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May 2013

ELECTRICALLY-CONDUCTIVE PLASTICS CLARIFIERS AND PROCESSING AIDS WOOD-PLASTIC COMPOSITES CHINAPLAS 2013 SHOW PREVIEW

The international conference on business strategies and new technologies for compounders
Compounding World magazine and AMI are pleased to announce the first Compounding World Forum. This international conference will feature a high-level program brought together by the editorial team of Compounding World, exploring and developing many of the magazines most popular themes in a live event. It will cover business strategies and new materials technologies, as well as providing practical advice on getting the most from compounding lines. The primary focus will be the production of technical compounds based on engineering thermoplastics, performance polyolefins and thermoplastic elastomers.

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for more details or contact Kelly Cressman kc@amiplastics-na.com Tel: +1 610 478 0800

December 10-11, 2013


Hilton Philadelphia City Avenue, Philadelphia, Pennsylvania, USA

Topics that will be addressed by our expert speakers include: growing a profitable compounding business in a fast changing world clean compounding for medical applications making compounding operations more sustainable metal replacement: finding new applications for compounds anticipating and responding to changing regulations anti-counterfeiting additives to fight product piracy developments in anti-microbials for thermoplastics pushing the limits of polypropylene performance practical advice for compounding bioplastics developments in flame retardants for engineering plastics natural fibers for high-performance applications thermally and electrically conductive compounds adding functionality to medical compounds top tips for getting the most from your twin-screw extruder optimizing twin-screw extruder configurations increasing loading levels and handling difficult ingredients

Speakers already confirmed from: A. Schulman, AMI, Century, Chroma, Entek, ESK, Leistritz, Sciessent, SPI, Techmer PM, Timcal and WoodForce, with many more to follow

Attend
Our packed programme will ensure a highly productive two days: learn about the latest industry developments, and network with key players from throughout the supply chain. Book your place before 31 May 2013 at a very special rate of just $790 (saving $400 on the full rate).

Exhibit
A limited number of table-top exhibition places are available, providing a great opportunity to promote your company to an influential and targeted audience. Reserve your space by 31 May 2013 at our special rate of $1,690 (this includes one free delegate place and is $300 less than the full rate).

Sponsor
We have a range of exclusive sponsorship packages for this exciting new event that are available on a first-come, firstserved basis. Book your package now to ensure maximum exposure on our website, brochure and adverts.

Organized by: Applied Market Information LLC & Compounding World

www.amiconferences.com

contents
05 Industry news
PAGE 15

The latest compounding industry news including international acquisitions and alliances, plus new investments and plant openings.

15 Creating compounds with clear benets


Pat Toensmeier reports on the latest developments in clariers, nucleating
PAGE 27

agents and processing aids for a growing range of applications.

27 Conference charts the progress of WPCs


The Wood-Plastic Composites 2013 conference provided very valuable insights into the latest market trends and technical developments.

PAGE 39

39 Adding conductivity to compounds


Recent advances in electrically conductive compounds and additives can increase performance and improve host-polymer compatibility.

PAGE 55

55 The compounders guide to Chinaplas


This months Chinaplas exhibition promises to be bigger than ever. We highlight a selection of exhibitors that will of interest to compounders.

65 New products: polymers and additives


PAGE 65

68 Compounder of the month: Kafrit Group 70 Dates for your diary

coming next issue


S PVC stabilizers S Compounding bioplastics S Improving and testing weather resistance
Click here to make sure you get your copy

contact us
Applied Market Information Ltd AMI House, 45-47 Stokes Croft, Bristol, BS1 3QP, United Kingdom Tel:+44 (0)117 924 9442 Fax:+44 (0)117 989 2128 www.amiplastics.com Head of business publishing: Senior editor: Contributing editor: Designer: Advertisement manager: Andy Beevers Chris Smith Jennifer Markarian Nicola Crane Claire Bishop E-mail: abe@amiplastics.com E-mail: cs@amiplastics.com E-mail: editorial@compoundingworld.com E-mail: claire@amimagazines.com Direct tel: +44 (0)20 8686 8139

Copyright Applied Market Information. No part may be reproduced without the prior written permission of the publisher.
www.compoundingworld.com May 2013 | COMPOUNDING WORLD 3

news

Chemtura completes antioxidants sell-off


Chemtura finalised the sale of its antioxidants and UV stabilizer business to the US private investment firm SK Capital Partners for approximately US$200 million on 1 May 2013. The newly-independent business has been rebranded Addivant. The business had sales of US$390 million in the 12 months to 30 September 2012. It produces Weston liq uid phosphites, specialty antioxidants, Anox NDB non-dust blends, light stabilizers, polymer modifiers and polymerisation inhibitors. Barry Siadat, a managing director of SK Capital and chairman of Addivant, said: The transition from a non-core business within a large public company to a stand-alone organisation will enable improved execution and a renewed emphasis on growth. Peter Smith, a former member of Chemturas leadership team and general Peter Smith says that Addivant will expand beyond antioxidants and light stabilizers manager of the business unit since 2009, has been named president and CEO of Addivant. He said: The company will continue to expand beyond the antioxidant and light stabilizer brands were known for. Our 500-plus employees and additives experts are working with a broad range of chemistries to formulate next-generation process technologies and product solutions that allow our customers to succeed in their markets. Addivant will be headquartered in Connecticut, USA, and will maintain its workforce and global footprint with 11 plants on five continents and nine existing technology and application testing centres worldwide.

PolyOne and Juffali open new plant


Juffali PolyOne Masterbatch opened its new specialty colour concentrates plant in Jeddah, Saudi Arabia, on 10 April. The company is a joint venture formed in October 2011 between PolyOne, which has a 51% share, and E.A. Juffali & Brothers, a leading commercial group in the region. The new facility is currently focused on colour masterbatch production, but it has the potential for expansion into other product lines in the future. Walid Juffali, chairman of Juffali, said: We are happy to have taken this important next step in our long and successful cooperation with PolyOne.

www.addivant.com

www.polyone.com

Schulman pushes again for Ferro acquisition


A. Schulman has asked the Ferro board to enter into serious discussions regarding its proposed acquisition of the company. It follows the rejection of Schulmans initial bid for the business in February 2013 in a deal that it valued at $563 million or $855 million including debt. Joseph Gingo, Schulmans chairman, president and CEO, said, Contrary to what the Ferro board of directors stated in a letter to Ferro shareholders dated April 18, 2013, our proposal is not a low-ball offer, and we have publicly stated that we are open to
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revising the terms and structure of our initial offer, provided we are given an opportunity to conduct customary due diligence and engage in a meaningful dialogue with Ferro. We have been and continue to be disappointed by the Ferro Boards refusal to talk. The two US-based companies are both major players in the additive and colour masterbatch markets. Schulman is also a supplier of thermoplastic compounds, while Ferros business also encompasses coatings and a wider range of materials, including pharmaceutical ingredients. l In separate moves, Schulman has opened its new corporate headquarters in the Joseph Gingo: disappointed by the Ferro Boards refusal to talk

USA, and it has inaugurated its new masterbatch plant in India. The new purpose-built 3,200 m2 HQ building is located close to the companys previous head office in Fairlawn, a suburb of Akron, Ohio, USA. The Indian masterbatch plant is the companys first in the country and is located in Vadodara in the State of Gujarat. It has an initial capacity of around 10,000 tonnes/year and target markets include flexible packaging, white goods and cosmetics manufacturers.

www.aschulman.com
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May 2013 | compounding world

news

Bayer pulls out of nanotubes


Bayer MaterialScience has announced that it is to end its Baytube carbon nanotube (CNT) activities as it believes that significant commercialisation of the technology is not likely in the foreseeable future. The company invested E22 million in a 200 tonnes/year CNT pilot production plant at its Leverkusen site in Germany in 2010. Speaking at the plants opening in 2010, Dr Joachim Wolff, a member of Bayers executive committee, said: Current forecasts predict an annual growth rate of 25% for carbon nanotubes. Within 10 years, the market is expected to be worth US$2 billion. However, the company has now said that the potential areas of application that once seemed promising from a technical standpoint are currently either very fragmented or have few overlaps with the companys core products. Patrick Thomas, chief executive officer of Bayer MaterialScience, said: We remain convinced that carbon nanotubes have huge potential. However, he added: Groundbreaking applications for the mass market relating to our own portfolio and therefore comprehensive commercialisation are not likely in the foreseeable future. The company says that the conclusion of the nano projects will not impact on its employee numbers, with all 30 people working in this sector being transferred to other suitable positions within the group. Bayer MaterialScience has been an active participant in Germanys Inno.CNT collabBayer MaterialScience had high hopes for its Baytube carbon nanotubes but volume sales have failed to materialise orative R&D initiative, which is backed by the German Federal Ministry for Education and Research. It said that much of the CNT knowledge that it has generated over recent years has been made available to other companies and research institutions within the alliance. Thomas added that Bayer does see potential for CNTs in lithium ion batteries and it is in contact with companies that are active in this field regarding its know-how. CNTs can be used as conductive additives in polymers. They are still produced in Europe by Arkema and Nanocyl, which operate 400 tonnes/year plants in France and Belgium, respectively. Showa Denko operates a similar capacity CNT facility in Japan, while CNano Technology has a 500 tonnes/year plant in China.

www.baytubes.com

Oxea has completed expansion


Oxea has completed construction of its new carboxylic acids plant in Oberhausen, Germany. It will boost its carboxylic acids capacity by 40%. The company said that the expansion was driven by growing global demand for synthetic fatty acids in applications including specialty phthalate-free plasticizers.

PlastiComp grows LFT capacity


PlastiComp has increased production capacity for long-fibre thermoplastics (LFTs) at its plant in Winona, Minnesota, USA. Its maximum throughput has been raised by approximately 5 million lbs/ year (2,300 tonnes/year) with the installation of a new compounding line. The company has also expanded its headquarters building in Winona, which it acquired in 2011, from 75,000 to 85,000 ft2 (7,000 to 7,900 m2). In addition, the building is undergoing modifications to add a new dedicated production line for carbon fibre LFT pellets and unidirectional tapes. Since the beginning of 2011, our sales have nearly tripled and the view ahead is even more robust, said Steve Bowen, PlastiComps president and CEO. PlastiComp primarily sells LFT pellets, but we also sell LFT technology. To date we have nine LFT lines installed in other companies under license. He added that the total number of lines, including its own production lines, will increase to 17 during 2013. We have interesting growth plans in medical markets, energy markets, and sporting goods applications, explained Bowen. Our focus is new applications.... We have little interest in pursuing share shift growth from competitors in LFT pellet sales. l Raj Mathur, vice president, technology and business development at PlastiComp, will be presenting a paper on new developments in longfibre reinforced plastics at the Compounding World Forum 2013 (http://bit.ly/CWF2013)

www.oxea-chemicals.com
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www.plasticomp.com
www.compoundingworld.com

compounding world | May 2013

news

Solvay and Ineos plan PVC merger


Solvay and Ineos plan to combine their European chlorvinvyls activities in a 50:50 joint venture that would be one of the worlds three largest producers of PVC. It would have combined sales of E4.3 billion based on 2012 figures, and around 5,650 employees. The agreement includes an exit mechanism for Solvay to sell its share of the joint venture to Ineos between four and six years after the merger happens. The joint venture will improve the competitiveness of its operations in a very challenging environment regarding feedstock and energy costs in Europe, said Jean-Pierre Clamadieu, CEO of Solvay. Jim Ratcliffe, chairman of Ineos, added, The newly combined business, which will be of world-scale, will be able to better respond to rapidly changing European markets and to match increasing competition from global producers.

