CW July 2012

July 2012
Cross-linking technologies Thermoplastic elastomers Colour measurement guide Whats new in nanotubes?
Introducing
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contents
05 Industry news
page 13
The latest compounding industry news including international acquisitions and alliances, plus new investments and plant openings.
10 Flame retardants face new challenges

Flame retardant additives are coming under fresh attacks from the mainstream media and legislators in both Europe and the USA.
page 21
13 PEX: adding the missing link

Producing cross-linkable compounds can be a real challenge. Jennifer Markarian looks at materials and processing options.
21 Guidelines for colour measurement

page 29
Colour measurement can be critical in the manufacture of high-quality products. Peter Smith of X-Rite provides useful advice on how to get it right.
29 TPEs provide a touch of class

New material developments are extending the scope and functionality of TPEs. Chris Smith reviews recent innovations.
39 Custom-made ERP for compounders

page 39
Polymer-Chemie invested in a custom-made ERP system for its compounding plants. Now the Poly.ERP system is available to other compounders.
45 Whats new in nanotubes?

We round up the latest developments in carbon nanotubes including new grades and applications for conductive compounds.
51 New products: polymers and additives

page 45
56 Compounder of the month: Perrite 58 Dates for your diary
coming next issue

Carrier materials PVC plasticizers Reactive extrusion
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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: Senior editor: Contributing editor: Designer: Advertisement manager: Andy Beevers Chris Smith Jennifer Markarian Nicola Crane Claire Bishop E-mail: abe@amiplastics.com E-mail: cs@amiplastics.com E-mail: editorial@compoundingworld.com 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 July 2012 | compounding world 3
The biggest little story in blending.

Steve Maguire, President and Founder Maguire Products, Inc. MaxiBatch Blender, Maguires largest blender at 14,000 lbs/hr is ideal for high throughput applications, compounding and wood composite applications). It can handle up to twelve ingredients including powders.
MicroBlender, Maguire's smallest blender; stainless steel hoppers; enhanced mix blade/static dam; improved handling of poorly flowing materials.
Leading bumper to bumper warranty in the industry.
When Steve Maguire popularized the gravimetric batch blender in the 80s, he started out small, working from his attic. From those early blenders, the line has grown both larger and smaller; big and little, if you will. Now, the new Maxi Batch is the largest volume blender at 14,000 lbs/hr and the littlest one- the Micro Blender- is still wellmicro. The concept however remains the same, actually improving through field trials. The real-world test is having nearly 40,000 units installed worldwide. Steve Maguire remembers his days as a processor and the ever-present pressure to produce. Technology, after all, is supposed
Maguire Headquarters: 11 Crozerville Road, Aston, PA 19014 Tel: 610-459-4300, 888-459-2412 Fax: 610-459-2700 E-mail: info@maguire.com Maguire Europe: Tel: +44 1827 265 850 Fax: +44 1827 265 855 E-mail: info@maguire-europe.com Maguire Asia: Tel: +65 6848 7117 Fax: +65 6744 3370 E-mail: magasia@singnet.com.sg
U.S. Patent 6,154,980. Other U.S. and International patents pending.
to work for you, not against you. Thats why Maguire sees blender logic as the gateway to process control in the future. Accuracy, precise dosing, economy of materials never go out of fashion. And little things count, especially as resin costs rise. With nearly 150 patents in the U.S. and internationally, Maguire is committed to developing unique products and systems in blending and beyond. So the big story is really about combining productivity with savings. Why not make a little move today and contact us? Who knows? It could make a big difference.
The perfect blend of simplicity and control.
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news
Schulman opens two new global innovation centres

International compounding group A Schulman announced last month that its recently completed global innovation centres in Germany and Mexico are now in full operation. The two centres the A Schulman Academy at Kerpen in Germany and Polynnova Group at San Luis Potosi in Mexico are designed to allow the company to undertake research and development projects with supplier partners and customers. The A Schulman Academy focuses on plastics engineering and application technology, providing access to state-ofthe-art machinery and laboratory equipment. The Polynnova unit manages collaborative projects using an open innovation network model. It will initially target Patricia Mishic says the new facilities address the need for market-driven innovation agriculture, aquaculture and nanomaterial projects. We are very pleased to have these opportunities to work so closely with some of our key customers and suppliers to address the very important need for marketdriven innovation, said Patricia Mishic, vice president and chief marketing officer. Expanding these critical relationships will help align our global technology and product development efforts with the current requirements and emerging needs of our customers and end-markets.
Hallstar buys Dow plasticizers

HallStar has acquired the TP-series product line of specialty plasticizers from Dow Chemical. The deal provides HallStar with a broader range of ester technology principally used in rubber modification. Louis Pace, executive VP of HallStar, said: Acquiring the TP-series product line broadens our global footprint and strengthens our portfolio of recognized plasticizer brands. In 2009, Hallstar bought the Dioplex plasticizer business from Dow.
www.aschulman.com
www.hallstar.com
German plastics machinery sales hold up

Sales of German plastics and rubber machinery are expected to decline by around 2% this year much less than anticipated and to bounce back again in 2013, according to the latest predictions from Germanys machinery industry association, the VDMA. The association predicts the total for this year will be E6.08 billion, but expects the figure to climb by 7% to reach E6.5 billion in 2013. As late as October last year, the association had predicted sales to drop by 7% in 2012, said association chairman Ulrich Reifenhuser. However, business performance in the second half of last year and in the first few months of 2012 proved better than anticipated, allowing us to revise our forecast. Reifenhuser said demand from customers in Germany will remain strong in both 2012 and 2013 due to on-going high levels of investment activity and consumer demand.
www.vdma.org
Fiat selects Borealis TPOs for new Panda

Automotive group Fiat is using a number of PP compounds from Borealis in exterior and interior applications on its latest Panda model. The car maker is using Daplen EE103AE-9543 TPO for the bumpers, selected for its good impact strength and stiffness and its ability to meet Fiats demanding panel-gap requirements over a wide
www.compoundingworld.com
temperature range. Daplen EE168AI-9533 is used on the dashboard and centre console for its low-gloss finish and resistance to scratching. The dashboard fascia uses XMod MSC65T20 for the carrier sub-structure and Daplen EG265AI for the surface. All of the parts are produced by Magneti Marelli.
www.borealisgroup.com
July 2012 | compounding world 5
news
Manner announces expansion

US-based PVC compounder Manner Plastics has announced a US$6 million investment in a new compounding line and factory expansion at its plant at McKinney in Texas. The investment will see the company add 325m of
2
BASF extends Astra additives agreement

BASF Plastics Additives Middle East has renewed its agreement with Astra Polymers, allowing the latter to continue producing one-pack antioxidant systems, which are branded Customer Specific Blends (CSBs), for BASF customers in the region. Astra Polymers has operated BASF-owned lines producing CSBs at its site at Dammam in Saudi Arabia for several years. These CSB products are sold by BASF in the Middle East. BASF says this arrangement will continue after it opens its own production facility in Bahrain in the final quarter of this year. We are extremely happy to continue CSB production in KSA [the Kingdom of Saudi Arabia] with a strong partner like Astra Polymers, said John Frijns, BASFs senior vice president plastic additives Europe/EAWA. BASFs combined global production capacity for antioxidants and CSB, paired with Astra Polymers plant in KSA, and our new facility in Bahrain, shows our on-going commitment to this growing market. Astra Polymers is a leading regional producer of compounds and masterbatch specialising in colour masterbatch and compounds for water and gas pipe production. The success of both companies in the growing plastics industry in the Middle East is proof that our cooperative agreement is well founded, adding value to both our companies and the industry, said Astra Polymers CEO Bandar N Al-Saqer. John Frijns of BASF and Astras Bandar Al-Saqer renew their antioxidants deal
new office space and 3,000m2 of production space to its existing plant, taking total floorspace to almost 8,000m2. The company will also install additional infrastructure to support the new compounding line, its sixth. Manner Plastics president Raj Bhargava said the company has seen considerable growth since 2009, when it acquired the intangible assets of Texas-based PVC Compounders. The assets we acquired in 2009 provided a platform to diversify our markets and expand our customer base, he said. Our revenues have grown by 60% over the past four years. Just as importantly we have doubled the number of customers we serve. Manner Plastics supplies flexible PVC compounds in the US, Canada, Mexico and a number of Asian countries. Its most recent development was a range of UL94 V-0 (1.5 mm and 3.0 mm) compounds for injection moulding applications.
www.basf.com www.astra-polymers.com
Scientists make plastics light up

Researchers at the Technical University of Eindhoven in the Netherlands have created a plastic that emits light when stretched. The work, which was reported in Nature Chemistry in June, incorporates a ring-shaped molecule (dioxetane) into the polymer. When strained, the ring breaks and emits light. The plastic will emit light as long as it is strained. It is possible to engineer the polymer to emit red, yellow, blue and green light. Professor of supramolecular chemistry at the university, Rint Sijbesma said the observed strain-induced response could be applied in the study of failure mechanisms in plastics. When the Eindhoven plastics are strained to the point of failure, a bright flash of light is emitted due to the simultaneous breakage of the dioxetane rings.
www.mannerplastics.com
6 compounding world | July 2012
www.tue.nl
solar reection with color

Huntsman introduces ALTIRIS infrared reflecting pigment
ALTIRIS pigment reflects infrared energy which can help reduce heat build-up in exterior polymer products, especially in dark and vibrant colors. ALTIRIS can give infrared reflectance from a single additive, making it easy to formulate into a wide range of colorful polymer products.
To learn more please visit the ALTIRIS pigments website or email us at altiris@huntsman.com
Follow @HuntsmanAltiris on Twitter For further info click here
This advertisement contains general information about the properties of the products described in it. Information is updated regularly. To check whether this is the most recent information, or if you would like more information, you can find contact details on www.huntsman.com/pigments. Huntsman does not recommend any of its titanium dioxide pigments for use in leadstabilized, rigid PVC formulations. Information is given in good faith but we do not guarantee the accuracy or completeness of the information. NOTHING IN THIS ADVERTISEMENT IS TO BE CONSTRUED AS A WARRANTY, EXPRESS OR OTHERWISE. IN ALL CASES IT IS THE RESPONSIBILITY OF THE USER TO DETERMINE THE APPLICABILITY OF THE INFORMATION AND RECOMMENDATIONS AND THE SUITABILITY OF THE PRODUCTS DESCRIBED FOR ITS OWN PARTICULAR PURPOSE. Unless otherwise agreed in writing, all sales of products referred to in this publication are subject to the general terms and conditions of sale of Huntsman International LLC or its affiliated companies. ALTIRIS is a registered trade mark of Huntsman Corporation or an affiliate thereof in one or more, but not all, countries. 2012 Huntsman Corporation.
news
PolyOne grows in Asia and Africa

