News from the Scottish Plastics and Rubber Association 2004 · Setup Reduction, Just-in-Time, Kanban, Kaizen, Cell Design, Theory of Constraints and Value Stream Mapping. The workshop

News from the Scottish Plastics and Rubber Association

2004

Newsletter Contents 2004 April 2004 Page SPRA Seminar: “Towards Smarter Manufacture” 2 Workshop on Lean Manufacture 4 Prof James Courtney awarded the Swinburne Medal 4 Polymer LEDs in microdisplays 5 VTS Royalite host a meeting on PVC stabilisers and thermoplastic sheet 6 Workshop: Joining with Adhesives 7 SPRA Dinner Dance 2004 7 June 2004 SPRA members vote to make SPRA a legal entity 9 “Future is Solid”: simulation software for injection moulding from FlowHow 9 New Medical Technology wins Plastics Industry Award 10 Tragic explosion at ICL Plastics 11 Funding for Modern Apprenticeships in Polymer Processing 11 SPRA Annual General Meeting 2004 12 Congratulations to SPRA Members, Jim McSporran and Dr Eric Boinard 12 September 2004 SPRA becomes a „Company Limited by Guarantee‟ 13 Development of safer beer bottles produced from safeglass 13 Polymer Study Tour 2004: residential course for teachers 14 Caledonian Industries produces biodegradable foam packaging 15 Polymer graduates at Napier University 16 December 2004 IOM3 Swinburne Award 2004: Prof James Courtney 18 Swinburne Address 2004: Polymers in Medical Applications 19 Ticona Roadshow: engineering thermoplastics and applications 22

News from the

Scottish Plastics and Rubber Association

April 2004

Features in this issue: Towards Smarter Manufacture Lean Manufacture Swinburne Award Micro Displays VTS Royalite Joining with Adhesives SPRA Dinner Dance 2004

TOWARDS SMARTER MANUFACTURE

"Towards Smarter Manufacture in the plastics and rubber sectors" was a one-day event, organised by the SPRA and held on 24 March in the Westerwood Hotel in Cumbernauld. It brought together a group of organisations that can help companies make the necessary organisational changes in order to remain competitive in the global market. For full proceedings of the Seminar click here

EXHIBITION The exhibition from 22 organisations was intended to act as a tool kit for progressive companies implementing innovation, efficiency, technology transfer and skills development.

Bell College British Plastics Federation Cogent SSC Ltd CompetitiveScotland.com Dialogues East Kilbride Group Training Assoc Faraday Plastics Partnership ICASS Innovation Relay Centre (Scotland) Knowledge Transfer Partnerships Learndirect Scotland Napier University Pera Technology PICME Polymer Training Ltd Queensgate Associates Ltd Rapra Technology Supply Chain Management Group Ltd Scottish Energy Efficiency Office Society of Plastics Engineers SPRA The Carbon Trust

www.bell.ac.uk www.bpf.co.uk www.cogent-ssc.com www.competitivescotland.com www.gla.ac.uk www.ekgta.com www.faraday-plastics.com www.icass.co.uk www.ircscotland.net www.ktponline.org.uk www.learndirectscotland.com www.napier.ac.uk www.pera.com www.picme.org www.polymertraining.co.uk www.queensgatea.co.uk www.rapra.net www.scmg.co.uk www.energy-efficiency.org www.4spe.org www.spra.org.uk www.thecarbontrust.co.uk

SEMINAR

The accompanying seminar featured 8 speakers, highlighting some of the exhibits alongside keynote presentations on innovation, supply chain management, technology translation and new ways of learning.

Session1: Chair: Colin Hindle (SPRA President)

10.30: Welcome: John Ramsay (CEO, Cogent SSC Ltd)

10.40: Innovation: Chris Thompson (Viadynamics)

11.20: How Can We Make It in Scotland?: Prof Umit Bititci (CompetitiveScotland)

11.40: Knowledge Transfer Partnerships: Anne Keane (East of Scotland KTP Centre)

12.00: New Approaches to Learning: Supporting Business: Frank Pignatelli (SUfI)

12.40 Lunch and Exhibition

Session 2: Chair: John Ramsay (Cogent SSC Ltd)

2.00: Supply Chain Management: Opportunities and Threats: Prof Douglas MacBeth (Glasgow University)

2.40: Innovating Beyond Your Competitors' Reach: Ian Cleathero (Pera Technology)

3.00: Begin with the End in Mind: Roger Dickinson (ITI Scotland Ltd)

3.20: Technology Translation: the Faraday Ethos: Prof Bill Banks (Strathclyde University)

4.00: Closing Remarks: Hugh Smith (SPRA Immediate Past President)

Chris Thompson

Chris Thompson, Viadynamics, gave delegates plenty to think about in explaining his approach to the innovation process -- address the uncertainty issues as early in the process as possible, rather than later when the associated costs are greater.

In his vision of the manufacturing sector in Scotland in 10 years time, Prof Umit Bititci, representing CompetitveScotland, saw a flexible and agile sector, dominated by small companies, focused on niche markets, not competing on cost/price and collaborating with like companies with complimentary competencies to win large international contracts.

Prof Umit Bititci

For full proceedings of the Seminar click here.

