[1]

[2]

[3]

[4]

[5]

[6]

[7]

[8]

Rapidparts throws the switch for Eaton’s moulded parts

The Middleton, Manchester-based facility of electrical product manufacturer Eaton Electric opted to use the services of Rapidparts, a fast-track plastic injection moulded parts manufacturer, when developing its latest range of modular grid switches.

The switches are small units that fit into frames mainly for use in office and commercial applications, but also for some domestic use.

Having analysed the design requirements for the new parts in depth, Eaton decided that some would require prototyping.

Having already used Rapidparts for a number of previous quick turnround injection moulding projects, Eaton found this an easy choice.

“Rapidparts said they would start machining rapid injection mould tooling immediately, and could provide parts in the actual design material (polycarbonate) within 15 days,” explains Eaton’s quality support engineer.

“We had tried rapid prototypes produced using stereolithography (SLA), but because of the material you don’t really get a true feel for the functionality of these components.

Using the service provided by Rapidparts we could give the parts a proper ‘form, fit and function’ test, including strength testing.”

Rapidparts prototyped the three main mouldings required for the new grid switch modules.

These were a base which houses the metal contact parts, a cover that fits over the base, and the internal rocker.

[9]

A small quantity of around 500 of each part was supplied and “worked very well” according to Eaton.

“There was a problem when one particular switch wasn’t functioning correctly,” says Eaton’s spokesman.

“However, we talked to Rapidparts and they quickly made a clear polycarbonate version so we could observe the switching mechanism in action.

"This revealed that one of the terminals wasn’t bedding down properly, so we made a small design change to compensate.

Ultimately it’s far cheaper to make changes at the prototype stage that when in production.”

By way of additional benefit, having prototypes in polycarbonate also allowed Eaton to prove its laser marking process.

The new range of Eaton electrical accessories is currently being launched in the UK.

The company’s current products are used in blue chip projects worldwide, including Heathrow Airport Terminal 5 and London's Canary Wharf.

*************************

[10]

3M offers lightweight PU alternative to plywood

ST PAUL, MINN. -- 3M Co. has developed a lightweight and rot-resistant polyurethane foam alternative to plywood. The PU foam boards with fiberglass reinforcement provide high strength in applications including marine, transportation and general construction, with a weight savings ranging from 30 to 60 percent vs.plywood, 3M said in a June 26 news release.

The reinforced PU foam is available in five densities ranging from 15 lb. to 26 lb. (6.8-11.8 kg) per cubic foot, and 3M said it complements its existing line of lighter density foam boards.

3M claims that unlike plywood, which can chip or pop loose during construction, its foam can be easily shaped with tools and secured to substrates with screws.

“Plywood is currently used in many applications where water causes it to degrade over time,” said Nick Harris, global business leader for 3M Engineered Products and Solutions.

“3M Reinforced Polyurethane Foam not only gives manufacturers a longer-lasting alternative to plywood, but one that delivers weight reduction as well.”

*************************

[11]

San Francisco proposal would require tap water

stations

SAN FRANCISCO -- It is not a direct attack on disposable plastic water bottles.

But San Francisco now has in its legislative hopper a bill that would require building owners and developers to install tap water filling stations in new buildings that are required by law to have drinking fountains.

The proposal was introduced June 26 by Board of Supervisors President David Chiu.

The measure would also require existing building with drinking fountains to add tap water filling stations when those buildings undergo major renovations of their plumbing systems.

San Francisco currently has water bottle-filling stations at the airport and at some schools and parks

The city—which was the first in the United States to ban single-use plastic bags—has had a law banning city departments from purchasing bottled water since 2007.

*************************

[12]

Back-to-the-Future Battery Spells Good News for

Energy

Mixing nanotechnology with Thomas Edison's nickel-iron design, Stanford scientists create a new battery with a 180-second recharge time, promising a boon for the renewable-energy industry.

Scientists have given a 21st-century makeover to the nickel-iron battery, a gadget conceived by Thomas Edison during the era of the steam engine and horse and buggy.

The upgraded battery can be recharged in around two and half minutes, as opposed to several hours at present, and discharges in under 30 seconds.

Because it can store and release energy so quickly, the battery could be a boon for the renewable-energy industry and also help power cars as Edison originally envisaged, the researchers say.

Devised by Edison and fellow inventor Waldemar Jungner in 1902, the nickel-iron battery comprises two electrodes, one made of nickel and the other of iron, that are immersed in an alkaline solution.

Its advantage is that materials are abundant and cheap and the solution is relatively harmless compared to toxic lead-acid batteries.

Nickel-iron batteries were marketed for cars until the 1920s, but then dropped out of the picture because they were not as powerful as petrol and diesel fuel engines.

Another downside was that they took a long time to recharge.

They remained a robust backup power source for railways, mines and other industries before falling out of favor in the mid-1970s.

[13]

Today, just a handful of companies make the batteries, mainly to store surplus electricity from solar and wind generators and release it during times of peak demand.

The new-generation battery comes courtesy of a team led by Hongjie Dai, a chemistry professor at Stanford University in California.

They have bonded the electrodes to carbon nanotubes and to graphene, a super-material made of carbon just one atom thick, gaining a dramatic boost in conductivity.

"Coupling the nickel and iron particles to the carbon substrate allows electrical charges to move quickly between the electrodes and the outside circuit," Dai said in a press release.

"The result is an ultra-fast version of the nickel-iron battery that's capable of charging and discharging in seconds."

So far, Dai's lab has made a small one-volt prototype that can operate a flashlight. Size for size, it has nearly 1,000 times the density energy of traditional nickel-iron batteries.

Scaling up the lab gadget to bigger applications should not be a problem, and it should find a ready outlet in situations where a quick jolt is needed from a power source that is easily replenished.

"Our battery probably won't be able to power an electric car by itself, because the energy density is not ideal," said researcher Hailiang Wang. "But it could assist lithium-ion batteries [in cars] by giving them a real power boost for faster acceleration.

[14]

" The battery could then be replenished from regenerative braking.

he chemical mix used in the battery is water with potassium hydroxide, which is stable, cheap and safe, he added.

The prototype does have a hitch, in that after lots of cycles of recharging, it no longer holds the charge so well.

After 800 cycles, the charge decays by about a fifth, a problem the Stanford team hopes to fix.

