A Canon Communications LLC Publication Published Continuously Since 1925

January 2010
THE GLOBAL PLASTICS MAGAZINE plasticstoday.com/mpw

Next stop: Recovery

You take the wheel

Tips for keeping your

machines running
smoothly

Like your current material?

Maybe you’ll like it more
if it’s greener

Mergers and acquisitions

flourish in spite of the
economy: What should
your company do?

Predicting plastics
futures

MW1001_001
MW1001 001 1 12/22/09 8:38:57 AM
 Now, more than ever,
you could use a really good
teammate.

If there was ever a time to add a little extra brainpower to your team, that would be now.
Fortunately, all you have to do is ask. Univar’s technical specialists can share ways
to improve productivity and lower production costs – from new formulations to Àne-tuning
your just-in-time inventories to streamlining your production processes. They’ll also show you
how adding tank telemetry and online ordering can keep both cash and supplies Áowing.
And, since Univar handles an extensive list of specialty and commodity chemicals,
we can give you options you can’t get just anywhere. So team up with Univar and
put our thinking, products, and 85 years of experience on your team.

www.univarusa.com | 1.800.234.4588 | univar.marketing @ univarusa.com

Univar Copyright ©2009

MW1001_002
MW1001 002 2 12/22/09 8:39:05 AM
 VOL. 87 NO. 1

JANUARY 2010

plasticstoday.com/mpw CONTENTS
COLUMNS
10 As I See It
Lead, follow, or get out of the way: It’s your choice
Plastics-focused M&A consultant Blaige & Co. says loosening credit in 2010
will mark the return of financial deals, with plenty of strategic action as well.

14 Modern Executive
Is now the time for plastic futures?
Proven accuracy in price tracking is appealing to OEMs and brand owners
looking to reduce resin price volatility.

ON THE COVER
12 Modern Executive
2009 in the rearview,
2010 steers toward
growth
Recovery will be shaped by the
willingness of consumers
worldwide to spend.
9
PROCESSING TECHNOLOGY
16 Processing Trends
Extrusion: Bevy of film development unleashed at in-house fair
Thermoforming: Thermoformer’s photovoltaic roof eliminates the need to
pay peak power rates
Biomaterials: Wheat straw and reclaimed carpet; Ford seeks greener paths
to components . . . and more.
22 Material Thoughts
28 Product Watch
FEATURE
34 Make Every Pellet Count
‘Preventive’ is key to making a maintenance program
work for you
Yes, saving energy saves some money; but don’t leave the rest of it on the
table by neglecting your machines.

WORLD TOUR
38 Malaysia seeks advanced manufacturing role
42 Bioplastics: Coming to an RFQ near you
18
SPOTLIGHT
50 Y.A. Liew’s ethos emphasizes capabilities
Precision engineering firm Polyparts (Ipoh, Malaysia).

ALSO IN THIS ISSUE

4 Contact MPW 46 Countdown to K
4 Web exclusives 47 Classifieds
7 Letter from the editor 49 Calendar of Events
8 First Look: News & Analysis 49 Advertiser index

plasticstoday.com/mpw MODERN PLASTICS WORLDWIDE • JANUARY 2010 3

MW1001_003
MW1001 003 3 12/22/09 8:39:54 AM
 M P W web exclusive
Online now at
plasticstoday.com/mpw
Be all you need Sr. Group Publisher
Patrick Lundy; +1 973-808-0494
to be patrick.lundy@cancom.com
Rather than farm out
work, automotive interior EDITORIAL
3300 E. 1st Ave., Ste. 370
components supplier IAC Denver, CO 80206 USA
+1 303-321-2322
has developed a broad +1 303-321-3552 fax
range of competencies,
Press releases
including compounding, mpweditorial@cancom.com
blowmolding, and injection Editor-in-Chief
Matthew Defosse; +49 69-90552-132
molding, and used them to
matt.defosse@cancom.com
become the dominant player
Managing Editor
in its space. Clare Goldsberry Amie Chitwood; +1 303-399-0109
amie.chitwood@cancom.com
reports on what makes this
company tick. Senior Editor/U.S.
Clare Goldsberry; +1 602-996-6499
clare.goldsberry@cancom.com
PLA developments gather speed Senior Editor/U.S.
Researchers around the world are spurring their efforts to Tony Deligio; +1 303-833-9195
tony.deligio@cancom.com
develop lower-cost methods of creating polylactic acid, a
plastic derived from plant starch. Those efforts hit high gear Senior Editor/Asia
Stephen Moore; +65 9687-0420
recently, as reported here. stephen.moore@cancom.com
Contributing Editor Robert Colvin
Breakthrough made with first silicon-on-plastic Assistant Editor/Germany
integration Yvonne Klöpping; +49 69-90552-140
yvonne.klopping@cancom.com
The ability to sinter silicon onto plastic film substrates at tempera-
Online Project Manager
tures of less than 200°C is now within reach. The technology could Jamie Quanbeck; +1 608-442-4467
help thermoplastics find their way into applications such as solar jamie.quanbeck@cancom.com
cells and thin-film transistors for liquid crystal displays, which are Online Editor
John Clark; +1 310-740-9045
currently dominated by glass or silicone. john.clark@cancom.com
Processor’s development raises the bar for heat-set CIRCULATION/SUBSCRIBER SERVICE
PO Box 3568
bottles Northbrook, IL 60065 USA
Developments in blow- +1 847-559-7590; +1 847-291-4816 fax
mpw@omeda.com
molded bottles for heat-
set bottles have been
MARKETING, ART & PRODUCTION
a (you guessed it) hot Marketing Manager
Patrice Aylward; +1 440-239-4986
sector of late. Processor patrice.aylward@cancom.com
Liquid Container recently
Art Director
weighed in with what it Marco Aguilera
marco.aguilera@cancom.com
calls its ThermaSet line.
Improved clarity and less Senior Associate Art Director
Robin Bernstein
shrinkage are two of the robin.bernstein@cancom.com
benefits promised.
Publications Production Director
Jeff Tade
jeff.tade@cancom.com
Asst. Publications Production Manager
Custom line helps steel Tanya Von Grumbkow
pipe get plastics’ edge tanya.vongrumbkow@cancom.com
A customized extruder setup Ad Management Services
Vanessa Marmon
supplied by Battenfeld Extrusion vanessa.marmon@cancom.com
Technology enabled this pipe
processor to run what he believes U.S. SALES OFFICE
7261 Engle Rd., Ste. 402
may well be “the most powerful Middleburg Heights, OH 44130 USA
hose jacketing extrusion coating +1 440-239-4594
+1 440-239-4595 fax
line in the world.” Plastics meets
steel in this application. North American Sales Manager
Deborah Plank; +1 480-699-7196
deborah.plank@cancom.com
Digital Sales Manager/
Thanks to our plasticstoday.com sponsors: Account Executive
John Guadagno; +1 203-601-3741
john.guadagno@cancom.com
Account Executive
Beth Berner; +1 440-239-4594
beth.berner@cancom.com
Account Executive
Tony Marsh; +1 310-445-3725
tony.marsh@cancom.com
4 JANUARY 2010 • MODERN PLASTICS WORLDWIDE
MW1001_004
MW1001 004 4
Account Executive and Classified/
Recruitment Advertising Manager
Cheryl Ackerman; +1 516-496-8891
cheryl.ackerman@cancom.com
Directory/Buyer’s Guide Manager
Iris Topel; +1 718-478-8104
iris.topel@cancom.com
Reprints
Foster Printing Service
+1 800-879-9144; sales@fosterprinting.com
Director of Circulation
Sandra Martin
sandra.martin@cancom.com
List Rental
Statlistics
Jennifer Felling, postal lists
+1 203-778-8700 x138; j.felling@statlistics.com
Turk Hassan, e-lists
+1 203-778-8700 x144; t.hassan@statlistics.com
Audience Development Director
Leonard Roberto
leonard.roberto@cancom.com
INTERNATIONAL SALES OFFICE
Germany, Austria, Scandinavia, Benelux,
Eastern Europe, UK
Canon Communications Deutschland GmbH
Goethestrasse 2
60313 Frankfurt, Germany
+49 69-90552-108
+49 69-90552-104 fax
Associate Publisher International Sales
Petra Hütte
petra.huette@cancom.com
Italy, Spain & Portugal
Ferruccio Silvera; +39 02-284-6716
ferruccio@silvera.it
Japan
Katsuhiro Ishii; +81 3-5691-3335
amskatsu@dream.com
China, Taiwan & Hong Kong
Rudy Teng; +886 2-2799-3110
rudy.teng@hintoninfo.com
Korea
Young Media; +82 2-2273-4818, 4819
ymedia@chol.com
India
Ajit D. Nagpurkar; +91 22-25295725
ajitn@vsnl.com
CORPORATE OFFICE
Canon Communications LLC
11444 W. Olympic Blvd., Ste. 900
Los Angeles, CA 90064-1549 USA
+1 310-445-4200
+1 310-445-4299 fax
Chairman & CEO
Charles McCurdy
charles.mccurdy@cancom.com
Chief Financial Officer
Daniel Koskovich
daniel.koskovich@cancom.com
Sr. VP, Publications
Ron Wall
ron.wall@cancom.com
Sr. VP, Events Div.
Kevin O’Keefe
kevin.okeefe@cancom.com
VP, E-Media
Jason Brown
jason.brown@cancom.com
VP, Operations, Publishing Div.
Roger Burg
roger.burg@cancom.com
plasticstoday.com/mpw
12/22/09 8:40:54 AM
 Super Ion Air Knife™
Produces a laminar sheet of airÀow
that Àoods an area or surface with
static eliminating ions.

Super Ion Air Wipe™

The uniform 360° ionized
airstream neutralizes and cleans
continuously moving surfaces.

Prevent Shocks, Jamming, Tearing and Static Cling!

When the humidity is low, static electricity problems will happen.
• Materials tear, jam or curl • Hazardous sparks or shocks Ion Air Gun™
• Webs and films cling • Product clings to itself, Eliminates static and dust from
parts prior to assembly,
to themselves rollers, machine beds packaging, painting or ¿ nishing.
• Electronic sensors fail, • Dust attraction ruins
making false readings surface finishes

EXAIR manufactures a complete line

Ion Air Cannon™
of static eliminators to remedy common
Ideal for hard to reach spaces
static problems. Many use our engineered airÀow products to or con¿ ned areas that require
minimize air use and noise while delivering maximum results a concentrated ionized Àow.
by moving more static eliminating ions to the product surface.

Watch Our Brief Video!

How To Get Rid of Static & Dust!

Ion Air Jet™

Delivers a concentrated blast of
ionized air prior to shrink
wrapping, packaging and printing.

www.exair.com/55/47055.htm

Ionizing Bar
If you would like to discuss an application or request a catalog, contact: Eliminates static cling, dust
attraction and jamming on paper,
plastics and ¿ lm.

Manufacturing Intelligent Compressed Air Products Since 1983

11510 Goldcoast Drive • Cincinnati, Ohio • 45249-1621 • (800) 903-9247 • fax: (513) 671-3363 @exair www.exair.com/55/470.htm
E-mail: techelp@exair.com • www.exair.com

MW1001_005
MW1001 005 5 12/22/09 8:41:12 AM
MW1001_006
MW1001 006 6 12/22/09 8:41:17 AM
 EDITORIAL
Happy New Year,
and thank you
ow! Almost 400 people were there,
W and it was a genuinely internation-
al event. There was a note of excitement
among the attendees too, a “things are
going our way” vibe.
I was so thrilled to see a successful
plastics industry event that I did it again:
Wow! No, I wasn’t channeling a teen-
ager; I was eyeing the attendee list. There
were OEMs and brand owners aplenty,
representing the packaging industry, of
course, as much of the current bioplas-
tics’ buzz is in that space, but also car-
makers, electronic device manufacturers,
and other consumer goods areas. Not
too many processors on here, though, I
thought; bit of a shame as surely these
are the people many processors would
like to meet.
As the event progressed and people
talked, it became clear the entire bio-
plastics arena—be it degradable materi-
als, materials sourced from renewably
resourced materials (RRM, the new
acronym to learn), or some combination
of the two—will in the next three to five
years grow from its current minor niche
status to somewhere between “main-
stream niche” (a films processor there
coined the term) or “a big wave” (that
one from the Coke exec in attendance).
OEMs and brand owners were leaning
toward the big wave future because sus-
tainability—overt sustainability, such as
the switch to bioplastics, not just shav-
ing another 0.3g off package weight—is
what their customers are demanding,
they said. It’s something for processors
to ponder.
plasticstoday.com/mpw
MW1001_007
MW1001 007 7
Those of us who hit the conference
and trade show circuit know that
attendance has been off 25%-50% at
most events for at least the past 15
months. All the more powerful was
the impression made by the 4th an-
nual European Bioplastics conference
in November in Berlin, Germany.
One other point to ponder struck me
as a potentially serious threat to plastics.
The paper and cardboard industries are
waking to the fact they have an intrin-
sically sustainable material, one with
a well-established and easy-to-use (for
consumers) recycling network in most
of the world. Throw a biodegradable
plastic coating on paperboard cups and
you’ve raised the marketing bar pretty
high for processors of PS or PP ones.
• • •
It’s a New Year, bringing with it new
luck and new opportunities, and as our
cover photo indicates, we’ve opted for
optimism. Clare Goldsberry’s As I See
It interview with Thomas Blaige shares
that expert’s insight into M&A in the
coming months, explains why M&A has
barely slowed during the recession, and
offers his advice for processors unsure
how to react to this industry’s changing
landscape. Tony Deligio’s 2010 forecast
feature offers food for thought on where
the industry, especially resin pricing and
supply, are headed. Our Spotlight article
MODERN PLASTICS WORLDWIDE
took Stephen Moore to Malaysia, where
he met a molder with some very interest-
ing insights and plenty of optimism too.
There is, of course, plenty more for
you in these pages. Starting in this issue
and continuing until October, you’ll find
our Countdown to K series. If you like,
think of it as our dose of cod liver oil
for you. You may not want to swallow
our argument. You’ll cite the travel, the
cost, the time out of the office: Who can
afford that? Our take on the situation:
How can you afford not to be at the
seminal industry event, the one where
you know there will be truly new tech-
nology affecting your business? Trust us,
it’s good for you, and good fun to boot.
A respected friend recently mentioned
he spends considerable effort thanking
his customers for their support of his
business. What a great way to start 2010,
I thought. Thank you for reading our
magazine. Your comments and sugges-
tions, whether in meetings at trade shows
or events, visits to your facilities, or in
your calls and notes to us, are the highlight
of our job. They are always welcome at
mpweditorial@cancom.com. MPW
Matt Defosse,
Editor-in-Chief
• JANUARY 2010 7
12/22/09 8:41:55 AM
 FIRST LOOK
Daily news and features at plasticstoday.com/mpw

NPE trades Windy City for

In Brief
Reliance courts
LyondellBasell
India’s Reliance Industries made a cash bid
for global polyolefins leader, LyondellBasell.
If the deal reaches fruition, Reliance would
become the world’s largest PP supplier.
PMT expands
Plastics Molding Technology Inc. has
added 20,000 ft2 to its El Paso, TX
facility to accommodate new molding
machines and more than 40 recent hires.
A dozen molding machines have been
added recently.
A. Schulman to buy ICO
Compounding giant A. Schulman (Akron,
OH) intends to acquire compounder and
material supplier ICO Inc. in a $191.4 million
stock and cash transaction. For the buyer,
the move enables it to expand into the rota-
tional molding and masterbatch market.
Tech Mold adds
whiteroom
To better facilitate the testing and quali-
fication of molds for medical OEMs, Tech
Mold, a designer and manufacturer of
high-cavitation injection molds, is adding a
whiteroom environment to its test facility,
initially housing two all-electric presses,
both from Arburg.
Magic Kingdom
After calling Chicago home for 38
years and 14 events, the Society of
the Plastics Industry (SPI; Wash-
ington, DC) has decided to shift its
triennial international plastics show-
case, NPE, to the city of Orlando,
FL and the Orange County Con-
vention Center, citing among other
things a cost structure in Chicago
that impacted the ability of attendees
to visit and exhibitors to participate.
In addition to a venue change,
there has been a date shift as well.
In 2012, the show will take place
from Sunday, April 1 through Thurs-
day, April 5, with the educational The floor at NPE2009; the show moves to Orlando in
program beginning on Sunday, and 2012.
Monday marking the first day of a
four-day trade show. taste, and touch,” Buonomo explained,
Jim Buonomo of contract manufacturer saying the lack of running machinery
Nypro, and SPI’s chairman of the board, didn’t go unnoticed by attendees.
said SPI’s 2009 operations committee, Jim Murphy of Davis-Standard, who is
which consists of 12 SPI member compa- also the vice chair of NPE2012, said that,
nies and NPE exhibitors, began a review on the basis of dissatisfaction with Chi-
of NPE’s costs in the March/April time cago, the operations committee began a
frame, considering a new locale due to the thorough review of other potential host
escalating price of Chicago’s McCormick cities, but in the end it came down to
Place convention center. Buonomo said a direct competition between Orlando
their research found that mounting cost and Chicago. Ultimately Orlando was
pressures were limiting the amount of chosen as the site for the next two shows
equipment that exhibitors were willing to in a unanimous vote; SPI’s board and
run at the show. executives affirmed the operations com-
“Our industry is very much into feel, mittee vote.

What you had to say Polling news

How do you feel about the decision

“I tend to agree with you that the slow evolution of ‘wear’ to move the next two NPE shows from
Chicago to Orlando?
is not likely to create a situation where we have good melt
Good idea; it was time for a change
pumping on Tuesday, only to have it fall apart on Wednes- Bad call; Chicago was fine

day. Screw melt pumping conditions DO change over time 70%

60% 64%
with wear, and particularly when aggressive screw and
50%
screw tip cooling are employed to ‘throw material around’ in 40%
profile tools.” 30%
36%

20%

10%
Part of a discussion on worn screws’ effects on surging at our online
0%
Extrusion Forum. Join the conversation at plasticstoday.com/mpw.

8 JANUARY 2010 • MODERN PLASTICS WORLDWIDE plasticstoday.com/mpw

MW1001_008
MW1001 008 8 12/22/09 8:43:25 AM
 FIRST LOOK

View from the field Names in the news

New officers at SPI: The Plastics Indus-

Smoke, drums, and a
light show entertained
attendees as W&H
unveiled its three-layer
Optimex blown film
line. More than 1200
went to the event in
November. (We did,
too; see p. 16 for
our report.)
Pricing summary: Don’t get caught out
Brought to you by The Plastics Exchange and Poymerupdate.com
In December markets were what you would
expect—calm—but this month and next
could bring the storm. Generally processors
work hard to limit the amount of cash tied
up in inventory, especially at year’s end, but
those who emptied silos last month stand a
good chance of paying a painful premium for
material this month.
According to spot trading market The Plas-
tics Exchange (TPE; Chicago), some North
American suppliers were expected to pare back
their output last month, only exacerbating the
situation if a processor is in need now. Also,
favorable feedstock costs (North American
polyethylene feedstocks are largely derived from
natural gas) mean suppliers there had a natural
advantage in export markets, giving them little
reason to lower PE prices for domestic custom-
ers. Polypropylene (PP) prices in North America
returned to almost $0.70/lb levels due to contin-
ued tight supply of propylene.
In Asia, price increases for HDPE, LDPE,
plasticstoday.com/mpw
Here are some of the stories you might have missed
at plasticstoday.com/mpw:
Caption
and LLDPE were marginal, reported plastics
pricing service Polymerupdate (Mumbai, India).
December was a wash in terms of pricing, and
this month will set the tone for supply and
demand, and pricing, for the coming weeks.
For PP in Asia, the story was similar but
in fact prices dropped last month. PVC prices
across Asia, including China, were firm, reported
Polymerupdate, while the price of polystyrene
rose in China on the back of a sudden spurt in
upstream prices of benzene and SM feedstock.
Buying volume was sluggish, however.
In Europe last month, a rise in ethylene
feedstock prices, coupled with firmer prices
of naphtha and a sudden lift in buying interest,
pushed HDPE spot prices higher. Processors of
LDPE and LLDPE, who had delayed purchases
in hopes prices would drop as they worked off
inventory, were caught out as prices held steady
or rose. Contract prices of LDPE for December
were reportedly about €20/tonne higher than in
November, and LLDPE spot prices were up.
try Trade Assn., include chairman of the
board Chris Keller, president of the Con-
air Group. Among others elected were
vice chairman Jay Cude (president and
CEO, Coeur Inc.), treasurer Fred Dan-
iell (COO, Kureha America Inc.), and
secretary Bob Hamilton (group president,
Illinois Tool Works).
Steven Bales, president of Bales Mold
Service (Downers Grove, IL), died sud-
denly on Nov. 18, 2009 in Harlingen,
TX, where his company has a facility.
He and his brother Mike started Bales
Mold Service in 1978 to offer diamond
polishing and hard chrome plating for
injection molds. The company is well
known for engineered coatings and fin-
ishes, among other products and services.
Jacob (Jake) Axel was named president,
effective Nov. 1, 2009, of the supplier of
mold releases and process aid additives of
the same name. His father Frank remains
with the company as chairman and CEO.
[ On the record ]
“What happens when China
becomes more costly, which will
happen? Do you then move to India,
or Vietnam, or Africa, or South Ameri-
ca? You will always be on the move!”
Y.A. Liew of Polyparts, our Spotlight pro-
cessor in this issue (p. 50).
“Probably the biggest difference that
we’ve seen on our production floor is
the utilization of RJG cavity pressure
transducers.” Gary Flattum, executive
VP of Venture Plastics, on what technol-
ogy development has been the most
influential on the company’s business as
it enters its 40th year.