LEAN MANUFACTURE

To introduce more companies to the concept of Lean Manufacture and to engender lean thinking throughout organisations, the SPRA, in conjunction with the Association for Manufacturing Excellence, AME (UK), organised an Introductory Workshop on Lean Manufacture on 31 March. The tutors, Chris McKellen (Manufacturing Awareness Ltd) and Ralph Woodhead (Open Logistics Ltd) guided participants through the basic approach to lean thinking and covered some of the essential tools, such as the 5 S's, Visual Management, Mistake Proofing, Cycle Time and Setup Reduction, Just-in-Time, Kanban, Kaizen, Cell Design, Theory of Constraints and Value Stream Mapping. The workshop was spiced up with practical exercises in which teams organised a mixed production line to keep pace with customer's demands, using Kanban principles.

Chris McKellen

tel: 01942816492 [email protected] www.manufacturing-awareness.com

Ralph Woodhead

tel: 01423 569 642 [email protected] www.go4lean.org.uk

SWINBURNE AWARD: Professor James Courtney

The Swinburne Award recognises the achievement of a person who has made an outstanding contribution to the advancement and knowledge of any field related to the science, engineering or technology of plastics. The Award consists of a gold medal and £250 honorarium.

Prof Douglas MacBeth, Centre for Supply Chain Management at Glasgow University, explained the changes in the outsourcing model in which OEMs have reduced their risk by passing design and technical capability to first level suppliers who gain added value at the expense of added risk. At other levels suppliers have to be prepared to get into the design process of their customers. The old thinking of "the customer is always right" has to be replaced by risk and reward sharing between customer and supplier and group co-operation when necessary. Other speakers urged companies to take advantage of the science and engineering capabilities in Universities and to look at new ways of learning to maintain skills development.

The Institute of Materials, Minerals and Mining has awarded the 2004 Swinburne Medal to Professor James Courtney, the SPRA's nomination. Prof Courtney, a founder member of the SPRA, is a world authority on the applications of polymers in medicine, with particular reference to haemodialysis membranes, polymer coatings on activated carbon for haemoperfusion and blood purification, blood compatibility of polymeric materials, burn wound coverings and artificial organs. Prof Courtney's interest in polymers had its roots in the rubber industry where he worked for MacLellan in Glasgow and Uniroyal (now Gates) in Dumfries.

Professor James Courtney

His research work in the Bioengineering Unit at the University of Strathclyde spans over 30 years, and with international collaborators, has led to over 200 publications and 6 patents.Prof Courtney's international reputation is reflected in visiting professorships, academic awards, representation on editorial boards for a number of learned journals, organisation of conferences and active participation in a number of learned and professional societies. He is a founder member and tenured professor in the International Faculty of Artificial Organs, whose objective is to coordinate, on a worldwide basis, teaching courses and programmes relating to artificial organs. His current research, in collaboration with clinical colleagues, is to reach a better understanding of biomaterial performance and to develop improved polymeric materials. The Swinburne Award is a fitting recognition of Professor Courtney's massive contribution to the development of polymeric materials in the field of medicine. A condition of the Award is that the recipient gives the Swinburne Address and the SPRA hopes that this will take place in Scotland later this year.

MICRO DISPLAYS

At the February meeting at SAMC in Livingston, Dr Jeff Wright gave SPRA members and non-members from the electronics sector an insight into the application of polymeric light emitting diodes (PLED) in display technology and the complexity of starting up a new high technology business, MicroEmissive Displays (MED). In 1999 Dr Jeff Wright, after completing research on novel polymers at Napier University, had teamed up with Dr Ian Underwood, a lecturer at Edinburgh University with experience in electronic display technology and Peter Denyer, an entrepreneur with experience in spin-off companies. A key step was the year that Jeff spent on the Royal Society of Edinburgh/ Scottish Enterprise Fellowship in Commercialisation which gave him the time and freedom to develop the business plan and establish contacts. Several investors were attracted, initially with a modest sum of £100 k, rising to $2.25 million the following year, $9 million in 2002 and a further $7.5 m in 2003.

Dr Jeff Wright (right) with

Dr Mike Barker (SPRA Academic Liaison Officer)

In parallel with the investment, the company was able to grow to 25 employees, develop the technology, license some of the key intellectual property, set up suppliers for silicon wafers in the Far East and introduce pilot production in Edinburgh in 2004.

The micro displays (7 mm across, 320 x 240 pixels, full colour) are built on silicon wafers using conducting polymer layers, polymer light emitting layers and colour filters. The PLED material, a conjugated main chain copolymer, costs in the region of £1 million per kg. Compared to a conventional LCD the PLED display operates at lower voltages, uses less current, has better viewing properties and eventually longer life. Because impurity particles, moisture and pinholes in the films are critical, MicroEmissive Displays has invested heavily in Class 10 clean room facilities. The electronics are designed to integrate with current systems to reduce the risk with potential customers. The market for the displays is in near-to-eye applications such as cameras, camcorders, mobile phones and headsets, a market that is

predicted to reach $2.2 billion by 2006.

MicroEmissive Displays Ltd Tel: 0131 650 7764

[email protected] www.microemissive.com

VTS ROYALITE

The March SPRA meeting, hosted by VTS Royalite at Newbridge, had something for everyone. The evening started with a guided tour of the Royalite production facilities for sheet extrusion and calendering. After a buffet and an opportunity for networking, Dr Michael Schiller, Chemson, treated the audience to a presentation on the latest on PVC stabilisation and some thoughts on the future of wood-PVC composites.

Lead Ca/Zn Ca/Zn OBS OBS OBS

Exposure Time

To minimise the use of heavy metals in PVC formulations, organic based stabilisers (OBS) are being developed to compete with lead, tin and calcium/zinc stabilisers. Dr Schiller demonstrated, from application of factorial design of experiments, that OBS competes on processability, initial colour, dynamic heat stability and artificial weathering resistance. Trials are underway to evaluate plate-out behaviour and outdoor weathering performance.

