www.conairgroup.com

Eriez will present its latest family of metal separators for the plastics industry, including models for throat or conveying line installation. model FF units mount on the machine throat and can detect magnetic and non-magnetic contaminants under free-fall conditions, isolating them from the feed stream with a flap diverter. The cFp is also throatmounted and features slide valve and venturi nozzle isolation. The cF unit includes self calibration and monitoring functions. The pn series of separators are designed for use in vacuum and pressurised material feed lines and can handle hot, abrasive and powder materials.
Booth: 51055 www.airproducts.com

BMSvision will show the latest version of its plantmaster manufacturing Execution Systems (mES) for the monitoring and management of plastics processing operations. Based on wireless data collection technology, mES includes software modules for real time production and process monitoring, production scheduling, Spc and Qc, and traceability. BmSvision will also present its Energymaster system for monitoring and managing energy usage and determining the co2 footprint of an operation. Energymaster maps different utility consumption rates (electricity, water, gas, compressed air and steam) and integrates with other mES-applications, such as machine and production monitoring, to provide Specific Energy consumption data for the fast identification of energy saving opportunities. The Eriez CF metal separator includes self calibration functions Conair will show the latest versions of its ilS intelligent loading System, FlX loading control and controlworks materials handling and management systems. The ilS system is now completely Ethernet-based, making it much more straightforward to cable and install
Booth: 2583 www.eriez.com

Foremost Machine Builders will be displaying its AT4540-Vii-ATVl gravimetric blender, a floor-mounted four-component unit mounted on a distribution box and equipped with vacuum chambers on each component hopper. The system will be linked to the uS-based companys Fdp-Vii-ATVl control package, which can manage up to six blending components, two vacuum pumps and eight loading stations. other Foremost exhibits will include its VF series of vacuum loaders, Format Vi-4 plc control panel, and SEp-pA-dp-3 throat-mounted metal separator.
Booth: 3683 www.bmsvision.com
Booth: 3263 www.foremostmachine.com

Kreyenborg will be using npE to highlight progress in its infrared dryer (ird) technology and in particular the use of its smaller ir Batch machine for the crystallization of pET masterbatches. it uses shortwave infra-red radiation instead of hot air as a heat source, providing fast and
Profiles
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International business and technology conference for the window, door, decking, fence and siding profile industry
Royal Dominion
Royal Dominion
Versatex Trimboard
Royal Dominion
June 5-6, 2012

Crowne Plaza Philadelphia Downtown, Philadelphia, Pennsylvania, USA
Trex
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nPE 2012
Maguires Loader Lift system helps to speed up change-overs
energy-efficient processing of PET. Unlike the larger continuous IRD systems, the IRD Batch is a discontinuous machine and it can efficiently handle batches from 10-400 kg. This makes it particularly suitable for the processing of masterbatches with regular colour changes and for handling other special products, including bioplastics. The batch operation allows the drum rotation and temperature to be optimised for the different steps of the drying process. Typically, the crystallization process is completed in 15 to 20 minutes. Highly-filled masterbatch pellets can suffer from sticking caused by electrostatic effects. A special masterbatch package for the IR Batch includes an ionization unit to deal with this issue. The machine is also designed for easy cleaning to speed up product changes. Kreyenborg also says that it will be unveiling a brand new development in backflush screen changers at the show.
Booth: 7271 www.kreyenborg.de

Lorenz Conveying Products will show its range of traps for the removal of angel hair and other fine contaminants from polymers. The companys square traps feature a standard 16-inch square bolt pattern and are intended for fitting direct to a silo or hopper shut-off. Inline versions are intended for applications in the material flow stream. Both types feature screens that can be quickly replaced. The traps will be shown alongside the companys extensive range of cyclones, diverters and pneumatic conveying products. Miller-Leaman is introducing its self-cleaning TurboDisc Filter designed to remove particles and other contaminants from process cooling water used in extrusion operations. The filter uses substantially less Maguire has recently received a US patent for its Loader Lift system that speeds up change-over times for gravimetric blenders that have loaders mounted on the hopper lid. The pneumatically powered system lifts the hopper lid at the touch of a switch, providing Kreyenborgs IRD Batch for the crystallization of PET masterbatches easy access to ingredient bins without needing to remove the loaders. It is available for an added cost of US$500 on Maguires popular MicroBlender and MicroPlus models. Two safety features prevent operators from accidentally having
56 coMPoUnDIng woRLD | March 2012
their fingers caught by the lid. This cannot be lowered unless the operator presses two buttons simultaneously; plus a large rubber flange protruding from the rim of each bin leaves more than enough room for fingers even if the lid is fully lowered.
Booth: 5963 www.maguire.com
Booth: 267 www.lorenz.ca
backwash water than conventional sand media filters. It is designed for full-flow or side-stream use; sidestream systems come complete with a pump. The design is modular multiple filter pods can be added to the system to handle the desired sidestream flow rate and the three-dimensional polypropylene disc media is available in multiple micron sizes. An onboard controller monitors the differential pressure across the filter system, triggering an automatic backwash when the filter becomes dirty.
Booth: 31046 www.millerleaman.com