BASF to cut back jobs in additives and pigments


BASF has announced that it will cut about 500 jobs worldwide in its Performance Products segment by the end of 2015. The restructuring covers plastics additives, pigments and water, leather and textile chemicals, which are mainly part of the former Ciba business which BASF acquired in 2010. The restructuring will impact the former Ciba sites in the Basel area of Switzerland where there will be around 350 job losses. BASF says that it is scaling down the Research Center Basel, which carries out R&D in plastics additives and pigments. In addition, supporting functions for the Plastics Additives business, such as technology and strategy management, will be consolidated in Ludwigshafen, Germany. European product and quality management and product safety for the Pigments & Resins business unit will also be concentrated in Ludwigshafen, while global product management will be located in Hong Kong. BASF said in a press statement: In some market segments, increasing standardisation and the entry of new competitors have changed the business environment significantly. It added that this especially applies to the markets for plastics additives. Michael Heinz, member of the board of executive directors of BASF with responsibility for the Performance Products segment, said: The expansion of our specialty business in the Performance Products segment made us more robust to economic fluctuations. However, the growth and profitability of the standard products do not yet meet our requirements. We have therefore identified numerous measures which we are implementing step by step. Further measures are being analysed. BASF said that it is aiming to adapt its businesses to the changed market environment and significantly increase their competitiveness in the coming years by streamlining processes, investing in new technologies and adjusting its portfolio and its organisational set-up. It added that it will attempt to find job opportunities in other BASF Group companies for as many employees as possible. BASF has announced that it is scaling down plastics additives research activities in Basel, Switzerland

www.solvay.com www.ineos.com

www.basf.com

Mitsubishi completes Comtrex acquisition


Mitsubishi Chemical has completed the purchase of Comtrex, a compounder of thermoplastic elastomers (TPEs) and flexible PVC, based in Areem, Michigan, USA. According to Mitsubishi, the acquisition is part of the
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strategy of its Performance Polymers business to expand the manufacture and sale of TPEs, cross-linked polymers, adhesive polymers, and conductive polymers. Mitsubishi has recently made other PVC and TPE

compounding acquisitions. In February 2013, it announced its purchase of CTS from Tessenderlo. CTS has PVC and TPE compounding plants in France, Poland and China. In December 2011, Mitsubishi acquired A. Schulmans share

of their Sunprene PVC compounds joint venture, and in the final quarter of last year it purchased Schulmans PVC compounding plant in Bellevue, Ohio, USA.

www.mcc-spd.com/en www.comtrexllc.com
www.compoundingworld.com

compounding world | May 2013

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news

Albemarle scales up production of its replacement for HBCD


Albemarle says that it expects to begin the supply of its GreenCrest polymeric flame retardant for commercial qualification by mid-2013. The high-molecular-weight brominated product is designed as an alternative to hexabromocyclododecane (HBCD) for use in extruded (XPS) and expanded (EPS) polystyrene applications. HBCD is subject to REACH restrictions from 2015. Albemarle announced last year that it is adding a new plant for GreenCrest production at its facility in Orangeburg, South Carolina, USA. Full commercial production is scheduled for next year. GreenCrest is based on proprietary chemistry licensed from Dow Chemical. The same technology has also been licensed by the two other Albemarles GreenCrest flame retardant is designed to replace HBCD in EPS and XPS applications leading brominated flame retardant manufactures Great Lakes and ICL. Dows brominated polymeric flame retardant is a block copolymer of polystyrene and brominated polybutadiene with a bromine content of 60-67 wt%. The aliphatic bromine ensures excellent fire performance, while the polystyrene block delivers good compatibility with EPS and XPS. The polymeric nature of the additive means that it is inherently safer than existing small molecule products because of its limited bioavailability/toxicity.

www.albemarle.com

Tickets on sale for Compounding World Forum


Special pre-programme tickets for the first Compounding World Forum are now on sale. The conference, which is being organised by AMI and The Compounding World Forum is a new international two-day conference that will feature a high-level programme brought together by the editorial team of Comprimary focus will be on the production of technical compounds based on engineering thermoplastics, performance polyolefins and thermoplastic elastomers. Topics being covered include: global business trends and strategies; clean compounding; regulatory issues; sustainable manufacturing; conductive compounds; anti-counterfeiting additives; long-fibre thermoplastics; anti-microbials; flame retardants; functional fillers; processing bioplastics; natural fibres; high-performance PP compounds; optimising screw configurations; and increasing loading levels. Speakers have already been confirmed from A. Schulman, AMI, Century, Chroma, Coperion, Entek, ESK, Foster, Imerys, Leistritz, PlastiComp, PolyOne, Sciessent, SPI, Techmer PM, Timcal and WoodForce, with more to follow. For more details about participating in the Compounding World Forum as a delegate, exhibitor or sponsor, please visit http://bit.ly/CWF2013 or contact Kelly Cressman, kc@amiplastics-na.com, Tel: +1 610 478 0800.

Compounding World magazine, takes place on 10-11 December 2013 in Philadelphia, PA, USA. Delegates who book their places before 31 May 2013, qualify for a special pre-programme rate of $790, which represents a saving $400 on the full price. For companies wishing to exhibit at the event, a limited number of table-top displays are available. These can be booked before 31 May at a special rate of $1,690, which includes one delegate place and is $300 less than the full rate.
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pounding World. It will explore and develop many of the magazines most popular themes in a live event. It will cover business strategies and new materials technologies, as well as providing practical advice on getting the most from compounding lines. The

www.amiconferences.com
www.compoundingworld.com

compounding world | May 2013

news

Degradable additives under fire


The US Association of Postconsumer Plastic Recyclers has issued a statement reinforcing its opposition to the use of degradable additives in plastic products that could be recycled. It is supporting legislation being considered in North Carolina and Alabama that would require containers with degradable additives to be labeled do not recycle. Get the full statement at: http://bit.ly/APR0413

Europe advances phase out of lead stabilizers


VinylPlus has reported a 76% decrease in the consumption of lead stabilizers in the European Union in 2012, compared to 2007. The organisation said that the industry is well on track to complete the substitution by the end of 2015. It has also announced that 362,076 tonnes of PVC were recycled in Europe in 2012, which it said represents a record total and means that the industry is on track to hit its target of recycling 800,000 tonnes/year by 2020. Launched in 2011, VinylPlus is the new 10-year voluntary agreement on sustainable development for the European PVC industry. To download the full 28-page VinylPlus 2013 Progress Report, go to http://bit.ly/VinylPlus.
photo: Recovinyl

www.plasticsrecycling.org

www.vinylplus.eu

PVC recycling has hit new heights in Europe

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nucleators and processing aids | additives feature

Pat Toensmeier reports on the latest developments in clariers, nucleating agents and processing aids that meet demanding requirements in a growing range of applications

Creating compounds with clear benets


Suppliers are expanding the performance of clariers, nucleating agents and processing aids for a variety of evolving needs, mostly in polyolens. Chief among these are changing polymer morphologies, continuing demands for sustainable production, and enhanced productivity in extrusion, injection moulding and other processes. There are also ongoing modications of product designs, especially in packaging, to achieve thinnerwalled, lighter-weight structures, as well as greater use of post-consumer recyclate (PCR) in resin formulations. Tack onto this a need to demonstrate reduced carbon emissions in product manufacturing, along with the goal of processors and OEMs to lower material and processing costs where possible, and the performance bar is rising for these additive categories. In clariers and nucleators, for example, developments are evident in the increased clarity and processability that new and upgraded versions of these additives provide to advanced polypropylene (PP) grades. Some suppliers maintain that recent clariers achieve levels of clarity in polyolens that are on a par with polyethylene terephthalate (PET) and other transparent materials, including glass. Enhanced PP grades, meanwhile, often have higher
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melt indexes and lower processing temperatures to speed up moulding cycles, providing benets in throughput, particularly in applications involving the high-cavitation production of food packaging and other volume products. These changes, however, affect the behaviour of conventional clariers and nucleators: faster cycles narrow the processing window and require accelerated crystallization rates in nucleators, while lower temperatures impair clarier solubility. Many new clariers and nucleators are tailored for these needs. Processing aids also contend with the demands of new resin formulations, notably in polyethylene (PE) lm grades. Here, enhanced versions of metallocenes and other catalysts are being tapped to produce LLDPE grades that can be extruded at relatively high throughputs, and which maintain toughness when down-gauged for packaging, stretch wrap and other end-uses. The latest processing aids achieve conventional benets of reduced die build-up and elimination of melt fracture during high-speed extrusion, while also maintaining desired nishes by suppressing shark skin, for example and sometimes speeding colour changeover. Additive suppliers are developing materials that keep pace with the changing requirements of polyolens and

Milliken describes HPN-68L for PP as a hyper nucleator due to rapid crystallization at high temperatures

May 2013 | COMPOUNDING WORLD

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additives feature | nucleators and processing aids

Milliken says its Millad NX8000 PP clariers achieve comparable clarity to PET and crystal PS

Millikens Millad 3988 DMDBS clarier. Killough says it will be a me too product because that is what the market wants. He claims, however, that the powder will have improved ow properties, similar clarity to the 2G MDBS chemistry, and a wide processing window. Other benets include high purity, good haze results, low organoleptics, and a low-to-high melt-ow rate. Loadings will be 2,000 ppm, comparable to 2G MDBS clariers and 20% less than the 1G DBS loading range. The next stage of our strategy will be to offer a product that is designed for the next generation of PP, Killough says. This means grades formulated for effective use in PP processed at around 200-215C (392-419F), lower than the 210-250C (410-482F) average of most PP grades. The clariers will remain soluble at lower temperatures without an impact on loading, he adds. Milliken acknowledges in a statement that some IP [intellectual property] on Millad 3988 is expiring, but notes that the company will still own a wide variety of IP other resins. As a result, compounders have access to a broad range of clariers, nucleators and processing aids that allow them to ne-tune products for processors and OEMs, and gain performance benets in key formulation, production and application areas. around its Millad products post 2020. A representative adds that investments in PP clarier technologies include more than 200 fourth generation Millad NX8000 nonitolbased grades available globally in a range of melt ows, the majority of them replacing Millad 3988, and many being specied for new transparent PP applications. Milliken states that some PP clariers, such as Millad NX8000, match PET and even glass in transparency, an obvious benet for food and other product packaging.

Clarier competition
One area of intense development is clariers. According to one supplier, the global market became more competitive on 6 May 2013. This is when patents on a certain production technology that New Japan Chemical developed and sold to Milliken in the 1980s expired worldwide. RiKA International, a wholly owned UK-based subsidiary of New Japan, plans to begin marketing its own version of the third generation (3G) of the acetalsorbitol-based clarier for PP, which uses 3,4-DMDBS (dimethyl-dibenzylidene sorbitol) chemistry. Liam Killough, CEO of RiKA International, says that New Japan lost a patent challenge to Milliken involving the development of 3G DMDBS chemistry (the initial license to Milliken reportedly involved 1G and 2G versions), and as a result could not market its 3G product. They got the children, Killough jokes about the decision, which followed what he terms an acrimonious legal proceeding. RiKA (and its US unit, RiKAmerica) plans to introduce the Gel-All DX Series of 3G powder clariers for PP shortly after the patents expiry date. It will also add 1G and 2G versions Geniset D (dibenzylidene sorbitol, or DBS) and Geniset MD (methyl-dibenzylidene-sorbitol, or MDBS), respectively. The initial Gel-All DX grade will compete with
16 COMPOUNDING WORLD | May 2013

Impact on sustainability
Such performance also enhances sustainable production, explains Fred Defenbaugh, Millikens product line manager for nucleators, since PP has lower specic gravity than other transparent options like PET and polycarbonate (PC). This means less material is used in PP packaging, thereby reducing resin use and contributing to savings. PET, additionally, needs drying before processing, which adds energy cost, while PC is a much more expensive and arguably over-engineered choice for comparable applications. While polystyrene (PS) competes with PP in price and clarity, one of its component materials, benzene, is becoming more expensive, which could affect cost compared with PP, Defenbaugh says. If you are a package designer at a major consumer products manufacturer, where sustainability and carbon footprint are concerns, and a package can be made in PP, youll likely specify PP over other plastics for regulatory concerns, he says. Whether the concern is valid or not, there is a trend away from PC and PS. The Millad NX8000 line of fourth generation clariers
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Introducing
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App sponsored by

Having led the way with high-quality digital-only magazines for the global plastics industry, AMI is now also making its titles available free-ofcharge on the iPad, iPhone and a wide range of Android-based smartphones and tablet computers. The dedicated apps for Compounding World magazine are now ready to download from Apples App Store and iTunes or from the Google Play Store. Just search for AMI Plastics. Current and past copies are available free-of-charge and new issues will be added to the apps as soon as theyre published. If you are using Apples latest iOS 5 operating system, then the magazines will appear in your Newsstand and new editions will be added automatically if you sign up for our free subscription. The Compounding World app is sponsored by Leistritz, a leading supplier of twin-screw extruders.