70% PVC: 30% wood flour 70% Polypropylene; 30% wood flour

Jonathan Tomlin gave an interesting account of the history of VTS Royalite, its present capabilities and current markets for thermoplastic sheet products. VTS Royalite is building on a tradition of over 40 years of success in ABS extrusion and PVC calendering in the Edinburgh area. Within British Vita there are 13 thermoplastic sheet companies, working together across Europe, each specialising in different products. At Newbridge, VTS Royalite concentrates on ABS (flame retarded, acrylic capped and PVC/ABS), PVC and acrylics for sheet up to 2.3 m wide and from 0.7 to 10 mm thick. Markets serviced include automotive, sanitaryware, aircraft interiors, building and construction including wall protection and doors. To round off the evening, Jonathan organised a quiz based on his presentation, the answers raising much debate, protests and general enjoyment. The winner, Alan McGurk from Honeywell, received a presentation bottle of whisky.

In the field of wood-thermoplastic composites, with 30-70% wood fibre, PVC has the advantage of not requiring coupling agents. The PVC composites can be processed on conventional dry-blend extrusion lines or on lines with specialised dosing units. In both cases the dies have to be specifically designed. Compared to wood-polypropylene composites, the wood-PVC materials have similar mechanical properties, better weathering resistance and significantly better burning behaviour.

Alan McGurk (Honeywell) receiving his prize

from Jonathan Tomlin (VTS Royalite)

(l to r) Jonathan Tomlin (VTS Royalite), Dr Michael Schiller

(Chemson), David Marshall (CEO VTS Royalite)

Chemson

[email protected] www.chemson.com

VTS Royalite [email protected] www.vtsroyalite.co.uk

JOINING WITH ADHESIVES

At a workshop "Joining with Adhesives" in Glasgow on 30 March, organised by the Scottish Association for Metals and Strathclyde University, Andrew Carter (R D Taylor & Co) introduced the afternoon with an overview of adhesives and joining techniques. Richard Court (TWI) described the DTI funded project to produce a website with an adhesives design toolkit, complete with design advice, an adhesives selection programme and details of adhesives suppliers. Professor Dick Pethrick (Strathclyde University) completed the event with an account of his research on developing a non-destructive test for adhesive joints based on dielectric analysis.

R D Taylor & Co

[email protected]

Adhesives Toolkit

www.adhesivestoolkit.com

R Pethrick

[email protected]

SPRA DINNER DANCE 2004

Once again the SPRA Dinner Dance proved to be a memorable evening for the 200 SPRA members, company hosts and guests. Back at the familiar surroundings of the Moat House Hotel, guests enjoyed the usual good Scottish food, good wine, energetic dancing and excellent company into the early hours. SPRA President, Colin Hindle had amongst his guests Donna Davis, President of the Society of Plastics Engineers all the way from Texas and Iain McColl, Master of the Worshipful Company of Horners, a London Guild closely associated with the plastics industry and supporters of the Polymer Study Tour. Closer to home Colin's other guest was Professor Jim Courtney of the Bioengineering Unit at Strathclyde University.

After introducing his honoured guests, Colin announced that Prof Courtney had been awarded the Swinburne Medal for 2004 by the Institute of Materials, Minerals and Mining. Colin also presented SPRA scholarships to three students from Napier University. After dinner, guests were entertained by a witty speech from Commodore Eric Thompson. It is strongly recommended that you make your booking for the 2005 event now.

SPRA President, Colin Hindle (centre) with top table guests back row (l to r) Iain McColl (Horners), Prof Jim Courtney (Strathclyde Univ), Colin Hindle (SPRA President), Eric Thompson

front: Mrs Ellen Courtney, Mrs Susan Hindle, Ms Donna Davis (SPE)

Address to the Haggis

SPRA Scholarship winners with Colin Hindle (l to r) Julie Thompson, Clare Sheppard (joint winners BSc Hons Product Design Engineering); Manthan Fadia - (BEng Hons Polymer Engineering)

News from the

Scottish Plastics and Rubber Association

June 2004

Features in this issue: SPRA: Legal Entity Future is Solid NMT: Award Winner Tragedy at ICL Plastics Adult Modern Apprenticeships SPRA AGM 2004 Congratulations

SPRA BECOMES A LEGAL ENTITY

Colin Hindle

SPRA President

On Thursday 17th June 2004 at an Extraordinary General Meeting of the SPRA it was unanimously decided, by postal ballot and the votes of those present, that the SPRA should become a legal entity, and the new "Memorandum of Association" and "Articles of Association" were accepted. Since then there has been a flurry of paperwork activity and an application has been lodged to enable the Scottish Plastics and Rubber Association to become a Scottish Private Company Limited by Guarantee (Non-Charitable). Once all the paperwork is processed we will have a registered office and all the privileges and responsibilities of a company. On a day-to-day basis nothing much will change, we will still rely on the dedication and enthusiasm of volunteers to carry out the normal business of our programmes. However, once we are a legal entity we will be eligible to access funding for specific projects directly from bodies such as the Scottish Executive, Scottish Enterprise and the European Union. Access to such funding is essential if the SPRA is to continue to extend its activities. Watch this space for further updates.