The research was published on Tuesday in Nature Communications.

Copyright Agence France-Presse, 2012

See Also:

"Report: Reducing Battery Cost is Key to Electric-Vehicle Adoption"

"Battery Modules for Hybrid, Electric Vehicles to Hit $47 Billion in 2020"

"MIT Startup, Backed by Bill Gates, Touts Liquid Battery as Source of Green Energy"

*************************

[15]

Don’t let pushback knock you off the path to scientific molding

The most difficult aspect of scientific injection molding isn't really what you might expect. Some folks might guess the biggest challenge to overcome is tooling design or machine repeatability, but, in my opinion, it is something much simpler: pushback.

"Pushback" is, simply put, the resistance that the old guard, or those that just don't quite understand the process, will put up during scientific molding implementation.

It is difficult for people that have been in the industry for a long time to come to terms with the fact that they have been doing it wrong.

That's why it's important to keep in mind that at some point and time, we were all doing it wrong, including myself.

Whether it is pride or just the belief that these theories won't work, this pushback is still alive and well in our industry.

Remember that you are trying to change culture and habits that have been in place for years.

Typically the pushback comes from supporting departments but it is absolutely not isolated to them.

After so many years of trial and error you might think that everyone has adopted these principles but facts are facts and it just isn't so.

Out of those who are attempting to process scientifically, several molders are still making drastic compromises to the process instead of making the necessary changes to run robust processes.

[16]

I will admit there are times when this is an absolute necessity, but when those compromises become the rule and not the exception is when problems arise.

The task that you are charged with is extremely important to the success of the business, and it can get frustrating at times.

I have personally been through this with several companies, and I have seen how successful it can be when everyone has finally seen the proverbial light and full buy in has been gained.

I have also seen what happens when the message has not been received, and success has been snatched out of your hands.

What I have learned throughout this process is that everyone needs to be trained in scientific injection molding not just those that are responsible for the process development or maintaining the process.

John Bozzelli offers several courses that are directed at specific job functions, including management, and RJGalso provides executive overviews for upper management.

I would recommend getting everyone involved to some extent, including quality engineers and managers, sales and customer service, toolmakers and engineers, maintenance techs, and project and manufacturing engineers.

Don't forget to educate your customers

The more all parties understand why we are doing what we are doing, the easier it will be and the less pushback you will receive.

The group that is often forgotten more than any other in this challenge to share the knowledge is an important one: your customers.

[17]

Educating your customers on the principles of scientific injection molding is absolutely key if you want to have a successful partnership with them.

Imagine your customers having a better understanding of what you are trying to accomplish. Ultimately the customer is the one that benefits the most from true robust process development.

I know for a fact that educating the customer is something that has not been focused on enough in our industry.

There is evidence enough considering that some customers still require molders to validate process settings as part of the validation process.

How do you accomplish this task? Well there are several ways.

The first, which is fairly straight forward, is you can always give an expert like John Bozzelli a call and hire him to do some consulting and provide a presentation for your customers.

Your customers may see a third-party expert as someone that doesn't have a personal stake in the success of the business.

Another way to spread the knowledge to your customers would be to invite them to your facility and give them a full presentation of your own.

As part of this presentation, I would recommend making it completely clear that this is an invitation to work together as a team to improve quality levels through robust process development.

Convey the message that it will absolutely take efforts from both companies to reach your goals.

[18]

I have gone through this exercise with several customers, and its has always been extremely positive and truly helpful in transitioning to scientific process development.

Implementation of scientific injection molding can be a difficult path filled with various roadblocks and challenges.

The best bet for success lies in educating the team around you and focusing on a common goal of robust, repeatable processes producing high-quality product.

About the Author: Robert P. Gattshall has worked 17 years in the automotive and medical injection molding industries, including 12 years in process engineering and process development.

Certified in John Bozzelli's Scientific Injection Molding for more than 10 years, Gattshall has developed more than 600 processes using scientific injection molding principles.

Certified in Lean 5S and SMED, Gattshall has also trained more than 50 process technicians and engineers on the principles of decoupled molding.

*************************

[19]

Compass' steers Saint-Gobain

global extrusion expansion

Saint-Gobain Performance Plastics is bringing to market a new silicone extrusion technology, called Compass, which targets a variety of medical tubing applications, including ophthalmic pumps, enteral feeding, and intravenous therapy.

"Compass Technology is about enhancing our ability to improve product performance by focusing on the both the raw material and an improved manufacturing process," Aaron Updegrove, marketing manager, Saint-Gobain Performance Plastics (Worcester, MA), told PlasticsToday.

The process starts with a customer dialogue to develop a custom silicone compound.

"We can target physicalproperties as tear strength, modulus, compression set, durometer, tensile strength and elongation," Updegrove said.

The material is then run on Saint-Gobain's newly developed tubing extrusion process.

"While the specifics of the Compass Technology extrusion process remain proprietary, in broad terms, we have optimized the manufacturing to reduce variation and maintain the tubing consistency from lot to lot."

Improved process control is one of the attributes of Compass Technology.

[20]

A closed-loop system automatically makes adjustments to reduce variation from production run to production run while monitoring manufacturing data.

The data is captured and available to expedite product validation for medical device OEMs.

One of the targets of the approach is to deliver products that meet expanding requirements for purity and low extractables.

As part of Compass Technology, Saint-Gobain Performance Plastics is also developing an advanced modeling platform for pump and fluid handling systems.

The goal is to provide insight into the effect of variables on system accuracy. From physical dimensions to dynamic properties of the material, it is hoped the model can function as a predictor for new designs.

"Although we have worked with external equipment and raw material suppliers, the uniqueness of the capability of Compass Technology is really the result of an intense internal R&D effort," Updegrove told Plastics Today.

Saint-Gobain has developed custom formulations for customer before, but the processing aspect is new technology.

"To bring Compass Technology to fruition, we invested heavily in equipment and technology related to both the material formulation and the extrusion process.

With the financial backing of Saint-Gobain, we have plans to expand the capacity in North America, and sites all over the world."

*************************

[21]

Sabic introduces photovoltaic PC panels

PITTSFIELD, MASS. -- Sabic Innovative Plastics has introduced what it says is the first polycarbonate building-integrated photovoltaic panel for roofing, cladding and glazing applications.