NPE 2012
PSI-Polymer Systems will introduce its newest screen changer at NPE. This all-new, patent-pending design includes a unique back flushing system, where the contaminated screen packs are flushed and discharged through a port underneath the screen changer housing. The company says that this creates a much cleaner and safer environment for operators. The new back flush screen changer is capable of processing materials with extremely high levels of contamination.
Pelletrons Pellcon3 systems combines three products to improve product conveying
Booth: 5991 www.psi-polymersystems.com

Rossi Gearmotors will be highlighting its broad range of gear reducers, gear motors, electronic speed variation systems and electrical brake motors at the Orlando show. It has experience in extruder applications and offers a large selection of sizes, up to 5,000+ hp in both gear reducers and gear motors.
Booth: 10051 www.rossi-group.com

Schenck AccuRate will be showing its Mechatron Vibro Feeder for metering easily damaged materials including powders, granules, chips, flakes and fibres. A conical hopper ensures consistent material flow to the feed unit, while the specially designed feed chute gently meters dry solid materials. Volumetric and gravimetric Pelletron will use NPE to promote its Pellcon3 pneumatic conveying system that is designed to deliver high-quality plastic pellets with minimum levels of dust or angel hair. Pellcon3 uses the companys StrandPhase technology for gently conveying pellets at a moderate velocity to avoid breakage and attrition of the product which can occur in dense-phase or dilute-phase conveying systems. The system also uses Pelletrons Pellbow pipe elbow which has an enlarged chamber between the inlet and outlet to reduce friction and impact levels for the conveyed pellets, reducing the creation of streamers. The final component of the Pellcon3 system is Pelletrons DeDuster for removing any dust and angel hair that is present in the pellets to create a high quality resin with dust levels below 30 ppm. configurations are available. The company will also be showing its SacMaster, a versatile and safe bulk bag unloading system. A number of features make it well suited to the handling of pigments, plastic pellets and a wide range of other bulk materials. These features include bag tensioning, hoist or forklift loading, height adjustability and the Posi-Flow
Booth: 433 www.pelletroncorp.com

Progressive Equipment Solutions specialises in new and refurbished screws, barrels and tip assemblies for twin- and single-screw extruders. At NPE it will be highlighting its ability to encapsulate parallel twin-screws with tungsten carbide to extend the working life of the components. PSIs new screen changer ensures a cleaner and safer environment for operators
March 2012 | cOMPOuNDINg wOrlD 57
Booth: 57054 www.progressivequipment.com

NPE 2012
agitation system that fluidizes compacted materials.
Syscon PlantStar will be demonstrating the latest additions to its real-time production monitoring software, including new effectiveness, scheduling and quality management tools. An expanded version of the companys Overall Equipment Effectiveness display is claimed to make it easier to extract data from the system while operators can now add cause and effect notes to the process journal to assist maintenance and QC staff. Also new is a KanBan scheduling module that can be used either with a card-based barcode system or in a fully electronic form. And the programs Gantt job scheduling capabilities now includes a tool conflict feature.
Booth: 3291 www.accuratefeeders.com

Sciences Computers Consultants will be demonstrating its Ludovic software for analysing and modelling the corotating twin-screw extrusion process. The data can be used to optimise the process and the material quality. It can also be used to assist the scale-up of compounding from lab-scale machines to production extruders.
Booth: 41043 www.scconsultants.com

Sweco will be displaying its DC Classifier, a multi-functional machine that is designed to dry, cool and classify plastics materials in one unit. It uses either positive or negative air flow to draw moisture and heat away from the particulates to dry and/or cool the material. Material continues through the machine to the classification stages where oversize and fine particles can be removed. The DC Classifier has modular decks that can be easily removed for cleaning in-between material or colour changes. The company will also be showcasing its new Fusion Screen which has an integral gasket. This special construction creates precise and repeatable tensioning of the screen. The integral gasket is one moulded part, as is the one-piece centre disc with Swecos DC Classifier dries, cools and classifies plastics in one unit integral strain relief. This unitary construction integrates the screen gasket directly into the tension ring. It reduces cracks and crevices, making the screen easier to clean.
Booth: 4143 www.plantstar.org
Materials testing
Cometech Testing Machines of Taiwan will be in Orlando to showcase its machines for tensile, abrasion, hardness and impact testing, as well as related equipment such as grips, extensometers, load-cells and v-shaped notching machines.
Booth: 8690 www.come-tech.com.tw

