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ISSN 2053-7182<br />

<strong>March</strong> <strong>2015</strong><br />

NPE <strong>2015</strong>: TAKING OFF IN FLORIDA<br />

CONTINUOUS & BATCH MIXERS FOR PVC<br />

LATEST DEVELOPMENTS IN POLYOLEFINS<br />

UPDATE: SCREW & BARREL TECHNOLOGY


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contents<br />

05 Industry news<br />

PAGE 5<br />

German plastics processing on the rise; Uponor invests $18m to expand PEX in North<br />

America; Rapid returns to Sweden; ADS expands in Canada; Fullerenes for cable<br />

protection<br />

11 Reaching a century: polyolefin developments<br />

Separate testing procedures have found that polyolefin pipes are likely to last beyond<br />

PAGE 11<br />

100 years – in both pressure and non-pressure applications. Lou Reade reports<br />

19 Turning a profit: screws and barrels<br />

New concepts in screws and barrels help to extend machine lifetime and boost<br />

throughput<br />

PAGE 23<br />

23 Creating a stir with the latest mixers<br />

Pat Toensmeier reports on recent developments in continuous and batch mixers,<br />

including improvements in rotor and machine designs<br />

31 NPE: lifting off in Florida<br />

PAGE 31<br />

NPE <strong>2015</strong> kicks of this month. We look at why it is shaping up to be huge success, and<br />

preview a selection of new products that will be on show<br />

41 Technology: Materials<br />

42 Technology: Machinery<br />

PAGE 41<br />

46 Extruder of the month: Tubi<br />

48 Dates for your diary<br />

coming next issue<br />

❙ Control & Instrumentation ❙ Laboratory extruders ❙ Computer modelling software ❙ Plast preview issue<br />

contact us<br />

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AMI House, 6 Pritchard Street,<br />

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Tel: +44 (0)117 924 9442<br />

Fax: +44 (0)117 311 1534<br />

www.amiplastics.com<br />

➤ Click here to make sure you get your copy<br />

Head of business publishing: Andy Beevers E-mail: abe@amiplastics.com<br />

Editor: Lou Reade E-mail: lou@pipeandprofile.com<br />

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www.pipeandprofile.com <strong>March</strong> <strong>2015</strong> | PIPE & PROFILE EXTRUSION 3


