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Aerogen featuring special flame treatment technology


Aerogen, a surface adhesion improvement specialist in the UK, will present its FT Auto FRC (Flame Treater Automotive Flow Ratio Control) flame treatment combustion generator device along with a variety of flame treating burner tools at Fakuma 2015.


The FT Auto FRC is a combustion generator device that is typically utilised throughout the automotive industry, providing the burner tool with a fuel mixture for the purpose of flame treatment surface adhesion improvement.


Applications for the equipment include flaming of car bumpers prior to painting, flaming of premium car instrument panels prior to laminating with leather, flaming of car interior components prior to flocking.


The FT Auto FRC features process and safety devices for autonomous flame operation managing the flame to an optimum condition for high quality reliable repeatable results with the ability for the auditing of process parameters.


This technology is a combination of flame optimization for the purpose of surface adhesion improvement and flame optimization in terms of efficient fuel usage.


Beck Automation launches Beck-Flex IML system


Beck Automation is launching its latest Beck-Flex IML system, a side-entry automated IML system designed for high flexibility.


Different types of labels, such as three or five sided labels, with or without closed edges, flat labels and 360° labels should all be possible with the Beck-Flex.


When re-tooling from one lid to another, Beck Automation specifies a changeover time of less than 30 minutes. Re-tooling from a lid to an inside gated container takes less than 60 minutes.


Along with fast changeover times, Beck-Flex can decorate labeled lids and containers up to dimensions of 220x100mm. The minimum diameter is 40mm, the maximum diameter is around 200mm. For containers, the maximum product height is 170mm.


In terms of performance, cycle times of around 4s with an intervention time of up to 1s are possible with the Beck-Flex. The system is designed for IML applications on injection molding machines with a maximum clamping force of 420 metric tons.


Covestro makes debut at Fakuma


Covestro, formerly known as Bayer MaterialScience, appears at a major trade show for the first time under a new identity.


Whereas the first syllable “co” stands for collaboration with partners, “vest” refers to investments in modern, large-scale production facilities. Finally, “stro” is derived from the English word “strong”.


One of Covestro’s highlights will be the coloration of its polycarbonates (PC), a key product of the company. Not just a wide range of shades, but fluorescence effects and even transparently and translucently colored products are available. Rounding out the portfolio are UV-resistant, lightfast and tailored infrared-absorbing grades.


The latest developments at Covestro enable increasingly precise surface formation. One way to achieve this is with sophisticated, dynamic tempering during the injection molding process.


The wall of the mold is heated prior to injection; cooling does not begin until after the cavity has been filled. This enables the targeted production of smooth and structured surfaces as desired.


Another topic is composite materials for lightweight, yet robust structures. Covestro is now planning to enter into the production of composites with the high performance plastic polycarbonate, primarily for the automotive, transport and IT industries.


The new materials are particularly thin and lightweight, and the solutions produced so far offer properties superior to those of existing solutions based on e.g. aluminum, according to the company. Furthermore, they are robust, freely formable, easy to process and can be recycled multiple times.


EREMA saving RegrindPro for Fakuma


EREMA is to present its highlight of the year - RegrindPro - the latest and highly efficient technology for the recycling of regrind material.


Recycling regrind as an alternative to virgin material has enormous potential for processors of plastics. With raw material prices increasing all the time, the demand for the processing of regrind to make high-quality recycled pellets is growing more and more, especially in the thick-walled packaging, electronics (WEEE) and automotive sectors.


The thick-walled input material (HDPE, PP, ABS, PS, etc.), however, requires a specific treatment process which is designed to be able to handle mixed fractions with varying compositions, high bulk density and moisture, plus strong and varying contaminants through a very wide variety of impurities.


The recycled pellets also have to meet exacting quality standards to be able to make end products from them with top surface quality and particularly high recyclate content.