ANDROID VERSIONS NOW AVAILABLE


CHECK OUT OUR OTHER FREE APPS: AMI has also launched free apps for its three other digital magazines Injection World, Pipe and Profile Extrusion and Film and Sheet Extrusion. Plus theres an additional AMI Conferences app featuring brochures for our forthcoming events. Simply search for AMI Plastics in iTunes, Apples App Store or the Google Play Store.

nucleators and processing aids | additives feature

is a development that gives compounders and processors broad latitude to tailor loadings for end-use requirements. Wim Van de Velde, global product line manager for Millad, says the clarity provided by NX8000 increases with higher loadings. It wasnt possible before to reach the clarity of PET or PS in PP, he remarks. Now, end-users can specify PP, a material with a low carbon footprint, and achieve the clarity of PET or PS. Its almost like having a new material to work with. For high clarity, he estimates loadings would be double compared with conventional clariers. But its tuneable, Van de Velde remarks. A 10 or 20% loading would produce good clarity. Loadings also depend on part thickness, although he says Millad NX8000 grades achieve clarity in shallow-draw parts. The cost of higher loadings is a concern, Van de Velde concedes, especially in packaging. But he adds, Polypropylene, even with a high loading of clarier, is still signicantly less expensive than other clear plastics. The NX8000 clariers, importantly, maintain the solubility of their loadings even at elevated levels down to 190C (374F). Low process temperatures, Defenbaugh notes, reduce energy use and carbon footprint, speed cycle times and improve productivity. Millikens HPN-600ei nucleator for thermoformed PP is formulated to speed crystallization

High-performance nucleators
Milliken also formulates PP nucleators for accelerated performance requirements. Of note are: HPN-68L and HPN-20E (also for PE), for injection moulding, and HPN-600ei, the most recent, for thermoforming. HPN-68L, which Milliken terms a hyper nucleator, is an example of an additive with benets for productiv-

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additives feature | nucleators and processing aids

speeding crystallization, upgrading heat-deflection temperature and increasing dimensional stability. Polyvel also supplies pelletized masterbatch process aids for PLA that increase melt strength. Examples include CT-L02, for film extrusion, and CT-L03, for moulding and foam extrusion. CT-L03 additionally improves impact strength. Polyvels additive masterbatches extend to pelletized antifogging agents for PP cast film packaging. VF-P01 and VF-P04 are for thermoformed hot-food containers, while VF-P03 is for cold-food packaging. The company wants to extend antifog offerings to PET and PS, Dodaro says. Work is underway to develop products, and commercialization could be in six to 12 3Ms SX 5927 fluoropolymer powder eliminates melt fracture, reduces die build-up and speeds up colour changeovers ity and part quality, and for efficient processing of PCR. The material has been available for some time, but remains a good example of advanced nucleator chemistry. The material, reportedly a norbornane carboxylic-acid salt, provides fast crystallization at high temperatures, speeding up part set-up and cycle times. Its isotropic shrinkage controls warping. The additive also reduces aesthetic blemishes such as sink marks, ejection pin marks and voids. And it can be used at relatively low loadings for example, 300-1,500 ppm. Importantly, HPN-68L overcomes the nucleation of pigmented plastics in PCR. Recyclate frequently contains multiple streams of polymers whose pigments can nucleate compounds. Defenbaugh says the additive overpowers these nucleants and blocks them from interfering with the properties of a compound using PCR. The latest nucleator from Milliken, HPN-600ei, meanwhile, has fast crystallization and improves thermoforming aesthetics while upgrading Gardner impact properties, top-load strength, flexural modulus and the ovality of packaging, cups and lids, and other parts. months.

Lower loadings
A recent development in processing aids is reported by 3M. The manufacturers line of Dynamar polymer processing additives was recently expanded with grade SX 5927. Dawn McArthur, marketing manager for advanced materials, describes it as a high-performance material for the extrusion of polyolefins and other thermoplastics, and which can be used at relatively low loadings of 200-1,000 ppm. The free-flowing material is formulated to eliminate melt fracture, reduce die build-up and increase throughput, all with no affect on the physical and surface properties of products such as blown and cast film, pipe and profiles, blow mouldings, and some wire and cable products. The additive also speeds up colour changeovers, by rapidly removing traces from a previous run. McArthur attributes the performance and low loadings of the additive to a unique and different fluoropolymer and synergist technology from 3M. Importantly, the material meets the US CFR (Code of Federal Regulations) A-H conditions for food contact, which means it can be used in packaging materials exposed to eight temperature levels. These range from sterilization (over 212F, or 100C), boiling water and hot-fill (above or below 150F, or 65.5C), to room temperature, refrigeration and frozen storage. Compounder PolyOne of Avon Lake, Ohio, has developed a processing aid for injection moulding, extrusion and blow moulding grades of PE and PP. Called OnCap CTR, the material, which is supplied as a concentrate or as a component of the companys Smartbatch additive for use with colour concentrates, has several benefits. It improves energy efficiency and throughput, yielding cycle-time reductions of 30% and more. According to PolyOne, the additive also enhances the consistency, dimensional stability and surface
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Enhancing biopolymers
One example of a specialty resin that is driving the development of clarifiers is polylactic acid (PLA), a biopolymer gaining use in packaging and other applications for its reduced carbon footprint and sustainability. However, PLA has property issues and needs additives to boost its performance, notably in clarity, says Dean Dodaro, a sales engineer at Polyvel, which makes clarifier and nucleator masterbatch concentrates for the biopolymer, as well as for PE and PP. Its masterbatches include CN-L01, an inorganic for foam extrusion, which reportedly has a high dispersion rate that optimizes nucleation. The grade complies with various US drug, cosmetic and food-use regulations. CN-L03, an organic clarifier and nucleator, improves the transparency of extruded film and moulded parts by up to 90% (to the level of crystal PS, Dodaro says), while
20 compounding world | May 2013

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nucleators and processing aids | additives feature

appearance of moulded products. In tests, OnCap CTR has reduced scrap by up to 50%. As a result, PolyOne representatives say that such significant improvements in product quality can give processors access to previously unattainable markets for example, those that may have been too costsensitive to be profitable without major reductions in scrap, or where in-shop and customer performance metrics mandate low rates of rejected parts, such as Six Sigma operations. PolyOne cites the example of an undisclosed auto parts moulder that was lagging in delivery of a black talc-filled PP radiator shroud to a luxury automotive OEM. The moulder was using a 1,500-ton injection machine with single-cavity mould. Rather than invest in a second machine to meet demand, PolyOne recommended the processor use the OnCap CTR additive in the PP compound. The additive increased process efficiency, yielding a 24% reduction in cycle time, and decreased the per-part cost by 5%. It also improved the dimensional stability of parts and brought critical moulding tolerances within spec, which lowered reject rates. The moulder, consequently, was able to maintain on-time deliveries with one machine, make significant gains in part quality and achieve sizeable savings. Work in nucleating agents is, predictably, leading to unintended but potentially beneficial consequences. Custom compounder Americhem of Cuyahoga Falls, Ohio, says its nucleating additives comprise unique products so much so that they are able to improve physical properties beyond clarity and crystallization, 3Ms SX 5927 processing aid can preventing shark skin on films (shown left)

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additives feature | nucleators and processing aids

PolyOnes OnCap CTR processing aid delivered 24% faster cycle times for this automotive radiator shroud

batches, or likely applications and targeted property improvements. But he says Americhem is encouraged enough by their potential to be considering whether to patent them. If this development leads to a new class of multipurpose additives, one in which masterbatches combine clarity and crystallization with other property improvements, it would signal a further evolution in the versatility and effectiveness of clarifiers, nucleators and processing aids.

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Wood-Plastic Composites 2013 | event review

The Wood-Plastic Composites 2013 conference provided very valuable insights into global market trends and the latest technology developments for WPCs. Asta Eder reports from the event

Conference charts the progress of WPCs


A large, inuential and international audience gathered in Vienna, Austria in February for AMIs ninth WoodPlastics Composites conference. They heard about the latest market trends and technical innovations from leading experts in the eld. Jon Nash, head of strategic research at AMI Consulting, opened the conference with an overview of the European market for wood-plastic composites (WPCs). He discussed the background of a changing picture for construction activity across the region. Where we once talked about the differences between East and West Europe, the difference is now between the North and South, he explained, showing gures that illustrated the relative growth of the North compared to the South. Looking specically at the WPC market in Europe, Nash said that three years of impressive growth leading up to 2010, had been followed by stagnation in 2011 to 2012, but growth is now expected to resume. Decking continues to be the dominant application for WPCs in Europe, with solid proles rising compared to hollow ones. The per capita market for WPCs in Europe still lags far behind North America where consumption is around twice as high. Nash said that the European industry is relatively fragmented and it needs to gain economies of scale to begin to match its American counterpart. He also highlighted Europes need to increase expenditure
www.compoundingworld.com May 2013 | COMPOUNDING WORLD 27

on marketing and brand building, which also falls way below American levels. In conclusion, Nash said that the rapid development of WPCs products is creating lots of exciting opportunities, but that these require commitment and focus from suppliers.

A recurring theme of the conference was the growing interest in solid WPC decking proles in Europe

Stateside situation
Valuable insights into the American market were provided at the conference by two global leaders in the WPCs industry, Timbertech and Trex. Paul Bizzarri, vice president of innovation at Timbertech, discussed the changes in the North American decking market, where capped composites

Conference delegates saw BattenfeldCincinnatis new berEX 114 extruder in action

event review | Wood-Plastic Composites 2013

Trex introduced its Elevations steel deck framing for supporting its WPC profiles

and cellular PVC are growing at the expense of traditional WPC profiles. The US/North American housing recovery finally seems real, said Bizzarri, before predicting growth in decking overall and a growing market share for PVC and composites compared to wood. Ronald Kaplan, CEO of Trex, focused on his companys introduction of its Elevations steel deck framing to support its WPC profiles, because as he put it: You dont put a filet mignon on a paper plate! He said that steel frames are stronger, straighter and smarter. Kaplan argued that dealers can reach higher profits by using steel under WPC constructions because of fewer returns, longer shelf life and more differentiated products. With just three different types of steel profiles required to build a deck, the product is also easy to stock and sell. Contractors can also profit from using steel frames under WPC decking, as they provide design flexibility, consistent dimensions and easy installation, according to Kaplan. Benefits for customers include a 25-year warranty, superior durability, safe construction, and a flat surface. high-end applications in both residential and commercial projects. Zodl stressed the importance of getting compound formulations correct and demonstrated the dire consequences of skimping on relatively expensive ingredients such as coupling agents or stabilizers. Rehaus premium Relazzo range of WPC decking is PP based for recycling reasons and incorporates additives and colour pigments selected for long-term weathering resistance. Zodl also emphasized the importance of meeting the right production certification (eg ISO 9001 and ISO 14001) as well as achieving the necessary product standards. The latter include: DIN 51097 for skid resistance; EN 317 for retention of dimensions after cold water storage; EN 321 and 310 for maintaining bending characteristics after freeze-thaw cycles; and DIN EN ISO 4892-2 for retaining bending characteristics after artificial xenon weathering. Another consideration is wood certification, with the PEFC label being widely used in Europe, while FSC is more common in America and Asia. Both are international sustainability labels, but they have different requirements and there is a problem with the amount of FSC certified wood available in Europe, according to Zodl. Such labels can help raise customer awareness and acceptance, particularly in Europe where there appears to be some scepticism about the credentials of WPC products. On the subject of standards, Claudine Bloyaert, technical marketing manager for PVC profiles at Solvin, reviewed progress with the European standard for wood polymer composites. She explained that the CEN TC249/WG13 group was formed in mid-2003 to answer

European insights
Frdric Lefranc, purchasing manager for outdoor products at Wolseley France, gave the audience insights from the point of view of a WPC distributor. He Rehau presented high-end applications of its WPC decking such as this residential project in Austria reported growth in WPCs share of the decking board market in France, increasing from 5% in 2005 to 22% in 2012, based on m . In value terms, the market share of
2

WPC is larger, and the higher profit margins for WPC products makes them more attractive for wholesalers, Lefranc explained. The premium WPC decking market in Europe was covered by Rehaus Harald Zodl, who is manager of the companys WPC competence centre. He showed a wide range of examples where WPC decking is being used in

28

compounding world | May 2013

www.compoundingworld.com

20/24 May, Stand I-100

event review | Wood-Plastic Composites 2013

The first WoodForce plant in Le Creusat, France has a capacity of 130,000 tonnes/year

the need for standardisation of WPC products. It published a draft Technical Specification in May 2007 covering test methods, general materials characteristics and product related characteristics. This TS 15534 document has subsequently been used as the initial basis for national quality WoodForce engineered wood fibres are supplied as easy-to-handle dice-like cubes marks, such as VHI in Germany. A larger group covering more EU countries came together in 2008 and resolved in 2009 to upgrade the Technical Specification to create the proposed EN 15534 standard, covering test methods, load bearing applications, characterisation of compounds and product specifications for different applications. Several parts of EN 15534 have recently been submitted for CEN enquiry and the other parts are currently under discussion. Marc Thometschek, CEO of the Belgium-based compounder Beologic discussed the growth potential for natural fibre and WPC compounds. The company has a production capacity for such materials of 24,000 tonnes/year and produces grades for a range of processes, including extrusion, co-extrusion, injection moulding, foaming and rotomoulding. It has recently expanded its production base with the addition of a new factory in Sweden focused on the production of technical natural-fibre compounds. Beologics compounds are based on a growing range of polymers, such as PP, PE, PVC, PS, various engineering plastics and thermoplastic elastomers, plus bio-based resins such as PLA, PHA and Braskems green PE. It uses a wide range of natural fillers and reinforcements, including PEFC and FSC certified wood, cork, coconut, almond, bamboo, coffee, flax and cellulose. The companys latest product development for extrusion applications is its Hydrostatic range of compounds that use treated wood fibres, plus mineral
30 compounding world | May 2013

fillers in some formulations, to reduce water uptake by as much as two thirds.