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news<br />

IMCD and<br />

Dow extend<br />

agreement<br />

GKV: German plastics<br />

processing rises in 2014<br />

IMCD is to distribute Dow’s<br />

German plastics processors<br />

added significant jobs in<br />

Paraloid impact modifiers<br />

increased their turnover again<br />

Germany in 2014,” said<br />

and Surecel processing aids<br />

last year, showing accelerated<br />

Westerheide. “Our industry<br />

in Germany, Austria and<br />

growth compared to 2013 –<br />

now has more than 311,000<br />

Switzerland from 1 <strong>March</strong>,<br />

and faster growth than the<br />

employees, which continues<br />

and in the UK from 1 June.<br />

economy in general.<br />

the upward trend of recent<br />

The new agreement is an<br />

Total sales in 2014 in-<br />

years.”<br />

extension of a long-estab-<br />

creased by 2.6% to reach<br />

He was confident for the<br />

lished partnership between<br />

E59bn (US$67bn) according to<br />

coming year, based on the<br />

the two companies. It also<br />

Dirk Westerheide, president of<br />

latest survey of GKV members:<br />

complements the recent<br />

trade association GKV, which<br />

63% of respondents expected<br />

appointment of IMCD as<br />

produced the figures.<br />

increased turnover this year,<br />

Dow’s pan-European<br />

“This achieved a new<br />

while 30% expected no change<br />

distributor for its Tyrin<br />

record,” he said.<br />

and 7% predicted reduced<br />

chlorinated PE range.<br />

Domestic sales were up<br />

Westerheide: “Sales in 2014<br />

turnover.<br />

Paraloid, Tyrin and<br />

1.9% to E37.8bn (US$43bn),<br />

achieved a new record”<br />

However, he said that<br />

Surecel additives are used<br />

while exports grew 3.4% to<br />

Germany’s high energy costs<br />

as impact modifiers and<br />

E21.2bn (US$24bn). At the<br />

the sector’s 2,866 companies<br />

– which continue to rise<br />

processing aids in a wide<br />

same time, the amount of<br />

also grew by 2.6% in the same<br />

because of the expansion of<br />

range of PVC compounds.<br />

material processed, at 13.6m<br />

period, he added.<br />

renewable energy – could<br />

❙ www.imcdgroup.com<br />

❙ www.dow.com/additives<br />

tonnes, rose by 3%. The rise in<br />

the number of employees in<br />

“The mainly medium-sized<br />

companies in our industry<br />

derail this growth in future.<br />

❙ www.gkv.de<br />

Rapid Granulator returns to Swedish hands<br />

Swedish size reduction<br />

not be impacted by the sale.<br />

processing tyres, cables,<br />

product line, so the Rapid<br />

company Rapid Granulator has<br />

Eldan Recycling is a global<br />

aluminium and various other<br />

acquisition is complementary<br />

changed hands – switching<br />

supplier of recycling equip-<br />

scrap materials. It does not<br />

to its activities.<br />

from US-based Ipeg to<br />

ment and systems for<br />

have its own granulator<br />

Toni Reftman, managing<br />

Sweden’s Lifco.<br />

director of Lifco subsidiary<br />

Rapid is based in Bredaryd,<br />

Eldan Recycling, will assume<br />

Sweden, while its North<br />

responsibility for the Rapid<br />

American operations are in<br />

business.<br />

Cranberry Township, USA. All<br />

“This acquisition will bring<br />

Rapid employees are expected<br />

together two companies that<br />

to remain with the company,<br />

are able to offer a fully<br />

other than CEO Kirk Winstead,<br />

complementary portfolio –<br />

who will remain within Ipeg.<br />

making us in effect the world’s<br />

Republic Machine, previously a<br />

largest recycling machine<br />

division of Rapid Granulator<br />

company in our field,” said<br />

Inc, is now a subsidiary of Ipeg<br />

Reftman.<br />

and will remain within the<br />

❙ www.rapidgranulator.com<br />

group. Other Ipeg companies<br />

– such as ancillary supplier<br />

Eldan’s Toni Reftman will also<br />

Conair and shredder manufac-<br />

assume responsibility for the<br />

turer Republic Machine – will<br />

Rapid business<br />

www.pipeandprofile.com <strong>March</strong> <strong>2015</strong> | PIPE & PROFILE EXTRUSION 5