PolyOne is expanding its global operations, announcing the opening of an enlarged technical facility in Shanghai, China, and a new liquid colour and additive service centre for its ColorMatrix subsidiary in Cape Town, South Africa. The Shanghai Innovation Centre has been doubled in size and now includes an enhanced training facility and improved capabilities for textile applications and material analysis. The company said it has also added a design showroom, where prospective customers can see how colour and special effects are influenced by product shape and texture. The Cape Town ColorMatrix facility, which will open in August, includes sales, technical support and an on-site colour laboratory for rapid colour development. The company said the initial aim for the operation is to better support customers producing PET containers for the beverage and personal care markets in the region. Opening this facility in Cape Town will provide us with a strong customer-focused presence in this important region, said William Ravenna, ColorMatrix managing director for Europe, Middle East and Africa. While initially servicing the ColorMatrix product line, the new facility is expected to help develop PolyOnes other businesses in the region in the future. When PolyOne acquired ColorMatrix last year, we committed to a global invest to grow strategy that would add value to our customers and our shareholders. Our new facility in South Africa illustrates our commitment to this strategy, said Robert Patterson, executive vice president and chief operating officer of PolyOne. ColorMatrixs new Cape Town facility will support PET processors in the region
www.polyone.com www.colormatrix.com
Erema and Coperion work on recycling systems

Austrian recycling systems developer Erema demonstrated a new upcycling technology developed with German compounding specialist Coperion last month at its annual Erema Discovery Day open house event. The Corema technology combines Eremas recycling know-how with Coperions compounding expertise. It comprises an Erema shredder/ compactor unit, single-screw extruder and melt filter which feed molten recyclate directly
8
into a Coperion twin-screw compounding extruder. Direct feeding of the molten recyclate into the compounding extruder is claimed to reduce energy costs and minimise residence time and shear, while allowing the system operator access to the full range of filler, reinforcing, degassing and blending technologies provided by a twin-screw compounding installation. According to Erema, the Corema system allows
recycled polymers to be used in formulations with up to 80% CaCO3 filler and up to 50% glass or wood fibre reinforcement - it is not possible to incorporate such high non-polymer addition levels in the standard Erema singlescrew recycling system, according to the company. It said this opens up possibilities to manufacture customised high added-value compounds for high-performance applications. Eremas Discovery Day
event also marked the official opening of the companys new
E5 million Customer Centre at

Ansfelden, near Linz in Austria. The 1,200 m2 facility (pictured above) houses seven recycling lines, which are available for customers to carry out trials and test runs using their own material feedstreams. It also includes injection moulding and cast film equipment for end product evaluation.
www.erema.at www.coperion.com
compounding world | July 2012
news analysis | Fire retardants
Fire retardants face new attacks

Flame retardants are facing fresh challenges from the media and legislators in both Europe and America, sparking debates about the balance of exposure risk over fire safety. The issues raised cover food contamination, plus applications in TV sets and furnishings.
Industry bodies on both sides of the Atlantic have issued statements criticising the conclusions of a new study that claimed to find detectable levels of HBCD (hexabromocyclododecane) flame retardants in a range of common US foodstuffs. Published in the Environwere selected from a group in which the presence of HBCD had previously been identified, introducing risk of bias, and that the researchers had based their conclusions on frequency of identification rather than levels measured, which were slightly lower than previous studies. The associations also said that last year, EFSA (European Food Safety Agency) analysed HBCD levels in 1,914 samples from seven European countries, concluding that: Current dietary exposure to HBCDs in the European Union does not raise a health concern. Two weeks earlier, EFSA had issued a statement (http://bit.ly/EFSA2012) expressing its concern that the International Electrotechnical Commission (IEC) TC108 committee had voted down amendments to the 60065 and 62368 fire safety standards for TVs that would have required device cabinets to pass a candle external ignition test. EFSA claimed that lobbying by environmental groups against the use of flame retardants on human health and environmental grounds ignored the fact that: The consumer safety benefits of candle ignition-resistant plastics have been established and peer-reviewed dozens of times at the TC108 and ACOS/ ACEA levels. The association said the IECs own task force had determined that the new generation of large flat panel TVs presented no less a risk from external ignition than their CRT predecessors. Meanwhile, a series of articles published by the pilot research study has found measurable increases in obesity in rats at much lower exposure levels than when it was previously tested (http://bit.ly/Tribune550). According to the newspaper, the US EPA (Environmental Protection Agency) will carry out a new risk assessment of two of the Firemaster 550 blend components next year. In addition, pressure on polybrominated diphenyl ether (PBDE) flame retardants is building in the US Congress with 26 senators, including three Republicans, pushing for EPA action which would limit the use of the flame retardant. Late last year, the American Chemistry Council, which includes NAFRA, issued a statement encouraging consumers to consider the benefits of flame retardants in furnishings. It said: Flame retardants play a key role in reducing the frequency and severity of fires in the home. Scientists at government regulatory bodies in the United States and Europe have reviewed the safety of flame retardants currently used in furniture and concluded that they are safe as used. Our companies work closely with home furnishing manufacturers and their supply chain to ensure that these products meet regulatory and voluntary performance standards for fire safety. We hope consumers consider the safety benefits of this chemistry and do not make decisions based on reports that lack the full scientific context.
mental Health Perspectives journal, the study on HCBD stereoisomers in US Food from Dallas, Texas analysed 36 foodstuff samples. These included lipid-rich products such as peanut butter, poultry, fish and beef. The researchers found detectable levels of HBCD in 15 of the samples and they concluded that food may be a substantial contributor to elevated -HBCD levels
observed in humans in other studies. EFRA (European Flame Retardants Association) and NAFRA (North American Flame Retardants Alliance) issued identical responses (http://bit.ly/EFRA2012) stating: HBCD was not detected in the majority of samples and in those where it was, it was far below the levels where one might see adverse effects. The associations pointed out that the foods analysed
10
Chicago Tribune newspaper in the US have raised concerns over Californias tough furniture fire resistance regulations which act as the default standard for the US. The newspaper claims flame retardant manufacturers lobbying for candle flame ignition tests which can only be met using foams containing what it describes as toxic flame retardant chemicals ignores the low incidence of such fires. The newspaper reports Californias regulators will shortly replace this with a smouldering cigarette test, which can be met using fire-retardant fabrics alone (http://bit.ly/TribuneFR). The Chicago Tribune has
also singled out Chemturas Firemaster 550 fire retardant blend in its fire retardants coverage, claiming that a new
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Organic peroxides for wire and cable

You name it, we produce it
Our range of crosslinking peroxides for the wire and cable industry is the worlds largest. Our product portfolio includes neat peroxides as well as an extensive range of clay, whiting, silica and polymer bound formulations. For example: Perkadox BC Dicumyl peroxide Perkadox 14S Di(tert-butylperoxyisopropyl)benzene Trigonox T for liquid dosing tert-Butyl cumyl peroxide Formulations with different phlegmatizers can be made available with due observance of safety characteristics and the appropriate environmental and transportation regulations. Whatever your particular requirements, we can develop the product to match. www.akzonobel.com/polymer
Cross-linking polymers | processing feature
Producing cross-linkable compounds can be particularly challenging because of the sensitivity of the additives and resulting formulations. Jennifer Markarian looks at the materials and processing options
PEX: adding the missing link