• Thermoforming: Prent plans new site in Denmark

• Stella Plastic acquires Rosti “Moving machines, molds, documen-
• Teijin breakthrough: First silicon-on-plastic integration tation isn’t hard. The most compli-
• Packaging processor seals exclusive deal for oxo-biodegradable cated part is moving the unwritten
additives knowledge.” Christer Landgren, strate-
• Blowmolding: Processor’s development raises the bar for heat-set gic account manager at Swedish injection
bottles
molder Nolato (Torekov, Sweden), on the
These and many more, daily, at plasticstoday.com/mpw. Start your day importance of knowledge transfer.
right; check back often.

plasticstoday.com/mpw MODERN PLASTICS WORLDWIDE • JANUARY 2010 9

MW1001_009
MW1001 009 9 12/22/09 8:43:32 AM
 AS I SEE IT
Lead, follow, or get out of the way:
It’s your choice
By Clare Goldsberry Chicago-based mergers and acquisitions (M&A) advisory and consultant

group Blaige & Co. posits that even a bad market is no reason to forego a good

strategic move.

n spite of the economic downturn,
I plastics M&A activity in 2009 was as
strong as the record number of transac-
tions completed in 2008. Chairman and
CEO Thomas Blaige shared his insight
into 2009’s activity and his outlook for
2010. Edwin Parkinson, president of
Blaige & Co., also participated in the
interview.
MPW: Given the downturn and the dif-
ficulty in securing financing, the high
number of M&A transactions in the
plastics industry seems surprising. What
drove strong M&A activity in 2009?
TB: The drivers in 2009 were somewhat
attendant to the economic climate, as
this can accelerate opportunities for con-
solidation. Many of the drivers that have
been apparent for a number of years,
however, continue in play—divest non-
core portions of the business, orderly
transition of a family business that does
not have interested family members to
take over the reins, opportunistic buys to
increase market share or enter into new
or complementary markets, geographic
diversification, and so on. Also, there are
two fundamental market drivers in that
the plastics industry is 1) newer and thus
much more fragmented than the gen-
eral industrial market, and 2) plastics are
benefitting from the migration of metal,
glass, and fiber to composite materials.
MPW: Looking at your latest report,
there are companies buying a company,
and then divesting some of that com-
pany’s businesses to another company.
Can you comment on what seems to be a
huge game of “musical companies”?
TB: Actually, it’s not musical companies.
It’s a matter of consolidators making
strategic moves to strengthen their posi-
tion as the economy improves. Those
that are strong are in a position to fur-
ther their reach, and improve business
results through synergies recognized in
the newly combined companies.
There’s a perception out there that
the economy is slow and therefore there
are no deals. With respect to the mega
deals that’s true, but with middle-market
and strategic deals, it’s not true. Behind
the scenes there’s an even more aggres-
sive effort for companies to expand their
strategic horizons, which is the case for
many of the leading companies. Their
number one goal is strategic—73% of
the activity we see is strategic, not finan-
cial. There’s been a significant move
toward selectivity by strategic buyers.
MPW: What about financial deal activity?
TB: Financial deals—which represent
27% of the M&A activity—largely drive
pricing, but with credit so tight, fewer
financial deals are happening. Financial
buyers are less selective and will do
many deals as long as they can service
debt. They don’t necessarily look at
delineating between proprietary business
vs. custom business. There are so many
companies in each niche of the market,
and there’s always someone looking for
that. Whether it’s a low-margin, high-
volume player or a high-margin, low-
volume company, there’s a range of busi-
ness models out there in each niche. And
whether that niche is in raw materials,
industrial molding, or rigid or flexible
packaging, there are participants that are
price oriented and those that are niche
oriented. Who are these players? Who
would value these types of companies
and how do we get the greatest price?
That’s what many of these financial buy-
ers are looking at. They’re looking to do
leveraged deals.
MPW: How are these consolidators
impacting the industry?
TB: These consolidators are very spe-
cific and making strategic moves, such
as combining other companies. The ther-
moforming sector, for example, con-
tinued its 2008 surge into the first half
of 2009, with 2008’s activity largely
driven by companies seeking to strategi-
cally broaden their market and capa-
bility portfolios or to vertically inte-
grate operations. Sabert Corp., a leading
high-end consumer packaging company,
acquired the packaging business of Gage

Thomas Blaige founded his company in 2003 after a career that included
serving as managing director at two generalist investment banks. The company
claims to have tracked more than 1500 sector mergers and acquisitions over the
past five years. His fervent plea is that processors come to his firm early on for
help with strategy and implementing tactics.

10 JANUARY 2010 • MODERN PLASTICS WORLDWIDE plasticstoday.com/mpw

MW1001_010
MW1001 010 10 12/22/09 8:44:35 AM

Industries, which consisted of dispos-
able CPET dual-ovenable and cold food
containers for use in the grocery, food
processor, institutional, and dietary meal
producer markets. This will enhance
Sabert’s product offerings to the market,
and position the company for future
growth. There are always the leaders and
followers, with 20% being the leaders,
another 20% the followers, and 60%
sitting in the middle with no strategy—
the “others.”
MPW: What are processors to do?
EP: They need to begin asking the strate-
gic questions: How will they proactively
pursue their strategy and grow? Will they
consolidate with a competitor? They
need to grow or they’ll realize attrition.
They don’t move sideways. The leaders
need to buy and followers need to sell.
The others, the 60% in the middle, don’t
do anything, and that’s amazing. Unless
they do something—think creatively and
proactively and develop a strategy as
plasticstoday.com/mpw
MW1001_011
MW1001 011 11
Executive Q&A with Thomas Blaige
to where they’ll go over the next year,
two years, five years—there will be a
slow erosion of their business or a com-
plete breakdown when a major customer
leaves. The danger is that they get com-
placent and things change and they get
caught without a strategy. We’ll help
them develop a strategy. We’ll spend a
lot of time with them and help them. All
companies have a core competency, and
our expertise is helping companies iden-
tify a strategy for their business and put
that whole process together.
MPW: What does 2010 look like?
TB: We’ll see credit loosening up a bit in
2010. Financial deals will come back and
strategic deals will continue next year. The
financial crisis has had a sobering effect on
family business owners. Previously, many
owners of companies thought they could
continue to pass the mantle to future gen-
erations without worry. Now, many don’t
think they can continue indefinitely as a
family business in a global environment.
MODERN PLASTICS WORLDWIDE
More and more company managers
and owners who are trying to make stra-
tegic moves through M&A are scared
straight. They need to talk to experts
and be serious about the future of their
business and what they’re going to do,
such as, “Let’s try to grow, but if we
can’t, we can sell to an attractive suitor
at the maximum price through an intel-
ligent strategy.” Finding the best buyer
at a high price is tough if they get forced
into doing a deal when the bank calls the
loan. Then they’ll call the first name on
the Rolodex, and often pull off a quick
(cheap) deal. It’s a little late in the game
when the bank cancels their credit line or
a major customer leaves, to say “Oh my
gosh, we need help!” MPW
plasticstoday.com/mpw
Read the full interview, including
Blaige’s guidance for small and mid-
sized processors in this climate of con-
solidation, at plasticstoday.com/mpw.
• JANUARY 2010 11
12/22/09 8:44:41 AM
 MODERN EXECUTIVE
2009 in the rearview, 2010 steers
toward growth
By Tony Deligio In the wake of the “Great Recession,” what are plastics’ prospects in 2010?

Given the historic collapse of 2009, it will be by default a year of growth and

one that faces lingering threats as well as opportunities.

ost economists now agree that

M the longest recession the U.S. has
endured since the 1930s bottomed out
in June of last year. Before descending to
that nadir, however, an ignominious list
of lowlights was compiled.
• For the first time since World War II,
global gross domestic product (GDP)
declined in 2009, falling by 2.3%.
• North American auto sales dropped to
levels last seen in 1982.
• Housing starts hit their lowest level
since data began being recorded in
January 1959.
• Some 8.2 million jobs were lost since the
recession officially began in December 2007.
The impact on plastics was marked,
according to Howard Rappaport, ther-
moplastics global practice leader at
industry consultant Chemical Market
Assoc. Inc. (CMAI; Houston, TX). CMAI
estimates that global commodity resin question, as we extricate ourselves from have been several plant startup delays,
consumption in 2009 totaled around the pit we fell into, remains, “Will the the majority of the investments are forg-
175 million tonnes, off approximately climb be steady and unfaltering, result- ing ahead and are expected to bring new
8% from 2008’s total consumption of ing in a V-shaped recovery, or will that resin capacity to the marketplace over
190 million tonnes. upward trend drop once again and result the next 12-18 months.
“From a macro perspective, the indus- in a W-shaped, double-dip recovery?” On the latter point, to this stage
try has experienced a contraction in For its part, CMAI sees a V more likely the recovery that began in June 2009
terms of overall demand for most major than a W in the economy’s future, with has been fueled by government stimulus
resins,” Rappaport says. “In the more some caveats. “If there was a major spike in developed countries and relatively
mature economies of North America and in oil or gas prices in 2010,” Rappaport uninterrupted growth in developing
Europe, this has been evident in negative says, “that may ripple through the resin economies like India and China. CMAI
growth between 2008 and 2009. In the cost structure and push prices up to and others say, however, that for a
emerging economies of Asia, the Middle uncomfortably high levels, as we saw meaningful and sustained rejuvenation
East, and Latin America, there has been back in the summer of 2008.” to occur, consumer spending will be key,
a marked slowdown in demand growth In determining the shape of the recov- particularly in developed markets. The
from the higher double-digit rates experi- ery, CMAI will consider several key U.S. traditionally makes up 25%-30%
enced before the economic slowdown.” metrics, including the pace and progress of the global economy, with two-thirds
of major capacity expansions planned of its economy linked to consumers’
V or W for the Middle East and the willingness pocketbooks.
Most economists believe the economy, at of consumers in developed economies to “One of the most important indica-
least in the United States, reached its bot- reopen their pocketbooks. On the first tors as we emerge from the recession will
tom in June 2009. Going forward, the point, Rappaport says that while there be consumer spending,” Rappaport says.

12 JANUARY 2010 • MODERN PLASTICS WORLDWIDE plasticstoday.com/mpw

MW1001_012
MW1001 012 12 12/22/09 8:45:29 AM

“Once the consumer gets back in the game
and is more confident in spending his
disposable income, this will create more
consumption in the major economies of
Europe and North America. These two
regions will ultimately play a role in the
longer-term recovery beyond 2010.”
According to the American Chemistry
Council’s (ACC; Arlington, VA) 2009
Year End Situation & Outlook, U.S. con-
sumer spending uncharacteristically con-
tracted for two years in a row, shrinking
by 0.2% in 2008 and 0.6% in 2009.
Consumers will begin increased spending
again in a limited fashion in 2010, lifting
outlays by 1.7%, predicts the ACC, with
2.5% spending growth in 2011. After
lifting spending by 1.6% in 2010, busi-
ness spending is forecast to accelerate to
5.8% growth in 2011.
Lingering fallout
The difficulties of 2008 and 2009 for the
plastics industry have resulted in a stress
test of sorts for resin producers, forcing
them to address their weaknesses or fall
by the wayside. Rappaport describes
the result as a “major shakeout,” where
companies have not only changed own-
ership, but in many cases completely
reoriented their business model. The new
landscape: The Middle East emerges as a
major exporter for several key commod-
ity resins; smaller, older, less efficient
operations in Europe and North America
close; and perhaps even sites in Japan,
Korea, and Taiwan could be shuttered,
Machinery outlook
According to Europe’s association
for plastics and rubber machinery
manufacturers (Euromap), not unex-
pectedly, 2009 marked a sharp drop
in demand after a record 2008. In an
October 2009 press release, Euromap
noted that although its members
began feeling a decline in machinery
demand in the final quarter of 2008,
a 1.2% boost in production and 1.5%
increase in exports lifted the year
to record totals. In 2009, however,
Euromap believed that overall pro-
duction would fall by 22% to a total
value of €13.6 billion. Core machin-
plasticstoday.com/mpw
MW1001_013
MW1001 013 13
as the Chinese add domestic capacity to
satiate their local needs. “Consolidation
will continue,” Rappaport says, “and
eventually there will be more assets in
the hands of fewer companies.”
On the whole, the ACC reports that
after investing $237 billion in new plants
and equipment in 2008, the chemical
business pared capital spending in 2009
by 3.9% to $228 billion. Going forward,
the ACC anticipates a 10.1% increase
in 2010 ($251 billion), with $284 bil-
lion invested in 2011. Fully 93% of
the incremental investment will come in
emerging markets from 2009-2014, with
“noteworthy gains” expected in China,
Africa, and the Middle East.
Those overseas capacity gains and
contractions in U.S. production and
exports have the ACC forecasting that
the United States will run a $1 billion
trade deficit in chemicals in 2011. In
2009, the country had a $2.4 billion
chemicals trade surplus, with a $3.9 bil-
lion surplus forecast for 2010.
GDP to expand in the U.S., globally
CMAI estimates global GDP growth will
average between 3.5% and 4% over the
next three to five years, with Europe
and North America registering between
2% and 2.5%. Countries like China
and India will begin to pick up momen-
tum and eventually reach annual GDP
growth rates of at least 10%-12%.
As the ACC assessed the detritus of
2009, it also attempted to look forward,
ery, which has a 62.7% share of
Euromap’s business, was expected to
contract by 30%.
Looking forward, Bernhard Merki,
Euromap president and CEO of Swiss
injection molding machinery supplier
Netstal, said his group’s assumption
is that the order decline has bottomed
out, although financing remains an
obstacle due to tight credit. “The
industry expects an upward trend in
time for K 2010 at the latest,” Merki
said, referencing the triennial show
that takes place this year from Oct.
27-Nov. 3 in Düsseldorf, Germany.
MODERN PLASTICS WORLDWIDE
Forecast for 2010
admitting that “forecasting at this junc-
ture involves considerable uncertainty.”
The association report states that the
general consensus is the recession is
definitely over and 2010 and 2011 will
be marked by recovery. After shrinking
in 2009, the ACC believes global GDP
will grow by 2.8% in 2010 and 3.2%
in 2011. U.S. GDP is forecast to expand
at a rate of 2.6% in 2010 and 2011
after contracting by 2.3% in 2009. After
jumping from 5.8% to 9.3% in 2009,
U.S. unemployment is expected to lag the
broader recovery and expand to 9.8%
next year and still be at 9.3% in 2011.
The ACC cautions that continuing
issues in the consumer sector and the need
to work through imbalances throughout
the economy mean that 2010’s recovery
will be less robust than previous cycles,
with the outlook for chemistry “some-
what muted.”
Resin supply/prices
The massive investment in capacity in
the Middle East and Asia could have far-
reaching effects in 2010, with world-scale
plants coming online at a time when any
recovery demand for materials will be
nascent at best. Because of this, CMAI
is anticipating that operating rates and
prices for resin producers could be ane-
mic this year. “[CMAI] anticipates resin
prices will soften in 2010,” Rappaport
says, “which in reality may be good news
for some resin buyers and bad news for
sellers. The only question mark will be
energy and its impact on the cost side of
the equation.” The ACC forecasts that
after chemical industry operating rates
slipped to an average of 70.1% in 2009,
they could climb to 78.5% by 2012. It’s
an improvement, but still at a level that
would suggest reduced margins.
The crucible of 2009, however, has
also changed how resin producers oper-
ate. “There was a tremendous amount
of discipline being exercised by many
of the resin producers as they strug-
gled with a weakened economy and
softer demand,” Rappaport said. “This
new discipline provided companies the
opportunity to trim out excess cost,
lower inventory levels, and recalibrate
their business models.” MPW
• JANUARY 2010 13
12/22/09 8:45:35 AM
 MODERN EXECUTIVE
Is now the time for plastic futures?
By Tony Deligio
mong the hallmarks of a success-
A ful futures contract—a high level of
liquidity, the ability to hedge against vola-
tility, and a well-regulated exchange that
instills confidence—one particularly vital
aspect is that its prices track physical pric-
es in the actual marketplace. In this last
instance, the London Metal Exchange’s
(LME) plastics futures contract, which
launched in May 2005, may now have
truly arrived. Correspondence between
LME prices and physical prices is quite
high at this time, reaching 95%-98% in
some cases, according to Robert Sheldon,
LME’s plastics business manager.
In addition to higher correlation, par-
ticularly with its North American prices,
another significant impetus has pushed
greater adoption of futures. “Volatility
is really the reason why people would
want to hedge,” Sheldon says, “and the
high levels of volatility that we’ve seen
since the middle of last year have really
highlighted the need for companies to
try to manage what is, effectively, an
unknown future (excuse the pun). I think
it’s really made clear the fact that there is
a new phase of price movement and price
volatility that the industry hasn’t had to
deal with before.”
Sebastian Castelli, director commod-
ity derivatives at LME ring-trading mem-
ber Société Générale, has seen a similar
spike in interest in futures from his
customers. “The decision [by Société
Générale] to support these markets was
made based on real demand coming
from the industry itself,” Castelli says.
“After a bumpy start, where some radi-
cal changes were made to the contracts,
demand for risk-management solutions
based on the LME sharply increased dur-
ing the last 12 months.”
Sheldon verifies that heightened activ-
ity, which rose relative to the incredible
volatility seen in resin prices, became very
evident in 2008 when key commodities
14 JANUARY 2010 • MODERN PLASTICS WORLDWIDE
MW1001_014
MW1001 014 14
Resin buying
Has plastics pricing started the shift from an at-times opaque index system to a
forward-looking transparent mechanism, with futures at its core?
The Chicago Mercantile Exchange has its pit; the London Metal Exchange has the
“ring.” Starting on Feb. 15, the LME will move price discovery to its LME Select elec-
tronic platform instead of open outcry in the ring. This makes it easier for more LME
members to be directly involved in price discovery and enables clients to access the
market through the members’ own trading platforms.
tested record highs and lows in the same or end users. “The consumers are push-
calendar year. “We were already seeing ing back down the chain through their
greater interest from the first quarter suppliers to the producers,” Sheldon
onwards of [2008],” Sheldon says, “but says, “saying they want LME-based pric-
since August/September of 2008, we’ve ing to bring about stability.”
been seeing greater interest in trying Société Générale’s Castelli says that
to manage risk, and people seeing the progression is typical for a futures contract,
LME as one of the avenues to do that.” with end users showing the most interest
Sheldon also says that in a time when because they have the biggest exposure.
money is tight, the ability for a processor Often buying raw materials at floating
to hedge a cost as large as materials great- prices, they then sell finished goods at fixed
ly promotes cash-flow management. prices over a long period of time.
“In the bullish and volatile environ-
OEMs and brand owners ment we have lived in over the last two
want a hedge years, [end users] suffered the most as
Sheldon says that at this point, the entire their margins were squeezed,” Castelli
plastics value chain—from producers to explains. “Producers and converters who
distributors to processors to end users— are buying and selling at floating prices
is involved in the market, if at varying suffer relatively less, but the rise in price
levels of participation. “We’re prob- volatility levels over the last few years
ably a little lighter on the supply side,” has made most participants in the plas-
Sheldon says, “but there are certainly tics value chain start seriously consider-
producers actively promoting these tools ing risk-management tools.” MPW
to their customers.”
Where the LME is seeing greater inter-
est, which could ultimately push broader
adoption of the contracts and their pric- Go online to read the complete article,
including the lessons LME learned with
ing, is at the opposite end of the chain,
its aluminum contracts and how they
from participants like retailers, OEMs, shape its work with plastics.
and brand owners—so-called consumers
plasticstoday.com/mpw
12/22/09 8:46:20 AM
 EXTRUSION PRIIN
PR NTTIIN
NGG CON
ONV
VEERT
RTIN
RTIN
NG

IN OUR SEARCH FOR CLARITY

WE’VE ALTERED OUR HEADS.

It takes a lot of brainpower to develop innovative solutions. So we have improved the design of our
die heads. The result is MAXICONE – a die featuring an extremely compact design with notably
reduced melt volumes. It excels with very high transparency. In addition, MAXICONE results in
even shorter changeover times and minimized scrap rates. For more information, please visit us at
www.wuh-group.com.