news<br />

Uponor invests $18m to<br />

expand PEX facility in US<br />

Eurocell to<br />

float in<br />

London<br />

Uponor is to expand produc-<br />

footprint will amount to more<br />

this expansion will ensure we<br />

Eurocell, a UK manufac-<br />

tion in the US by investing in<br />

than 650,000 sq ft in the area<br />

match forecast growth and<br />

turer and distributor of PVC<br />

its facility in Apple Valley,<br />

– on 50 acres of total property.<br />

demand for our PEX systems.”<br />

window, door and roof<br />

Minnesota.<br />

The expansion is needed in<br />

Uponor has added more<br />

products, is to float on the<br />

The company is making an<br />

order to meet estimated<br />

than 130 new jobs in the area<br />

London Stock Exchange.<br />

$18 million investment to<br />

growth for PEX tubing in<br />

over the past three years<br />

The company generated<br />

expand production of cross-<br />

plumbing, fire sprinkler,<br />

– taking the total to around 500<br />

sales of £173.1 million in<br />

linked polyethylene (PEX) pipe<br />

radiant heating and cooling<br />

– and expects to add more<br />

2014, and EBITDA of<br />

at the plant. The extra 88,000<br />

and hydronic piping systems<br />

following the expansion. This<br />

£26.1m. The profiles<br />

sq ft will accommodate new<br />

used in residential and<br />

year marks the compay’s<br />

division accounted for 42%<br />

equipment and office space.<br />

commercial structures.<br />

25-year anniversary in Apple<br />

of sales, and the building<br />

Construction is expected to be<br />

“It’s an exciting time in the<br />

Valley.<br />

plastics division 58%.<br />

finished by the end of the year.<br />

building industry, especially<br />

Uponor CEO and president<br />

Patrick Bateman, CEO of<br />

The company’s North<br />

after the downturn we<br />

Jyri Luomakoski added: “Our<br />

Eurocell, said: “Over the<br />

American headquarters are<br />

experienced just a few years<br />

North American region has<br />

last few years, Eurocell has<br />

also located in Apple Valley,<br />

ago,” said Bill Gray, Uponor<br />

consistently boosted profits<br />

developed a leading UK<br />

while it has a distribution<br />

North America president.<br />

and seized market share, both<br />

position in window, door and<br />

centre and resin-processing<br />

“We’re seeing significant<br />

in the residential commercial<br />

roofline PVC products. This<br />

centre in nearby Lakeville. By<br />

growth in commercial and<br />

segments.”<br />

is supported by our national<br />

year-end, the company’s<br />

residential construction, and<br />

❙ www.uponor-usa.com<br />

network of branded<br />

branches. This has enabled<br />

Uponor will expand its<br />

us to deliver adjusted<br />

North American plant<br />

EBITDA growth of 57.0%<br />

by 88,000 sq ft<br />

and 70.8% for the year<br />

ended 31 December 2013<br />

and 2014, respectively.”<br />

Eurocell was founded in<br />

the UK in 1974. It was<br />

owned by Tessenderlo of<br />

Belgium between 2008 and<br />

2013 – when it was acquired<br />

by H2 Equity Partners.<br />

❙ www.eurocell.co.uk<br />

Advanced Drainage Systems makes Ideal move<br />

Advanced Drainage Systems<br />

“The acquisition of Ideal<br />

competitive position compared<br />

adding to existing ADS factories<br />

(ADS), a global manufacturer of<br />

<strong>Pipe</strong> further strengthens our<br />

to manufacturers of concrete,<br />

in Ontario and Quebec.<br />

corrugated pipe, has acquired<br />

position in Canada by increas-<br />

steel and PVC pipe.”<br />

The acquisition also extends<br />

Ideal <strong>Pipe</strong> of Canada for<br />

ing our size and scale in the<br />

With the acquisition, ADS<br />

the combined company’s<br />

CAN$56.8 million (US$45.7m).<br />

market, and enhancing our<br />

increases its Canadian<br />

Canadian field sales and<br />

Ideal, which makes HDPE<br />

manufacturing, marketing and<br />

manufacturing footprint from<br />

engineering staff, allowing<br />