Colin Hindle (SPRA President)

THE FUTURE IS SOLID

At the April meeting, John Gosden (FlowHow) gave an excellent overview of the developments in modelling for injection moulding simulation technology. Simualtion analysis is not a magic wand but is only as good as the inputs (cavity geometry, material data and process conditions). The injection moulding process can go wrong in so many ways that trouble shooting on-line can become an expensive exercise.

Having good advance knowledge, through simulation analysis, of how a particular mould will behave leads to better

mould design, better process efficiency and improved product quality. Over 20 years ago flow analysis was based on

2D branching flow using lay-flat models. In 1982 finite element analysis was introduced, breaking the model into a mesh of triangular elements each with 3 nodes. Mesh size had to be limited to less than 3000 elements and calculation times could be in excess of 15 hours. Today a number of simulation products are on the market, all based on mesh models, the differences being in the shape of the elements -- triangular, prismatic, tetrahedral and cuboid. To date the most popular approach has been the shell (midplane) model, in which the cavity is represented as a meshed plane with sets of elements assigned thicknesses. This is adequate for many mouldings with mostly constant wall thickness but modelling can be labour intensive to get the best results. For more complex shapes the midplane models do not simulate true 3-D flow. Meshes based on pyramidal and cuboid elements simulate 3-D flow but the latter is best suited to block mouldings such as edge connectors and less attractive for parts with curvature.

For best results there has to be at least 6 - 10 elements across the thickness and this leads to massive computing time. The hybrid mesh approach adopted by Moldex 3D uses mesh with non-linear prism elements in the skin layer (laminar flow region) and non-linear tetrahedral elements in the bulk (3-D flow) region. This model better mimics the real filling pattern of a skin layer and fountain flow in the centre of the wall section.

John illustrated the application of this hybrid technology with a number of case studies which could assess the use of copper alloy inserts, predict cycle time reductions, reduce material consumption and reduce part costs as well as improving part quality. The system can also be applied to overmoulding. Today simulation systems can accept solid modelling data from a range of CAD systems and automatically prepare mesh for simulation analysis. Some systems can also create cooling lines for cooling analysis and warpage analysis. Compared to midplane modelling, 3-D analysis gives more information about internal effects, realistic solid cooling displays and better representation of weld lines and air traps. With advances in computer technology it is possible to take advantage of increasing speed and reducing computing costs. Moldex 3D R7.0 is the first parallel computing flow simulation package for a PC/Windows platform.

John Gosden 07760316580 [email protected] www.flowhow.dk

NEW MEDICAL TECHNOLOGY -- AWARD WINNER

The New Medical Technology Group were deservedly awarded the top spot in the Consumer Product Design category at the Plastics Industry Awards in May, for their innovative use of two-shot moulding technology in the design of their second generation safety syringe designed to minimize injuries from needles in the healthcare industry (over 100,000 in the NHS in 2001). Earlier NMT designs were based on the principle of the needle retracting into the barrel of the syringe when the plunger is fully depressed at the end of drug delivery. The 2nd Generation product range retains this principle but incorporates new features and uses 2-shot injection moulding technology to create multi-functional components, benefiting from the properties of the two parent materials. NMT has applied the 2-shot concept to medical components that act as a seal for the delivery of the drug, but then separate at a closely defined force and distance to retract the needle mechanism inside the device and render the product safe.

The judges felt NMT's product was a clear winner and used a good understanding of the plastics manufacturing process to develop an intelligent product. "The fitness for purpose is clearly excellent," said one judge. "The way the group has produced this as an advance on a previous product and the clever use of two-shot moulding makes it this year's winner." The judges were also impressed with the company's understanding of legislative issues.

NMT said the choice of materials was critical to the syringe's function and its market acceptability; its principle concerns were drug and bio-compatibility. Polymer grade has a significant impact on the retraction mechanism performance. The design was verified using six sigma design of experiments on prototype 4+4 impression two-shot moulding.

New Medical Technology believes the technology and patents of the product have given it a world-class advantage in the development of safety products for the healthcare industries.

www.plasticsawards.com

TRAGEDY AT ICL TECHNICAL PLASTICS

The tragic events on Tuesday 11 May, at the premises of ICL Technical Plastics and Stockline Plastics in Glasgow, have stunned the plastics and rubber community in Scotland and beyond. The explosion, which demolished the four-storey building, caused the deaths of 9 employees, including most of the management team, and left many injured.

The SPRA extends its sympathies to the families of the bereaved and wishes the injured a speedy recovery. There has been much speculation in the media about the cause of the accident but the industry rightly awaits the outcome of the enquiry that has been set up.

Glasgow City Council has launched a fund, known as the Grovepark Fund, for immediate family of those who died, survivors and those directly affected by the incident. Donations can be made by cash or cheque to Glasgow City Council, 45 John St, Glasgow G1 1JE or at any branch of the Royal Bank of Scotland, quoting Grovepark Fund, account no. 00223403; sort code: 83-44-00

The SPRA has already made a donation to the fund. Companies may also wish to contribute individually to this worthy cause.

'ADULT' MODERN APPRENTICESHIPS

East Kilbride Group Training Association Ltd has secured funding through Scottish Enterprise to assist employers in the Polymer Sector in Scotland with the costs of developing staff and improving skill levels under the Modern Apprenticeship umbrella. Modern Apprenticeships which qualify for this specific financial contribution are in Engineering, Polymer Processing and Management. For existing employees in SMEs, EKGTA has secured a one-off funding package for 50 candidates aged 25 or over but the programme must start before the end of 2004. It is anticipated that the funding will go a long way to covering the cost associated with the training and assessment of candidates.