PASSION FOR INNOVATION

Windmöller & Hölscher KG | Phone: +49 5481 14-0 | Fax: +49 5481 14-2649 | info@wuh-group.com | www.wuh-group.com

MW1001_015
MW1001 015 15 12/22/09 8:46:29 AM
 PROCESSING
TECHNOLOGY PROCESSING TRENDS
EXTRUSION

Bevy of film developments

unleashed at in-house fair
By Robert Colvin

First in line to show what visitors to this year’s K 2010 show can expect is
A Filmex cast film line was demon-
strated at W&H’s autumn open house
film processing equipment maker Windmöller & Hölscher (W&H, Lengerich, with a 17-layer nano feedblock pro-
ducing stretch film suitable for hand-
or machine-wrap rolls.
Germany).

he company premiered a number of expensive yet also lower-quality competi- cooled lines. This permits line height to be
T film production technology develop- tive units. Herschbach admits there is, of reduced, a factor expected to appeal to pro-
ments at its open house in late autumn. course, the danger that processors who cessors with low plant ceilings. The unit’s
Christof Herschbach, division manager might ordinarily opt for a three-layer haul-off is stainless steel to protect against
engineering–extru- Varex line will water corrosion.
sion equipment, told instead choose Equipped with a Varex module pack-
MPW at the event the cheaper Opti- age of extruders, Maxicone die head, and
that top on the list mex, but he sees Filmatic T winder, the line can handle
of debuts is the a market for three- to nine-layer processing. During the
company’s Optimex both product open house W&H was churning out three-
three-layer blown lines. Unlike the layer polypropylene (PP) infusion bag film
film line. company’s Basic (20-μm soft PP/13-μm stiffer PP/50-μm soft
Despite extrusion blown film line PP), designed to substitute for similar appli-
trends towards five-, The W&H MDO stretching unit for bar- introduced back cations in PVC. All PP materials were from
seven-, and nine-lay- rier film improves machine direction in 1995, which Danish compounder Melitek (Nr. Alslev).
er lines, processors toughness and transparency of barrier represented a The Aquarex’s output is suitable for sub-
films.
still have a need for stripped-down sequent upgrading on an MDO (machine
lines that produce machine for a direction orientation) stretching unit.
standard, commodity web for such things lower price, the Optimex, says Hersch- W&H unveiled an MDO unit similar to
as auto packaging applications, carrier bach, is based on a standardized line of one it first mentioned at K 2007. The new
bags, laminating films, as well as shrink high-quality components said to guaran- MDO line is said to improve web tensile
and stretch wrap, says Herschbach. The tee cost-effective manufacturing. strength and rigidity while providing better
new unit is designed to “keep it simple” Also new from the company is an shrink performance. Bumping up gloss and
and is intended for the processor who inverted, water-cooled blown film extru- clarity are additional advantages. It features
may not need or even want all the bells sion line, Aquarex, designed to nibble away 12 temperature-controlled rollers, 12 lay-
and whistles on the company’s modular, at the cast film market. It likely won’t com- on rollers, and two stretching nips. Stretch
but more costly, Varex three-layer line. pete with cast lines on output, but W&H ratio is to a maximum of 1:12.
The Optimex is more off-the-shelf than says it promises an Herschbach
Varex and offers just two three-layer amorphous end says film stretching
die options in 160- to 315-mm (6- to product with simi- offers the potential
12-inch) or 250- to 400-mm (10- to lar or better gloss, for processors to
16-inch) configurations. Extruder com- haze levels, and use less expensive
binations are either 60/70/60.30 L/D or mechanical proper- resins to get a high-
60/90/60.30 L/D to produce film widths ties (such as dart- quality end product
of 1300, 1600, or 1800 mm (51, 63, or drop, puncture, and while reducing the
71 inches) or hood production of 2200 tear strength). Tem- use of expensive
or 2600 mm (87 or 102 inches). pered, demineral- barrier materials
A total of five blown film lines produc-
W&H sees the “Made in Germany” ized water quenches ing a wide line of films, including barri- such as nylon or
label on this unit as a big seller to pro- the bubble faster er and biopolymer web, were featured ethylene vinyl alco-
cessors who might typically opt for less than traditional air- during the open house. hol (EVOH). Lab

16 JANUARY 2010 • MODERN PLASTICS WORLDWIDE plasticstoday.com/mpw

MW1001_016
MW1001 016 16 12/22/09 8:47:48 AM
 r
"EWFSUJTFNFOU
r

CORPORATE PROFILE
WEIMA America Inc.

W
&*."
"NFSJDB
UIF
/PSUI
"NFSJ- To learn more about WEIMA America and our products visit our “newly designed”
DBO
EJTUSJCVUJPO
DFOUFS
GPS
8&*."
website at www.weimaamerica.com. See material photos, video demonstrations, prod-
.BTDIJFOFOCBV
(NC)
IBT
CFFO
uct brochures and more!
TFSWJOH
UIF
6OJUFE
4UBUFT
BOE
$BOBEB
GPS

PWFS

ZFBST

5IF
'PSU
.JMM
4$
MPDBUJPO

QSPWJEFT
CPUI
TBMFT
BOE
TFSWJDF
TVQQPSU
PO

BMM
TISFEEJOH

CSJRVFUUJOH
FRVJQNFOU
UP
UIF

QMBTUJD
XPPE
QBQFS
BOE
SFDZDMJOH
NBSLFUT


5IF
GBDJMJUZ
IPTUT
B
XBSFIPVTF
GPS
TUPDL
NB-
DIJOFT
BOE
QBSUT
B
USJBM
TIPXSPPN
TFSWJDF

BOE
SFQBJS
DFOUFS
BT
XFMM
BT
TBMFT
BOE
BENJO-
JTUSBUJWF
PGGJDFT

8&*."
"NFSJDBT
NBJO
HPBM

JT
UP
QSPWJEF
PVS
DVTUPNFST
XJUI
NBDIJOFT

EFTJHOFE
UP
àU
UIFJS
TQFDJàD
BQQMJDBUJPO
BOE

WPMVNF
SFRVJSFNFOUT

WEIMA’s German-built shredders can

handle most materials including pipe,
purge, spruce/runners, film, fibers, bottles,
crates/bins and more. Our single-shaft
shredders are ideal for shredding scrap
prior to a granulator or repelletizing line.
Shredders allow for bulk feeding without
the need to pre-cut materials. When con-
sistent piece sizes are fed into a granulator
it regulates material flow while eliminat-
ing spikes in power which helps to lower
energy costs.

WEIMA shredders offer many features

that are specific to customer’s applica- WEIMA’s shredding, grinding and briquetting
tions. The V-Rotor is designed for the
equipment can help your company reduce
shredding of hard plastics while the E-
both its landfill footprint and bottom line.
Rotor is for woven and non-woven film
For a decade WEIMA America has been a market
and fiber materials. Special optional
features include a lift-up door for easy leader in size reduction technology. When it comes
maintenance, multiple knife configura- to shredding plastics, we’re known for building
tions, custom hoppers, remote monitoring tough, reliable equipment that handles whatever you
device and more. throw in it. Contact WEIMA today to learn more
about our extensive line of size reduction equipment.

For more information

8&*."
"NFSJDB
*OD

$FOUSF
$JSDMF
'PSU
.JMM
4$

64"
5FM

5FM
 Call today 888-440-7170
'BY
 www.weimaamerica.com // info@weimaamerica.com
JOGP!XFJNBBNFSJDBDPN

plasticstoday.com/mpw MODERN PLASTICS WORLDWIDE • JANUARY 2010 17

MW1001_017
MW1001 017 17 12/29/09 3:48:24 PM
 PROCESSING
TECHNOLOGY
tests at W&H show that by offline stretch-
ing a 40-μm barrier film, a processor can
expect a 30% barrier improvement com-
pared to the same film if it is not stretched.
Other innovations shown during the
open house included an improved Opti-
cool air ring system said to provide high
cooling capacity thanks to its double-deck
air ring. In winding, W&H was showing
its Filmatic N winder used in conjunction
with a three-layer Varex blown film line.
It can handle films up to 3600 mm (102
inches). A vacuum cutter drum (VSK)
enables roll start with no foldback as well
as automatic shaft handling. On the cast
film side, the company was producing a
17-layer stretch film on its Filmex cast
line using eight extruders and a Cloeren
(Orange, TX) 2700-mm die with encapsu-
lation and a nano-layer feedblock. Nano
layers permit combining stiff and soft resins
to get improved puncture resistance, better
stretch, and downgauging.
INJECTION MOLDING
Thin-walled IML
proven for trans-
parent PS cups
The next time you are in flight, pay
close attention to the polystyrene
cups used by many airlines. They
could soon contain inmold labels.
That, anyway, is now a possibility, as
proved by a trio of companies at Fakuma
last fall. Injection molding machine man-
ufacturer Engel (Schwertberg, Austria),
Inmold labeling of PS cups, done with
transparent PS labels.
moldmaker Glaroform (Näfels, Switzer-
land), and Beck Automation (Oberengstrin-
gen, Switzerland) teamed for a molding cell
18 JANUARY 2010 • MODERN PLASTICS WORLDWIDE
MW1001_018
MW1001 018 18
PROCESSING TRENDS
THERMOFORMING
Thermoformer’s photovoltaic roof
eliminates the need to pay peak
power rates
By Tony Deligio
Thermoforming company Plastic Package has completed the installation
of a specialized cylindrical solar panels array on its roof that will supply the
company with 323,649 kWh of power annually, enough to power 60 homes or
eliminate the need to purchase power during peak periods.
Already using recycled content, biobased
materials, and overall less plastic through
package redesign, thermoformer Plastic
Package Inc. (Sacramento, CA) hopes to
further build its “green” standing with the
startup of a new 208-kW thin-film solar
system that will power the production of
100% postconsumer recycled containers.
Rita Edwards, marketing manager
with Premier Power, the company that
installed the system, told MPW that
Plastic Package took advantage of a
tax-free cash grant to help fund the
project. This was in lieu of an invest-
ment tax credit from the federal govern-
ment that is paid by the U.S. Treasury
within 60 days of a system going live.
In addition, the processor also receives
a performance-based incentive from its
local utility provider.
Edwards said the system will be used
to offset the most expensive power Plas-
tic Package buys by eliminating the need
to pay peak electric rates. Such rates
equate to about one-third of the proces-
sor’s total electricity usage. The solar
cells are designed to produce 323,649
kWh per year, which is roughly enough
to power 60 homes. Edwards says
return on investment for the technology
is calculated to occur between four and
six years.
Saying that plastics converting is
not normally thought of as a “green
business,” Jim Kaye, Plastic Package’s
chairman, explained in a release that his
company’s sustainability push is helping
it make major strides toward a more
environmentally friendly characteriza-
tion by using recycled bottles and bio-
based materials in its products. “Now
that we’ve added solar, we want to let
These solar panels are able to
capture sunlight over a 360° pho-
tovoltaic surface, helping California
thermoformer Plastic Package elimi-
nate the purchase of electricity at
peak rates.
the community and our clients know,
so they can feel comfortable that when
they use our packaging, they are part of
the sustainable process,” he explained.
Using technology developed by a
company called Solyndra (San Fran-
cisco, CA) and installed by Premier
Power Renewable Energy (El Dorado
Hills, CA), Plastic Package says the
208-kW system installed on its roof will
initially handle all of its peak demand
and reduce its summer peak loads dur-
ing the hottest part of the day.
The company also installed a white
membrane roof, helping boost the effi-
ciency of Solyndra’s cylindrical solar
panels. Those panels are able to cap-
ture sunlight over a 360° photovoltaic
surface, with the technology targeting
large, low-slope rooftops, common on
commercial buildings.
Started in 1970, Plastic Package vac-
uum- and pressure-forms packaging for
industries ranging from food to medical,
specializing in thin-gauge applications,
with sheet thickness from 4-60 mils and
draws to 6 inches deep.
plasticstoday.com/mpw
12/22/09 8:47:53 AM
 PROCESSING
TECHNOLOGY

processing PS cups that were inmold-labeled with PS labels.

The benefits include offering a one-material package that’s
easily recycled, and also labels that can be as transparent as
the cup (or other PS package). Difficult, though, is handling of
the PS labels, which generally are thicker and more rigid than
standard polyethylene or polypropylene inmold labels. For the
molding cell at Fakuma, Italy’s Viappiani supplied the labels.
The cell included an Engel speed 180/55 running Glaro-
form’s four-cavity mold at 3.3-second cycles. Shot weight was
41g, with each cup weighing 10.25g and having walls 0.5 mm
thick. Using a side handling system, Beck Automation placed
GEARBOXES FOR
the labels and simultaneously removed the completed cups. MD
SINGLE-SCREW EXTRUDERS

IMD parts with textile

surfaces, no glue
A German processor claims a novelty with its process for
thermoforming the semi-finished textile-covered parts,
which are then back injection molded to become arm-
rests, headliners, or other similar parts that could see use GEARBOXES FOR
in automotive applications. The fabric is laminated to its COROTATING AND
backing film in the thermoforming tool and with no need COUNTER-ROTATING
TWIN SCREW EXTRUDERS
for adhesives.

Officials at Reiss Kunststofftechnik GmbH (Tettnang, Ger-

many) say the process is particularly suitable for processing of
high-end parts with surfaces of textiles, foam, or fleece. Parts
can be formed with textile
covering their entire sur-
face or with only partial
covering. A part’s geome-
try and complexity is said
not to hinder the process.
Direct lamination of the
textile to a backing film is
done in the tool as the film
Reiss performs inmold decorating is thermoformed. After this, GEARBOXES FOR
with fabric on automotive parts. the semi-finished parts are ELECTRIC INJECTION
punched and trimmed, and MOULDING MACHINES
then ready for use in inmold decoration (IMD). Reiss automates the
handling, forming, and binding of the textile to the plastic sheet dur-
ing thermoforming; it says this brings both economic and quality
(haptic) advantages vs. other direct-lamination procedures.
Reiss has been processing the laminated thermoformed parts
for some years, but only struck gold with use of these in IMD late
last year, when the process was first used commercially for an auto- Sede Centrale / Head Of fice & Factor y
motive part. Further development has resulted in a metal surface
via Manzoni, 46 - 20020 MAGNAGO (MI) - I TA LY
finish on insert molded parts. New is that customers requiring a
Te l . +39 0331 307616 - Fax: +39 0331 309577
small to medium-sized order of parts can ask for enhancement of
e-mail: info@zambello.it - http://www.zambello.it
the insert film via an individual silk screening of the extruded film.
The printed films are then suitable for thermoforming and can be U.S.A Office: 55 Haul Road Wayne,New Jersey 0740
back injection molded. With use of a transparent film, the printed Phone: +-1-973-696-4330 or Toll Free: 1866-696-4330
Fax: +1-973-694-0551
design can be protected and, because it is on the back of the film, E-mail : extruder1@usa.net or sales@atstc.com
offers depth to the appearance of a part. MD

plasticstoday.com/mpw MODERN PLASTICS WORLDWIDE • JANUARY 2010 19

MW1001_019
MW1001 019 19 12/22/09 8:48:04 AM
 PROCESSING
TECHNOLOGY
BIOMATERIALS
Wheat straw and reclaimed carpet; Ford seeks greener
paths to components
Ford is taking a two-pronged approach to greener car components: applying bio-based materials, including wheat
straw, and upping the amount of recycled content in its vehicles, turning postconsumer carpet into nylon cylinder
head covers.
In two announcements in November,
automotive OEM Ford Motor Co. showed
progress in its efforts to build a “sustain-
able materials portfolio”—offering details
first on nylon cylinder head covers recov-
ered from postconsumer carpet, and sec-
ond on storage bins that use wheat straw
to fortify polypropylene (PP).
Automotive supplier Dana Holding
Corp. (Maumee, OH) is molding the
reclaimed nylon into cylinder-head cov-
ers for Ford’s 3.0-liter Duratec engine,
which is used in the 2010 Fusion and
Escape. Called EcoLon, the nylon was
created in conjunction with compound-
er Wellman Engineering Resins (John-
sonville, SC), which helped Dana test,
develop, and supply the material. Well-
man grinds used nylon carpeting into
fiber and takes it back to its resin stage
through a proprietary process.
In addition to resource reuse, the com-
ponents boost Ford’s green cred through
weight and thereby fuel savings. The
nylon cylinder-head covers are nearly
20% lighter than aluminum diecast ver-
sions. The components are part of a
module-based sealing system Dana sup-
plies for the Ford Fusion and Escape pro-
grams that also includes the engine cover,
gaskets, fasteners, baffle/air-oil separator,
and isolators. Dana developed, tested, and
The third-row storage bins of the 2010
Ford Flex utilize a 20% wheat-straw-
filled polypropylene, with the biomass
increasing flexural modulus with a lim-
ited addition to part mass.
20 JANUARY 2010 • MODERN PLASTICS WORLDWIDE
MW1001_020
MW1001 020 20
PROCESSING TRENDS
is manufacturing the
cylinder head covers
at its Composite Seal-
ing Center in Paris, TN.
Ford applies postcon-
sumer recycled resins from
sources as disparate as deter-
gent bottles, tires, and battery
casings in a variety of compo-
nents, including aerodynamic, splash and
radiator air-deflector shields. Through
these efforts, it estimates that between 25
million and 30 million lb of plastic are
diverted from landfills.
According to Wellman, a number
of automotive components currently in
production utilize its EcoLon material,
including fans, shrouds, interior/exterior
door handles, radiator support and fascia
brackets, and more. The cam covers are
new this year, and radiator end tanks,
carbon canisters/brackets, air-intake man-
ifolds, and even oil pans utilizing EcoLon
are currently under development.
The wheat-straw-reinforced third-
row storage bins of the 2010 Ford
Flex were developed by the automaker,
academic researchers, and compounder
A. Schulman (Akron, OH). The compos-
ite material contains 20% wheat straw
bio-filler, which reportedly allows the
application to conserve 20,000 lb/year
of petroleum by displacing plastic, while
reducing annual carbon dioxide emis-
sions by 30,000 lb.
Ellen Lee, technical expert in Ford’s
plastics research group, told MPW that
the natural fiber, which is supplied by
Canadian firm Omtec (Mississauga,
ON), is mixed with PP. The wheat straw
composite was originally proposed to
Ford by the University of Waterloo in
Ontario as part of the Ontario BioCar
Initiative, a multi-university effort among
the universities of Waterloo, Guelph,
Toronto, and Windsor. Lee said Omtec’s
Auto supplier Dana
Holding worked with
compounder Wellman
Engineering Resins to
develop a line of
reclaimed nylon
that’s seeing use
in underhood
applications,
including these
cylinder-head covers for
Ford’s 3.0-liter Duratec engine.
proprietary process cleans, chops, and
dries the wheat straw so that it can
be compounded. The parts themselves
are molded by International Automotive
Components (IAC; Dearborn, MI).
A. Schulman’s lab was used to create
a composition that not only was odor-
less, but also met industry standards for
thermal expansion and degradation, rigid-
ity, moisture absorption, and fogging.
Ford says that less than 18 months after
the initial proposal was made to Ford’s
Biomaterials Group, the wheat-straw-
reinforced plastic was approved for the
Flex, which is produced at Ford’s Oakville
(ON) assembly complex. As for feedstock
supply, the carmaker says wheat straw,
which is the byproduct of growing and
processing wheat, is typically discarded,
with Ontario, for example, having 30 mil-
lion tonnes available at any given time.
Lee says the company sees a great deal
of potential for other applications utiliz-
ing the filler due to wheat straw’s impact
on mechanical properties, particularly
its ability to offer a lightweight means
to greater stiffness. Use of the composite
in center console bins and trays, interior
air registers and door trim panel compo-
nents, and armrest liners is already under
consideration by Ford.
The automaker’s sustainable materials
portfolio also includes soy-based polyure-
thane seat cushions, seatbacks, and head-
liners; postindustrial recycled yarns for
seat fabrics; and postconsumer recycled
resins for underbody systems. TD
plasticstoday.com/mpw
12/22/09 8:48:09 AM
 r
"EWFSUJTFNFOU
r

C O R P O R A TPROCESSING
E P R O F ITRENDS
LE
PROCESSING
TECHNOLOGY

Macro Engineering
& Technology Inc.