pipe and related accessories,<br />

distribution capabilities,” said<br />

two to five facilities.<br />

ADS to leverage products like<br />

had sales of CAN$43m<br />

Joe Chlapaty, chairman and<br />

Ideal has manufacturing<br />

its Allied line through Ideal’s<br />

(US$34.5m) for the last 12<br />

CEO of ADS.<br />

plants in Western Ontario,<br />

sales network.<br />

months.<br />

“This puts us in a stronger<br />

Eastern Ontario and Manitoba,<br />

❙ www.ads-pipe.com<br />

6<br />

PIPE & PROFILE EXTRUSION | <strong>March</strong> <strong>2015</strong><br />

www.pipeandprofile.com


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news<br />

Fewer plastic pipe sites in Europe<br />

The number of plastic pipe<br />

extrusion sites in Europe has<br />

fallen by nearly a quarter in<br />

the last 15 years.<br />

According to AMI’s<br />

directory of plastic pipe<br />

extruders in Europe, there<br />

were 625 sites in 2001 and<br />

just 480 today – an overall<br />

reduction of 23%.<br />

In 2008, the total was 559<br />

sites – around 12% higher that<br />

today.<br />

The worst affected areas<br />

have been Spain, Italy, France<br />

and the UK – which accounted<br />

for 60-70% of the site<br />

Other<br />

Central<br />

Eastern Europe<br />

11%<br />

Other<br />

West Europe<br />

10%<br />

Benelux<br />

6%<br />

Nordic<br />

7%<br />

Spain<br />

7%<br />

Germany<br />

20%<br />

UK<br />

8%<br />

France<br />

9%<br />

Italy<br />

13%<br />

Distribution of plastic pipe<br />

production in Europe, 2014<br />

Source: AMI, <strong>2015</strong><br />

Poland<br />

9%<br />

reduction in Europe. The most<br />

common reason for plant<br />

closures has been either<br />

group rationalisation within<br />

a country or the transfer<br />

of production abroad.<br />

However, there have also<br />

been many bankruptcies<br />

and acquisitions resulting<br />

from liquidation.<br />

Germany is still Europe’s<br />

largest producer of plastic<br />

pipes, with 20% of production in<br />

2014. This has increased over<br />

recent years as it is the only<br />

West European country that has<br />

seen output recover to 2007<br />

levels of demand.<br />

European production of<br />

plastics pipes is still around<br />

20% below that of 2007.<br />

A second AMI report, a<br />

review of the market’s top 50<br />

players, puts Wavin (now part<br />

of Mexichem), <strong>Pipe</strong>life and<br />

Russia’s rapidly expanding<br />

Polyplastic in the top three<br />

positions.<br />

The top 10 companies<br />

account for 40% of production<br />

by volume. AMI estimates that<br />

the industry is worth around<br />

€7.5bn.<br />

❙ www.amiplastics.com<br />

Window<br />

maker sells<br />

division<br />

AmesburyTruth, a US-based<br />

manufacturer of window<br />

and door components, is to<br />

sell its non-fenestration<br />

custom extrusion business<br />

to VIP Rubber and Plastic<br />

Products.<br />

The 72,000 sq ft facility,<br />

in Ontario, California,<br />

employs 50 people and<br />

makes both fenestration and<br />

non- fenestration products.<br />

The company will now move<br />

its fenestration opeations to<br />

a facility in Minnesota.<br />

“Our goal is to be North<br />

America’s number one<br />

supplier of window and<br />

door components,” said<br />

AmesburyTruth president<br />

Jeff Graby.<br />

AmesburyTruth is a<br />

subsidiary of UK-based<br />

Tyman.<br />

❙ www.amesburytruth.com<br />

Fullerenes shown to protect<br />

plastics insulation in cables<br />

Researchers from Borealis and<br />

the Chalmers University of<br />

Technology in Sweden have<br />

demonstrated the use of<br />

fullerenes to protect plastics<br />

insulation in highvoltage<br />

cables.<br />

They say that the<br />

nanometre-sized<br />

carbon balls enable<br />

polyethylene to<br />

withstand a 26% higher<br />

voltage, which could<br />

increase the efficiency of<br />

power grids in the future.<br />

The research work involved<br />

the addition of very small<br />

