Windsor Group Coming Out with New Line of Injection Presses

By: Matthew H. Naitove 27. October 2015

Received this tip at the Fakuma 2015 show in Germany two weeks ago: Windsor Group, Inc., Mason, Ohio, will launch a new line of injection machines in the next couple of months. Up to now, the company has been providing support for the installed base of Klockner-Windsor machines, serving primarily the auto industry. For example, Windsor Group has upgraded older presses with new controls and with energy-saving variable-frequency electric drives (VFDs). Evidently, it aims to raise its profile with a new line of presses.

New Family of High-Performance LLDPE-Like Resins for Packaging

By: Lilli Manolis Sherman 27. October 2015


It’s always exciting to report on new resin technology and when it’s in the commodity resins realm, perhaps a bit more so. So, today, Dow’s Packaging and Specialty Plastics business is launching Innate Precision Packaging Resins, a new family of polyethylene resins that is aimed at addressing key challenging performance gaps in flexible packaging, most notably: unmatched stiffness/toughness balance, processing ease and improved sustainability profiles.


I had a nice opportunity of speaking with key Dow sources yesterday including Nestor deMattos, marketing director for Dow Packaging and Specialty Plastics, regarding this new family of resins. The Dow sources confirm that the Innate resins represent a new category of ethylene-based copolymers which fit within the range of LLDPE resins. As with other Dow technologies, these resins can be produced using various comonomers—octene, hexene or butene. They also confirm that their creation has been enabled by a breakthrough, patented non-metallocene molecular catalyst coupled with a new non-Insite advanced process technology that reportedly allows for accurate and consistent control of the resin chemistry for marrying film properties like never before.


According to deMattos, Innate resins exhibit outstanding toughness without compromising stiffness along with excellent flex crack resistance, allowing for increased lightweighting without compromising the integrity of the end-use product—be it flexible food packaging such as stand-up pouches, bags, liquid  packages; industrial stretch film for heavy-duty shipping sacks; or, artificial turf. Excellent tear and puncture resistance are also claimed. They can be used as one or several film layers in multilayer packaging, allowing for the design of new and improved film structures.


The Dow sources also emphasize the excellent processability of the new resins for large diameter bubbles without blending; a key benefit for industrial films. Moreover, Innate resins exhibit high-melt strength for excellent bubble stability and more shear thinning to enable lower amps and melt temperatures.


The initial group of grades to be launched within this family, according to deMattos, will have densities within the 0.915-0.930 g/cc (typical LLDPEs fall within the 0.905-0.940 g/cc range). The very first developmental grade is Innate  XUS 59910.02, with a 0.918 g/cc density and melt index of 0.85 g/10 min. Properties of a 1-mil blown film made with it include: dart impact of 1645 g; tensile strength at yield of 1800 psi (MD) and 1600 psi (CD); tensile strength at break of 5150 psi (MD) and 4130 psi (CD; tensile elongation at break of 425% (MD) and 550% (CD); and, Elmendorf tear of 265 g (MD) and 532 g (CD).


According to deMattos, Dow has selected key partners for field testing, particularly companies that have been struggling with downgaging their products, and expects that commercial use of the new resins is forthcoming within the next year. Although this novel family of resins will be priced at a premium, deMattos says, “We want to offer converters something that makes sense in terms of providing better performance while making it economically viable.”



Haitian Shows New Models & Upgrades At Fakuma Show; More Coming in 2016

By: Matthew H. Naitove 26. October 2015

A Jupiter II 650-tonner.


At the Fakuma 2015 show in Friedrichshafen, Germany, a couple of weeks ago, Haitian of China and its Zhafir German subsidiary showed a number of new developments and previewed some of next year’s machine introductions.


 •  The Haitian Jupiter II Series of servohydraulic two-platen models (shown at NPE2015 in Orlando) is now available in “Jupiter II plus” versions with a redesigned clamp that offers 40% faster dry cycle (i.e., cut from 6.5 sec to 4.2 sec for a 450-metric-ton model) and eliminates lubricating cylinders around the tiebars. New linear guides replace tiebar guidance, and a digital, contact-free position-measurement system is said to provide rapid response and high-precision positioning.


 •  The Zhafir Venus II all-electric machine has been upsized from the previous limit of 550 m.t. to 650 m.t. (as seen at NPE), and a 1000-m.t. model is due next year.

Venus II 230-m.t.


 •  The new Zhafir Zeres all-electric line with integrated servohydraulics for nozzle touch, ejection, and core pulls was shown at NPE, has been extended beyond the original size range from 40 to 230 m.t. to 550 and 650 m.t., with larger models to come.


 •  In development is a new generation of Zhafir Mercury all-electric tiebarless models, which also will have integrated servohydraulics for secondary functions. The first prototypes of this German-designed ME-X line are being built in China.


Haitian and Zhafir machines are sold here by Absolute Haitian, Worcester, Mass.

New Plastics Recovery Facility To Open in Baltimore

By: Heather Caliendo 26. October 2015

One of the biggest barriers to increasing recycling rates is a lack of infrastructure. In 2013, lack of recycling infrastructure caused U.S. cities to collectively spend over $5 billion dollars to landfill over $11 billion worth of commodities that could have been recycled, according to Closed Loop Fund, which is a consortium aimed at providing municipalities access to zero- and low-interest loans to build comprehensive recycling programs. Partners include big corporations such as 3M, Coca-Cola, Colgate-Palmolive, Goldman Sachs, Johnson & Johnson Family of Consumer Companies, Keurig Green Mountain, PepsiCo and the PepsiCo Foundation, Procter & Gamble, Unilever, Walmart and the Walmart Foundation.