Cross-linked polyethylene (PEX) is widely used in pipes and in wire and cable. The cross-linking process is used to improve properties such as tensile and impact strength, chemical resistance, temperature resistance and creep resistance compared to standard PE. Cross-linking can be achieved with peroxides, silanes, or radiation. Peroxide cross-linking (European category PEX-A) uses compounds containing peroxides, and the extruded part is cross-linked under elevated temperature. Silane or moisture-cure cross-linking (PEX-B) uses compounds containing silane-grafted PE and a cross-linking catalyst. These can be made in a one-step process where vinylsilane, peroxide grafting catalyst, and a cross-linking catalyst are compounded at once. Alternatively, a two-step process can be used where silane grafting is followed by compounding with the cross-linking catalyst. Silane additive suppliers such as Dow Corning and Momentive supply masterbatches for both process
types. Cross-linking of PEX-B occurs in a water bath or steam after the part is extruded. Making both types of cross-linkable compounds requires careful mixing and temperature control. A third type, radiation cross-linkable compounds (PEX-C), do not require additives to initiate cross-linking. After the part is extruded, it is cross-linked in a separate process by electronic-beam, beta, or gamma radiation.
Pipes and cables are benefiting from the improved properties of cross-linked polyethylene
New kneaders
Cross-linking and other additives can be compounded using twin-screw extruders, continuous mixers or reciprocating kneaders. An advantage of the kneader is the capability to inject liquids through a mixing tooth, into the centre of the polymer at low pressure, anywhere along the processing chamber. Many cross-linking agents come in either liquid or meltable-solid form and when injected directly into the
processing feature | Cross-linking polymers
Internal view of the Buss MX 4 being used to produce silane-crosslinkable HFFR compounds
Mixing
Grafting of PE
Feeding of ATH
polymer matrix they are immediately and efficiently incorporated, says Mike Irish, vice president of the US subsidiary of Buss, the Switzerland-headquartered manufacturer of reciprocating kneaders. For halogen-free flame retardant (HFFR) wire and cable compounds, flame retardant fillers such as magnesium dihydroxide or aluminium trihydrate are used at high levels of up to 75% and can be temperature sensitive, which makes the compounding process a challenge. The Buss Kneader excels in the feeding and mixing of high filler levels and in the gentle treatment of shear- and temperature-sensitive polymers and additives, claims Irish. Silane-cross-linkable HFFR compounds for wire and cable applications are typically made in two compoundA liquid injection pin is used to add cross-linking additives in the B&P Process TriVolution Tri-Kneader ing steps in order to adequately mix the high levels of mineral flame retardants. First the polymer is grafted with silane or peroxide cross-linking agents and pelletized, and then this grafted polymer is compounded with flame retardants, coupling agents, and other additives and again pelletized. The final pelletized compound is extruded into cable and cross-linked after extrusion using water or steam.
Feeding of polymers
Buss recently introduced a 22 L/D version of its MX 4-flight kneading compounder, which is 50% longer than the previous 15 L/D MX machines and, because it is long enough to handle multiple tasks, is capable of replacing the two-step compounding process with a single-step process. After the polymer is melted, the silane is injected into the melt. There is a long residence time in the grafting zone to allow the silane to graft onto the polymer. Next, the flame retardant filler and other additives are fed into the melt and further mixed (see the picture above). A final degassing zone releases residual volatiles. Throughout the process, the melt temperature remains safely below the decomposition temperature of ATH. According to Buss, the advantages of the one-step process are lower energy use, easier logistics due to eliminating storage of an intermediate compound, and simplified quality control due to testing one compound rather than two. B&P Process Equipments TriVolution Tri-Kneader, a reciprocating kneader introduced last year, can be used to efficiently process cross-linked compounds, says Michael Lazorchak, global product manager for mixing systems at the company. Higher levels of cross-linking additives are typically added to a formula in order to achieve the target levels in the finished product and compensate for any losses created by over-shearing, high heat history, long dwell times, lubricity of the mass, and other factors. The TriVolution, however, is designed to eliminate these losses through its triple stroke per revolution, its multitude of pin/flight interfaces, and its capability to fine-tune shear, explains Lazorchak. A uniform dwell time, low heat history, and finely tuned dispersive vs. distributive mixing profile helps dial in the optimized solution, he notes. Achieving the target level of cross-linking while maintaining a specific temperature profile is a key challenge. When compounding peroxide-cross-linked
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Cross-linking polymers | processing feature
PE or silane-grafted PE, temperature control is critical to avoid flashing off liquid additives in the compounding process. Standard peroxides must be compounded below 160-170oC to prevent premature peroxide decomposition and cross-linking in the extruder (i.e., scorching). Akzo Nobel, a major supplier of cross-linking peroxides, introduced a higher-temperature peroxide, Trigonox 311, several years ago that extends this temperature range by 20-30oC. Lubricity is also an issue, notes Lazorchak. He says that traditional kneaders have a tendency to slip and become inefficient when processing liquid additives, while twin-screw extruders may over-shear the product and produce a heat history that flashes off much of the liquid, thereby creating both a hazard and waste product. The TriVolution is designed to optimize mixing of liquid additives. The TriVolution has also been used to crosslink a blowing agent used for foaming a part during injection moulding. The blowing agent was set to activate as a foaming effect in the injection moulding of the finished part, explains Lazorchak. The temperatures of the compounding process had to be tuned to compounding and cross-linking, but not to activate the blowing agent in the extruder. We essentially compounded a loaded gun pellet that would fire in the injection moulding phase.
Harnessing radiation
Radiation cross-linking uses high-energy radiation to break chemical bonds and release free radicals to initiate cross-linking. Although PE does not require any additives to make it radiation cross-linkable, some other resins such as polyamides and PVC must use cross-linking activators, either compounded in or added via masterbatch during processing of the part. Beta Gamma Services in Germany uses high-energy beta and gamma radiation to cross-link a wide range of polymers in many types of parts, including pipes, wire and cable insulation, tubes for heat-shrink products, and injection moulded parts for automotive and other sectors. Radiation cross-linking can be used for parts containing multiple materials, such as metals and polymers. The degree of cross-linking can be varied within a part using shielding to protect some areas from radiation. US-based E-Beam Services uses electron-beam irradiation to cross-link polymers for wire, cable, and tubing. Typically, part manufacturers use a contract service provider rather than in-house equipment, because e-beam systems are complex, capital-intensive, and require specialized maintenance and regulatory oversight, notes the company.
www.bgs.eu www.ebeamservices.com
premature reactions in cross-linking applications. Along with the standard closed-barrel co-rotating twin-screw extruder, the company also offers such machines with a clam-shell or sliding-barrel construction for easy cleaning in several size models, typically from 90 mm up to 130 mm. The underlying idea of the design is that cleaning is key ingredient to provide a quality product for such a technical application, notes Giorgio Colombo, managing director at ICMA. KraussMaffei Berstorff is active in the cross-linked polyethylene (PEX) pipe market which is already well established and is now expanding into new market and application areas thanks to further improvements in properties. Daniel Lachhammer, product manager for pipe extrusion at the company, says that growing applications for PEX include potable and hot water pipes, gas pipelines, district heating systems, heating and sanitary pipes, industrial applications, geothermal pipe systems, and air conditioning systems. The move to cross-linked materials in these markets is being driven by the materials improved temperature resistance at both high and low extremes, plus its chemical and creep resistKraussMaffei Berstorff offers conical twin-screw extruders for the production of PEX-A pipes
Twin-screw options
Twin-screw compounding extruders are also widely used to produce crosslinkable compounds for direct extrusion, in which compounding and extrusion are performed in-line in one step. For example, Coperion twin-screw extruders are used for both pelletized compounds and direct extrusion of PEX for pipe and wire and cable applications. The machines are also used in the direct extrusion of foamed and cross-linked specialty films. ICMA San Giorgio has developed a special screw design to restrict
July 2012 | compounding world
17
processing feature | Cross-linking polymers
ICMA San Giorgio supplies extruders with clam-shell barrels for easy cleaning when producing crosslinked compounds
ance and its ability to withstand notching and cracking even at low temperatures. Apart from high-end solutions for PEX-B and PEX-C pipe production, KraussMaffei Berstorff develops and sells complete lines for single- and multi-layer PEX-A pipe. In this process, a pre-mixed, peroxide-cross-linkable compound is extruded into pipe using a counterrotating twin-screw extruder with a special pipe head, followed by in-line cross-linking in an infrared irradiation oven. In KraussMaffei Berstorffs integrated system, the cross-linking oven is supplied by its exclusive partner, Crosslink Finland. Click on the links for more information:
www.dowcorning.com www.momentive.com www.busscorp.com www.bpprocess.com www.akzonobel.com www.coperion.com www.icmasangiorgio.it www.kraussmaffeiberstorff.com www.crosslink.fi
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Starch-based Polymeric Materials and Nanocomposites

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Colour monitoring | quality control
Colour measurement is critical for the manufacture of high-quality plastic materials and products. Peter Smith of X-Rite provides some useful advice on how to get it right
Guidelines for colour measurement

All manufacturers share the basic need to measure colour accurately and reliably to meet their customers specifications. To assist them, instrument companies have designed sophisticated tools that can help anyone to learn and apply the language of colour for quality control. Just like a workman needs the proper tools to complete a project, manufacturers should first spend time understanding from their customers exactly what needs to be measured and to what accuracy. Here are some common questions to consider: those that give only a coarse resolution. For instance, a colorimeter gives one of the above mentioned standard values with moderate accuracy, and a 31-point spectrophotometer gives all the standard colour values, plus a full reflectance curve data, at a high level of accuracy. X-Rites Vericolor non-contact spectrophotometer provides accurate in-line colour measurements
3) What system of tolerancing does the customer use and how tight is the tolerance?
Some common tolerancing systems include CIELab, CMC Lab, DE 2000 and HunterLab. It is important to select the appropriate system of tolerances to guard against release of product that doesnt meet customer specifications and delay the shipping of good product. Loose tolerances may require only a colorimeter, while tight tolerances may require a 31-point spectrophotometer.
1) Which colour scale does the customer use?

Instruments generally assign a number to each of the three basic elements of colour: hue, chroma and value. There are three common standards that communicate a particular colour in the vast universe of possible colours: CIE Xyz, CIE L*a*b*, and CIE L*C*h.
4) How smooth is the surface you are measuring?

Is it smooth like a car panel or relatively rough like an embossed plastic part? Some textured surfaces such as cloth are angularly sensitive, meaning that the colour measurement is affected strongly by the orientation of piece.
2) What level of spectral resolution does the customer require?

Instruments that provide a very fine resolution of the visible spectrum are more expensive than
s
21
quality control | Colour monitoring
The three typical types of spectrophotometers: spherical, 0/45 or 45/0, and multi-angle
5) What type of illumination is the customer using?

Many colours undergo a common colour phenomenon called metamerism when viewed under different light sources. Two colour samples may appear identical when viewed under incandescent illumination, but appear very different under daylight. In general terms, customers choose a standard illuminant that best represents the source that will light their products where they are sold. Some standard illuminants include A, C, D50, D65, F2, F7, and F11.
precise colour measurements on a wide range of materials, such as paper, paint, plastics and textiles. Manufacturers also regularly use 0/45 or 45/0 spectrophotometers that mimic the behaviour of the human eye, based on the attributes of sample texture and gloss. Many 0/45 spectrophotometers have to physically touch test surfaces or transparent holders to take their readings. However a new generation of 0/45 spectrophotometers can take readings from a distance, without contacting the actual product. The non-contact technology allows manufacturers to easily measure wet paints or coatings as part of process quality control.
6) Getting to grips with spherical

To precisely measure the colour of paints and coatings, manufacturers frequently use any of three types of spectrophotometers: spherical, 0/45 or 45/0, and multi-angle. A spherical spectrophotometer uses a hollow sphere made of a special ceramic material to measure the colour and gloss of test surfaces independently, which can be an important consideration for painted and coated surfaces. Handheld sphere spectrophotometers generally are convenient to use, cost-efficient and designed to provide fast,
7) Adopting an effective angle

Multi-angle spectrophotometers are being adopted by automakers and their suppliers to measure effect paints and coatings that contain micronized aluminium, mica, titanium dioxide or other additives. The demand for these special effect paints and coatings has been growing strongly over the past decade because consumers want the changes in colours and shimmer that come from viewing products
at various angles.
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quality control | Colour monitoring
8) Sophisticated measuring for accurate results

Spectrophotometers are among the most sophisticated instruments for measuring colour and appearance, but there are other instruments such as colorimeters, densitometers and gloss meters that can provide more limited or less exact data on colour and appearance for less cost. One new technology for colour measurement uses a number of LEDs in the visible and ultraviolet wavelength ranges to illuminate test surfaces and mathematically calculate areas of colour density. The technology allows companies to accurately identify up to four specific colours from one measurement on a wide variety of textures and surface finishes, including fabrics, smooth plastics and paints and coatings. Improved instrumentation often provides better data, and that data analyzed properly with advanced software can yield some effective results for manufacturers. More powerful software packages makes it possible for companies to link objective numerical data for instance, the degree of hue, chroma and saturation of a particular paint sample with shop floor There are different standards for sharing the three basic elements of colour: hue, chroma and value Since light from effect pigments is reflected in many directions, multi-angle spectrophotometers may take colour measures at aspecular angles of 25, 45, 75 and/or 110, with a 15 angle used as necessary. An aspecular angle is defined as the different angle to the direction of the specular reflection of the incident beam. Like the newer 0/45 spectrophotometers, multi-angle spectrophotometers can take readings from a distance. variables during the manufacturing process. These could include the recipe of a particular formula, the method of applying paints or the mixing time.
More information:
For more help in understanding colour measurement and selecting the best instruments for a process, contact Peter Smith at X-Rite Europe: PSmith@xrite.com.
www.xrite.com
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Colour measurement | new products
Konica Minolta introduces new spectrophotometer