With the new product INTAREMA RegrindPro, EREMA has succeeded in developing a plant system which is designed exactly for these thick-walled materials. Thanks to gentle processing and efficient filtration, the new system enables the recycling of regrind into application-oriented secondary raw materials.


Ettlinger highlights a complete range of melt filters


At Fakuma, Ettlinger Kunststoffmaschinen will show its complete range of high performance melt filters, designed for continuous processing of any kind of feedstock from virgin material to heavily contaminated recycled plastics.


Ettlinger’s ECO melt filters, recently launched in the market, have been specially developed for film and sheet extrusion. Rated for a maximum contaminant level of 1.5% by weight, they enable cross-linked and high-molecular fractions contained in the melt to be removed when processing virgin material along with any gels or partial impurities.


ECO melt filters come in two different sizes: the ECO 200 for throughputs up to 1,000kg/h and the ECO 250 can process up to 3,000kg/h. In addition to the “standard” ECO model, this filter can also be supplied as a polyethylene terephthalate (PET) version for filtering easy-flowing melts such as polyester or PA.


Ettlinger’s ERF melt filter series are particularly suitable for heavily contaminated feedstock. Continuous processing is guaranteed with up to 18% contamination by weight.


Ettlinger ERF filters are offered in three sizes: in addition to the new ERF 500 with throughputs up to a maximum of 6 tons per hour (t/h), an ERF 250 with a maximum throughput of 3t/h and an ERF 200 which can process up to 1t/h are also available.


Whereas conventional piston screen changers can require many screen changes per day, each one causing the filtration process to be interrupted, both the ECO and the ERF achieve a service life of several weeks with no disruptions to production. The screen of both filter types remains open throughout the production phase to permit stable processing with a constant volume and pressure.


The central component of the ECO and ERF melt filters is a rotating, cylindrical filter screen with millions of conical holes that can be supplied with a wide variety of ratings.


When melt flows through these filters, contaminants are retained on the outside of the screen while the cleaned melt on the inside of the drum travels to the downstream pelletizing machine or mold via a system of flow channels. The rotary motion of the filter drum simultaneously supports the blending effect and ensures optimal homogeneity in the melt.


geba announces new addition to its TPU portfolio


geba Kunststoffcompounds GmbH will present its portfolio of engineering and high performance plastics at Fakuma 2015.


The highlight of this year’s show is the Desmovit DP R CF which was jointly developed earlier this year by geba and Covestro. The thermoplastic polyurethane (TPU) series is ideal for projectors, sports equipment applications, protective cases for tablets and smartphones, and for use in durable housings for tools, watches and binoculars.


Depending on the level of reinforcement, the carbon-reinforced TPU is also anti-static, meaning that it can be used in the production of industrial rollers and cogs.


Herbold puts focus on efficient recycling solutions


Herbold Meckesheim GmbH will focus on energy and cost effective recycling solutions at Fakuma.


Herbold plastcompactors, available for throughputs of up to 1,500g/h, are able to agglomerate a wide variety of materials which includes thermoplastic materials such as fibers, small tapes, foams, films, stretch or thin films, fine particles, powder or shavings.


Its newly developed SB series granulators are ideal for all types of size reduction applications from PET bottles to pre-shredded material. As a secondary granulator in continuous operation for barrels and hollow bodies, an SML 60/100 SB (rotor 600x1,000mm, drive 75kW), can obtain a throughput of 3,400kg/h (screen size 8mm).


The construction design of the SMS series has been overhauled by Herbold to cope with demanding heavy-duty applications in one single step. These machines are manufactured with rotor widths ranging from 600mm to 2,000mm and with drive capacities between 45kW and 315kW. The knife design is segmental, thus ensuring a quick and easy exchange of the cutting tools.


For processing large waste plastic pipes up to a diameter of 3m, Herbold has designed a new shredder of the HOS series.


Kraiburg unveils new series for automotive and consumer applications


Kraiburg TPE will unveil several new compound series for automotive and consumer applications at Fakuma.