Material benefits
Christophe Chambonnet, global manager for WoodForce at the wood panel manufacturer Sonae Industria, presented an engineered wood fibre for biocomposites that the company produces under exclusive license from Scion of New Zealand. The first WoodForce production plant is in Le Creusat, France, and it has a capacity of 130,000 tonnes/year. The densified wood fibres are supplied in easy-tohandle dice-like cubes that minimise dust content and simplify feeding into a compounding line. These cubes contain real fibres with a high aspect ratio for reinforcing plastics, as opposed to wood flour that acts as a filler, explained Chambonnet. Tests with plastics filled with 40% wood flour or 40% WoodForce showed the latter increased tensile Youngs modulus, tensile stress at break, Notched Izod impact strength, flexural Youngs modulus and flexural stress at break. Only tensile elongation at break was slightly lower with Wood Force. According to Chambonnet, a 30% loading of WoodForce in PP gives increases in tensile and flexural modulus that are comparable to those achieved with 20% glass fibres. Tensile and flexural strength are also increased to about 80% of the values achieved with glass. The density of wood fibres is less than that of glass fibres (around 1.4 compared to 2.4) leading to lighter products, while WoodForce also offers environmental benefits. Results of a life cycle assessment (LCA) show that PP plus 30% WoodForce is more sustainable than unreinforced PP or PP with 30% glass fibres, based on a wide range of environmental measures. Recyclability is also claimed to be improved with greater retention of tensile strength after the first recycling/second extrusion cycle 93% for PP plus
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Wood-Plastic Composites 2013 | event review

WoodForce, compared to 75% for PP plus glass fibre. Dr Hans Korte, president of PHK Polymertechnik also presented an alternative natural fibre additive, which he described as a hydrophobic, non-swelling, non-decaying, heat-stable biofiller for thermoplastics. PHK has developed a hydrothermal process to convert fresh purpose-grown lignocellulose into the biofiller, which is marketed under the Nerolit 100 brandname in Europe and NeroPlast in North America. Additives for improving the properties of WPCs were presented by Juan Bravo, international technical manager for plastics at Struktol. He explained that the proper selection of lubricants has eliminated many of the problems encountered when processing WPCs at higher extrusion rates. The optimisation of lubricants has helped to overcomes issues such as blooming or migration. In addition, there has been the introduction of lower cost processing lubricants that maintain effectiveness levels, particularly for co-extruded capstock production. An example of the latter is Struktols SA1114 low-cost lubricant for formulations not using maleic anhydride (MAH) coupling agents. Its darker colour is still acceptable in WPCs and it can be used in profile cores, where colour is not an issue. For formulations using MAH, the company offers its SA1149 lubricant. Bravo said that Struktols TPW 243 pastille and TPW 244 powder coupling agents for PE-based WPCs offer significant improvements in modulus of elasticity (MOE) compared to MAH additives. In addition, they provide better retention of MOE after freeze/thaw cycles and are said to be easier to process. They also work with any PHK uses a hydrothermal process to convert lignocellulose into its hydrophobic biofiller

event review | Wood-Plastic Composites 2013

type of lubricant, including those containing metallic stearates. Another Struktol additive aimed at WPC applications is its RP 17 odour mask, which is designed to reduce or mask smells in WPC products, especially those containing recycled material. Bravo said the additive has received positive feedback in customer trials. The company also produces a flame retardant specifically for WPCs SA0832 is designed to slow down the burn rate at lower loadings than traditional FR compounds. Dr Jungil Son, project leader with LG Hausys (an LG company based in South Korea), presented a combined WPC technology based on a core layer supplied by Tech-wood and a co-extruded skin layer supplied by LG Hausys. He explained that the core contains relatively long wood fibres (up to 6 mm), at loadings of 72% or more in the PP matrix. New patented compounding technologies are used to ensure good dispersion. The resulting material provides high strength and modulus combined with low creep and thermal expansion. In addition, the high wood loadings and line speeds provide cost competitiveness. The co-extruded skin provides excellent appearance plus the required weatherability, durability and scratch-resistance. Matt McLaughlin, product manager at NWP, talked about the optimisation of additives in WPC formulations. The US-based company has produced WPCs for the automotive market for more than 30 years so has extensive experience of evaluating additives for such compounds. BattenfeldCincinnatis new fiberEX 114 is particularly suitable for extruding solid WPC profiles McLaughlin discussed work to investigate the relative benefits of different combinations of lubricants and coupling agents. Initial investigations indicated that the improved interfacial bonding achieved with coupling agents in the lab did not translate to real-world applications. Preliminary tests also showed that there was an interaction between lubricants and coupling agents. The choice of lubricating materials zinc stearate or

calcium stearate produced different results, as did the selection of different wood flours. A design of experiment (DOE) was used to evaluate the interaction of the different ingredients. Using the Minitab statistical analysis tool, the company took a scientific approach to optimising formulations, rather than relying on guesswork. McLaughlin presented a case study for an application where impact strength was the most important physical property. By optimising the combination of lubricant and coupling agent it was possible to increase the impact strength by 191% compared to the formulation without either additive.

Processing progress
Sonja Kahr, product manager of the construction division at Battenfeld-Cincinnati Austria, which was the events headline sponsor, presented the historic development of the WPC industry in Europe, focusing on the shift from hollow to solid profile decking. While the leading market of America focused predominantly on solid profiles based on highly filled PE formulations, Europe started with mostly hollow profiles, mainly based on PP formulations. However, Battenfeld-Cincinnati is now seeing an increased proportion of its extrusion lines being used for solid profiles 30% for the period 2010-2013, compared to 12% for 2005-2010. Over the same period, the share of machines used for hollow profiles has fallen from 64% to 44% (the balance of around 25% in each period is made up of other applications, such as compounding). Kahr said that the changes have been driven by growing co-ex applications to cut materials costs and the fact that the Gtesiegel European seal of quality has boosted the image of solid deck, particularly in the German market. Examining the benefits of solid decks, Kahr listed: higher amount of regrind can be processed; no complex calibrating table needed; no cover caps required; easier to market through wood sales channels; flexible designs and diagonal cuts are made possible; and they are easier to emboss. On the other hand, hollow decks have their own advantages, including a lower weight per metre and therefore reduced transport costs, lower material costs and higher line speeds. In addition, lower cooling capacity is required and installation is simplified and theres no loss in mechanical or physical properties. The event featured a demonstration of Battenfeld-Cincinnatis latest parallel twin-screw

34

compounding world | May 2013

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event review | Wood-Plastic Composites 2013

Leistritz says that the wide processing window of its ZSE Maxx can help compounders control the flow behaviour of masterbatches

extruder, the fiberEX 114. This high-performance machine is designed for WPC applications with output ranges from 280 to 520 kg/hour. It can be used for all standard applications, but is especially suited to solid profiles and panels. It also handles difficult, low-density bulk materials without any problems and permits maximum degassing performance, according to Battenfeld-Cincinnati. Sven Wolf, managing director of Leistritz Extrusionstechnik gave a presentation on colour masterbatch viscosity and its influence on WPC production. He explained that although masterbatches can contain a large number of ingredients, their viscosity is mainly influenced by the polymer substrate. Substrates with a higher melt-flow index (MFI) typically ensure better distribution of ingredients, homogenous performance of the finished material and easy processability. Variations in the MFI values of colour masterbatches can cause process instabilities as they shift plasticizing or gelification process points within the extruder. Wolf showed several examples of how masterbatch MFI variations can also cause a range of visible problems on the finished product. These include: flow shadows; cracks through flow inhomogenity; flow scales on profiles; and blockages inside calibrators due to different die swelling behaviour. Wolf encouraged WPC producers to pay close attention to the viscosity levels of the masterbatches that they use, as well as the colour and the UV stability that they provide. He recommended incoming quality checks to monitor the range of masterbatch MFI values. The choice of the right substrate materials is also an important consideration, especially when one colour masterbatch needs to be used with different WPC polymer matrix materials. Selecting the right masterbatch substrate will reduce down-time and scrap rates, and will therefore improve production economics. There was also advice for masterbatch producers in Wolfs concluding remarks. He encouraged them to develop colour masterbatches with equal flow behaviours independent of the type and concentration of pigment/ additive that they contain. The viscosity levels can be adjusted or improved through the use of additional lubricants. Wolf also said that compounding machines with wider process windows, such as Leistritzs ZSE Maxx, can also help to meet these requirements. Martin Hetz, processing engineer at Hans Weber Click on the links for more information: Maschinenfabrik, discussed the advantages of counter-rotating twin-screw extruders for WPC processing. Such machines offer low shear, high torque, high pressure stability, materials handling flexibility and options for atmospheric of vacuum degassing. In particular for WPC processing, counter-rotating twin-screw extruders provide self-cleaning of screws, short residence times, low shear melt temperatures and the intake of material is proportional to the screw speed. The company has developed special screw designs and venting systems for WPC applications. Looking ahead to future developments, Hetz predicted the emergence of new WPC applications, further optimisation of screw designs and dosing systems, more cost-effective wear protection, and extrusion lines with increased energy efficiency.

More information
The proceedings from the Wood Plastics Composites 2013 conference can be purchased from Plastics Information Direct: http://bit.ly/WPCs2013. AMIs next Wood Plastics Composites conference will take place in November 2014. For more details, contact Maud Lassara: ml@amiplastics.com, tel: +44 117 924 9442.

www.amiplastics.com www.timbertech.com www.trex.com www.wolseley.com www.rehau.com www.solvinpvc.com www.beologic.com www.woodforce.com www.phk-polymertechnik.de www.struktol.com www.lghausys.com www.nwpinc.net www.battenfeld-cincinnati.com/en www.leistritz.com www.hansweber.de
www.compoundingworld.com

36

compounding world | May 2013

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Electrical conductivity | additives feature

Recent advances in conductive compounds and additives increase performance, improve host-polymer compatibility and can also add complementary properties. Pat Toensmeier reports

Adding conductivity to compounds


Though the market for conductive compounds, antistats and electrostatically dissipative (ESD) materials is large and diverse, developments in these products are typically incremental, with compositional tweaks more common than formulation breakthroughs. However, the pace of change appears to be accelerating, as suppliers and compounders respond to growing end-user needs with materials that reect broader performance and product-quality demands. One important need, of course, is higher performance of personal electronic devices. The quantity of data being transferred from mobile devices is rising, and users want that data to be transferred faster, says David Stonecipher, electrical and electronics global marketing director at PolyOne. To prevent cross-talk interference at higher data speeds, there is a demand for higher EMI/RFI (electromagnetic interference/ radiofrequency interference) shielding that in turn requires greater conductivity. Virtually no application is untouched by the materials being produced. While the highest prole products that use conductive compounds, antistats and ESD materials remain the burgeoning markets of advanced electronics, less ashy but no less signicant end-uses ranging from exible packaging to household appliances inuence developments as well. The result is that more materials are available with benets that include extended performance, compatibility with the mechanical properties of host polymers, cleaner ingredients, improved processability, and occasionally combining other properties such as thermal conductivity, lubricity and antifogging. Developments are taking place as well in nanomaterials. Some compounders are producing grades with carbon nanotubes, which not only improve conductivity at lower loadings than conventional materials, but can also enhance mechanical properties and contribute to weight reduction in parts owing to their low density.
www.compoundingworld.com

