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www.compoundingworld.com September 2010 | compounding world �

04 Industrynews

09Deutschlanddelivers As the world’s plastic industry gets ready to converge on düsseldorf, Ami’s carole

Kluth examines market trends in the german plastics industry.

19 Thewhitestuff:trendsinTiO2 A new TZmi report analyses trends in the titanium dioxide industry which impact on

the production of white masterbatch and compounds.

24 Bringinthereinforcements lilli Sherman reports on the latest developments in reinforcements for

thermoplastics, including new glass, carbon, aramid and natural fibres.

43 Selectingtherightgear Stefan Knieling of Henschel examines how gearboxes have been developed to

deliver extreme levels of torque for twin-screw extruders.

49 Fightingfrictionandwinningthewaragainstwear Eric Salmon and carsten wehling of Superior graphite have been testing pA 66

compounds incorporating their resilient and isotropic graphitic carbon.

54 ThecountdowntoK2010 our K 2010 preview includes the pick of new developments from BASF, coperion’s

record-breaking pelletizer and clariant’s medical plans.

64 CompounderoftheMonth:TisanEngineeringPlastics

66 Datesforyourdiary

comingnextissue❙ K 2010 show issue ❙ European masterbatch markets ❙ carbon black ❙ compounding bioplastics

➤ Click here to make sure you get your copy

contents

pAg

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Applied Market Information LtdAmi House, 45-47 Stokes croft, Bristol, BS1 3Qp, united KingdomTel:+44 (0)117 924 9442Fax:+44 (0)117 989 2128www.amiplastics.com

contactusHeadofbusinesspublishing: Andy Beevers E-mail: [email protected]

Contributingeditors: lilli Sherman E-mail: [email protected]

nadya Anscombe E-mail: [email protected]

Advertisementmanager: claire Bishop E-mail: [email protected]

direct tel: +44 (0)20 8686 8139

compounding world | September 2010 www.compoundingworld.com�

news

Kingfa Technology is

planning to establish a new

compounding and materials

development operation in the

Kunshan Economic and Tech-

nological development Zone

in Jiangsu province, china.

The new subsidiary will be

called Jiangsu Kingfa

Technology development and

the initial investment is

estimated at 640 million Yuan

($94 million), according to

statement issued by the

board of directors on 31 July.

Kingfa is the largest

plastics compounder in china

with plants in guangzhou,

Shanghai and Sichuan and an

annual capacity in the region

of 1 million tonnes. it

supplies the country’s

appliance, consumer goods,

electronics and automotive

markets with flame retardant

and reinforced compounds as

well as masterbatches.

❙ www.kingfa.net

Kingfa plans new plantin Jiangsu

cabot has opened its new

black masterbatch manufac-

turing plant in the Jebel Ali

Free Zone in dubai. The facility

has an initial capacity of 25,000

tonnes/year and began

production in August.

The plant currently houses

one masterbatch line based

around a coperion twin-screw

extruder, but there is space to

add two further lines which

would take the total capacity to

Asahi Kasei plastics north

America has developed a new

pp compound that its says can

compete with long-glass-fibre-

filled pp, while offering the

economic benefits of short-

glass-filled pp. Thermylene p8

is claimed to give superior

creep resistance at room

temperature and comparable

creep resistance at elevated

materials.

The compound has been

selected by Faurecia interior

Systems for the inner door

Asahi Kasei pp compound competes with lFTs

module on the Jeep liberty

SuV. one of the reasons for

specifying Thermylene p8 for

this part, which would typically

75,000 tonnes/year. The dubai

facility also includes laborato-

ries and administration offices.

it will allow cabot to meet

the growing demand for

masterbatch in the middle

East, Europe and Asia pacific

regions. Sean Keohane,

cabot’s vice president and

general manager for the

performance segment, said:

“within the middle East there

is already a strong demand for

polyethylene and polypropyl-

ene compounds for use in

building infrastructure for

water supply, electricity and

telecommunications projects.

These are key applications for

black masterbatch.”

cabot now operates

masterbatch plants in dubai,

Hong Kong, Belgium and italy.

it closed its uK masterbatch

facility in 2009.

❙ www.cabot-corp.com

This inner door module for

the Jeep Liberty is being

moulded using Asahi Kasei’s

PP compound

cabot opens dubaimasterbatch plant

be moulded using long-fibre-

filled pp, was the compound’s

screw/torque retention.

❙ www.asahikaseiplastics.com

Cabot’s new Dubai plant houses one compounding line with space for two more

news

www.compoundingworld.com

BASF and Astra Polymer

Compounding have ended

plans to form a joint venture

for the production of custom-

er-specific anti-oxidant blends

in the Middle East. The plans

were originally drawn up

between Astra, which has its

headquarters in Saudi Arabia,

and Ciba prior to the latter

company being acquired by

BASF in 2009.

A statement from BASF

said that the termination of the

JV plans will have no impact

on the existing tolling agree-

ment between the companies

to produce customer-specific

anti-oxidant blends for the

region. However, BASF is

considering several options for

BASF and Astra end plans foranti-oxidant JV

investing in local production

for such products.

“We are convinced of the

strategic importance of the

Middle East Region and the

need for a local production unit

for customer specific blends,”

said John Frijns, senior vice

president plastic additives for

Europe/EAWA at BASF. “A

thorough evaluation following

the integration of the legacy

Ciba Plastic additives business

into BASF has furnished new

options that will deliver more

value to both our customers

and BASF,” he added.

Astra is the leading

manufacturer of masterbatch

in the Middle East.

❙ www.basf.com

F&D Plastics is increasing

capacity for colour concen-

trates at its plants in Leomin-

ster, Massachusetts, USA, and

in St-Laurent, Quebec,

Canada. It is installing four

brand new compounding lines

based on Coperion and

Theysohn extruders with screw

diameters from 26 to 50 mm.

The first new line was

installed in July, two more are

being commissioned in

October with the final one

scheduled for installation in

November. Two are being

F&D Plastics boosts masterbatch capacity

added at the Leominster plant

and two at St Laurent; in total

they will boost the company’s

capacity by 37%.

The company’s president,

Darren Rosbury says that the

new state-of-the-art lines will

help to meet growing demand

from the housewares, lawn

and garden, hardware and

medical markets. F&D has

also added five new recruits to

its team, including three

chemists and two technical

sales representatives.

❙ www.fdplastics.com

k-online.de

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over 50 countries present the latest products and

concepts – from standard to high-tech solutions.

With its first-class range of exhibits, both in terms of

quantity and quality, K is the most important busi ness

and contact platform for the industry worldwide.

In 19 halls, everyone is represented, from the market

leaders to the niche market suppliers who decide the

future of the industry.

Be there when the world-class suppliers of plastics

and rubber meet in Düsseldorf !

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compounding world | September 2010 www.compoundingworld.com�

news

it is increasingly likely that the

Eu will increase taxes on the

import of glass fibre from

china into Europe from 7% to

50.6%. The increase is

scheduled to come into effect

on 16 September on a

temporary basis while further

investigations are carried out.

Eu poised to raise tariffs for chinese glass fibre

The increase has been

supported by fibreglass

producers who have com-

plained about the dumping of

chinese material at illegally

low prices.

However, it has been

fiercely fought by the users of

fibreglass who believe that the

increased tariff will leads to

material shortages and

increase their costs.

india and Turkey have

already imposed tariffs of

40.86% and 38% respectively

on glass fibre originating in

china with the aim of combat-

ing dumping.

Bankrupt compounder leased bySo.F.TerSo.F.Ter is leasing p group,

an italian compounder of

engineering plastics that is

currently bankrupt. A court

will decide later this year

whether p group can be

acquired by So.F.Ter or any

other interested parties. p

group compounds pp, pBT

and pA at its facilities in

Ferrara and has a sales office

in germany.

So.F.Ter says that the

agreement will strengthen its

presence in the automotive

market, particularly in

germany. it also says that it

complements its acquisition

of matrixx Europe in 2008 and

will strengthen its portfolio of

reinforced plastics.

❙ www.softerspa.com❙ www.p-group.biz

A. Schulman has made

several senior management

appointments in America and

Asia. Gustavo Perez has

been named as general

manager and coo of the

Americas. He joined the com-

pany in 1995 and since 2008

People on the move: new appointmentshas been general manager for

masterbatch in north America.

Roberto Lopez has been

promoted to the position of

business unit leader of

masterbatch for the Americas.

He was previously responsible

for the company’s mexican

masterbatch business.

Schulman has also announced

that Derek Bristow has been

appointed as general manager

and coo of Asia. He was

previously general manager

for Australasia at ico which

was acquired by Schulman in

April. He replaces Jack Taylor

who is retiring at the end of

the year after 32 years with the

company.

Teknor Apex has appointed

Stanly L.K. Tan as the new

managing director of Singa-

pore Polymer Corporation

(Spc), replacing Cheah Sin

Hua who is retiring after more

than 40 years with the

company. Tan was previously

with dSm Engineering

plastics as manager of its pA

66 business in Asia. Spc was

acquired by Teknor in 2001.

Gustavo Perez

Derek Bristow

Stanly L.K. Tan

plastic color corporation

(pcc) has opened a new

research and development

facility at its colour and

additive masterbatch plant in

Asheboro, north carolina,

uSA. The lab is equipped with

the latest analysis and testing

equipment and will be used to

help customers develop new

products.

pcc opens new laboratory“The opening of the new lab

is just the beginning of our

investment in a state-of-the-art

customer development and

customer support centre in

which new-age resins can be

developed upon request,” said

pcc president, doug Borgsdorf.

“we have more equipment on

order already that will keep us

at the leading edge.”

pcc has also achieved

accreditation of its lab in

calumet city, illinois, uSA,

from the American Association

for laboratory Accreditation.

This organisation tests quality

control measures, record

keeping, calibration and

conformity to iSo/iEc

17025:2005 requirements.

❙ www.plasticscolor.com

news

Gabriel and RAL devise new colour standardsAustrian masterbatch maker

Gabriel Chemie is working

with the German colour

matching organisation RAL to

implement new standard

colours for plastics. The new

colour range will be launched

at the K 2010 exhibition in

Düsseldorf, Germany, next

month.

The RAL Plastics range

initially covers the 100 most

frequently requested colours

from the RAL Classic colour

collection and there are plans

to extend this to 200 colours.

Gabriel Chemie is responsi-

ble for the technical imple-

mentation of these RAL

colour standards.

❙ www.gabriel-chemie.com

A. Schulman has announced

that some production at its

plant in Crumlin, Wales, UK, is

being relocated to the compa-

ny’s facilities in Bornem,

Belgium and in Givet, France.

Schulman shifts production from UKApproximately 10,000 tonnes of

masterbatch production will be

moved to the larger, more

cost-efficient plants.

Several production lines

will be shut down at the

Crumlin site with the loss of

approximately 30 jobs. The

plant will now focus on smaller

lots of colours and other

speciality compounds for the

local market. As part of this

Solvay and Entegris combine CNTs and PEEK

strategy, Schulman recently

invested $1.2 million in a

versatile continuous mixer for

specialised products at the

Crumlin plant.

❙ www.aschulman.com

Solvay Advanced Polymers and

Entegris are working together

on carbon nanotube (CNT)

enhanced PEEK compounds

for applications in the medical,

aerospace, automotive and oil

and gas industries.

Solvay is supplying its

KetaSpire PEEK materials for

the compounds which are

produced by Entegris using its

proprietary technology for the

uniform dispersion of CNTs in

thermoplastics. The resulting

materials are aimed at

applications requiring weight

reduction, enhanced physical

properties, thermal manage-

ment and static discharge

dissipation.

Greg Jack, senior business

development representative

for Solvay Advanced Polymers,

said: “This partnership will

spur greater use of our

materials and open up new

end-use applications where

consistent electrostatic

discharge properties and

improved thermal stability are

required”.

Quantum Polymers of

Newark, Delaware, USA,

recently introduced stock

shapes made using CNT-filled

KetaSpire PEEK supplied by

Entegris. Its extruded rods and

plates can be used to replace

metal parts in semi-conductor

materials handling and

chemical cleaning systems.

❙ www.entegris.com❙ www.solvay.com

These stock

shapes are extruded

using CNT-filled PEEK

www.compoundingworld.com September 2010 | compounding world �

germany’s plastics industry | markets feature

germany is the powerhouse of the European plastics

industry. it is the largest market both in terms of

production and demand, dominating nearly every

sector of the processing industry and accounting for

over 20% of thermoplastics demand.

The market performed strongly in the period

2005-2007, driven by the strength of the german

economy and strong demand from central Europe.

However, the impact of the global recession saw

demand collapse for nearly all polymer materials in Q4

2008 with plastics processing activity remaining weak

throughout most of 2009. According to Ami data, after

reaching a peak in demand in 2007 of 8.6 million tonnes

of thermoplastics processed in germany, the market

dropped by 6% in 2008 and nearly 8% again in 2009,

which effectively wiped out five years of growth for the

industry.

production of plastics materials suffered an even

steeper 15% decline in volumes in 2009 according to the

trade association plasticsEurope deutschland. Both

domestic and export demand figures were down,

reducing germany’s traditional trade surplus in

polymer materials. The impact of the global recession

has also been severe for german producers of capital

goods, such as plastics processing machinery, as

companies around the world slashed their investment

spending. Sales of german plastics and rubber

machinery were down 30% in 2009 according to the

industry association VdmA.

The economic downturn has inevitably reduced the

number of plastics processing operations. in its survey

of german injection moulders, Ami found there had

been a net loss of 5% of companies over a three year

period. over 60% of these were lost because of

insolvency or because of transferring moulding

operations to Eastern Europe or china. A number of

companies ceased to exist because of the retirement of

owners or because of plant rationalisations or mergers.

others chose to withdraw from processing activities

preferring to sub-contract out their moulding require-

ments or to refocus their activities on tooling, assembly

or finishing operations.

