K2010 packed with possibilities

 
220 000 trade visitors from over 100 countries. Topics from energy efficiency to environmental protection and sustainability were all addressed, as well as current trends.

Plastics can look forward to a bright future as a material for creative ideas. The concurrent ‘Visions in Polymers’ conference highlighted development trends on the horizon and novel applications.

The verdict from Ulrich Reifenhäuser, chairman of the exhibitor council for K 2010, was entirely positive: ‘K 2010 was held at the right time and has provided all areas of our industry with new impetus. The many contracts entered into at the fair speak for themselves!’
The PPM team gathered the latest news in plastics packaging technology and was encouraged to meet several South African plastics industry experts, eager to discuss new business ventures and ideas.

Extrusion efficiency with Macchi

MACCHI hosted hoards of international visitors  at its impressive stand, which featured the company’s latest CoexFlex coextrusion blown film line.
In what is believed to have been a ‘world first’, Macchi was producing nine-layer barrier coextruded blown film on the exhibition stand. Macchi not only ran the CoexFlex line throughout the show, but – in record time and with minimal material wastage – also started it up every morning and shut it down every evening in full view of visitors. This was a major test of the Italian company’s technological and organisational capability and a testament to why it’s considered one of Europe’s leading film extrusion equipment producers.
The line was combined with Macchi’s nine-layer compact CoexFlex die. This extremely flexible die is available in many different sizes to meet converters precise requirements.
Local Macchi representatives, Jeff and Peter Cawcutt from Maritime Marketing, welcomed a number of South African visitors to the stand. Two latest-generation Macchi CoexFlex lines have been purchased by a local plastics converter and are currently on pre-shipment trials. Peter promises more exciting Macchi news in 2011!

Rajoo and Wonderpack show united front

WITH the recent Wonderpack merger, technical collaboration with Hosokawa Alpine and a JV with Italian company Bausano & Figli, 2010 was
a landmark year for Rajoo Engineers.
K has always provided a perfect platform for Rajoo to showcase its technology, innovation, range and experience, but now the combined entity of Rajoo and Wonderpack is leveraging both companies’ respective strengths – resulting in what is claimed to be highly efficient thermoforming solutions backed by a proven support network.

‘A lot has changed since the last K. The world emerged from global recession – a phase which challenged Rajoo and Wonderpack. But both companies emerged with flying colours and posted significant increases in sales,’ reports Sunil Jain, Rajoo president.

Meeting challenges is a way of life at Rajoo, and the company has worked hard to dispel myths relating to high investments needed in sheet extrusion lines for producing PET sheet from bottle flakes. Visitors to the Rajoo stand saw its latest PET sheet line, complete with crystalliser and dehumidifier, producing 300kg/hour of 700mm wide three-layer (ABA) crystal-clear PET sheet, with a thickness range of 0,2 to 1mm.
Called the Lamina RS1X 1490-50/900 rPET, it comes with the lowest investment cost/ton of installed capacity, providing fast payback with 100% PET bottle flakes as input.

The Wonderpack stand showcased a one-of-a-kind four-axis servo-controlled form-and-cut-in-place thermoformer, designed for speeds of 60 strokes/min. With this versatile combination, Rajoo and Wonderpack offer an affordable system of extrusion with in-line thermoforming for enhanced productivity levels – and all at low investment cost. ‘The Rajoo and Wonderpack booths experienced stupendous responses, much more than we expected, and the concept of hybrid blown film lines at affordable price levels, offered by Rajoo and Hosokawa Alpine, generated a lot of interest among blown film producers from India and Africa,’ remarks Sunil.

Rajoo has emerged as a leading global player in blown film and sheet extrusion lines and enjoys a premium market position in this segment. Being technology driven, product innovation, world-class quality, state-of-the-art workmanship, increased energy efficiency and high levels of sophistication and automation have become hallmarks of Rajoo products.

Windmöller & Hölscher excels

THE tills were ringing on the Windmöller & Hölscher stand and visitors jostled for space on the demonstration floor to watch records being broken by the very latest five-layer Varex blown film extrusion line.
With over 1 000kg/hour of high-quality 40µm film being produced, it was certainly the highlight on the stand. It wasn’t only the output of the 2 200mm-wide line that attracted visitors’ attention but also the new Maxicone P five-layer die with a die diameter of 400mm fed from direct driven extruders. This was developed specifically for innovative polyolefin-based film structures.

