Strictly-Extrusion

Low density polyethylene is one of the oldest plastics – and continues to be in demand. LDPE is primarily used for films, carrying bags, and sacks, but can also be used to reinforce levees, for example.  Screw caps and lids are also produced from this soft, ductile, and flexible material.  LDPE can hold its ground against competition from newer plastics, as a result of its advantageous characteristics:  low melting point, high clarity, and good process-ability.  “The trend of substituting LDPE with other polymers is declining again throughout the industrialized nations,” says Oliver Kutsch, owner of Ceresana Research: “Opportunities for LDPE can be seen, for example, in the application of coatings and packaging for medical products.  These applications will recover relatively quickly from the effects of the economical crisis.”

Recovery in Sight

LDPE prices fell by as much as 30 percent in certain regions during 2009, and Western Europe and North America exhibited considerable decreases in demand. Consequently, global revenue fell by 15.9 billion € (22.2 billion US$).  However, Ceresana Research expects to see growth again starting in 2011.  The Asia Pacific region in particular, already the largest consumer of LDPE, will see growth and increase its share of global consumption to more than 39 percent.

Upsurge in the Middle East

LDPE production is particularly being expanded in the oil-rich countries of the Middle East:  Capacity increases of approximately 3.5 million tons are planned to take place by 2014.  Accordingly, Saudi Arabia, Qatar, Iran, and the other countries that make up the region will be the world’s largest plastic exporters.

A Useful Reference Work

The multi-client Market Study: Polyethylene – LDPE provides a concise overview of the most important information regarding this plastic on 870 pages: from manufacturing, to legal questions, to recycling.  Then the LDPE market is closely analyzed– including prognoses until 2016: Individual data regarding production and capacities, consumption in individual application areas, as well as imports and exports is presented for the entire world, seven regions, and in detail for 67 countries.  The study is particularly extensive in its analysis of the 12 countries with the highest revenues.  Current and future LDPE manufacturers are introduced with 87 company profiles.  The world’s most comprehensive market report on LDPE is available immediately in English or German from Ceresana Research: www.ceresana.com/en/market-studies/plastics/polyethylene-ldpe/

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There is an increasing demand for PE pipes worldwide due to a surge in public works projects and state stimulus packages to revive local economies. Polyolefin pipes are used for a wide range of applications, e.g. floor heating, gas distribution and drinking water supply. This is one of the reasons why the high-speed polyolefin pipe extrusion line LeanEx™, developed by B+C Extrusion Systems Ltd. (www.bcc-extrusion.com), has become such a success since its launch in May 2009. The new LeanEx™ system is a complete extrusion line for the production of polyolefin pipes in a diameter range of 16 mm to 63 mm. B+C Extrusion Systems Ltd. is the Chinese operation of Battenfeld-Cincinnati.

Photo: B+C Extrusion Systems Ltd.

The grooved 60 mm single-screw extruder with a 30 L/D ratio is able to deliver a maximum output of 320 kg/h (HDPE pipes). The extruder is equipped with a 90 kW DC motor and B&R control system (incl. 5.7″ TFT colour touch-screen). Different designs of die sets and calibrating sleeves can be supplied for a wide range of materials, incl. PE-RT, PP-R, PE-HD and PB. The right tooling is crucial and the key to achieve high line speeds. For instance, a maximum line speed of 25 m/min for the production of PE-RT pipes (dimension 20×1.9 mm) can be guaranteed.

The company offers two different types of belt haul-off. Both models have in common that each belt is driven by a separate drive, which ensures synchronized speed of the upper and lower belt. The two models are different regarding the belt contact length and the size/ratio of the drives. The different executions ensure sufficient and constant haul-off force over the entire speed range.

Cutting of pipes at high speed can be critical. Besides the very cost-effective flying knife cutter for pipes of up to 40 mm, LeanEx63™ provides another solution for the swarfless cutting of polyolefin pipes of up to 63 mm. This PC63 cutter can be used to cut pipes with a wall thickness of up to 13mm at high line speeds. Hence high pressure polyolefin pipes, e.g. the S2 series PP-R pipes, can be produced.