amounts of different variants<br />

of the C 60<br />

carbon ball, a<br />

nanomaterial in the fullerene<br />

molecular group that is also<br />

known as a buckminsterfullerene<br />

or bucky-ball. Such<br />

materials have already been<br />

tested in the conductive parts<br />

of high-voltage cables, but it is<br />

Fullerenes can<br />

help to prevent<br />

the formation of<br />

electrical trees in<br />

high-voltage cable<br />

insulation<br />

believed that<br />

this is the first<br />

time that it has<br />

been shown they can bring<br />

benefits to the insulation<br />

material.<br />

The Chalmers researchers<br />

say that fullerenes are the best<br />

voltage stabilizers identified<br />

for insulation plastics thus far.<br />

They help to capture electrons,<br />

preventing them from<br />

destroying other molecules<br />

and forming electrical trees<br />

within the plastic.<br />

A paper on the initial<br />

research, entitled “A new<br />

application area for fullerenes:<br />

voltage stabilizers for power<br />

cable insulation”, has recently<br />

been published in the Advanced<br />

Materials journal. The next<br />

stage of the project will involve<br />

testing the technology on a large<br />

scale in complete high-voltage<br />

cables with both alternating<br />

current and direct current.<br />

❙ www.chalmers.se<br />

8<br />

PIPE & PROFILE EXTRUSION | <strong>March</strong> <strong>2015</strong><br />

www.pipeandprofile.com


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Polyolefin developments | materials feature<br />

Separate testing procedures have found that polyolefin pipes are<br />

likely to last beyond 100 years – in both pressure and non-pressure<br />

applications. Lou Reade reports<br />

Reaching a century:<br />

polyolefin developments<br />

An independent project, commissioned by The European<br />

Plastic <strong>Pipe</strong>s and Fittings Association (Teppfa), has<br />

concluded that polyolefin sewer pipes have a service<br />

lifetime expectancy of at least 100 years. The results of<br />

the two-year project were scrutinised by Heinz Dragaun<br />

from the Technical School for Higher Education (TGM) in<br />

Vienna.<br />

The starting point for the project was that predicting<br />

life expectancy of pressure pipes is well documented,<br />

but this is not the case for non-pressure applications in<br />

sewage and drainage. The project studied pipes made<br />

from PE and PP-B by investigating thermo-oxidative<br />

degradation, maximum allowed stress, long-term<br />

behaviour under constant strain and the effect of sewer<br />

conditions (such as chemicals) and temperature.<br />

The project involved the excavation of many samples<br />

from in-service pipe networks, which were then tested<br />

and assessed in the laboratory. The findings are<br />

expected to favourably influence sewer operators that<br />

are faced with major capital investment in new or<br />

replacement networks, said Teppfa.<br />

“Designers, owners and operators of sewer networks<br />

can be confident that these sewer systems will<br />

have an in-service life of at least 100 years when<br />

materials, products and installation practices meet the<br />

appropriate requirements,” said Tony Calton, Teppfa<br />

general manager. “It will lend further appeal and allow<br />

polyolefin sewer pipes to be specified with increased<br />

confidence as they perform consistently throughout<br />

their very long asset life.”<br />

Many European countries have old sewer networks<br />

that need to be modernised or replaced. Life expectancy<br />

is a critical factor in any investment decision. Polyolefin<br />

pipe systems have been widely used for over 40 years<br />

and compared to non-plastic pipe materials, they have<br />

consistently offered a longer term solution. However,<br />

Dow’s PE-RT<br />

pipes have<br />

achieved the<br />

highest<br />

chlorine<br />

resistance<br />

classification<br />

www.pipeandprofile.com <strong>March</strong> <strong>2015</strong> | PIPE & PROFILE EXTRUSION 11