It is clear from these and other developments that conductive compounds, antistats and ESD materials are no longer one-dimensional in performance. End-users increasingly want wider performance envelopes that dont involve trade-offs in properties, processability or price. And they are usually able to nd what they want. Earlier, the surface resistivity value was the key [in materials specication], but lately converters and end customers have started to look for material solutions which full the end-product requirements in all aspects, says Jouni Hillberg, director of customer applications and of sales and marketing for the EU and Americas at IonPhasE of Finland. IonPhasE produces inherently dissipative polymers (IDP) based on what the company describes as a self-organizing, co-continuous polymer structure with ion conductivity. Its IonomerPolyElectrolyte (IPE) grades can be used for compounding in polyolens, polycarbonate blends and styrenics, along with some high-heat resins like PMMA (polymethyl methacrylate), PPE (polyphenylene ether) and mPPO (modied polyphenylene oxide). Hillberg declines to reveal the composition of the
May 2013 | COMPOUNDING WORLD 39

additives feature | Electrical conductivity

Performance ranges from 1 X 103 to 1 X 1012 ohms/sq. Depending on the grade and compounding formulation, the powders are typically used at 15-40% loadings for stable resistivity. As inorganics, their performance is independent of temperature and humidity, and Morris adds that static properties are permanent. The compounding powders feature a core-shell structure in which a dense layer of antimony-doped tin oxide crystallites encases one of three core materials: hollow silica (high efciency and low density), mica (improved translucence in thin coatings), or titanium dioxide (shear resistance and good opacity). The materials are bonded together in a precipitation reaction, calcined at around 800C (1,500F) to fuse them, then milled to a particle size of 0.5-8 microns depending on the core material. There is also one coreless grade that consists of just antimony-doped tin oxide, which is used for transparent and UV-absorbing Estane supplies Stat-Rite polymer alloys for protective packaging of sensitive electronics grades, but says the ion conductivity levels out charge imbalances in part surfaces and neutralizes static elds without grounding. Static dissipation is permanent, and works at low relative humidity (RH) as little as 12% compared with 40-50% for most conventional materials. The grades are clean, with no outgassing or contamination of components, and properties reportedly remain stable in thin layers. Loadings average 5-15% for injection moulding and 15-25% for extrusion. Hillberg says that IDPs are nding greater use in consumer products, automotive components, electronics packaging, and chemical and food packaging. Evolving requirements for these applications include compatibility with a polymers mechanical properties, recyclability especially in packaging and of course, cost savings. As an example of performance gains, IonPhasE recently introduced IPE hSTAT, for high-heat (up to 330C, or 626F) engineering thermoplastics. applications. The company recently led patent applications for a formulation that will be more compatible with white and bright colours. Morris says antimony-doped tin oxide is inherently blue/grey, and even low loadings discolour parts. The new material will alleviate this. Slated for an undisclosed consumer product, it should be commercial in six months, he says.

Keep it clean
There is a move toward greater use of clean resins in sensitive applications ie polymers that dont generate static charges which can attract dust and contaminants, therefore making them suitable for clean-room manufacturing and other specialty processes. It also includes materials such as exible packaging and stretch wrap that keep sensitive electronics, ammable products and even explosives safe from static build-up, and polymer-rich household appliances like vacuum cleaners that can resist

No static at all
The ability to provide static dissipative materials that are effective and compatible with host polymers is important considering the cost of latent product damage caused by static charge. In the US alone, the damage exceeds several billion dollars annually, says David Morris, technology manager for Zelec conductive powders at Milliken. IonPhasEs inherently dissipative polymers use ion conductivity to neutralize static
40

Milliken supplies Zelec inorganic conductive powders for static dissipation. Much of the material goes for coatings on solid parts, adhesives and ooring applications. But the powders have a benet for compounding, Morris says. Based on antimony-doped tin oxide, Zelec powders create an interconnecting, particle-to-particle network that disperses static build-up.
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COMPOUNDING WORLD | May 2013

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Electrical conductivity | additives feature

To meet these needs, end-users seek permanent conductive and static dissipative materials, along with a wider selection of polymers treated with them. Suppliers working in this area include the Estane division of Lubrizol. There is a trend for more permanent static dissipative performance, typically above 106 ohms/sq, says Kurt Edwards, marketing manager for North America. Estane, which is vertically integrated, develops conductive compounds called Stat-Rite Polymer Alloys from IDPs, proprietary materials that the company polymerizes itself. IDPs are tailored for and compounded with base resins, such as PMMA, PS, PETG, polyolens, PVC, polyurethane and polyurethane elastomers (TPU). A sister division, Lubrizol Electronic Products, uses these compounds in nished goods like tote bins and product trays. Estane also sells masterbatches. New products that the company is working on include grades for low-density and linear-low-density polyethylene (LDPE and LLDPE) lms that withstand high alloying temperatures. The current limit is 246C (475F). The new grades will be targeted at thin lms for stretch wrap and other applications. Another supplier that uses polymers to develop conductive networks within compounds is BASF. The companys Irgastat P range of IDPs use polyamide/ polyether block copolymer technology to create 3D co-continuous networks through controlled phase separation so-called conductive percolating networks. The static dissipation is inherent in the chemical Irgastat P grades from BASF are effective at low RH and low loadings

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additives feature | Electrical conductivity

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masterbatch concentrates grades XS6057 and XS6135 for styrenic TPEs. Cabot uses carbon black and undisclosed additive packages to achieve conductivity. Cabot is backward integrated in carbon black, which allows it to increase investments in the material and develop t-for-purpose grades that meet emerging market needs, says Haines. He notes that the company has reduced trade-offs between conductivity and mechanical properties and processability with carbon black in Cabelec compounds. In one polystyrene compound, Cabot improved resistivity to 104 from 108 at the same loading, while increasing exural modulus and impact strength. In a PC compound, conductivity was similarly increased, along with melt-ow index, which rose to 25 g/min from 10 g/min. Additional functionalities that Cabot is researching for its conductive compounds include thermal conducIDPs and other antistats can preventing dust build-up on household appliances from triboelectric charges composition and morphology of the block copolymer, says Joel Fay, technical fellow. Irgastat grades can be compounded with many polymers, such as polyolens, PVC, TPU, styrenics, polyamides and polyesters. Surface resistivity is in the range of 109-1012 ohms/sq, and properties are unaffected by low humidity. Good performance has been tested at 10% RH. This is a plus, Fay notes, because the compounds are often used to fabricate parts in air-conditioned factories and clean-rooms, which have low humidity. The material is typically specied for transparent lms and moulded parts. Four grades are available: Irgastat P 16, P 18, P 20 and P 22. The P 18 and P 22 grades reportedly form more distinct networks and so can be used at lower loadings (4-15%). The P 16 and P 20 grades are generally used at higher loadings (8-25%), which broadens their processing window. P 18 and P 22 have boosters, and so do not require pre-compounding. tivity. While Haines declines to discuss specics, he does allude to one potential application of a conductive compound that also has thermal conductivity: heat creation in electric cars as an alternative to conventional heating systems. Another supplier of specialty carbon black products for adding electrical and/or thermal conductivity to thermoplastics is Timcal. It has recently announced that it is increasing production capacity for its conductive and highly conductive carbon black grades at its plant in Willebroek in Belgium. The new capacity is due on stream by the end of 2013. The company says that the expansion is in response to the massive potential of conductive carbon black growth coming from the conductive polymers market and from the lithium-ion batteries market. Thermal conductivity, in fact, is raising interest among many end-users as an added performance feature of conductive compounds. More customers are talking about thermal conductivity, says Neil Hardwick, conductive products marketing manager at compounder RTP Company. Thermally-conductive compounds can provide a heat sink in applications such as LED lights and automotive components. They can also be used to replace metals in part design, or to enhance existing plastics designs. RTP runs computer simulations to show how thermally conductive compounds cool parts as efciently as metal, Hardwick says. Thermal conductivity can be achieved with electrically conductive additives, which cost less than electrically isolative additives, notes Christopher Murphy, global business director of specialty compounds at Sabic Innovative Polymers, whose business-

Flexible strategies
New choices for conductive polymers include thermoplastic elastomers (TPE) and TPU. Among companies working with these materials is Cabot. George Haines, global segment manager for plastics, says that branching into TPEs and TPUs is a logical extension of conductive compounds for automotive applications. Automotive continues to be the dominant user of TPEs, he remarks. The development of electrical and hybrid vehicles will increase demand for these materials. Cabot calls its conductive compounds Cabelec, and they come in a number of materials polyolens, styrenics, EVA, PA 6, POM and PC. The company is developing a grade, Cabelec XS6308, for TPU, as well as two
44 COMPOUNDING WORLD | May 2013

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Electrical conductivity | additives feature

With the rapid growth in LED lighting, thermally conductive compounds represent potentially good metal-replacement solutions for heat sinks, he adds. PolyOnes Stat-Tech family of conductive and static dissipative materials includes thermal conductivity in some grades. Together with high levels of EMI/RFI shielding and ame-retardant properties, the grades achieve uniform dispersion of conductive elements to eliminate hot and cold spots in parts, says Stonecipher. Specifying a conductive compound with thermal properties can be tricky. Loadings will probably be on the high side owing to the thermodynamics of heat dispersion. Heat requires multiple paths to disperse, while electrical charges follow a path of least resistance to the ground. Another supplier that combines functionalities in one compound is PCC Chemax of Piedmont, South Carolina, part of the PCC SE group of companies based in Duisburg, Germany. Some of its Chemstat antistat grades have antifogging properties, says Stephanie Angelo, technical account representative. This makes it easier for a large compounder to use one grade for different applications, she explains. Many compounders also want to limit the types of chemicals in their plants. Recent formulations from PCC Chemax include Chemstat LD-100, an amide-based antistat in solid and powder form, which maintains properties down to 12% RH. The additive also complies with MIL-B-81705C, the US military specication for electrostatic-protective exible barrier materials used in the packaging of Cabot is exploring graphene applications based on technology from XG Sciences

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Electrical conductivity | additives feature

sensitive electronic devices and assemblies. PCC tailors many of its grades for individual users and has no minimum purchase requirements, Angelo says. Its antistats are based on proprietary formulations, as well as amine, glycerol, ester, polyglycerol ester and quaternary ammonium cations. Sabic also identifies a need for conductive materials with additional functionality. One area is industrial paper-handling applications. Murphy says that the company sees a need to combine different effects such as electrical conductivity and lubricity into a single compound. Sabic is also interested in developing conductive compounds with higher heat, impact resistance and flame-retardant properties for handheld devices and other electronics used in potentially explosive environments, as well as for business machines, automotive interiors and healthcare diagnostic equipment.

achieving conductivity at very low loadings to minimize impact on mechanical properties or processability, while bringing additional functionality such as thermal conductivity and barrier properties, says Haines regarding work at Cabot. The company signed a licensing agreement with the graphene technology specialist XG Sciences in November 2011 (details at http://bit.ly/CabotXG). A benefit to compounders and other suppliers of conductive materials is that many companies are scaling up CNT production and reducing their prices. Some say that the drop in prices is moving CNT use toward the mainstream, though they remain mostly niche materials that are used when their benefits of improved conductivity, greater physical properties and low contamination are necessary. CNTs work well in compounds because, although their loadings are low relative to other additives, they have a high aspect ratio. When properly dispersed, the nanotubes create extensive networks within a polymer matrix that increase conductivity and other properties. RTP, for one, has invested considerable time and money in learning how to efficiently compound CNTs. It took us years to do, says Hardwick, but once we got the process down, we were able to produce large volumes of conductive compounds at up to a 75% reduction in conventional filler loading. Hardwick does Compounders developing formulations incorporating carbon nanotubes include RTP and PolyOne

Small wonders
One emerging area of conductivity is nanomaterials. Compounders can use carbon nanotubes (CNT) as well as graphene (a pure carbon material whose atoms are arranged in a repeating hexagonal pattern in sheet one atom thick) to enhance electrical performance while reducing trade-offs in mechanical properties. Graphenes offer interesting attributes in terms of

Profiles
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Background image courtesy of: CertainTeed Corporation Other images courtesy of: PolyOne Corporation

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Electrical conductivity | additives feature

not discuss the process, beyond saying CNTs are supplied in clumps and the company has learned how to meter them into a compound and disperse them without affecting their length, which would reduce performance. Another supplier of CNT-based compounds is PolyOne, with Stat-Tech NT. The CNTs are compounded in acetal, polyetheretherketone, polyetherimide and PC. Target applications include media storage, integrated circuit packaging and semiconductor devices. Sabic uses nanomaterials, but only for niche applications and unique customer requirements, says Murphy. These are usually compounds where customers cannot use high loadings of conventional fillers because of other performance requirements such as impact strength or specific gravity, he explains. Typically, we achieve similar conductivity with traditional filler systems at a much lower cost compared to nanomaterials. Work on commercialising nanomaterials is focusing on making them cost-effective for compounders. Dave Arthur, CEO of SouthWest NanoTechnologies (Swent) of Norman, Oklahoma, explains how the company is reducing loading levels and planning to scale up production. He says that Swents SMW specialty multiwall CNTs have a higher average aspect ratio than other multiwall materials. This means that they can achieve greater conductivity and a better mix of properties. Although SMW nanotubes are 2-3 times more expensive than competitive multiwall grades, their reduced loadings compared with most other CNTs leads to lower compound costs that reduce or eliminate price Electrical compounds with thermal conductivity are an efficient way of combining properties for high-heat products like LED

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additives feature | Electrical conductivity

other electronics. The shielding is permanent, the company says, adding that the Toho Tenax fibres can be compounded with other polymers, as well. Another supplier of metal fibres is Bekaert, a global company with headquarters in Belgium. The suppliers Beki-Shield GR stainless steel fibres are chopped and coated with polymer binders, and sold as a melt compound, masterbatch or for dry blending. Loadings average 4-15%, and the company says that the materials provide electromagnetic interference shielding and electrostatic dissipation.