The new BIPV panels, developed in collaboration with Italian flexible photovoltaic panel manufacturer Solbian Alternative Energy Ltd., will be commercially available in the second half of 2012.

They have been installed and are now in use at a Sabic manufacturing facility in Italy.

“The new Lexan BIPV panels show Sabic’s commitment ... to find better solutions and create practical innovations for customers in the building and construction industry,” said Jack Govers, general manager for specialty film and sheet at Sabic Innovative Plastics when the new panels were introduced June 13 in Munich, Germany.

“Our collaboration with Solbian has created a technology that can transform conventional roofing and glazing systems and provide new choices for the integration of solar systems into building designs across the globe.”

The flexible photovoltaic panels are made from Lexan Thermoclear PC sheet from Sabic and flexible PV laminated monocrystalline cells from Solbian, which is headquartered in Avigliana, Italy.

Unlike traditional BIPV materials, the Sabic panels can be easily cold bended on site to form graceful, curved roofing systems that integrate daylighting and photovoltaics into facade, roofing or skylight systems.

[22]

The companies said that the new panels reduce energy consumption by up to 17 percent when compared to traditional high-return, double-pane glass glazing.

This is a “new, high-performance solution that will no doubt drive broader adoption of photovoltaics across many types of commercial and residential structures and geographies,” said Enrique Garcia, president, Solbian Alternate Energy.

The Lexan BIPV panels will be available in 10, 16, 20, 25 and 40 mm gauges, in rectangular and X-wall

Configurations, and include a color palette of clear, opal white, bronze, green, blue and gray.

Separately, Sabic said that it has entered into a collaboration with VU University Amsterdam to develop lightweight, more energy efficient and lower cost solar thermal panels.

VU University has developed and patented a technology that uses what the university calls an “optical switch” to create a prismatic structure of the thermoplastic panels made from Sabic’s Lexan polycarbonate sheet so that the sunlight can be reflected before the panels get too hot.

Pittsfield-based Sabic Innovative Plastics is wholly owned subsidiary of Saudi Basic Industries Corp.

*************************

[23]

Composites lighten the load in monorail trains

Thermoset composite parts in monorail trains have the potential to reduce weight significantly as evidenced by development work and commercialization of components by Malaysian processor DK Composites Sdn. Bhd. (Melaka). In partnership with Gurit GmbH (Kassel, Germany) and its Australian subsidiary, together with Umeco(Warwickshire, UK), DK Composites has developed a series of glass-reinforced composite panels for users in Malaysia and India.

A ceiling, seat and apron door for Mumbai Monorail. The ceiling adopts a sandwich construction made from a phenolic/glass prepreg —offering fire retardant properties while delivering the target weight—and PET (polyethylene terephthalate) foam was developed.

A vacuum-infused epoxy/glass laminate was used for the molding

process.

The ceiling weighs in at 413 kg per train carriage, representing a 53% weight reduction versus an aluminum composite panel with a tubular steel frame.

The ceiling meets British Standard BS 6853 for fire/smoke/toxicity requirements. Development started in June 2010 and it was commercialized in February 2012.

The seat development started in April 2010 but was subsequently cancelled due to a change in specifications by the client.

Monorails make weight reduction through heavy composite use.

[24]

In order to further reduce weight, a high pressure laminate (HPL) and aluminum honeycomb were introduced together with acrylic resin, which enables a higher loading of flame retardant to be incorporated.

The seat is also 53% lighter than a traditional seat made of stainless steel sheet with a tubular frame, and total seat weight per train carriage is 760 kg.

The apron door development started in August 2010. It is currently on hold and may be proposed to Kuala Lumpur Monorail instead.

Here, a sandwich construction made from ATH- (alumina trihydrate) or red phosphorus-filled epoxy/glass prepreg and aluminum honeycomb was employed.

The door enables a 49% weight reduction versus an aluminum composite panel with a tubular steel frame.

745 kg of weight comprises such doors in a train carriage.

Development of the nose cab mask for Kuala Lumpur Monorail commenced in November 2010, with the first production unit delivered in January 2012.

Production is on-going.

A sandwich construction made from red phosphorus filled epoxy/glass prepreg and PET foam is adopted.

The main advantages of the new components include weight reduction, compliance with fire standards and appearance of the final parts (shapes impossible to realize using metal).

The nose cap mask weighs in at 268 kg, which is 30% lighter than the previous hand-laminated polyester/glass/PVC foam system.The overall target market for

[25]

DK Composites work is the complete renovation of Malaysia's railway and mass transit systems using lightweight composites to replace metal parts for the coachwork, internal furniture and related parts.

This effort could transform Malaysia into a leading provider of GFRP components for rail transport in ASEAN countries.

The team won a JEC Innovation Award in the Railway "exaequo" Category that will be presented at the upcoming JEC Asia show in Singapore to be held June 26-28, 2012. —mpweditorial@ubm.com

*************************

[26]

Aluminum components get a boost

A surface coating is now available that?s reportedly capable of enhancing the physical properties of aluminum components.

Tufram surface coating combines the hardness of aluminum oxide ceramic with the properties of selected proprietary polymers.According to the manufacturer, this combination provides aluminum mold parts with new levels of hardness, wear and corrosion resistance, and permanent lubricity.

Depending on the alloy used and the variety of the coating chosen, treated metals reportedly have a hardness of 40 to 65 Rockwell C.

Corrosion resistance is also reportedly greater than conventional hard anodizing, particularly for common chemicals where it offers up to 15,000 hours of protection. The Tufram process converts aluminum surfaces without affecting the high conductivity of the parent metal.

These coatings have full compliance with FDA, USDA, NSF, and AgriCanada codes, making it suitable for food and pharmaceutical applications.

An ultrathin version of the original coating is also available. Tufram 2000 is said to offer a high degree of precision with .0005- to .0007-inch thickness, while still providing extremely high resistance to wear and corrosion.

General Magnaplate Corp. Linden, NJ Phone: (908) 862-6200 www.magnaplate.com

************************

[27]

Chemical vapor deposition allows ultra-thin lubricious

coating for mold components

A chance meeting at a trade show has brought a coating technology that originated in the semiconductor industry into injection molding, giving mold components an inert, lubricious coating that eliminates the need for grease in medical and packaging applications, among others.