Recognising a need in the market, W&H worked with resin manufacturer ExxonMobil Chemical, one of the world’s leading manufacturers of metallocene polyethylene, to create a new-generation of five-layer films using a polyolefin base. The results are improved film properties as well as thinner films compared to conventional three-layer films on the market, allowing significant downgauging. The new films are said to achieve a substantial reduction of raw materials, a priority for W&H under their ‘Greenovation’ philosophy.

The new Opticool air ring, successor to the well-known double air ring Multicool D, is key to the high output achieved by this line. Thanks to improved air flow control, which avoids pressure drops of intake air, the Opticool has a very high cooling capacity and enables the blown film line to reach higher outputs than dual air rings, as well as easier line start up.

The line is also equipped with the Multinip oscillating haul-off with direct-driven turning bars and easy-running carbon fibre rollers. The Variocage film sizing cage with soft lacquer-coated carbon fibre rollers was also featured. The Procontrol TS operator panel with self-explanatory menu guide via a touch screen ensures easy operation and control of the entire line. High-quality film rolls are produced on the multifunctional Filmatic S winder, which finishes the process with perfectly wound films with excellent roll geometry. Even at the output of 1 000 kg/h there was no edge trimming required, thanks to the accuracy of W&H’s proven IBC control system.

Also presented by W&H was the latest Miraflex AM 8 CI flexographic press. Launched just over a year ago, it has proved highly popular with packaging companies worldwide. This latest addition to the Miraflex range highlighted a new generation of the Easy-Family automation modules that save resources and reduce waste. At the company’s in-house expo, which ran parallel to the K 2010 show, a MiraflexCM 10 was also shown in production.
Markus Bauschulte, W&H’s technical sales executive for printing presses and finishing equipment, remarked on a busy week: ‘It’s been much better than 2007 with lots of potential new business for Miraflex AM and CM. We’re very happy with response from the show.’
 In 2010, the latest Miraflex AM was installed at Venk-Pac by local representatives, Ipex Machinery (PPM Sept 10, p12). It is, says Markus, ‘the perfect machine for the South African market’.

 

Rapid’s ‘open hearted’ granulator

FOR the first time ever, Rapid displayed its entire ‘open hearted’ granulator range at K2010.
Now complete, the 600 Series is offered in three widths: 900mm, 1 200mm and 1 500mm. And, thanks to extensive modular rotors and cutter house designs, it can be offered in 45 standard base configurations and tailored to suit virtually any large granulation application.
‘The 600 Series uses the same patented technology that has already proven successful in Rapid’s 300, 400 and 500 Series granulators, brought to the market in 2004,’ remarks Bengt Rimark, Rapid group marketing director. ‘The concept is completely modular and can be tailored to any application within the plastics processing and recycling industry.’
The 600 Series machines also come with Rapid’s patented Mineral Composite Technology base, a vibration-absorbing platform, helping to reduce noise levels during operation.

‘Open-hearted describes the machine’s ergonomic design that, during a production change, for example, allows the operator to gain complete access to the rotor and cutter at the heart of the machine in just three steps and without the aid of tools. This provides for a rapid “visibly clean” confirmation, eliminating the risk of granulate contamination after colour or material changes. The same quick access benefits maintenance work as well. In both cases, it significantly reduces machine downtime and improves productivity,’ explains Bengt.
Centrally located or beside the press, the 600 Series is designed for high-volume granulation of injection moulded, blow moulded or extruded plastic parts and waste, and can handle throughput up to
3 500kg/h.

Headquartered in Sweden, Rapid exports around 97% of its production. With nearly 100 000 machines installed across five continents, it’s considered a world-class leader in its field. Rapid is represented in South Africa by Maritime Marketing.