Datacolor will be demonstrating its new 45G, a highaccuracy handheld spectrophotometer with integrated gloss measurement. It can be used for the colour appearance evaluation of plastic parts, printed packaging or painted surfaces. Measurements made with the 45G capture the effect of base colour, gloss and texture on the overall visual appearance. The instrument enables quality control of multiple components to a close numerical tolerance in order to achieve an overall match in colour appearance. It features: simultaneous measurement of gloss and
Booth: 51020 www.sweco.com
AMI Strategy Seminars

These one-day seminars are given by an AMI director and provide invaluable insights into market trends and industry strategies. They are held in small groups and provide ample opportunities for questions and discussions.
29 March 2012: Singapore 17 May 2012 : Hamburg, Germany 19 June 2012: Vienna, Austria
25 June 2012: Chicago, USA 16 October 2012: Cologne, Germany 5 November 2012: Philadelphia, USA
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www2.amiplastics.com/Seminars
COMPOUNDING & PROCESSING 2012

International industry conference on the profitable use of bioplastics
May 8-9, 2012

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POLYMER SOURCING 2012

Shaping the industry for profit and growth
HEaDLINE SPONSOR
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14-16 May 2012

Marriott Hotel, Hamburg, Germany
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NPE 2012
colour for quality control; 45/0 optical geometry to correlate with visual appearance; and a modern, ergonomic design with colour screen and Bluetooth connectivity. The software on the device enables storage of standards and batches, calculation of colour values, and indication of pass/fail in quality control.
places the sample in the barrel, inserts the piston, closes the cover and presses start no intervention is required until after the result is obtained. Instron will also be introducing its new Ceast HDT Vicat 500 (HV500) Aloxide tester, which is approved for Vicat testing to ASTM D1525. The semi-automatic instrument is designed for testing up to 500C, does not use silicone oil, and offers improved safety over traditional methods. It performs HDT and Vicat tests on three independent test stations that are automatically raised and lowered by a pneumatic system at the beginning and end of each test. It is possible to perform HDT and Vicat tests simultaneously with the same temperature ramp conditions. Datacolors new 45G spectrophotometer has integrated gloss measurement
Booth: 55013 www.datacolor.com

Instron will be showing its new Ceast 7028 multi-weight melt flow tester, which can be used on a wide variety of polymers and is in full compliance with ISO 1133 A and B, and ASTM D1238 procedures A, B, C, and D (the multi-weight procedure). It is said to be ideal for quality control and acceptance of incoming thermoplastics, verifying if the plastics grade is within the required fluidity range. The Ceast 7028 provides enhanced safety features including an interlocked safety shield and the automatic placing and lifting of the weights. The operator simply
Booth: 2403 www.instron.com

Netzsch will be showing its latest development, the TG 209 F1 Libra thermobalance which is ideally suited to polymer analysis. The instrument allows tests to be carried out faster, more accurately, and across an extended temperature range. Its special BeFlat function automatically compensates for any external factors influencing the measurement. The calculated DTA signal, c-DTA, yields valuable information on a polymers phase transitions. This additional information allows Netzsch will be showing its latest Libra thermobalance for polymer analysis
Maag Group is the innovative solution provider for pump, pelletizing and filtration systems. We deliver high-quality components and complete systems, from extruder tips to pelletizers. In addition to our primary locations in Switzerland and Germany, we have eight sales and service offices around the globe to provide our customers with full service par excellence.
1 - 5 April 2012 West hall stand 5563
brands of maag group
Automatik Plastics Machinery GmbH Ostring 19 63762 Grossostheim Germany T +49 6026 503 0 info@maag.com Maag Pump Systems AG Aspstrasse 12 8154 Oberglatt Switzerland T +41 44 278 82 00 welcome@maag.com www.maag.com
NPE 2012
Tinius Olsen says its new MP1200 Melt Indexer offers high levels of accuracy
for an unknown sample to be identified and characterized much more easily and precisely. The vacuum-tight design of the TG 209 F1 Libra not only allows for the creation of a pure inert atmosphere via evacuating and filling, but also for the execution of measurements under vacuum conditions. The mass loss steps from the evaporation of the plasticizer and the decomposition of the polymer can be clearly separated. Therefore it becomes possible to characterize the plasticizer content precisely.
unique to PTFE such as low coefficient of friction, excellent chemical resistance and outstanding thermal performance. Fluon melt processable compounds are based on FEP, ETFE, PFA, PVDF, MFA and ECTFE. There are seven different product types: colour concentrates, foam concentrates, cross linkable, conductive, glassfilled, lubricated, and rotomolding grades.
Booth: 15023 www.agcchem.com