However, the trend for plastics processors to

relocate to Eastern Europe or Asia has generally been

less evident in germany than elsewhere in western

Europe. Although german companies have established

operations in central Europe, this has not always been

at the expense of their home plants. germany’s

proximity to central Europe also benefited its proces-

sors prior to the downturn. The growth in demand for a

wide variety of products in central Europe from

packaging to technical components, could not always be

met by local processors, either because of capacity

deutschland delivers

As the world’s plastics industry gets ready to converge on düsseldorf for next month’s K show, Carole Kluth takes a close look at trends in

the german plastics market which is showing signs of recovery

compounding world | September 2010 www.compoundingworld.com10

markets feature | gemany’s plastics industry

constraints or a lack of competency. german companies

were well placed to meet this shortfall in capacity or

technical know-how and are likely to benefit again, once

economic growth returns to the region.

Various government initiatives during 2009 sought to

mitigate the effects of the recession and they did have

some impact on plastics demand. The car scrappage

scheme helped to sustain demand for new cars but

production still declined by 10%. However, this was con-

siderably less than was seen in most other west

European countries where car production was down

anything from 20% to 50%. government infrastructure

investments also helped to sustain some building

product demand. As these measures are now ending,

there are signs that the underlying strength of german

manufacturing and engineering is helping to lift the

plastics industry out of recession quicker than in many

other countries and a more optimistic feel is beginning

to emerge about the future prospects for germany’s

plastics industry. last month it was announced that

germany’s gdp grew by an impressive 2.2% in the

second quarter, the strongest three-monthly gain since

reunification in 1990. The growth is being driven by

rising production levels and exports in areas such as

machinery, vehicles and chemicals. As result, business

confidence has reached its highest level in three years.

Material movementsThe materials that appeared to have been least affected

by the downturn were pET and EpS where there was

relatively little loss of volume, although both these

materials had been experiencing strong growth up until

the recession hit. The pET market had been driven by

the move to pET bottles for one-way packaging

replacing cans, glass bottles and cartons, led by the

discount stores such as Aldi and lidl. EpS demand had

been driven by initiatives to improve the energy

efficiency of buildings in line with the Eu directive.

For most other polymer materials the story was one

of shrinking demand during 2009 with the scale of

decline dependent on the extent to which the market

was driven by packaging, building, automotive or

consumer goods. The downturn in automotive produc-

tion, although not as severe in germany as

elsewhere in Europe, still contributed to

weak demand for most engineering

polymers and pp compounds. reduced

production of consumer electronic and

domestic appliances also led to steep

falls in the moulding and extrusion of

technical components and cable

products. These markets all saw a

contraction in the region of 10-15% in

terms of polymer volumes used last

year. with the exception of insulation

materials, building product demand was

also weak through the year, despite some

end use markets for thermoplastics in germany 2009

source: ami

germany’s

machinery

manufacturers

have seen a

sharp increase

in demand this

year

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markets feature | gemany’s plastics industry

investment in infrastructure products. The collapse in

demand for profiles in Eastern Europe and russia also

badly affected the production of pVc window profiles.

packaging, as is often the case through a recession,

was less affected but the market still declined by

between 5 and 7% overall largely due to weak demand

for industrial and transit packaging products with

consumer packaging demand holding steady.

with its high reliance on building and wire and cable

markets, pVc saw the largest falls in demand last year,

declining by around 15%. in addition to weak local

demand, profile producers also suffered from a collapse

in export sales to Eastern Europe and russia which had

grown significantly in the period to 2007, while pVc

cable markets had been weak for sometime because of

a combination of substitution by polyolefins and the

growth in imports of cheap finished low-voltage cables

from central Europe, which is the main market for pVc

cable compound. The drop in car production and

electronics manufacturing further impacted on

demand.

The decline in demand for polyolefin materials last

year was slightly less severe at around a 6% drop,

thanks to the higher proportions of the market in

packaging applications. The weakest performance

appears to have been for linear and low density grades

because of weak demand for agricultural, building and

technical films which are significant markets in

germany. demand for protective films were weak

because of the downturn in furniture and automotive

markets. Agricultural film demand was affected by the

long, cold winter and stretch film markets were weak

because of a decline in demand for transportation

packaging. pipe and cable demand was slashed

because of the slump in building activity. These were

offset by the demand for food packaging and hygiene

films holding up.

A similar story applied to HdpE resins with demand

for smaller containers and closures holding up, while

industrial containers, car fuel tanks and pipe production

have all seen significant drops over the past two years.

in polypropylene it is again the consumer packaging

markets which have sustained some areas of demand

for products such as thin wall containers and Bopp

films for food packaging. Automotive, electrical and

consumer good sectors have all been weak as have

most fibre markets although hygiene and medical

markets have performed better.

The decline in general-purpose high-impact

polystyrene was also not as severe as might be

expected given the weak fundamentals this market has

been experiencing for several years. This has seen the

market decline from a peak of 430,000 tonnes of

demand in 2002 to around 380,000 tonnes currently.

Volume had already been lost because of a decline in

production of consumer electronics, the development of

flat screen TVs and competition from pp and pET in

some thin wall applications. The insulation trends that

have helped maintain the EpS market have helped drive

demand for XpS despite the downturn in the building

market. Food packaging markets have also maintained

their demand for polystyrene packaging.

As would be expected given the size and sophistica-

tion of germany’s plastic processing industry, the

country is an important market for the use and

development of engineering resins. Having enjoyed

strong growth in the period to 2007, which saw demand

reach nearly 1 million tonnes, there has been an

estimated 150,000 tonne decline in volume across these

various materials, which include ABS/SAn, pA, pBT,

DEMAND FOR THERMOPLASTICS

IN GERMANY2001-2009

Source: AMI

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PC, PMMA and other high heat thermoplastics.

However, this is not surprising given their high reliance

on automotive, electrical and other technical sectors.

Compounds bounce backCompounding production in Germany has naturally

mirrored these trends in polymer demand. Thus from

the end of the second quarter in 2008 the first bad signs

began to emerge resulting in a catastrophic collapse in

demand for products in the final quarter. The first half

of 2009 continued in this high crisis mode with many

businesses teetering on the edge of bankruptcy.

Government initiatives to help support wages during

this time proved a lifeline for many of the major, well-

established companies, enabling them to keep hold of

staff while they rode out the storm. From mid-2009

business began to pick up again and since the end of

2009 there has been at times a rapid and dramatic

recovery in demand, which some companies are

struggling to meet because of the cutbacks and

rationalisations in capacity that were made during the

downturn and because of shortages of raw materials.

The weakest sectors during the recession were the

technical compounds and PVC compound markets

because of the downturn in automotive production,

appliance manufacturing and building activity. Injection

moulding customers were the most affected, and some

of these smaller companies went out of business.

Output of compounds is estimated to have shrunk by

more than 300,000 tonnes over the two-year period

2007-2009. Even so, Germany still accounts for 25% of

compound production in Europe.

Germany’s plastics industry | markets feature

Making more machinesGermany’s machinery makers have seen sharp increases in

demand in the first half of the year according to their industry

body, the VDMA Plastics and Rubber Machinery Association.

“Developments turned out much better than expected at the

beginning of the year,” says Thorsten Kühmann, managing

director of the Association. He adds: “[Our] members are also

optimistic regarding the outlook for incoming orders in all

customer regions in the second half of the year”.

The Association says that although exports fell sharply last

year as a result of the global downturn, Germany still main-

tained its market leading position, accounting for 24% of global

deliveries. In Europe as a whole, Germany’s market share is

31%, according to the VDMA, while in Asia it is just under 24%,

placing the country ahead of the previous leader Japan. Sales

across the Atlantic give Germany a market share of 26% of

global deliveries in North America, 18% in Central America

and 20% in South America. In Africa, Germany has a 15%

share, placing it behind China with 22% and Italy with 19%.

❙ www.kug.vdma.org

SupplierS’ ShareS in World exportS

Source: VdMa/Federal Statistical office

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in 2010

The collapse in production at the end of 2008 came

after a period of steady growth of around 2%/year. As

the economy recovers, this is expected to be the growth

trend for industry going forward. Continuing trends for

PP and engineering resin compounds to replace metals

and other traditional materials in automotive and

electrical applications will remain an important driver

for the industry. Before the recession, PVC compounds

had a resurgence thanks to a boom in demand for

window profiles. It is hard to see this business bouncing

back as rapidly given the weak state of the building

industry in Germany, which is mainly reliant at present

on public sector spending. The masterbatch industry

has probably seen the quickest recovery within the

compounding sector, thanks to its significant use in

packaging markets, which were less impacted by the

downturn. The market will also continue to be driven by

the trend among resin producers to move away from

providing a variety of compound grades to supplying to

the processor standard grades with a masterbatch.

Germany is destined to remain the largest consumer

and producer of plastics in Europe and its apparent

recovery is good news for the rest of the European

industry as it will help to drive demand throughout the

continent for some time to come.

This article is based on AMI’s 2009 European Plastics

Industry Report and AMI’s guide to the thermoplastics

compounding industry in Europe. Further information

available from:

❙ www.amiplastics.com

PRODUCTION OF THERMOPLASTIC

COMPOUNDS IN GERMANY 2009

Source: AMI

Germany’s plastics industry | markets feature

Why three letters define the market. ZSK – the embodiment of modern processing machinery and plant design for compounding technology. Our twin screw compounders continually set new standards in the plastics, chemical and food industry. They are the high-end, high-tech core of our plants. More than 10,000 compounding systems installed worldwide are proof of our unique system and process competence. And despite all our engineering skills, there’s still one thing we haven’t forgotten: We listen to what our partners say! And that’s why we are able to supply them with tailor-made solutions for their compounding and extrusion tasks. That’s what we mean when we say “confidence through partnership”. www.coperion.com

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www.compoundingworld.com September 2010 | compounding world 19

Titanium dioxide | markets feature

The white stuff:trends in Tio2

The TZmi group launched the inaugural edition of its Tio2

pigment Annual review in July. The company has

published information on the uS$11 billion global

titanium dioxide pigment industry since 1997, but this

latest publication now adds an annually recurring update

on the dynamics of the Tio2 industry to TZmi’s regular

offering. Here we look at some of this year’s key findings.

Pigment demandglobal Tio2 demand was 4.7 million tonnes in 2009, down

3% over 2008 and 8% over the historical peak in 2007. in

the more mature western markets, Tio2 pigment

demand collapsed by more than 16% over the past two

years and it is not expected to recover before the end of

the forecast period to 2015 (Figure 1). However, demand

in the emerging regions contracted only marginally. The

strength of the emerging markets, particularly those in

Asia-pacific and the middle East, are expected to lift the

global pigment consumption rate to 2015 while mature

economies are expected to remain static at best. Since

2000, china has emerged as the dominant growth

market for Tio2 pigment, supported largely by the rise of

a domestic sulphate-process Tio2 industry.

in recent years the ultrafine, or nano-Tio2, markets

have undergone significant growth, both in terms of

volume and scope of application. However, while these

markets are currently highly profitable, the total

volumes are no more than 1% of the global marketplace.

Pigment productionThe global Tio2 pigment industry reached a record

production level of 5.1 million tonnes in 2007. The

following two years have seen declining output; falling

by more than 15% to 4.4 million tonnes in 2009. The

fourth quarter of 2008 was a turning point following the

onset of the global financial crisis: worldwide output for

the full year declined by 3.3% to 4.95 million tonnes.

The first quarter of 2009 was one of the worst the

industry has ever encountered, with production down

movements in the titanium dioxide market have a direct impact on the

producers of white masterbatch and compounds. A new report from TZmi

provides a valuable insight into how the industry is shaping up

Global TiO2

demand was

4.7 million

tonnes in 2009

and is forecast

to grow at an

average of 2.1%

per annum over

the period

2007-2015

pH

oTo

: Hu

nTS

mA

n

Figure 1: Global demand annual growth rate: 2007-2015 2007-2015

Asia-pacific 4.1%

central & South America 3.2%

central and Eastern Europe 2.4%

middle East & Africa 5.6%

north America -0.1%

western Europe -0.4%

World 2.1%


markets feature | Titanium dioxide

34% compared to the first quarter in 2008. consumers

of Tio2 saw product sales drop off sharply in the fourth

quarter of 2008 and as a result orders for pigment

collapsed. Some pigment producers predicted the

oncoming rise in inventories early and moved to trim

production levels, while others were less reactive. The

latter group had to cut production even more drastically

in the first, and in some cases the second quarter of

2009. while most plants were operating at full rates

again in the second half of the year, others did not

survive the recession; the grimsby (Huntsman) plant

was the first to be shut, closely followed by Savannah

(Tronox). The Baltimore (cristal) plant was cold idled,

and cristal recently announced permanent closure of

base pigment production at this plant.

Pigment tradein international trade there are five main inter-regional

routes, where more than 100,000 tonnes/year of Tio2 is

traded. when the uS housing market started to deflate

in 2006, domestic demand for Tio2 began to decline and

north America significantly increased Tio2 exports into

western Europe, Asia-pacific and South and central

America. The export rate (exports divided by production)

increased from a level of approximately 20% to more

than 35% (Figure 2). TZmi expects the position of north

America as a major exporter to remain unchanged,

based on excess production capacity and the relatively

low regional manufacturing cost.

western and central Europe export similar quanti-

ties of pigment to each other; high-quality, high-cost

products flow into central Europe from western Europe,

while the relatively low-cost product from central

Europe flows back into western Europe.

Asia-pacific is a net importer of Tio2 pigment,

although it has the largest manufacturing base of all

regions. The imports tend to be of a higher quality than

is widely available within the region.

Capacity expansionover the past five years, industry transactions have

been executed at real 2009 uS dollar capacity tonne

values of uS$1,500-2,000. This is in stark contrast with

the cost of greenfield expansions which have averaged

almost uS$5,500 per tonne of annual capacity (real

2009 uS dollar total investment basis including land

and support services).