ASB ahead of the trend

K2010 provided a perfect platform for Nissei ASB to introduce the HSB-6M, a new two-step reheat stretch blow moulding machine for wide-mouth hot-fill PET containers.
Trends indicate continued global demand for wide-mouth hot-fill PET jars for foods such as sauces, pickles and jams, many of which require filling at high temperatures (above 90ºC). According to ASB, hot-fill PET jars yield major weight reduction and sustainability advantages over glass, including reduced freight costs and lower carbon footprint.

‘The market for wide-mouth hot-fill food containers appears ready to convert from glass to lightweight PET and we have the technology that will meet the demand of this high-growth segment.’ So says Jamie Pace, VP and general manager of Nissei ASB in the US.
ASB’s technology enables production of PET jars that can be filled at temperatures above 90ºC. The HSB-6M produces 300ml to 600ml hot-fill PET jars with a standard 63mm diameter, with twist-off neck finishes at a production rate of 6 000 jars/hour. The new two-step reheat system incorporates the company’s ‘double blow moulding’ technology, which has been successfully used in Asia for more than 15 years to produce narrow-neck hot-fill bottles. In the double blow moulding system, the preform is first blown in a primary mould and then undergoes high-temperature conditioning before passing to the final, secondary mould.

Also launched at K, and popular with visitors to the Nissei stand, was the ASB-150DPW one-step stretch-blow moulding machine. The new ASB-150DPW has the same footprint as the market-leading ASB-150DP model but features a double-row configuration, doubling cavitation to a maximum of 36.
‘Brand owners and packaging companies are demanding sustainability improvements and carbon footprint reductions for products requiring medium to high production rates; this new model is perfect for those requirements,’ continues Jamie. ‘Our latest machine gives processors the ability to make up to twice the number of bottles in the same machine footprint as before, with almost the same energy.’

The ASB-150DPW can produce 50ml to 1,5-litre containers at a rate of up to 9 000 bottles/hour, depending on design and cavitation. Targeted applications range from liquor and energy-drink containers to wide-mouth containers for peanut butter, mayonnaise and toys. Tooled appropriately, the machine is capable of processing PET, PLA, PC and rPET in neck sizes up to 94mm. It also offers major sustainability benefits, reducing the energy cost per container by approximately 40%, compared to the single-row ASB-150DP machine.

Urola protects the environment

UROLA, represented in South Africa by the Maritime Marketing-Seecor joint venture, claims to be one of the few companies in the world that deals with the design and construction of blowing machines for both PET and extrusion blowing.
In response to global market demands, Urola presented the Urbi-6 at K, seeking access to medium-sized production companies in the food and non-food segments requiring PET packaging.

Said to be the most compact machine in its class, the Urbi-6 features a production rate above 9 000 bottles/hour with six moulds. With the development of this machine, Urola has achieved several important improvements, including better energy efficiency, faster accessibility and improved power.
Packaging weight reduction is an important market driver and the show provided Urola with an opportunity to demonstrate another of its modern solutions, the M12 rotary machine. It’s equipped with 12 moulds for multilayer bottles at high outputs for food, milk, juice and sauce containers up to 1,5-litres. As a rotary concept, it has a single head that provides many advantages including bottle uniformity, both in weight and technical characteristics, and weight reduction; low power consumption; and high flexibility to produce any size container.
Worldwide, Urola and its representatives work closely with customers on aesthetic and technical packaging requirements, to provide moulds and pilot samples.

Husky ready for anything

HUSKY wowed visitors with an array of new technology at K.
Flying the flag for South Africa was Ashley Henry, who reported an excellent week, with many African visitors to the stand. ‘We‘ve had amazing interest this year,’ he confirms, ‘We received a number of orders from African customers, especially from emerging markets. Overall, the show was a huge success.’
Highlights on the Husky stand included the H/PET preform equipment, ideal for the lower volume end of the market, especially suiting emerging markets and manufacturers of private brands. As it offers lower investment and therefore a lower risk, plus good flexibility and quality, it’s the ideal entry-level model for new customers.

‘Provided with a full warranty from Husky, and combined with complete customer after-sales support, the complete system is ideal for establishing great customer trust and confidence. Husky can also provide customers with the perfect upgrade incentive during business growth,’ assures Ashley.
Star of the show was the HyPET HPP4.0. ‘This next-generation high-performance preform equipment really does stamp our authority as the outright leader in preform production,’ Ashley insists.