Asahi Kasei will display examples of its latest polymer developments, with the focus on new eco-friendly halogen-free and low emission grades. Xyron PV is its latest modified PPE for solar panel applications, offering UL5VA and V-0 compliance without halogenated flame retardants, while the Tenac Z-series acetals are said to meet the VOC emission requirements of leading global OEMs. The company will also show its Thermylene P4 nondecabrome flame-retarded PP compounds, which are available in unfilled, talc and mineral-filled, plus glassreinforced versions.
Booth: 56046 www.netzsch.com

Tinius Olsen will launch its new MP1200 Melt Indexer at NPE. Described as a significant upgrade of its MP600 model, the new extrusion plastometer uses three-zone temperature control to give high levels of accuracy and thermal stability. The integral touch-screen control panel features a user-friendly interface based upon the companys Horizon software. A convenient die release enables simple orifice removal for cleaning, while a built-in mirror allows easy inspection of the barrel. The MP1200 can be used to conduct Procedure A or B tests and it conforms to ASTM D1238 and D3364, ISO 1133, BS 2782, DIN 53735, and JIS K7210.
Booths: 33013, 34013 www.akplastics.com

Chase Plastics, a leading North American distributor of thermoplastics, will be discussing the recent expansion of its warehouse facilities and technological capabilities. Its warehouse services include blending, repacking and labelling. The company has also been integrating its Prophet 21 inventory and supply chain management software. The sales team can now access pricing, order history and real-time inventory data via tablet computers while they are in the field.
Booth: 51017 www.tiniusolsen.com
Polymers & compounds

AGC Chemicals will showcase its high-performance Fluon fluoropolymers resins and its Aflas fluoroelastomers at NPE. The company works closely with customers to develop custom solutions for a range of demanding industries including transportation, chemical processing, oil and gas exploration, electronics and life sciences. Its Fluon filled PTFE compounds are used in applications such as seals and gaskets, coatings and additives where mechanical strength, chemical resistance, and lubricity are essential. AGC uses proprietary technology to add the fillers that include glass, carbon fibre, graphite and metal powders such as bronze and molybdenum disulfide. These provide enhanced capabilities including wear resistance, creep resistance, thermal conductivity and electrical conductivity while preserving the core properties that are
62 COMPOUNDING wOrLD | March 2012
Booth: 37027 www.chaseplastics.com

China New Materials Holdings will be showcasing its integrated manufacturing capabilities for biodegradable plastics. Its products include fully biodegradable polybutylene succinate (PBS), plus high-purity BDO, which is a key raw material for PBS production. It claims to be the only producer of BDO in China.
Booth: 64043 www.china-newmaterials.com.hk

DuPont will display novel applications for its range of engineering polymers, including a new lightweight prosthetic foot made in its Hytrel polyester TPE.
NPE 2012
The Niagara foot, developed by Canada-based Niagara Prosthetics & Orthotics International, is moulded using DuPonts Hytrel TPC/ET resin. The new design is claimed to provide a lightweight solution that delivers better stability and mobility for amputees. The company will also show two of the latest automotive applications for its renewable resins - biodiesel fuel lines produced in its Zytem RS polyamide for Fiat, and air conditioner louvres moulded in its Sorona EP polymer.
Kraiburgs Thermolast W offers optimum grip even in the presence of moisture
Booths: 35013, 57046 www.dupont.com

Dyna-Purge will exhibit its latest process equipment cleaning products, including the newly-launched DynaPurge E2 purging compound for high-temperature resins. E2 is said to be suitable for use with PEEK, PEI, PPS, PPA and PSU resins and is claimed to purge equipment more effectively, more quickly and at lower cost than alternatives such as mechanical or chemical purging systems. The claim is backed up by data from tests carried out at the University of Akron which compared E2 against highly glass filled polycarbonate and chemically modified polyolefin compounds. FKuR will be showing examples of its latest bio-based, biodegradable and natural-fibre-reinforced plastics compounds. These include new developments in renewably-resourced materials for injection moulding and film extrusion applications. Elastocon will launch a new soft addition to its 8000 series of TPEs that is claimed to provide very good scratch and mar resistance together with a reduced tendency to collect dust and debris. The 8078NL grade provides a Shore A hardness value of 80 and displays a low frictional surface, along with good sound and shock deadening performance. According to Elastocon, the new grade is particularly well suited to the production of parts such as cup holders and storage trays in automotive interiors. The company will also be showing its 2600 series of high performance TPEs, its SMR series of TPOs and the STK series of alloys for overmoulding applications. Invista will use NPE as the launch pad in North America for its new premium polyamide brand, Torzen. This covers a wide range of PA 66 grades including feedstock for compounders, plus a variety of glass-and mineralfilled formulations as well as toughened, lubricated, heat-stabilized and fast-cycling products. They are said to provide a significant improvement in continuous use and peak temperatures. Target markets include the automotive, electrical and appliance sectors. Another highlight will be the companys first compounds containing Braskems Green PE that is derived from sugar cane. These compounds will be marketed under the Terralene name.
Booth: 4252 www.dynapurge.com
Booth: 57042 www.fkur.com
Booth: 57021 www.elastocontpe.com
Booth: 25016 www.invista.co www.invista.com