More information
Electrically- and thermally-conductive compounds will be covered in a special session at the Compounding World Teijin uses its Toho Tenax nickel-coated carbon fibre in a PC compound to shield personal electronic devices differences. Arthur says, for example, that conventional multiwall grades generally require 3% loadings for conductivity. The SMW grades, in contrast, achieve similar performance at 1% loadings. The company makes CNTs in a proprietary catalytic process that is engineered to grow long tubes, which enhance aspect ratio, conductivity and other properties. The CNTs are 10 nanometres (nm) in diameter and 400-500 nm long. Swent is scaling up operations from its current capacity of 1 ton per month. A very different way to use carbon to add electrical conductivity to plastics comes in the shape of metalcoated carbon fibres. Suppliers include Teijin of Japan, which recently applied its Toho Tenax nickel-coated fibre to the companys PC resin. The result, a representative says, is a lightweight material with conductivity and high strength that is being promoted for electromagnetic shielding in smartphones, tablets and Click on the links for more information: Forum 2013, which takes place in Philadelphia, PA, USA, on 10-11 December. Details at: http://bit.ly/CWF2013.

www.polyone.com www.ionphase.fi www.milliken.com www.lubrizol.com www.basf.com www.cabot-corp.com www.timcal.com www.rtpcompany.com www.sabic-ip.com www.pcc-chemax.com www.xgsciences.com www.swentnano.com www.teijin.com www.bekaert.com

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END OF LIFE PLASTICS 2013


International conference and exhibition on commercial markets and options for end of life plastics
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Chinaplas 2013 | exhibition preview

This months Chinaplas exhibition in Guangzhou promises to be bigger than ever. We highlight a selection of exhibitors that will be of interest to compounders

The compounders guide to Chinaplas


The 27th Chinaplas exhibition is taking place in Guangzhou, China, on 20-23 May and it promises to be bigger than ever. The annual event, which alternates between Shanghai and Guangzhou, is now rmly established as the worlds second biggest plastics industry exhibition after the K show in Dsseldorf, Germany (see table). Adsale, the events organiser, says that it is expecting over 2,900 exhibitors in Guangzhou, and that more than 500 of these will be participating in Chinaplas for the rst time. It is also predicting record visitor numbers of 115,000, which compares to almost 110,000 at last years event in Beijing and just over 94,000 for the 2011 show in Guangzhou. The show is being held across 25 halls at the China Import & Export Fair Complex, Pazhou, Guangzhou. Its opening hours are 09:30 to 17:00, and tickets cost RMB 30 for a one-day pass or RMB 50 for all four days. Alternatively, visitors who pre-register online before 16 May will obtain free admission. Compounders will be pleased to note that pigment and masterbatch companies will be gathered together Exhibition K 2010 Chinaplas 2013 (predicted) Chinaplas 2012 NPE 2012 Visitors 222,486 115,000 109,858 55,359 Exhibitors 3,094 2,900 2,729 1,933 Automatik Plastics Machinery and Maag Pump Systems will exhibit together at Chinaplas. Automatik will display a Sphero 50 underwater pelletizing system, plus a locally manufactured Baoli 200 strand pelletizer. Maag will show melt pumps and melt ltration systems. The latest Sphero 50 features improved ergonomics for faster start-ups, process reliability even with difcult products, and outstanding pellet quality, says Automatik. All of its components are mounted on a mobile frame, offering easy access from all sides. This simplies cleaning of the machine and product changeovers. It is the smallest underwater pelletizer in Automatiks range and is suitable for applications in technical centres as well as smaller production runs with Left: How Chinaplas compares with the recent K and NPE shows (based on organisers gures and predictions)
55

in Hall 9.3 in Zone B, while additive companies will be located in Hall 10.3. More than 170 companies will be included in these two zones, according to Adsale. Over the following pages we look at a range of exhibitors that will be of interest to compounders and masterbatch makers, including a selection of local suppliers.

Above: More than 2,900 exhibitors and 115,000 visitors are expected to head to Guangzhou for Chinaplas 2013

S www.chinaplasonline.com

Machinery and equipment

www.compoundingworld.com

May 2013 | COMPOUNDING WORLD

exhibition preview | Chinaplas 2013

German machine makers see fall in exports to China after recent growth
Germanys plastics machinery makers reported a 16.4% decline in exports to China in
Canada 3.1% France 3.9% Republic of Korea 5.3% Italy 5.3% USA 5.8% Others 10.4% Germany 30.9%

2012. After growing rapidly to reach a new high of 766.4 million in 2011, sales fell to 640.4 million in 2012, according to the VDMA, Germanys Plastics and Rubber Machinery Association. It says that the decline represents a certain consolidation after two years of above-average growth in exports to China (a remarkable 64.4% in 2011 and 30.5% in 2010). Germany is the leading exporter of plastics and rubber machinery to China. Full data for 2012 is not yet available, but in 2011 it had a share of 30.9% of the total export market, which it valued at 2.48 billion. Japan was second with a 23.8% share, followed by Taiwan with 10.8%, the USA with 5.8% and Italy with 5.3%.
Japan 23.8%

World exports of plastics and rubber machinery to China in 2011 (total: 2.48 billion)

Taiwan 10.8%

The German Pavilion at Chinaplas will feature 140 exhibitors and will occupy more than 3,800 m2.

S www.vdma.org

throughputs up to 600 kg/h. The cutter hub and the cutting chamber have been designed to optimize the ow of pellets in order to minimize dust generation. The Baoli dry-cut strand pelletizer is a tried and tested product with more than 500 installations in China alone. Manufactured at Maags new Shanghai facility using German technology, the machines are available with operating widths of 100, 200 or 300 mm. State-ofthe-art cutting tools ensure both a long equipment lifespan as well as very high throughput rates - up to

facility in Shanghai using key components, such as gears and bearings, that are made in Maags European facilities. The EA pump covers most standard extrusion applications, providing a differential pressure of up to 200 bar, and it represents a versatile yet cost effective solution.

S www.maag.com
Brabender of Germany will be showing its Plastograph EC Plus, an economical table-top version of its Plasti-Corder Lab-Station universal torque rheometer. It has a digital 3.8-kW motor, a torque measuring range of 200 Nm and a speed range from 0.2 to 150 min-1. It can be used in conjunction with Brabenders 30 and 50 series measuring mixers, type 19 measuring extruders, and its conical twin-screw extruder. Applications include raw material and recipe development, materials testing, quality control, process optimization, and lab-scale sample production.

Automatiks Sphero 50 is designed for easy access

3,000 kg/h for PBT or PET compounds. Maag Pump Systems will unveil its brand new Extrex EA pump, which has been developed specically for the Asian market. It is assembled in the companys new

S www.brabender.com
C.A. Picard will be using Chinaplas to highlight its expertise in wear-resistant replacement parts for twin-screw extruders, including screw elements, barrels, liners and shafts. These are offered in a wide range of materials to deliver the required levels of abrasion and corrosion resistance. They cover machines with screw diameters from 12 to 380 mm. With operations in Germany, the USA, China and Japan, the company also offers barrel measurement and repair services for extruders, as well as machine dismantling expertise.

S www.capicard.com
56 COMPOUNDING WORLD | May 2013

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Order online or by telephone, fax or email. Contact Matt Wherlock, Tel: +44 (0)117 924 9442 Fax: +44 (0)117 9892128 email: mjw@amiplastics.com All prices are correct at the time of publication but may be subject to change. Please check the Plastics Information Direct website for current prices and shipping charges.

exhibition preview | Chinaplas 2013

system at Chinaplas. This simple device measures the productivity and efficiency of the feeding line, monitoring material consumption in real time and providing statistics on production volumes. The Ryng device is inserted between the loading container and the storage hopper with a high-precision weighing device placed inside it to give an instant and precise measurement of the quantity of material transferred. This allows operators to take prompt action on the machines operating parameters and recieve information on the machines effective productivity. Brabender will be showing its Plastograph EC Plus torque rheometer Global Precision Machinery Industries, which has operations in Taiwan and China, manufactures singleand twin-screw extruders plus a range of pelletizers including strand, water-ring and underwater designs. The company will be highlighting its GPM E-Type 50 twin-screw extruder and underwater pelletizer equipment, designed for stable performance and high output. The die-head is configured for easy cleaning and quick colour changes. Servo-control of the pelletizers cutter provides precise force regulation, reduces die wear, and increases process stability. The system uses proprietary software, incorporating specific algorithms which filter and interpret the gathered data to indicate the actual quantity of transferred material. Ryng measures the quantity of material that the container loads into the hopper, therefore allowing real-time comparisons to be made between the machines expected throughput and its actual production rates. In addition, the software is programmed to exclude or reduce to a minimum any measurement fluctuations that may be caused by the inevitable vibrations felt throughout the feeder system due to the machines normal operation. Therefore, the system achieves KRD Industry System of Shanghai, China, will be showcasing its materials handling equipment for bulk materials and powders. Its extensive product range includes discharging, conveying, feeding and dosing systems, plus a variety of bulk handling valves, vibrating screens and mixers. ProTec Polymer Processing of Germany is making its first appearance as an exhibitor at Chinaplas this year. It will be presenting systems for improving the properties of technical polymers, especially polyesters and Kreyenborg will be displaying melt filtration systems, melt pumps and its IRD infrared drum for drying and crystallising recycled PET. On the same stand, the groups BKG operation will be showing its latest underwater pelletizing systems, including an Optigon line. Kreyenborg offers the full range of screen-changer designs from discontinuous and continuous systems to fully automatic backflush designs. They permit the processing of highly contaminated material to highquality products in very sensitive applications. BKG will be showing its Optigon underwater pelletizer BKGs underwater pelletizing systems are supplied ready for use with drying, water circulation and control systems. The range covers throughputs ranging from 2-80 kg/h for the Labline 100 up to with 35,000 kg/h for the largest systems. The company has also developed the CrystallCut in-line crystallisation and pelletizing system specifically for PET processing applications. polyamides. The systems range from vacuum reactors to complete turn-key lines for polymer recycling, such as the bottle-to-bottle recycling of PET. The companys OHL tumble reactor is used for the PET treatment process, purging the pellets of any volatile contaminants, while also carrying out postcondensation to increase the materials intrinsic viscosity. The rPET produced by the OHL process has an acetaldehyde content of less than1 ppm and exhibits high-precision measurements with a maximum error rate of less than 1%.

www.continent-machine.com

www.piovan.com

www.krdbulk.com

www.kreyenborg-group.com
Piovan, the Italian materials handling and control systems supplier, will be introducing its new Ryng
58 compounding world | May 2013 www.compoundingworld.com

Chinaplas 2013 | exhibition preview

properties just like virgin PET product, says ProTec. In addition, the OHL tumble reactor can carry out decontamination and post-condensation of other polyesters, such as PBT or PEN, as well as processing polyamides. ProTec Polymer Processing will also use Chinaplas to provide information on its Somos range of materials handling systems, including dryers, conveyors and dosing systems.