Access to the newer chloride process has been tightly

held by a handful of global manufacturing companies

and those organisations that successfully licensed

technology from these companies during the 1970s and

1980s. no greenfield chloride route pigment plants have

been commissioned since 1994.

new processes for the manufacture of Tio2 pigment

are constantly under development, but no alternative

manufacturing routes have been successfully commer-

cialised to date.

Figure 2: North AmericAN exports vs. demANd: 2001-2009

Figure 3: reAl 2009 us$ weighted AverAge globAl tio2 pigmeNt priciNg

s

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Titanium dioxide | markets feature

PricingThe long term real TiO2 global

pigment price has declined over

the past 20 years in US dollar

terms (Figure 3). However, there

are significant differences in the

pricing behaviour within different

regions and different end-use

markets. The declining price levels

have resulted in margin erosion below

re-investment economics, especially in the last three

years.

As a result of re-stocking, unplanned capacity

outages and plant closures, the current supply for TiO2

has become very tight, despite the fact that demand has

not fully recovered to pre-crisis levels. This has resulted

in a deluge of price increase announcements by the

major producers and climbing prices throughout the

global markets.

In most growth markets for TiO2 products, the global

financial crisis of 2008/09 is a past memory, while in

other more mature markets the demand outlook is still

somewhat conservative. The full extent of the changing

forces in the industry will be felt as

2010 unfolds, so this new publication

is most timely in seeking to put all

these items into perspective.

More informationThe content of the TZMI

Group’s TiO2 Pigment Annual Review is structured as a combination

of data presentation, interpretation and analysis,

interspersed with some historical reference to give the

reader a context from which to draw their own

perceptions. By not only providing historical and

forecast data on supply, demand, pricing and

trade, but also providing the necessary back-

ground information such as pigment properties,

quality requirements, demand fundamentals and

manufacturing processes, the Review is

accessible and informative for all readers,

independent of prior experience with the

industry. Click here to download a six-page

brochure about the review

❙ www.tzmi.com

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polypropylene can perform in a whole new way.

Vistamaxx™ propylene-based elastomers let

you demand more from existing polypropylene

applications -- and might even lead you to new

ones. This versatile portfolio of products can

improve strength, softness, flexibility and clarity.

Because they’re halogen-free and lighter weight,

Vistamaxx / polypropylene blends may be an

effective alternative in PVC applications. How

cool would that be? Fetch more information on

www.gomaxxgo.com

Vistamaxx™

Propylene-based Elastomers Maxximize Performance

Reinforcing fibres provide the hidden strength in high-performance compounds. Lilli Sherman looks at how the market is growing,

reviews recent developments in glass, aramid, carbon andnatural fibres, and examines some novel alternatives

New developments in fibre reinforcements for thermo-

plastics have continued at a steady pace despite the

economic downturn. In addition, there has been some

recovery in demand for reinforced thermoplastics from

the beginning of this year in both the automotive and the

electrical and electronic (E&E) industries, the two major

growth areas. Fibre suppliers and compounders agree

that while demand has not recovered to the levels of two

years ago, they expect 2010 to finish with positive growth.

Recent advances have been announced in glass,

carbon, aramid and natural fibres designed to give

thermoplastic compounds improved properties and

processing characteristics along with increased cost

competitiveness. There are also some innovative

technologies emerging as alternatives to conventional

fibre and filler reinforcements.

Meanwhile, there are continued developments from

custom compounders well known for their strength in

reinforced thermoplastics. These are aimed at meeting

increasingly tough cost/performance requirements as

well as the drive towards improved sustainability and

recyclability.

Market movementsFibre-reinforced thermoplastics have traditionally been

largely dominated by nylon 6 and 66 with glass fibre

reinforcements aimed primarily at the automotive

sector. While that dominance still exists, a shift has

been taking place. Reinforced PP is making major

inroads in both exterior and interior automotive

applications. There is also steadily increasing growth in

the broad E&E market sector where other fibre-

reinforced engineering resins have been gaining speed,

ranging from PET, PBT and PC to high-performance

polymers like PEEK, PPO, and LCP. In addition, there is

an increasing demand for reinforced thermoplastics in

consumer goods such as appliances.

“The market for reinforced fibres for thermoplastics is

Bring in the reinforcements

COMPOuNdINg WORLd | September 2010 www.compoundingworld.com24

materials feature | Reinforcing fibres

The suppliers

of glass fibres

are in an

upbeat mood

with new

applications

emerging in a

range of

markets

very strong at the moment. Not only in Europe but also in

Asia and the Americas,” says Co den Besten, global

marketing manager for chopped fibres at PPG Industries.

Manuel Agudo, global commercial & product leader

at Owens Corning, adds: “We see the automotive and

E&E industries shifting to reinforced thermoplastics for

greater heat resistance, strength, durability and, very

key, reduced systems costs. Many of these products can

be used in place of more expensive resins without sacri-

ficing performance.”

One key trend driving increased demand for reinforced

thermoplastics in the automotive sector, according to

Agudo, is that the under-bonnet environment has become

hotter due to the drive to maximize space usage.

Components located close to the engine need excellent

high-heat resistance for optimized performance, and

exceptional resistance to chemicals such as oil and petrol

to withstand corrosion and other potential damage. In

addition, weight reduction is increasingly important to cut

fuel consumption and reduce emissions. Agudo notes

applications such as oil pans, air-intake manifolds,

radiators and other critical components, where glass fibre

reinforced materials have been gaining an edge.

Noting similar trends in this arena is Eric Martin,

Ph

OTO

: 3B

This air intake is the first to be produced using PP and is a good example

of how demand for glass fibres is shifting. Mahle Filtersystems in the UK

is producing the part for VW using a 36% glass-fibre-reinforced PP

compound from Borealis. The Xmod GB306SAF – 9502 grade was chosen

as it provides long-term resistance to chemicals and high temperatures.

The part is being used on 1.4 and 1.6 litre engines in the VW Golf and

Polo, as well as Seat and Skoda models. The component is moulded

using existing tooling and is generating significant cost savings

compared to the previous PA version. Borealis says that it also provides

improved acoustic behaviour and a 15% weight saving.

Reinforcing fibres provide the hidden strength in high-performance compounds. Lilli Sherman looks at how the market is growing,

reviews recent developments in glass, aramid, carbon andnatural fibres, and examines some novel alternatives

thermoplastics product manager at

3B The Fibreglass Company. “Weight

reduction remains the central focus of

the automotive industry. This impacts all

vehicle areas”. He adds that the adoption of rein-

forced plastics is also strengthened by OEMs’ shifting

priorities. “Low-cost vehicles and engine downsizing

definitely translates to new requirements in thermal

stability. The development of hybrid electrical vehicles

also is clearly a segment for rapid plastics growth since

weight constraints will be more important for achieving

adequate efficiency”. Martin points out that hybrid

electrical vehicles are expected to represent 10% of

total vehicle volume by 2020, creating demand for mate-

rials that offer wear-friction resistance, thermal

conductivity, and fatigue resistance at high tempera-

tures. “Typical applications are start-stop systems,

bearing cages, solenoid caps and in the near future will

include battery trays, battery protection, convertors and

charging stations,” he explains.

Discussing opportunities in the E&E sector, Owens

Corning’s Agudo says: “We are essentially talking about

the manufacture of high-performance connectors, the

use of which cuts across several market sectors –

automotive, consumer electronics etc – and where the

trend is for greater miniaturisation. Glass-fibre-

reinforced thermoplastics play a major role here, as they

must deliver extreme high-heat resistance to protect

delicate circuitry as connectors become smaller.”

Danny Wilms Floet, sales manager composites at

Teijin Aramid, notes that in both the automotive and the

E&E market sectors, the trend is toward components

such as gear wheels, slide bearings and bushings that

are more compact, lighter, stronger and are subject to

greater stresses such as higher temperatures and

operating speeds. “Glass fibres are used to improve the

mechanical properties of thermoplastics. Aramid fibres

also improve some mechanical properties but their

www.compoundingworld.com September 2010 | COMpOunDinG WORLD 25


materials feature | reinforcing fibres

main function is to reduce wear of a plastic part and

minimize abrasion to the counter surface of the

application.” while glass fibres are lower in cost –

typically by a factor of around 10 – they are more

abrasive and can erode the materials with which they

come into contact.

Teijin Aramid has been putting considerable

development efforts toward furthering the expansion of

aramid fibre reinforcement to the engineering plastics

composites market sector. The company has developed

a special sizing and cutting process to manufacture

small rod-like pellets of its Twaron and Technora para-

aramid short-cut fibres specifically for engineering

plastics. The result is easy and precise dosing of these

fibre reinforcements, allowing plastics compounders

and processors to achieve the exact endurance

properties required for their particular applications.

Addressing glass fibre reinforcements in thermo-

plastics, ppg’s den Besten, says that there are really

two main segments. The first is short-glass-fibre-

reinforced thermoplastics based on chopped strand

products. The second segment is long-fibre thermo-

plastics (lFTs) based on long glass fibres. Although

lFTs are mainly used in automotive applications, this

segment has suffered the least of all glass fibre

segments in the economic downturn through 2009.

According to den Besten, this can be explained by

further penetration of lFT composites replacing metals

in many new models. “despite the downturn in car

production, the use of lFT product stayed at a stable

level in 2009. in 2010, we have seen growth of more

than 15%, which is in line with previous years.”

This is in contrast with an unprecedented 30% drop

in demand for the chopped fibre segment between

fourth quarter 2008 and through much of 2009.

nevertheless, recovery has been taking place through

the first half of this year. den Besten explains: “despite

some uncertainties in the market with respect to

demand in the automotive segment for the second half

of 2010, the order books for reinforced thermoplastic

compounds for the third quarter seem to be at a

continued high level.” ppg estimates that demand in

2010 could be close to 50% stronger than in 2009, which

also means chopped fibre will be in tight supply for the

rest of 2010. “The pipe line is still relatively empty and

the industry will struggle to fill it up in 2010. This might

only happen in 2011, although it should be noted that

glass fibre suppliers have a number of furnace repairs

scheduled to take place in 2011,” says den Besten.

overall, lFT applications are currently one-tenth the

size of the chopped strand market. However, lFTs are

beginning to replace glass-mat thermoplastics (gmT)

because of cost and production advantages.

industry sources estimate that about 85% to 90% of

lFT goes into automotive applications compared to a

maximum of 50% for chopped fibre reinforced plastics.

The other key markets for the latter are reinforced pA

and pBT in electronics housings and electrical tools,

plus reinforced pp compounds in washing machines.

ppg’s den Besten says “glass-filled pp has traditionally

been used only in lower-end automotives components,

although Borealis made a breakthrough a couple of

years ago with its glass-reinforced pp which was used

to substitute a glass-reinforced nylon in the inlet

manifold of a new vehicle.”

New product developmentglass fibre reinforcement suppliers say they have been

expanding their glass fibre technologies to meet the

drive for lighter weight, greater strength, and excellent

The growth in

sales of hybrid

cars, such as

this Honda CR-

Z, is expected

to create a

range of

opportunities

for glass-

reinforced

thermoplastics

Electrical connectors are another important growth

market for glass-reinforced thermoplastic

compounds. These examples are SMT pin connectors

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overall performance in both new and existing growth

markets.

Addressing the lFT segment, den Besten of PPG says

that while the company’s success started with its

general-purpose product Tufrov 4588, they have seen a

lot of market penetration with the company’s resin-

specific lFT rovings Tufrov 4599 for pp and Tufrov 4510

for pA in recent years. last year, ppg introduced a next-

generation lFT roving, Tufrov 4575 for use in pp. The use

of this reinforcement has been shown to give enhanced

performance in pp-lFT compounds. “This either results

in a higher performance in mechanical properties or,

when a certain level of properties is required, it can be

achieved with less coupling agent, which can be a

significant cost saving,” explains den Besten. Future

developments in ppg’s lFT product portfolio include

plans to introduce resin-specific lFT products for pBT,

pET and HdpE.

in the larger, chopped fibre

reinforced thermoplastics seg-

ment for pA 6 and 66, ppg has

traditionally based its success

on its general-purpose

products chopVantage Hp

3540 and its hydrolytically-

resistant specialty product

chopVantage Hp 3660.

However, there has been a

shift with the introduction

of the company’s multi-

purpose product chopVantage

Hp 3610 two years ago. “This

product proved a very successful

addition to our portfolio and now ac-

counts for our highest selling

product. in many cases, it has replaced our older

products. it offers additional value in hydrolytic

resistance as well as in impact modified and lubricated

compounds and has also proved to result in excellent

performance in high-temperature nylons. Hp 3610 is

now available from local manufacturing sources in

north America, Europe and Asia,” says den Besten.

ppg says that it will soon launch a hydrolytically-

resistant product for pBT compounds. it has already

been demonstrated to provide enhanced performance in

strength and impact properties in such compounds

after immersion in hot water.

According to den Besten, the growth of the market is

supported with recent investment in additional capacity

for chopped fibre in north America at the company’s

plant in Shelby, north carolina. This is scheduled for

production start-up in fourth quarter. Further capacity

expansions are envisioned for 2011 at the company’s

plants in the netherlands, china and the uS. mean-

while, the growth of lFT rovings is supported with new

product development for pA, pBT, pET and HdpE. ppg

has plans to add capacity for direct rovings for wind

energy and lFT applications at its locations in north

America and china, with announcements expected in

the near future.

reinforced pp compounds for automotive applications

have been a key focus at 3B The Fibreglass Company. in

addition to their widespread use in exterior and interior

components, reinforced pp compounds are increasingly

being used in even more demanding applications which

have previously been dominated by reinforced pA. 3B’s

martin cites new reinforced pp air-intake manifolds and

climate control units as perfect examples.

in addition, chopped strand reinforced pp com-

pounds are replacing long fibre materials in some

3B says its DS

2200-13P

chopped strand

for PP offers an

excellent

balance of

stiffness/

toughness. It is

being used in

demanding

automotive

front end

applications

PPG’S TuFRov 4575 RovInG haS Been Shown To

GIve ImPRoveD PeRFoRmanCe In

LFT aPPLICaTIonS

TufRov 4575 LFT RovingImprovement of 15 to 25% in all PP GLFT samples – 4575 vs 4599

4599 verses 4575 unnotched impact strength vs.