For further details contact:

Stuart Waugh

tel: 01355 229985

[email protected]

www.ekgta.com

SPRA AGM 2004

At the SPRA AGM on 13 May at Napier University, Officers reported on the busiest year the SPRA has experienced in its 10-year history. In addition to the normal technical meeting programme, the SPRA has been heavily involved in two one-day events: a seminar on "Waste Electrical and Electronic Equipment", organized in conjunction with the Electronic Design Support Centre at Livingstone, and a seminar/exhibition "Towards Smarter Manufacture in the plastics and rubber sectors". The latter was part of a major collaborative project with Cogent SSC Ltd with funding from the Scottish Executive. The SPRA's other contribution to the Polymer Sector Development Project was to visit companies in the sector to make them aware of current developments and the organization of a workshop on Lean Manufacture. Membership is showing signs of recovery after the losses in the last two years as a result of so many leaving the industry and leaving Scotland during a difficult trading period. Although numbers were down again, the annual Dinner Dance proved to be the usual highly enjoyable evening. The finances of the SPRA continue to be in good health.

At the AGM, four Council Members tendered their resignation, due to pressure of work and changing circumstances. John Wilcox (Gaeltech Associates) has been the Institute of Materials and Institute of Materials, Minerals and Mining (IOM3) representative on the Council since the SPRA was formed until his post at IOM3 disappeared in December 2003 due to regional restructuring. John has made a major contribution to the SPRA's development. Another long standing member, Andrew Cockburn (Anveco Ltd), the Industrial Liaison Officer is also standing down. The SPRA Council expressed its appreciation of the time and effort that both have given on behalf of the SPRA.

Andrew Cockburn

John Wilcox

Colin Hindle (Napier University) was re-elected as President for a further year and Jim MacSporran (Caledonian Ferguson Timpson) was elected as Vice President and he agreed to combine that with the role of Industrial Liaison Officer. Tom Campbell (Plastech Moulding) was elected as a Council Member.

CONGRATULATIONS

Congratulations are extended to SPRA members for their recent achievements.

Jim MacSporran, Operations Director at Caledonian Ferguson Timpson Ltd and the new Vice-President of the SPRA, has graduated from Glasgow Caledonian University with a Masters in Business Administration.

Jim MacSporran

Eric Boinard (Polaroid UK) has been granted Chartered Engineer (CEng) status by the Engineering Council through the Institute of Materials, Minerals and Mining.

News from the

Scottish Plastics and Rubber Association

September 2004

Features in this issue: SPRA: Now Legal Entity 'Safeglass' Beer Bottles Polymer Study Tour 2004 Biodegradable Foam Packaging Class of 2004

SPRA NOW A LEGAL ENTITY

'SAFEGLASS' BEER BOTTLES

As a late replacement speaker for the June meeting, Ralph McNeill, MD of Safegalss (Europe) Ltd, rose to the challenge and delivered a fascinating talk on the development of Safeglass material, an innovative plastic material designed to mimic glass, and the trials and tribulations of forming and expanding a new company. With a background in special effects in the film industry, Ralph saw the potential for a material that appears like glass but fractures easily without producing sharp

fragments.

The Scottish Plastics and Rubber Association became a Scottish Private Company Limited by Guarantee on the 2nd of July 2004, Company No. 270173. Becoming a legal entity puts the SPRA in a better position to act on behalf of the plastics and rubber industry in Scotland in securing grants for specific projects, acting as the voice of the industry and forging stronger links with other bodies, such as the British Plastics Federation, the Scottish Executive, Scottish Enterprise, Cogent-SSC and other relevant bodies. To allow this to happen, the SPRA needs strong support from the industry through Corporate Membership and the

Scottish Polymer Employers Network.

From an initial idea sitting on a train to the formation of the company took 5 years but within another 3 years Safeglass had captured 80% of the transport market in the UK for the use of Safeglass panels in break-glass applications in emergency procedures.

The next challenge is to develop a beer bottle that looks and feels like glass but, when broken, produces no sharp edges. Currently plastic beer bottles are made from PET and immediately recognised as plastics from their mechanical properties, contributing to customer resistance. Safeglass, a styrene based thermoplastic, is more rigid than PET, even sounds like glass but is much safer than glass. With a lower processing temperature than PET, the Safeglass material has access to a wider range of barrier materials, essential in the design of a beer bottle. Finite Element Analysis has been carried out to establish the optimum wall thickness for rigidity and pressure resistance. Creep tests have been carried out at a range of temperatures including pasteurisation temperatures.

Finite Element Analysis: Radial displacement for 1.5 mm wall bottle

under 200 psi internal pressure

Safeglass (Europe) Ltd 01355 272 438 [email protected] www.safeglass.co.uk

POLYMER STUDY TOUR 2004

At the end of June, 23 teachers of science, design and technology from across the UK, enjoyed a 4-day residential course at Napier University. The course, organized by the Worshipful Company of Horners, run by Colin Hindle and supported by the SPRA, was designed to give teachers a better understanding of polymeric materials and an insight into the plastics and rubber industry.

Introductory talks on the Sunday, from David Oxley on The Plastics Industry and Colin Williamson on History and Design of Polymer Products was followed by the usual rocket car race in which teams had to construct a vehicle from a PET bottle, a vacuum formed chassis, injection moulded

Rocket Car Race: the pits

Globally the beer market (over $180 million) is mature but not growing. Consequently the big players are competing for market share through initiatives such as innovative packaging. Current legislation on banning glass bottles from pubs and clubs also provides a huge potential for the Safeglass bottle.

wheels and the odd piece of rubber band which was then powered by compressed air from a bicycle pump.