The fund plans to invest $100 million in the U.S. recycling infrastructure by 2020.


Closed Loop Fund’s first investee is a joint venture between QRS and Canusa- Hershman (CHR) to create what it calls a “one-of-a-kind” Plastic Recovery Facility (PRF) in Baltimore.


Currently, 40% of communities across the U.S. are not able to collect and recycle #3 - #7 plastics. QRS and CHS will combine technology that can both separate these products and turn them back into raw materials for new products and packaging. The facility is able to process 4,500 tons of materials every month – double the capacity of what’s presently possible in the U.S. The group believes that this will help drive significant increase in recovery of hard-to-recycle plastics and ensure a stable market.


Beginning in November, QRS-CHR will service the majority of the East Coast – from Maine to South Carolina. The opening of the facility is expected to help divert 440,000 tons from landfills and reduce 555,000 tons of greenhouse gas emissions. Closed Loop Fund says that QRS-CHR is a business model that can be replicated across the U.S. and beyond.


"QRS-Canusa's newest Plastic Recovery Facility in Baltimore provides all communities and recyclers throughout the Northeast and Mid-Atlantic regions with a reliable, domestic processing solution for mixed, post-consumer plastic containers,” said Greg Janson, CEO of QRS. “Working in conjunction with other QRS facilities, the Baltimore PRF targets virtually all polymers in the single stream mix for recovery, returning high volumes of quality material to the manufacturing base. This purpose nests perfectly with the mission of the Closed Loop Fund and we are excited for their support of the project."


Additional investments


Closed Loop Fund’s two other investments are in Quad Cities, Iowa, and Portage County, Ohio. These investments will allow the two communities to convert from dual stream recycling systems to single stream, making it easier for citizens to recycle and significantly increasing recycling rates. Again, Closed Loop says that the funding will prove models that help expand single stream recycling to similar communities across the country.


Over the next 10 years, in Portage County alone, 37,000 tons will be diverted from landfills with a reduction of 110,000 tons of greenhouse gas emissions. Quad Cities is expected to see 86,000 tons diverted from landfills and 250,000 tons of greenhouse gas emissions reduced.


“We’ve spent months reviewing proposals from cities and recycling facilities that have the potential to transform recycling systems across the country,” said Rob Kaplan, co-founder and managing director of Closed Loop Fund. “We know that when done right, recycling is a profitable business that can save city and taxpayer money. That’s why Closed Loop Fund invests in business models like QRS-Canusa, Quad Cities and Portage County that solve key bottlenecks in the recycling system, create economic value for cities, and make recycling more accessible for citizens.”


Closed Loop Fund has pretty big goals. By 2025, it aims to do the following:


  • Reduce greenhouse gas emissions by more than 50 million GHG tons reduction 
  • Divert more than 20 million cumulative tons of waste from landfills
  • Create 20,000+ local jobs across the U.S.
  • Save nearly $1.2 billion for American cities
  • Prove replicable models that will help unlock additional investment in recycling.

Solvay Recycling Airbag Textiles Into Polyamide 6.6 Grades

By: Heather Caliendo 21. October 2015

Project site in Gorzów, Poland. Photo Courtesy: Solvay

More than 70% of car airbags are made of silicon-coated polyamide in Europe and there is up to 10,000 tons of post-industrial airbag waste per year in Europe. While regulations such as directive 2000/53/EC have set high targets for end-of-life recycling and reuse of materials in vehicles, there is no sustainable solution in place for post-consumer airbag waste in Europe. Solvay, Brussels, Belgium, hopes to change this with its Move4earth project that is working to recycle technical textile waste from post-industrial sources. The project is focused on designing, implementing and validating a new recycling process designed to revalue technical textile waste, initially from airbags, into high-quality polyamide 6.6 (PA6.6) grades with reduced environmental impacts to complement Solvay Engineering Plastics’ Technyl Force portfolio of engineering polymers.


The company says that validation of the technology has been completed and construction is underway for an industrial-scale facility to become operational in 2016 at the project site in Gorzów, Poland. Move4earth project is one of several Solvay initiatives supported by the European Commission as part of its LIFE+ program.


“Our mid-term objective is to establish an efficient and sustainable way of re-using these resources and provide pure high-grade PA6.6 recycle compounds with stable properties near those of virgin Technyl resins for a wide range of eco-designed applications,” said Richard Bourdon, Move4earth project director at Solvay.


Peter Browning, Solvay engineering plastics general manager, said that a revision of the waste legislation will be released by the European Commission by the end of 2015. As part of the Circular Economy Communication, new legislative initiatives on eco-design and recycling are anticipated by major customers in all PA6.6 markets, he said. Most of them are already targeting recycle contents in their products over 20% by 2020.


“Move4earth underscores our efforts aimed at reducing the environmental footprint of our activities and those of our customers, and it confirms our dedicated reliance on European industrial assets,” Browning said.


The project also addresses a need for more effective recycling solutions to help minimize large volumes of valuable engineering plastic waste.


Solvay has developed an advanced proprietary recycling technology for separating the airbag fabrics from the coating. The new process is said to deliver a PA6.6 premium recycle with no significant loss in material properties, including stable viscosity and robust mechanical performance. 


Next steps in Solvay’s Move4earth project is to bring the new facility fully on-stream to ensure a continuous target throughput under stable process conditions, and to validate value-creating options for the silicone coating by-product separated from the airbag fabrics, which can amount to 15% of the material flow. “The new recycle grades will be manufactured to the same high standards of quality as all Technyl resins,” Browning said. “We can guarantee a grade with up to 100 percent recycle matrix and secure supply.”

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