% coupling agent and % glass in PP LFT

TIMCAL Ltd. HeadquartersStrada industriale, CH-6743 Bodio, Switzerland

Tel. +41 91 873 2010 Fax +41 91 873 [email protected]

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Engineering wear resistance in plasticsEngineering plastic components are subject to increasingly stringent requirements, such as higher temperatures and operating speeds.

Our specially sized high-performance aramid fi bers Twaron and Technora are easy to dose to the mix and will signifi cantly enhance the endurance of your plastic products. R&D statistics have shown that adding 10-15% of Twaron to PA66 results in a reduction in wear by a factor of 20. Furthermore, the frictional coeffi cient of the plastic product is not aff ected, while the abrasion of the counter surface is minimized.

TEIJIN ARAMIDTel: +31 88 268 91 59

[email protected]

structural applications, such as front-end carriers or

door panels, as a result of their lower costs and parts

integration capabilities. “The reinforcement perform-

ance of the glass fibre product is key,” says Martin. “In

this context, it now has been established that 3B’s DS

2200-13P chopped strand has set a new standard with

an unrivalled stiffness/toughness balance,” he claims.

According to the company, DS 2200-13P is approved

at major PP compounders because its innovative sizing

technology has been shown to provide an increase in

stiffness of at least 10% and an increase in impact

strength of 10-15% compared to conventional glass

fibre products used in automotive PP formulations.

“There is no negative impact on viscosity and as such

cycle times are improved, which definitely supports the

switch to PP compounds,” adds Martin. In addition, DS

2200-13P is claimed to give enhanced mechanical

properties at high temperature (above 100oC) as well as

outstanding fatigue performance. Its use is currently

being evaluated in high-end appliances such as high-

speed washing machines. The most innovative applica-

tion to date is a reinforced PP front-end carrier.

For PA-based applications, 3B introduced a multi-

purpose product – DS 1128-10N chopped strand – two

years ago. Martin claims: “This product provides a

fantastic compromise of performance and handling/

feeding properties.” In addition to providing strong

performance in a wide range of thermoplastic com-

pounds, including impact-modified and hydrolytically-

resistant versions, this product can be used for glass-

fibre bulk supply and high-speed pneumatic conveying,

Martin adds. “GF conveying should never be underesti-

mated since the results of poor feeding on properties

can be dramatic. 3B has more than 10 years experience

in GF bulk conveying. When plastics compounders and

processors are looking to lower production costs and

optimize their supply chain, this unique expertise is

definitely a benefit.”

Soon to be launched by 3B is a new chopped strand

product for PA that is specifically targeted for use in

under-the-hood automotive applications. “The future will

be exciting as we have started work on very innovative

Reinforcing fibres | materials feature

AGY hAs demonstrAted thAt its s-1 GlAss offers improved performAnce At lower loAdinGs in pA 6 compAred to e-GlAss.

europe/Africa/Asia/Australiasuperior Graphite europe ltd

Box 13000s-85013 sundsvall sweden

tel: +46 60 14 41 18fax: +46 60 13 41 28

[email protected]

north & south Americasuperior Graphite company

10th south riverside plaza, suite 1470chicago, illinois, 60606, UsA

tel: +1 312 559 2999fax: +1 312 559 9064

[email protected]

Providing unique properties to promote unique materials

www.superiorgraphite.com

click here to view our brochures



options, including the addition of carbon nanotubes

(cnTs) directly onto the surface of glass fibres,” says

martin. Click here to see more details of 3B’s collabora-

tion with nanocyl on cnT sizing technologies.

within the last year, two new products have emerged

from AGY, a global producer of glass fibre yarns and

high-strength glass reinforcements. The first is S-1

glass high-performance glass rovings, primarily for use

in lFT applications. According to drew walker , the

company’s vice president of sales & marketing, S-1

bridges the cost/performance gap between E-glass and

higher performance glass such as S-2 glass.

designed for use with a range of engineering

thermoplastics such as pc, pEi, pBT and pA 66,

primarily in under-the-bonnet automotive applications,

field trials with S-1 have demonstrated higher hydro-

lytic stability, a 30% improvement in tensile properties

and an 18% improvement in tensile modulus compared

to traditional E-glass solutions. moreover, it has been

demonstrated that a 32% S-1 glass fibre content in lFTs

can deliver the same performance as a 60% E-glass

filled product. “reduced fibre loadings translates into

higher impact levels, better surface

appearance and easier processing.

on the other hand, the use of higher

loading levels would allow for new

application opportunities due to the

increased mechanical performance

that can be obtained with S-1 glass,”

explains walker. The product is

available as a roving for use in lFT as

well as in chopped form for glass-

filled thermoplastic compounds, such

as pA 6 and 66.

AgY has also developed a

specialty chopped fibre product with

properties tailored for high-perform-

ance niche applications such as

medical implants.

walker explains that AgY has entered into long-term

development projects in north America and Europe for

application of its proprietary S-3 glass in engineering

thermoplastics. For example, S-3 glass has been used

in pEEK to produce dental crowns. in this application, it

offers the high impact of ceramic but at lower cost,

according to the company.

Arguments for aramid Teijin Aramid says that its Twaron yarn fibres are five

times stronger than steel weight-for weight, whereas its

Technora yarns are eight times stronger than steel and

three times stronger than glass fibre, polyester or nylon

yarns. Specifically developed for engineering thermo-

plastics, Teijin’s Twaron and Technora short-cut aramid

fibre reinforcements each bring a different combination

of properties. However, both reduce the wear and

abrasion rates of plastic compounds, allowing moulders

to produce strong, lightweight, compact mechanical

systems that require minimum maintenance.

in addition, the aramid short-cut fibres can be

engineered precisely to the level of wear resistance

required, without affecting and sometimes even

lowering the compound’s frictional coefficient. when

combined with pTFE, they reduce the frictional

coefficient even further. in addition, because Twaron

and Technora-based engineering compounds dissipate

energy efficiently, their damping properties reportedly

are significantly improved, making them well suited to

applications where controlled vibration is needed.

Twaron has a more attractive price-to-performance

ratio and as such has been getting more play in a wide

range of automotive and E&E applications, according

wilms Floet. Technora, on the other hand, is said to be

the best option where maximum strength and rigidity

are required, such as dynamic performance applica-

Teijin Aramid

highlights the

excellent wear

properties of

its aramid

fibres

Teijin ArAmid’s TwAron And TeChnorA ArAmid fibres siGnifiCAnTlY reduCe The weAr rATe of PA66 even AT relATivelY low loAdinGs

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› Increased productivity

› Weight reduction

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High performance additives for polyolefins

www.hyperform.com

tions that involve significant motion. The advantages of

the company’s aramids in engineering plastics have

been extensively documented by the Netherlands

Organization for Applied Scientific Research (TNO). For

example, experiments have shown that adding 10-15%

of Twaron to PA 66 results in a reduction in wear by a

factor of 20 while POM becomes twice as durable by

adding 10-15% of the aramid fibres. Both Twaron and

Technora are available in a variety of lengths, and

depending on the plastic matrix used, sized with either

PUR or PET. Both are also offered without any sizing.

Twaron is available in lengths from 0.25 mm to 12 mm,

while Technora comes in lengths from 1 mm to 6 mm.

Twaron is also available as a very fine, specially treated

powder that allows for fine dispersion.

The compounders’ perspectiveGlobal custom compounders and their customers lead

the way in the development and innovative uses of

fillers and reinforcements. As always, they are striving

to deliver materials with excellent physical performance

and processing properties. However, they are also

responding to demands for compounds that are ‘green’

and ‘sustainable’.

Andrew Lamberson, corporate development

manager at RTP Company, says that the firm has been

working extensively on the use of bioplastics and

recycled resins as well as recycled reinforcing fibres.

“We are now able to provide the market with very

‘green’ high-performance structural products”, he

states. These compounds – which the company can

manufacture at its plants in the US, Europe and China –

give OEMs the opportunity to be ‘green’ while still

meeting structural and impact specifications.”

For example, RTP has been collaborating with

leading aerospace equipment Boeing Company on the

use of reclaimed carbon fibres from the latter’s

manufacturing process. RTP is developing high-

performance structural compounds utilizing these

reclaimed fibres in a variety of

engineered resins including

prime, bioplastic, post-industrial

and post-consumer recycled

feedstock. “Initial evaluations of

these compounds by Boeing have

demonstrated that their mechan-

ical performance is excellent,”

says Lamberson. RTP’s target

markets for these ‘green’

materials include defence,

aerospace, sporting goods,

automotive and industrial.

In addition to recycled content and bioplastic-based

compounds, RTP has recently introduced two new

products that address specific needs in the market. The

company developed a VLF (very long fibre) thermoplas-

tic masterbatch, which allows the moulder to utilize a

PP concentrate that is reinforced with 60% long glass

fibres by weight. VLF masterbatch is optimized for

blending with neat PP during moulding to obtain 10% to

40% glass-fibre loadings that can be tailored to meet

the requirements of a moulder’s specific application.

VLF concentrate is produced via a melt-impregnated

manufacturing process that fully wets-out the fibre and

couples it with the resin. Resulting pellets reportedly offer

superior physical properties, a resin-rich surface finish

without glass bundles, and minimal glass fibre fines

during handling for consistent quality moulding. The VLF

route is especially suited to large parts and high-volume

manufacturing without the investment and complexity of

direct in-line compounding. Standard VLF pellets are 12

mm long and can be custom cut from 8 to 25 mm.

Another innovation from RTP is its Controlled

Geometry Pellets (CGP) technology. This patent-

pending compounding process provides engineered

structural compounds for compression moulders that

reportedly result in significant increases in product

performance and output from the moulding process. As


RTP’s VLF very

long glass fibre

thermoplastic

material is

being used by

Hunan

Zkenergy of

China to

injection mould

the blades of

this small-

scale wind

turbine

the revolution in colourmeasurement technology continues

X-Rite MA94 and MA96Two new portable Multi-Angle Spectrophotometers

Visit us at the K-Show in hall 10 at stand A75 or xrite.com/MA9X

a fully compounded solution, the fibres and other

additives in CGP are completely wetted with polymer.

Featuring precision width-to-thickness and length-to-

width ratios which allow the pellets to nest tightly, CGP

grades can be used to produce stock shapes and thick-

walled parts with superior mechanical properties.

Shapes made with CGP are more uniform and void-

free. They boast better dimensional stability, less

moulded-in stress, and very low porosity, all of which

allow the production of precision parts with lower reject

rates. Initially available in PEEK and PPS compounds,

the technology can be extended to other thermally-

stable resins like PES, PEI and PPA.

At A. Schulman, industry demands and environmen-

tal pressures continue to drive the exploration of unique

plastic modifiers and fillers, according to marketing

manager Chris Kerscher. One recent example is a line

of products reinforced with agricultural bio waste, such

as wheat-straw fibre which is a by-product of harvesting

wheat. It is claimed that these biofillers offer equivalent

physical properties compared to traditional mineral-

based fillers and fibres as well as weight-reduction

opportunities. In addition, some of Schulman’s biofiller

materials have been shown to impart a distinctive,

natural aesthetic to finished articles. Fully-compounded

products are sold under the AgriPlas brand name and

are available from the company’s Engineered Plastics

Division. Biofiller masterbatches are also available as

Polybatch Concentrates from the company.

Schulman’s AgriPlas PP compound containing wheat

straw fibre bio-filler made its commercial debut in

Ford’s new Flex crossover vehicle. This first industrial

application of a wheat-straw-reinforced plastic is in the

injection-moulded storage bin and inner lid for the

interior of the vehicle.

Advantages of the AgriPlas compound compared to

talc- or glass-filled PP as demonstrated in this

application include: weight savings of about 10%;

increased dimensional stability; lower energy usage in

manufacturing due to lower machine temperatures; and

a lower carbon footprint. Based on Ford’s analysis, it

produces 1.30 kg less C02 per kg of product. Additional

moulding applications are under evaluation within the

transportation, consumer goods and lawn and garden

markets, according to Kerscher.

So.F.teR, which has compounding plants in Italy,

materials feature | Reinforcing fibres

Mexico and Brazil, recently launched a new line of

vegetable-fibre reinforced polyolefin compounds that

are claimed to offer very good properties. These fully

recyclable compounds utilise fibres that originate from

long-leafed plants such as flax, sisal and hemp or are

derived from wood flour and working scraps.

The company characterizes its new line of com-

pounds by their strength and lightness. Tests have

shown them to have properties equivalent to glass-

fibre-reinforced compounds, but with a 10% lower

weight advantage due to their lower density. Better

sound-deadening and anti-vibration properties along

with better shock- and high-temperature resistance are

also touted. So.F.teR sees them as ideal for automotive

applications, as the reduction in vehicle weight yields

lower emissions. Functionally, these compounds are

well suited to the production of interior parts and

panels, but the company also notes their application

potential for visible parts because they can provide

“very innovative and good-looking aesthetic effects”.

The UK division of Teknor Apex recently formulated

a carbon fibre-reinforced PA 66 compound for the

frames of swimming goggles. Called Carbon Race, the

new goggles were launched in early 2010 by BlueSev-

enty and were developed by the Blue Fuzion Group

based in Hong Kong.