The Poco Graphite technology, marketed to the injection molding industry by PCS Co. as UltraC coatings, creates what the companies call diamond-like carbon (DLC) coatings that reportedly enhance durability and mold productivity while reducing friction and corrosion.

At Plastec East 2011, PCS and Poco Graphite were nearly neighbors as exhibitors and over the course of the show and several discussions perceived the potential for a collaboration to bring the DLC coating into injection molding.

Following a formal meeting in December of that year, the companies moved forward and commercialized the UltraC line of coated mold components at NPE2012.

The coatings are derived from a proprietary mixture of gases applied to the components via plasma-enhanced chemical vapor deposition (PECVD).

The result is a chemical bond to the substrate, which can be in a variety of materials, including metal and plastic.

[28]

The companies stress the result is a chemical bond on molecular level, not etching. Entegris, which owns Poco Graphite, says the high-performance coatings are formed using a proprietary low temperature (<150°C) process that deposits the layer in a high-vacuum environment.

Conformally coating the exposed surface with a layer that is 80 millionths of an inch thick, the technology allows mold components to be coated without having to make any tool adjustments.

PCS says potential applications in molding include: Ejector pins Cores and sleeves Slides Thread cores Cavity surfaces Wear plates Beyond injection molding, PCS is promoting potential use for blowmolds and aluminum die casting. Also, since it's a low-temperature process, some plastics can be coated as well. In terms of benefits, PCS sites: Lubricity Reduced coefficient of friction Short cycle times since galling in components is eliminated Complete seal of the surface, making it inert to moisture/gases Corrosion resistance

*************************

[29]

India poised to become a polymers powerhouse,

report says

India's growing population has driven the demand for polymers, however, it has not achieved its full potential, Research Analyst Ashok Pant told PlasticsToday.

According to a new report from GlobalData, India is currently the world's third largest consumer of polymers, behind China and the U.S., with a share of 5.7% of the 2011 global total—an increase from its 2000 share of 3.5%.

Pant said the growth of the polymer industry in India has been gradual. The major polymer end-use sectors, such as packaging, automotive, and construction, gained momentum after the economic liberalization in 1991.

The real growth period started in the last decade when India's retail industry provided a boost to the packaging sector, which resulted in a demand for plastic packaging materials.

The automotive sector received a great degree of autonomy, and production increased by more than four times in the last decade.

In 2009, India surpassed Japan as the third largest per capita consumer of polymers. This level, however, is still much lower than the global average of 28.9 kg.

The per capita plastics consumption in India was 7.4 kg in 2010, while per capita consumption in China was 24.2 kg, Pant said. In North America and Europe, it is more than 100 kg.

"This shows India's position as a potentially large, growing yet untapped market," he said.

[30]

"The polymer market has a bright future in India, as all the end-use sectors are poised to grow in the long term."

Production levels are soaring in order to keep up with India's demand, according to GlobalData.

In 2011, the manufacture of polymer products was 7.377 million metric tons per annum (MMtpa), and this will surge at a Compound Annual Growth Rate (CAGR) of 9.4% to reach 11.575 MMtpa by 2016.

GlobalData's research indicates that polymer demand in India is outstripping the country's strong GDP growth.

From 2000 to 2011, India's GDP climbed at a CAGR of 7.6%, whereas polymer consumption across all areas grew at a CAGR of 9.1%.

Pant said India's polymer industry is highly dependent on the packaging sector, which is the biggest demand driver for the country.

Demand for polymers in the packaging sector will grow further as the share of the organized retail is set to increase from 4.8% in 2010 to 23.5% in 2020.

Plasticulture, the use of plastic in agriculture, is another important factor that will impact the polymer industry in the future, Pant said.

With an increasing Indian population, the demand for food will also grow rapidly.

Since the country has limited agricultural resources such as land and water, plasticulture is considered a solution to improve agriculture productivity, Pant said.

Micro-irrigation, which comes under plasticulture, is viewed as an efficient method to reduce water requirements and improve productivity.

[31]

The government is planning to bring 10 million hectares of land under micro-irrigation, which is estimated to create 0.495 MMtpa of polymers demand by 2017. India's government has played a key role in boosting the significance of polymers, in terms of both consumer demand and in the production industry, according to Pant. The government has delineated Petroleum, Chemicals and Petrochemicals Investment Regions (PCPIRs), and four of these PCPIRs have been approved so far and two more are in the pipeline.

The government also approved 100% Foreign Direct Investment (FDI). This allows foreign firms to have 100% ownership of food processing companies, which will in turn create a higher demand for plastic packaging materials, according to the study. Pant said due to the low level of per capita polymer consumption, fast-growing middle class, growth in the economy, and strong end-use sectors, polymer demand will only grow in India.

"The country will continue to witness irreversible processes of industrialization and urbanization at a fast pace," he said. "This will provide a boost to the packaging, automotive, construction and electronic sectors in the future as well, and consequently, to the polymers demand in the country."

GlobalData's research methodology includes both secondary and primary research for various markets. The company mines hundreds of petrochemicals news sources, national bodies, associations and companies to capture information to feed into the database.

The research group conducts approximately 1000 primary interviews in the petrochemicals industry annually. GlobalData's pool of primary research candidates for petrochemicals eTrack databases include CEOs, VPs, business development managers, market intelligence managers, and national sales managers.

*************************

[32]

Clariant’s soya lubricant smooths PVC production

Clariant has introduced a PVC lubricant derived from soya bean oil.

Licocare SBW11 TP is a chemically modified wax claimed to offer technical performance in PVC processing superior to that of the fatty acid esters or complex ester mixtures traditionally used for lubrication.

The lubricant is particularly suitable for the processing of rigid PVC compounds, says the company, especially for calcium/zinc (Ca/Zn) and tin (Sn) stabilised photovoltaic film and extrusion applications.

The lubricant acts both externally and internally in the material.

Clariant cites several performance benefits:

Release and anti-sticking better than with traditional lubricants;

No mould deposits thanks to low volatility and good compatibility with PVC;

Excellent thermal stability ensuring stable colour;

Produces balanced rheological behaviour in material;

Effective performance at low dosage (0.3 to 1.0 parts per hundred).

Licocare SBW11 TP can also be used as a lubricant in PVC injection moulding.