For consumer applications, the German thermoplastic elastomer (TPE) supplier developed a new compound series with a high cost-effectiveness ratio: these TPEs feature improved adhesion to engineering thermoplasts such as PC and ABS.

Innovations in the materials for “slit valves” - valves made of food-compliant TPE - will also be presented: Kraiburg TPE offers new compounds with the US Food & Drug Administration (FDA) and EC 10/2011 food certifications.


Also in time for Fakuma the THERMOLAST V compound series will go into production for seals in demanding applications such as under the hood. The new series features high temperature resistance, an improved compression set and good adhesion to polyamides (PA).


LPKF appears with a wealth of laser welding eqipment


LPKF, the specialist for laser plastic welding, is showcasing a broad-based product portfolio at Fakuma.


LPKF InlineWeld systems are space saving and flexible. Laser sources and controls are housed in a separate module. The compact welding head can be integrated into the original production lines.


The stand-alone units of the LPKF PowerWeld line are all-rounders, suitable for all production configurations. Depending upon handling and laser source, they can be configured for small, medium or large series production runs.


The LPKF TwinWeld3D is a robot-assisted hybrid welding system designed for welding large 3D free form components in thermal fields. They are suitable for visible, high quality, economic welds, e.g. for auto taillights. The rotary table helps reduce non-productive times and can produce pairs of taillights in one process.


LPKF PrecisionWeld complements and extends the spectrum of applications in laser plastic welding. The new LPKF ClearJoining laser process can weld transparent plastics without requiring absorbent additives. The system has a positioning accuracy of only 10µm, creating welded seams of 100µm width, making this innovative system also suitable for ultrafine microfluidic components with sensitive channel structures.


Visitors can also review the transmission properties of plastics at  LPKF’s booth with the new TMG 3 unit.


The device determines transmission properties at the welding laser wavelength. The material tests can be performed with a stand-alone system or integrated in the production line.


Milacron emphasizes comprehensive expertize in injection molding


Milacron Inc. will have a major presence at Fakuma 2015, with new processing technology combining the individual strengths of its brands Ferromatik, Mold-Masters, Uniloy, DME, Tirad and CIMCOOL.


Elektron Evolution, Milacron’s new all-electric injection molding machine, uses the advanced Ferromatik-Series control system Mosaic. The machine reportedly uses 60% less energy and 90% less water than hydraulic injection molding machines.


Its stroke precision of servo-driven axis is also significantly greater than top hydraulic systems. With no oil disposal, leaks or slipping hazards, Elektron Evolution is suitable for clean room environments.


At Fakuma, the Elektron Evolution (EO 75) will be producing a two-component part made of PA 6 GF 30 and TPE using a mold from moldmaker Braunform. The TPE will be injected using Mold-Masters E-Multi auxiliary injection unit.


Novel plasticizing system from Nordson Xaloy for high clarity parts


Nordson Xaloy is introducing a new plasticizing system that combines special component designs and flow surfaces to help injection molders of optical-grade PC, acrylic, and similar polymers to produce high clarity parts.


The Nordson Xaloy PC Molding System addresses common challenges encountered in molding optical-grade polymer by delivering a homogeneous melt with a minimum level of the shear that can cause yellowness or discoloration in PC; and by avoiding polymer sticking points or “dead” spots where blemishes such as black specks can form.


Nordson recommends the system for processing lens-grade or colored PC for automotive lighting, eyeglasses, optical disks, and electrical and telecommunications components.


The components of the Nordson Xaloy PC Molding System include:


- Pulsar II Mixing Screw Modified for PC. Nordson has developed a version of the Xaloy Pulsar screw whose design minimizes the color degradation of PC caused by shear during mixing and prevents the sticking of material at sites on the screw where specks can form.


- Barrel with X-800 Inlay. Composed of a nickel-based alloy with tungsten carbide, the X-800 inlay provides an especially hard surface with release properties that prevent polymer from sticking to the barrel.