Blue Fuzion selected Teknor’s Beetle 66CF4 carbon

fibre-reinforced PA66 instead of PC which is typically

used in such applications. The new compound proved to

be both lighter and stronger than the PC, allowing the


Schulman’s AgriPlas PP compound containing wheat straw fibre is being used to mould a storage bin for Ford’s Flex crossover vehicle

hf-mixinggroup.com

27 Oct – 3 Nov 2010

Düsseldorf, Germany

Hall 9

Booth A24

Contact us to find out more.

MIXING GROUP

Focused competencePlastic Compounding

Banbury®, tangential mixer (N-series) • Intermix®, intermeshing mixer (E-series and VIC-series) • Continuous Mixers FCM™ Compact Processor CP-Series II™ • Long Continuous Mixer LCM • Convex™, twin screw dump extruders • Advise™, mixing room automation systems

With the integration of Harburg-Freudenberger Maschinenbau GmbH,

Farrel Corporation and Pomini Rubber & Plastics Srl to HF MIXING

GROUP, we set the course for a better future – a future that concerns

the quality of all our products and services. With the combined

resources of HF MIXING GROUP, we are able to provide our custom-

ers with proactive products and solutions. For plastics compounding,

we offer the most efficient and productive processors to ensure your

maximum success.



designers to reduce the thickness of the frame,

particularly in the torsion points where other compo-

nents of the goggles come together, such as the nose

bridge and the strap. The carbon race goggles report-

edly are 12 to 15% lighter than conventional goggles.

Another Teknor Apex division, chem polymer has

been working on the challenge of achieving a good

surface appearance for parts moulded with glass-

reinforced thermoplastics. its chemlon 217 gi, a 17%

glass-fibre-reinforced pA 6 compound, has been shown

to have an excellent surface finish while providing the

combination of strength and stiffness required for

injection-moulded applications that undergo challenging

dynamic forces. Examples include office chairs, outdoor

power equipment, outboard motor covers, and gun-stock

components. in addition, the compound’s outstanding

flow characteristics make it suitable for large parts, says

the company.

one of the initial commercial applications of a

customised version of this compound is the one-piece

moulded inner shell of office chairs, where the right

balance of flexibility and stiffness is needed to combine

structural strength with user comfort.

Novel options to considerAdding to the mix of innovative reinforcement options

on offer to compounders is Milliken’s Hyperform Hpr

(High performance reinforcement) which is described

by the company as “an inorganic fibrous mineral”.

launched at last year’s npE show, the reinforcing agent

was specially developed for polyolefins used in moulded

automotive, appliance and consumer goods.

The first commercial grade, Hyperform Hpr-803, is

primarily aimed at pp automotive applications where it

can replace fillers such as talc at lower loadings.

milliken quotes loadings of 10% compared to 25-30%,

leading to weight reductions of up to 15%. it has been

shown to provide both better stiffness and higher HdT

than higher loadings of talc. while as a replacement for

chopped glass, Hpr-803 is claimed to exhibit a

noticeably better surface finish and improved weather-

ability. According to milliken, this makes it suitable for

exterior components such as bumpers and door panels.

Another novel alternative is neroplast from new

polymer Systems. The bio-based reinforcement is

based on modified lignocellulose fibre, which also

occurs naturally in lignite coal. it is being launched as a

cost-effective alternative to conventional fillers that

offers higher moisture and temperature resistance.

company president Joachim roesler explains: “we can

produce a low-cost filler – more so than a reinforce-

ment – in that it does have some improvement on

mechanical properties and at half the weight if not quite

at the strength level of glass. Essentially, we have a bio-

derived fibre that is much lighter than mineral fillers,

but which is heat resistant and hydrophobic, unlike

other organic fillers.”

So far, the efficiency of this new ‘green filler’ has

been shown in pp, HdpE and pA, but roesler says there

is potential in other resins. “we are competing most

directly with wood flour, calcium carbonate and talc

fillers. This new filler is similar cost-wise, but half as

heavy as talc or calcium carbonate”.

in terms of processing neroplast into thermoplas-

tics, it can be used in can be used in a wide range of

applications including injection moulding, sheet

extrusion and thermoforming, but not thin films or spun

fibres. roesler says: “Someone with a single-screw

extruder would need a masterbatch of the product,

whereas it can be added directly in twin-screw extruder

processing”. He adds that neroplast also has a broader

processing window than wood flour, working beyond

230˚c, equivalent to talc or calcium carbonate but at

half the weight – 2.5-2.7 g/cc for conventional talc and

Teknor Apex

formulated a

carbon fibre-

reinforced PA

66 compound

for the frames

of these Carbon

Race swimming

goggles

Properties of Chemlon 217GI, a 17% glass-fibre-reinforced nylon 6 compound

Source: chem polymer, a unit of Teknor Apex company

bookshelf browse and buy......all the latest titles.

Visit the Plastics Information Direct bookshop at K 2010.

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calcium carbonate fillers compared to 1.3 g/cc for

Neroplast and 1.4 g/cc for wood flour.

One limitation of Neroplast is that the material’s

colour ranges from dark grey and brown to black.

Roesler explains “For a light-coloured exterior, it would

have to be co-extruded with a lighter colour on top.

Alternatively, it can also be a replacement for carbon

black pigments in certain applications.” Although

loading levels would be much higher for Neroplast

because of its larger particle size, it is significantly less

expensive by weight says Roesler. He cites as an

example a recycler of PE and PP that typically uses 1 to

2% of carbon black to achieve a uniform black coloured

product. “With as little as 5% of our filler, you can get

the black colour required at lower cost despite the

higher use level, as a side benefit,” he explains.

Mechanical properties that have been achieved with

Neroplast in PP include a 10-50% increase in tensile

strength and a doubling of the tensile and flexural

modulus of filled PP compared to neat resin. Within the

next three months, the company will be able to share

more accurate values on such mechanical property

advantages, according to Roesler.


Milliken is

targeting

automotive

exterior

applications with

its Hyperform

HPR-803

reinforcing agent

that promises an

excellent surface

finish

Click on the links for more information:

❙ www.ppg.com ❙ www.owenscorning.com❙ www.3B-fibreglass.com ❙ www.teijinaramid.com ❙ www.agy.com ❙ www.rtpcompany.com ❙ www.aschulman.com ❙ www.softerspa.com ❙ www.teknorapex.com ❙ www.millikenchemical.com ❙ www.newpolymersystems.com

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Hall 9Stand a60

If you are exhibiting at the K 2010 exhibition in Düsseldorf this year, then you need to let the world know about it!

Our focused digital magazines with their global distributions provide the perfect platforms for you to promote your presence at the world’s biggest plastics industry exhibition and attract new customers to your stand.

We are publishing extra editions to cover all the product launches and news from the show. Plus we will be exhibiting there ourselves on two stands: 70C07 in Hall 7.0 and EN03 in the North Entrance.

Here’s our line-up of 18 special issues providing comprehensive coverage of the big event for our global readership ➙

stand out from the crowd atcompounding worldJuly/August: First look at K 2010September: K 2010 show previewOctober: K 2010 show issueNovember: K 2010 review part oneDecember: K 2010 review part two➤ Click here to download the full media pack

Injection worldJuly/August: First look at K 2010

September: K 2010 show previewOctober: K 2010 show issue

November: K 2010 review part oneDecember: K 2010 review part two

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film and sheet extrusionSeptember: K 2010 show previewOctober: K 2010 show issueNovember: K 2010 review part oneDecember: K 2010 review part two➤ Click here to download the full media pack

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September: K 2010 show previewOctober: K 2010 show issue

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Advertising space is selling fast in these special show issues.To guarantee your position, contact our advertisement manager,Claire Bishop. E-mail: [email protected]. Tel: +44 20 8686 8139

Press releases on your K show product launches and news should be sent toAndy Beevers: [email protected]

www.amimagazines.com


Extruder gearboxes | machinery feature

Stefan Knieling of Henschel Antriebstechnik provides an inside view on how gearboxes for twin-screw extruders have been developed to deliver the extreme levels of torque demanded by today’s compounders

unlike their relatively simple single-screw relations,

twin-screw extruders require highly sophisticated

gearboxes to drive the co- or counter-rotating extruder

screws. This is particularly true for parallel twin-screw

extruders that require gearboxes to distribute the

highest possible torque evenly to both extruder screws

while taking up a minimal amount of space. Henschel

has been involved in manufacturing gearboxes for 38

years and here we examine how the latest designs have

been developed to meet increasingly tough demands for

the highest performance extruders.

getting back to basics, the gearbox is an absolutely

essential component of the extruder. it reduces the

motor rpm to the required optimised speed for the

extrusion process, and simultaneously builds up the

necessary torque on the screws. The driving forces have

to be distributed evenly to both screws and the gearbox

needs to withstand the high back-pressure forces from

the extrusion process.

The gearbox design is primarily influenced by the

relatively small centre distance of the output shafts and

the required output torque, while both specifications are

determined in turn by the extrusion process. The gap

between the extruder screws limits the allowable

distortion and the permissible axial deformation of the

gearbox output shafts in relationship to each other.

in order to have a specification for the torque density

of the extruder independent of the actual gearbox size,

the torque factor (fmd) was defined as measurement. To

calculate this torque factor, the output torque of an

extruder screw shaft is divided by the distance between

the centres of the screw shafts cubed:

fmd = Tshaft / a3 [nm/cm3]

Figure 1 shows the development of the torque factor

for extruders over the course of the past 30 years with

the introduction of different Henschel gearbox series.

Selecting the right gear

Figure 1: Over the past 30 years, considerable progress has been made in

the torque factor per shaft for modern twin-screw extruders such as

Century’s Apex machine pictured at the top of the page.

pH

oTo

: cEn

Tur

y


machinery feature | Extruder gearboxes

These have been designed to meet the industry’s

requirements for higher and higher torque levels.

Such high torque outputs require special design

procedures for efficient and reliable power distribution,

while custom-designed thrust bearings absorb the

back-pressure forces from the extrusion process.

Design solutionsover the years, a multitude of power distribution

configurations have been developed with different

designs distinguished by the number of shafts in the

distribution gear unit. These can include two, three,

four or as many as seven shafts.

Henschel’s view is that gearboxes that combine a

simple design of the distributor gear unit with high

torque density provide the best solution. it uses this

approach in its doS-V and T1mAX gearboxes which

deliver extremely high torque densities.

The company’s twin-shaft extruder gearbox series is

designed in a modular way that can be adapted easily to

customer specifications. The gearbox consists of four

sections. The reduction gear unit transforms the motor

rpm into the required output speed preparing for the

proper output torque. connected to the reduction gear

unit is the thrust-bearing unit. This in turn is attached

to the distribution gear unit ending in the adapter

housing forming the connection to the extruder. The

distributor gear unit consists of a helical gear stage

capable of transmitting extreme torque.

The separate mounting of each gear set with

bearings helps to ensure long life spans, despite the

limited space. under full load, at least 20,000 hours or

even more than 40,000 hours can be easily achievable.

The gears are designed for maximum durability in

terms of tooth breakage, pitting, and scuffing. The

appropriate safety and application factors, calculated

according to din 3990 and iSo 6336 respectively, are

agreed with the customer to meet the requirements of

their application. The safety factors are typically set

between 1 and 2 for pitting, from 1.4 to 2.5 for tooth

breakage and from 2 to 4 for scuffing. State-of-the-art

gear designs are produced using the latest technical

standards, while the precise grinding process carried

out for each gear tooth profile ensures that there are no

defects, such as micro-pitting.

Joined to the distributor gear unit is the set of thrust

bearings built to receive the axial forces from the

extrusion process. one of the two extruder screws is

supported by a multi-row axial cylindrical roller bearing

(tandem bearing), which combines a minimal outside

diameter with a high load rating. The axial bearing of

the second output shaft is located on the back of the

gearbox. As there is enough space available, the

bearing is not limited in its outside diameter and can be

designed in a single-row fashion.

The easy accessible design allows for straight-

forward servicing as well as easy mounting of pressure

sensors and other instrumentation for process control.

This modular gearbox design is also the best option for

the thrust bearing unit, allowing a wide range of back-

pressures to be handled from around 100 bar up to

considerably more than 500 bar in special applications.

The reduction gear unit represents the link between

the motor and the distribution gear unit. depending on

the drive method (direct-drive or belt-drive) gear ratios

of 0.8 through to 80 are normal for modern extruders.

Inside a co-rotating extruder gearbox. I - basic gearbox with reduction gear unit (1) and power distribution (2).II – thrust bearing housing with tandem bearing (3).III – distributor gear unit with DOS-gear stage(5 & 6). IV – adaptor housing with output shaft (7) designed as throughputshaft with axialbearing (4).

s

At K 2010 we will present our ultimate dryerlessextrusion system for recycling PET into high viscosity pellets.

(patent pending)

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Extruder gearboxes | machinery feature

The torque distribution in the final stage is tailored to

the type of extruder, either counter- or co-rotating.

Figure 2 shows the diverse requirements placed on

counter- and co-rotating extruder gearboxes.

The design of the gears and the choice of bearings is

based on the bearing capacity, efficiency, and the noise

level in accordance with the latest research results. The

forced lubrication is adapted to the individual applica-

tion and guarantees superior heat dissipation and

lubrication while obtaining the highest efficiency levels

from the gearbox. All gears are case hardened and

precision-ground.

The connection to the processing unit of the extruder

is in form of an adapter housing or tie rods. The

extruder screws are connected to the transmission

output shafts via coupling sleeves. The shafts are

secured radially and, if necessary, also against axial

forces.

Henschel continues to innovate and is a long-term,

active member of Forschungsvereinigung Antriebstech-

nik, the German research association for power

transmission.

More informationThe author of this article, Stefan Knieling is divisional

director for extruder gearboxes at Henschel Antrieb-

stechnik, based in Kassel, Germany. Click here to

download the company’s 48-page catalogue of Durumax

gearboxes for twin-screw extruders.