Rocket Car Race Winners

On the Monday, Colin Hindle delivered lectures on polymer science, materials and processing followed by a talk from Charlie Geddes on the Polymer Industry in Scotland, before the teachers were let loose in the polymer workshop to gain hands on experience of a number of processes and test methods. As light relief from their exertions the teachers joined SPRA members in their June meeting for a talk on Plastics Beer Bottles delivered Ralph McNeill, MD of Safeglass (Europe) Ltd and an SPRA Council Member.

Rubber mixing: 2-roll mill Rubber mat moudling

Polymer Study Tour Dinner

Plastics identification

Colin Hindle (4th left) with teachers and sponsors before the Study Tour Dinner

Wednesday morning saw the students back in the laboratories for polymer identification and more hands-on processing and testing before the final set of talks on the Materials Profession by Diane Talbot of the Institute of Materials, Minerals and Mining and Polymers in a Sustainable Environment by John Sale.

For more details contact: Colin Hindle, School of Engineering, Napier University

0131 455 2622 [email protected]

BIO-WISE: BIODEGRADABLE FOAM PACKAGING

"Biodegradable foam packaging is a feasible alternative to expanded polystyrene" was the clear message reported in Renfrew in June at a meeting to signify the end of the DTI funded BIO-WISE project carried out by Caledonian Ferguson Timpson Ltd (CFT), in conjunction with Linn Products and Scottish Enterprise.

On the Tuesday the group visited three local companies, BP Chemicals, Carron Phoenix and Bausch & Lomb to see polymer manufacture and processing at first hand. At the Tour Dinner in the evening the teachers, tutors, sponsors and guests listened to an entertaining history of the Horners Guild by the main speaker, David Beynon, Past Master of the Worshipful Company of Horners, the principal sponsors of the Polymer Study Tour.

This worthwhile course, aimed at improving the image of the polymer industry and demonstrating career prospects, needs financial support for the 2005 event. A company can sponsor a teacher from their local school for as little as £600. With prospective employees becoming more difficult to find, this sounds like a wise investment.

laminated corrugated foam sheet

assembled packaging

Caledonian Ferguson Timpson Ltd

Tel: 0141 882 4691 Fax: 0141 810 3402 [email protected] www.caledonian-group.co.uk

During the presentation it was demonstrated how the foam can dissolve in water in around 20 minutes and is biodegradable. Not only did the foam perform well in packaging tests when laminated to cardboard but the foam also biodegrades at the same rate as cardboard in composting of waste. CFT see an exciting future for this biodegradable foam, particularly in lower density forms and in moulded products. Obvious markets include fruit and food trays where the product life span is less than 30 days.

Jim McSporran (Operations Director) with die cut biodegradable foam sheet

CLASS OF 2004

Napier University's Graduation Ceremony at the Festival Theatre on Thursday 15 July marked the end of an era in more ways than one as the last student on the MSc Plastics Moulding Technology graduated. Bruce McLaren successfully completed his project dissertation, "Gate Design and its Effect on Mould Filling and Part Quality", just in time for the graduation ceremony. Bruce started his studies at Napier University in 1994 when he entered the BEng Hons Polymer Engineering programme as a full-time student. After his industrial placement at Tenma he stayed on working with them and subsequently with Rosti whilst moving over to part-time study on the MSc Plastics Moulding Technology.

Bruce McLaren MSc Plastics Moulding Technology

This year Napier University produced a bumper crop of 11 graduates from the Polymer Engineering programme, including the 3 Honours graduates shown left:

from l to r: Simon Spence, William Braule, Manthan Fadia

SPRA Scholarship winners for 2003-04 returned the compliment with each gaining 1st class Honours awards in their respective programmes at Napier University. from l to r: Clare Sheppard (BSc Hons Product Design Engineering) Manthan Fadia (BEng Hons Polymer Engineering) Julie Thompson (BSc Hons Product Design Engineering)

During the project CFT demonstrated that the initial starch-based foam, supplied in 1.4 m wide corrugated sheet by Novamont, proved difficult to cut and lamination to itself was a problem. Reduced density foam not only provided a cost reduction but was easier to die-cut and gave more consistent corrugation and hence better lamination.

News from the

Scottish Plastics and Rubber Association

December 2004

Features in this issue: Swinburne Award Swinburne Address Engineering Thermoplastics

SWINBURNE AWARD 2004 : Professor JAMES McNIVEN COURTNEY

Introducing the Swinburne Address, Colin Hindle, President of the Scottish Plastics and Rubber Association, paid tribute to the career and international reputation of Professor James McNiven Courtney, recipient of the Swinburne Award for 2004 from The Institute of Materials, Minerals and Mining. After reading the Citation for the Award, which made reference to Prof Courtney's massive contribution, over a period of 38 years, to the development of polymeric materials in the field of medicine, Colin Hindle called on Mr Jeff Smith, President of The Institute of Materials, Minerals and Mining, to present Prof Courtney with his gold medal, Certificate and

£250 Honorarium.

Professor James Courtney

Jeff Smith presenting Swinburne medal

Prof Courtney's international reputation is reflected in visiting professorships, academic awards, representation on editorial boards for a number of learned journals, organisation of conferences and active participation in a number of learned and professional societies. He is a founder member and tenured professor in the International Faculty of Artificial Organs, whose objective is to coordinate, on a worldwide basis, teaching courses and programmes relating to artificial organs. His current research, in collaboration with clinical colleagues, is to reach a better understanding of biomaterial performance and to develop improved polymeric materials.