M
BDSP
&OHJOFFSJOH

5FDIOPMPHZ
JOOPWBUJWF
TPMVUJPOT
UP
DPNQMFY
QSPDFTTJOH

*OD
IBT
CFFO
QSPWJEJOH
JOOPWB- SFRVJSFNFOUT

5IF
SPPU
PG
UIF
DPNQBOZT

UJWF
NBDIJOFSZ
UP
UIF
QMBTUJD
àMN
QIJMPTPQIZ
MJFT
JO
JUT
DPNNJUNFOU
UP
SFTFBSDI

BOE
TIFFU
JOEVTUSZ
GPS
PWFS

ZFBST

5IF
BOE
EFWFMPQNFOU
XIJDI
LFFQT
.BDSP
BU
UIF

DPNQBOZ
IBT
FBSOFE
B
HMPCBM
SFQVUBUJPO
BT
B
GPSFGSPOU
PG
QMBTUJD
FYUSVTJPO
UFDIOPMPHZ

5IF

IJHI
UFDIOPMPHZ
FRVJQNFOU
TVQQMJFS
UISPVHI
DPNQBOZ
IBT
PWFS

NBDIJOFSZ
BOE
QSP-
JOEVTUSZ
MFBEJOH
FRVJQNFOU
MJLF
BJS
SJOHT
DP- DFTT
QBUFOUT
BOE
QMBZT
BO
JNQPSUBOU
SPMF
JO

FYUSVTJPO
EJFT
BOE
DVTUPN
CVJMU
XJOEFST
BOE
QJPOFFSJOH
OFX
UFDIOPMPHJFT
BMTP
UISPVHI
UIF
DPNQBOZT
BCJMJUZ
UP
QSPEVDF

For more information

.BDSP
&OHJOFFSJOH

5FDIOPMPHZ
*OD

5SBEFST
#PVMFWBSE
&BTU
.JTTJTTBVHB
0OUBSJP
$BOBEB
-;
&
5FM

'BY

XXXNBDSPFOHDPN
TBMFT!NBDSPFOHDPN

plasticstoday.com/mpw MODERN PLASTICS WORLDWIDE • JANUARY 2010 21

MW1001_021
MW1001 021 21 12/22/09 9:23:21 AM
 PROCESSING TECHNOLOGY

MATERIAL THOUGHTS New developments

RESINS & COMPOUNDS

PolyOne reformulates healthcare

solutions
The Trilliant HC line of engineered compounds showcased at the
Compamed show in Düsseldorf, Germany (Nov. 18-19) reflects
the company’s efforts to focus on healthcare customers’ perfor-
mance needs in challenging medical applications.
The Trilliant HC portfolio specifically addresses performance
characteristics within the context of healthcare application and
regulatory requirements (USP Class VI, ISO 10993, FDA),
and is produced in accordance with the U.S. Food & Drug
Administration’s current Good Manufacturing Practices (cGMP)
for medical devices.
According to Stephen Schlegel, healthcare marketing manager,
PolyOne Specialty Engineered Materials, in response to ques-
tions from MPW, “The technology platforms in the Trilliant HC
portfolio were developed previously for a broad range of applica-
tions under several different brand names—Edgetek, Stat-Tech,
Lubri-One, and Gravi-Tech, for example. But rather than newly
marketing them for medical applications under the Trilliant HC
brand, we have reformulated the compounds and the process
steps so that we can provide a solution to healthcare customers’
critical requirements. The additional development includes using
USP Class VI raw materials, FDA-compliant colorants and addi-
tives, processing according to cGMP standards, and formulation
lockdown. These steps mean that Trilliant HC materials are for-
mulated differently and carry a ‘brand promise’ that correspond-
ing non-HC grades do not.”
PolyOne says that among the critical performance areas target-
ed by the line are X-ray shielding and radiopacity (high-specific-
gravity compounds for lead replacement in X-ray shielding and
weight balancing for surgical equipment, along with production of
radiopaque materials); structural performance (high-strength and
-stiffness compounds for metal substitution); electrical conductiv-
ity (conductive and dissipative materials); thermal conductivity
(insulating as well as conductive forms); high lubricity (reduction
of force needed to move gears, pumps, switches, and buttons, and
extension of device life); and flame retardance (available in various
polymer systems, and in halogenated or nonhalogenated forms).
Schlegel says that lots can be as small as 50 lb (22 kg).
PolyOne, Avon Lake, OH, USA; www.polyone.com

Sticky stuff: Double the
adhesion for TPE to HDPE
Thermoplastic elastomer (TPE) compounds
with double the adhesive strength of stan-
dard TPEs when overmolded onto HDPE
are new from this custom compounder.
The super-sticky grades will be avail-
able in the company’s Medalist range of
medical-grade elastomers, a reflection of
the North American medical device mar-
ket’s broad adoption of multishot injection
molding as a way to eliminate assembly.
In a 180° peel adhesion test that com-
pared HDPE samples overmolded with an
HDPE-bonding Medalist TPE and samples
with one of the company’s own standard
hydrogenated styrenic block copolymer
(HSBC) TPEs, the median adhesion, or peel
strength, of the Medalist TPE was twice as
great as that of the HSBC—42.086 lb per
linear inch compared to 21.412. In addi-
tion, the variation in peel strength among
different test samples was less than half as
great with Medalist as with HSBC.
According to the company, the new
grades will not only provide stronger
bonds to HDPE but also exhibit less
variation in bond strength. The new com-
pounds officially debut at the MD&M
West show next month in California.
Teknor Apex, Pawtucket, RI, USA;
www.medalistmd.com
Plastics make moves in
automotive, airline seating
Recent discussions make clear that engi-
neering thermoplastics potentially could
shake up the airline and automotive seating
industries, as developments speed ahead in
Opel’s Insignia seating makes use of BASF
materials.
a bid to replace more metal in these high-
volume applications.
The most vivid example was displayed
by plastics supplier BASF at the Fakuma
trade show last October. The company
highlighted the use of a number of its
materials in the new Opel Insignia OPC
passenger car, including components in
the vehicle’s front seats. Opel worked with
Tier One supplier Recaro on the seating.
The seats are made of two of BASF’s
Ultramid polyamide (PA) materials and its
Neopolen expanded polypropylene (EPP)
foam. BASF assisted with its Ultrasim
simulation software in the design of the
seat pan, backrest shell, and crossbar. The
plastic parts are replacing steel frames.
The seat pan is molded of Ultramid
B3ZG8, a stiff PA6 that ensures high ener-
gy consumption values. Ultramid B3G10 SI
was specified for the freestanding backrest
shell as well as in the crossbar. The insert
for the backrest shell is made of Neopolen
P 9225 K (EPP), energy-absorbing foam
that also covers edges and serves as a mod-
ule carrier for motors and seat components
such as the spinal column support.
Prototypes of the seats were shown
back in October 2007 at the K trade
show, with the same trio (Opel, Recaro,
and BASF) involved.
One company working closely,

22 JANUARY 2010 • MODERN PLASTICS WORLDWIDE plasticstoday.com/mpw

MW1001_022
MW1001 022 22 12/22/09 9:01:49 AM
 PROCESSING TECHNOLOGY r
"EWFSUJTFNFOU
r

MATERIAL
CORP THOUGHTS
ORATE PRO FILE
New developments

E
9"*3
$PSQPSBUJPO
NBOVGBDUVSFT
*OUFM-
MJHFOU
$PNQSFTTFE
"JS¡
QSPEVDUT
UIBU

QSPWJEF
JOOPWBUJWF
XBZT
UP
CMPXPGG

ESZ
DPPM
WBDVVN
DPOWFZ
MJGU
BOE
FMJNJOBUF

TUBUJD
FMFDUSJDJUZ
4JODF

&9"*3
QSPE-
VDUT
IBWF
CFFO
FOHJOFFSFE
UP
JNQSPWF
UIF

PWFSBMM
FGGJDJFODZ
PG
B
XJEF
SBOHF
PG
JOEVTUSJBM

QSPDFTTFT
5IFJS
TUBGG
PG
RVBMJàFE
BQQMJDBUJPO

FOHJOFFST
JT
GBNJMJBS
XJUI
B
XJEF
WBSJFUZ
PG

NBOVGBDUVSJOH
QSPDFTTFT
BOE
PGGFS
IFMQ
UP

JOEJWJEVBMT
USZJOH
UP
àOE
UIF
CFTU
TPMVUJPO
UP

UIFJS
QSPCMFN

Line Vac Air Powered Conveyors

&9"*3T
DPNQSFTTFE
BJS
QPXFSFE
-JOF

7BD
PGGFST
B
MPX
DPTU
XBZ
UP
DPOWFSU
PSEJOBSZ

IPTF
UVCF
PS
QJQF
UP
DSFBUF
B
QPXFSGVM
JOMJOF

DPOWFZPS
GPS
CVML
NBUFSJBMT
5IF
DPNQBDU

EFTJHO
GFBUVSFT
MBSHF
UISPBU
EJBNFUFST
GPS

NBYJNVN
UISPVHIQVU
DBQBCJMJUZ
-JOF
7BD
SFHVMBUPS
"O
PQUJPOBM
CSBDLFU
QFSNJUT
FBTZ
GPS
UIF
&9"*3
QSPEVDUT
UP
CMPX
BXBZ
BOZ

DPOWFZPST
BSF
JEFBM
GPS NPVOUJOH
/P
NPWJOH
QBSUT
PS
FMFDUSJDJUZ
BT- DPOUBNJOBOUT
BOE
UIF
TUBUJD
FMFDUSJDJUZ
5IFZ

TVSFT
NBJOUFOBODF
GSFF
PQFSBUJPO
&MFWFO
BSF
JEFBM
GPS
r
)PQQFS
MPBEJOH TJ[FT
JO
BMVNJOVN
BOE
UFO
JO
TUBJOMFTT
TUFFM

r
$IJQ
SFNPWBM BSF
TVJUFE
UP
B
XJEF
WBSJFUZ
PG
USBOTGFS
BQ- r

)BSE
UP
SFBDI
QMBDFT
PS
PCTUSVDUFE

r
'JCFS
UFOTJPOJOH QMJDBUJPOT
)FBWZ
%VUZ
-JOF
7BD
NPEFMT
BSF
TVSGBDFT
r
8BTUFUSJN
SFNPWBM BMTP
BWBJMBCMF
GPS
NPWJOH
NPSF
NBUFSJBM
PWFS
r
1SPEVDU
NPWJOH
BU
IJHI
TQFFET
r
.BUFSJBM
DPOWFZJOH MFTT
UJNF
XIJMF
SFTJTUJOH
XFBS r
4VSGBDFT
XJUI
BO
FYUSFNFMZ
IJHI
DIBSHF
r
1BSU
USBOTGFS
r
'JMMJOH
PQFSBUJPOT Static Eliminators $PNQSFTTFE
BJS
DPOTVNQUJPO
BOE
OPJTF

&9"*3T
4UBUJD
&MJNJOBUPST
DPNCJOFT
FO- GPS
UIFTF
TUBUJD
FMJNJOBUPST
BSF
NJOJNJ[FE

-JOF
7BD
DPOWFZPST
NPWF
MBSHF
WPMVNFT
HJOFFSFE
BJSáPX
QSPEVDUT
BOE
JPOJ[FST
UP
QSP- XIJMF
QSPWJEJOH
GPSDF
UIBU
DBO
CF
BEKVTUFE

PG
NBUFSJBM
PWFS
MPOH
EJTUBODFT
5IF
NBUFSJBM
WJEF
TVQFSJPS
TUBUJD
FMJNJOBUJPO
BOE
DMFBOJOH
GSPN
B
iCMBTUu
UP
B
iCSFF[Fu
5FTUT
TIPX
UIFTF

áPX
SBUF
JT
FBTJMZ
DPOUSPMMFE
XJUI
B
QSFTTVSF
QPXFS
5IF
MBNJOBS
BJSáPX
NBLFT
JU
QPTTJCMF
JPOJ[FST
QPTJUJPOFE
UXP
GFFU
NN

BXBZ

GSPN
B
DIBSHFE
TVSGBDF
UP
CF
BT
FGGFDUJWF
BT

BO
*POJ[JOH
#BS
XJUIPVU
BJS
EFMJWFSZ
QPTJUJPOFE

POFIBMG
JODI
NN

GSPN
UIF
TVSGBDF

&9"*3
QSPEVDUT
BSF
NBEF
JO
$JODJO-
OBUJ
0)
BOE
DBO
CF
GBDUPSZ
NPEJàFE
UP
TVJU

TQFDJàD
BQQMJDBUJPO
SFRVJSFNFOUT
"MM
PG
UIF

DBUBMPH
QSPEVDUT
TIJQQFE
UP
64
BOE
$BOB-
EJBO
DVTUPNFST
IBWF
B

%BZ
6ODPOEJUJPOBM

(VBSBOUFF
BOE
TIJQ
GBDUPSZ
EJSFDU
GSPN
TUPDL

For more information

&9"*3
$PSQPSBUJPO

(PMEDPBTU
%S
$JODJOOBUJ
0)


5FM

'BY

XXXFYBJSDPN
UFDIFMQ!FYBJSDPN
UXJUUFS!FYBJS

plasticstoday.com/mpw MODERN PLASTICS WORLDWIDE • JANUARY 2010 23

MW1001_023
MW1001 023 23 12/22/09 11:08:13 AM
 PROCESSING TECHNOLOGY
MATERIAL THOUGHTS
though not exclusively, with BASF, spe-
cifically of late on development of fiber-
reinforced polyethersulfone (PES) com-
pounds, is PlastiComp (Winona, MN).
One of PlastiComp’s customers recently
developed airline seating using one of
these PES-based compounds in which
those parts passed the 16G crash test
(other seating components not made of
the fiber-reinforced PES did not pass).
Airline seating still is largely metal. If
some of the airline developments even-
tually move into automotive seating,
“it could be a game changer,” reckons
Stan Verbraak, business development
manager for PlastiComp Europe GmbH
(Steenbergen, the Netherlands).
Verbraak says many of the company’s
most recent developments have been with
carbon-fiber-reinforced compounds. The
price of these fibers has dropped as sup-
ply has increased, making them a more
viable economic option. Also, although
glass is still offered in more tow sizes,
carbon-fiber suppliers are expanding
their product range.
Carbon fiber is more difficult to work
with than glass or aramid, he notes, as
the rovings are more difficult to open
and impregnate. Poor carbon-fiber wet-
out leaves loose fibers that can float in
a facility and even short-circuit electrical
systems. “So you need to get it [the com-
pounding] right,” he notes.
Beyond seating, opportunities could
appear in military applications, sports
and leisure products, and more; replace-
ment of metal EMI (electronic magnetic
impulse) shielding also is possible.
At the IAA automotive trade show in
September, Tier One supplier Johnson
Controls (Boeblingen, Germany) revealed
its new seating concept, the Synergy-
Seat, which it hopes to bring to market
in 2012. The seats, slimmer than stan-
dard seating so that rear passengers have
about 5 cm more legroom, make heavy
use of recycled plastics, especially PP.
The amount of PUR foam in the seats
has been reduced and is based on bio-
polyols. An MPW editor who sat in it
said it seemed fine, but would need a
long roadtrip to pass final judgment on
its comfort. The seats weigh up to 30%
less than comparable current ones.
24 JANUARY 2010 • MODERN PLASTICS WORLDWIDE
MW1001_024
MW1001 024 24
BASF, Ludwigshafen, Germany,
www.basf.com; PlastiComp, Winona, MN,
USA, www.plasticomp.com
Long-term PC prospects
remain positive
While the global recession might have
dented polycarbonate (PC) demand sub-
stantially, the impact was apparently
less severe than on other materials, and
long-term growth rates double that of
GDP growth are expected, according to
Günter Hilken, global head of the Bayer
MaterialScience polycarbonates business.
Speaking to MPW via a video call
from Guangzhou, China, where he was
officiating at the inauguration of the
company’s latest Color Competence and
Design Center, Hilken recalled that in
early 2009 the company mothballed
300,000 tonnes/year out of its global
capacity of 1.3 million tonnes/year of PC
capacity in North America and Europe.
Since then, 100,000 tonnes/year have
come back onstream. “We will bring the
remainder back online in coming years as
demand recovers,” he said.
Hilken adds that although demand
from one of the key applications, opti-
cal media, had peaked, “We expect only
a moderate decline going forward, but
solid growth in auto, IT, and electronics
is anticipated. We definitely see continued
growth at double the GDP growth rate.”
Commenting on the influence of pub-
licly announced capacity additions from
the likes of Sabic Innovative Plastics and
the joint venture of Mitsubishi Chemical
and Sinopec, Hilken said, “The global
market is in the range of more than 3
million tonnes and growing. If you do the
math, additional capacity can be absorbed
within one to two years, but it does depend
on individual actions of suppliers.”
While acknowledging that PC precur-
sor bisphenol A (BPA) continues to have
a prominent, negative profile in the main-
stream press, Hilken said, “Very clearly,
BPA is one of the most evaluated materi-
als in the chemical industry. . . . Based on
the principles of sound science, if you use
products made from BPA, in the appro-
priate way, they are safe to use.”
Bayer MaterialScience, Leverkusen,
Germany, www.bayerbms.com
New developments
Rhodia introduces
new materials for fuel
containment jobs
With strict regulation of gasoline vapor
emissions already in place, and even
stricter rules for some applications set
to take effect in 2011, polyamide sup-
plier Rhodia bets new grades, part of its
Technyl PA6 range, could be the answer
to some processors’ concerns. Not only
will the materials, as mono-layer fuel
cans or small gas tanks for offroad vehi-
cles and the like, satisfy stricter emissions
limits, but they also can be readily pro-
cessed on standard extrusion blowmold-
ing machinery, with optimum results
returned if a PA-specific screw is used.
Alan Dubin, business development
manager in the supplier’s Cranbury, NJ
Processors of small fuel tanks such as this one
can benefit from the new materials.
offices, says the as-yet unnamed materials
also can be run on multilayer blowmold-
ing machinery, and on existing molds.
Rhodia has offered similar materials
outside North America for some time. The
two new materials now being introduced
to the North American market have been
improved upon, especially in terms of
their cold impact strength, which he said
has been tested down to at least -20°C
“and can probably go lower.” Scrap from
blowmolding can be ground and reintro-
duced into the process with no loss of
barrier performance, he added. Experience
in production applications and in indus-
trial trials has shown no cycle time loss vs.
high-density polyethylene.
Most jerry cans and small fuel tanks
for motorcycles, lawn mowers, snowmo-
biles, and other vehicles are made on mul-
tilayer extrusion blowmolding machinery
with between three and six layers used.
Barrier layers of ethylene vinyl alcohol
may be embedded between polyethylene
plasticstoday.com/mpw
12/22/09 9:01:59 AM
 r
"EWFSUJTFNFOU
r

CORPORATE PROFILE
Univar
Stronger than Ever

Y
PV
QSPCBCMZ
SFDPHOJ[F
6OJWBS
BT
B

HMPCBM
MFBEFS
JO
DIFNJDBM
EJTUSJCVUJPO


XJUI
Special Services and Capabilities
:PV
LOPX
VT
BT
UIF
DPNQBOZ
XJUI
UIF

VONBUDIFE
OBUJPOXJEF
MPHJTUJDBM
SFTPVSDFT

QSPBDI
UP
PVS
DVTUPNFS
SFMBUJPOTIJQT
4QF-
UIF
DPNQSFIFOTJWF
QSPEVDU
MJOF
BOE
UIF
BD-
DFTT
UP
B
TUFBEZ
TVQQMZ
PG
NBUFSJBMT‡BO

JOEVTUSJBM
DIFNJDBM
DIBNQJPO

#VU
ZPV
NBZ
OPU
LOPX
UIBU
6OJWBS
USBDFT

JUT
CFHJOOJOHT
CBDL
PWFS

ZFBST
UP
B
TNBMM

:PV
DBO
DPOTJEFS
6OJWBS
ZPVS
EFEJDBUFE
r
*OUFSOBUJPOBM
TPVSDJOH
OFJHICPSIPPE
àSN
*O


(FPSHF
7BO
8B- UFBN
PG
QFSTPOBM
DPOTVMUBOUT

XJUI
BDDFTT
r
-PU
USBDLJOH
BOE
TFHSFHBUJPO
UFST
BOE
/BUF
3PHFST
PQFOFE
VQ
TIPQ
JO
4F-
BUUMF

8BTIJOHUPO
UP
QSPWJEF
MPDBM
DVTUPNFST
4USVHHMJOH
XJUI
B
OFX
GPSNVMBUJPO
3FRVJSF

XJUI
QSPEVDUT
MJLF
TPEB
BTI
BOE
DBVTUJD
TPEB

8FSF
TUJMM
DPOOFDUFE
UP
UIPTF
TNBMMUPXO

Access to expert assistance
8FSF
BMTP
OJNCMF
BOE
SFTQPOTJWF
MPDBM
DPOOFDUJPOT
BOE
B
DPOTVMUBUJWF
BQ-
r
$PSQPSBUF
BDDPVOUT
QSPHSBN
DJBMJ[FE
UFDIOJDBM
TVQQPSU
JT
BMXBZT
KVTU
B

QIPOF
DBMM
PS
NPVTF
DMJDL
BXBZ
0VS
VOQBSBM-
MFMFE
TFSWJDF
JT
EFTJHOFE
XJUI
ZPVS
TVDDFTT

JO
NJOE
UP
JOEVTUSZ
FYQFSUT
XIP
BSF
QPJTFE
UP
IFMQ

r
5IJSEQBSUZ
MPHJTUJDT
DVTUPN
QBDLBHJOH
PS
MBCFMJOH
-PPLJOH
GPS

BTTJTUBODF
XJUI
JOWFOUPSZ
NBOBHFNFOU‡QFS-
IBQT
+*5
EFMJWFSZ
)PX
BCPVU
FOWJSPONFOUBM

r
$IBOHF
NBOBHFNFOU
r
$VTUPN
CMFOEJOH
r
&MFDUSPOJD
EBUB
JOUFSDIBOHF
r
&OWJSPONFOUBM
BOE
SFHVMBUPSZ
FYQFSUJTF
r
'FFGPSTFSWJDF
XBSFIPVTJOH
r
'PSNVMBUJPO
BTTJTUBODF
r
5BOL
UFMFNFUSZ
r
7FOEPS
DPOTPMJEBUJPO
r
7FOEPSNBOBHFE
JOWFOUPSZ
r
8BTUF
NBOBHFNFOU
$IFN$BSF¡