Kraiburg TPE will use NPE to highlight new products such as its Thermolast W wet grip technology. This produces TPE materials with optimum grip even in the presence of moisture for a range of consumer, industrial and medical applications. The company will also be promoting its OBC blends
DuPont will display the Niagara foot moulded using its Hytrel TPC/ ET resin
March 2012 | COMPOUNDING WORLD
63
npE 2012
offers good thermal and light stability and is available in a range of colours. lTls display will also include its recently expanded antimicrobial medical compound line. colorrx Am grades contain a silver ion antimicrobial additive and can be supplied a wide range of polymer types as a masterbatch or ready-to-use product. The colorrx products are said to provide medical plastics products with additional protection from the pathogenic bacteria that cause hospital-acquired infections.
Booth: 50020 www.ltlcolor.com

Polymera is a new company that will be making its npE debut. it will be launching its meraBlend wood-plastic composite (wpc) materials, as well as it support services. in addition to supplying compounds, it can also manufacture profiles and provide consultancy to help a company make its first moves into extruding wpcs. Teknor Apex is targeting a range of applications with its new BioVinyl compounds that it says offer outstanding mechanical performance together with enhanced flow, hand oil and chemical resistance. They also deliver improved adhesion to engineering thermoplastics for use in electronic devices. Kraiburgs recently introduced polar Alloy blends are described as an important development in the area of haptics with increased abrasion resistance, minimal creep, and ease of colouring compared to silicone and vulcanizate blends. Their improved haptics result in a silky, non-stick, smooth surface and they have significantly higher overmoulding bond strength to engineering thermoplastics. Purac will be promoting its new pllA and pldA biopolymers, which it claims make it possible to develop plA polymers with enhanced thermal stability for injection moulding applications. now available commercially, purac pllA and pldA resins are said to make it possible to lift the thermal stability of plA to as high as 150c. current typical plA grades soften at temperatures of around 55c.
Booth: 27045 www.polymera.com
Booth: 61027 www.kraiburg-tpe.com

LTL Color Compounders will introduce a new ul-listed flame retardant homopolymer pp injection moulding compound at the show. pp1-FrV2 1-FrV2 is Purac lifts the thermal stability of PLA bioplastics a non-blooming roHScompliant compound that 94 V2 at 1.5mm. achieves ul94 The company says it
Booth: 54048 www.purac.com

Star Thermoplastics will be displaying its latest TpE developments. These include Starprene, an SEBS material that is said to provide similar flow to many TpV grades, along with better tensile strength and elongation. According to the company, it is also easier to colour, provides material cost savings and eliminates the need for pre-drying. The company is also introducing Starclear products that are said to Star provide very high levels of clarity and offer hardness values from 30 to 60 Shore A. The TpEs also provide good overmouldT ing performance, says Star.
Booth: 59020 www.starthermoplastics.com

T&T Marketing, the uS-based polymer distributor, has added several new product lines including wire and cable compounds and masterbatches produced by
64 compounding world | march 2012 www.compoundingworld.com
template Polymers in Cables 2012 2012

The international conference and exhibition for the plastics cable industry
April 18-19, 2012

Hyatt Regency Miami, Miami, Florida, USA
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npE 2012
Mixer of italy. These include EpdM and cpE plus highquality colour concentrates for all polymers. T&T also distributes many other products including various FEp compounds which have excellent thermal stability, inertness and electric insulation properties plus a low coefficient of friction.
Booth: 18023 www.ttmarketinginc.com

Teknor Apex will introduce a range of vinyl compounds manufactured using dows Ecolibrium line of bio-based phthalate-free plasticisers. As reported in last months
compounding world, the two companies recently signed