Konica Minolta has launched a new bench-top spectrophotometer, the CM-3700A. It is an updated version of the now discontinued CM-3700d that adds a USB communication interface, an extended sample area for larger sheet samples, plus a newly engineered soft close sample holder that is designed to protect samples from damage. The CM-3700A can measure both the reflectance of opaque objects and the transmittance of transparent or translucent solid plastics. The device also provides accurate measurement of materials containing fluorescent whitening agents. These require precise control of the UV component of the illumination, which the CM-3700A provides using a 400 nm UV cut-off filter that is inserted into the instruments illumination light path. The positioning of the filter can be performed automatically using Konica Minoltas SpectraMagic NX colour data software. The latter has just been updated with the launch of version 2.2.
Pantone adds new collections

Pantone has added two new Plastic Standard Chips collections: the Color Collection Volume 1 and the View Inspiration for Interiors 2013 design set. These special packages offer 50-60% cost savings compared to purchasing individual chips. The Color Collection Volume 1 contains 154 of Pantones most soughtafter on-trend colours. These include selections from all major colour families, key-trending neutrals, lustrous metallics and vibrant neons. The Pantone View design set includes large-format plastic chips in 73 colours
www.konicaminolta.com
HunterLab finds the best angle

HunterLabs latest generation ColorFlex EZ spectrophotometer uses a 45/0 design for very precise colour measurement. The compact, easy-to-use instrument features a large 3.7 (94 mm), high-resolution display and improved connectivity with three USB ports. These can be used to link the spectrophotometer to keyboards, barcode scanners, printers or computers. The latter can be used to plot data using HunterLabs Easy Match QC software. The ColorFlex EZs built-in software provides 250 set-up configurations with product standard values and tolerances for a wide variety of parameters including colour scale, indices and illuminants.
that were highlighted in the companys recent home and interiors 2013 forecast. Pantones Plastic Standard Chips can be produced in all of the 3,400 colours in the companys Plus Series and Fashion + Home colour system libraries, as well as in custom colours. Moulded in polypropylene, the chips include both gloss and matte finishes and are tiered with thicknesses ranging from 1 to 2 mm.
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X-Rite shines a light on samples

X-Rite has launched a new light booth, the SpectraLight QC. It allows users to assess whether their products are meeting their customers exacting specifications for colour and appearance under daylight, incandescent, fluorescent and other illumination conditions. According to the company, the SpectraLight QC offers highly accurate simulation of daylight. In addition, its SmartLogic technology and other built-in features help to increase productivity, accelerating throughputs for fast and accurate colour approvals.
www.xrite.com
www.pantone.com
27
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POLYMERS IN PHOTOVOLTAICS 2012 CONFERENCE INFORMATION

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Thermoplastic elastomers | materials feature
TPEs provide touch of class

In a world dominated by visual communication it is easy to forget that our perception of the everyday products that surround us is judged not only their appearance but also by their physical interaction with us the way they function and feel. And in terms of feel few materials match the tactile feedback of TPEs, which deliver a warm and soft touch while often simultaneously enhancing durabililty and functionality. The tactile response of TPEs can also provide a valuable safety function, offering improved grip in wet or damp environments, for example. This wet grip performance has been a key area of development for TPE producers in recent months, with a number of enhanced grades coming to the market. Teknor Apex announced the introduction of a Wet Grip line within its Monoprene family of styrenic block copolymer (SBS) TPEs earlier this year. Available in hardness ranges from 10 to 45 Shore A, the new grades are said to retain all of the elastic and mechanical properties of the companys standard Monoprene grades but exhibit much improved wet grip performance. This is important not only in outdoor applications, says the firm, but also for applications such as tool grips where sweat can make standard TPEs slippery. In tests comparing the coefficient of friction of the
New material developments are extending the scope and functionality of TPEs. Chris Smith reviews recent innovations
new grades against standard sytrenic TPEs the company measured a 25% improvement when exposed to water and a 175% improvement when exposed to soapy water. According to Teknor Apex senior consumer market manager Brian Mulvaney, the Wet Grip line is suitable for a wide range of houseware, personal care, power and hand tool, and sporting goods applications and is the result of more than a year of compound optimisation. The TPEs retain their suitability for processing via multi-component, coinjection or insert overmoulding techniques. The proprietary wet-grip chemistry that we have developed addresses everyday situations in the real world, where workers must handle tools, cooks use utensils and golfers grip clubs regardless of surface
Main image: PolyOne GLS developed a custom TPE grade for Kor Waters new Delta bottle
materials feature | Thermoplastic elastomers
Right: Two-shot moulding is used to integrate the TPE closure seal on the Delta bottle
conditions, Mulvaney says. Improved wet grip performance was also the driver for Kraiburg TPEs development of its Thermolast W range of SBS products, which the German company claims deliver coefficients of friction in wet conditions up to three times that of its standard grades. According to Kraiburg, the improved wet grip performance has been achieved without the use of tackifiers so there is no risk of migration, which can cause stickiness at the surface. It also means there is no negative impact on processibility using multi-component injection moulding techniques. The company says the wet grip technology can, however, be combined with tackifiers if required. Thermolast W products are available with hardness values of between 25 and 60 Shore A and provide all the performance characteristics of Kraiburgs standard SBS grades, including high transparency and ease of colouring. The company is targeting applications such as anti-slip mats, tool grips, fitness equipment, surgical instruments and household goods. It also expects to be able to adapt the chemistry to its Thermolast styrene-ethylene-butylene-styrene (SEBS) TPEs in the future.
result is a soft touch part with high resistance to indenting. Santoprene 8211-85MM350 TPV is filling a gap for TPE-V use in the automotive industry, as its good optical and haptical properties can be applied to a broad range of automotive interior applications, says Mathias Dietz, manager of sales and development at German component maker ElastomerTechnik Gedern and a Santoprene user. The soft, low-gloss comfort touch achieved enhances the appearance of automotive interiors and provides a perception of high-quality to customers, he says. ExxonMobil says it has also been focusing on improving the processibility of its TPV products, with its Santoprene M200 series targeted at applications calling for easy processing and demanding aesthetics. One of the target application areas for the products is in encapsulation of glass window elements, where the ability to reduce injection pressures by up to 40% and lower melt temperatures by around 10C reduces the risk of glass breakage. According to ExxonMobil, the good flow of the M200 series TPVs means the surface finish can also be matched closely to that of extruded parts used on the glazing line such as EPDM extrusions by the use of specific mould surface graining techniques. Santoprene 121-XXM200 TPV grades are part of our ongoing innovation to develop new TPVs that meet automotive industry requirements for lower cost and lighter weight engineered applications, while improving functional and aesthetic performance, says Michael Russo, global brand manager for Santoprene TPV at ExxonMobil. The commercialisation of Engels Dolphin technology earlier this year in the latest Mercedes Benz Actros truck could mark a further significant step forward in the penetration of TPE into the automotive interior sector. It uses physical foaming techniques to create a TPE surface with a more cushioned effect than traditional direct overmoulding. The technology is being used to produce four panels that make up the 2 m wide dashboard on the new truck, including a complex lower section with fold away drawers. Italian compounding company SO.F.TER provides the resins for the application Re-blend PC/ABS blend for the rigid carrier mouldings and Pibiflex TPE from SO.F.TERs P-Group subsidiary for the soft surface while production is carried out by Italian automotive component maker SOLE at the Mercedes plant at Wrth in Germany. The parts are produced on an Engel Duo injection machine with a horizontal
Automotive innovations
Meanwhile, TPEs are finding growing application in the automotive industry, where their low emissions can help meet the demanding odour and fogging requirements set by the automotive OEMs for interior parts. ExxonMobils Santoprene 8211-85M350 TPV has been formulated for such applications and is being used by VW to produce the roll top trim for the door on its Multivan and for the glove box cover on its Beetle car. In both cases it is used as a solid skin applied over a PP core using a multi-component moulding process. The
Comparison of wet and dry coefficient of friction for Kraiburgs Thermolast W wet grip TPEs against standard alternatives
TPE Compound Target hardness COF, wet COF, dry
Control A Wet Grip A Control B Web Grip B Control C Wet Grip C Control TPV
Source: Kraiburg TPE
30 Shore A 30 Shore A 40 Shore A 40 Shore A 50 Shore A 50 Shore A 55 Shore A
1.6 4.3 2.0 3.4 1.8 2.9 1.0
3.0 4.4 1.8 4.0 1.8 3.7 1.2
30
cover logo plates, which it is making for the first time using a two stage overmoulding process in place of manual assembly. The TPE is used to create the undercut bearing elements that retain the rigid polyamide logo plate in place on the engine cover. By injection moulding the TPE onto a slotted ring on the logo plate, the hard and soft materials are mechanically fixed together. The bond is strong enough at demoulding temperatures to allow the undercuts to be produced with no risk of separation. Kraiburgs Hipex TPEs provide hardness values of 70 Shore A and are suitable for continuous operation at 150C and short term use at up to 170C. The TPEs are also resistant to oils and a wide range of chemicals found in automotive environments. German firm Mues is using Kraiburgs Hipex TPE to secure its engine logo plates intermediate rotary table, multi-axis robot and Mucell physical foaming unit. The mould is by Swiss mouldmaker Georg Kaufmann. The two-step moulding process involves first producing the rigid carrier followed by overmoulding with TPE, which is foamed using the Mucell microcellular foam moulding technology developed by US-based Trexel. According to SO.F.TER, the Dolphin technology produces excellent haptic and aesthetic results. Particular benefits in this first application include well differentiated grain zones, elimination of joints, and good colour matching in the two colour options (beige/ black and black/grey). It says the Pibiflex TPE also meets the UV resistance, thermal stability, scratch resistance, recyclability, and odour and fogging requirements of Mercedes Benz. This is the latest in a string of innovative TPE automotive applications developed using SO.F.TER TPEs. The company worked closely with Rchling Automotive Italia in the development of the projectile injection moulding technology used to produce the cowl grille on the Ford C-Max model, launched in 2010. That part comprises a rigid PP cowl with a flexible seal overmoulded onto one edge in SO.F.TERs Forprene TPV. The seal is hollowed out using Rchlings patented projectile technique, which employs pressurised gas to force a polyamide bullet through the TPV seal in the mould to core it out. The result is a 30% weight saving, while the wall thickness is said to be more consistent than could be achieved using gas or water assisted techniques. BASF has also developed a high temperature resistant version of its Elastollan TPU, providing a continuous operating temperature of up to 150C. Like other products in the Elastollan range, the 785A10HPM grade is a hard phase modified (HPM) TPU and is intended primarily for cable applications. However, other grades in the Elastollan range have proved highly suitable for injection moulded interior trim applications, with one of the most notable applications in the centre console of the current VW Golf model. This is produced at the Innovative Components Technologies site at Lennerstadt in Germany (formerly part of Key Plastics Europe) by overmoulding onto a PC/ ABS rigid substrate. Outside of the automotive sector, PolyOne GLS Thermoplastic Elastomers worked with US companies KOR Water and RKS Design to develop a new version of its KOR Delta Dehydration Vessel a stylish and easy to use water bottle for sports and leisure use. One of the key goals of the redesign was to incorporate the closure sealing gasket into the cap using an overmoulding process to simplify assembly and long term use of the bottle. PolyOne GLS developed a custom TPE material for the application, which delivered a 30 Shore A hardness value and compression set of less than 30% at both ambient and elevated temperatures (75C). It also provided a good bond to the cap, which is produced in Tritan copolyester from Eastman Chemical. The Delta container is manufactured in two sizes (500 ml and 750 ml) and four colour tints. The PolyOne GLS TPE is used to form the cap gasket, as well as for the cap cover and base pad.
Taking the heat