SPPUT
GPDVTFE
PO
UIF
QFSTPOBM
UPVDI
8IFO
PS
SFHVMBUPSZ
FYQFSUJTF
$PTU
SFEVDUJPO
+VTU

ZPV
DIPPTF
6OJWBS
GPS
ZPVS
SBX
NBUFSJBM
BTL
OFFET
ZPV
CFOFàU
GSPN
6OJWBST
TUSFOHUI
For more information
BOE
TVCTUBOUJBM
SFTPVSDFT
#VU
ZPV
BMTP
HBJO

B
USVTUFE
QBSUOFS‡XIFO
ZPVS
CVTJOFTT
TVD- 
DFFET
XF
TVDDFFE
UPP
8F
PGGFS
PVS
DVT- XXXVOJWBSDPSQDPN
UPNFST
BO
JOEJWJEVBMMZUBJMPSFE
FYQFSJFODF
VOJWBSNBSLFUJOH!VOJWBSDPSQDPN
ESBXJOH
PO
PVS
TUSPOH
SFHJPOBM
QSFTFODF
BOE

NZSJBE
PG
DVTUPNJ[FE
TFSWJDFT
GSPN
3%

BOE
GPSNVMBUJPO
BTTJTUBODF
UP
2$
BOE
NBS-
LFUJOH
TVQQPSU

What you need, when you need it

8FSF
B
QPXFSIPVTF
PG
B
DPNQBOZ‡PVS

SFQVUBUJPO
BOE
PVS
MPOHTUBOEJOH
SFMBUJPO-
TIJQT
XJUI
NBOVGBDUVSFST
XPSMEXJEF
BMMPX

VT
UP
PGGFS
PVS
DVTUPNFST
B
WBTU
TFMFDUJPO
PG

DPNNPEJUZ
BOE
TQFDJBMUZ
QSPEVDUT
POFTUPQ

TIPQQJOH
BOE
B
DPOTJTUFOU
SFMJBCMF
TVQQMZ

FWFO
JO
UJHIU
UJNFT

"OE
XJUI
UIF
NPTU
FYUFOTJWF
TUSBUFHJD

EJTUSJCVUJPO
JOGSBTUSVDUVSF
JO
UIF
JOEVTUSZ‡XF

IBWF
PWFS

MPDBUJPOT
JO
/PSUI
"NFSJDB

BOE
&VSPQF‡XFSF
QPTJUJPOFE
UP
GVMàMM
ZPVS

DPNQBOZT
DIFNJDBM
SFRVJSFNFOUT
PO
ZPVS

TDIFEVMF
XIFUIFS
JUT
USVDLMPBET
PG
DPN-
NPEJUZ
DIFNJDBMT
PS
B
TNBMM
RVBOUJUZ
PG
B

TQFDJBMUZ
JOHSFEJFOU

plasticstoday.com/mpw MODERN PLASTICS WORLDWIDE • JANUARY 2010 25

MW1001_025
MW1001 025 25 12/22/09 3:33:44 PM
 PROCESSING TECHNOLOGY
MATERIAL THOUGHTS
layers, for instance, or fluorination can be
used to provide a vapor barrier.
According to Rhodia, the two grades
offer gasoline permeation performance on
fuels like E10 that exceeds that of existing
blowmolding materials like HDPE and
PBT, and equals or exceeds multilayer
material solutions. Rhodia is now in the
final stages of product optimization and
prototype testing on a number of new
applications. Dubin says the supplier is
still in the process of characterizing the
new grades’ processing windows, but that
results so far point to significantly wider
processing windows than standard PA6.
Testing by an external North American
lab and on customer parts has proven
the ability of these materials to meet or
even exceed permeation regulations from
CARB (California Air Resources Board)
and the U.S. EPA, meaning processors
can satisfy permeation performance
requirements without investing the $3
million-$6 million a multilayer blow-
molding machine might cost. Processors
also need not send parts out for fluorina-
tion, another means of improving a part’s
permeation performance. The materials
may also be injection molded and can be
hot plate and vibration welded.
Rhodia, Cranbury, NJ, USA, www.rhodia.us
ADDITIVES & FILLERS
Songwon opens Middle
East, Africa headquarters
in Bahrain
Korean additive supplier Songwon
Industrial Co. Ltd. has opened its Middle
East and Africa headquarters in Bahrain,
saying demand for its core products in the
region is growing rapidly as it becomes
“one of the most important markets for
us,” according to Jongho Park, chairman
and CEO of Songwon Industrial. The
new regional facility, which also includes
recently established local warehouses,
will be led by Peter Fleming, who was
named sales director Middle East and
Africa effective Nov. 24. Fleming’s prior
experience includes stints with Chemtura,
where he led its Asia-Pacific business, as
well as at Polysar, which was acquired
by Bayer. Most recently Fleming worked
as a management consultant at Oriental
26 JANUARY 2010 • MODERN PLASTICS WORLDWIDE
MW1001_026
MW1001 026 26
Pacific Consulting PTE Ltd.
The move into the region continues
the company’s efforts to expand its geo-
graphic reach. In May 2009, it announced
the creation of a new Japanese subsid-
iary, Songwon Japan KK. Last January,
the company added two new distributors
in India: Jayvee Organics Private Ltd.
and Qualichem Specialties Private Ltd.
Songwon supplies antioxidants, light sta-
bilizers, UV light absorbers, heat stabiliz-
ers, plasticizers, lubricants, surface coating
agents, polyurethane, alkyl phenols, biphe-
nol, flocculants, and other chemicals.
Songwon Industrial Co. Ltd., Ulsan,
South Korea, www.songwonind.com
Royal Blue pigments get
that desired effect
Lumina Royal Blue and Lumina Royal
Exterior Blue pigments are said to be of
use in creating eye-catching effects for
standard and high-end products. The
Checkmate: New pigment outperforms current
interference blue effect pigments.
industrial version of the pigment can be
used to visually enhance mobile devices,
consumer electronics, appliances, sport-
ing goods, and cosmetic and personal
care packaging. The exterior version of
the pigment is coated with the supplier’s
chrome-free surface treatment (CFS) for
improved durability in applications that
require humidity resistance and excellent
adhesion, such as automotive, coil, and
powder coating applications.
Royal Blue is the first high-chromaticity
effect pigment being launched as part of
the company’s extension to its Lumina
effect pigment portfolio.
BASF, Florham Park, NJ, USA,
www.basf.us/luminaroyal
New developments
Bio-based modifier
provides FR, enhanced
properties
A group of patent-pending bio-based
polymer modifiers reportedly enhance
flame retardancy and add flexibility to
otherwise rigid plastic products. Jemini
100 is the first in a line of nonhalo-
gen flame-retardant additives that are
RoHS, WEEE, and REACH compli-
ant. Described as an “agri-derived liq-
uid,” Jemini 100 modifiers are ignition
resistant, thermally stable up to 280°C,
and allow high loadings of fillers in
compounds, many of which cannot be
processed without the addition of a
modifier.
Bill Hamilton of Jemini developer JJI
Technologies told MPW that he couldn’t
divulge the exact composition of Jemini
100, but said that more than 90% of it
is derived from naturally occurring sub-
stances. “While it is not a flame retardant
itself, it does not add to the fuel load like
other polymer modifiers, which are min-
eral based,” Hamilton explains.
While mineral-based flame retardants
can impact physical properties, making
compounds brittle in some instances,
Jemini 100 is said to improve elongation,
flex modulus, and impact resistance due to
its plasticizing effect. The Jemini line was
originally developed as a way to impart
superior flexibility to nonhalogen flame-
retarded polypropylene wire and cables,
without compromising the flame rating or
other key properties.
Hamilton says the modifiers have thus
far been used with PE and PP, with the
liquid injected directly into the barrel,
although JJI believes it could also be
added at the feedthroat. Letdown ratios
have ranged from 2%-5%, depending
on the application and desired result,
whether it’s process improvement or
enhanced magnesium hydroxide flame-
retardant performance.
Speaking to MPW in early November,
Hamilton said Jemini 100 was at that time
in the final stages of commercialization.
Several companies were using it in scale-up
situations involving highly filled materials
such as magnesium hydroxide, he added.
JJI Technologies, Painesville, OH, USA,
www.jji-technologies.com
plasticstoday.com/mpw
12/22/09 9:02:07 AM
 Cool T O - T HE Touch ™

MW1001_027
MW1001 027 27 12/22/09 9:02:19 AM
 PROCESSING TECHNOLOGY

PRODUCT WATCH
INJECTION MOLDING

Mold-Masters introduces new

hot runner temperature
control at Euromold
Mold-Masters launched its new TempMaster K-Series hot runner temperature controls at the Euro-
Mold event (Dec. 2-5) in Frankfurt, Germany. Made possible in part by the company’s recent (Octo-
ber 2009) acquisition of PMS Systems, the company describes the modular controls as compact and
economical, especially for hot runners with a high number of temperature zones (up to 240).
Benefits include a proven design borne out by an installed base that’s been in the field for 10
years, plus an easy-access design for simplified service. The unit has a full-color 10.4-inch touch-screen
control, which includes the latest software improvements. Dirk Echtermeyer, VP sales Europe at
Mold-Masters, said this system will prove reliable and economical for any applications with 60 or
more control zones. Mold-Masters’ new TCUs
Mold-Masters Ltd., Georgetown, ON, Canada, www.moldmasters.com debuted last month.

Haitian shifts European
HQ to Germany;
Mercury’s rising
Acknowledging that Germany is the conti-
nent’s leading machinery market, and tak-
ing a pronounced step into the backyard of
its leading competitors, the world’s most
prolific manufacturer of injection molding
machinery is shifting its European HQ
from Italy to Germany.
From June 2010, Haitian Europe will
operate in Germany. The move is designed
to help Haitian capture more of the Ger-
man market, it says, with both its Haitian-
brand machines as well as with its high-end
Zhafir machinery, which is designed and
assembled in Germany and wholly owned
by Haitian and its management. This is
something of a switch from the company’s
announced strategy when it formed the
Zhafir business unit; at that time it said the
Zhafir presses most likely would be mar-
keted only into Asia. But market interest
prompted the change, say officials.
Zhafir Plastics Machinery is based in
Ebermannsdorf, Germany. Haitian Europe
will be based near Nuremberg, about two
hours from Ebermannsdorf.
Haitian Europe is one of parent com-
pany Haitian International’s five regional
offices worldwide and for years has been
based in Italy, a layover from when the
company was a Haitian distributor owned
by Italian management. Eric Taveau, gen-
eral manager of Haitian Europe, said,
“After all, Germany is the largest and most
significant European market. The advan-
tages of positioning yourself as close as
possible to the client are clear. By relocat-
ing our place of business we are guarantee-
ing optimum sales and service support.”
The Zhafir facility recently expanded
its assembly capacity, and the parent
company predicts its Venus series of
all-electric machines will find favor in
Europe’s molding community. Haitian
already has a market-leading presence
in Turkey, it says, and also sells well in
some Eastern European countries. Zhafir
expects to start assembly of a high-end
all-electric molding machine, to be called
the Mercury Series, at the site in Eber-
mannsdorf this year.
Haitian, Ningbo, China, www.haitian.com
Coinjection allows barrier
caps, closures in one step
After hinting at the capability at
NPE2009, coinjection technology spe-
cialist Kortec Inc. will formally introduce
a system to injection mold one-piece
barrier caps and closures, potentially
eliminating the need for closure manu-
facturers to add butyl rubber discs or
aluminum seals after molding of thermo-
plastic closures Kortec says the caps and
closures will better preserve food and
beverage freshness and be less expensive
to produce than traditional two-piece
closures.
Russell Bennett, VP of sales and mar-
keting at Kortec, told MPW that at this
point, the company has not undertaken
any performance testing of the caps. “We
really are at the early stages of our devel-
opment work,” Bennett said, “but it is
showing a lot of promise from the perspec-
tive of capability to place the barrier in the
These polypropylene caps feature a thin, coin-
jected layer of EVOH for barrier, resulting in
one-piece, one-step closures that could replace
two-piece systems on the market today.
cap.” The current target markets for the
technology are those served by two-piece
closure systems, including plastic caps
with aluminum heat-sealed foil. “That
naturally leads us to sterilized or pasteur-
ized foods and juices, vitamin-enriched
beverages, and hot-filled foods,” Bennett
said, adding that Kortec plans to work
with cap makers to test efficacy. Initially,

28 JANUARY 2010 • MODERN PLASTICS WORLDWIDE plasticstoday.com/mpw

MW1001_028
MW1001 028 28 12/29/09 9:55:25 AM
 PROCESSING TECHNOLOGY
Innovation & Optimization
Place

EVOH has been applied as the barrier
material, but others are on Kortec’s “radar
for evaluation,” according to Bennett.
Kortec has branched out from its mul-
tilayer, barrier polyethylene terephthalate
(PET) preform business to extend its coin-
jection technology to new markets, most
recently thin-wall containers. In terms of
the benefits of its latest offering, Kortec
says multilayer caps, when used in con-
junction with multilayer containers, extend
the protection of product freshness across
the entire package. Kortec also points out
that packaging manufacturers can now
look at Kortec as a single-source supplier
that can provide the know-how and tech-
nology for an entire barrier package.
Kortec, Ipswich, MA, USA, www.kortec.com
EXTRUSION
New blown film lines use
a single air ring
New from this company, formed last
summer through the fusion of Kiefel
Extrusion and Reifenhäuser’s blown film
division, is a cooling concept for blown
film extrusion lines based on a cooling
ring that can be adjusted in height. The
“counter cooling process” used for this
air ring design means that the cooling
New cooling concept for blown film extrusion
lines.
air is not only conveyed upward to the
air lips, as is the case in conventional air
rings, but also downward to an addi-
tional air exit. As a result, only one air
ring is needed to achieve stabilization of
the film bubble.
The manufacturer says the end result
includes not only higher output but—
depending on the film structure—also
improved film with regard to proper-
ties such as transparency, gloss, and
strength.
In related news, Reifenhäuser has
completed its move to a new 10,000-ft2
North American headquarters in Dan-
vers, MA, closing its previous office in
Ipswich, MA, as well as newly acquired
Kiefel Inc.’s Hampton, NH site. All but
one Kiefel employee was transferred to
the new building, which was renovated to
accommodate the company. Kiefel Tech-
nologies, the thermoforming division still
held by Brückner, remains in Hampton.
Reifenhäuser Kiefel Extrusion, Worms,
Germany; www.reifenhauser-kiefel.com
PET sheet system
eliminates crystallization,
drying
A polyethylene terephthalate (PET) sheet
system precludes drying and provides

Upcoming 2010 directories

;ZWgjVgn Medical
6eg^a Bioplastics & sustainability
?jcZ Compounding
6j\jhi Additives
DXidWZg K 2010
9ZXZbWZg Primary processing machinery
& auxiliary equipment

Don’t delay!
Make sure you are listed in these directories.
Call Iris Topel at +1 718-478-8104
Fax +1 718-478-8105
iris.topel@cancom.com
13047_MW09
13047_MW09

INDUSTRY DIRECTORIES
plasticstoday.com/mpw MODERN PLASTICS WORLDWIDE • JANUARY 2010 29

MW1001_029
MW1001 029 29 12/29/09 9:55:36 AM
 PROCESSING TECHNOLOGY

PRODUCT WATCH Innovation & Optimization

Place

throughputs of 2000 lb (900 kg) per process postconsumer or industrial flake crystallizing and then drying PET not
hour with lower overhead compared to PET. only takes time, but also requires more
nonvented extrusion processes. Utilizing In the conventional setup, moisture energy, equipment, and plant space.
Davis-Standard LLC (D-S; Pawcatuck, and volatiles must be removed through With the new technology, a blender
CT) engineering, project management, drying so that the polymer chain doesn’t combines postconsumer or industrial
and winding with a Multi Rotation Sys- break down during the melt phase. In flake PET with virgin pellets from each
tem (MRS) extruder from Gneuss Inc., order to be dried, the feedstock must be component’s blender hopper in one step.
the collaborative result aims to replace crystallized to withstand elevated tem- Once blended, the resin is vacuum con-
single-screw extruders currently used to peratures. Gneuss and D-S point out that veyed to the feedthroat of the MRS
extruder for processing without having
to crystallize or dry the material.
Gneuss says the operations of its
MRS extruder are comparable to the
vent section of a single- or twin-screw

Faster. Better. Cheaper. extruder, in which melt-stream degassing

occurs under precise vacuum control. In
the case of the MRS, however, the degas-
North America’s Automation & Assembly sing section is much larger, surpassing
Events for Advanced Manufacturing the surface exchange of a twin screw by
25 times and a single screw by 50 times,
making it possible to remove moisture

April 28–29, 2010 June 8–10, 2010

Charlotte Convention Center Jacob K. Javits Convention Center
Charlotte, NC New York, NY
AM-Expo.com ATXeast.com

Davis-Standard and Gneuss have joined forces

and equipment for a PET sheet system that can
extrude PET without having to crystallize and dry
the material.

September 28–30, 2010 February 8–10, 2011 and volatiles in the melt stream more
Donald E. Stephens Convention Center Anaheim Convention Center
Rosemont (Adjacent to O’Hare Airport), IL Anaheim, CA efficiently.
ATExpo.com ATXwest.com Among the reported advantages to be
gained, a more moderate vacuum level
can be applied, enabling processors to
use less expensive and easier-to-maintain
vacuum equipment. In addition, the melt
undergoes low shear and thermal stress;
strong pressure buildup can eliminate
the need for a gear pump; and overall
less energy and space are required. FDA
approval for processing PET bottle flakes
For information on attending or exhibiting, please call
310/445-4200 or visit the show Web sites above. is pending.
In addition to the blender loader hop-
per and the MRS, the system includes a
S _ATX10
AS_ATX 10

Pro
o duc
d ed an
and
nd ma
n manag
nag byy CANON
a ed b A
ANO C OMMU
MMU
M NII C ATIONS
ATIO
TI NSS LL
LLC
LC
Ca n onT
Can onTra
r eSh
rad eShowsows.co
ow .co m
.co
.c
Gneuss RSFgenius melt-stream filter, an
13894_AS
4_AS
_AS

inline viscometer, an online X-ray gaug-

1389

ing system, a roll stand with independent

roll-speed control, and a turret winder

30 JANUARY 2010 • MODERN PLASTICS WORLDWIDE plasticstoday.com/mpw

78208.indd C30 12/29/09 3:43:07 PM

 r
"EWFSUJTFNFOU
r

CORPORATE PROFILE Stop Riding The

Resin Price Rollercoaster
Vecoplan Shredders Get Your Feet
Back On Solid Ground!
Vecoplan Vecoplan Single-Shaft Shredders are designed to
reclaim and reprocess your plastic scrap
The Leader in Plastics - saving you money and time.
Particle size can be controlled
Reclamation and and adjusted with a quick
10 minute screen change,
Recycling Technology! inexpensive cutting
inserts save time on
maintenance, and
variable program
modes allow the
flexibility to process
material in the most
efficient manner.

S
JOHMFTIBGU
SPUBSZ
TISFEEFST
BSF
UIF
NPTU
FGGJDJFOU
NBDIJOFT

GPS
SFDZDMJOH
QMBTUJDT
BOE
7FDPQMBO
NBOVGBDUVSFT
UIF
NPTU
SF • Patented
àOFE
BOE
NPTU
SFMJBCMF
QMBTUJDT
TISFEEFST
PO
UIF
NBSLFU
UPEBZ
Single-Shaft
Cutting System
Vecoplan invented the single-shaft rotary shredder, intro- • Large Hopper
duced it to the plastics industry, and holds numerous patents on
the technology. Vecoplan also has more machines in the field, • Processes Large
Purgings, Bales
more repeat customers, and more crossover customers than any
competitor. Vecoplan designs, engineers and manufactures the • Precise Feed Ram
highest quality, most durable and best performing plastics shred-
• Low Noise,
ders available - period. Service, parts availability, size of staff,
High Torque
number of stock units, and systems engineering capabilities – Operation
you guessed it – Vecoplan is the leader in these areas too!
• Special Designs for
The features and benefits of Vecoplan shredders are to nu- Special Applications
merous to list in this limited space, but become apparent when
performing a side-by-side comparison with imitators.
Call 336-861-6070 or visit www.vecoplanllc.com, review our
site, literature and videos.
We welcome
the opportunity to
be compared and
will be happy to
provide you with
customers that
already use Veco-
plan shredders
in an application
just like yours!

