The K2013 countdown begins…

Clariant’s added-value proposition (H8aJ11)

Visitors can experience Clariant’s customer- and segment-oriented approach, with its commitment to ‘Performance-People-Planet’ at the heart of all its featured developments.

‘K2013 is an exciting opportunity for Clariant to show the plastics industry the philosophy of our fresh branding,’ comments Christian Kohlpaintner, member of the Clariant executive committee.

Formulations are firmly focused on reinforcing efforts by the plastics and coatings industry to achieve greater cost-efficiency, improved environmental performance, and product differentiation. Highlights include AddWorks, the new branding for Clariant’s polymer additives, delivering original formulations that address the needs of various manufacturing sectors.

Clariant’s toolbox of cutting-edge, efficient phosphinate flame retardants continues to expand, with tailor-made formulations that include Exolit OP 1400 for polyamides with special requirements, and Exolit OP 1260 for polyesters. The Exolit OP product line is also renowned for its good environmental and health profile.

From  a broad portfolio of speciality waxes, Clariant is focusing on the added-value for plastics manufacturers offered by Montan wax specialities such as Licomont NaV 101 and CaV 102 that significantly reduce cycle times and provide excellent release and flow properties for injection-moulded polyamides and polyesters. The innovative Licocene grades are also highlighted for high-performance masterbatch.

At K2013, Clariant is bringing liquid masterbatch to life with a novel integrated system designed to enhance product properties and process parameters for converters. The global sales and service network, selling liquid and pellet masterbatch, is a core element of Clariant’s liquid masterbatch system and enables Clariant to work with converters to design an original and valuable granule, additive and/or liquid masterbatch recipe.

Recent developments have focused on advancing extrusion blow moulding monolayer production processes that offer a significant reduction in colour change time, and a trouble-free and continuous manufacturing process. Its liquid masterbatch also limits the influence on product properties, achieving an excellent appearance.

CYPET’s all-electric enhancements (H14C58)

According to Cyprus-based CYPET Technologies, PET processors can finally manufacture PET bottles up to 20-litres and PET jars up to 145mm neck diameter with   the world’s first all-electric single-stage injection moulding machines.

Called K19E and K30E, based on CYPET’s proprietary servo-hydraulic PET processing technology, they feature servo motors to drive hydraulic pumps, accurately delivering the required oil pressure and flow without energy waste. Besides saving an estimated 30% of electricity, this technology is said to have a faster response time and a higher movement repeatability and process consistency, compared to conventional hydraulic technologies.

The primary advantage of all-electric PET processing is cleanliness, eliminating the risk of contamination from hydraulic oil leaks. Further benefits include low electricity consumption, precision and process repeatability, availability of parallel movements for saving cycle time and minimal maintenance. 

CYPET claims that its all-electric machines offer all these important benefits at an affordable investment cost, resulting in a minimal effect on total PET container production cost. Additionally, these servo-hydraulic machines offer flexibility with respect to container sizes that can be produced on a single machine thanks to swift and efficient mould changing.

Kiefel advanced stacking (H3C92)

Kiefel is presenting two innovative stacking systems designed to increase plastics packaging manufacturing productivity. ‘We constantly think about how to support plastics converters in the best possible way and, particularly, how to increase their output,’ states Kiefel MD, Thomas Halletz. ‘The forming and punching stations of our speed pressure forming machines already work efficiently, yet time can still be saved during the following steps,’ he adds.

An all-new stacking station called BEST, with an original vertical stacking concept, is being demonstrated in-line with Kiefel’s high-performance KTR 5 SPEEDFORMER cup forming machine.

‘The BEST stacking station creates optimal conditions for automated steps, such as sleeving and packaging,’ remarks Thomas. ‘Vertical stacking saves time and increases productivity and this particular model is designed specifically for the food packaging industry. No wear parts are included, guaranteeing high product safety.’

Other highlights on the stand include an ultra-efficient stacking system integrated into Kiefel’s latest KMD 78 Speedformer pressure-forming machine.

By means of a 16-up tool, biscuit trays made of PP are being produced during K2013. According to Thomas, factors such as optimal material processing and outstanding stackability have a positive impact on the quality of the formed parts. ‘The stacking system already comprises the formation of horizontal stacks and is extremely efficient,’ he says.

Wicked wicketing from Hudson-Sharp (H3B17)

Being put through its paces on the Hudson-Sharp stand is the latest version of the highly-successful 5750W wicketing machine, featuring several fresh elements designed to increase output, reduce downtime, save energy and ensure complete operational safety.

A leading global producer of wicketing machines for the production of bread, poultry, produce and hygiene bags for automatic filling, Hudson-Sharp’s technology is widely-used in South Africa by several leading flexible packaging converters.

Represented locally by Gary Kieswetter, Advanced Packaging Technology, the company has a reputation for building strong, durable and efficient machines.

Adapted with modern material key components and the latest servo technology, the popular 5750W features an efficient top cycle speed of 450 bags/min. Contributing to a reduction in energy costs are an all-new airless anti-static system and servo-driven wicket punches.

An automatic seal bar cleaner, programmed to remove debris at pre-set intervals, reduces downtime and enhances production quality. This cleaning cycle lasts less than12 seconds, compared to minutes for a manual clean.

Besides wicketing machines, Hudson-Sharp is demonstrating options to ease handling of finished bag stacks. Ranging from a simple stack processor to a robotised system for automatic boxing, equipment can be customised. Automation includes insertion of wicket wire, boards and grommets and placing of finished stacks into boxes.

Also being showcased is the WASP (Wicket Automation Stack Processor) that’s ergonomically designed to reduce repetitive operator strain injuries, plus two- and three-side seal, stand-up and side-gusseted pouch machines, a continuous motion rotary machine for garbage bags on the roll, Inno-Lok and Pour-and-Lok patented transverse zipper technology and versatile flat belt side-weld machines.