The HyPET HPP 4.0 is capable of moulding thinner wall preforms, allowing further lightweighting of bottles. In line with market trends, it also offers improved flexibility. It can inject any preform that a bottle blower can blow and is very stable both in acceleration and deceleration.
‘We’ve also introduced the HyPET RF, which can process rPET flakes from 0-100% without any moulding issues,’ continues Ashley. ‘Our customers want the very best technology and we’re ready,’ he concludes.

Future solutions from Engel

TRUE to its motto ‘inject the future’, Engel presented tomorrow’s intelligent injection moulding solutions, offering converters the necessary economy and efficiency to boost productivity.
The use of energy-saving systems was the highlight of Engel’s presentation at K and with a total of 20 Engel machines on show (11 at its own stand and nine on Engel partners’ stands) it gave an impressive demonstration of performance centred on competence in injection moulding machine manufacturing.
Demonstrated was the fully-electric Engel e-cap 3940/420 T series for packaging. It delivers the market requirements in cap production with respect to short cycle times, a high level of flexibility and low energy consumption. With a cycle time of less than three seconds, Engel believes the e-cap has a far lower energy consumption than competitor machines.

It boasts a premium-quality injection unit, increased ejector force and a reinforced clamping drive. The e-cap 3940/420 T features a 96-cavity mould by Schöttli (Switzerland) for production of HDPE caps, with a cycle time of less than three seconds. In addition, quality control is integrated in the form of a QVision system.

An Engel e-motion 740H/440M/280 WP was also put through its paces, producing a tube, including a PP cap, with a four-cavity mould. Production relies on a rotary cube and a second moving unit on the mould fixing platen. The tubes are produced in the first cycle with the cap injected in the second – all in a single step. The machine on show also featured an in-mould labelling system.

Haitian hits the high notes

THERE was a constant buzz of activity on the Haitian stand, as visitors viewed the company’s diverse, high-speed injection moulding technologies in action.
Represented in South Africa by GF Plastic Machinery, Haitian offers a variety of machines including the new Mars Eco with extremely low energy consumption, the two-platen Jupiter series and the new energy saving Pallas. The all-electric Zhafir Venus Series and the ground-breaking Zhafir Mercury series, designed for the high-end sector, were further highlights.

The Zhafir Venus Series is said to offer all-electric technology at the price of a European hydraulic machine. The VE/p (packaging version), introduced at Chinaplas 2009, performs at extremely high acceleration and, with a response time of approximately 25m/sec, it guarantees dynamic injection and a precise part weight – even with thin wall parts. A specially developed high-performance screw guarantees improved melt homogeneity and a steady flow of material.

Star of the show was the Zhafir Mercury Series, with a totally new overall concept in high-end injection moulding. The machine design displays new approaches in the primary drive axes; tie bars become side walls and consequently take on more functions; the clamping system is reduced to the most essential moving parts; and the separation of plastification and injection permits the combination of different screws and injection piston diameters, allowing for an extraordinarily high melt quality.

The injection process is also highly dynamic and the piston facilitates a constant injection volume, which in turn promises consistent part weight.
George Ferreira, owner of GF Plastics Machinery, was on hand during the show to assist with many African buyer enquiries on the full Haitian range of injection moulding solutions.

 

Easy use and high finish results

ASHE Converting Equipment launched its K2010 campaign with the renowned Sapphire S2 and the cost-effective Diamond slitter rewinder.
The Sapphire, prized for its versatility and speed, is now available in three rewind diameter configurations: 600mm, 800mm and 1 000mm. With features to minimise set-up time, the machine also incorporates a vacuum pull roller to give perfect tension isolation without nip rollers and S wraps.
With state-of-the-art AC digital flux vector drives and PC touch screen controls, the S2 is easy to use. The machine has built-in electrical panel, pneumatics and operator panel with remote diagnostics capabilities. There’s a maximum speed of 700m/min for optimum productivity and perfect tension isolation and superior winding avoids slips and scratches.