For more information T H E U L T I M A T E S H R E D D I N G M A C H I N E

7FDPQMBO
LLC AY`_V+$$')'"'!(!•7Ri+$$')'"%$#*

10
#PY

XXX7FDPQMBO--$DPN
)JHI
1PJOU
/$

JOGP!7FDPQMBO--$DPN gVT`a]R_]]TT`^
plasticstoday.com/mpw MODERN PLASTICS WORLDWIDE • JANUARY 2010 31

MW1001_031
MW1001 031 31 12/29/09 9:55:49 AM

k-online.de
For show information: For hotel and travel
Messe Düsseldorf arrangements:
North America TTI Travel, Inc.
150 North Michigan Avenue Tel. (866) 674-3476
Suite 2920 Fax (212) 674-3477
Chicago, IL 60601
Tel. (312) 781-5180
Fax (312) 781-5188
E-mail: info@mdna.com
http://www.mdna.com
32 JANUARY 2010 •
kmd1002_85x254_US.indd 1
MW1001_032
MW1001 032 32
International Trade Fair
No. 1 for Plastics
and Rubber Worldwide
Official Airline
MODERN PLASTICS WORLDWIDE
10.12.2009 16:51:14 Uhr
PROCESSING TECHNOLOGY
PRODUCT WATCH
for 48-inch-diameter rolls weighing more than 5000 lb (2200
kg). The system utilizes D-S’s Epic closed-loop winder control.
The system was engineered so that finished sheet can be fed
directly into a thermoformer shaping trays for use with fresh
food items like strawberries and tomatoes.
Davis-Standard LLC, Pawcatuck, CT, USA, www.davis-standard.com;
Gneuss Inc., Matthews, NC, USA, www.gneuss.com
ASSEMBLY & JOINING
Multiple welds, one machine, and a
happy carmaker
Assembly and joining machinery manufacturer Forward Tech-
nology has custom-built a unit for carmaker Ford that will be
used to drive more efficient manufacturing on some of its soon-
to-be-introduced full-size pickup trucks and SUVs. The project
and machine developed for the OEM performs multiple welds
on one machine, with a single operator, for a job previously
requiring at least two of each.
The challenge was to help Ford integrate its HVAC duct-
work into the vehicles’ consoles. Console size has increased
as more amenities are integrated: cup holders, of course, but
also coin slots for spare change, and large storage compart-
ments, plus auxiliary power plugs (12V) and even, increas-
ingly, power inverters (110V) for charging laptop computers
or other equipment.
These consoles mount directly to the floor of a vehicle, which
reduces the amount of floor space for airflow (heating and air
conditioning) between the front and rear seating area. Forward
Tech’s welding unit helped Ford to tap into the main HVAC
unit in the dash and divert some of that air to the rear seating
area through the console. The main console housing (a single
molding) has channels molded in (passenger and driver side)
that can be used for airflow. In order to channel the air properly,
side panels are needed to enclose these channels. Since these
ducts are on both the passenger and driver side of the console,
this requires two separate welding operations.
Usually such an operation would require two welding units
plus operators, or one welding unit with frequent tool changes.
Forward Tech’s answer, says Doug Grabinger, project manager
at the company, was to accommodate both welds simultaneously
by designing a holding fixture for the main console housing that
was positioned between the normal right- and left-hand jaws of
the company’s vertical hot plate welder, Model VH-1445.
Explains Grabinger, “We then designed our typical nest-
ing fixture for each side panel. Of course, this also required
doubling up on the heat platen to be able to melt both sides
of the console housing as well as both side panels. While this
did require enlarging our standard welder to accommodate
this large application, our in-house design, fabrication, and
machining capabilities allow us to do that with ease. Ulti-
mately, our customer ended up with one piece of equipment
that requires one operator and produces one fully welded
assembly per cycle.”
Forward Technology, Cokato, MN, USA, www.forwardtech.com
plasticstoday.com/mpw
12/29/09 10:02:08 AM
 r
"EWFSUJTFNFOU
r

CORPORATE PROFILE
InnoPlast Solutions Inc.

W
F
BU
*OOP1MBTU
4PMVUJPOT
BSF
JO
r
4PMWJOH
$PNQMFY
1SPCMFNT
JO
1PMZNFST


UIF
CVTJOFTT
PG
PGGFSJOH
$POTVMUB- 1MBTUJDT
*OEVTUSZ
WJB
&YDFMMFODF
JO


UJPO
$POGFSFODFT

$PVSTFT
BOE
"OBMZUJDBM
4DJFODFT
"OBMZUJDBM
4FSWJDFT
JO
BSFBT
XIFSF
XF
IBWF
B
r
1BUFOU
*OGSJOHFNFOU

-JUJHBUJPO
EFNPOTUSBUFE
SFDPHOJUJPO
JO
UFSNT
PG
QVCMJDB- r
/ZMPOT

1PMZBNJEFT
UJPOT
JO
TDJFOUJàD
KPVSOBMT

CPPLT

FODZDMP- r
1MBTUJD
1BDLBHJOH
'JMNT
QFEJB
64
QBUFOUT
JOUFSOBUJPOBM
BXBSET
BOE
r
1MBTUJDT
.PEJàDBUJPO
WJB
"EEJUJWFT


OVNFSPVT
CVTJOFTT
BXBSET $PNQPVOEJOH

$PBUJOHT
*OOP1MBTU
TFSWJDFT
BSF
EFTJHOFE
UP
EF-
MJWFS
B
EJGGFSFOUJBUFE
WBMVF
UP
JUT
DVTUPNFST

UIF
EJGGFSFOUJBUJPO
DPNJOH
GSPN
UIF
FYQFSJ-
FODF
BOE
KVEHNFOU
PG
UIF
PSHBOJ[FS
8JUI
B

QBSUJDVMBS
NJTTJPO
JO
NJOE
XF
XPVME
TFMFDU
B
For more information
UFBN
PG
UFDIOJDBM

CVTJOFTT
TBWWZ
FYQFSUT
*OOP1MBTU
4PMVUJPOT
*OD
UP
XPSL
XJUI
VT
BT
B
UFBN
BOE
EFMJWFS
FYDFM- :BTI
1
,IBOOBW
1I%
MFOU
SFTVMUT
UP
PVS
DMJFOU
"HBJO
JEFOUJGZJOH
UIF

"SBO
%SJWF
SJHIU
FYQFSU
JT
PVS
TUSFOHUI
#FMPX
BSF
UIF
3PTXFMM
("

64"
TQFDJàD
BSFBT
XF
FYDFM 5FM

.PCJMF

'BY

XXX*OOP1MBTU4PMVUJPOTDPN

plasticstoday.com/mpw MODERN PLASTICS WORLDWIDE • JANUARY 2010 33

MW1001_033
MW1001 033 33 12/29/09 9:56:05 AM

‘Preventive’ is key to making a
maintenance program work for you
By Clare Goldsberry
Lack of maintenance on processing equipment can cost a company a lot in energy,
processing inefficiencies, and downtime. The flip side, proactive maintenance, is almost
purely positive and can pay big dividends in the long run.
P rocessing machinery that is main-
tained properly typically means
decreased energy consumption,
increased productivity, better part qual-
ity, and reduced downtime, giving the
equipment greater availability. While few
people think of machine maintenance as
connected to “sustainable production,”
a recent Aberdeen Group survey on
the latter showed there is a direct
correlation between how well a
processor maintains his equipment
and how well his company looks
on its bottom line.
Operational efficiencies and
overall costs to manufacture are
tied closely to processing equip-
ment. Paul Caprio, president of
KraussMaffei (Florence, KY),
which manufactures injection
molding, extrusion, and polyure-
thane processing machinery, says
while KraussMaffei’s customers are
concerned with energy consumption, the
issue remains secondary to precision
and output. “Even though energy sav-
ings is a buzz word, quality parts and
high productivity are what count on the
manufacturing floor,” says Caprio. “Our
customers are more attuned to making
the machine run better.”
That said, Caprio adds that many
customers are getting rid of older injection
molding machines that tend to consume
more energy—particularly hydraulics—
and replacing them with new or newer
machines that have more energy-efficient
motors and pump systems.
Aberdeen Group’s Sustainable Produc-
tion report revealed that its “Best-in-Class”
34 JANUARY 2010 • MODERN PLASTICS WORLDWIDE
MW1001_034
MW1001 034 34
Make every pellet count
respondents are integrating sustainable
features across their operations, “taking
into consideration information related to
energy, emissions, product, process, and
employee safety—while optimizing pro-
duction, maintenance, and engineering
processes.” One example the report cited
is including energy as one of the factors,
in addition to asset condition, to monitor
when scheduling maintenance.
Who will handle your maintenance?
Machine maintenance always has been
recognized as critical to quality parts and
high productivity, but one thing that has
changed, notes KraussMaffei’s Caprio, is
the greater reliance on machine OEMs to
supply that maintenance.
“There’s no question that over the
past two years, the customer base is
absolutely relying on the machine manu-
facturer to handle the preventive mainte-
nance on the equipment,” says Caprio.
“Many processors have gotten so lean in
laying people off and other cost-cutting
measures that they’re not doing machine
maintenance in-house. One of the safety
valves KraussMaffei offers is planned
regular checkups, quarterly, semi-annu-
ally, or annually.”
His firm is not alone; maintenance
and service programs at most processing
machinery manufacturing firms used to
play second fiddle to new equipment
sales, but now often are almost as
important as a source of revenue.
The transition at both processors
and their suppliers is not entirely
negative, since it gives each good
reasons to pay closer attention to
machine maintenance programs.
That may be more important than
ever now, notes Jimmy Langsdon,
president of Columbia Machine
Works Inc. (Columbia, TN), whose
business specializes in machinery
maintenance and repair, including
injection molding machinery. He
notes that many times, especially when the
economy is slow, companies get too lean.
“A lot of people make the mistake of
cutting their maintenance budget when
dollars get tight,” says Langsdon. “This
is the worst thing you can do. Keeping
your machinery in tip-top shape is the
most important thing to your business.”
So important is it, in fact, that Scott
Paulson, president of Paulson Training
(Chester, CT), which offers courses for
plastics processors, says his company has
integrated machine maintenance into a
variety of its injection molding training
programs. “Maintenance is part of the
efficiency equation. Maintenance affects
downtime—which is a killer—so it’s
plasticstoday.com/mpw
12/22/09 9:06:06 AM
 refreshing
e x t r u s i o n
technology

ZSE MAXX SERIES

How do you increase the productivity of your twin screw compounding line in the future?
Here is the solution:
up to 50% throughput increase by means of an optimized volume/torque ratio (maXXshaft,
maXXvolume)
increased product quality, because of a more efficient cooling system (maXXcooling)
reduction of unproductive times
higher flexibility in terms of processing tasks
The range of ZSE MAXX extruders (27 - 180mm) opens up new horizons for a more efficient
compound production.

maXXvolume maXXshaft maXXcooling maXXtorque

Larger, free volume in the Unique high total torque by 30% increased barrel cooling Highest available specific
screw (OD/ID = 1.66) new splined shaft design capacity by means of opti- torque with co-rotating twin
mized flow of the liquid coolant screw extruders (15.0 Nm/cm3)
See us at PLASTEC WEST 2010, Booth 4050 through the barrel cooling bores

EXTRUDER LEISTRITZCOM  WWWLEISTRITZCOM  PHONE     

78201.indd 35 12/30/09 8:24:48 AM

 Make every pellet count

vitally important,” Paulson says. “We have a [training] pro-

gram on machine maintenance and how efforts in this area can
increase efficiency.”
Langsdon says the primary problem he sees with molding
machine maintenance is the tendency to cut obvious corners. “We
see a lot of molding machine failures due to poor lubrication, either
a lack of lubrication or dirty lubricant,” he comments. “When we
rebuild injection molding machines, common things we see are
those bearings that are worn out due to lack of lubrication.”
Andy Routsis, president of A. Routsis Assoc. Inc. (Dracut,
MA), which provides online plastics processing skills develop-
ment and training, agrees with Langsdon’s comments and adds
that the problem is persistent, even with all-electric machines.
“All of them have toggle clamps,” notes Routsis. “We have
a program for training machine maintenance personnel, and
I cover the things that aren’t typically covered in the OEM’s
maintenance manual.”
There’s definitely a huge payoff in maintaining processing
machinery, and often it’s the areas that people don’t think about
that can cause the biggest problems, like lubrication. “They
don’t lubricate the machine properly—that’s always a prob-
lem. Another big one is leveling, particularly in the larger-size
presses like a 400-ton running an 8-second cycle—that machine
is rockin’ and rollin’,” emphasizes Routsis, who recommends a
bubble level or digital level, or better yet a laser level, to check
the level of a machine and to re-level it periodically.

Simple steps make big differences

Another problem that arises on new equipment has to do with
the laws regarding shipping a machine. “The machinery maker
will do a run-off to test all the functions of the machine before
shipping to make sure it’s running correctly,” explains Routsis.
“One of the things it must do by law is empty the machine of
oil. From the run-off, you get a lot of chafings from the rubber
hoses—they fill up with oil—and it leaves the grit. Before refill-
ing the machine with oil, pull the tank plate, wipe out the tank,
and then swap out the filters. Most people figure it’s a new
machine, so why do they have to do that? But it’s important.”
Routsis also recommends checking the platens for simple
flatness, something that he finds rarely done. “Take a 12-inch
or 36-inch steel ruler and lay it across the stationary platen by
the locating ring,” he suggests. “If you see a gap between the
platen and ruler, you know it’s not flat.”
Additionally, he adds, check the movable platen sup-
ports. The reinforcements on the platens should be cast, not
machined. “You want the give,” says Routsis. “We talk all
about these things in the maintenance training course. It’s
always something basic that fails.” MPW

plasticstoday.com/mpw
When is the best time to perform PM? Is it worth it to do an
efficiency audit? Find answers to these questions and more
as this article continues at plasticstoday.com/mpw.

plasticstoday.com/mpw

MW1001_036
MW1001 036 36 12/22/09 9:06:16 AM
MW1001_037
MW1001 037 37 12/30/09 8:17:45 AM
 ASIA-PACIFIC
WORLD TOUR
Business, Strategies & Markets

Malaysia seeks advanced

manufacturing role
By Stephen Moore Sensing an urgent need to climb the technology tree amid intense competition

from its ASEAN neighbors and other Asian countries, Malaysia has unveiled a

series of initiatives to expand investment and attract more advanced manufac-

turing activity.

igh on the list of moves made is
H the East Coast Economic Region
(ECER) located along the relatively
underdeveloped eastern shore of penin-
sular Malaysia. The initiative’s objective
is to create 560,000 new jobs via cumu-
lative investment of around $35.5 billion
through 2020. A fair proportion of this
investment will be in manufacturing, and
plastics processing is not missing out.
Natural gas resources in the area
attracted raw material suppliers to the
region even before ECER was mooted,
and already polyethylene, PVC, acrylic,
polyacetal, polyester, and PBT are avail-
able locally from Malaysian and global
suppliers such as joint venture Toray
BASF (Kuantan), Japan’s Polyplastics
(Tokyo), and Eastman Chemical (King-
sport, TN).
Next on the agenda is further devel-
opment of the Kertih Polymer Park.
Phase I of the park spans Prestige’s Tan (right)
an area of 90 hectares,
with Phase II set to occu-
with director Travis Tan:
Medical is a promising
segment for plastics in
py another 50 hectares. Malaysia.
Eventually, the devel-
opers are targeting rev-
enue of approximately
$600 million and cre-
ating 7000 jobs at the
park. Investing compa-
nies can enjoy incen-
tives such as a 10-year
income tax exemption,
and Mohd Fadzil Abdul
Latif, branding manager
at park developer ECER
Development Council, says, “Processors (Kuala Lumpur) locating an R&D and
from all over the world can enjoy these technology center within the park.
benefits. We welcome any investment One of the first investors in the park
from abroad.” Further, processors will was Malaysian wire and cable producer
not be without technical support, with Hi Essence Cable (Puchong), which has
leading local resin supplier Petronas invested around $25 million in a manu-

More stretch capacity for Malaysia

Malaysia’s Evermal Industry (Johor) has taken delivery of its second stretch film line,
this time a state-of-the-art 650-m/min unit from SML Extrusion Technology (Lenzing,
Austria). The new line employs a W4000 turret winder for winding of machine rolls
onto 3-inch shafts up to a roll diameter of 420 mm. The majority (80%) of Evermal’s
production is machine rolls, whereas an estimated 50% of Malaysian stretch film pro-
duction is hand rolled. The line also features an inline recoStar basic repelletizing unit
from Starlinger (Vienna).
SML’s Ausweger: Stretch film contin-
ues on its downgauging trend. Gerald Ausweger, chief representative of SML’s Far East Regional Office, says
the stretch film line processes 1400 kg gross of polyethylene every hour at 17 μm
film gauge, of which 250 kg is recovered scrap that is fed back in its entirety with no adverse effect on final film properties. “You
could even use 80% recycled material in the three core layers with no gelling occurring,” he says. Virgin material would only be
required for the outer layers.
Speaking at the recent M-Plas show, Ausweger also revealed that SML systems were now capable of producing 2-inch hand
rolls with gauge down to 8 μm. Standard gauge is 14-15 μm. The 8-μm stretch film typically incorporates a 40% core layer, two
20% sandwich layers, a 10% slip layer, and a 10% cling layer. Production speed is up to 450 m/min.

38 JANUARY 2010 • MODERN PLASTICS WORLDWIDE plasticstoday.com/mpw

MW1001_038
MW1001 038 38 12/22/09 9:07:26 AM

 

       

First, MPW provides our publication in a digitally delivered format so you

can receive it right at your computer desktop and help save a tree. Just visit
plasticstoday.com/subscribe to change to digital delivery.
Second, we’ve launched a new e-newsletter, Greening of an Industry, to help
plastics industry professionals keep up with the myriad of subjects related
to sustainability.
Just visit plasticstoday.com/newsletters to subscribe.
www.plasticstoday.com/newsletters

Let 
  
 be your guide.

MW1001_039
MW1001 039 39 12/29/09 3:49:59 PM
 ASIA-PACIFIC
WORLD TOUR
Business, Strategies & Markets

is better suited to high volumes.

Kertih Polymer Park targets investment globally.
facturing facility. Latenfield Pipe Indus-
tries, meanwhile, has ploughed close to
$12 million into its PVC pipe processing
operation there, while FMD Polypipes
Industry is spending $6 million on its
pipe extrusion operation.
ECER also plans to develop the Pekan
Automotive Industrial Park, positioning
it as a manufacturing, assembly, and
R&D hub. Around $1.2 billion in invest-
try in Malaysia,” says Tan Wee Ming,
managing director of processor Prestige
Dynamics Industries (Penang). “While
we are in fact a quite mature industry,
we can handle sophisticated production
and fast turnarounds with our expertise
built up over many years that may not
be possible in China.” In Tan’s view,
Malaysia can provide low volumes,
speed, and high technology, while China
Prestige Dynamics is also a strong
player in the power tool segment, where
its particular forté is two-shot molding of
housings. “We work together with one
of our key customers to develop tool-
ing,” says Tan. Not resting on its laurels
though, Prestige Dynamics is increasing
its role in the medical segment, which
currently accounts for 10% of turnover.
For example, the processor currently
ships around 200 oxygen dispenser hous-
ings per month to a medical device man-
ufacturer in Europe. “We can compete
with local [European] molders because
we can build the tool for half the price,”
says Tan. Prestige is also leveraging its
two-shot molding prowess in the medi-
cal sector, but standards are much more
stringent than electronics or power tools.
“You have to guarantee 20 years of color
stability, for example,” says Tan. His
company, and others in the country, say
they welcome the challenges. MPW

ment is targeted. Malaysia recently par-

tially liberalized its automotive sector.
It now allows 100% foreign ownership
and offers a 10-year tax break, training
and research grants, and excise duty
exemption for assemblers and manufac-
turers of hybrid and electric vehicles and
components. The luxury vehicle segment
has also been liberalized.
Malaysia is also aggressively develop-
ing South Johor’s Iskandar zone, which
is home to various manufacturing and
petrochemicals activities. The govern-
ment expects it to create 800,000 jobs
and attract around $100 billion in invest-
ment over 25 years. Key economic activi-
ties currently found in the zone include
general manufacturing, chemicals and
chemical products. Besides development
of manufacturing, investment in infra-
structure there is set to boost demand for
plastics processing.
Local electronics expertise
Electronics also remains a strong com-
ponent of Malaysia’s manufacturing
sector, contributing significantly to the
country’s manufacturing output (30%),
exports (56%), and employment (29%).
“There is still a lot of commitment
to the electronic and electrical indus-
Riches from recycled resin in a tough
economic environment
Amid a challenging business environment in Malaysia, film processors are turn-
ing to advanced recycling solutions for in-house scrap to improve their bottom
lines, according to NGR (Next Genera-
tion Recyclingmaschinen GmbH; Feld-
kirchen, Austria). Having just opened
a regional office in the ASEAN nation,
chief representative Walter Schmedler
says local film processors are look-
ing for every available opportunity to
trim costs, and this means utilizing
in-house scrap to the fullest. Leading NGR’s Schmedler says Malaysia pro-
Malaysian stretch film producers Thong cessors appreciate the cost-saving
Guan Industries (Ipoh) and BP Plastics potential of high-quality recyclate.
(Johor) are among users of NGR’s recy-
cling machines, as are blown film processing giants Klang Hock Plastic Industries
(Selangor) and Daibochi Plastic (Melaka).
Speaking at the recent M-Plas show in Kuala Lumpur, Malaysia, Schmedler said,
“We installed our first recycling machine in Malaysia five years ago, and since then
our user base has expanded and we’ve been getting repeat orders.” The E:Gran
machine, with capacity of 10-50 kg/hr, is popular for edge trim recycling, while higher
recycling capacities are provided by the vendor’s A:Gran and S:Gran machines.
“With quality of the product sufficient to go straight back into high-end film prod-
ucts, processors are finding they can pay back their investment in 12 months,” noted
Schmedler. “Without our systems, the best they could hope for was to offload the trim
as bargain basement scrap.”