Here, says the company, “flowability” is significantly improved with less influence on the Vicat softening temperature than that of traditional lubricants.

As a result, Clariant claims Licocare SBW11 TP can achieve better dimensional stability for the injection moulded product.

*************************

[33]

Sim-pull closures foil tamperers

Two all-in-one foil closure solutions for the food industry have been launched through a licence agreement between Dorking-based Bapco Closures and Aptar,

which claims leading status in dispensing closure solutions.

The new Sim-pull and Trilogy closures both feature a proprietary aluminium-to-plastic bonding technology (“BAP”), for which ease of opening, built-in tamper proofing and excellent seal integrity are claimed.

The Sim-pull solution has a flip-lid design, allowing consumers to open lids with one hand, according to Bapco.

Ease of opening is claimed to suit elderly consumers and children It is designed for a diverse range of contents including snack and granular products such as nuts, crackers, baking agents and sweeteners. A variety of ring-pull configurations enable manufacturers to tailor the closure to their particular product specifications. The Trilogy is a two-piece spout and closure design. Bapco Closures CEO Stephen Dawson says: “These new solutions meet a growing demand for re-sealable closures for on-the-go and at-home eating. They are perfect for occasions when consumers want to consume a single portion of food and then save the rest for later”. “Sim-pull and Trilogy are particularly suitable for elderly consumers and children because of their ease of opening.” Aptar’s UK facilities are located at Leeds and Milton Keynes.

*************************

[34]

European firms look at shifting

investment from China

GUANGZHOU, CHINA -- A growing number of European firms are considering shifting investments from China to other emerging markets, although the country remains a top investment destination and an increasingly important strategic market, according to a new report from Europe’s largest business group in China.

The European Union Chamber of Commerce in China said in its May 29 annual survey of business conditions that rising costs and regulatory challenges are the biggest issues facing its companies in China, and said that 22 percent of them were considering shifting investment away from the country.

It called that a “significant” percentage.

“There are indications from this survey that as reform continues to stall and costs rise, a previously reliable stream of FDI may slow and planned investments may be shifted to other emerging markets,” said Davide Cucino, president of the Beijing-based European Chamber.

“We are happy to report that European companies are continuing to invest and create jobs in China, but the lack of reform of the regulatory environment is worrying and has a disproportionate impact on foreign business as well as on the domestic private sector,” he said.

Still, the chamber’s report said the European firms continue to put money in China. A little more than 60 percent of them plan new investments there, more than half are looking at entering new provinces, and almost three-fourths of them plan to hire more staff in the next two years.

[35]

As China’s economy has grown quickly amid problems in Europe — China contributed the most in real terms to global growth for the sixth consecutive year — the country has become a more important market, the chamber said.

Chinese operations now make up 10 percent of worldwide revenue for half of the survey respondents, up 50 percent from 2009.

But the report also hit at what it called “growing frustration that the reforms of the 12th Five-Year Plan are not being carried out” and it repeated a Chamber complaint that China’s regulatory environment “will continue to discriminate against foreign companies.”

The survey was based on responses from 557 companies, given in a two-week period in February.

*************************

[36]

Sour grapes: Does boxed wine leave

a plastic taste behind?

The bottle versus bag-in-box. For wine lovers, this debate can bring strong emotions that only a glass of wine can help to calm down.

It all boils down to one question - does boxed wine leave a different taste than bottled?

I did a Google search on this crucial topic, and found there are several discussions evaluating these ideas.

Some believe bagged wine to "leave a plastic taste" while others feel boxed wine passes the taste test with flying colors.

Well, to add fuel to the fire, a group of researchers from the Joint Research Unit Agropolymer Engineering and Emerging Technologies in Montpellier, France, claim

bag-in-box wine loses key flavor and aroma compounds to the plastic packaging, according to an article by the Royal Society of Chemistry (RSC), the largest organization in Europe for advancing the chemical sciences.

However, the researchers have not yet showed how the loss of these compounds affects the taste.

The objectives of this study were to demonstrate that the presence of ethanol in a solution containing two esters and two aromatic alcohols has several consequences

[37]

on the sorption of these compounds into polyethylene (PE) film, according to the researchers.

The researchers mixed the two esters and two aromatic alcohols into an ethanol solution that helped to create a model for wine.

Ethyl butyrate and ethyl hexanoate are compounds that give wine fruit flavors, whereas phenylethyl alcohol provides a floral odor almost like rose with hints of honey, and 4-ethylphenol release a smoky note.

These compounds were quickly absorbed by the polyethylene film with ethyl hexanoate having a particularly strong affinity for the non-polar polyethylene. After five days, a quarter of the ethyl hexanoate had been "scavenged" by the film, according to the RSC.

The research stated the material in contact with the wine might interact with aroma compounds, which may induce losses and modify the aromatic profile.

There are many studies and speculations on how packaging may have an influence on the quality of wine. Wine oxidation is said to be one of the main causes of the loss of quality.

Another study from the Institute of Vine and Wine Sciences (ISVV) of Bordeaux looked into the evolution of wine quality in different packaging configurations.

An analysis was carried out of the influence of packaging on the sensory characteristics of red and white wine over an 18 months period.

Glass bottles, Bag in Box, and polyethylene terephthalate bottles were used in this investigation.

[38]

Significant differences were brought to light, according to the researchers. Packaging has a significant impact on the evolution of white wine during storage.

White wine was noticeably affected after six months of conservation in PET bottles.

The white wine in PET bottles and plastic bags had an increase in oxygen along with decreases in carbon dioxide and sulfur dioxide.

When it came to red wine, however, there weren't any significant differences between the different packaging.

So does this mean red wine can handle any type of packaging, but white wine is a bit trickier? It's hard to tell if we'll ever come to a conclusion.

Tell me, what are your thoughts about these studies? Does packaging influence what

*************************

[39]

The why of wine-in-a-box's odd taste

Bag-in-box wine loses key flavour and aroma compounds to the plastic packaging it is stored in, according to a study by French researchers.

But the authors have yet to show how the loss of these compounds affects the taste.

When flavour compounds in food or drink are absorbed by packaging it is

called ‘flavour scalping’ – a problem the juice industry is well aware of.

Synthetic corks seem to draw flavour and aroma compounds from wine more strongly than natural corks.