www.sp-protec.com
Tecnofer of Italy will be in Guangzhou to show off its plastics recycling systems. It produces a range of heavy duty equipment for washing, drying, separating, shredding, grinding, agglomerating, mixing and storing plastics waste. It also supplies complete washing lines with capacities from 150 to 4,000 kg/hour. Custom-built systems are offered for PET bottles, PE or PP films, and rigid PE or PP products such as bottles, containers or crates. In addition, Tecnofer makes compact integrated lines for recycling plastics waste on a smaller scale. flame-retardant PBT grades for electronic and automotive components. The company also supplies white masterbatch products for food packaging applications, plus it produces special weather-resistant grades for use in industrial protection films. ProTecs OHL tumble reactors are used for improving the properties of polyesters and polyamides Croda will be focusing on two new additives at ChinapZhongshan Guzhen Huaxin Plastic Machinery will be showcasing its integrated plastics recycling lines. These typically include: a vented extruder; an underwater pelletizing system; a vertical de-watering unit; a vibrating screen; an air-feeding system; and a material collector. The company highlights a number of benefits of using underwater rather strand pelletizing, including reduced dust formation, improved pellet quality, and more efficient pellet drying. las. The first is Atmer 7373, an anti-fog concentrate for clear PP food packaging. It is effective in both hot and cold fogging applications, preventing droplet formation on plastic surfaces to keep the food looking fresher for longer. The company says that the 40% concentrate is particularly useful for converters who can easily handle its pellet form. It is also useful for masterbatch producers who either cannot or do not wish to handle soft and pasty raw materials. The other new product being showcased by Croda is its IncroMax TM 300 additive for polycarbonate processing. It reduces surface friction and improves mould release characteristics to enhance the extrusion and moulding of polycarbonate. Target applications include glazing products for the construction and automotive Arrotin Plastic Materials of the US will be focusing on its wide range of recycled plastics materials, which include ABS, PMMA, PET, PE, PET PS, PVC and PC. The company is a large buyer and supplier of post-industrial materials and it operates facilities in California and Indiana. Egyplast will be showing its PVC compounds, plus its range of masterbatch products. The former include rigid and flexible grades, while the latter include black, white, colour and special effect products. It also offers HFFR and XLPE compounds for cable insulation. Beautiful Color Plastic Chemical of Foshan, Guangdong, China, will be showing a range of its masterbatches and engineering plastic compounds. The latter include flame-retardant ABS grades for electrical industry applications, plus glass-fibre-reinforced,
www.compoundingworld.com 

www.mzc.cc

www.tecnofer.biz

www.huaxinsj.com

Polymers and additives

industries where high optical clarity is required.

www.croda.com/pa

www.arrotin.com

The Egyptian-headquartered company is a subsidiary of the cable producer Elsewedy. It was initially formed to meet internal requirements, but has subsequently grown to become a major compounder in the Middle East.

www.elsewedy-plastic.com

May 2013 | compounding world

59

exhibition preview | Chinaplas 2013

tions areas such as electrical and construction. They are claimed to have the highest limiting oxygen index (LOI) for any thermoplastic processable polymer. The US-headquartered company is currently building its first commercial-scale plant in Antwerp, Belgium. It is due to be completed by the end of this year.

www.frxpolymers.com
Holliday Pigments will be highlighting its ultramarine products including its Premier FRX pigment, which is designed for applications where dispersion, transparency, impact resistance and tensile strength are of paramount importance. Examples include fibre masterbatches, PET bottles and automotive components. Huaxin Plastic Machinery will be demonstrating the benefits of underwater pelletizing ExxonMobil Chemical will be in Guangzhou to discuss how its Vistamaxx propylene-based elastomer can be used in a broad range of compounding applications including masterbatch products. For example, Shanghai Xiner Low-Carbon Environmental is using Vistamaxx to simplify the manufacturing process, reduce costs and improve the quality of its filler masterbatch products. The addition of Vistamaxx to masterbatch compounds can reduce compounding costs as it enables increased calcium carbonate (CaCO3) levels and lower processing temperatures. It can also enhance the manufacturing process due to the generation of less dust. With the addition of Vistamaxx to CaCO3 masterbatch products, which are typically based on hPP or LLDPE, end-products can benefit from a combination of enhanced impact and tear strength, improved tenacity and better dispersion. ExxonMobil says that adding Vistamaxx to masterbatch compounds improves the dispersion of the CaCO3, which can also improve surface finish and reduce failure and defect rates. When running at faster line speeds of 120 to 140 metres per minute, PP woven bag manufacturers can benefit from better anti-fibrillation performance, less yarn breakage and fewer dusting problems for monoEgyplast offers a range of colour masterbatches filaments. In addition, the let-down ratio in PP raffia tapes, which is usually about 10%, can be doubled using Vistamaxx to partially replace the incumbent polymers and increase the CaCO3 loading level. Jinan Subang Chemical of Jinan City, Shandong Province, China, will be exhibiting at Chinaplas 2013 to The company will also be showing its new violet and pink ranges. Premier VSB is a violet, strong blue shade pigment, while Premier VSR is a violet, strong red shade. Both grades exhibit a 20% higher tinting strength compared toexisting industry standard pigments, according to Holliday. Premier PX is a new ultramarine pink that is claimed to extend the tinting strength of the companys red shade inorganic product by a further 10%.

www.holliday-pigments.com
Invista will be promoting its Torzen range of PA 66 resins and compounds. These includes feedstock for compounders, plus a variety of glass- and mineral-filled formulations as well as toughened, lubricated, heatstabilized and fast-cycling products. They are said to provide a significant improvement in continuous use and peak temperatures. Target markets include the automotive, electrical and appliance sectors.

www.invista.com

www.exxonmobilchemical.com

FRX Polymers will be promoting its Nofia flame retardant polymers that can be used as an additive in other plastics or as a stand-alone inherently flame retardant material. The environmentally-friendly grades are based on polyphosphonate homopolymers, copolymers and oligomers. The plastics are said to be tough, transparent and simple to process and are intended for use in applica60 compounding world | May 2013 www.compoundingworld.com

PLASTICS IN PHOTOVOLTAICS
2 0 1 3
International conference on backsheets, encapsulants and other polymer materials in photovoltaic systems
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September 10-11, 2013


Images courtesy of: EVONIK INDUSTRIES AG and SBM SOLAR INC.

Hilton Philadelphia City Avenue, Philadelphia, Pennsylvania, USA

SPECIAL OFFER: Save $200 if you register before August 2, 2013


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exhibition preview | Chinaplas 2013

Songwon Baifu Chemicals started the production of thioester antioxidants last year

promote its range of optical brighteners and pigments. Optical brighteners with different chemistries and tints are offered for use in a wide range of polymers. For example, its EBF grade is suitable for applications in PVC, PS, PP, PE, ABS, PA and PPMA.

www.sbchem.cn
Jinge Fire-Fighting Materials will be promoting not only fire retardant additives, but also thermally-conductive fillers for polymers. Based in Foshan, Guangdong, the company supplies a range of fire retardant additives, including aluminium hydroxide, magnesium hydroxide and zinc borate. Its thermally conductive additives include aluminium oxide.

www.gdjinge.com
PolyOne will be showing medical compounds from its subsidiary Neu Specialty Engineered Materials. Neu recently collaborated with FinLumen, a Beijing-based medical tubing extruder established by the Chinese medical device supplier Demax Medical Technology. The companies worked together to improve the performance, processability, part quality and appearance of a minimally invasive surgical catheter. Neu developed a specialty material that meets the end-use and regulatory requirements of the device, while reducing scrap rates by 50%. Songwon will be promoting its growing polymer stabilizer business at Chinaplas 2013. It is already a producer of such additives in China through its Songwon Baifu Chemicals joint venture with Tangshan Qingdao Operate New-Material will be using the Guangzhou exhibition to raise awareness of its non-halogenated flame retardant additives. It offers a range of grades for applications in PBT, ABS, PS, polyolefins, polyamides, TPU, TPE and epoxies. The phosphinate-based additives achieve their flame retardant effect through intumescence. Baifu Chemical. This venture successfully commenced operations in July 2012 with an annual production capacity of 8,000 tonnes of thioester antioxidants. The company will also be discussing growth of its one-pack system (OPS) business. It has doubled capacity to 14,000 tonnes at itsGreiz facility in Germany, plus it recently started production at a 7,000 tonnes/ year plant inHouston, USA. Next year it will add another 7,000 tonnes of capacity in Abu Dhabi. Holliday Pigments Premier FRX products are aimed at demanding applications such as PET bottles S.A. Revert, which has its headquarters in Spain, will be exhibiting its range of calcium carbonate products at Chinaplas. It obtains the mineral from two deposits in Spain and one in Mexico. Its two production plants in Spain have a combined annual capacity of close to 1 million tonnes, while its Mexico plant has a maximum output of more than 500,000 tonnes/ year. The company says that its calcium carbonate fillers for thermoplastics offer high purity and low abrasiveness. It offers treated or untreated, micronized
62 compounding world | May 2013

and ultra-micronized grades of white calcite and extra white marble.

www.reverteminerals.com

www.polyone.com

www.qdoperate.com

Songwon has also entered into a long-term distribution agreement withSabo to distribute the Italian companys HALS (Hindered Amine Light Stabilizer) products on a global basis.

www.songwon.com
Weifang Kaihong Chemical will be promoting its hexabromocyclododecane (HBCD) brominated flame retardants at this years Chinaplas. These can be used in extruded and expanded polystyrene (EPS and XPS). The company, which is based in Chinas Shandong province, offers masterbatch quality grades.

www.kaihongchem.com

www.compoundingworld.com

BOPP FILM 2013


The international conference and exhibition for the bi-oriented polypropylene lm industry
CLICK HERE FOR DETAILS

Images courtesy of: Brckner Maschinenbau GmbH & Co. KG

PLATINUM SPONSOR

25-27 June 2013


Marina Bay Sands Hotel, Singapore

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Download the programmes for these forthcoming conferences


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

Masterbatch
M A S T E R B AT C H
2 0 1 3
Connecting with downstream customers

Proles
This years edition of AMIs well-established Masterbatch conference will be held in Frankfurt, Germany, on 3-5 June. This brochure has the full programme which includes speakers from Coca-Cola, Danone, Nokia and Johnson & Johnson.

Profiles

2013

International business and technology conference for the window, door, decking, fence and siding profile industry

HEADLINE SPONSOR

AMIs international business and technology conference for the window, door, decking, fence and siding prole industry is being held in Philadelphia, PA, USA on 4-5 June. Download the brochure for full details.

3-5 June 2013


Marriott Hotel, Frankfurt, Germany
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Background image courtesy of: CertainTeed Corporation Other images courtesy of: PolyOne Corporation

June 4-5, 2013


Hotel Sofitel Philadelphia, Philadelphia, Pennsylvania, USA

SPECIAL OFFER: Save $200 if you register before April 26, 2013

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End of Life Plastics


END OF LIFE PLASTICS 2013
International conference and exhibition on commercial markets and options for end of life plastics

Multilayer Packaging Films


Multilayer Packaging Films 2013
International business and technology conference for the flexible packaging industry

4-6 June 2013


Maritim Hotel, Cologne, Germany
* + 19% German VAT

Taking place on 4-6 June in Cologne, Germany, this international conference will address the commercial markets and options for end of life plastics. The programme includes experts on legislation, waste management and recycling technologies.

Returning to Chicago in June, the Multilayer Packaging Films conference features an impressive line-up of speakers covering the latest industry trends and new developments in materials and processing technology.

June 5-6, 2013


The DoubleTree Chicago Magnificent Mile, Chicago, Illinois, USA
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Fire Retardants in Plastics


FIRE RETARDANTS Template IN PLASTICS 2013
Trends and technical developments in the international flame retardant industry

Thin Wall Packaging USA


THIN WALL PACKAGING 2013
International conference on lightweight plastic tubs, trays, jars, containers and cups for food packaging

Images courtesy of: GBH International and ICL-IP

Images courtesy of: Danone and Printing Company Verstraete

June 13-14, 2013


Grand Hyatt Denver Denver, Colorado, USA

AMI is holding its third US conference on Fire Retardants in Plastics in Denver, Colorado, on 13-14 June. The packed programme covers the latest FR technologies as well as addressing environmental issues, legislation and testing standards.

HEADLINE SPONSOR

The American version of AMIs Thin Wall Packaging conference returns to Chicago on 18-19 June. This brochure has the full programme which covers the latest developments in thermoformed and injection moulded packaging.