40 JANUARY 2010 • MODERN PLASTICS WORLDWIDE plasticstoday.com/mpw

MW1001_040
MW1001 040 40 12/22/09 9:07:42 AM
 HARMONY through
TECHNOLOGY
THE BLUE WAVE OF NEW EXTRUSION !

Blown film lines

REIFENHÄUSER-KIEFEL EXTRUSION is combining the joint innovation and performance
potential in blown film line development to move to the top of technology, expertise and
service in international competition. REIFENHÄUSER-KIEFEL EXTRUSION, a member of
the Reifenhäuser group of companies, is developing into the most important manufacturer
of blown film extrusion machinery and equipment.

In the future, two of the most renowned companies of this sector will be forming a business
model able to respond in a targeted manner to the changing demands of global markets
by providing a comprehensive portfolio and unique customer orientation.

www.reifenhauser-kiefel.com
info@reifenhauser-kiefel.com

MW1001_041
MW1001 041 41 12/22/09 4:07:42 PM
 EUROPE
WORLD TOUR
Business, Strategies & Markets

Bioplastics: Coming to an RFQ near you

By Matt Defosse Hidden in the new material hoopla is that much of the real bioplastics

excitement surrounds materials that are just “greener” versions of polyolefins,

polyamides, or other thermoplastics. OEMs and brand owners are making clear

they intend to specify these materials.

as well as chair-
t is difficult for many processors to get
I excited about bioplastics, which many
have filed away as a group of materials
man of the Euro-
pean Bioplastics’
little is known about except their price board of direc-
(high) and their properties (water and tors. He made
heat resistance? Set your sights low). Oh his comments
yes, and limited capacity means they are at the European
tough to find even if you do want them. Bioplastics con-
But negative perceptions are bound to ference in Ber-
dissipate in the next two to five years as lin, Germany in
vast supply enters the market, as the body November. The
of knowledge on processing these materi- conference drew a
als increases, and as additives suppliers global audience of
and compounders busily work on improv- 380, a significant
ing their mechanical properties. Based on feat in a recession Capacity is expected to triple in the next three years.
recent announcements, the European Bio- where conference
plastics trade group estimates production and trade show attendance has plunged. what’s now available,” specifically citing
capacity of bio-based plastics will increase “the Braskem approach.”
from 360,000 tonnes in 2007 to about Improve what’s already there Braskem, the giant Brazilian plastics
2.3 million tonnes by 2013. But even for processors who understand- and chemicals supplier, is Latin America’s
The pace of development also is so ably get lost in the bioplastics’ acronym largest plastics supplier and a fast-growing
rapid that a processor who tested, for soup—PLA, PHB, PHA, and all of the force on the global stage. As reported previ-
example, polylactic acid (PLA) just two rest—there is little need to wait for some of ously, the supplier is hard at work improv-
years ago, and was disappointed, probably the most interesting developments, which ing the process to derive ethanol from
needs to revisit the material. “If you’ve focus not on developing new materials sugarcane; ethanol, converted to ethylene,
tried these materials before and failed, but instead on lessening the environmen- forms the basis for polyethylene (PE).
try again,” urged Andy Sweetman, global tal impact of the materials that processors Rui Chemmes, director of Braskem’s
marketing manager of sustainable technol- and their customers already purchase and PE operations, also speaking in Berlin,
ogies at Innovia Films, a €400 million/yearuse, such as polyethylene, polypropylene, said the ethanol-based polyethylene has
(about $600 million/year) films processor, and polyamide. Also speaking at the con- exactly the same characteristics as PE
ference was Hans- derived from petroleum. Plus, he added, it
Josef Endres, a is nine times as efficient to derive ethanol
professor at the from sugarcane as from corn, and 4.5
University of times as efficient compared to ethanol
Applied Sciences derived from sugar beets.
& Arts in Han- “Sugarcane is a 4m-high plant” that
nover, Germany, grows quickly and with little assistance,
who said indus- he explained. Other environmental ben-
try’s research efits include its work as “a real vacuum
and development cleaner of carbon dioxide.” One pound
efforts should of petroleum-based PE releases 2.5 kg
The European Bioplastics event drew almost 400 attendees, therefore focus of carbon dioxide to the atmosphere,
including representatives of major OEMs and brand owners. on “improving he said, whereas the same amount of

42 JANUARY 2010 • MODERN PLASTICS WORLDWIDE plasticstoday.com/mpw

MW1001_042
MW1001 042 42 12/22/09 9:10:12 AM
 r
"EWFSUJTFNFOU
r

CORPORATE PROFILE
Battenfeld Extrusion Group
complete intelligent extrusion solutions from a single source

B
BUUFOGFME
&YUSVTJPOTUFDIOJL
BOE
PG
UIFJS
QJQFT
BOE
TJNVMUBOFPVTMZ
JODSFBTF

JUT
TVCTJEJBSJFT
&YUSVTJPO
,FNQFO
UIFJS
QSPEVDUJPO
PVUQVU
5IF
OFX
TZTUFN
DBO

(FSNBOZ

"NFSJDBO
.BQMBO
$PS- CF
VTFE
JO
UIF
QSPEVDUJPO
PG
CPUI
NPOPMBZFS

QPSBUJPO
64"

BOE
#$
&YUSVTJPO
4ZTUFNT
BOE
NVMUJMBZFS
QPMZPMFàO
QJQFT
*U
JT
TVJUBCMF

'PTIBO

-UE
OPU
POMZ
TUBOE
GPS
UIF
MBUFTU
FO- GPS
BMM
QJQF
EJBNFUFST
CFUXFFO

BOE
 

HJOFFSJOH
BOE
JOOPWBUJWF
UFDIOPMPHZ
CVU
BMTP
NN
XJUI
XBMM
UIJDLOFTTFT
PG
VQ
UP

NN
GPS
UISFF
EFDBEFT
PG
FYQFSJFODF
JO
FYUSVTJPO

MJOF
DPOTUSVDUJPO
#Z
PVS
TLJMM
BOE
FYQFSUJTF
Profile extrusion – perfect integra-
XF
IBWF
CFDPNF
POF
PG
UIF
NBSLFU
MFBEFST
tion of all components for first-rate
JO
FYUSVTJPO
UFDIOPMPHZ
8F
QMBO
BOE
CVJME
product quality.
QSPDFTTJOH
QMBOUT
BOE
HSBOVMBUPST
DPNQMFUF
#BUUFOGFME
BMTP
PGGFST
EFDJTJWF
BEWBO-
QJQF
BOE
QSPàMF
FYUSVTJPO
MJOFT
BOE
IJHIQFS- UBHFT
XIFO
JU
DPNFT
UP
DPTUFGGJDJFODZ
'SPN

GPSNBODF
àMN
BOE
TIFFU
FYUSVTJPO
TZTUFNT
JOEJWJEVBM
DPODFQUT
UP
EFUBJMFE
DPVOTFMJOH

*O
PVS
NBDIJOFSZ
GVODUJPOBMJUZ
SFMJBCJMJUZ
JO
QSPDFTT
UFDIOPMPHZ
JODMVEJOH
BMM
BTQFDUT

SFTPVSDF
FOFSHZ
BOE
DPTUFGGJDJFODZ
BSF
PG
UIF
NBOVGBDUVSJOH
QSPDFTT
m
FWFSZUIJOH

UPQ
QSJPSJUJFT
8JUI
PVS
IJHI
RVBMJUZ
TUBOEBSET
DPNFT
GSPN
B
TJOHMF
TPVSDF
#BUUFOGFMET

BOE
DPOWJODJOH
àSTUSBUF
TFSWJDF
XF
BSF
SFBM
DPTUFGGJDJFOU
XJO#&9
NJOJ#&9
UFDI#&9

QBSUOFST
UP
PVS
DVTUPNFST
8F
QMBDF
TQFDJBM
BOE
CBTF#&9
TUBOEBSEJ[FE
TPMVUJPOT
BSF

FNQIBTJT
PO
DPNQSFIFOTJWF
DPVOTFMJOH
JO
BMM
BCPVU
DPNCJOJOH
UIF
SJHIU
DPNQPOFOUT
UP

QSPDFTT
UFDIOPMPHZ
XIJDI
JT
POF
PG
PVS
QBS- BDIJFWF
BO
PQUJNJ[FE
TZTUFN
UJDVMBS
TUSFOHUIT
8JUI
PVS
NPEFSO
DPODFQUT

XF
XJMM
DPOUJOVF
UP
TFU
OFX
TUBOEBSET
JO
FY- Battenfeld’s extrusion line concepts
USVTJPO
UFDIOPMPHZ
m
JO
DPPQFSBUJPO
XJUI
PVS
for manufacturing semi-finished
DVTUPNFST
BOE
UP
UIFJS
BEWBOUBHF sheet products focus on individual FYUSVTJPO
MJOFT
IBT
CFFO
EFWFMPQFE
EVSJOH

customer requirements. UIF
MBTU
GFX
NPOUIT
DPOTJTUJOH
PG
BO
FYUSVEFS

Manufacturing pipe extrusion lines 0O
#BUUFOGFME
MJOFT
B
MBSHF
OVNCFS
PG
BOE
B
QPMJTIJOH
TUBDL
GPS
JOMJOF
BQQMJDBUJPOT

is part of our traditional core com- NBUFSJBMT
DBO
CF
QSPDFTTFE
JOUP
NPOP 5IF
TFSJFT
JT
DVSSFOUMZ
BWBJMBCMF
JO
GPVS
EJGGFS-
petence. MBZFS
PS
NVMUJMBZFS
TIFFU
5P
NFFU
UIF
FWFS FOU
TJ[FT
5P
PGGFS
FWFO
NPSF
DVTUPNFS
CFO-
#BUUFOGFME
MJOFT
PGGFS
UIF
QFSGFDU
DVTUPN- JODSFBTJOH
EFNBOE
GPS
UIFSNPGPSNJOH
TIFFU
FàU
UIF
PVUQVUT
IBWF
CFFO
BEBQUFE
UP
NBUDI

J[FE
TPMVUJPOT
17$
PS
QPMZPMFàO
QJQFT
.PTU
QSPEVDUT
#BUUFOGFME
&YUSVTJPOTUFDIOJL
IBT
UIF
QFSGPSNBODF
PG
FTUBCMJTIFE
BVUPNBUJD

SFDFOU
EFWFMPQNFOUT
QBSUJDVMBSMZ
GPDVT
PO
EFWFMPQFE
B
IJHIQFSGPSNBODF
TIFFU
MJOF
UIFSNPGPSNJOH
FRVJQNFOU
SFTPVSDF
BOE
FOFSHZ
FGGJDJFODZ
8JUI
UIF
OFX
GPS
JOMJOF
BOE
PVUPGMJOF
VTF
#VJMEJOH
PO
UIF

&GGJDJFOU
"JS
$PPMJOH
&"$

QJQF
NBOVGBDUVS- TVDDFTT
PG
NPSF
UIBO

VOJUT
TPME
TJODF
Transparency and efficiency make
FST
BSF
OPX
FBTJMZ
BCMF
UP
JNQSPWF
UIF
RVBMJUZ
UIFJS
JOUSPEVDUJPO
B
TUBOEBSEJ[FE
TFSJFT
PG
extrusion more economical.
5P
TJNQMJGZ
NPOJUPSJOH
PG
BMM
FYUSVTJPO

MJOF
QBSBNFUFST
#BUUFOGFME
IBT
EFWFMPQFE

B
NPEVMBS
DPODFQU
DPOTJTUJOH
PG
UISFF
DPN-
QPOFOUT
FOFSHZ
NPOJUPSJOH
QSPEVDUJPO

NPOJUPSJOH
BOE
NBJOUFOBODF
NPOJUPSJOH
5IF

TZTUFN
JT
JOUFHSBUFE
JO
UIF
#.$UPVDI
DMJFOU
TFSWFS
PQFSBUJOH
TZTUFN
TP
UIBU
BMM
SFMFWBOU

EBUB
DBO
CF
DMFBSMZ
TIPXO
BU
BOZ
QMBDF
BOE

BU
BOZ
UJNF

For more information

#BUUFOGFME
&YUSVTJPO
(SPVQ
,PFOJHTUSBTTF


#BE
0FZOIBVTFO
(FSNBOZ
1IPOF

'BY

XFMDPNF!CFYCBUUFOGFMEDPN
XXXCFYCBUUFOGFMEDPN

plasticstoday.com/mpw MODERN PLASTICS WORLDWIDE • JANUARY 2010 43

MW1001_043
MW1001 043 43 12/28/09 4:00:32 PM

WORLD TOUR
sugarcane-based PE captures that same
amount of the gas.
Chemmes said the supplier has devel-
oped low-density, linear low-density, and
high-density polyethylene grades from
the ethanol, and even a polypropylene,
though this last as yet has only been
achieved on a lab scale. This year the
company will start a 200,000-tonnes/
year-capacity plant for PE, he said, add-
ing quickly that this smaller facility is
“just a start.” According to Chemmes,
the next facility will be capable of output
of 1 million tonnes or more annually.
“We want to be mainstream” with these
materials, not a niche, he stated.
Soon after the event, carton-creating
giant Tetra Pak tasked Braskem to supply
it with high-density polyethylene (HDPE)
derived from sugarcane for closure mold-
ing. Starting next year, Braskem will begin
supplying Tetra Pak with 5000 tonnes/year
of the “green” HDPE, a volume Tetra Pak
says is a bit more than 5% of its annual
HDPE requirement. Linda Bernier, direc-
tor of corporate PR at Tetra Pak, told
MPW that the company injection molds
some of its closures but also buys them on
the market, and has not yet decided who
will process the Braskem material.
That beverage company in Atlanta
Five thousand tonnes is barely a drop in the
plastics market ocean, but there is a huge
consumer-driven wave en route that will
drive demand much higher, very quickly,
predicted Cees van Dongen, a senior mem-
44 JANUARY 2010 • MODERN PLASTICS WORLDWIDE
MW1001_044
MW1001 044 44
Business, Strategies & Markets
Innovia’s Andy Sweetman: If
you’ve tried bioplastics before
but were disappointed, it’s time
to try again.
ber of The Coca-Cola Co.’s global Environ-
ment, Health & Safety Council. In a panel
discussion at the conference, he elaborated,
saying, “We expect a big wave. We think
commodity plastics will be substantially
replaced by bioplastics,” with consumers
driving the shift. While acknowledging that
change already is swift, “The wave will
increase in both height and speed” in the
coming years, he added.
Probably no brand owner will make
as big a splash as Coke, which, like Tetra
Pak, intends to start by replacing some of
its petroleum-based thermoplastics with
plastics sourced from renewable materi-
als. In a project that entered the market
in the past weeks, the beverage bottling
giant began a limited trial in western
North America and Denmark, replacing
up to 30% of each bottle’s polyethylene
terephthalate (PET) with material sourced
from renewable resources.
Van Dongen said the program is the
first along a path to greater sustainability.
In the U.S., about 30% of the bottles’
weight will be made from mono-ethylene
glycol (MEG) derived from sugarcane
and molasses; in Denmark the percent-
age of plant-derived MEG will be half
that but those bottles will include 50%
postconsumer recyclate (PCR). He said
there is not enough PCR-PET available in
the western United States for use in these
bottles, as most of the PET collected in
that part of the U.S. is exported to Asia.
MEG and purified terephthalic acid
(PTA) are the building blocks of PET.
EUROPE
Ethanol derived from sugarcane will be
fermented to create the bio-MEG, he
explained. According to Coke, the Plant-
Bottles will be the first beverage bottles
that include content derived from renew-
able resources that still can be recycled in
standard PET recycling streams.
The beverage bottler’s goal is to use 2
billion of the bottles by the end of 2010,
in a variety of products but including its
flagship Coca-Cola band. Future launch-
es are being planned in other markets,
including Brazil, Japan, and Mexico, and
for China’s Shanghai Expo in 2010.
Based on total tonnage, about 55% of
Coke’s packaging is PET, Dongen said.
Because PET bottles’ design has already
been nearly optimized to limit weight, and
because the material’s manufacture is the
most negative aspect of the material from
an environmental viewpoint, the best way
to limit the environmental impact of PET
bottles is to replace the PET, he said. The
PlantBottles are indistinguishable from
standard PET bottles, he added. The goal,
he said, is to develop feedstocks suitable
for 100% bio-based PET.
However, Dongen said Coke sees little
future for the current crop of biode-
gradable bioplastics as primary beverage
packaging. “For the next five to 10 years,
we don’t see biodegradable plastics as an
option for our bottles,” though the com-
pany is looking closely at their use for sec-
ondary and tertiary packaging, he said.
What do all of these developments
mean for processors? Change can be con-
fusing, but it also is notorious for creating
opportunities. The examples above are
in packaging, but in fact just as much
development is under way in increasing
the renewably resourced material content
in plastics destined for durable goods. It
seems a bright future awaits processors
able to track and take advantage of the
many developments. MPW
plasticstoday.com/mpw
Use the search tool at plasticstoday.
com/mpw, keyword “bioplastics,” to
find dozens of recent articles, includ-
ing more on that Coke project, on the
conference, and on a Korean team’s
recent announcement of an improved
means to produce PLA.
plasticstoday.com/mpw
12/22/09 9:10:22 AM
 r
"EWFSUJTFNFOU
r

CORPORATE PROFILE
Struktol
Intelligent Additive Solutions
Struktol Company of America
For more detailed product information,

S
USVLUPM
MPDBUFE
JO
4UPX
0IJP
64"
JT
please visit the Struktol website at www.4struktol.com.
B
HMPCBM
MFBEFS
JO
QSPWJEJOH
*OUFMMJHFOU

"EEJUJWF
4PMVUJPOT
UP
UIF
QMBTUJDT

JOEVTUSZ

4USVLUPM
BEEJUJWFT
FOIBODF

Struktol Products
When it comes to plastic additives,
Struktol’s vase chemical experience
is translated into the most intelligent
solutions available anywhere. Each of
Struktol’s 30+ plastic additives is tested
and retested to insure maximum product
quality and performance consistency.
Struktol’s products offer:
t
4VQFSJPS
WJTDPTJUZ
DPOUSPM
Can adding cost to my product
t
*NQSPWFE
NPME
SFMFBTF
t
3FEVDFE
GSJDUJPO
QMBUF
PVU
BOE
NPME

save me money?
splay
t
*NQSPWFE
NJYJOH
BOE
VOJGPSN
GJMMFS

dispersion
t
(SFBUFS
JNQBDU
SFTJTUBODF

Struktol Expertise
For more than twenty years, Struktol
has the production, technical and support
staff to meet the market needs in the
polymer industry.
t
0VUTUBOEJOH
DVTUPNFS
BOE

technical services
[ Struktol Intelligent Additive Solutions are designed to do just that.]
t
(SFBUFS
NBSHJOT
QFS
QJFDF

more product per run
t
4UBUFPGUIFBSU
MBCPSBUPSZ
» increase productivity
capabilities
t
$VTUPN
VOJRVF
QSPEVDU

development
» improve performance

» expand possibilities

For more information

www.4struktol.com
4USVLUPM
$PNQBOZ
PG
"NFSJDB

&
4UFFMT
$PSOFST
3PBE
4UPX
0)