TPEs are also proving capable of managing the higher operating temperatures experienced in the engine compartments of modern cars. German automotive supplier Mues Product & Moulds is using Kraiburgs Hipex high performance TPEs in its new range of engine
Medical extensions
PolyOne GLS has also announced an extension to its Versalloy HC line of TPVs for medical applications. Manufactured at ISO13485 medical compliant sites to
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PolyolefinAdditives2012
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Thermoplastic elastomers | materials feature
FDA current Good Manufacturing Practice standards, the Versalloy HC 9220-70, HC 9220-80 and 9220-90 grades are intended as drop in replacements for three medical TPVs that ExxonMobil will decommercialise at the end of this year. PolyOne and ExxonMobil have collaborated in the development of the new products, which are manufactured using ExxonMobils Santoprene TPVs. The new grades will be marketed in Europe and the US and product is available now, says PolyOne. The grades provide Shore A hardness values of 70, 80 and 93 and are said to be characterised by low levels of extractables and good flex-life performance, fluid compatibility and wet grip. UK-based Elasto recently extended its line of medical grade TPEs to include coloured products. The new Mediprene coloured TPEs are manufactured from medical grade ingredients using pigments and carriers that comply with USP Class VI and relevant parts of ISO10993. All are manufactured in ISO 13485 facilities. In the US, medical moulder Plas-Tech Engineering is using Medalist TPEs from Teknor Apex to produce plunger tip seals on its latest line of single-use syringes for cosmetic facial drug applications. The devices are manufactured in three different sizes 0.5, 1.0 and 1.5cm3 volume in either polycarbonate or cyclic olefin copolymer (COC). COC types are typically marketed as a safer alternative to glass designs while offering a longer shelf life than polycarbonate or polyolefin-based alternatives. Plas-Tech selected two different Medallist TPEs: translucent MD-145 for the polycarbonate versions and MD-555 for the COC types. MD-555 has been formulated to be compatible with COC resins, which can display stress cracking effects when in contact with
some TPE grades, according to Teknor Apex. Both grades are suitable for gamma and autoclave sterilisation, do not interact with drugs, and provide the required compression set and resistance to heat ageing neded to maintain seal integrity. Medalist elastomers process at higher rates than traditionally used polyisoprene rubber and permit cost-effective production in high cavitation and hot runner injection moulding. Their consistent shrinkage allows for extremely tight dimensional tolerances without trimming or other post-moulding processes, says Lisa Charno, medical market manager for the TPE division of Teknor Apex.
Above: Microcellular foamed TPE features in the dashboard of the latest Mercedes truck
Below: PlasTech uses Teknor Apex Medallist TPEs for the tip seal in these single use syringes
Sustainable developments
The thermoplastics processing characteristics of TPEs, such as reduced process energy consumption, together with their recyclability means they can often present a more sustainable option than traditional thermoset
35
Cowl moulding for the Ford C-Max
materials. That sustainable advantage is now being leveraged further through the introduction of products based on renewable or part-renewable feedstocks. Merquinsas established Pearlthane Eco line of polyester TPUs is available with hardnesses ranging from 70 Shore A to 55 Shore D and offers a renewable content of between 24 and 80% (measured to ASTM D6866). DuPonts Hytrel RS family of thermoplastic polyester TPEs cover the range from 30 to 82 Shore D and feature renewable contents of between 35 and 65%. More recently, Tessenderlo subsidiary Cousin Tessier (CTS) extended its TPE compound portfolio to include the Green Tefabloc series, which offer renewable contents of between 25 and 50% and hardness values starting from 50 Shore A. It claims the products set a new standard for softness in the renewable TPE sector. The company says it is using a range of bio-derived resins to produce the new range of TPEs, including the Gaialene grafted starch-based polymers developed by Roquette, as well as fillers such as ground oyster Click on the links for more information: shells. According to CTSs innovation and sustainable development manager, Aline Grudget, the Green Tefabloc products are intended to deliver a low carbon footprint without compromising performance or lifespan. Applications are expected in automotive and consumer sectors.
www.teknorapex.com www.kraiburg-tpe.com www.exxonmobilchemical.com www.basf.com www.glstpes.com www.polyone.com www.elastotpe.com www.merquinsa.com www.dupont.com www.cts-compounds.com
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PolymerFoam2012
International conference on blowing agents and foaming technology for thermoplastics and elastomer
October 9-10, 2012

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ERP for compounders | software feature
Custom-made ERP for compounders

Getting the most out of a plastics compounding operation is far from easy. It requires extremely skilful and responsive planning to deliver a wide range of materials to a diverse selection of customers just when they need them, and frequently at short notice. Managing the deliveries of resins and additives into the plant has to match throughputs so that the right ingredients are always available and inventories are maintained at a reasonable level. At the same time, careful and flexible production scheduling is critical to ensure that the manufacturing resources are used efficiently and that machine downtime is kept to a minimum. Integrating and communicating this information across an organisation is vital to ensure the efficient and timely manufacture of high quality products to meet customer requirements. These are the common-place issues that faced Polymer-Chemie, a leading European compounder of polyolefins, PVC and technical plastics. However, while the issues may be familiar, the companys response was more unusual. Based in Bad Sobernheim, Germany, Polymer-Chemie is part of the privately-owned Polymer Group which has a total compounding capacity of 150,000 tonnes/year, employs around 400 people across seven subsidiaries
Polymer-Chemie has invested in a custom-made ERP system for its compounding operations. Now the Poly.ERP system is available to other European compounders. Compounding World takes at a look at its development and implementation
and achieved sales of approximately E150 million in 2011. Other Polymer Group subsidiaries that have plants in Bad Sobernheim include Polyblend, TechnoCompound, PolyMIM and Sun Alloys Europe. The Group also has production operations in Russia with its OOO Tula Polymer subsidiary. Back in mid-2008, Polymer-Chemie decided to invest in a new software system to oversee its complex manufacturing and corporate processes. Until then it had been using software modules that were developed in-house and covered inventory management, production and quality assurance. These systems had
software feature | ERP for compounders
processes of all the Groups companies in a standardised but also industry-specific way. Its instruction for the development work was as standardised as possible and as individual as necessary! The company selected Kirchhoff Datensysteme Software (KDS) to develop the industry-specific ERP system. With offices in Erfurt and Mainz, Germany, the software development and system house has been operating for more than 22 years and has more than 100 employees. The goal was to have a system that ensures all operational processes are consistently monitored in an integrated corporate database so that all of the companys departments can work together to complete their work processes effectively. The number of silos at the Polymer Group site in Bad Sobernheim indicates the scale and complexity of its operations served the company well, but as the business grew and became more diversified, they struggled to keep up. External consultants initially suggested that the company should introduce a standard off-the-shelf enterprise resource planning (ERP) system to solve the problem. They developed an initial software roll-out scenario and a rough cost estimate. However, Polymer-Chemies management decided to take a closer look at the options after hearing from some other companies about negative experiences with standard ERP systems. Gerald Hauf, managing partner of Polymer Group, says that they spoke with other companies that they had a good relationship with to find out about their experiences with well-known and widely used ERP systems. Their responses raised some important questions. A detailed analysis revealed that many process steps that, at first glance, seemed to have been standardised, did not improve our corporate processes when you analysed them more closely. However, implementing more efficient processes was a key objective of introducing the system. A second analysis focused on which of the companys operational processes needed to be covered by the system in an industry-specific way, and how suitable systems could support these processes. It also examined whether the new processes would improve the efficiency of work task handling. Asked whether commissioning a customer-specific ERP system was very risky, Hauf responds, Of course!. However, he quickly adds: We were able to limit the financial risk by concluding an unusual master agreement. We had the following idea: Polymer-Chemie would finance development of parts of an industry solution for polymer compounders. In return, it would receive a tailor-made, comprehensive ERP system to meet our own specific requirements. Of course, we could not completely eliminate implementation-related risks, but we considered these risks to be lower than the risks of other alternatives.
Framework for success

Several factors helped towards the successful completion of the project. The existing individual modules, which had been developed in-house by the head of the companys IT department, provided a robust framework for process and functional analyses. This was because they had been originally developed with an in-depth understanding of a compounding operations processes. Polymer Group consists of seven, independent companies. Although they all are polymer compounders, each company has its own process specifics. These are sometimes due to their different types of business, while in other cases they are based on historical developments or management decisions. This meant that from the very beginning of the project, there was a lot of pressure to identify business-critical special demands and industry-specific requirements for standardisation. KDSs new Poly.ERP system was developed and introduced on a modular basis. The first modules went live at the PVC compounding subsidiary in August 2010. A number of fundamental changes in work processes were introduced at the same time. For example, the company adopted barcode-controlled inventory adminiswww.compoundingworld.com
Industry-specific applications
The result of this second analysis was surprising. It revealed that instead of a standard system, the operation would require three or four partially industryspecific industry applications to efficiently depict the relevant business processes. In addition, these systems had to closely dovetail with each other. Polymer-Chemie therefore took the unusual step of commissioning the development of a specialised industry solution that was able to cover the business
PLASTICS IN PHOTOVOLTAICS
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The international technology and business conference on plastics, adhesives and elastomeric materials in solar modules CLICK HERE FOR DETAILS
September 19-20, 2012