The Swinburne Award is a fitting recognition of Prof Courtney's massive contribution to the development of polymeric materials in the field of medicine.

Citation For over 35 years, Professor James McNiven Courtney, BSc, PhD, Dr sc nat, ARCST, EurChem, CChem, FRSC, FIMMM, FCS, has been a world authority on the applications of polymers in medicine, with particular reference to haemodialysis membranes, polymer coatings on activated carbon for haemoperfusion and blood purification, blood compatibility of polymeric materials, burn wound coverings and artificial organs. His research work in the Bioengineering Unit at the University of Strathclyde and with international collaborators has led to over 200 publications and 6 patents.

Prof Courtney and Colin Hindle

Sir James Swinburne Bart. FRS

(1858 - 1958)

Jeff Smith presenting Swinburne

Certificate

James Swinburne was born in Inverness, educated at Clifton College and served his apprenticeship as an engineer in Manchester. Swinburne became an outstanding figure in the electrical industry. He worked with Swan on the first electric light bulb and coined the words 'stator' and 'rotor'. He was the first President of the Institution of Electrical Engineers and the nominees for his Fellowship of the Royal Society included some of the most illustrious names in science - Kelvin, Crookes, and Lodge among others. Swinburne became interested in plastics in 1902 when he was introduced to the phenol formaldehyde reaction. He was able to make an excellent hard lacquer for coating metals such as brass - then in fashion for making bedsteads. Although Swinburne had taken out a number of patents, in 1907 the more important of these were pre-dated (by one day) by those of Leo Baekeland in the USA for a range of phenol formaldehyde-based products, which sold under the Bakelite trademark. In 1927, Swinburne concluded an agreement with Baekeland in which Swinburne's company was merged with two other English companies to form a new company, Bakelite Limited. Sir James Swinburne was appointed its first Chairman.

Extracted from the Plastics Historical Society website www.plastiquarian.com

Swinburne medal

SWINBURNE ADDRESS: POLYMERS IN MEDICAL APPLICATIONS

Acknowledgements

Professor Courtney prefaced his address by giving acknowledgement to the contributions made to his work from his colleagues in the Bioengineering Unit at the University of Strathclyde, clinical colleagues at various medical establishments and industrial collaborators. His warmest thanks were reserved for the generations of research students who had been instrumental in pushing forward his research efforts. Having undergone surgery twice in recent months, Prof Courtney's interest and dedication to polymeric biomaterials was illustrated by a polymer-coated stent, his souvenir from his operations.

Biomaterials

Rather than turn the Swinburne Address into a catalogue of his various research projects, Prof Courtney chose to focus on three specific areas -- polymers with biomaterial interest, sorbents and blood compatibility assessment - with particular reference to extracorporeal applications, haemodialysis membranes and blood tubing. Biomaterials for such applications must have compatibility with blood, stability and some functional characteristic. Secondary requirements include processability, sterilisability and a breadth of application. Proteins adsorbed on the biomaterial can influence blood platelet reaction such as coagulation and fibrinolytic activity. In simple terms albumin adsorption is "good" and fibrinogen adsorption is "bad". Coagulation, platelet adhesion and complement activity can be controlled by surface modifications - ionic, polar or hydrophobic.

In the last 200 years various researchers have pondered on why natural surfaces behave differently from artificial surfaces, why two types of artificial surfaces behave differently and why there are changes when surfaces are modified. The basic questions relating to biomaterials are:

What is the nature of the surface? What is the alteration in the blood component?

Professor Courtney's research in the field of biomaterials has covered three important issues:

synthesis of new vinyl copolymers for membrane applications; refining the formulation of plasticized PVC; modification of the polymeric surface through heparinisation.

Membranes

In artificial kidneys, the semi-permeable membrane, separating the blood flow and dialysate flow, allows selective removal of blood toxins. The key properties of such a membrane are permeability to water and desired solutes, impermeability to blood proteins and to bacteria and viruses in the non-sterile dialysate. Blood compatibility is an additional factor. Regenerated cellulose was the original industry standard but Professor Courtney started his research career by developing synthetic membranes based on vinyl copolymers. A balance of desirable properties was achieved by varying the type and proportions of the two monomers. One monomer contributed wet strength and film forming properties while the second monomer controlled water sensitivity and permeability. Today similar membranes are used in artificial liver devices. Many of Professor Courtney's early ideas have been applied in the development of modern, commercially successful, hollow-fibre membranes based on cellulose acetate.

Blood Tubing

Turning to blood tubing, Professor Courtney alluded to the enigma of plasticized PVC, a material which he considers still has a very important role as a blood contact material but which environmental pressure groups prefer to portray as a poison. PVC's emergence as a popular manufacturing material can be attributed to its useful combination of properties, ready availability and its economic attraction. It is recognised that PVC brings with it problems related to the toxicity of the monomer precursor, environmental questions related to additives (particularly plasticizers), poor thermal stability and issues surrounding the disposal of PVC.