As an option the line can be equipped with a double-station coiler. Two different models are available, one for pipes of up to 40 mm and another for up to 63 mm. Both are equipped with a continuous traversing unit for a smooth winding of the pipes. Due to the mechanical design and the electrical control, one operator can master the challenging task to change-over and start a new bobbin at a speed of 25 m/min.

For more information: yang.c@bcc-extrusion.com

Sarlink TPV (www.sarlink.com) has announced that it has developed a new series of low durometer Sarlink TPVs based on dynamically vulcanized rubber in a polypropylene matrix, thus combining superb elastic properties with the processing ease of thermoplastics. These Sarlink 5725 and 5735 grades are characterized by their extremely low hardness of 25 and 35 Shore A in combination with excellent processing behavior.

Low durometer Sarlink TPV instead of EPDM foam
Sarlink 5725 and 5735 can replace thermo set EPDM foam materials, used in many extrusion applications in the automotive industry as well in the building and construction industry. Very low compression deflection forces in combination with excellent elastic recovery are typical characteristics for EPDM foamed products.

Processing and performance advantages
These new Sarlink grades are an addition to the existing Sarlink 5700 series of products, which are characterized by their fully optimized and superb UV resistance and improved fogging properties, combined with excellent elastic and sealing performance. What makes this new Sarlink series unique is its extremely low hardness of 25 and 35 Shore A in combination with excellent processing behavior, such as good collapse resistance and superb flow behavior to obtain good surface finish. Another great advantage is that these low durometer Sarlink grades can be co extruded in combination with higher hardness grades to create complex sealing systems.

Focussing on performance, these new Sarlink grades show low compression set and deflection forces in combination with good relaxation behaviour. These are typical characteristics to obtain excellent elastic and thus sealing performance.

Sarlink TPV: considering the environment
Looking at the advantages of Sarlink 5725 and 5735, these new products offer numerous new potentials compared to EPDM foam materials, especially in the automotive industry. Ger Vroomen, Business Development Manager at Sarlink: “Many EPDM foamed products are used in combination with spray coatings to obtain specific functional properties. The industry sees the use of spray coating systems as an environmentally questionable system in combination with relatively high cost. These new Sarlink grades can be co-extruded in combination with the Sarlink proprietary slip coatings (like GRC 03 and GRC 22). The combination of both material groups could result in a cost reduction in an environmentally friendly way, as the application of the slip coating occurs in the same processing stage as the product itself. In addition to the reduction of the coefficient of friction and improvement of abrasion resistance, these material combinations can also result in easier assembling of parts. This is just a glimpse of numerous possibilities.”

Continuous innovation process
Sarlink’s Global Marketing Director Rolf Schrauwen about Sarlink 5225 and 5735: “In general, compared to thermoset rubber, using Sarlink products will reduce production costs due to its shorter cycle times, reduced energy needs, and a very high material efficiency as a result of its recyclability. Add to that all the benefits these new Sarlink 5725 and 5735 offers and we have what we call ‘a winning number’. Our key message is that there are plenty of applications that demand to be converted to Sarlink TPV and we are making continued and continuous investments in our products and our resources to help make this happen. The 5700 series is a good example of this continuous innovation process; more grades with an even lower hardness will be added to the range of grades soon. This means that, again, new applications can benefit from the great advantages offered by Sarlink TPV.”

Merquinsa (www.merquinsa.com) today announced its participation at CHINAPLAS 2010 in Pudong, Shanghai from April 19-22, where it will collaborate with its recognized Chinese distributors Ngai Hing Engineering Plastic (Hong Kong) Ltd. and Paceco Industrial Supplies Pte Ltd.
Merquinsa will present on this occasion its new Bio polyester and polyether based TPU (thermoplastic polyurethanes) PEARLTHANE® ECO resins along with its TPU specialties PEARLCOAT®, & PEARLTHANE® portfolio, including special extrusion polyether TPU grades & non-yellowing aliphatic TPU resins.
Merquinsa’s Green TPU with a bio content from ca. 20 to 90%, according to ASTM D-6866, offers outstanding performance and sustainability benefits vs. standard petroleum-based TPUs for a wide range of sport & leisure, consumer electronics and automotive applications.
“We are pleased to contribute to the promotion of Merquinsa’s unique range of Bio TPUs for the Chinese Market and support Chinese customers to turn to Green Plastics & Green TPUs, said Jackson Ng Sales Director of Paceco. “Merquinsa has built its name for a premium supplier of High Quality TPUs. Ngai Hing specializes in supporting application development with unique aliphatic TPUs for the Chinese automotive, electronics and sport industries“, said Ben Ng President and Co-Founder of Ngai Hing Engineering Plastic (Hong Kong) Ltd.