❙ www.henschel.eu

Figure 2: The

wide range of

specifications

that can be

handled by

counter- and

co-rotating

extruder

gearboxes

Counter rotating Co-rotating

Drive Direct or by belt Direct

Gear ratios 12-80 0.8-10

Output RPM ‹5-150min-1 (in special cases also above) 300-1200min-1 (in special cases also below)

Torque factor per shaft Up to 23 Nm/cm3 Up to 16 Nm/cm3

Back pressure from extrusion process Up to 500 bar (in special cases also above) Up to 250 bar (in special cases also above)

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reducing friction and wear | technical paper

Tests carried out by Superior graphite demonstrate that its resilient and isotropic graphitic carbon products have a positive effect on the

friction and wear properties of pA 66. Eric Salmon andCarsten Wehling report on their company’s results

it can be concluded that all four samples have a very

close chemistry. concerning average particle size,

grade A has a d50 value similar to igc8503 while grade

B resembles rgc39A.

The resiliency of a material gives an indirect idea of

the product morphology (porosity and shape) as well as

its degree of graphitization. The tests show that rgc39A

exhibits an extremely high resiliency of 108 % whereas

the other products range from 19-35%, which are

typical values for synthetic graphite. X-ray diffraction

indicates that A and B are perfectly graphitized whereas

both igc8503 and rgc39A exhibit graphitization in the

range of 83-92%.

Trial procedureBreaking up agglomerates into individual particles and

distributing them homogenously is a crucial issue. The

fillers were therefore incorporated into the pA 66 matrix

(Schulamid 66 mV 3 from A. Schulman) using a

Berstorff ZE25x44 co-rotating twin-screw extruder. The

thoroughly pre-dried pA 66 and some of the fillers were

fed via K-Tron gravimetric high-precision feeders

through the extruder’s main feed throat. Fibres were

Fighting friction and winning the war

against wearGears are one

application

where friction

and wear

properties can

be critical

factors in

compound

formulation

The purpose of this study is to investigate the effect of

the addition of different amounts of resilient graphitic

carbon (rgc) and isotropic graphitic carbon (igc) on the

friction and wear properties of pA 66. Both rgc and igc

were compounded into pA 66 in two different amounts

(5 and 10 vol %). The tribological performances were

compared to typical values of two synthetic graphites. in

order to attribute observed differences directly to the

individual grades, no other additives or friction

modifiers such as carbon fibre or pTFE were added.

The products under testThe two synthetic graphites tested (simply referred to

as graphite A and B) are both standard commercial

materials widely used in polymer applications. The two

materials from Superior graphite – igc8503 and

rgc39A – are both thermally purified carbon products

based on a different precursor.

All four graphites are fine milled products with d50

values between 3 and 10 µm, achieved by air jet milling

or equivalent methods. Superior graphite’s laboratory

in chicago, illinois, uSA, has analysed the four products

and the results are shown in Table 1. From the analysis


technical paper | reducing friction and wear

introduced via a side feeder. Extrusion parameters were

optimised to achieve homogeneous dispersion of the

fillers. The resulting granulate material was moulded

into type 1A tensile bars (din En iSo 3167) using an

Arburg Allrounder 320S injection moulding machine.

The mechanical properties of the materials were

studied by quasi-static tensile testing. Tests were

conducted using a Zwick 1485 universal testing machine

according to din En iSo 527-2 at an ambient tempera-

ture of 23˚c. Young’s modulus was determined as the

secant modulus under static conditions at a strain of

0.05 to 0.25 % with a crosshead speed of 1 mm/min.

After the determination of Young’s modulus, crosshead

speed was increased to 5 mm/min and kept at this rate

until the end of the test; i.e. at the point of rupture of

the test piece, where the tensile strength is obtained.

in order to assess the impact of the various fillers on

the friction and wear behaviour of pA 66, block-on-ring

wear tests were performed on all compounds in

accordance with ASTm g 137. wear test specimens

were machined from the tensile tests bars. Hardened

and ground 100cr6 bearing steel rings were used as

counter bodies. The surface hardness was 60 Hrc and

surface roughness (ra) was 0.1-0.2 µm. All tests were

conducted at standard ambient temperature (23˚c), and

at a relative humidity of 50 %. The sliding speed was

1 m/s and the contact pressure was 145 psi. no

lubricants were used and test specimens and counter

bodies were cleaned according to ASTm g 137.

wear was detected by tracking the height loss of the

test specimens by means of optical displacement

measurement. The most important advantage of this

time resolved wear tracking is the possibility to clearly

see the running-in phase of the materials and the

steady state wear during the experiment. in this steady

state, the differential wear rate w=∂h/∂t was computed.

it represents the specimen’s height loss over time

measured in µm/h. due to its mathematical definition it

is equal to the slope of a linear regression of the time

resolved height loss data (see Figure 1).

during the experiment, the friction force FF is also

recorded. division by the applied normal force Fn yields

the coefficient of friction µ:

µ = FF

Fn

Eight separate tests were conducted per material in

order to obtain a sufficient statistic reliability of the test

results. Each of these eight test samples was subjected

Sample No. Graphite “A” Graphite “B” RGC39A IGC 8503

LOI (%) 99.98 99.98 99.99 99.95

Ash (%) 0.02 0.02 0.01 0.05

Moisture (%) ‹ 0.10 ‹ 0.10 ‹ 0.10 0.1

Sulfur (%) ‹ 0.005 ‹ 0.005 ‹ 0.005 ‹ 0.005

Resiliency (%) 19 35 108 25

Resistivity (ohm in.) 0.0416 0.0255 0.0203

Scott Volume (g/cu.in.) 0.93 1.38 1.99 0.83

Microtrac D95 (micron) 7.324 20.16

Microtrac D90 (micron) 5.976 16.59 21.21 7.06



Surface Area (m^2/g) 20.63 13.82 16.13 26.6

XRD Values

D002: 3.356 3.353 3.369 3.361

Graph Grade (Maire & Méring) 98% 101% 83% 92%

Crystallite Size : Angstroms 600 700 520 580

Δh

μ

FIGuRe 1: TIMe ReSOLVeD heIGhT LOSS DATA OF The

SpeCIMeN (ReD) AND weAR RATe w

AS SLOpe OF The LINeAR

ReGReSSION (BLue) OF The

heIGhT LOSS’S STeADy STATe

Table 1:

analysis of the

four samples

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Cray Valley Hydrocarbon Specialty Chemicals is a

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to statistical analysis according to ASTM E 178 in order

to identify results that deviated markedly from the

others in the sample. These outlying results were

eliminated and the corresponding tests were repeated.

Results and discussionThe wear rates and the coefficients of friction (listed in

Table 2 and shown in Figures 2 and 3) were determined

in the steady states of the corresponding wear tests.

The numbers represent the arithmetic means of the

samples, while the stated ranges represent the

corresponding confidence range.

The comparison of the different PA66 compounds

shows that a 5% addition of graphite has almost no

impact on the specific wear rate for Graphite A or B, or

for IGC 8503. However, with RGC39A, a reduction of more

than 50% is observed. The coefficient of friction is

reduced by 35% with Graphite A and Superior Graphite’s

IGC8503 as well as RGC39A, which exhibit the lowest

absolute value, whereas 25% is achieved with Graphite B.

At 10% addition, the wear rate is significantly

reduced with all graphite fillers. Graphite B is the least

effective with a 33% reduction. Graphite A achieves a

55% reduction. The most effective fillers are IGC8503

and RGC39A, which reduce the wear by 80% and 85%

respectively. The coefficient of friction is lower for all

the 10% samples than with a 5% addition. However, due

to the variability of the data and limited number of

experiments, no clear statistical distinction can be

made among the graphite fillers.

Concerning the compounds’ mechanical properties,

the following observations have been made. For all

graphite fillers, a reduction of the tensile strength has

been observed at both 5 and 10% addition rates,

although the reduction is below 15%.

Typically the reinforcement of the mechanical

properties is not compatible with improving lubrication

and wear properties. At least here it can be concluded

that some graphite fillers offer a great improvement in

terms of wear without losing too much in terms of

mechanical properties; this is the case with Superior

Graphite IGC8503 and RGC39A.

In contrast to a moderate modification of the tensile

strength, a significant increase of the tensile modulus

was observed for all graphite fillers at both addition

rates. The increase is close to linear with the percent-

age of addition, except in the case of the RGC39A where

a decrease with increased filler is observed. Both

samples A and B exhibit a quite strong increase of

modulus indicating that the compounded material is

becoming more rigid and brittle. IGC 8503 and RGC39A

also increase the modulus but to a lesser extent. With

RGC39A, it was observed that a 10% addition has less

influence than a 5% loading.

The elongation at break is significantly reduced for

all graphite fillers at both 5 and 10% addition rates,

confirming that the PA 66 is becoming brittle. Both

Graphite A and B have a similar effect at both addition

levels. For IGC8503 there is a clear difference between

5%, where the embrittlement is clearly lower than both

A and B, but the reverse occurs at 10% addition.

RGC39A has the highest elongation at break values at

both 5% and 10% addition levels and is consequently

the best filler in terms of embrittlement.

ConclusionsThe wear tests conducted on the PA 66 compounds

show that Superior Graphite’s IGC 8503 reduces wear to

a significantly greater extent than synthetic graphite.

However, RGC 39 A has been shown to be even more

CoMPoundInG WoRld | September 2010 www.compoundingworld.com52

technical paper | Reducing friction and wear

Figure 2: SpeciFic wear rateS oF the pa66 compoundS

0 5 10 5 10 5 10 5 10

Filler content [Vol.-%]

pressure: 145 psi (1 mpa)Sliding speed: 1 m/sSliding distance: 21.600m

40

30

20

10

0

Figure 3: coeFFicient oF Friction oF the inVeStigated pa66 compoundS

0 5 10 5 10 5 10 5 10Filler content [Vol.-%]

pressure: 145 psi (1 mpa)Sliding speed: 1 m/sSliding distance: 21.600m

1

0.8

0.6

0.4

0.2

0

Spec

ific

wea

r ra

te w

s [μ

m /

h]

Coef

fici

ent o

f fri

ctio

n μ

Reducing friction and wear | technical paper

effective, reducing the wear of PA 66 by almost 85% at a

10% filling rate.

Concerning friction, only slight numerical but no

statistically significant differences were observed.

Overall, the two Superior Graphite fillers outperform

the two graphite fillers in terms of their friction and

wear reduction capabilities.

The test compounds with IGC8503 and RGC39A have

tensile strengths comparable to those of the com-

pounds filled with Graphite A and B, but exhibit

significantly lower tensile moduli. This is an indication

of an increased brittleness in the Graphite A and B

formulations. Compounds incorporating IGC8503 and

RGC39A are significantly less brittle than those using

Graphite A or B, giving the compounder greater

freedom to incorporate higher loadings and other fillers

without making the material too brittle.

❙ www.superiorgraphite.com

Material name Graphite/RGC Coefficient Tensile Young’s Elongation type and content Sample Wear of friction strength modulus at break [vol. %] size w [µm / h] µ [MPa] [GPa] [%]

Schulamid 66 MV3 Natur None 8 26.5 ± 6.9 0.74 ± 0.04 76 ± 3 3.05 ± 0.01 9.7

PA66/MV3-A/5 Graphite A/5 % 8 26.9 ± 6.4 0.46 ± 0.08 70 ± 1 3.83 ± 0.03 3.2

PA66/MV3-A/10 Graphite A /10 % 5 11.6 ± 3.7 0.41 ± 0.06 72 ± 1 4.69 ± 0.07 3.4

PA66/MV3-B/5 Graphite B /5 % 4 20.7 ± 5.3 0.54 ± 0.05 69 ± 1 3.85 ± 0.03 3.7

PA66/MV3-B/10 Graphite B /10 % 12 17.8 ± 6.0 0.36 ± 0.04 73 ± 1 5.24 ± 0.03 3.5

PA66/MV3-IGC8503/5 IGC8503/5 % 4 27.5 ± 5.6 0.47 ± 0.12 73 ± 3 3.61 ± 0.02 4.8

PA66/MV3-IGC8503/10 IGC8503/10 % 8 5.4 ± 1.7 0.42 ± 0.02 70 ± 3 4.13 ± 0.03 2.8

PA66/MV3-RGC39A/5 RGC 39A/5 % 8 13.1 ± 4.3 0.41 ± 0.02 73 ± 5 3.47 ± 0.03 5.7

PA66/MV3-RGC39A/10 RGC 39A/10 % 8 4.0 ± 1.0 0.39 ± 0.06 68 ± 1 3.11 ± 0.09 4.0

Table 2:

Numerical

results of the

friction, wear

and tensile

tests

The countdown to K 2010

Kreyenborg promotes its PET projectsThe Kreyenborg Group will be

using K 2010 to highlight

progress in its wide range of

equipment that includes

screenchangers, pelletizers

and infra-red dryers. The

company has been particularly

successful in supplying these

systems into the PET industry,

both for the production of

virgin and recycled material.

For example, it says that its

four-channel back-flush

screenchanger is the market-

leading filtration technology in

applications involving the

extrusion of recycled PET

bottle flake. In total, Kreyen-

borg has supplied more than

400 screenchangers for PET

extrusion applications.

The company is also active

in this market with its infra-

red dryers (IRD) which offer

fast and energy efficient

processing of PET. In March of

this year the company

delivered what it claims is the

largest IRD. It has a capacity of

3,500 kg/h and it is being used

to dry post-consumer PET

flakes at a European plant.

At the other end of the

scale, the company has

recently developed a batch IRD

which is particularly suited to

the processing of master-

batches and other special

products, including bioplastics.

It uses the same short-wave

infrared drying technology as

the larger continuous versions

but can efficiently handle

batches from 10-400 kg.

On the pelletizing front, the

Group’s BKG division says that

its underwater systems are

being widely used to pelletize

virgin PET – it claims that

more than 6,000 tonnes of

virgin PET is processed each

day using BKG equipment. For

recycled material, its Crystal-

Cut underwater systems is

being specified on rPET

pelletizing lines for the in-line

production of uniform

crystallised pellets.