- Valve for Free-Flowing Melt Delivery. Nordson provides a valve with internal geometry designed for PC viscosity and recommends different valve types for screw diameters less than 80mm, screw diameters greater than 80mm, and flame retardant compounds, respectively. Valves with DyClad hard chrome plating are available to provide extra-hard, frictionless surfaces.


- Nickel-plated end cap designed to smoothly transition the PC melt from the screw to the injection nozzle.


PolyOne to unveil new color choices for reSound NF


New developments in natural fiber reinforced materials, conductive thermoplastics, and specialty engineered materials for metal replacement will be the highlights for PolyOne at Fakuma.


The US material supplier will also update on the status of developments, such as its reSound NF natural fiber reinforced solutions. Introduced in March 2015, these sustainable formulations - with at least 30% engineered natural fiber by weight - offer an alternative to glass fiber reinforced PP compounds, with comparable mechanical properties at 5-10% lower density.


Currently, reSound NF is available in black, brown or natural. At Fakuma 2015, PolyOne will announce the availability of the material in other colors. The company will also reveal the development of reSound NF formulations for use in the extrusion process for applications in building and construction, sport and leisure, furniture manufacturing, and other industries.


In addition, PolyOne will present an update to its 3D-MID (three dimensional molded interconnect device) manufacturing technology, made possible due to the thermally conductive properties of the company’s Therma-Tech engineered polymers.


As said, a developer has succeeded in establishing a time and cost saving means to produce the 3D-MIDs serving as heat sinks in LED lighting, which could prove an alternative to the complex printed circuit boards now fairly ubiquitous in these applications.


SOMOS T140 auxiliary dryer from ProTec makes maiden appearance at Fakuma


ProTec Polymer Processing will introduce the new energy-efficient large SOMOS T140 eco auxiliary dryer with its updated design.


The new SOMOS T140 eco auxiliary dryer provides higher material throughput to the SOMOS T/TF eco series of mobile dry air dryers, offering hopper volume of 400L and dry air throughput of 140m³/h.


The new dryer also features an updated touchscreen controller which offers numerous drying parameters tailored to the specific material as well as versatile documentation functions.


Like all SOMOS auxiliary dryers, the new T140 eco consists of a dry air generator and an insulated stainless steel drying hopper. Other features include automatic adaptation of drying air volume to material throughput (ALAV) and the SUPER SOMOS control mechanism for adapting desiccant regeneration to the particular moisture loading of the adsorbent.


Drying temperatures of 60°C to 140°C at a drying air dew point temperature of -35°C are standard while a high-temperature version is also available for drying temperatures of up to 200°C.


Reduction Engineering announces latest version of cantilevered strand pelletizer


Reduction Engineering GmbH has introduced the latest cantilevered strand pelletizers, SGS-E6 with working widths of 100mm, 200mm and 300mm.


The latest product with improved cutting geometry reduces the unguided length of the strands between the feed-rolls and the cutting edge and extends the processing range especially when processing very soft and/or elastic materials.


The SGS-E6 is capable of strand speeds up to 120m/min (with and without adjustment of the pellet length), increasing the overall performance of the pelletizers.


Numerous improvements around the cutting tools improve access and maintenance when changing product and reduces unproductive downtime.


For easier operation, especially when using one pelletizer on multiple production lines with different spatial requirements, the SGS-E6 pelletizers are now equipped with a detachable control panel as an option.


This allows setting and changing of process parameters from different positions around the machine. Along with this the safety concept of the pelletizer was completely re-engineered and offers a higher standard mechanically and electrically.


Sigma presents the latest version of SIGMASOFT Virtual Molding technology


At Fakuma, Sigma Engineering GmbH will present the latest version of its SIGMASOFT Virtual Molding technology, which makes it possible to combine for the first time the flow simulation of melt and tempering media.


Until now, the tempering media was assumed as a fixed geometry with a defined global coefficient of heat transfer (HTC). This assumption about homogeneous performance of the tempering channel was accurate for simple tempering channels.