an agreement that gives Teknor Apex exclusive rights to market compounds based on the innovative additive for certain applications in north America. The company says that the new BioVinyl compounds will typically incorporate less than 35% petrochemical content and will be suitable for a wide range of applications where they can offer a more pricecompetitive option than some alternative green products. Key markets the company is focusing on include consumer and industrial products, automotive components, and certain medical devices and wire and cable uses. Galata Chemicals, the pVc additives business bought out from chemtura, is planning to announce a series of new initiatives at npE 2012. These include investments in an expanded range of vinyl and beyond vinyl additives, and a new applications laboratory in the uS. new launches for the pVc market include: highperformance organic based stabilisers; tin stabilisers designed to replace existing butyl tin products; rEAcH friendly liquid mixed metals for flexible and semi-rigid Americhem is introducing its nShield antimicrobial masterbatches that inhibit the growth of odour-causing bacteria in synthetic fibres and plastics products. They are said to be highly effective at low levels against a wide range of micro-organisms in a variety of applications, including apparel, filtration, synthetic turf and automotive interiors. dr Vaman Kulkarni, director of business development at Americhem, says: The success of our antimicrobial agents in textiles throughout the past few years has led us to officially introduce the technology and offer it to our customers as nShield. Because it is engineered into the end product, nShields antimicrobial effect is non-migratory and results in good durability. nShield antimicrobial agents also resist discoloration and degradation caused by bacteria for long-lasting aesthetic appeal. Laurel Biocomposite will introduce its new Bio-res pellets, which are said to provide an easy way for processors to lift the renewable content of their resins on-site at low cost. Bio-res pellets are produced from corn-based distillation grain and can be incorporated as an additive in resins such as polyolefins and plAs. The pellets can be added at the processing machine and used at ColorMatrix, which is now part of polyone, will be showing its Excelite liquid foaming agent for producing
pVc sheet ready for digital printing. it delivers a more consistent cell structure and smoother surface finish for greater print definition. it is also said to be easier, cleaner and safer to use than solid/powder alternatives.
Galata will be showing a range new additives for PVC
Booth: 39006 www.colormatrix.com
Booth: 58083 www.teknorapex.com
Additives
pVc applications; and new impact modifiers for pVc. galata is also expanding into non-vinyl markets with products such as Blendex specialty modifiers for engineering polymers. during April, the company will open a new applications laboratory at its manufacturing site in Taft, louisiana, uSA. The new facility will help to speed up product evaluations and new product development for customers.
Booth: 37062 www.galatachemicals.com
Booth: 39021 www.americhem.com
loadings of between 20% and 40%, according to the
company.
March 2012 | coMpounding world
67
npE 2012
blocking, anti-static, slip, matt, stiffening, anti-fog and lubrication products (see this months compounder of the month profile for more information).
Booth: 51027 www.bestpolybatch.com/en

Struktol has expanded its V-Series line of lubricant additives for rigid pVc used in calendered or extruded sheet and profiles. its VlB 602 product is a combination of internal and external lubricants for clear extrusions, especially those that require printing, laminating or bonding. it is designed to provide maximum clarity in combination with a very wide processing window. The company has also introduced a vegetable-based version, VlB 618, for those processors who require formulations with non-animal-based additives. VlB 618 provides the same processing and visual characteristics Penn Color targets building applications with its Optimax masterbatches laurel Biocomposite says that the Bio-res additives enhance the flow of the base resin and generally have a modest positive impact on stiffness and tensile modulus. They are aimed at markets such as garden products, agriculture and automotive. as the VlB 602 grade. For rigid pVc extrusion applications, Struktol has developed SA 0720, a novel functional additive that provides a matte finish surface. This is ideal for water channelling applications or for parts that require lowgloss aesthetics. with loading levels of 3% or below, this product is a cost-effective alternative to polymeric surface modifiers. PolyOne will use npE to launch reFlex 100, the first commercial bioplasticizer to be produced from its development work with Archer daniels midland. The company describes the additive as a high solvating plasticizer that has excellent potential to replace, in whole or in part, butyl benzyl phthalate (BBp) or other high solvating plasticizers. Target applications include toys, consumer goods, flooring, carpet backing, and other building and construction end uses. The new product is now available for sampling or sale. Guangdong Meilian New Materials Technology will be showcasing its masterbatch range based on pE and pp carrier materials, including white, black, colour and additive products. The chinese company also produces pE compounds. it has 18 compounding lines and an annual capacity of more than 40,000 tonnes. Target applications include blow moulding, film, sheet, injection moulding, cables and tubing. Rajiv Plastics of india will be promoting its latest additive masterbatches. These include several new products for blown film applications: Freshness plus and Agri Fresh for enhancing the shelf-life of fruit and vegetables; photo- and oxo-degradable masterbatches; and Vci anti-corrosive products. The company also offers anti-microbial grades and anti-rodent masterbatches for pipes or wire and cable applications. Penn Color will promote its pET Essentials line of masterbatches including its highly-loaded white products. The pET Essentials line also features a broad range of packaging colorants, including: uV-protection products for pharmaceuticals; oxygen-neutral colorants for wines, spirits, food and beverages; special-effect colours for cosmetic and personal care; and additive masterbatches for protecting contents. All use the Shantou Best Science and Technology will be promoting its additive masterbatches for Bopp, BopET, plus blown and cast film applications. These include anti68 compounding world | march 2012
Booth: 61058 www.laurelbiocomposite.com
Booth: 31017 www.struktol.com
Colorants
Booth: 39006 www.polyone.com
Booth: 19023 www.stmlhg.com
Booth: 61018 www.rajivplastics.com
companys pennacle pET carrier resin for improved processing. in addition, penn color will be discussing its optimax
This months free brochure downloads