To find out how our products can improve your process,
5FM



call 330.928.5188 or
5FM



email solutions@struktol.com
'BY



XXXTUSVLUPMDPN
DVTUPNFSTFSWJDF!TUSVLUPMDPN

plasticstoday.com/mpw MODERN PLASTICS WORLDWIDE • JANUARY 2010 45

MW1001_045
MW1001 045 45 12/29/09 3:51:37 PM
 COUNTDOWNTOK 9 months

Dateline: Oct. 27, 2010

Düsseldorf, Germany
t seems a bit early to think about a trade
I show taking place this October, but as
persons who have attended know, the K is
not just any trade show. Without a plan—
if you invest in plane fare and a hotel
room but not in planning your time on the
show floor—you will be
lost. With at least some
semblance of a plan,
you have good odds
of finding and learning
about the leading-edge
developments that will
define the industry for
the coming decade and
separate processors in
the black from those in
the red. K show has proven time and
That is where we again a great place to find
want to help. Our and befriend the former and
Countdown to K series to learn about the latter.
is designed to help with Finally, and very openly,
your planning to make we’ll build some excitement
the most of your atten- around the event and encour-
dance both at the show age your attendance at it.
and even around town Though we like to believe
(the downtown isn’t sometimes called expect to that reading our global cov-
“the world’s longest bar” for nothing). find there. erage—in our daily, weekly,
In this series, starting now and extending Success and monthly digital newslet-
to our October issue, we’ll offer you tips in the plas- ters or in our monthly flag-
based on our years of attending the show. tics process- ship magazine—is enough
We’ll throw out questions you prob- ing industry to keep you up-to-date, we
ably should have answered in your head depends in large part on two pillars: know that seeing is believing. You will
before you make the trip. And, of course, making and developing good contacts, never see more of the best of this industry
we’ll highlight the technology you can and being able to apply technology. The in one place than at the K.MPW

Basic K 2010 facts

Who: More than 200,000 attendees and 3000-plus exhibitors
What: World’s largest plastics trade show
When: Oct. 27-Nov. 3
Where: Düsseldorf, Germany
Why: Soak up more plastics-related info in one place at one time than is possible anywhere else

More info: Go to www.k-online.de

MPW: Official publisher of the K 2010 Show Daily newspaper

46 JANUARY 2010 • MODERN PLASTICS WORLDWIDE plasticstoday.com/mpw

MW1001_046
MW1001 046 46 12/22/09 9:11:10 AM

For information Contact: Cheryl Ackerman (516) 496-8891 • Fax (516) 496-8762 • cheryl.ackerman@cancom.com
Recruitment
PLASTIC PLACEMENT NATIONWIDE
Specializing in the Compounding and
Colorants Industries Since 1978
plasticsjobsearch.com
All inquiries handled in confidence
Fees paid by employer
JOHN ANDERSON & ASSOCIATES
ph: 817-514-1920 fx: 817-514-1922
email: johnanderson-assoc@airmail.net
Custom Services
Allgrind Plastics
CUSTOM GRINDING
• PULVERIZING
• GRANULATION Building, Real Estate & Equipment included.
• CRYOGENIC PULVERIZING
• SIFTING/BLENDING
N.J.: 908/479-4400
www.allgrind.com info@allgrind.com
Shaft Seals
®
for C.E.M.A.-standard and Metric
Screw Conveyors
- Low air consumption -
MECO quality in a standard seal
Manufactured by
WOODEX Bearing Company, Inc.
Georgetown ME 04548 1 800 526 8800
http://www.woodex-meco.com
plasticstoday.com/mpw
MW1001_047
MW1001 047 47
CLASSIFIED ADVERTISING
Custom Core Pins Nozzles
Custom Core Pins
AY-MAC PRECISION, INC.
679 Academy Ct. Windsor, CO 80550
Ph (970) 674-1661 Fax (970) 674-1811
email: aymacprecision@aol.com
“The Core Pin Specialists”
Business for Sale
Materials for
Sale/Wanted
For Sale
Custom Injection Molding Co.
CONTAMINATED
DON’T DUMP, WE CAN USE
Turnkey operation located in Wisconsin Also need clean cellulosics, Acrylics,
Profitable Polycarbonates or wide range of plastic scrap
Asking: $1.5 mil ENTIS ASSOCIATES
1600 Beacon St. Suite 506, Brookline, MA 02246
715-833-1510
Tel: 617 267 2322 Fax: 617 277 9493
Purging Compounds
ULTRA PURGE!
RECOMMENDED BY HUSKY INJECTION MOLDING SYSTEMS
Save time and reduce scrap during color
changes without stopping your production.
Benefits:
- Food Grade Certified and FDA Approved
- No Smell or Liquid Mess - Pellet Form
- Machine Safe - Non Abrasive
- Formulation for Every Application or
General Purpose Grade
Ultra Purge cleans: Use with:
• Screws • Injection Molding Machines
• Barrels • Blow Molding Machines
• Hot Runners • Extrusion Machines
• Accumulators • Hot Runners
Ask about our NEW
“COLOR CHANGE ON THE FLY” TECHNOLOGY!
For more information or a FREE SAMPLE,
call 714-708-2663 or visit www.ultrapurge.com
MODERN PLASTICS WORLDWIDE • JANUARY 2010 47
12/22/09 11:21:20 AM
 CLASSIFIED ADVERTISING
For information Contact: Cheryl Ackerman (516) 496-8891 • Fax (516) 496-8762 • cheryl.ackerman@cancom.com
Professional Services
TIME-CRITICAL CONFIDENTIAL
PROBLEM SOLVING SINCE 1973
• CHEMICAL ANALYSES
AND CHARACTERIZATION
• THERMAL ANALYSIS AND RHEOLOGY
• MECHANICAL TESTING
• ORGANIC SYNTHESIS
• LAB COMPOUNDING, PELLETIZING
AND INJECTION MOLDING
• FAILURE ANALYSIS
• QUALITY ASSURANCE
• CHEMICAL RESISTANCE
• ACCELERATED WEATHERING
• FDA EXTRACTIONS
•R&D
LABORATORIES, INC.®
http://www.polyhedronlab.com
48 JANUARY 2010 •
MW1001_048
MW1001 048 48
Machinery for Sale/Wanted
WWW.TIMBERLINEMACHINERY.COM
$2,000,000 Inventory
Injection Molders
Blow Molders
Extruders
Call Ed Makepeace
Ph: 603-889-7233 (USA) tmi@timberlinemachinery.com
Fax: 603-889-7300 (USA) 100 MACHINES IN STOCK
Buying and Selling Quality,
Used Plastics Machinery
www.hunterplastics.com
100 Pratts Junction Rd., Sterling, MA 01564
Ph: 978-422-8222
Fax: 978-422-8223
Solid Waste Management Products
REQUIRED pre-owned blow/injection
moulds in excellent working condition for
solid waste containers, trash cans, bins, etc
from 200 ltr - 3200 ltr capacity.
Also required suitable blow/injection mould-
ing machines to operate the above moulds.
Contact : email : projects37@gmail.com
Modern Plastics Worldwide
Classified Advertising
Are you looking to get
Cylinder Engraving worldwide recognition and
exposure for your company?
A small ad in Modern Plastics reaches
over
60,000
qualified readers of the print
Jacobsen Lenticular Tool & Cylinder version around the world.
Engraving Technologies (JacoTech)
Our digital subscribers top over
• Lenticular Design & Cylinder Engraving •
Cylindrical Extrusion/Embossing/Casting 20,000.
Plastic Processing Moulds • Optical Moulds:
• PLASTICS Lens Arrays for Solar Concentrators, We give you the best bang for your
Display, Security, Illumination, Diffusers, buck.
• POLYMERS Reflective, Decorative, etc • Lenses,
Prisms, V-Grooves, 4-Side Pyramids, In these hard economic times you
• RUBBER Concave/Convex, Faux, etc. • 1-5 Multi Axis need to make sure that every
CNC Diamond Turn/Mill – 42” OD x 177”
• ASTM dollar counts.
Email: GJ@JacoTech.com /www.JacoTech.com Contact: Cheryl Ackerman
281-879-8600 Phone: 630-467-0900 / Fax: 630-467-0901 cheryl.ackerman@cancom.com
105 E. Irving Park Rd. Itasca, Illinois 60143 USA
FAX 281-879-8666
10626 KINGHURST 516 496 8891
HOUSTON, TX 77099
MODERN PLASTICS WORLDWIDE plasticstoday.com/mpw
12/22/09 11:21:24 AM
 CALENDAR OF EVENTS ADVERTISER INDEX
JANUARY COMPANY PAGE
7-10 International CES (Consumer Electronics Show), Las Vegas, NV
Consumer Electronics Assn. | +1 301-694-5243
Adsale Exhibition Services Ltd. 36
cesreg@ce.org; www.cesweb.org Arburg GmbH + Co KG BC
9-12 PlexpoIndia 2010: 5th National Plastics & Packaging Exhibition
Ahmedabad, Gujarat, India Battenfeld Extrusionstechnik GmbH 43, IBC
Gujarat State Plastics Manufacturers Assn. Canon Communications LLC Trade Events 30
+91 79-2657-9204
info@plexpoindia.com; www.plexpoindia.com Exair Corp. 5, 23
12-14 Automotive News World Congress, Detroit, MI Fong Kee International Machinery Co. Ltd. 37
Automotive News | +1 313-446-0326
congress@autonews.com; www.autonews.com InnoPlast Solutions Inc. 33
19-22 International Builders Show, Las Vegas, NV Korea E+EX Inc. 6
National Assn. of Home Builders | +1 847-940-2393
nahb@experient-inc.com; www.buildersshow.com Leistritz Extrusionstechnik GmbH 35
26-29 Interplastica, Moscow, Russia
Messe Düsseldorf North America | +1 312-781-5180
Macro Engineering & Technology Inc. 21
erowe@mdna.com; www.mdna.com Messe Düsseldorf GmbH 32
27-28 Managing SVHCs under REACH and
Understanding & Implementing CLP, Brussels, Belgium
Reifenhäuser GmbH & Co. KG Maschinenfabrik 41
iSmithers | +44 1939-250383 Struktol Co. of America 45
conferences@ismithers.net; www.ismithers.net/conferences
Technovel Corp. 11
FEBRUARY Tempco Electric Heater Corp. 27
1-2 BIOMEDevice Europe, Pharmapack, Paris, France
Canon Communications LLC
Univar USA IFC, 25, 29
+1 310-445-4200 Vecoplan LLC 31
www.canontradeshows.com
9-11 Plastec West, MD&M West, Electronics West, Weima America Inc. 17
Pacific Design & Manufacturing, WestPack, ATX West, Windmöller & Hölscher 15
Green Manufacturing Expo West, Anaheim, CA
Canon Communications LLC Zambello Riduttori Group 19
+1 310-445-4200
www.canontradeshows.com
16-18 Thermoplastic Concentrates 2010, Phoenix, AZ
Applied Market Information LLC MODERN PLASTICS WORLDWIDE
+1 610-478-0800 UPCOMING DIRECTORIES
lf@amiplastics-na.com; www.amiplastics-na.com
21-24 International Polyolefins Conference 2010, Houston, TX
Society of Plastics Engineers
MEDICAL
+1 713-829-9226 February 2010
suzbiggs@comcast.net; www.spe-stx.org/polyolefinsconference.htm
Contact Iris Topel
MARCH Tel: +1 718-478-8104
2-3 Plastics Recycling Conference 2010, Austin, TX Fax: +1 718-478-8105
Resource Recycling Inc. | +1 503-223-1305, ext. 118 iris.topel@cancom.com
jef@resource-recycling.com; www.plasticsrecycling.com
5-9 Taipei Plas, Taipei, Taiwan
Taiwan External Trade Development Council
+866 2-2725-5200
www.taipeiplas.com.tw
8-10 Global Plastics Environmental Conference (GPEC) 2010 Extrusion Monthly and e-Weekly:
Orlando, FL Free newsletters from MPW to help you get the
Society of Plastics Engineers
+1 203-740-5452
information your business needs.
www.4spe.org
8-10 Plastics Modification via Additives, Compounding & Coatings Sign up at plasticstoday.com/newsletters
Atlanta, GA
InnoPlast Solutions
+1 973-446-9531
www.innoplastsolutions.com MODERN PLASTICS WORLDWIDE (ISSN 0026-8275) is published monthly, except for February, May, July,
14-16 International Home & Housewares Show 2010, Chicago, IL and December, by Canon Communications LLC, 11444 W. Olympic Blvd., Los Angeles, CA 90064-1549.
International Housewares Assn. Periodicals postage paid at Los Angeles, CA and at additional mailing offices. Canada Post International
+1 847-692-0100 Publications Mail Product Sales Agreement No. 40612608. Canada Post return address: BleuChip
www.housewares.org International, P.O. Box 25542, London, ON N6C 6B2.

APRIL Modern Plastics Worldwide has no connection with any company of similar name. The name “Modern Plastics”
19-22 Chinaplas 2010, Shanghai, China is registered with the U.S. Patent Office. ©2010 Canon Communications LLC. All rights reserved. Printed in
the USA. Copying for other than personal or internal reference use without the express permission of Canon
Adsale Exhibition Services Ltd. | +852 2516-3374
Communications LLC is prohibited. Requests for special permission, or bulk orders should be addressed to
www.chinaplasonline.com
the publisher.
26-28 Emerging Trends in Plastics Packaging, Atlanta, GA
InnoPlast Solutions
SUBSCRIPTIONS: Please send all circulation correspondence, subscription orders, and change of address
+1 973-446-9531 notices to Modern Plastics Worldwide, P.O. Box 3568, Northbrook, IL 60065 USA. For subscriber service
www.innoplastsolutions.com call +1 847-559-7590, fax +1 847-291-4816, or e-mail mpw@omeda.com. Basic subscription price in the
USA and possessions is 1 year $59.00, 2 years $99.00, 3 years $139.00. Canada is 1 year $110.00, 2 years

plasticstoday.com/mpw $199.00, 3 years $295.00. All other countries are 1 year $150.00, 2 years $250.00, 3 years $300.00. Please
allow 6-8 weeks for shipment. Back issues (except for Encyclopedia issue) $25 each, plus S/H.

Seminars, symposiums, webinars—there’s more at POSTMASTER: Send all address changes to Modern Plastics Worldwide, P.O. Box 3568,
plasticstoday.com/mpw. Just click on Events. Northbrook, IL 60065 USA.

plasticstoday.com/mpw MODERN PLASTICS WORLDWIDE • JANUARY 2010 49

MW1001_0TXT49
MW1001 0TXT49 TXT49 12/30/09 1:31:16 PM
 SPOTLIGHT Ipoh, Malaysia
Hat Yai
ON POLYPARTS Sadao
Kota Ba
e Town Kua
Ipoh
Malaysia

Ku

Kuala L
J

Serving as an all-round service provider,

from tool design through to subassembly,
with an accent on processing engineering
thermoplastics, has placed the processor
in good stead when it comes to retaining
clients and expanding business amid com-
petition from lower-cost neighbors.

Y.A. Liew’s ethos shifted manufactur-

emphasizes capabilities
Liew goes further in classifying his
company as a precision engineer-
ing firm that just happens to be in
plastics, rather than a processor of
precision plastic components. “Nowa-
days, a customer typically wants to
reduce its number of vendors, so we
try to do as much as we can, includ-
ing design and fabrication of injection
molds, and qualifying and sourcing
metal or rubber components for sub-
sequent assembly,” he explains. “We
get involved deeply with nonplastic
components, and we have to ensure
we have a capable supply network.”
In-house, Polyparts operates 25 injec-
tion machines from Arburg, Demag,
Fanuc, and Nissei. All are equipped with
hardened screws and barrels for the run-
ning of engineering plastics containing up
to 40% glass fiber. Secondary processes
handled include cleanroom spray paint-
ing, pad printing, ultrasonic cleaning
and welding, and assembly. Key indus-
tries served include consumer electronics,
industrial electronic components, office
automation, computer peripherals, and
automotive electronics.
Liew remains sanguine regarding
competition from China, and this despite
ing facilities to the
Mainland. “China
probably has com-
panies with similar
capabilities to us, but they are just as
expensive,” he says. “Utility and logistics
costs are higher, and the [local currency]
Renminbi is also strong,” he also notes.
“Chinese processors are also losing a lot of
their government incentives, coming to be
subject to more regulations, and they now
face minimum wage requirements.”
Backing up his claims with substance,
Liew says several European clients, includ-
ing manufacturers of customized telecom-
munications equipment, solar and heating
controls, and micromotors, have desig-
nated Polyparts as their Asia-Pacific supply
hub for specialized components that are
shipped to Thailand, Singapore, China,
and sometimes even the United States.
“They view us as a strategic vendor with a
good logistics advantage,” he says.
Liew notes that multinational custom-
ers, wherever they are in the world, want
to find suppliers who can delivery consis-
tently, and not just pass the initial qualifica-
tion test. Customers also want reassurance
that if they consign a mold for low-volume
runs, it will be looked after. “We handle
runs of 500 or 1000 as long as it fits in
with our core capabilities,” says Liew.
The Malaysian business culture is
also a plus, according to Liew, who says,
and this is a major trust builder.”
Liew says 100% of Polyparts’ produc-
tion ends up offshore, either as direct
exports or indirect exports comprising part
of finished product exports. This presents
challenges in ensuring that part quality is
not compromised in any way. “We have to
make our components as durable as pos-
sible and ensure that we have full control
over our processes,” he says. “We cannot
afford to have problems when the part is
halfway around the world.”
Polyparts has never considered ventur-
ing overseas in search of lower labor costs
and a broader footprint. “What happens
when China becomes more costly, which
will happen?” he asks. “Do you then
move to India, or Vietnam, or Africa, or
South America? You will always be on the
move!” Liew explains that his company’s
“global footprint” entails exhibiting at the
K and Hannover shows rather than hav-
ing a factory footprint. “If your priority is
chasing low labor costs, you lose sight of
your real competencies,” he says.
Polyparts prefers to look inwards to
find its true capabilities, and recognizes
the need to continually innovate in terms
of technology, quality management sys-
tems, and business processes. Says Liew,
“My definition of innovation is more
than just technical capabilities. It also
includes the way you go about doing
business. It’s about building confidence
with your customers.” MPW

Malaysia’s electronics industry having suf- “Our business culture is close to what
fered at the hands of OEMs that have Western companies are accustomed to, Stephen Moore • stephen.moore@cancom.com

50 JANUARY 2010 • MODERN PLASTICS WORLDWIDE plasticstoday.com/mpw

MW1001_050
MW1001 050 50 12/22/09 9:12:58 AM
 Battenfeld Extrusion Group
Global: 5 production sites on three continents
and a worldwide sales network
– Everywhere close by.
Competent: Extruders and complete, modular
extrusion lines, perfectly matching components
– Everything from a single source.
Solution driven: Flexible, customized solutions
for pipe, profile, film and sheet extrusion
– Our know-how for your success.

ideas

Battenfeld Extrusion
Battenfeld American Maplan B+C Extrusion Systems (Foshan) Ltd. Kabra Extrusiontechnik Ltd.
Extrusionstechnik GmbH Corporation 2 Jinxiang Road, Daliang, Shunde,
Königstraße 53 823 S. By-Pass, P.O. Box 832 Foshan, Guangdong, PRC “Kolsite House”, Veera Desai Road,
D-32547 Bad Oeynhausen USA - McPherson, KS 67460 P.C.: 528300 Andheri (West), Mumbai - 53, India
Phone +49 (0) 5731 242-0 Phone +1 620 241 6843 Phone +86 757 2238 0112 Phone +91 22 2673 4822 25/6695 2681
Fax +49 (0) 5731 27124 Fax +1 620 241 2142 Fax +86 757 2238 0195 Fax +91 22 2673 5041/6695 2680
welcome@bex.battenfeld.com welcome@maplan.com welcome@bcc-extrusion.com sales@kolsitegroup.com
www.bex.battenfeld.com www.maplan.com www.bcc-extrusion.com www.kolsitegroup.com

MW1001_051
MW1001 051 51 12/22/09 3:36:48 PM
 High-quality: automatic Productive: innovative Fast: servo-electric clam-
clamping force control drive concept ping unit

ne
rgy-efficien

t
e

High performance. The new ALLROUNDER H machines. Perfect for energy-efficient,

cycle-time optimised thermoplastics processing. Clamping units with servo-electric precision. Injection
units with dynamic accumulator technology for increased hydraulic performance. HIDRIVE: Powerful
hybrid machines at an extremely attractive price. Made by ARBURG - Made in Germany.

www.arburg.com

ARBURG GmbH + Co KG
Postfach 11 09 · 72286 Lossburg / Germany
Tel.: +49 (0) 74 46 33-0
Fax: +49 (0) 74 46 33 33 65
e-mail: contact@arburg.com
| (BR) Brasil: ARBURG Ltda. · Tel.: +55 (11) 5643 7007 · brasil@arburg.com | (CN) China: ARBURG (Shanghai) Co., Ltd. · Tel.: +86 (0) 21 5488 8866 · shanghai@arburg.com |
ARBURG Machine & Trading (Shenzhen) Co., Ltd. · Tel.: +86 (0) 755 8343 3750 · shenzhen@arburg.com | (HK) Hong Kong: ARBURG (HK) Ltd. · Tel.: +852 (2) 886 3007 ·
hongkong@arburg.com | (MX) Mexico: ARBURG S.A. de C.V. · Tel.: +52 55 5363 7520 · mexico@arburg.com | (MY) ARBURG Sdn Bhd · Tel.: +60 (0) 3 5636 6213 ·
malaysia@arburg.com | (SG) Singapore: ARBURG PTE LTD. · Tel.: +65 6778 8318 · singapore@arburg.com | (US) USA: ARBURG, Inc. · Tel.: +1 (860) 667 6500 ·
usa@arburg.com |

MW1001_052
MW1001 052 52 12/22/09 9:13:17 AM