materials feature | Polyolefin developments<br />

A PE100+<br />

project aimed<br />

to evaluate butt<br />

fusion test<br />

methods for<br />

large PE pipe<br />

Dow’s Hypertherm<br />

2399<br />

PE-RT material<br />

allows<br />

installers to<br />

bend water<br />

lines at turning<br />

joints to ease<br />

installation<br />

whereas the life expectancy of polyolefin pipes has been<br />

discussed for many years, a definitive conclusion has<br />

never been determined.<br />

Excavated pipes that were tested had already been in<br />

use for up to 40% of their proposed in-service lifetime.<br />

The tests showed that no excessive deterioration or<br />

degradation has occurred over this time.<br />

“Although the oldest excavated pipes were manufactured<br />

using ‘first generation’ material formulations, a<br />

residual lifetime of more than 50 years was calculated,”<br />

said Calton. “And we should also bear in mind that<br />

current formulations offer even greater lifetime<br />

performance than those earlier materials.”<br />

Other key factors investigated in project were found<br />

not to affect life expectancy adversely. These included:<br />

the chemical composition of the sewer water; the<br />

temperature profile of sewer flows; and variations in the<br />

kind of installation practices used. The influence of<br />

higher concentrations of sewer effluent that are<br />

typically associated with structured wall pipe systems<br />

was also examined.<br />

The full technical report and a summary technical<br />

report are available on Teppfa’s website, as is a<br />

four-page leaflet outlining the project scope. The<br />

project was co-ordinated by Teppfa in conjunction with<br />

LyondellBasell, Borealis and TGM (Austria).<br />

Joining assessment<br />

PE 100+, the industry organisation for suppliers PE 100<br />

pipe materials, recently carried out a project to assess<br />

the joining – and testing – of large diameter, thickwalled<br />

PE pipe. It has been working to further develop<br />

test methods and harmonise global standards for butt<br />

fusion procedures, and endorse their suitability for this<br />

type of pipe.<br />

“Test methods for butt fusion welds are potentially<br />

misleading, and they exist in ISO, European and many<br />

national and industry standards,” said Steve Beech, who<br />

led the butt fusion harmonsation project.<br />

There are short-term destructive tests, which<br />

include a variety of tensile tests on small specimens cut<br />

from the weld, impact tests, pressure tests and tensile<br />

tests on whole pipe assemblies. Long-term tests<br />

include creep tests on full thickness specimens, Full<br />

Notch Creep Tests (FNCTs) and pressure tests on the<br />

pipe assembly.<br />

The key to success for the project has been the<br />

evaluation of test methods to fully understand shortand<br />

long-term properties of the welds. An important<br />

aim was to evaluate welds in large diameter, thick<br />

walled pipe with a range of wall thicknesses. This was<br />

done by short term, long term and Full Notched Creep<br />

testing.<br />

The minimum service life of the butt welds tested<br />

was estimated in accordance with Vogt et al. A maximum<br />

longitudinal stress of 4MPa, a result of the<br />

maximum design hoop stress of 8MPa for an unrestrained<br />

PE 100 pipeline, gives a conservatively<br />

estimated lifetime of 215 years at 20°C in water. Based<br />

on this calculation, it can be safely concluded that for<br />

water and gas applications at 20°C, a properly made PE<br />

100 butt fusion joint is predicted to achieve a service life<br />

well in excess of 100 years.<br />

Overall, the results of the project indicate that<br />

rationalisation and some harmonisation of the three<br />

procedures could take place – if the industry is willing<br />

to do this, said Beech.<br />

Bending round corners<br />

Dow has launched Hypertherm 2399, a polyethylene<br />

resin for domestic and commercial hot and cold water<br />

plumbing pipes. The PE-RT material enhances pipe<br />

flexibility, allowing installers to bend water lines at<br />

turning joints to ease installation.<br />

“Turning joints have always been a challenge when<br />

installing copper, steel and rigid plastic pipe,” said Oray<br />

Talu, market manager for Dow pipe and irrigation<br />

12<br />

PIPE & PROFILE EXTRUSION | <strong>March</strong> <strong>2015</strong><br />

www.pipeandprofile.com


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materials feature | Polyolefin developments<br />