June 18-19, 2013


The Westin Chicago North Shore, Chicago, Illinois, USA

SPECIAL OFFER: Save $200 if you register before May 3, 2013


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To see our full line-up of more than 25 plastics industry events over the next 12 months, please visit www.amiconferences.com

Polymers and additives | products

Rockwood obtains FDA food contact approval for Solaplex


Rockwood Pigments Solaplex bright yellow to orange inorganic pigments have been granted a Food Contact Notification (FCN1252) by the Federal Drug Administration (FDA). They are based on Color Index Pigment Yellow 216. The FDA approval will enable formulations to be developed for many specialist applications involving indirect food contact including childrens toys and play equipment, food and personal care packaging, household goods and bake-ware. Rockwood says that Solaplex delivers brilliant shades with long-lasting UV durability, good hiding power and stability at high temperatures up to 400C. The eco-friendly rutile tin zinc chemistry was introduced more than 10 years ago and is well established as an alternative to lead chromates and other heavy metal containing pigments. The company claims that new regulatory concerns over nickel-containing inorganic pigments will further extend its use.

pigments

pvc additives

Eastman adds new plasticizer


Eastman Chemical has expanded its portfolio of non-phthalate plasticizers with the addition of Eastman 168 SG (sensitive grade). This new grade is targeted at highly sensitive applications, such as medical devices, toys, childcare articles and food-contact products. The new plasticizer can be used as an easy replacement for DEHP and TOTM, providing clean toxicological and regulatory profiles while remaining cost-efficient.

www.rockwoodpigments.com

www.eastmanplasticizers.com

mineral fillers

Renewable filler enters new application


US Aragonite has announced a new high-volume application of its Oshenite renewable mineral filler which is harvested from the sea. The material is being used by Western Industries for the manufacture of the Styleworks Tough Tote, a blowmoulded HDPE storage container that is sold through major American retailers such as Wal-Mart and Home Depot. The mineral filler in this application has been switched from mined calcium carbonate to a 20% loading of the renewable ocean-precipitated calcium carbonate. John Mars, executive director of operations at Western Industries said: Our team has over 100 years of cumulative experience in the blowmoulding business so they are typically sceptical of anything new and anything new has to work with the same efficiencies and effectiveness as the technically
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the huge sizes we do. Oshenite is an oolitic aragonite that is harvested by US Aragonite from the seabed in the Bahama Banks. The high-purity calcium carbonate is formed from microscopic marine materials such as algae and plankton. This is a localised phenomena caused by the confluence of warm and cold ocean currents in the area around the Bahamas. The material is being compounded by sound system we have in place before the substitution. Oshenite worked seamlessly. We didnt have to change our tooling set-up at all. Mars added: Not only does Oshenite provide a more sustainable, eco-friendly additive, it also allows for more costeffective production through faster production times, lower processing temperatures, and more consistent quality in the blow-moulded product. This is no easy feat when you are moulding at Bayshore Industrial, which is part of A. Schulman and operates a plant in La Porte, Texas. Earlier this year, US Aragonite announced that Oshenite is being used by United Dairy in its EcoJug one-gallon milk bottle (Compounding World, March 2103). For more details on Oshenite, see the mineral fillers article in the September 2012 edition of Compounding World - http://bit.ly/fillers. www.usaragonite.com
May 2013 | compounding world 65

products | Polymers and additives

compounds

RTP solves tricky medical problem


RTP has developed a radiopaque nylon compound for Mexican medical device manufacturer Plsticos y Materias Primas (PyMPSA). The biocompatible material is used to extrude a new catheter for epidural anaesthesia, and it overcomes production problems encountered with compounds from another supplier. With our original supplier, the extruded nylon ended up with a lot of air bubbles, so it was far from meeting the quality criteria we and our customers demand, explains Claudia Mancilla Ramirez who is an engineer with PyMPSA. She adds that RTP listened to their problems and requirements. Not only did they develop a custom material for our application, they backed it up with technical support. They sent an extrusion technician here who worked side-by-side with our extrusion engineer RTP worked with PyMPSA to overcome production problems with its new catheter Lily Daz to ensure production of a high quality product. RTP developed a custom RTP 2900 Series polyetherblock-amide (PEBA) thermoplastic elastomer compound for the catheter that included radio pacifiers and solved the air bubble problem. The success of the catheter project has led to PyMPSA working with RTP on producing the catheter in several different colours to help medical and manufacturing personnel quickly identify different diameter versions.

www.rtpcompany.com

waxes

Vlpker broadens scope for montan wax


Vlpker is highlighting a wide range of benefits that montan waxes can deliver in compounds based on a variety of resins including PVC, PA, PC, TPU and SMA. It says that montan ester and acid waxes can function as lubricants, nucleating agents and dispersion aids. The special molecular structure of montan waxes, which includes both polar and non-polar components, means that they can function as both internal and external lubricants. For example, their good solubility in PVC formulations means that they can decrease shear heating for injection moulding or for other applications which require a low melt viscosity. They can also act as
66

release agents by accumulating at the interface, while still being firmly anchored in the polymer, ensuring that no plate-out occurs. In addition to working as lubricants, montan waxes can also function as nucleating agents in engineering plastics such as polyamides. A further application for montan waxes is as dispersion aids in colour masterbatches to promote the successful distribution of pigments in the host polymer. In addition, Vlpkers Waradur E grade is used as a processing aid in TPU, for example in the production of sport shoe soles (pictured right). Vlpker obtains its crude montan wax from the worlds

largest producer of the material, Romonta, which extracts bituminous lignite from its own open-cast mine in Amsdorf, Germany. The wax content of this material is especially high. It is also in plentiful supply, with existing deposits expected to last until at least 20302032, while further deposits are being explored to extend this supply still further. Following various purification operations, the crude montan wax undergoes complex saponification, oxidation and esterification processes in the Vlpker manufacturing facilities to produce a partially synthetic,

very bright-coloured and extremely hard montan wax derivatives with excellent lubrication properties.

www.voelpker.com

compounding world | May 2013

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This months free brochure downloads


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

C.A. Picard: extruder technology


EXTRUDER TECHNOLOGY

Feddem: twin-screw extruders


Twin-Screw Extruder FED-MT

This 10-page brochure from C.A. Picard International covers its high-quality replacement parts for extruders, mixers and kneading machines. These include screw elements, kneaders, screw shafts, barrels, cylinders and bafes.

This eight-page brochure from Feddem showcases the German companys FED-MT range of twin-screw extruders. These exible machines can handle a wide range of tasks and are designed for quick changeovers.

FEDDEM GmbH & Co. KG Member of the Feddersen Group

Click here to download

Mosaikweg 19 53489 Sinzig Germany Phone: +49 2642 90781-30 Fax: +49 2642 90781-99 info@feddem.com www.feddem.com

Click here to download

Buss: Kneader for cable compounds


BUSS Kneader Series MX High-end compounding technology for high-grade cable compounds

ICMA: compounding systems


This 20-page brochure from ICMA San Giorgio covers the companys advanced compounding and extrusion systems. These include special lines for recycling, direct extrusion, reactive compounding, and processing natural bres.

This eight-page brochure from Buss focuses on the companys MX Kneaders and their use in the production of high-grade cable compounds, including HFFR products. The Kneaders feature quantec four-ight screw technology.

ONE CO-ROTATING HEART IS BEATING IN OUR SYSTEMS

CO-ROTATING TWIN SCREW EXTRUDERS

BUSS Kneader Technology

COMPOUNDING

ADVANCED RECYCLING

NATURAL FIBERS

DIRECT EXTRUSION

LAB SYSTEM

OUR PEOPLE MAKE THE DIFFERENCE

Click here to download


13394_216_Buss_MX_final_12.1.indd 1 16.01.12 09:39

www.icmasg.it

Click here to download

Timcal: carbon addtives


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

Steer: SPL40 turn-key lines


This eight-page brochure covers Steer Engineerings new SPL40 compounding pelletizing systems that include feeders, extruders, strand die heads, water troughs, air knives, pelletizers and classiers.

Click here to download

Click here to download

If you would like your brochure to be included on this page, please contact Claire Bishop. claire@amimagazines.com. Tel: +44 (0)20 8686 8139

compounder of the month

Kafrit Group
Head ofce location: Date founded: CEO: Ownership: No. of employees: Sales 2012: Plant locations: Production 2012: Prole: Kfar Aza, Israel 1974 Mr. Avi Zalcman Public company traded on the Tel Aviv stock exchange 400 US$180 Million Kfar Aza, Israel; Rthen, Germany; Suzhou, China; Langley, Canada 55,000 tonnes Kafrit, which has been in the market for 40 years, is an innovative producer of customized masterbatches and compounds for the plastic industry. The group has grown primarily via acquisitions including: Constab Polyolen Additives, Germany (2003); Chinas Suzhou Constab Engineering Plastics (2008); and the latest holding control in Canada-based Silon Compounds (with 51% of shares acquired in 2009). Kafrit supplies masterbatches, compounds and additives to a wide range of industries including packaging lms (BOPP, CPP, PE), PC sheet, agricultural lms, biopolymers, ame retardant applications, PEX pipes, bres and nonwovens. The portfolio includes: white masterbatches; ame retardants; antistatic, antifog, antiblock and antislip compounds; UV absorbers and stabilizers; processing aids; PEX compounds; and many more. Kafrit Group sees itself as an innovative producer of high-quality and costeffective masterbatches and compounds.

Product line:

Product strengths:

Forthcoming features
The next issues of Compounding World magazine will have special reports on the following subjects: June PVC stabilizers Focus on weather resistance Compounding bioplastics July Anti-microbials and biocides Screenchangers and melt ltration Understanding and monitoring colour

Editorial submissions should be sent to Andy Beevers: abe@amiplastics.com For information on advertising in these issues, please contact Claire Bishop: claire@amimagazines.com Tel: +44 (0)20 8686 8139

Catch up on our recent issues for FREE


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Compounding World April The 50th edition of Compounding World reports on sustainable compounding in action, plus it examines market drivers and technology innovations for wire and cable applications. It also covers developments in antioxidants, and troubleshooting for pellet defects. Click here to view Compounding World March The March edition of Compounding World looks at the latest options in natural bre reinforcement and reviews additives for enhancing PET properties. It also explores the latest twin-screw extruder developments and trends in the polymer distribution sector. Click here to view

Injection World May Injection Worlds May edition is packed with information on the latest automotive applications, developments in process cooling, plus the latest in TPEs. It also has a guide on design for demoulding, and reports on the highlights of Chinaplas. Click here to view

Injection World April This issue of Injection World covers polymers for LEDs, recycled PP for automotive parts, multi-component moulding of connectors, real-time process monitoring, high-performance bioplastics, and mould design developments. Click here to view

Pipe and Prole March/April The March/April edition of Pipe and Prole Extrusion looks at the latest developments in extrusion screw design, techniques for joining plastics pipes and new developments in polyolens for pipe applications. This issue also looks at highlights of the Chinaplas exhibition. Click here to view

Film and Sheet - April The April edition of Film and Sheet Extrusion looks at developments in waterproof membrane technology and the newest innovations in production of stretch lm. Plus, this edition has updates on the latest thermoforming machinery and material handling systems. Click here to view

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dates for your diary

Global exhibition guide


7-10 May 14-16 May 20-23 May 20-24 May 6-8 June 18-19 June 18-20 June 19-22 June 20-23 June 3-6 September 5-7 September PlastPol, Kielce, Poland Plast-Ex, Toronto, Canada Chinaplas, Guangzhou, China Feiplastic, Sao Paolo, Brazil Plastics Printing Packaging Tanzania PDM, Telford, UK Plastec East, Philadelphia, USA PlastExpo, Casablanca, Morocco InterPlas Thailand, Bangkok Applas, Shanghai, China Plasti & Pack, Lahore, Pakistan Plastec Midwest, Chicago, USA Mediplas, Birmingham, UK PPP Africa, Nairobi, Kenya K 2013, Dsseldorf, Germany Plastics & Rubber Indonesia, Jakarta Plast Eurasia, Istanbul, Turkey www.plastpol.com www.plast-ex.org www.chinaplasonline.com www.feiplastic.com.br www.pppexpo.expogr.com www.pdmevent.com www.plasteceast.com www.plast-expo.com www.interplasthailand.com www.applas.com www.pk-plastipack.com www.plastecmidwest.com www.mediplasuk.com www.pppexpo.expogr.com www.k-online.de www.pamerindo.com www.plasteurasia.com

10-12 September 25-26 September 4-6 October 16-23 October 5-8 December

20-23 November

AMI conferences
14-15 May 14-16 May 3-5 June 4-5 June 4-6 June 13-14 June Polymers in Cables, Miami, FL, USA Polymer Sourcing, Vienna, Austria Masterbatch, Frankfurt, Germany Profiles, Philadelphia, PA, USA End of Life Plastics, Cologne, Germany Fire Retardants in Plastics, Denver, CO, USA Polyolefin Additives Agricultural Film, Madrid, Spain Medical Grade Polymers Fire Resistance in Plastics, Cologne, Germany Polymer Foam, Hamburg, Germany Compounding World Forum, Philadelphia, PA, USA

10-12 September 16-18 September 17-18 September 12-14 November 19-21 November 10-11 December

For information on all these events and other conferences on film, sheet, pipe and packaging applications, see

www.amiplastics.com

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