In addition to the PET

market, BKG says it has also

been particularly successful in

supplying its pelletizing

systems for use on PA

polymerisation lines with

throughputs of up to 20

tonnes/h. At K 2010 it will also

be promoting its large

pelletizers for the production

of EPS micro-pellets.

It has also developed wear

reduction designs for pelletiz-

ing plastics filled with abrasive

glass fibres. The machines

feature exchangeable parts,

including hardened, surface-

coated and wear-resistant

components in both the

pelletizer and the drying unit.

❙ www.kreyenborg.de❙ www.bkg.de

The countdown to the world’s largest plastics exhibition is well underway

with less than two months to go before the big event. K 2010 will fill all 19

halls at Messe Düsseldorf in Germany on 27 October to 3 November.

There will be around 3,000 exhibitors promoting their raw materials,

additives, semi-finished products, machinery, ancillary equipment and

services for the plastics industry.

Over the following pages we look at a range of the new products that

will be on show, including reports on companies that we met up with

over the summer at special pre-K press events in Germany and the

Netherlands.

We will be previewing lots more new product launches in our special

K show issue next month. If you are exhibiting at K, then please let us

know about the latest machinery and materials that you will be showing.

Send your press releases to [email protected].

❙ www.k-online.de

Kreyenborg’s latest batch infra-red drier can be used for

masterbatch production applications

COMPOuNDING WORlD | September 2010 www.compoundingworld.com54

event preview | K 2010

K 2010 | event preview

Polyscope Polymers will use K

2010 to promote the benefits

that its Xiran styrene maleic

anhydride (SMA) can deliver as

an additive in amorphous and

to some extent crystalline

thermoplastics. The material

is well established as a high-

performance plastic in its own

right, but increasingly it is

being used as a functional

additive, particularly in ABS

and PMMA.

The company says that SMA

can be used in such resins to

improve their thermal stability

and broaden their processing

window. In addition, it can make

parts easier to bond, paint, print

or plate, and it can be used as a

compatibiliser in resins that are

normally immiscible, such as

PA and ABS.

SMA’s special properties

derive from its combination of

polar maleic anhydride, which

contributes stiffness, thermal

stability and chemical

reactivity, plus non-polar

styrene, which provides the

ease of processing. The ratio

of these block copolymer

components can be adjusted to

suit different applications.

Polyscope says that Xiran

SMA’s high range of glass

transition temperatures (145-

175˚C) make it a cost-effective

way of boosting the high-

temperature performance of

PMMA and ABS, while also

improving dimensional

stability. The addition of 1.5-

3.3% SMA typically raises the

Vicat softening point of ABS by

around 1˚C, which makes it

more economic than competi-

tive technologies such as N-

phenyl maleimide (NPI) or

alpha-methyl styrene acryloni-

trile (AMSAN) according to

Polyscope.

In PMMA, the additive can

improve thermal performance

plus resistance to stress

cracking and chemicals while

maintaining good optical

properties. As little as 1.8-

2.3% SMA is needed to deliver

a 1˚C increase in thermal

performance.

SMA can also be used in

PVC to improve Vicat B values

for injection moulding

applications, says the company.

❙ www.polyscope.eu

SMA can be used as an additiveas well as a thermoplastic in its own right

Polyscope pushes SMA as an additive

1 New stabilizer for agricul-

tural film. BASF’s new Tinuvin

XT200 fills a gap in the

company’s current line-up of

light stabilizers for agricultural

film applications. It sits

between the high-end Tinuvin

NOR 371 and the more

economic Tinuvin 494. It offers

higher performance than the

latter at a more affordable

price than the former. BASF

says that Tinuvin XT200 allows

the production of economical

LDPE films that can withstand

severe agricultural chemical

levels and provide a service life

of two or more years even

under intense sunlight. It also

offers good performance when

in contact with wood and iron.

The additive has undergone

extensive laboratory and field

tests around the world.

2 Long-lasting orange

pigment. Sicopal Orange K 2430

is a new highly-stable inorganic

mixed oxide pigment from

BASF. It offers strong resistance

to UV and weathering and can

withstand aggressive chemicals

and high temperatures. The

pigment is also intensely

coloured with very good

covering capacity; it is much

redder than chromium titanates

such as the company’s Sicotan

Yellow K 2001 or K 2112. The

pigment has been given its own

colour index – Pigment Orange

82. It is stable at processing

temperatures above 320oC and

it can be used in PE, PP, PVC,

PS, ABS, PC, PET, PBT or PA.

BASF says that it is an option

for replacing products contain-

ing lead or cadmium. 3 Highly-stable UV absorber.

BASF has developed its CGX

UVA 006 UV absorber for

transparent plastic glazing

used in applications such as

greenhouses, conservatories,

and the roofs of large shopping

centres or stadiums. It is

claimed to absorb more UV

radiation than conventional

products while offering

extremely high resistance to

light, heat and weathering. The

additive’s low volatility and

good compatibility are also

said to provide excellent

processability. Based on a very

stable chromophore which

belongs to the class of

triazines, CGX UVA 006 can be

used in films or sheets made

from PC, PET or PMMA.4 Heat-resistant PA 66. BASF

has developed its Ultramid

Endure glass-fibre-reinforced

PA 66 for under-the-hood

applications, replacing metal in

parts very close to the engine.

The company says that it

combines outstanding resist-

ance to heat aging with the good

processability of PA 66. Thanks

to the use of new stabilization

technology that forms a

protective outer layer, the new

compounds resist continuous

use temperatures of 220oC as

well as spikes up to 240oC. This

compares with 170oC long-term

heat resistance for standard

Ultramid A3WG7 with the same

glass content. Target applica-

tions include the charge-air

stage of diesel engines

including intercooler caps,

resonators and charge-air lines.5 New flame-retardant PA

and PBT grades. BASF’s new

Ultramid FRee and Ultradur

FRee grades are halogen-free

and light-coloured, allowing

electrical components to be

produced in a range of colour

tones. The first four grades

include Ultramid FRee A3U40

G5, a PA66 compound that

meets the latest IEC 60335-1

household appliance safety

standard, and Ultramid FRee

B3U31 G4, a PA6 grade for

circuit breaker applications.

Ultradur FRee B4440 G5 and

B4450 G5 are PBT grades that

meet UL94 class V0, the former

at low thicknesses (0.4 mm),

while the latter boasts a high

tracking resistance (CTI of 600).6 Long-glass-fibre-rein-

forced PA. BASF is launching

Ultramid Structure LF, its first

long-glass-fibre-reinforced PA.

Produced using the pultrusion

process, the material is

delivered as 12 mm long

pellets that can be used on a

conventional injection

moulding machine. The

company says that this gives a

three-dimensional network of

fibres which are mostly 3 to 6

mm long in the finished part,

delivering strength and

stiffness combined with impact

and creep resistance. Target

applications include automo-

tive components such as

engine mounts, seat struc-

tures and crash absorbers.

Ultramid Structure LF is

initially being offered in PA 6

and PA 66 grades with fibre

levels between 40 and 60%.7 High-flow PA 6. BASF is

completing its family of high-

flow engineering plastics that

already includes PBT and PA

66 grades with the addition of

new PA 6 compounds. The first

product to be launched is

The best of the bunch from BASFBASF will be launching a whole host of new additives, polymers and compounds at K 2010,

including innovations from the former Ciba business which it acquired last year. Here’s our

selection of the top ten technologies to seek out on the company’s stand in Düsseldorf

COMPOUNDING WORLD | September 2010 www.compoundingworld.com56


7

2

K 2010 | event preview

Ultramid B3WG6 High Speed.

In spiral flow tests it flows at

least 50% further than

standard grades; with a spiral

flow thickness of 2.5 mm, it is

possible to achieve flow path

lengths of up to 1 m. The

company says this means that

large under-the-hood PA 6

parts, such as engine covers

and intake manifolds, can be

produced using lower injec-

tion/filling pressures.8 PBT with enhanced laser

transparency. Ultradur Lux is

a new PBT grade that BASF

has developed to offer 30-60%

higher laser transparency,

allowing the polymer to be effi-

ciently laser welded for the

first time. Higher welding

speeds are now possible and

the processing window is

considerably wider. In tests,

using standard PBT with a

1064-nm laser gave a welding

speed of 5-12 mm/s, but this

was boosted to 10-70 mm/s

with Ultradur Lux. Its trans-

parency also allows thicker

parts to be welded.9 New glass-reinforced PA

610 grades. BASF is expanding

its range of PA 610 products

which are partly produced

using castor oil. The new

Ultramid Balance glass-fibre-

reinforced materials – S3EG6,

S3WG6 and A3HG6 with 30%

fibre content, plus S3WG7 with

35% - are being offered in

sample quantities in Europe

starting this month. BASF says

that the compounds offer low

density, reduced moisture

uptake and good dimensional

stability as well as resistance

to hydrolysis and stress

cracking. The S grades can be

used for over-moulding metal

and electronic components

that come into contact with

aggressive fluids. Other target

applications include transmis-

sion components, plus connec-

tors, tubing and reservoirs in

coolant circuits. The A3HG6

grade is a blend of PA 610 with

PA66 and is aimed at applica-

tions such as oil pans, oil filter

housings, radiator end caps

and wheel speed sensors.10 Heat-resistant, high-gloss

ABS. A new addition to BASF’s

High Heat ABS range, Terluran

HH 102 is claimed to combine

very high toughness and

flowability with a high-gloss

surface. It has a particularly

low level of blooming, plus

high scratch and abrasion

resistance. It is currently being

launched commercially and is

being tested by a leading

vacuum cleaner manufacturer.

❙ www.basf.com

8 3



medical and pharmaceutical

applications will be a major

focus for clariant at K 2010.

Steve duckworth, head of

global marketing for medical

and consumer goods at

clariant masterbatches

explains that the market is

growing for a number of

reasons. “There is more

demand for colour in medical

applications, for example to

assist safe identification and

for improving visual appeal in

products such as insulin

pens”. He adds that there is

also a growing market for

additive masterbatches for

medical mouldings. Examples

include anti-microbial and

laser-marking additives plus

products designed to reduce

friction in drug delivery devices

clariant is responding to

these demands by implement-

ing iSo 13485 standards at

plants in Asia, Europe and

America. it already has

accreditation for its facilities in

malmö, Sweden, and in

Singapore, while it is on target

to achieve approval for its

clariant highlights medical focus

plant in lewiston, maine, uSA

in September 2010. These

three locations have dedicated

lines for medical materials and

can produce “harmonised

products” in all three regions.

The iS0 13485 standard is

widely applied by medical

device manufacturers and is

now being adopted by their

suppliers who are implement-

ing gmp (good manufacturing

practice). it includes evalua-

tion of risk potential within the

manufacturing process and

establishing controls to

address this. For clariant, this

covers the formulation of a

masterbatch, incoming raw

materials, production proc-

esses and the finished product.

duckworth says that

implementing iSo 13485 has

taught the company lessons

that are also useful in other

markets such as packaging and

toys. “it is much more rigorous

that iSo 9001,” he adds.

clariant has also developed

a range of standard colours

that are pre-tested to iSo

10993 and/or where ingredi-

ents have been biologically

evaluated according to uSp

class Vi part 87 and 88. There

are differences between the

methodologies used in iSo and

uSp biological evaluations. For

example, uSp requires

extraction testing with four

fluids compared to two for iSo.

To help bridge this gap,

clariant has adopted the

approach of “iSo10993 plus 2”

in its evaluations using the

missing extraction fluids.

customers switching between

the two standards can

therefore have confidence

when comparing data.

❙ www.clariant.com

Econ will be running demonstrations of its patented underwater pelletizer system

each day at 11:30 and 15:30, showing the easy operation that its design provides.

The Austrian compay will also use K for the first public showing of its Eup 50 lab-

scale pelletizing line. As reported in compounding world, June 2010, the new system

can run at rates from 1-70 kg/h and it uses the same unique die-plate

design as the company’s larger models. This separates the die-plate from

the nozzle to provide thermal insulation resulting in quick and easy start-

ups and improved temperature control across the die face.

The company also promises that it will be unveil its brand new Eup 150

underwater pelletizer at the K show. watch this space for more details.

❙ www.econ.eu

Econ’s new lab pelletizer will make its public debut in Düsseldorf

Econ pushes pelletizing innovations

Clariant is running dedicated clean compounding lines for medical applications

BEAT THE CLOCK!Nan-O-Sil ASD processing aid for cycle time reduction Nan-O-Sil ASD is a unique, ultra-high-purity amorphous silicon dioxide with discrete spherical shaped particles that are easy to disperse.

Real benefits for injection molding compounds at low loadings*:

l Reduce cycle times by 20-30% in glass-filled Nylon 66 and unfilled Nylon 6, PBT, ABS and PP.

l Improve the tensile strength and flexural modulus of Nylons, PBT and PP resins by 3-8%.

l Reduce energy demands and motor torque levels in polymer processing.

l Improve color dispersion and reduce pigment requirements for molded Nylon and PP parts.

l Reduce flow lines and surface defects.

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coperion will be using K 2010

to highlight the benefits of its

Feed Enhancement Technology

(FET), as well showing an

enhanced version of it twin-

screw degassing unit plus the

die-plate of the world’s largest

pelletizer.