In biomaterial applications, Prof Courtney considers that the advantages considerably outweigh the perceived disadvantages. In blood compatibility applications, the key influence is not the PVC base polymer but the plasticizer. In the bulk state, plasticized PVC contains around 55% PVC, 22% plasticizer and 13% other additives. In contrast, at the surface the plasticizer content is as high as 70% and the PVC base polymer as low as 2%. For many years the standard plasticizer in PVC has been di-(2-ethylhexyl) phthalate (DEHP) which has the disadvantage of being extracted into the blood. Prof Courtney found that reducing the concentration of DEHP reduces fibrinogen adsorption. Replacing DEHP with higher molecular weight plasticizers reduces extraction rates but has considerations of cost and influences blood in other directions. To maintain mechanical properties, more plasticizer has to be used in the bulk phase and hence higher concentrations at the surface.

Surface Modification

Prof Courtney showed that attaching heparin (an anticoagulant) to PVC surfaces reduces the influence on blood components, partly by reducing plasticizer levels at the surface. Cyclodextrins on the surface provide hydrophobic cavities in a hydrophilic shell, again influencing fibrinogen adsorption. The latest approach is to insert a complex between the heparin and a low molecular weight copolymer, resulting in reduced plasticizer extraction and improved blood compatibility. This technique has possible applications in other areas of biomaterials.

Reflection

Looking to the future, Prof Courtney can see potential in using a porous carbon monolith with a glassy carbon filtration layer on the inside bore.

The presentation was peppered with appropriate quotations and anecdotes, which confirmed that, as well as making significant contributions to the development of polymeric materials in medicine, Prof Courtney has gained much pleasure and satisfaction from his life's work and from his contact with other researchers.

In his vote of thanks Andrew Cluley, Polymer Co-ordinator for The Institute of Materials, Minerals and Mining, noted the overlap between Prof Courtney's scientific research and the field of medical engineering and reminded scientists in the audience that, if they were ineligible for Chartered Engineer status they could now apply to be registered as Chartered Scientist through the Institute.

The warm applause from the 100+ audience for Prof Courtney's entertaining, informative and thought-provoking address reflected the friendships he has cultivated with colleagues, respect from his research students and esteem from the rest of the scientific, medical and engineering communities.

Prof James Courtney

Bioengineering Unit University of Strathclyde

tel: 0141 548 3108 [email protected] www.strath.ac.uk/bioeng

The Swinburne Address 2004 was organised by the Scottish Plastics and Rubber Association with financial and in-kind support from The Institute of Materials, Minerals and Mining, the Scottish Association for Metals, Vascutek Ltd and the University of Strathclyde

www.spra.org.uk www.iom3.org www.scottishmetals.org www.vascutek.com www.strath.ac.uk

ENGINEERING THERMOPLASTICS: TICONA ROADSHOW

The 2004 version of the Ticona Roadshow in Cumbernauld on 30 September, exploited the well-tried formula of a series of short presentations, interspersed with case studies and backed up with discussion, displays and extensive literature. Peter Burke started with an overview of Ticona and its portfolio of engineering thermoplastics, ranging from the mature families such as acetal (Hostaform) and polyester (Celanex and Impet) to the relatively new cycloolefin copolymers (Topas), the only amorphous polymer from Ticona.

John Maslen showed how a mature product range such as Celanex is being continually developed to offer grades with particular properties maximised -flame retardance, impact resistance, mouldability, bearing wear and hydrolysis resistance.

John Maslen

Peter Burke (l) and Shaun Gurteen

HEALTHCARE OPPORTUNITIES Peter Burke outlined the attraction of the healthcare industry for engineering plastics, a market that already has a substantial penetration (>50%) for plastics, is considered recession proof, has an impressive growth rate (>10%) and is associated with high added value products. Sectors particularly suited to engineering thermoplastics are diagnostics, medical devices and pharmaceutical devices and packaging, the first two not always being constrained by clean room requirements. The key requirements are low levels of extractables, FDA approval, consistency of formulation, long term availability and a robust supply chain. Reaction to sterilisation is a key feature. Vectra (LCP) and Fortron (PPS) are best for radiation sterilisation while Topas is good for ethylene oxide treatment, with added properties of transparency and chemical resistance.

AUTOMOTIVE: 42 volt Shaun Guteen drew attention to the dramatic changes about to be introduced in the automotive industry with the switch to 42 volt from the current 12 volt system. The higher voltage will allow thinner wiring and a reduction in size for some components. Demands on engineering thermoplastics will increase, particularly arc tracking resistance, flammability, EMI shielding, thermal stability, chemical resistance and thermal expansion to match metals.

CONDUCTING PLASTICS A review by John Maslen of conducting plastics, for static dissipation, RFI and EMI shielding and conduction, covered the options of modifying the polymer chain, applying coatings and the use of additives such as graphite, metals and carbon fibre.

Discussion time

RECYCLING Shaun Gurteen addressed the changing attitudes to recycling, particularly in relation to the End of Life Vehicle Directive that aims at 85% recovery by 2006 and the WEEE Directive that will generate over 300,000 tones of waste plastics in the EU. Data on plastics in vehicle components will be provided in a data system format acceptable to all OEMs.

Geoff Forward

CASE STUDIES The highlight of the evening was the case studies in which the Ticona team acted out the role playing dialogue between Ticona advisors and the customer. Materials selection is based on starting with a comprehensive design specification and tackled using techniques such as spidergraphs. Advice is also given on part design, finite element stress analysis and moulding simulation analysis. Case studies ranged from an automatic water valve to a rack strip on a tripod and to a car front end and door module.

Finite

Element Stress

Analysis on

Pump Component

Spidergraph

Materials Selection

Car Door Module (above) Warpage Analysis (right)

Ticona UK Ltd

Hotline: 01952 213 456

[email protected]

www.ticona.co.uk