Comexi’s creative approach to converting (H4B21)

Another important principal in Advanced Packaging Technology’s stable is Spanish machinery manufacturer, Comexi.

Innovation and sustainability are the cornerstones of Comexi’s recent global expansion and featuring at K2013 are ten ground-breaking machines. Processes such as printing without solvents (water-based inks or EB curing), solventless lamination and cleaning through distillation with no dry residue are just a few of the latest technologies incorporated into this line-up.

A series of talks and seminars on this stand are set to provide more information on key trends affecting the flexible packaging value chain.

Throughout the show, Comexi is providing a daily air shuttle service between Düsseldorf and its Spanish manufacturing premises for an ‘open house’ event where visitors can tour the site, including the newly-opened Manel Xifra Boada Technological Centre, and learn more about Comexi’s printing, laminating and cutting developments, including round-table discussions.

Additionally, a daily live broadcast connection will enable visitors who cannot attend the open house to participate in the seminars and discussions.

Inometa optimises roller technology (H4C35)

Inometa is pushing the boundaries in roll technology with modern materials such as CFRP (Carbon Fibre Reinforced Plastic).

‘We’re the perfect partner for precision and high-end solutions in the CFRP and aluminium roller manufacturing industry,’ explains Michael Kassebeer, Inometa’s film/paper sales manager. ‘This year, we plan to impress K2013 visitors with our extensive range of tailor-made lightweight rollers, winding cores, functional surfaces and CFRP designs for mechanical engineering applications,’ he adds.

Inometa’s portfolio covers the entire process chain and provides perfectly-matched products to achieve short set-up times, minimum wear and high performance. This year, focus is placed on ‘high damping’.

‘Running smoothness and process stability at high processing speeds are vital to efficiency and maintaining a competitive edge,’ remarks Michael. ‘Likewise, getting a grip on unwanted vibrations is critical to achieving longer machine component service life. The introduction of a new material can open up whole new perspectives on issues such as vibrations, thermal expansion, mass moment of inertia, degree of slenderness and corrosion,’  he continues. ‘Instead of redesigning an entire machine, CFRP can be used to optimise individual components so that they work perfectly in existing equipment, saving time and money.’

Applying finer and denser coating systems to achieve minimum surface roughness is Inometa’s trademark and today aluminium rollers can be covered with an extremely resistant hard metal coating and a roughness depth of Rmax < 0.2µm or mass-optimised CFRP rollers with chrome surfaces. For Inometa, the future lies in the integration of actuators and sensors in functional rollers and it will be demonstrating its ALDS lay-on roller with adjustable pressure application line and a sensor roller with integrated web tension sensors. The analysis software tool HCC-Easy, for measuring signal processing and evaluation, will also be available.  The efficiency of modern surface coatings helps increase machine performance and reduce costs and Inometa’s high-performance Protek coatings can be integrated into individual applications. Designed to perfectly match the respective application, Protek coatings also help increase product quality. Inometa’s WinCore winding cores are produced with narrow tolerances and high concentric accuracy in order to provide excellent winding quality. The use of aluminium makes them extremely pressure-resistant and allows for continuous processes, even in humid environments. The durable aluminium winding cores can also be equipped with an RFID chip. Sacmi injection moulding excellence (H13A63)

When it comes to innovative cap, preform and container manufacturing systems, Sacmi has it all!

Taking centre-stage this year is the IPS 220 B, an injection preform press launched in 2012, with an advanced control system that allows real-time control of process parameters, resulting in excellent size changeover flexibility and user-friendliness. Easily incorporated inline via Sacmi’s PVS 2B system – capable of testing up to 1 200 preforms/hour – the IPS manufactures preforms up to 190mm long.

For plastic cap production – a sector in which Sacmi has installed 1 200 compression machines worldwide – an upgraded version of the CCM 48S is on show, producing 2 000 closures/min. According to Sacmi, the cycle time of 1.5 seconds is an industry first.

With over 4 500 vision and quality control systems installed globally, Sacmi is using K2013 to launch CHS Lean, described as a ‘total inspection’ concept.

In addition to high inspection rates – up to 150 000 closures/hour – CHS Lean allows all-round 360° cap control, from the side wall to the tamper band slit profile.

Sacmi’s latest CBF container manufacturing machine, introduced last year, is achieving global success, especially in the production of HDPE, PS, PET and PP plastic containers. On show at K2013, highlights of the CBF include continuous extrusion with thermo-regulation of the preform while in the mould, allowing container forming via stretch-blowing.

Sacmi is represented in South Africa by Comass.

Apex for speed and flexibility (H4E22)

US-owned Apex Machine Company specialises in the manufacture of advanced product handling and printing systems for products such as caps and closures and cartons.

This year, the company is launching a high-speed, multicolour strap printing system and another for printing cylindrical and conical substrates.

These versatile systems, designated S-11 and C-40 respectively, deliver high-impact and cost-effective printing for an ever-increasing array of speciality applications.

For instance, the S-11 is capable of printing continuous webs such as plastic strapping at speeds exceeding 120 m/min/lane and the latest C-40-HSS can print plastic or paper candy sticks at speeds up to 2 000 parts/min.

Each Apex printing system is individually engineered with a range of parts and sizes to maximise flexibility, machine efficiency and product yield.

These decorating systems utilise a variety of printing methods, including dry offset and rotogravure offset. For example, FlexApex is an offset printing process that utilises modified flexographic inking technologies and UV-cured inks in combination with dry offset printing in multicolours and at high speeds, providing a viable alternative to silkscreen, hot stamping or pad printing.