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software feature | ERP for compounders
easily made using parameter control. In addition to expanding modules and departmental functions, Polymer-Chemie and KDS worked together to establish continuous process improvement procedures. Operating managers from all areas have worked with the system developers to increase the efficiency, practicality and controllability of work processes and the related system functions. The results of this work are routinely included in new software releases.
Delivering benefits
Reviewing the development and implementation of Poly. ERP, Polymer Groups Hauf says: Today, we have Along with the implementation of the new ERP system, PolymerChemie adopted barcode-based inventory control tration using mobile data terminals. Using this system, containers are marked with a barcode upon receipt through to consumption, and again from manufacture through to shipping. As a result, they can be tracked throughout their lifecycle. The simple, user-friendly scan functions have been designed so that they can be easily used by production and logistics employees. The production control station is directly connected with booked order data so that integrated production planning based on specified delivery dates can be made without circulating documents. The software also considers industry-specific order types such as toll compounding orders, master call-off orders and special production runs, such as blending processes, as well as start-up control for granulate materials. All production processes - including batch tracking, raw materials consumption, material demand and manufacture of finished products are directly recorded by a scanner and are available for review in the system. The modules were developed one after another and successively introduced in the Polymer Group companies. A comprehensive ERP system was developed over the period of almost five years to cover all operational processes of the company. Special solutions were implemented in addition to the normal business processes of a formulation-based compounder. For example, a business integration module for external companies was implemented. This interface manager enables an externally operated logistics centre to be connected with Poly.ERP. With this configuration, for example, documents are electronically exchanged between the Groups Polyblend subsidiary and an important customer. The extension of the Poly.ERP system to Polymer Groups Russian subsidiary meant that several countryspecific system processes also had to be covered. This was helped by the fact that the software architecture was designed for multi-lingual use throughout the system. In addition, modifications to suit the customerspecific processes of a polymer compounder can be
system-supported processes throughout all departments of our company. Since introduction of Poly.ERP, we have been continuously working on improving our processes and making them more efficient. We have made a lot of progress in doing so, but, of course, there is still a lot of work to be done in this area in future. He adds that an additional benefit for the company has been the improved process transparency. Today, many processes and inter-relationships are much clearer than they were prior to the introduction of Poly. ERP. And of course, that is crucial for making good corporate decisions. Summarising the benefits that Poly.ERP has brought to Polymer-Chemie and the other companies within the Polymer Group, Hauf says: I am sure that if you speak with the various managing directors of the Group and with the respective department heads of the individual companies, each one will naturally have a different view of what is beneficial. From my point of view, I feel that it is very helpful for the Group that, thanks to standardised processes, we have an ever better understanding of what is going on in the companies. At the same time, their industry-specific topics are efficiently depicted. A good example of the above is the transparency we have gained regarding gross profit performance.
Commercial launch
Following from its successful implementation of Poly. ERP at the Polymer Group, KDS made the ERP system commercially available in Europe at the start of this year. By offering a specialised industry solution for polymer compounders, KDS is aiming to become the market leader in this particular sector. It says that it will continue to develop the system, adding that each new customer will help it to further expand the functionality of the software for the benefit of all users. Click on the links for more information:
www.polymer-chemie.de www.kds-kg.de
The international conference on advanced elastomer, composite and thermoplastic materials in oil and gas applications
23-25 October 2012

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Medical Grade Polymers 2012

International technology and market conference on polymer materials in medical device manufacturing
September 25-26, 2012

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Marissa Hann Conference Coordinator mh@amiplastics-na.com Ph: +1 610 478 0800 Fx: +1 610 478 0900
Nanotubes | additives news
SouthWest launches two new nanotube grades

SouthWest NanoTechnologies (SWeNT) has added two new grades to its SMW line of specialty multi-wall carbon nanotubes (MWCNTs). They are designed to increase the electrical conductivity of polymer compounds and to performance at lower filler loadings than either carbon black or other MWCNTs in a variety of polymers. Both of the new grades are synthesized using SweNTs CoMoCAT catalytic technology, which delivers very consistent CNT products. SMW200 is a purified grade, with a CNT purity of more than 96%, while SMW210 is an as produced grade, with CNT purity of 70%+ and the balance being mainly metal oxides used in the catalyst. Because post-synthesis purification is not carried out for SMW210, its pricing is improve cathode performance in lithium ion batteries. The company says that the new grades SMW200 and SMW210 disperse easily and have very low percolation thresholds. This enables electrostatic discharge (ESD) much lower. In thermoplastic compounds, there is little performance difference between SMW200 and SMW210 with respect to ease of dispersion, conductivity and percolation. . The purified SMW200 can be used as a carbon black replacement in lithium ion battery cathodes. It is claimed that very low loadings (1 wt %) of SWM200 have resulted in a doubling of cycle life, higher capacities, lower heat build-up and better low-temperature performance. We have already generated a great deal of customer interest in these materials, and resulting demand is driving us to increase capacity, says SWeNT CEO David Arthur. We have just shipped our first 100 kg of SMW210 for a customers full-scale qualification trial for a high-volume conductive polymer application. Also, several Li-ion battery manufacturers are testing SMW200 now. To meet anticipated demand in 2013, SWeNT is adding capacity of multiple tonnes per month.
CNTs make PA12 yarn conductive

Lati and Gimac have collaborated to produce electrically conductive yarn obtained by the drawing of a PA12 compound containing carbon nanotubes (CNTs). The compound is produced by Lati, while the yarn is produced using micro-extrusion technology developed by Gimac. Different material formulations and yarn thicknesses have been produced during experimental trials carried out by the two Italian companies. The conductive yarn has a thickness of less than 0.2 mm with the CNTs evenly distributed in the matrix, ensuring uniform electrical properties. A resistance of about 8 k is measured per cm of yarn, although this can be adjusted by varying the CNT loading as well as the conversion parameters. According to the companies, the electro-
www.swentnano.com
FutureCarbon turns up the heat

FutureCarbon has developed an inner panel for car doors that takes advantage of the thermal properties of nanotubes. The prototype was shown at the Inno.CNT conference in Germany earlier this year. The high thermal conductivity of the carbon nanotubes enables the panel to be used as panel heating, explained
FutureCarbon is using carbon nanotubes to make heated panels for car doors
heat composites and coatings. In July of last year, it signed a long-term agreement with Konrad FutureCarbons Dr. Walter Schtz. FutureCarbon has been exploring a number of ways to use carbon nanomaterials to Hornschurch to develop artificial leather with integrated heating for automotive applications.
conductive yarn is not fragile and is perfectly flexible due to the absence of CNT agglomerates. Target markets include the electronics, automotive and medical sectors.
www.future-carbon.de
www.gimac.com www.lati.com
additives news | Nanotubes
Researchers add conductivity to PP

Researchers at the Polymer Technology Center at Texas A&M University in the US have just published the results of their work on electrically conductive polypropylene compounds incorporating disentangled nanotubes. They disentangled slightly oxidised clusters of multi-wall carbon nanotubes (MWCNTs) in a solution that also contained exfoliated -zirconium phosphate nanoplatelets and was subjected to mild sonication. The disentangled MWCNTs were then isolated using acid-induced coagulation to precipitate the nanoplatelets and they were subsequently reacted with octadecylamine. The treated MWCNTs were easily dispersed in a commercial PP matrix and they acted as more efficient nucleating agents compared to untreated additives. The resulting compounds exhibited an extremely low percolation-like transition in electrical conductivity, which the researchers attributed to the preservation of a random dispersion of disentangled MWCNTs upon cooling from the melt. It is also reported that the thermal stability of PP in air is substantially enhanced at loadings below the percolation threshold due to the extremely large interfacial area between the polymer chains and the free radical scavenging MWCNTs. The researchers concluded that the technology provides an efficient and potentially scalable route for the commercial production of conductive semi-crystalline thermoplastics. In addition, the method may be adapted to uniformly disperse MWCNTs in other polymer matrices. The full findings of the study were published in the Elsevier journal Carbon and they can be purchased at http://bit.ly/MWCNTs.
http://plastics.tamu.edu
Consortium focuses on nanotubes

A new international consortium has been formed to speed up the commercial adoption of nano-carbon materials such as carbon nanotubes and graphene. The Nano-Carbon Enhanced Materials Consortium was launched in Cambridge, UK, in May of this year. Members of the new consortium include: the University of Cambridge (UK); Nokia Research Centre (UK); ST Microelectronics (Switzerland); the International Copper Association(USA); Nexans (France); Bosch (Germany); Oxford Instruments (UK); and Codelco (Chile). The Nano-Carbon consortium is being organised by the Centre for Business Innovation.
Axson purchases Nanoledge

Axson has acquired Nanoledge, a Canadian company specialising in blending epoxy resins with nanoparticles such as carbon nanotubes. Previously owned by Telesystem, Nanoledge has developed proprietary nanoblending technologies to significantly improve the mechanical, electrical or thermal performance of composite materials. In 2009, Nanoledge entered a collaboration to develop composites using Bayer MaterialSciences Baytube carbon nanotubes for applications in lightweight vehicles being developed by Velozzi. Charles Churet, chairman and CEO of Axson said: Nanoledges nanoblending technology is an innovation enabler. Beyond improving Axson product performance in existing markets, this technology will also be a key element to Axsons further development in new expanding markets. Nanoledge has been working with Velozzi
www.axson-group.com
Rhein Chemie mixes CNTs and rubber

Rhein Chemie highlighted the benefits that carbon nanotubes (CNTs) can bring to rubber compounds at the German Rubber Conference (DKT) which was held in Nuremberg earlier this month. The company has developed pre-dispersed CNT masterbatches to simplify handling and provide better compounding results. It used the conference to showcase the benefits that such additives can have on the dynamic and mechanical properties of nitrile rubber (NBR) vulcanizates. Target applications include radial shaft seal rings and engine mounts.
www.cfbi.com
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www.rheinchemie.com
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This case study looks at how ExxonMobils Vistamaxx propylene-based elastomer helped Halsall Toys Europe improve the impact performance of an innovative toy without the need for costly mould modifications.
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Plastribution:
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Plastributions new 20-page Plastic Fantasti c magazine looks at the compan ys award winning work on an indestructible prison chair, lists its full range of materials, and looks in detail at a selection of new resins.
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This 19-page brochure outlines the complex inorganic colour pigments (CICPs) produce d by The Shepherd Color Company, which has offices in the USA, Europe, Japan and Australia.
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like your broc hure to be inclu Claire Bishop. ded on this page claire@amim , please conta agazines.com. ct Tel: +44 (0)20 8686 8139
Click here
to download
examples of all three options, contact Claire Bishop (claire@amimagazines.com Tel: +44 208 686 8139).
Can you produce a digital magazine or brochure for my company?