Sabic has<br />

completed its<br />

Vestolen A<br />

portfolio with<br />

an orange<br />

HDPE grade for<br />

gas distribution<br />

pipe<br />

products. “These are typically the first points of failure<br />

and a major contributor to call-backs.”<br />

Dow’s new material eliminates the need for breaks<br />

at joints, which reduces the likelihood of leaks.<br />

According to Dow, the resin is the first product to meet<br />

US building codes and product standards for plumbing<br />

while also achieving Level 5 chlorine-resistance certification.<br />

This accreditation gives contractors and homebuilders<br />

the flexibility to install continuous loop, on-demand<br />

recirculation, and traditional plumbing systems.<br />

The material can be used as a drop-in replacement<br />

for cross-linked polyethylene (PEX), with minimal<br />

tooling changes.<br />

At the same time, pipes made from Dow’s Dowlex<br />

2388 PR-RT resin have received the highest chlorine<br />

resistance certification (Class 5). The certification was<br />

issued by Jana Laboratories in Canada. The pipes were<br />

subjected to different temperatures and pressures at a<br />

chlorine concentration of 4.4 ppm and have been tested<br />

for more than two years until a failure could be<br />

observed.<br />

Meanwhile, Sabic has completed its Vestolen A pipe<br />

portfolio with a new orange high density polyethylene<br />

(HDPE) grade for gas distribution.<br />

The grade, Vestolen A 6060R, is long-lasting and can<br />

be used for mono- as well as for multi-layer co-extruded<br />

pipes. It has good resistance to slow crack growth<br />

and rapid crack propagation, as it is classified as a<br />

PE100 compound and comes with a 10.0 MRS (Minimum<br />

Required Strength) rating.<br />

The grade builds on the existing Vestolen A range<br />

which is known as a reliable, low weight and easy to<br />

install HDPE material, says Sabic.<br />

Louis Loos, segment leader for pipes at Sabic said:<br />

“We will continue to invest in the pipe industry, to anticipate<br />

its future developments and requirements.”<br />

Because die deposits are significantly reduced<br />

during the extrusion process of the new grade, it also<br />

offers benefits to converters as the production process<br />

does not need to be interrupted as frequently as when<br />

using standard material – meaning that higher levels of<br />

throughput can be achieved.<br />

“When developing new materials we pay particular<br />

attention to the conversion process. Vestolen A 6060R is<br />

an example of how we support converters to optimise<br />

their production process,” said Ralph Handstanger,<br />

technical marketing engineer for HDPE at Sabic Europe.<br />

Multi-layer performance<br />

Massimiliano Fenili, technical manager of Tecnomatic,<br />

told delegates at last year’s <strong>Pipe</strong>s in Infrastructure<br />

conference in Dusseldorf that multi-layer pipe can<br />

boost performance, and perform beyond the capability<br />

PEX guidance<br />

A 144-page design guide on cross-linked polyethylene (PEX) has recently been completely updated.<br />

The Residential PEX Water Supply Plumbing Systems Design Guide is now available online. The<br />

guide, which includes expanded information on green construction codes, can help homeowners,<br />

designers, builders, plumbers and architects plan and understand the features and benefits of a<br />

PEX pipe residential water system.<br />

It includes comprehensive design concepts and installation guidelines for the proper use of<br />

PEX pipe systems. The guide was a collaborative effort between the Plastics <strong>Pipe</strong> Institute (PPI),<br />

Home Innovation Research Labs, International Code Council (ICC) and Plastic <strong>Pipe</strong> and Fittings<br />

Association (PPFA), and can be downloaded from the websites of all four organisations.<br />

“This edition includes many enhancements to manage increased usage of PEX systems in a<br />

variety of residential applications such as water reuse and retrofitting,” said Randy Knapp,<br />

director of engineering of PPI’s Building and Construction Division (BCD).<br />

New information was added to almost every chapter including standards, all applicable<br />

national plumbing, mechanical, and building codes including new green construction codes, updates to fitting systems, and new<br />

design information on fixture flow rates and water hammer.<br />

14<br />

PIPE & PROFILE EXTRUSION | <strong>March</strong> <strong>2015</strong><br />

www.pipeandprofile.com


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materials feature | Polyolefin developments<br />