The company launched FET

at its open House event in

January 2009 and the technol-

ogy has now been successfully

used to increase compounding

throughputs with difficult

materials. it incorporates a

porous wall section in the

feeding zone where a vacuum

is applied to suck powdered

bulk material into the

extruder, compacting the

material in the process. This

can considerably increase the

throughput of hard-to-handle

materials.

in addition to being used on

the company’s ZSK twin-screw

extruders, FET can also be

applied on its ZS-B twin-screw

side feeder that doses

powdered materials directly

into the melt. Such a system

will be on show in düsseldorf.

coperion customers reapthe benefits of FET

Since the technology’s

launch, FET systems have

been built into new coperion

machines as well as being

retro-fitted to existing lines. in

one example on a 240 mm

diameter ZSK twin-screw

extruder processing polyolefin

powders, the throughput was

increased by 20% from 14 to 17

tonnes/hour. Even bigger

increases were achieved by a

customer producing talc-filled

compounds on a ZSK 92

machine. They increased

throughputs by 40% from 2.4

to 3.3 tonnes/hour at a filler

loading of 20%, and by 30%

from 1.1 to 1.4 tonnes/hour

with a 48% loading.

Another application on a

pilot line at the Borealis innova-

tion HQ in linz, Austria,

involves a very fine talc used in

filled pp. Here throughput was

boosted by up to 200%. Tests

carried out by coperion using

ZSK 40 and ZSK 50 lines have

also shown very large increas-

es in throughput when handling

graphite, flame retardants or

hollow micro-spheres.

in addition, FET has been

applied upstream on two

compounding lines producing

halogen free flame retardant

(HFFr) cable compounds – a

ZSK 76 megavolume plus and

a ZSK 92 megacompounder

plus. in both cases, back

venting was no longer required

while the output of the ZSK 92

was lifted by 57% from 1.4 to

2.2 tonnes/hour.

coperion will also be

showing a new improved

version of its ZS-Eg twin-

screw degassing unit,

featuring a variable speed

drive and an optimised screw

set. The standard models are

designed for an absolute

vacuum of up to 50 mbar with

lower degassing pressure

available on request.

one customer, Solvay

Advanced polymers in the uSA

is using a ZS-Eg to boost

throughput on a ppA com-

pounding line. in germany,

Bayer materialScience is using

one of the units to ensure high

and uniform product quality

when manufacturing pc

compounds. in both cases

downtime for maintenance and

cleaning has been reduced.

on the pelletizing front,

coperion will be showing a

die-plate from its new ug

1.250, the world’s largest

underwater pelletizer with a

cutting diameter of 1.25 m and

11,000 die holes. it can handle

throughputs of more than 100

tonnes/hour for pE and water

flowrates as high as 1,500

m3/hour. The first ug 1.250 will

go into production soon.

Sticking with huge items of

equipment for polyolefin lines,

coperion has extended its melt

pump range with its largest

model, the mp 450, which can

handle throughputs as high as

65 tonnes/hour. The first such

unit is currently in the final

stages of installation at a pp

plant where it will have a

throughput range of 30 to 50

tonnes/hour. Two more pumps

of the same type are being

prepared for delivery to the

client and will be used to pump

pE at 40 to 50 tonnes/hour.

❙ www.coperion.com

An FET system fitted to a ZS-B twin-screw side feederCoperion says that this is the world’s largest underwater pelletizer

Video ShowcaseJUST CLICK AND WATCH

If you would like your video to appear on this page, please contactClaire Bishop. [email protected]. Tel: +44 (0)20 8686 8139

ArkemA: nAnotubes

this informative video looks at the production and application of carbon nanotubes as well as addressing health and safety issues.

running time: 4 minutes.

www.arkema.com

steer tWIn-sCreW eXtruDers

this informative video shows the production of steer engineering’s twin-screw extruders. It also has footage of a range of compounding lines in operation.

running time: 7 minutes

www.steerworld.com

roCktron: eComInerAls

this fascinating video looks at how rocktron is producing sustainable high-performance mineral fillers from fly ash from coal-fired power stations.

running time: 3 1/2 minutes.

www.rktron.com

Automatik will be launching its

new generation of Sphero

underwater pelletizers at K

2010. The new design features

a improved straight-line exit

for the pellet-water slurry,

which ensures even better

process water flow through the

system. As a result, cleaning is

simplified, wear levels are

reduced and there is reduced

risk of clumping with materi-

als such as TPEs.

Another innovative feature

of the new generation Sphero

is its redesigned interlock

device that allows the cutting

chamber to be flipped open

using just one hand (pictured

right). Automatik says that this

is an industry first.

Automatik updates Sphero system

In addition, the cutting head

assembly has been redesigned

with a new universal joint

which keeps the cutting edges


AMI Strategy Seminars 2010These one-day seminars are given by an AMI director and provide invaluable insights into market trends and industry strategies. They are held in small groups and provide ample opportunities for questions and discussions.

Places are very limited, and these seminars frequently sell out.Book your place now to avoid disappointment.Europe & Middle East contact:Katy Brotherhood. [email protected]. +44 117 924 9442USA contact: Marissa Hann. [email protected] +1 610 478 0800

H O U S T O N – C O L O G N E – D U B A I

The Plastics Industry Strategy Seminar – 14 October 2010, Houston, Texas , USAClick here to download the programme and booking form

The Plastics Industry Strategy Seminar – 26 October 2010, Cologne, GermanyClick here to download the programme and booking form

The Plastics Industry Strategy Seminar – 29 November 2010, Dubai, UAEClick here to download the programme and booking form

opportunity to boost the energy

efficiency of the Sphero

systems with these new

generation designs. The

redesigned cutting chamber

geometry reduces power

requirements, while the pellet

dryer blower uses 50% less

energy than its predecessor,

and further savings are

delivered by the new SuperFlow

thermally-insulated die-plate.

The operating range of the

Sphero family has also been

extended with the addition of

the Sphreo 560 which has a

throughput rate of up to 32

tonnes/hour compared to 18

tonnes/hour for the previous

largest model.

❙ www.automatikgroup.com

perfectly alligned to the die

plate. This increases the life of

the knives by up to 30%.

Automatik has taken the

This month’s freebrochure downloads

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

If you would like your brochure to be included on this page, please contact Claire Bishop. [email protected]. Tel: +44 (0)20 8686 8139

Century Extrusion: total package

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CENTURYEXTRUSIONYour Partner in Productivity

Twin Screw Extruders, Replacement Parts,

and Services

This six-page brochure from Century Extrusion covers the company’s twin-screw extruders, its supply of replacement parts for most leading brands of compounding lines, and its comprehensive support services for compounders.


Buss Kneader technology

This 16-page brochure examines how the Buss Kneader can be used for the efficient compounding of masterbatches, PVC formulations, wire and cable compounds, bioplastics, TPEs and a variety of other materials.


Wind Turbine Blade Manufacture

The first international AMI conference on Wind Turbine Blade Manufacture takes place in Düsseldorf, Germany, on 7-9 December 2010. Download the brochure to see its excellent line-up of expert speakers.

➤ Click here to downloadOrganised by:


Images courtesy of: repower Systems aG

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7-9 December 2010Maritim Hotel, Düsseldorf, Germany

Sponsored by:

* + 19% German VAT

Media sponsor:

International conference on windmill blade manufacture from design, through composites processing and materials, to in-service performance

Econ pelletizing case study

This five-page publication looks at the unique design features of Econ’s underwater pelletizers and examines how they are delivering big benefits at Horst Müller Kunststoffe’s compounding plant in Germany.


Simply Complex

Although we have been in the

compounding business for more

than 40 years, and have always

endeavored to improve the processes,

ECON succeeded to surprise us with

the ECON underwater pelletizer’s

enormous saving potential. Now it is

up to us to make use of ECON’s

potential, by gradually exchanging the

pelletizers with the new efficient ECON

underwater pelletizing system.

CitationGeorg Ender

manager and head of development

at Müller Kunststoffe GmbH

Leistritz ZSE MAXX extruders

This 12-page brochure from Leistritz has details of its ZSE Maxx twin-screw extruders which combine high levels of torque with high free volumes to give increased throughputs and flexible processing capabilities.


LEISTRITZ EXTRUSIONSTECHNIK GMBH

ZSE MAXX SERIES

r e f r e s h i n g e x t r u s i o n t e c h n o l o g y

PLAS MEC mixer technology

This 24-page corporate brochure coversPLAS MEC’s HC, RV and RO turbo-mixers, along with its complete mixing lines for PVC compounding and masterbatch production.


Headofficelocation: Istanbul(Alemdag),Turkey

Datefounded: 1975

CEO: MrMustafaTelli

Ownership: Privately-owned

No.ofemployees: 100

Plantlocation: Istanbul(Alemdag),Turkey

Production2009: 20,000tonnes

Profile: TisanEngineeringPlasticsisafamily-ownedbusinessestablishedin1975.TodayitisoneofthelargestproducersoftechnicalcompoundsinTurkeyanditalsoexportsmaterialstoItaly,Germany,Egypt,Iran,Tunisia,Romania,Russiaandothercountries.Itscompoundingplantfeaturesseventwin-screwandthreesingle-screwextrusionlines.

Productline: TisanproducesacomprehensiverangeofcompoundsbasedonPA6,PA66,PP,ABS,PBT,PS,PC,PE,PBTandPET.Theseincludeglass-andmineral-filledproductsaswellasflameretardant,UVandantioxidantgradesinvariouscolours.Thecompany’sproductsaremarketedunderthefollowingtradenames:Tislamid(PA),Tisakril(ABS),Tisester(PBT),Tissan(SAN),Tisetilen(PE),Tisarbon(PC),Tisren(PS),Tisapet(PET),Tisapom(POM)andTisblend(PC/ABS).

Productstrengths: WithitsR&Dfacilitiesandtechnicaldepartment,Tisaniswellplacedtosupportthematerialdevelopmentrequirementsofitscustomers.Targetmarketsincludetheautomotive,durablegoods,electricalappliances,furnitureandconstructionindustries.

TisanEngineeringPlastics

compounder of the month

Forthcoming featuresThenextissuesofCompoundingWorldmagazinewillhavespecialreportsonthefollowingsubjects:

October2010CompoundingbioplasticsCarbonblackEuropeanmasterbatchmarketK2010showissue

November2010CompoundingnanocompositesFlameretardantsPolypropylenemarkettrendsK2010showreview(partone)

EditorialsubmissionsshouldbesenttoAndyBeevers:[email protected]

Forinformationonadvertisingintheseissues,pleasecontactClaireBishop:[email protected]:+44(0)2086868139

Take out your own free subscriptions to any of the magazines.Click on the logos below to simply register on-line.

Catch up on our recent issues for free

Simply click on the cover to see the full magazine

Compounding World – JuneThe June edition of Compounding World has features on wire and cable market trends, developments in twin-screw extruders, and the race to commercialise carbon nanotubes.

➤ Click here to view

Compounding World - July/AugustThe July/August issue of

Compounding World is packed with features on wood-plastic

composites, automotive market trends, filler technology and

new mixers for PVC compounds.


Injection World – May/JuneThe May/June issue of

Injection World has features on bioplastics, medical

materials, European market trends, materials handling

equipment and screw speed selection.


Pipe and Profiles – July/AugustThe July/August issue of Pipe

and Profile Extrusion boasts articles on making it big in the

Middle East, specifying screenchangers, developments

in control systems and the latest additives for PVC.


Film and Sheet – June/JulyThe June/July edition of Film and Sheet Extrusion is packed with features on flexible packaging market trends, applications in photovoltaics, additives for polyolefins and extruder die technologies.


Injection World – July/AugustThe July/August edition of Injection World boasts features on developments in masterbatches, automotive market trends, temperature controllers and optimising machine settings.


dates for your diary

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www.compoundingworld.com

And don’t forget to tell your colleagues, customers and suppliers about the magazine. You can use the e-mail button above (the

envelope symbol in the browser) to help spread the word.

4-8 October Colombiaplast,Bogota,Colombia www.colombiaplast.com 27 Oct – 3 Nov K2010,Düsseldorf,Germany www.k-online.de 2-5 December PlastEurasia2010,Istanbul,Turkey www.plasteurasia.com 8-11 January ArabPlast2011,Dubai,UAE www.arabplast.info 20-24 January Plastivision,Mumbai,India www.plastivision.org 25-28 January Interplastica2011,Moscow,Russia www.interplastica.de 8-10 February PlasTecWest,Anaheim,CA,USA www.plastecwest.com 16-18 February NanoTech2011,Tokyo,Japan www.nanotechexpo.jp/en 22-24 February ExpoPlasticos,Monterrey,Mexico www.expoplasticos.com.mx 15-16 March MassPlastics,Fitchburg,MA,USA www.massplastics.com 26-28 April Plastic,PackagingandPrintAsia,Pakistan www.plastpackasia.com 1-5 May ANTEC,Boston,MA,USA www.4spe.org 9-13 May BrasilPlast,SaoPaulo,Brazil www.brasilplast.com.br 12-18 May Interpack,Düsseldorf,Germany www.interpack.com 17-20 May Chinaplas2011,Guangzhou,China www.chinaplasonline.com 24-27 May Ausplas,Melbourne,Australia www.ausplas.com

Global exhibition guide

AMI conferences 14-15 September MedicalGradePolymers2010,Philadelphia,PA,USA

20-22 September MERLOilfieldEngineeringwithPolymers,London,UK

12-13 October StretchandShrinkFilm2010,Atlanta,Georgia,USA

22-24 November AgriculturalFilm2010,Barcelona,Spain

29 Nov – 1 Dec FlexiblePackagingMiddleEast,Dubai,UAE

30 Nov – 2 Dec WaterproofMembranes2010,Cologne,Germany

1-2 December MineralsinCompounding,Atlanta,Georgia,USA

7-9 December FireResistanceinPlastics2010,Düsseldorf,Germany

7-9 December ThinWallPackaging2010,Cologne,Germany

7-9 December WindTurbineBladeManufacture,Düsseldorf,Germany

1-3 February ThermoplasticsConcentrates2011,Phoenix,AZ,USA

7-9 February PipelineCoating2011,Vienna,Austria

15-17 February PVCFormulation2011,Düsseldorf,Germany

15-17 March Cables2011,Cologne,Germany

For information on allthese events and other

conferences on film,sheet, pipe and

packaging applications, see

www.amiplastics.com