Yes - we offer contract publishing services. We can help you to produce a customer magazine or brochure, providing writing, editing and design services as required. We can then turn it into a digital publication using the same state-of-the-art on-line platform that we use for Compounding World. Once it is produced, we can make it available to our readers in the ways listed above. For details, contact Claire Bishop (claire@amimagazines.com Tel: +44 208 686 8139).
I have another question to ask, or a suggestion to make. Who should I contact?

Please contact Andy Beevers, our head of business publishing, at abe@amiplastics.com.
agricultural film 2012

International industry conference on greenhouse, tunnel, mulch and agricultural films and covers
6-8 November 2012

Hotel Meli Castilla, Madrid, Spain
* +18% Spanish VAT
Images courtesy of: Aspla S.A., Britton Unterland GmbH, Frilvam S.p.A., RKW SE
Special offer: Save 100* if you register before 5th October 2012
Rocio Martinez Conference Organiser rmm@amiplastics.com Ph: +44 117 924 9442 Fax: +44(0)117 311 1534
Polymers and additives | products
antistatic additives
IonPhasE adds new dissipative polymers

IonPhasE has upgraded its range of antistatic polymeric additives which deliver permanent antistatic properties. The latest IPE U grades can be used in a range of resins and they replace the companys previous products for compounding, extrusion and injection moulding applications. The Finnish companys static-dissipative polymers are based on a patented technology that involves a combination of ionomer and polymer polyelectrolyte (IPE). Plastic products incorporating the material have immediate static dissipative properties that remain unchanged over time and work in low relative humidity. There are three grades in IonPhasEs latest range. U1 is aimed at applications in PC blends, for example providing dust protection to automotive interior components and appliance external parts. It can also be used to provide electrostatic discharge (ESD) protection for electronics products such as covers and housings, as well as carrier tapes and reels. Aimed at styrenics applications, the companys U2 grades can deliver dust protection for ABS automotive interior parts. Alternatively they can add ESD protection to PS and HIPS used in electronics applications. The third grade, U3, has been developed for polyolefins used in compounding, extrusion and injection moulding applications. Examples include various electronics components as well as PP moulded parts for car interiors.
www.ionphase.fi
colorants
Novosystems opens up new markets for microbatches
antimicrobials
Neu and Microspec fight bugs

Neu Specialty Engineered Materials, a subsidiary of PolyOne, has formed a strategic relationship with Microspec to develop antimicrobial formulations for small-diameter catheters and medical tubing based on PolyOnes Withstand
Novosystems now offers its Novopearls in 100 kg batches Novosystems of Seevetal, Germany, is now selling its Novopearls micro-granulates in smaller batches making the microbatch colorants more appealing for moulding applications. They can also be mixed with liquid colours, according to the company. The minimum order size was previously 1,000 kg which means that the colour micro-granulates have primarily been used in
antimicrobial technologies. Neus antimicrobial solutions for medical devices such as catheters and tubing extrusion applications. Now they are being offered in batches as small as 100 kg, which opens up numerous applications in injection moulding. Launched at the Fakuma exhibition last year, Novopearls were described as filling the gap between liquid colours and conventional masterbatch pellets. They are now also being successfully used in conjunction with liquid colours to give significant increases in coloration performance compared to using only liquid colours. The spherical Novopearls are highly pigmented and have an average diameter of 450 microns. They use a wax carrier with a melting point of just 85C, ensuring rapid, streak-free mixing of the pigment in a wide range of host plastics. enhance the ability to kill bacteria at the point of treatment. Microspec has earned a global reputation for extruding small, complex medical tubing with tight tolerances. It can layer antimicrobial additives in the outer portion of multi-lumen tubing, which can help to keep costs down and places the antimicrobial where it is needed most.
www.novosystems.de
www.neuinc.com
products | Polymers and additives
medical plastics
Tungsten-filled polymers help to locate catheters
BIOdegradable PLASTICS
Putnam Plastics is using tungsten-filled plastics to create marker bands for the fluoroscopic illumination of catheter tips used in minimally invasive medical procedures. They reduce costs by replacing traditional gold or platinum marker bands and they also offer greater adhesion to the catheter shaft tip. The marker bands provide high levels of visibility under fluoroscopy (radiopacity). This allows surgeons to precisely locate the catheter deep within the body for the deployment of balloons, stents, and other devices in blood vessels. Traditional metal marker bands require a multi-step forming process to create seamless small diameter tubes. Special equipment is used to crimp or swage the metal bands to the polymer shaft tip so that they do not fall off during medical procedures. This process is costly and time consuming, and quality controls are needed to guarantee sufficient mechanical bonding between the dissimilar materials. Putnams marker bands are made from tungsten-filled polymers, such as nylons, urethanes and thermoplastic elastomers. Using the same polymer as the catheter shaft allows heat bonding of the band for a more secure assembly. Tungsten loadings range from 65% to 80% by weight to meet radiopacity requirements. The bands are cut from tubes extruded in a single process. Putnam uses a proprietary co-extrusion technology to applies an unfilled polymeric outer surface to the bands.
Frilvam and FiPlast add bioplastics

Italian companies Frilvam and FiPlast are working together on the manufacture and distribution of PrismaBio 91319, a biodegradable plastic compound for film extrusion. The new material, which meets the UNI-EN 13432 norm and is certified by Vincotte, is aimed at packaging applications, such as shopping bags, as well as agricultural mulch film. It is claimed to have higher heat stability than many other biopolymers, which improves its processability. Frilvam specialises in masterbatch production, while Cossa Polimeri subsidiary FiPlast produces thermoplastics compounds.
www.putnamplastics.com
www.frilvam.com www.fiplast.it
antimicrobials
Sanitized targets bio-based applications

Sanitized has developed a new antimicrobial additive to protect PVC formulations containing bio-based plasticizers, plus another new product aimed at extending the life of biodegradable plastics. The company says that bio-plasticizers are fully biodegradable products derived mainly from vegetables and that as a result they are constantly at risk from microbial attack and therefore being biologically decom52
posed. It has therefore developed a new antimicrobial additive that prevents premature deterioration of the bio-based plasticizer caused by microbial attack from bacteria and fungi. Sanitizeds other new development is an antimicrobial additive that prevents rapid degradation of biodegradable polymers by protecting them against microbe and fungal attack. They allow the functional life of biodegradable polymers,
such as PLA, to be controlled, while still remaining fully biodegradable. Target applications include biodegradable agricultural films which need to remain in place for a defined period of time, typically three to six months, allowing seedlings to propagate and become established so that they can flourish when the film degrades and they are exposed to the open air.
www.sanitized.com
POLYETHYLENE FILM PRODUCTION IN EUROPE

What are the strategies of the leaders in the market?
A NEW report from AMI offers you essential information on the leading groups in Europe. This invaluable report gives a market analysis of the fty leading extruders of stretch and shrink lm, packaging lm, industrial and agricultural lm and manufacturers of carrier bags, heavy duty sacks and refuse sacks.
Click here to view sample pages and to order this brand NEW report
Polyethylene Film Extruders - 9th Edition Amongst the leading groups included:
British Polythene Industries Plc RKW SE Grupo Armando Alvarez S.A. Britton Group Papier-Mettler Trioplast Industrier AB and more...
For each group listed, you will nd: Corporate strategy and development analysed, including latest investments and acquisitions Up to date nancials Complete listings of extrusion plants in Europe Film extrusion activities outside Europe Product offering and specialisations
This report is of great relevance to all companies involved in the polyethylene lm extrusion business, providing useful benchmark information and giving unrivalled information on the size and structure of the industry.
APPLIED MARKET INFORMATION LTD.
www.ami-publishing.com
Applied Market Information publishes over 50 different reports and databases covering thermoplastics markets globally. The range of publications aim to provide complete listings of plants carrying out particular plastics processing operations and to give an analysis of the leading groups. AMI also produces authoritative industry reports which provide cost effective statistical data and analysis on polymer trends. For more information go to our website or contact Rgine Futter or Elizabeth Carroll on sales@amiplastics.com or Tel: +44 (0) 117 9249442.
Download the programmes for these forthcoming conferences

Simply click on the brochure cover or link to download a PDF of the full publication
Multilayer Packaging Films

Multilayer Packaging Films 2012
International conference on the technology and markets for specialty and barrier packaging films
Oilfield Engineering with Polymers

The MERL Oilfield Engineering with Polymers conference returns to London, UK, on 23-25 October 2012. The programme covers advanced elastomers, composites and thermoplastics for oil and gas applications.
*+20% UK VAT
AMIs eighth international conference on Multilayer Packaging Films is being held in Cologne, Germany, on 16-18 October. This brochure has the full line-up of expert speakers.
The international conference on advanced elastomer, composite and thermoplastic materials in oil and gas applications
23-25 October 2012 16-18 October 2012

Images courtesy of: EXTENDO GmbH and Macchi S.p.A.
* + 19% German VAT
Millennium Gloucester Hotel, London, United Kingdom

Images courtesy of: Harald Pettersen/Statoil
SPECIAL OFFER: Save 200* if you register before 7th September 2012
SPECIAL OFFER: Save 150*/135* if you register before 21st September 2012
o +44 (0) 117 311 1534
Click here to download
Organised by: Applied Market Information Ltd. and
Sponsored by:
Media supporters:
Fax back to +44 (0) 117 311 1534
Polyolefin Additives
AMIs fifth international conference on developments in polyolefin compounding takes place in Cologne, Germany, on 23-25 October. Check out the impressive programme in this brochure.
Flexible Packaging Middle East

Flexible Packaging Middle East 2012
Market opportunities for films driven by technical sophistication
heaDline spOnsOr
12-14 November 2012

Shangri-La Hotel, Dubai, United Arab Emirates
The Flexible Packaging Middle East conference takes place in Dubai on 12-14 November. It will cover new materials and machinery developments, as well as featuring presentations from leading packaging producers in the region.
Images courtesy of: reifenhuser Kiefel extrusion Gmbh, norner as, Borouge pte ltd., Dow europe Gmbh
speCial OFFer: Save 200 if you register before 28th September 2012
Organised by: Applied Market Information Ltd.
Also sponsored by:
Media supporter:
Fax back to +44 (0) 117 311 1534
Thin Wall Packaging

Thin Wall Packaging 2012
International conference on market trends and developments in plastics tubs, cups and tray packaging
Plastics Industry Strategy Seminars

AMIs one-day Plastics Industry Strategy Seminars are delivered by Andrew Reynolds and provide insights into key trends in the global polymers market. This brochure lists our 2012 events in Europe, America and the Middle East.
Images courtesy of: natureworks llC, nestl, printing Company Verstraete nV., rpC Containers ltd. and sem plastik
AMIs seventh Thin Wall Packaging conference has attracted a great line-up of speakers from companies such as Nestl, RPC, Linpac, General Mills and EDV Packaging. This brochure has the full programme.
3-5 December 2012