However, less is known about flavour scalping of wine in Tetrapaks and plastic bladders.

‘The material in contact with wine is known to interact with aroma compounds,’ says lead author of the study, Pascale Chalier of the Joint Research Unit Agropolymer Engineering and Emerging Technologies in Montpellier, France.

‘These phenomena could induce losses and modify the aromatic profile. Our study shows that it is important to consider these aspects.’

Chalier’s team mixed two ethyl esters and two alcohols into an acidified ethanol solution to create a simple model for wine.

Ethyl butyrate and ethyl hexanoate are compounds that give wine fruity flavours, while phenylethyl alcohol provides hints of honey and 4-ethylphenol a smoky note.

[40]

These compounds were quickly absorbed by the polyethylene film, or permeated through it.

Ethyl hexanoate, as the most apolar molecule, had a particularly strong affinity for the apolar polyethylene – after five days, a quarter of the ethyl hexanoate had been scavenged by the film.

Helene Hopfer, an expert in wine packaging and flavour at the University of California Davis in California, US, says the study is ‘well done’ but neglects any taste implications for the consumer.

‘[The authors] did not conduct any sensory trials, so we can only assume that the drastic reduction in ethyl esters would be picked up by a human subject.’

Taste tests are planned, says Chalier. However, her team did show that losses in volatile compounds led to changes in the odour activity value – a measure based on concentration rather than human perception – of each of the esters.

So can such a simple model system tell us much about the changes that occur in real wine? The simple answer is no, according to Markus Herderich, group manager, research at the Australian Wine Research Institute in Urrbrae, South Australia.

‘These results are difficult to extrapolate to a wine,’ he says.

In real wine, interactions between many different flavour and aroma compounds, and macromolecules, might affect the taste and smell.

Chalier says a ‘more global approach’ to the evolution of the aromatic profile of wine is possible and could be useful in predicting the shelf life for bag-in-box products.

*************************

[41]

Cleaning PET bottles without water

Pre-fill rinse systems, often used to remove dust, fibres or larger debris from finished blow moulded products, can be voracious consumers of water.

One well known beverage company is reported to use 2.43 litres to create a 1 litre end product equivalent to 59% waste water for each bottle.

The alternative cleaning method of ionised air rinsing can deliver significant savings in water consumption for blow moulding operations.

The use of water during manufacturing has come under increasing attention recently.

Water is an increasingly scarce resource.

Integrated production line from Sidel suits aseptic bottling of any kind of beverage

[42]

The United Nations predicts that by 2030 almost 50% of the world’s population will live in areas of high water stress, and by the same date the European Commission expects annual water usage in the EU to rise by 43%.

Today’s consumers are increasingly responsible in their attitude to the environment.

To meet their demand for environmentally friendly packaging, brand owners and packaging companies have to place sustainability at the heart of their production planning.

Ionised compressed air systems inject a jet of ionised air into the bottle to neutralise any static electrical charge on its inner surface.

Contaminants are released and simply fall out of the inverted container. However, there are still some drawbacks.

In the first place, because contaminants are commonly released into the atmosphere, re-contamination is possible. Secondly, air compression consumes expensive energy.

To resolve these issues, Meech International has launched its IonRinse system. Instead of using compressed air, IonRinse is a fan-driven system combining powerful AC ionisation, a custom-designed airflow distributor and high-quality inline filtration.

Delivered at a high velocity, filtered ionised air exits the IonRinse head unit via an airflow distributor and enters the container.

The accurately controlled airflow, coupled with the neutralisation of static charges, releases contaminants from the container’s inner walls.

[43]

Contaminants are caught immediately by a vacuum airflow and extracted to an inline high-efficiency particulate air (HEPA) filtration system, capable of capturing 99.99% of particles of size 0.3 micron.

To maximise cleaning performance containers are fully inverted (opening facing down) as they pass over the IonRinse head.

Because different containers require different airflow characteristics to achieve maximum rinsing performance, air flow and velocity are fully adjustable to allow accurate set-up for each application.

IonRinse’s all-in-one blow, vacuum and filter unit is designed to make installation and set-up as simple as possible.

The incorporation of contacts for automatic start and stop allows the system to run in series with the production line, reducing energy consumption even further.

Parameters such as filter condition and ionisation status are monitored via LED displays.

The air inlet and vacuum feeds can be connected to either end of the head unit, and a drop-down access panel makes maintenance particularly straightforward – the ionising bars simply drop out of the head unit mounted on the panel.

*************************

[44]

Healthier hospital handrails apply antimicrobial-infused

PVC

Of the more than 62,500 critical touch points in 103 medical institutions, a recent study determined that only 34% were effectively cleaned post-discharge.

This reflects what InPro Corp. (Muskego, WI) calls the "double-barreled risk" of inadequate hand hygiene and ineffective cleaning, prompting the company to

launch its new SureContact line of antimicrobial handrails for hospitals.

SureContact incorporates antimicrobial additive supplier Sanitized's Zinc Pyrithione non-leaching organic salt to help reduce microorganisms.

During manufacturing, InPro said the zinc pyrithione is "anchored into the material substrate at the molecular level" rather than applied to the surface

post extrusion.

The active ingredient in Sanitized's additive electrically depolarizes a microbe's membrane and inactivates it creating a permanently protected surface.

This physical mode of action does not promote microbe cell mutation and does not leach into the surrounding environment, according to Sanitized.

[45]

The SureContact antimicrobial option is available on seven solid-color InPro handrail models.

InPro recently combined its manufacturing and distribution operations under one roof, as part of a plant expansion project that added an 88,000-sq-ft three-level addition to its existing building in Muskego.

InPro had leased 45,000 sq ft of warehouse space in the New Berlin industrial park.

The company noted that due to increased demand for its Sanparrel rigid vinyl sheet product, it would purchase machinery for a second extrusion line.

Earlier this year at Plast2012 in Milan, Sanitized launched three new products: a new silver technology with greater efficiency; protection for PVC with bio-based plasticizers; protection for biodegradable plastics in agriculture.

*************************

[46]

Engineering plastics make inroads in EVs

The impressive 351-km range of a high-performance electric car under development in Japan is credited to a unique "in-wheel" motor system and extensive use of lightweight materials according to project leader SIM-Drive Corp. (Kawasaki, Japan).