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Steer: SPL40 turn-key lines

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HPF: high performance fillers

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This eight-page brochure covers PlasMecs TRM Turbomixer, which can be used for mixing PVC dryblends, producing woodplastics composites (WPCs) or the hot/cold dispersion of masterbatches/additives.
Shepherd: pigments for plastics

This selection guide from Shepherd Color Company has details of 20 different pigments with their properties, regulatory approvals and applications listed in an easy-to-read table.
If you would like your brochure to be included on this page, please contact Claire Bishop. claire@amimagazines.com. Tel: +44 (0)20 8686 8139
NPE 2012
Plastics Color Corporation (PCC) is launching its new LiquiSol liquid colour and additive system for polymers. Vice president of business development Tim Workman explains: LiquiSol is not a product. Its a full system designed to integrate liquid into our customers operation, not as a replacement to colour resin concentrates, but as alternatives for specific manufacturing processes. Last August, PCC acquired Polysource, a liquid and additives company in Phoenix, Arizona. Since then, it has been developing LiquiSol as an easy-to-use turnkey system. The company recently constructed a liquid colour and additive production line at its Sun Valley, California plant. PCC claims there are often advantages of liquid over PCC is extending its liquid colour offering with its LiquiSol system masterbatch products which have been developed specifically for the building and construction industry. These include Optimax WPC for wood-plastic composites, Optimax LG for low-gloss PVC profiles and Optimax WG for wood-grain effects. They are all designed to offer superior weatherability. solid concentrates for certain applications including lower let down ratios, better thermal stability, reduced storage space requirements and versatility in formulations. Since we manufacture and distribute both liquid and colour concentrates and additives, we have no bias either way, adds Workman.
Booth: 21037 www.penncolor.com
Booth: 43035 www.plasticscolor.com
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compounder of the month
Shantou Best Science & Technology

Head office location: Date founded: CEO: Ownership: No. of employees: Shantou City, Guangdong Province, China. 2001 Yang Bo (head of business), Wang Jinjiang (head of technology) Privately owned 50
Sales 2011: US$16 million Plant locations: Production 2011: Shantou City, Guangdong Province, China. 8,000 tonnes
Profile: Shantou Best Science & Technology specialises in the manufacture of functional additive masterbatches primarily for producers of BOPP film but also for BOPET, blown or cast film. Its capacity exceeds 15,000 tonnes. Since 2007, the company has been expanding its customer base outside of China. Product line: Product strengths: Its product range includes anti-blocking, antistatic, antistatic & slip, slip, antiblocking & slip, matt, stiffening, anti-fog and lubrication masterbatches. Shantou Best Science & Technology sees itself as a manufacturer of high-quality masterbatches with top class customer service and yet with competitive pricing. Its AS masterbatch products (antistatic and antistatic & slip) have high loadings and low dosage rates giving significant cost savings. The company says that more than 300 tonnes of these grades are sold each month. www.bestpolybatch.com/en
Website:
Forthcoming features
The next issues of Compounding World magazine will have special reports on the following subjects: April Anti-oxidants Clarifiers, nucleating agents & processing aids Materials handling Chinaplas & Plast previews May Anti-stats and conductive additives Twin-screw extruders Pellet screeners and de-dusters
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Compounding World Feb This February issue of Compounding World is full of features on new ways to boost the thermal conductivity of plastics, plus antimicrobials for medical devices, machinery for processing wood-plastic composites and direct extrusion for PET films. Click here to view Compounding World Jan The January edition of Compounding World is packed with articles on developments in impact modifiers, additives for polyolefins, compounding lines for PVC and trends in LFT applications. Click here to view
Injection World March Injection Worlds March edition is packed full of features on trends in bioplastics, developments in thin-wall packaging, making the right connections for mould cooling, plus a 14-page guide to NPE 2012. Click here to view
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dates for your diary
Global exhibition guide

