Modern Plastics Worldwide - July/August 2009 - dae uptlax

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PROCESSING TECHNOLOGY Traditionally, highly filled polyolefin compounds have been produced by repeated loading via several feed positions on the compounding extruder, followed by mixing up to three or more times. This, says Eitel, is done because CaCO 3 , with a bulk density of 600-800 kg/m 3 , tends to be sticky and build bridges, often creating headaches for an operator. To overcome such problems, agitators are often used, hoppers are designed with special geometry to improve material drop, or flexible walls can be incorporated that can shake up the filler to break up bridging. Coperion says experience has shown, in its latest line design for such applications, that, during refilling of loss-inweight feeders using slide, butterfly, or rotary valves, the valve itself needs to be installed closer to the feeder hopper so that it can react quickly in shutting PROCESSING TRENDS Specific energy input drops, and pressure increases, as filler content increases: that has been Coperion’s experience with its new line for highly filled compounds. off. This is necessary to avoid overfilling. The company developed a new layout for its ZSK compounder by mounting the CaCO 3 feeder directly above the unit’s co-rotating twin-screw side feeder, ZSB. This setup, says Eitel, results in the need for only two feeders and two refill hoppers for the CaCO 3 . It also provides Bioplastic barrier fi lm matches EVOH, PA By Matt Defosse Blown- and cast-fi lm extrusion line manufacturer Colines (with manufacturing sites in Novara and Varese, Italy) says recent testing proves that PLA/PVOH fi lms extruded on the company’s cast- and blown-fi lm lines with structures of up to 7 layers and with thicknesses from 50 to 90 μm offer sufficient oxygen barrier properties, while also maintaining top optical performance, as shown by the values of haze and gloss and the fi lm’s printability. Colines officials say the lines have been modified so as to render the same performance as lines running barrier films containing polyamide or ethylene vinyl alcohol (EVOH) barrier materials, with no loss in line productivity. The combined structure of polylactic acid (PLA), based on plant starches, and polyvinyl alcohol (PVOH, a biodegradable, water-soluble polymer) in these barrier films offers sufficient gas barrier performance to prove them suitable for use in applications such as packaging of meat and fish, and, in particular, fruit and vegetables. The company invited interested processors to its open house from July 27-31, 2009, and requested email preregistration at marketing@colines.it. Also during that open house the company planned to run a line extruding breathable film with an in-line double mono-orienting unit (MDO). The line, which can extrude breathable film in PE and in PP, has a useful width of 2200 mm and the double-MDO unit offers orientation of up to 600% (2 x 300%). It will feature post-stretching embossing and comes outfitted with a thickness control before and after the a longer mixing section for the filler, better dispersion, and higher output. With the increase by percentage of the compound/weight of filler, the discharge pressure in bar is increased while the specific energy input measured in kWh/kg is reduced. Farrel takes a different approach to compounding highly filled concentrates. Its FCM (Farrel Continuous Mixer) operates on the principle that the material is exposed to a variable mixing intensity in the form of shear stress and strain developed between the rotor tips and chamber wall, as well as melt blending by the kneading action between the rotors. “The measure of dispersion through either visual examination or filter pressure values are as good or better than those achieved with twin-screw extruders,” says Broadhead. “Besides that, we get the added benefit of lower energy costs.” stretching, with automatic adjustment according to the set target. Trim is recovered directly and pelletized. It also includes the firm’s Fast AdJUST (Elav) system for micrometric adjustments of the stretching parameters of the line. Colines reports it has worked with this system and is able to offer processors the option of live monitoring of the data relative to the extrusion lines. The report system lets a user track consumption data (energy and raw material), various trends (throughout and machine data), recipes, management of the production orders, ordinary and preventive maintenance, and diagnostics. The acquisition and processing of the data are incorporated directly in the automation system, with the data then able to be sent to computers on the other side of a facility or even further afield. 18 JULY/AUGUST 2009 • MODERN PLASTICS WORLDWIDE mpw.plasticstoday.com
PROCESSING TECHNOLOGY Johnson Controls applies PP fi lm to claim auto awards; KM takes home three By Tony Deligio The Mercedes-Benz E-Class door panel and rear-side panel of the new Mini Convertible earned Johnson Controls GmbH (Burscheid, Germany) two interior-system prizes at the Society of Plastics Engineers (SPE) Central Europe’s 12th Automotive Div. Awards. The door panel earned marks for overall quality and a scratchresistant map pocket, with the rear side panel also offering a scratch-resistant surface. The new Mercedes door panels are 10% lighter than the previous model and represent a full subassembly with map pocket, center panel, armrest, and upper trim panel. Johnson Controls also integrated ambient lighting above the door’s center panels and in the door handles, with sun shades built into the rear door. The company says this allowed it to improve the window cover in a minimum of space. Johnson Controls opted for what it calls polypropylene (PP) thin film for a variable degree of glossiness that can match other components’ finish. A Johnson Controls representative told MPW that the technology, which it presented for the first time at the 2007 Frankfurt Motor Show before launching it at the end of last year, was used for the map pocket of the E-Class door panel and in the rear side panel of the new Mini Convertible. The PP thin film consists of a composite foil constructed from several—primarily PP—layers, which are manufactured in a direct mold-behind process. According to Johnson Controls, the film is extruded by its partner Nordenia, and then preformed at Johnson Controls’ production plant. The preformed film is then back-injection molded and inmold grained. The process allows all types of PP to be used as substrates, even fiberglass-reinforced and recycled materials. Johnson Controls says that unlike painted component surfaces, the foils are not easily scratched and since their gloss level can also be varied, they can more easily match the finish of adjacent components. Depending on the design, a one- or two-step production process can be applied, with a two-step system used for deep-molded products, like the map pockets in the doors. KraussMaffei’s (KM; Munich) machinery was utilized in three award-winning parts. A support element for the louvered grille of the Mercedes-Benz CLS Coupe took the top prize in the Body Exterior category, applying a metallic effect without extra painting. In the same category, KM won for a bodywork component on a forage harvester that used KM reaction machinery. In the Powertrain category, a glass-fiber-reinforced roll restrictor for the Opel Insignia was recognized. MPW mpw.plasticstoday.com You can find pictures of these winning parts online at www. plasticstoday.com/articles/johnson-controls-applies-pp-film. mpw.plasticstoday.com design@giannirusconi.it Safe Steady Made in Italy since 1954 info@triaplastics.com www.triaplastics.com Reliable CLICK mpw.plasticstoday.com/infolink MODERN PLASTICS WORLDWIDE • JULY/AUGUST 2009 19
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Modern Plastics Worldwide - July/August 2009 - dae uptlax

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