These materials include several engineering plastics.

SIM-Drive is working with a team of 34 companies including DuPont (Wilmington, DE), Toray Industries (Tokyo), Bosch (Stuttgart, Germany) and Polyplastics (Tokyo), on the prototype SIM-WIL next-generation EV vehicle that features nearly 50 new technologies.

It was unveiled in March this year.

The SIM-WIL's range is reportedly 30% farther than today's mass-produced EV vehicles.

Yet it also delivers a maximum speed of 180 km/hr (110 mph), sports-car acceleration from 0-100 km/hr (0-60 mph) in 5.4 seconds, and offers a higher level of interior

space and comfort.

New generation SIM-Drive SIM-WIL electric vehicle features eight DuPont materials which help extend range, improve reliability, performance and appearance.

Motor bobbin molded from DuPont Zytel HTN PPA for new in-wheel electric motor for SIM-WIL EV is stronger, lighter, and more cost effective than the PPS it replaces, and offers speed winding and productivity advantages.

[47]

Increased reliability, performance, reduced weight, and an appealing interior and exterior have, in part, been achieved by the use of eight DuPont products including high-performance plastics, film, paper, and paint in a collaborative development program between the DuPont Japan Innovation Center in Nagoya, Japan, and SIM-Drive.

"Especially in electric vehicle (EV) applications, these high-temperature, chemically resistant products and electrical insulation materials contribute to increased EV system reliability and performance under severe conditions such as wide-ranging temperatures and high voltage," says Tomoyuki Shinkai, vehicle development co-ordination division general manager at SIM-Drive.

DuPont high-performance plastics such as Zytel HTN PPA (polyphthalamide) in the in-wheel motor and Kapton polyimide film in indicator lighting helped SIM-DRIVE keep weight lower than EVs on the road today.

Zytel HTN used in key in-wheel motor bobbins are said to be stronger, lighter, and more cost effective than the polyphenylene sulfide (PPS) it replaces.

Kapton, known for use in high-reliability applications from the Mars Rover to mobile devices, replaces the need for a circuit board, shaving 80% of the weight from the lighting component. Furthermore, bio-based Sorona polytrimethylene terephthalate (PTT) resin improves the environmental footprint and is used in interior applications.

"This project shows how lightweight, high-performance materials such as Zytel HTN PPA can take extremes, allowing designers to bring innovation to electric and hybrid electric vehicles without adding weight associated with metal," says James Hay, regional director, DuPont Performance Polymers, Asia Pacific. —mpweditorial@ubm.com

*************************

[48]

Heal thyself: Polymer bleeds, heals

The concept of self-healing polymers isn't new, but a researcher says his proposed material, which combines repair and sensing attributes into one polymer that 'bleeds' when damaged and heals in sunlight, is novel.

Marek W. Urban, a professor at the University of Southern Mississippi's School of Polymers and High Performance Materials in Hattiesburg, MS, initially published his findings in the journal, Nature Chemistry, in January 2012.

That paper described a "reversible covalent reaction in which two oxygen-insensitive radicals combine to form a carbon-carbon bond provides the mechanism by which a polymer gel can self-heal at room temperature without the need for any external stimulus."

In March, at the 243rd National Meeting and Exposition of the American Chemical Society (ACS), Urban provided additional details on the development, describing copolymer films that when scratched change color from clear to red in the damaged area.

Then, when exposed to sunlight, temperature, and/or acidic vapors, the damaged area

repaired itself, returning to the initial colorless appearance.

Marek W. Urban, a professor at the University of Southern Mississippi's School of Polymers and High Performance Materials.

[49]

Urban said the process is reversible and functions through the ring-opening-closure of spironapthoxazine (SNO) segments to form merocyanine (MC), which are recovered back to the SNO form.

A University of Southern Mississippi article on the technology speculated that self-repairing surfaces could be applied in a variety of products, including cell phones, laptops, and military weapons.

In the same article, the professor said the initial concept came to him in a dream.

"I dreamed of developing this after thinking about how human skin repairs itself when damaged, and how blood coming from the injury works as a sign of that damage," Urban said in the article.

"Sometimes, damage to material may not be visible to the human eye, but with the release of the colors that mimic bleeding we have a warning of damage."

Urban sees additional potential future usage in vehicles, including cars, planes and spacecraft, as well as large infrastructure, where seeing structural damage is vital.

*************************

[50]

Heinz sued over Dip & Squeeze packaging

When Heinz launched its "Dip & Squeeze" ketchup packet, consumers were dipping their food with appreciation for this new form of packaging.

All Scott White could see was red.

White, an independent inventor, has filed a patent infringement lawsuit against Heinz, alleging that the ketchup giant stole his idea when the company launched

the Dip & Squeeze product.

Heinz VP of Corporate and Government affairs Michael Mullen told PlasticsToday that Heinz won a similar lawsuit earlier this summer.

"This is another frivolous lawsuit and we will aggressively defend our position and demonstrate that the allegations are

groundless and without merit," he said.

"As a leader in proprietary packaging innovation for more than a century, Heinz worked for years to develop its patented dual-function Dip & Squeeze package."

White told PlasticsToday he could not comment on this pending legal matter at this time.

"When the matter concludes, I will have more latitude to talk," he said.

John Leja, an attorney for White, said they don't typically make their clients available for interviews.

[51]

"We would not have filed the action if we believed Mr. White's claims lacked merit and/or that his patent was not valid," he said.

Tomato fight: Dispute over packaging innovation

In the lawsuit, White said the idea for the package stemmed from his frustration by the obstacles of neatly consuming fast food and its attendant condiments in the comfort of his vehicle.

Frustration turned into a "flash" of inspiration for White. He invented a condiment container called the CondiCup, for which he filed a patent application in 2005.

The next year, White read a Wall Street Journal article detailing Heinz attempts to rekindle a relationship withMcDonald's by offering innovative packaging solutions.

The lawsuit states that White saw an opportunity to market his invention to the company, and he emailed a Heinz executive and described his patent-pending CondiCup packaging design.

The executive invited White to Heinz's headquarters in Pittsburgh to present to the company.

White's lawsuit states that instead of dealing fairly with him, Heinz cut him out.