* + 19% German VAT
speCial OFFer: Save 210* if you register before 2nd November 2012
Organised by: Applied Market Information Ltd. Sponsored by: Media supporters:
o +44 (0) 117 311 1534
To see our full line-up of more than 25 plastics industry events over the next 12 months, please visit www.amiconferences.com
This months free brochure downloads

Simply click on the brochure cover or link to download a PDF of the full publication
C.A. Picard: extruder technology

EXTRUDER TECHNOLOGY
Maguire: blenders
This 16-page brochure from Maguire covers its wide selection of blenders. Its range includes more than 76 models capable of handling up to 12 ingredients and offering throughputs up to 5,000 lb/hr or 2,270 kg/hr.
This 12-page brochure from C.A. Picard International covers its high-quality replacement parts for extruders, mixers and kneading machines. These include screw elements, kneaders, screw shafts, barrels, cylinders and baffles.
Poly.ERP: case study

This 16-page case study from Kirchhoff Datensysteme examines the development of its Poly.ERP customised ERP system for compounders and how it was successfully implemented at Polymer Chemie.
PlasMec TRM Turbomixers

Techne Industrial Fluidised Baths
How to use an Industrial Fluidised Bath to quickly and cost effectively clean extrusion tooling without the risk of damage to the tools
This new eight-page brochure covers Technes range of industrial fluidised baths that are designed for the rapid and efficient cleaning of extrusion tooling without risking damage to the components.
Timcal: carbon addtives

This new 24-page technical brochure from Timcal covers the companys carbon additives for polymer compounds, including its Ensaco conductive carbon blacks and its Timrex graphite and coke.
Steer: EPZ screw elements

This 20-page brochure from Steer Engineering features its wide range of screw elements including many innovative designs developed by the company. It also covers replacement barrels and shafts.
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
compounder of the month
Perrite
Head office location: Date founded: General Manager: Ownership: No. of employees: Warrington, UK 1975 Perrite Europe David Johnson; Perrite Malaysia Mark Lewis The Vita Group 200
Sales 2011: 100 million Plant locations: Production 2011: Warrington, UK; Johor Bahru, Malaysia; LArbresle, France 40,000 tonnes
Profile: Perrite is an engineering polymer compounder owned by the Vita Group. The company was originally based in Europe with two separate companies: Perrite in the UK and Jackdaw Polymers in France. A 25,000 tonnes/year facility was added in Malaysia in 2003. In 2010, the European operations were combined into the Perrite Europe group. Product line: The Perrite group supplies the injection moulding and extrusion industries, serving customers in the electrical, automotive, sanitary goods, household appliances and oil markets. A broad range of materials and grades are produced including coloured, reinforced, heat stabilised and flame retardant compounds based on ABS, PC/ABS, ASA, PA/ABS, PC/ASA, PP, PC, PS, PA, POM and PBT. Perrite designs and produces bespoke grades to meet specific applications and also offers assistance in all stages of product development from design, polymer selection, testing and approval through to optimising tool design and processing.
Product strengths:
Forthcoming features
The next issues of Compounding World magazine will have special reports on the following subjects: August PVC plasticizers Reactive extrusion Carrier materials September Pigments and colorants Weathering resistance Fillers and coupling agents
Editorial submissions should be sent to Andy Beevers: abe@amiplastics.com For information on advertising in these issues, please contact Claire Bishop: claire@amimagazines.com Tel: +44 (0)20 8686 8139
Catch up on our recent issues for free

Simply click on the cover to see the full magazine, or download the issue in the relevant iPad/iPhone app
Compounding World June The June issue of Compounding World is packed with articles on cable industry trends, PVC stabilizer developments, medical compounding applications, bioplastics innovations, plus more top tips for twin-screw extruders. Click here to view Compounding World May Compounding Worlds May edition takes a close-up look at turnkey twin-screw compounding systems. It also looks at new additive technologies for controlling static discharge as well as the latest developments in pellet screening technology. Click here to view
Injection World June Injection Worlds June edition is packed with articles on thermoplastic composites for automotive applications, aluminium tooling, temperature controllers, masterbatch trends, plus the latest in John Goffs moulding masterclass series. Click here to view
Injection World May The May issue of Injection World is a medical special including a look at novel IML developments. Plus the magazine boasts features on optical moulding, TPEs, PP nucleation and temperature controllers. Click here to view
Pipe and Profile May/June The May/June edition of Pipe and Profile Extrusion looks at the latest developments in processing WPCs and recycled resins. It also reviews how software is being used to improve die performance and profiles a water pipe replacement project in Casablanca. Click here to view
Film and Sheet June/July The June/July edition of Film and Sheet Extrusion looks at developments in polymers for photovoltaics, reviews the market for heavy duty sacks, and examines Europes leading PE film producers. Click here to view
Take out your own free subscriptions to any of the magazines. Click on the logos below to simply register on-line.
dates for your diary
Global exhibition guide

10-12 August 6-9 September 10-14 September 17-19 September 21-25 September 24-27 September 25-26 September 26-27 September 1-5 October 5-8 October 16-20 October 24-27 October 14-15 November 29 Nov 2 Dec 2013 7-10 January 29 Jan - 1 Feb 6-7 March 12-15 March 12-15 March 3-6 April 10-11 April 14-16 May Sri Lanka Plast, Colombo, Sri Lanka Plastex, Cairo, Egypt Plastex, Brno, Czech Republic Kenya Plast, Kenyatta, Kenya TaipeiPlas, Taipei, Taiwan Plast Alger, Algiers, Algeria Mediplas, Birmingham, UK Kunststoffen, Veldhoven, Netherlands ColombiaPlast, Bogota, Colombia IndPlas, Kolkata, India Fakuma, Friedrichshafen, Germany VietnamPlas, Ho Chi Minh City, Vietnam Expoplast, Montreal, Canada Plast Eurasia, Istanbul, Turkey ArabPlast, Dubai, UAE Interplastica, Moscow, Russia Plastec South, Orlando, FL, USA Plastimagen, Mexico City, Mexico Pro-Plas Expo, Johannesburg, South Africa Tiprex, Bangkok, Thailand PlastTeknik, Malmo, Sweden Plast-Ex, Toronto, Canada www.kmgindia.com www.plastex-online.com www.bvv.cz/plastex www.kmgindia.com www.taipeiplas.com.tw www.plastalger.com www.mediplasuk.com www.kunststoffenbeurs.nl www.colombiaplast.com www.indplas.in www.fakuma-messe.de www.vietnamplas.com www.expoplast.org www.plasteurasia.com www.arabplast.info www.interplastica.de www.plastecsouth.com www.plastimagen.com.mx www.proplasafrica.co.za www.tiprex.com www.easyfairs.com www.plast-ex.org
AMI conferences
25-26 September 9-10 October 23-25 October 27-28 November 27-29 November 29-31 January 18-20 February 25-27 February 5-7 March 19-21 March Medical Grade Polymers, Boston, MA, USA Polymer Foam, Newark, NJ, USA Polyolefin Additives, Cologne, Germany Minerals in Compounding, Atlanta, GA, USA Fire Resistance in Plastics, Cologne, Germany Thermoplastic Concentrates, Coral Springs, FL, USA The Grass Yarn & Tufters Forum, Cologne, Germany Wood-Plastic Composites, Vienna, Austria Cables, Cologne, Germany Green Polymer Chemistry, Cologne Germany
For information on all these events and other conferences on film, sheet, pipe and packaging applications, see
www.amiplastics.com
Dont miss a single issue

Register now for your free subscription at:
And dont forget to tell your colleagues, customers and suppliers about the magazine. You can use the e-mail button above (the @ symbol in the browser) to help spread the word.

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July 2012

ANDROID VERSIONS NOW AVAILABLE

10 Flame retardants face new challenges

13 PEX: adding the missing link

21 Guidelines for colour measurement

29 TPEs provide a touch of class

39 Custom-made ERP for compounders

45 Whats new in nanotubes?

51 New products: polymers and additives

56 Compounder of the month: Perrite 58 Dates for your diary

coming next issue

The biggest little story in blending.

Leading bumper to bumper warranty in the industry.

The perfect blend of simplicity and control.

Schulman opens two new global innovation centres

Hallstar buys Dow plasticizers

German plastics machinery sales hold up

Fiat selects Borealis TPOs for new Panda

Manner announces expansion

BASF extends Astra additives agreement

Scientists make plastics light up

solar reection with color

PolyOne grows in Asia and Africa

Erema and Coperion work on recycling systems

event also marked the official opening of the companys new

E5 million Customer Centre at

compounding world | July 2012

news analysis | Fire retardants

Fire retardants face new attacks

compounding world | July 2012

quan tec 96 EV-10C

BUSS KNEADER TECHNOLOGY

Cutting-Edge Compounding Technology MX and quan tec BUSS Kneader Series

Buss AG Hohenrainstrasse 10 4133 Pratteln Switzerland

Phone +41 61 825 66 00 Fax +41 61 825 68 58 info@busscorp.com www.busscorp.com

Organic peroxides for wire and cable

Cross-linking polymers | processing feature

PEX: adding the missing link

processing feature | Cross-linking polymers

compounding world | July 2012

Conductive Carbon Black electrical conductivity easy-dispersion high purity

Graphite & Coke thermal conductivity electrical conductivity lubrication

Cross-linking polymers | processing feature

July 2012 | compounding world

processing feature | Cross-linking polymers

www.dowcorning.com www.momentive.com www.busscorp.com www.bpprocess.com www.akzonobel.com www.coperion.com www.icmasangiorgio.it www.kraussmaffeiberstorff.com www.crosslink.fi

Supervisory Control Integration

Silo Inventory Management

Brought to you by Plastics Information Direct Online Bookshop

Compatibility of Pharmaceutical Solutions and Contact Materials

Starch-based Polymeric Materials and Nanocomposites

Polymers for Electricity and Electronics: Materials, Properties and Applications

Twin Screw Extrusion - technology and principles

More info/Buy here

Colour monitoring | quality control

Guidelines for colour measurement

1) Which colour scale does the customer use?

4) How smooth is the surface you are measuring?

2) What level of spectral resolution does the customer require?

July 2012 | compounding world

quality control | Colour monitoring

5) What type of illumination is the customer using?

compounding world | July 2012

compounding world | July 2012

compounding world | July 2012

_____ _ _ _____

compounding world | July 2012

compounding world | July 2012