CHINAPLAS: Ngai Hing Engineering Booth #W2L51 & Paceco Booth #W2T01

As a result of working closely with end users to develop an in depth understanding of their requirements, American Kuhne (www.americankuhne.com) has satisfied the need for reduced floor space with a line of compact extruders. These extruders are designed to produce precision medical tubing within the space limitations that often exist in clean rooms.

The unique Compact MD series extruder is designed specifically for clean room and/or controlled environments. The electrical controls are easily serviced and integral with the extruder frame, providing the benefit of reduced machine width and reduced floor space. The low profile control panel enables the operator’s unobstructed view across the clean room production area. The machine is designed with smooth external surfaces and rounded corners that allow for quick and easy wipe down.  The ergonomically designed rotating operator control station can include simple discrete controls or the customer’s choice of three levels of AKcess touch screen control solutions. The Compact series extruder is also available with an option to include the entire main frame and safety guards to be made entirely of stainless steel in place of standard painted steel. The Compact Series is offered in 0.5” (12.7mm) to 1.75” (44mm) sizes. All extruders, systems and controls sold into Europe are CE labeled.

The Compact MD extruder is also available in an optional “Modular” variation where the barrel diameter and/or L/D can be quickly and easily changed to achieve different output ranges and/or simply to accelerate change-over and clean-out time.

Each American Kuhne extruder includes a Steward Barrier Screw that is designed specifically for the application. The Steward Barrier Screws are the heart of the process and provide a number of critical benefits. The screws are designed to maximize pressure stability for the tightest possible dimensional tolerances, ideally +/- 1.0% or better and minimize melt temperature variation, ideally +/- 1 degree or less. The screws provide the optimum melt temperature for the best possible product performance and surface finish. All design parameters and performance data is generated in AK’s Extrusion Lab and in the field, not the result of hypothetical computer modeling.

KraussMaffei Berstorff has received an order from the well-known pipe producer P.E.S. Co. for an extrusion line to produce extra-large, smooth-walled HDPE pipe with diameters up to 2400 millimetres. Producing smooth-walled pipe in these large diameters is a world first – once again KraussMaffei Berstorff is pushing out the limits in pipe extrusion.

Photo: KraussMaffei

P.E.S., for many years a satisfied KraussMaffei Berstorff customer, has been producing HDPE pipe, including extra-large pipe up to 1600 mm diameter, on a range of Krauss Maffei Berstorff single-screw extruders for almost a decade. The extra-large pipes produced by the company in the Persian Gulf region are used in many applications, chiefly in the pipelines supplying seawater to desalination plants and cooling water to oil refineries. P.E.S. has many years of intensive experience in the production of PE pipe and in laying and installing complete pipeline systems. The company is enthusiastic about its productive business relationship with KraussMaffei Berstorff. Mohsen Jamalian, P.E.S. managing director and owner, says: “Working together with KraussMaffei Berstorff we’re setting a new milestone in the world of large scale pipe extrusion. Thanks to KraussMaffei Berstorff and its top technology – from single-screw extruders to pipeheads and spiral distributor concepts – we can transfer the expertise we’ve accumulated with our 1600-mm extrusion line to the challenge of producing 2400-mm pipe. Also making a major contribution to our success in this area is the low-sagging polyethylene XLS12B from Total Petrochemicals.”

Extrusion technology from the world market leader
The extra-large pipe extrusion line ordered from KraussMaffei Berstorff will enable P.E.S. to advance into new dimensions and to add smooth-walled HDPE pipes 1800, 2000, 2200 and 2400 millimetres in diameter to its production spectrum. The new line, headed by a KME 150-36 B/R single-screw extruder and a KM-RKW 40-2400 pipehead, has all the key features that have established KraussMaffei Berstorff as the technology leader in extra-large pipe extrusion. This includes the proven design of the 36D single-screw extruder, a pipehead concept where the spiral distributor design incorporates the latest rheological research, and a KraussMaffei Berstorff calibration system.