However, for complex tempering layouts the effects of water flow were ignored. This simplification produces inaccuracy in the prediction of the part cooling behavior, and, in worst case, it also affects the prediction of the warpage behavior.


The newest SIGMASOFT version 5.1, allows a simultaneous prediction of flow effects in the melt and the tempering media. In this way it is possible not only to calculate the local cooling performance, determined by the flow rate, but the user also clearly recognizes the poor tempered areas, which are caused by flow stagnation in the cooling channels.


Further improvements available in SIGMASOFT v5.1 contain the implementation of new material models, besides a totally renewed user interface.


Teknor Aepx’s new styrenic TPE series for window seals


A new series of styrenic block copolymer elastomers from Teknor Apex Company exhibits performance comparable to that of thermoplastic vulcanizates (TPV) widely used in window gaskets while offering new options for building product manufacturers.


Unlike most TPVs used for weatherproof seals in metal, wood, or polyvinyl chloride (PVC) window frames, Monprene IN-23000 Series styrenic thermoplastic elastomer (TPE) are readily available in small lots and pre-colored grades and require no pre-drying.


Some grades in the new Monprene IN-23000 series can be processed with the same tooling used for PVC profiles at similar throughput rates and die pressures.


In the co-extruded structures widely used for window gaskets, the new series shows good adhesion to PP or high-modulus TPE substrate that serves as the rigid supporting component. They provide sufficient stiffness to facilitate window assembly and resist staining from paints.


Like TPVs, Monprene IN-23000 Series TPEs exhibit the end-use properties essential for air and moisture-proof window gaskets, including rubberlike seal recovery, low temperature toughness, and UV resistance.


Increases pellets purity with Tomra’s optical sorter


Tomra’s Genius optical sorting machine is able to sorts polymer and resin pellets based on color, structure and shape, improving the quality of the end product by detecting and removing all kinds of defects and foreign material such as cross-contaminations, discolorations, black specks, light-yellows, dye drips, burn specks, twins, angel hair and tails.


The Genius pellet sorter offers an advanced optical sorting solution combining different cutting-edge sensor technologies in a one-pass process. This process includes three major sections that are the fundamental components of optical sorting: product handling, high resolution detection and high accuracy ejection.


The stability of the pellets is controlled thanks to a fast moving conveyor-belt offering high capacity product handling.


With high resolution cameras and lasers, the Genius sorter offers different inspection technologies in different inspection zones. For instance RGB or color cameras focus on discolored pellets, whilst the double-sided high resolution monochromatic cameras detect micron specks in one pass.


Wittmann rolls out new FEEDMAX B203 net single loader


The Wittmann Group will be introducing its new FEEDMAX B203 net, which, despite its appearance as a single loader, can reach a high material throughput and handle material conveyance over longer distances with high performance blowers.


The word net in the name FEEDMAX B203 net points to the possibility of controlling several units simultaneously via a single remote touch control unit. The self-explanatory colored display of the control system includes a status indicator and enables setting of loading times, dosage ratios and cleaning cycles for up to six units.


The FEEDMAX B203 net is made of stainless steel. Its ambiLED signal lamp makes it possible to read the loader’s current operational status from a considerable distance. The lamp signals any shortage of material in the conveying process, which may happen, for example, if the material container needs to be refilled or replaced.


The material inlet of the new loader is also made of stainless steel and consists of two parts: a massive stainless steel casting with about 5mm wall thickness, and a reducer also made of stainless steel. The latter is connected to the casting by a clamping ring and serves to connect the feed hose.


The FEEDMAX B203 net can be combined with vacuum generators of up to 7.5kW capacity, a standard value taken over from the FEEDMAX B200 series. The flap lid is completely separated from all connections, which is easy to open for any cleaning which may become necessary. The slanted aperture provides unrestricted access to the complete interior of the material loader.     

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