17-19 March 27-29 March 1-5 April 11-13 April 11-14 April 18-21 April 8-11 May 8-12 May 10-13 May 14-17 May 29-30 May 29 May 1 June 18-22 June 19-21 June 21-24 June 6-9 September 10-14 September 21-25 September 24-27 September 25-26 September 16-20 October 3P Plas Print Pack, Lahore, Pakistan JEC Europe, Paris, France NPE, Orlando, USA Plastic Japan, Tokyo, Japan Indoplas, Jakarta, Indonesia Chinaplas, Shanghai, China Elmia Polymer, Jnkping, Swden Plast, Milan, Italy Plastech, Izmir, Turkey Plastivision Arabia, Sharjah, UAE PDM, London, UK Plastpol, Kielce, Poland Argenpls, Buenos Aires, Argentina IIME/Plastics Fair, Ho-Chi-Minh, Vietnam InterPlas Thailand, Bangkok, Thailand Plastex, Cairo, Egypt Plastex, Brno, Czech Republic TaipeiPlas, Taipei, Taiwan Plast Alger, Algiers, Algeria Mediplas, Birmingham, UK Fakuma, Friedrichshafen, Germany www.plasprintpack.com.pk www.jeccomposites.com www.npe.org www.plas.jp/en www.indoplas.com www.chinaplasonline.com www.elmia.se/polymer www.plastonline.org www.izmirfair.com.tr www.plastivisionarabia.org www.pdmevent.com www.targikielce.pl www.argenplas.com.ar www.machinery-vietnam.com www.manufacturing-expo.com www.plastex-online.com www.bvv.cz/plastex www.taipeiplas.com.tw www.plastalger.com www.mediplasuk.com www.fakuma-messe.de
AMI conferences
20-22 March 20-22 March 26-28 March 18-19 April 8-9 May 14-16 May 5-6 June 14-15 June 19-21 June 25-26 September 23-25 October 27-29 November PVC Formulation 2012, Dsseldorf, Germany Green Polymer Chemistry 2012, Cologne, Germany Masterbatch Asia 2012, Singapore Polymers in Cables 2012, Miami, FL, USA Bioplastics Compounding & Processing, Miami, FL, USA Polymer Sourcing, Hamburg, Germany Profiles, Philadelphia, PA, USA Fire Retardants in Plastics, Denver, CO, USA Masterbatch 2012, Vienna, Austria Medical Grade Polymers, Boston, MA, USA Polyolefin Additives, Cologne, Germany Fire Resistance in Plastics, Cologne, Germany
For information on all these events and other conferences on film, sheet, pipe and packaging applications, see
www.amiplastics.com
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March 2012

17 Europes leading masterbatch producers

25 New ways to promote the performance of PET

37 Cutting edge technology: advances in pelletizers

47 The compounders guide to NPE 2012

72 Compounder of the month: Shantou Best 74 Dates for your diary

coming next issue

Huge pET recycling plant opens in california

Ampacet moves and expands Europe HQ

roquette starts up new bioplastics unit

rusnano drives forward russian investments in nanocomposites

dover corporation acquires the Maag group

E130 million in 2011.

lcA backs Vinyloop recycled compounds

Huntsman gay acquires citadel from wind point

Farrel installs new mixer at SKZ

compounding world app attracts 1,000 users

compounding world magazine

compounding world | march 2012

HEAT MANAGEMENT FOR EVERY COLOR UNDER THE SUN

BioAmber signs big bio-based deals

www.bio-amber.com www.lanxess.com www.natureworksllc.com

Baerlocher sets up in Turkey

Brazil buys four mrS extruders

compounding world | march 2012

Intelligent Resins, Custom Compounds from AGC...

quan tec 96 eV-10c

BUSS Kneader Technology

cutting-edge compounding Technology MX and quan tec BUSS Kneader Series

Enhanced mixing quality and dispersion Energy savings up to 25%

West Hall Stand 7463

Hall 5.1 Stand T 75

Buss AG Switzerland www.busscorp.com

So.f.ter adds new ICMA lines

www.auserpolimeri.it www.barnet.com PolyOne has opened an

www.polyone.com The European Chemicals

EPI joins UAEs list of oxo suppliers

www.echa.europa.eu PSI-Polymer Systems, the

metabolix comes under scrutiny over bioplastics joint venture

www.hbsslaw.com www.metabolix.com www.adm.com

lifocolor expands in poland

BYK adds to app for additives

rTp acquires clariants conductive compounds

polyplast licenses Thermylene

radco to market Aura uV protection for pc

compounding world | march 2012

19-21 June 2012

Organised by: Applied Market Information Ltd.

Also sponsored by:

European masterbatch makers | markets feature

Examining Europes leading masterbatch producers

markets feature | European masterbatch makers

other companies 37%

largest supplier of masterbatch in Europe in terms of

top 10 masterbatcch producers

markets feature | European masterbatch makers

EuropEs Top 10 masTErbaTch producErs (basEd on 2010 proucTion volumEs)

markets feature | European masterbatch makers

About the author

companies will increase their activity in the

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