This industry-leading engineering produces pipe where wall thicknesses, outer diameter and ovality are kept within very tight tolerances. Considering that, for some types of pipe, the cost of material accounts for up to 90% of total manufacturing cost, keeping variation to a minimum delivers huge material savings, especially in production of very large pipe. Furthermore, when the pipe is laid, the pipe sections will fit exactly together, making for uniform, high quality welds. Defect-free welds are of utmost importance in laying pipelines with optimal stability under pressure and long service life.

The new window profile systems from Gruber Extrusion (www.gruberextrusion.com) are setting international standards of efficiency and flexibility. These are the outstanding issues for the future of windows production. The many specialist visitors and customers who crowded the Gruber exhibition stand at fensterbau/frontale were able to convince themselves between 24 and 27. March 2010 in Nuremberg, Germany.

Five strides to success

Gruber Extrusion offers its customers a clear concept for success in window systems technology. One system – five strides to independence: Low start-up investment; a fast start for efficient marketing and production; comprehensive support in service, accessories and all materials processing questions; flexible and modular expansion of the profile systems and extrusion capacities and a minimizing of risk through the advantages of a major international network. The Upper Austrian extrusion expert supports its customers with highest quality products and comprehensive know-how from a small production unit through to complete turnkey solutions.

Globally active

Gruber Extrusion has a vital global network of partner companies at its disposal. In addition to the company headquarters at Pettenbach, Austria, the company locations maintained in Shandong, China, Minneapolis, USA plus a Russian branch in Moscow assure professional working of international markets. The wealth of synergies resulting from all of this is used to the benefit of customers. Quality through effective action brings business success. One world, one vision, one system

Battenfeld Extrusionstechnik GmbH (www.bex.battenfeld.com), Bad Oeynhausen, Germany constructed and installed custom-made extrusion components for Salzgitter Mannesmann Line Pipe GmbH in Hamm, Germany, which were perfectly integrated into the existing line for producing steel pipes with plastic jackets. With two new BEX 1-150-30B extruders and the U 700-2 VSI 4/8 FS coating die, the pipe manufacturer was able to double the previous line output to more than 3,000 kg/h and extend its product portfolio to include pipes of up to DN 600.

Salzgitter Mannesmann Line Pipe (MLP) specializes in the production of plastic coated steel pipes for demanding applications, such as oil fields. To produce such pipes, steel pipe segments with a length of up to 18 m are manufactured on site in a High-Frequency Induction (HFI) electric resistance welding process and subsequently covered with a three-layer plastic jacket. To make the jacket, first a coat of epoxy resin primer and then an adhesive are electro statically applied to the blasted and induction-heated steel pipe. The pipe thus prepared is subsequently guided through the extrusion station with a coating die, where the outer layer, which consists either of PP or PE, is applied by a vacuum hose extrusion process.

“The task we set Battenfeld Extrusionstechnik, to replace older, less efficient equipment with new components without making any structural alterations to the building, was not easy”, René Richter, Plant Manager at MLP, comments. “Nonetheless, they have mastered it to perfection.“

The machine manufacturer installed two single-screw extruders laid out for polyolefin processing in Hamm, each with a 150 mm screw diameter, a processing length of 30 D and a maximum output of 1,500 kg/h. To fit the equipment into the small space available, the extruders were arranged in V configuration, connected with the die via a short melt channel and equipped with high-performance drive units flanged on laterally as a customized solution. The U 700-2 VSI 4/8 FS die is the VSI coating die with the highest throughput built by Battenfeld Extrusionstechnik so far in this dimensional range. It was designed so as to weigh only 7.5 tons instead of 10 tons, in spite of its enormous dimensions for pipes with a maximum outer diameter of up to 610 mm. This weight limit was very important for the pipe manufacturer, as the maximum permissible crane load could not be exceeded. In addition, the die is equipped with the proven two-step distributor concept consisting of a spiral mandrel and a lattice basket distributor, and a custom-made handling solution for dimensional changeover at maximum speed.