According to Ashe Converting’s Matthew Godbold, the Diamond slitter rewinder technology, based on the renowned Sapphire range, is the most cost-effective solution if performance and a fixed budget are focus.
Ideal for running a wide range of substrates from paper, film, aluminium, foil and laminates, it’s available in widths between 1 000mm to 1 800mm and can run at a maximum speed of 500m/min.

A vacuum pull roller for perfect tension isolation avoids slippage or scratches even on sensitive materials and all-electric operation makes for excellent hygiene control. An intuitive PC touch screen with job memory storage also makes for easy operation.
Marketed locally by Ipex Machinery, Ashe Converting’s slitter rewinders play an integral role in many of South Africa’s packaging and printing concerns.

 

Hudson-Sharp has show appeal

THE latest version of Hudson-Sharp’s successful 5750 W high-speed single-lane wicketer for 22µm three-layer coextruded PE proved a huge success at K, with sales secured from Tropic Plastics, Durban, among others.
The 5750 W includes several standard and optional features designed to increase output, reduce downtime, save energy and ensure complete operational safety.

Average running speeds exceed 100m/min on standard bags and 90m/min on square bottom bags. However, for certain applications and under optimum conditions, the machine can run consistently in a production environment at cycle speeds of 450/min. Much market attention is currently focused on reducing energy costs and, with the new standard airless anti-static system and servo-driven wicket punches on the 5750 W, downtime is reduced.
Production quality is also enhanced thanks to Hudson-Sharp’s automatic seal bar cleaner.
Hudson-Sharp is represented in South Africa by Advanced Packaging Technology, Cape Town.

Local success for Comexi

UNDER the theme ‘The Meeting Point of Sustainable Innovation’, Comexi reported more than 1 500 international visitors and eight days of intense face-to-face activity.
Comexi representatives closed important deals on flexo printing presses, laminators and slitters with customers from the Middle East, Latin America, South Africa, China, Europe, among others, and news spread fast that Durban’s Tropic Plastics was the latest purchaser of a ten-colour F Plus press.
Gary Kieswetter of Advanced Packaging Technology represents Comexi in South Africa and reports that much of his ongoing success is based on regular and personal contact with his customers. The purchase by Tropic Plastics really was the cherry on the top as that was where Gary completed one of his first machine installations over 22 years ago.

Manel Xifra, CEO of Comexi Group, was delighted with Comexi’s show success. ‘Our goal was far exceeded. Despite the economic crisis, we were able to attract customers from around the world, and close important sales. Moreover, Comexi’s brand image has been reinforced by our ability to offer innovative and profitable solutions,’ he recounts.

Comexi’s value proposition is innovation with the aim of improving converting efficiency and developing environmentally sustainable processes.
Its latest flexographic press, F4 FlexoEfficiency, involves a revolutionary concept in flexographic printing, dramatically improving efficiency. It’s a newly-developed technology that meets the tendency to shorter job runs while helping flexo printers to expand into the label market. The elimination of photoinitiators through eComexi solutions, utilizing EB technology in high-performance flexographic printing is another possibility offered by this product range.

Also seen was a live demonstrations of Comexi’s e-Turret slitter-rewinder with double turret mechanism, which was sold during the exhibition. Its productivity is said to be higher than a conventional duplex slitter, helping to eliminate bottlenecks in the cutting area that occur with the higher downtime of conventional slitters.

K2010 success for Bobst

AN excellent turnout of visitors to the Bobst group stand confirmed the high level of interest for the latest printing and converting developments presented by companies within Bobst’s Web-Fed BU. Present on the stand was the team from Beswick Machinery, Bobst’s local agent.
Developments on show included flexo printing technology from Fischer & Krecke (Germany), vacuum web coating and metallising from General Vacuum Equipment (UK), and gravure printing, coating and laminating from Rotomec (Italy).

Fischer & Krecke (F&K)’s gearless CI flexo presses for printing flexible materials are renowned for their exceptional reliability and performance, coupled with fast changeovers, while also delivering consistently high-end graphics. Comprehensive information was available on all models of the Flexpress series with a special focus on the FP 15-S, the latest addition to the Flexpress family. This model, inclusive of the latest smartGPS version, was also demonstrated at F&K’s production plant in Bielefeld, Germany, during the show period.