"The behemoth international company could not be bothered to contract with a start-up American small business," the lawsuit stated.

White heard nothing from Heinz during the next four years, but was surprised to discover in 2010 that Heinz was on the cusp of launching a substantial marketing push centered on "a familiar looking condiment container."

[52]

In 2011, Heinz launched the Dip & Squeeze to consumers claiming it would change the way Americans eat on-the-goforever.

The Dip & Squeeze was the company's first ketchup packet makeover in 42 years.

"The response from consumers who have had the chance to experience the new Dip &

Squeeze Ketchup package has been overwhelmingly positive," said John Bennett, Vice President of Marketing at Heinz, in a news release at the time.

"People have been telling us that they love the convenience and functionality of the new package, and we are thrilled that it is now available to people nationwide."

The Heinz Dip & Squeeze gave consumers two options: a peel back lid for dipping, or the ability to tear off the tip and squeeze onto their foods.

The bottle-shaped package consists of three times the amount of a traditional 9g film package.

Consisting of polyester laminated to a high-barrier sealant web, the package incorporates a squeezable dip cup for easy opening.

A proprietary sealant and molded-in dispensing features make the dip and squeeze format controlled.

Since the launch, the company received tons of praise, including awards from the packaging industry such as being honored with the Silver Award in Innovation from the DuPont Awards for Packaging Innovation.

The Dip & Squeeze was also recognized by the National Restaurant Association during its Food and Beverage Product Innovation Awards.

[53]

In 2012, Heinz reported it sold more than one billion packages of the Dip & Squeeze and called it a "global priority for the company."

The U.S. Patent and Trademark Office issued White a patent for his CondiCup application this past July. In his lawsuit, it states that the Dip & Squeeze infringes on one or more claims of the patent.

Leja said the U.S. Patent and Trademark Office issuing the patent to White is significant.

"We seek to enforce it against those who are infringing.

We believe Heinz to be infringing," he said "You may have additional questions, but this is all we can provide you at this point in time."

Heinz states it holds more than a dozen patents, and the company says two of which apply to the Dip & Squeeze container.

White is seeking a trial by jury as well as compensation for patent infringement.

*************************

[54]

Profitable Plastics: Profit is the Thing

In general, businesses with commodity price risk (e.g. oil companies, transportation companies ... and resins processors) manage that risk to achieve different objectives - cost certainty, budget or forecast targets, job and business security, competitive advantage, customer loyalty, etc.

IMHO, the primary purpose of managing commodity price risk should be to secure and improve profit margins.

Profits keep the doors open and people employed. Resins processing may be tons of fun, but profit is the thing.

For processors, managing profit margins means controlling (hedging!) resins costs consistent with the way revenues are generated: the timing and type of resin cost hedges should reflect the timing and nature of product sales.

In simplest terms, what you do with one side of the operation should take into account what's happening on the other side.

(Think oil refinery and crude oil costs. Hedging crude oil costs independent of gasoline pricing isn't hedging. It's betting.)

Resins costs beyond immediate needs (i.e. medium to long-term) should only be locked in against fixed and certain product prices.

If product prices need to be flexible to respond to competitive and customer pressures, then resins costs should be capped, not locked in.

In other words, if you can't easily raise product prices to offset higher resins costs and profit margins are tight, then capping resins costs is the right and most prudent hedging strategy.

[55]

(How to cap resins costs will be a major topic in this column going forward.)

Commodities costs are usually controlled (hedged!) with financial tools for reasons such as cost effectiveness, better buying decisions, capital constraints, etc.

But financial transactions and the physical transactions they substitute for need to be in sync as much as overall cost control needs to be in sync with revenue flow.

Consider the generic processor:

Processors like the generic processor who focus on and manage margin risk will outperform and outlast competitors because they spend more time meeting customer needs and wants and less time worrying about profits.

*************************

[56]

Minnesota State Fair sends a message through a bottle

State fairs are known for insane food creations on a stick, rides that feel like they might fall apart, musical acts, auto shows, petting zoos, the list goes on and on.

However, the Minnesota Pollution Control Agency wants to make sure those attending the state fair receive a lesson in recycling.

Presented by the Minnesota State Fair and the Minnesota Pollution Control Agency (MPCA), the Eco Experience at the fair brings together organizations, ideas, and hands-on activities to show what people can do at home to help the environment.

This year the Exo Experience features a 30-ft-long and 15-ft high tunnel of discarded plastic bottles that comprises the new Bottle Buyology exhibit.

The purpose of the exhibit is to give people a wake up call about the amount of waste that is produced.

"This tunnel represents just 5 minutes of [bottle]

generation in Minnesota," Wayne Gjerde, who manages the Minnesota Pollution Control Agency's (MPCA) recycling division, told the Minneapolis Star Tribune.

[57]

"When people walk up to it, they say, 'Holy cow! That's disgusting.'" About 46 plastic bottles are sold in Minnesota every second, with 2760 every minute. According to the Container Recycling Institute, Minnesotans generate nearly 1.5 billion plastic bottles a year. "About 75% percent of those bottles are carelessly thrown away," the MPCA stated in a news release. "We need to recycle more!"

The MPCA estimates Minnesotans throw away 1.3 million tons of recyclable material (paper, bottles, cans, etc.) every year with a value of $312 million. It costs Minnesotans an additional $200 million to throw this material away.

The MPCA believes residents can actually help the economy by recycling more. Approximately 37,000 jobs in Minnesota are directly and indirectly supported by the recycling industry.

On an annual basis, these jobs pay an estimated $1.96 billion in wages and add nearly $8.5 billion to Minnesota's economy. The MPCA status report indicates that the agency wants more Minnesotans to put bottles curbside in bins on recycling day and to start recycling programs at work, according to the Minneapolis Star Tribune article.

Personally, I think it's great the MPCA has taken such a visual initiative to showcase the need for recycling. There are tons of possibilities for recycled plastic bottles. From the world's longest bridge made out of plastic bottles and other household plastic waste to Nike Olympic uniforms made from up to 13 recycled bottles to plastic bottles that can be repurposed into recycled content for high-end glasses, shoes and bags - recycling gives plastic bottles a new life.

Instead of wearing shirts with the classic Nike slogan "Just Do It," maybe the PET and recycling industries should adopt, "Just Recycle it." Top of Form

*************************