Additional features of this customized solution for MLP are stand-alone operating and control cabinets also designed to fit into the limited space, a gravimetric multi-component throughput control unit, and a customized control system. “In Battenfeld Extrusionstechnik we have found a highly competent partner who offers us a high degree of operational reliability and stands ready to assist us at any time even after the equipment has gone into operation“, Richter is pleased to note. www.bex.battenfeld.com

“The profile extrusion business has changed radically. In 2009 up to 90 percent of all turnkey projects were implemented only in a combination package with the financing needed for them”, is the finding of Gruber Extrusion (www.gruberextrusion.com) CEOs Peter Gattinger and Richard Füsslberger. Tooling retrofitting is also increasingly financed on the same basis. Gruber Extrusion is now offering a highly popular alternative to classic financing through Vendor Finance GmbH of the parent company Greiner Tool.Tec – in the form of medium to long-term installment transactions to fixed conditions and flexible collateral possibilities.

Pettenbach, 18th March 2010 – Profile extrusion investment projects usually offer very high returns. This is a potential that often goes unused since the investment costs can often not be covered from the company’s own financial base. Classic loan financing through the banks has long been the rule of the game. But bank loans are becoming ever more subject to intensive tests, they are restrictive and above all expensive. Gruber Extrusion can by contrast generally deal with financing inquiries of this kind within two days and with no great bureaucratic hurdles through its cooperation with the Greiner Tool.Tec own specialist Vendor Finance GmbH. “We have been able to provide our customers with a thoroughly a comprehensive package for turn-key projects from the planning through the financing down to commissioning”, Peter Gattinger said. “Some 80 to 90 % of all our project business in this area is financed by this means”, CEO Richard Füsslberger added.

Pay as you earn

The advantages for investors are clear: the repayment installments can be covered from earnings of the financing project itself (pay as you earn). The clearly defined cycles have succeeded in achieving capital goods financing with low complexity and high flexibility. A contact partner for the project implementation and financing takes care of direct and fast communication. Thanks to the international alignment and global network of Gruber Extrusion, country specific features can be given the best possible consideration in financing deals. This attractive package is now exerting its pull not only in project business. Over the past 18 months this method has also been increasingly turned to by customers in the classic market (the tooling market).

ECVM (www.pvc.org), the trade association of the European PVC plastic producers, in partnership with Dutch NGO Agua4All, have donated PVC pipes and technical expertise for a new waste water system on Pemba Island in Zanzibar. The project, which uses international aid to enable local communities to help themselves, is designed to improve the quality of life for local residents, minimise the environmental impact of waste water on the marine ecology and sustain the local economy.

Waste water challenges in Pemba Pemba Island, part of the Zanzibar Islands, is situated in the western Indian Ocean. A combination of the
natural terrain, lack of awareness around pollution and financial restraints, has resulted in raw sewage being discharged into the marine environment.This untreated waste affects the ecological balance and sustainability of coastal systems that support the livelihood of the coastal population. Fishermen in Chake Chake, the main commercial area of Pemba, have seen a significant decline in fish catches over recent years. Waste water discharge into the sea is seen as a key cause of this trend.The elongated natural drainage channels in the Msingini, Mtoni and Kichungwani wards of Chake Town, which serve 650 households and carry away storm and waste waters, are interrupted by unplanned settlements. This has a big impact on the efficiency of the waste water system. Additionally, many septic tanks and soak pits are old and leaking, causing pollution and health risks for the local communities.

A new system To tackle these problems, a brand new sewage system with a sub-surface flow constructed wetland, was built to serve Msingini, Mtoni and Kichungwani.A new network of pipes was laid, coupled with the construction of an anaerobic pond and sub-surface flow constructed wetland for biological treatment of the waste collected in the pond. The treated waste is then brought into the ocean via existing open channels.

ECVM donated 80,000 euros worth of PVC piping totaling a length of 12.1 km, as well as 590 inspection chambers. Additionally, ECVM experts’ assisted local teams with the project design to help, advise and develop the details of the technical assistance required for implementation.The benefit of donations in kind, such as the PVC pipes supplied by ECVM, compared to direct funding is that they generate the structural and logistical conditions from which local communities can benefit. This includes creating employment.

For more information: amelie.debien@plasticseurope.org