General Vacuum provides world-leading technology in vacuum web coating and metallising for the deposition of conventional aluminium and clear barrier coatings for flexible packaging materials, plastic film, decorative and label applications, photo-voltaic and high technology security coatings. At K2010, General presented the latest developments and additional features of the K5000 vacuum metalliser, arguably the world’s finest metalliser for today’s plastic film and flexible packaging industries.

According to the company, the K5000 provides a competitive edge by increasing product quality, reducing operating costs and producing the highest output of metallised film per hour than its closest competitors.

Alongside its comprehensive range of well-established gravure printing solutions for flexible materials, Rotomec presented the new RS 4003MP HS press, the high-speed version of the best selling RS 4003MP model, featuring production speeds up to 500m/min. Rotomec’s latest waste-saving features in gravure printing were of great interest to converters seeking ‘less waste-more productivity’ solutions.  These included the TAPS (Total Automatic Pre-register Setting) system, which enables waste reduction at unprecedented levels at press makeready and changeover, as well as the new ‘Smart Sample’ function for fast colour matching. 

Also featured was the Rotomec CL 850/CL 1000 range of high-performance duplex and triplex multi-technology laminating machines; SL 850/SL 1000 laminators with dedicated configuration for high-speed solventless lamination; and Rotomec’s leading-edge coating and laminating technology for flexible materials.

Extrusion coating technology, another field of expertise for Rotomec, is epitomised by the RX 400F/RX 700F extrusion coating and laminating lines for flexible packaging. These are fully integrated turnkey lines which can be custom-built for a wide variety of applications and feature advanced components and technical solutions as a result of close collaboration with Reifenhäuser Extrusion.

 

New beginnings for Atlas

BREAKING news at K2010 was the MBO of Atlas Converting Equipment from the Bobst Group
(PPM Festive 10, p7).

‘Our intention is to have a global service and sales network,’ Alan Johnson, MD, told journalists at the
K 2010 press conference.

The new company was officially launched at K2010 with an adjacent stand to Bobst, displaying the latest Atlas and Titan branding and corporate identity for the first time.

Featured at the show were primary and secondary slitters for film with speeds up to 1 500m/min on the primary models. Titan is currently promoting 1 000 to 2 250mm width duplex slitters and rewinders with 750m/min speed.

Atlas Converting Equipment continues to be represented in South Africa by Beswick Machinery.

 

Clariant powers performance

THE launch of Mevopur, a brand of masterbatches and compounds specifically for the medical and pharmaceutical sector, capacity expansion of safer, more environmentally-compatible flame retardants, and the launch of efficiency-boosting processing agents – these were among the highlights of Clariant’s ‘Power Your Performance’ commitment to the plastics sector at K2010.

Key aspects of Clariant’s strategy are safety, ecology and efficiency. The company applies high safety standards to its products and processes, helping customers to navigate plastics and chemical regulations and practices.

With three global centres of competence, Clariant provides a diverse range of colour solutions for sensitive applications such as medical devices, food packaging and toys.

Features of the company’s stand at K included the Mevopur brand that provides a controlled, consistent and compliant portfolio to address safety challenges in the sensitive and demanding pharmaceutical and medical sectors; and the innovative Licocene waxes for plastics that act as a combined dispersing and carrier agent for pre-mix formulations.

These high-performance metallocene-catalysed Licocene grades allow processors to achieve better control, more highly-filled and effective formulations, and faster dispersion of colorants, additives and fillers for almost universal applications.
Clariant’s also focusing on creating a cost-effective manufacturing network and has completed phase one of REACH regulations on all pigments, launching a range of non-halogenated pigments at K. In fact, Clariant was among the first pigment producers to foresee legislation regarding lead chromate, adding lead chromate-free pigments to its colour ranges long before the 2012 REACH restriction emerged.

‘These are all flagship developments to improve customers’ profitability,’ explains Marco Cenisio, head of pigments at Clariant. ‘It’s a step-change in Clariant’s processing efficiency.’

Clariant will be extending its capacity to 2014 with further investments, products and regulatory foresight. ‘We’re ready to deliver the performance of a lifetime for a lifetime of performance,’ concludes Marco.

Ed’s note: Don’t miss the second episode of the K2010 saga in our February issue!