System Group’s<br />

Sow Flow AMR<br />

pipe is intended<br />

for use in<br />

drainage<br />

systems on<br />

steep hills<br />

of single-walled pipe.<br />

He cited the case of Omani pipe extruder Muna Noor,<br />

which has commissioned an extrusion line from<br />

Tecnomatic to make multi-layer PE pipe – the first in<br />

the Middle East, it says. The line has an output of up to<br />

2000 kg/h, making pipes with a maximum diameter of<br />

1200mm.<br />

Muna Noor, part of Kuwait’s Boubyan Petrochemical,<br />

specialises in the production of PE pipe in sizes up to<br />

800mm. It recently opened a new factory in Sohar to<br />

produce PP double wall corrugated sewer pipes up to<br />

1200mm, plus fittings, manholes and PE multilayer<br />

safety pipes. The pipes are produced under a technology<br />

licence from Wavin Overseas.<br />

Multilayer pipe offers a practical solution to problems<br />

in the installation and jointing of PE systems, providing<br />

high security at minimum additional cost. By combining<br />

the best materials for specific loading conditions, they<br />

provide protection and long-time durability. The new<br />

generation of pipe will be ideal for the poor, stony soils<br />

of the Oman and other Middle East countries – which<br />

can produce high stresses in the pipe wall.<br />

One answer is to use High Stress Crack Resistance<br />

(HSCR) PE 100 materials – such as BorSafe HE3490-<br />

LS-H HSCR PE100 from Borouge in this project.<br />

The materials are ideal for rocky soil conditions<br />

where no imported pipe surround is available, and are<br />

equally resistant to Slow Crack Growth (SCG) caused by<br />

external surface damage and point loads. The materials<br />

can be used for pipes that are installed using a wide<br />

variety of trenchless technology – from the renovation of<br />

existing pipelines using insertion or pipe-bursting<br />

techniques, to installing new pipes using high speed<br />

ploughing or horizontal directional drilling.<br />

At the same event, System Group of Italy presented<br />

details of an HDPE pipe system that is engineered to<br />

make water flow more slowly – such as when it is<br />

running down a steep hill.<br />

Its corrugated HDPE pipes have an artificially<br />

introduced roughness on the inner surface, in order to<br />

hinder the flow of water. The system is called Slow Flow<br />

AMR. The pipe is the result of research at Bari Polytechnic.<br />

Marco Maroncelli, marketing manager, told delegates<br />

that the inner surface roughness leads to<br />

turbulence which limits the speed of water flow. The<br />

pipes can be combined with ‘vortex’ manholes to further<br />

reduce water velocity in sewage and drainage systems.<br />

l Proceedings for the conference are available for<br />

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Click on the links for more information:<br />

❙ www.teppfa.org<br />

❙ www.pe100plus.com<br />

❙ www.dow.com<br />

❙ www.sabic.com<br />

❙ www.tecnomaticsrl.net<br />

❙ www.boubyan.com (Muna Noor)<br />

❙ www.borouge.com<br />

❙ www.tubi.net (System Group)<br />

❙ www.plasticpipe.org<br />

❙ www.ppfahome.org<br />

❙ www.iccsafe.org<br />

❙ www.homeinnovation.com<br />

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Screws & barrels | machinery feature<br />

New concepts in screws and<br />

barrels help to extend<br />

component lifetime and<br />

boost throughput<br />

Turning a profit:<br />

screws and barrels<br />

Screws and barrels are at the coalface of plastics<br />

processing, and are often the components that wear<br />

down first. So, enhancing wear resistance can be the<br />

first consideration for extending machine lifetime.<br />

Nordson Xaloy Europe has developed a bimetallic<br />

barrel alloy with enhanced resistance to corrosive and<br />

abrasive wear, which extends the working life of<br />

extrusion barrels in general-purpose applications.<br />

The key to the corrosion resistance of the X220 alloy<br />

is its higher chromium content relative to other barrel<br />

inlays for general-purpose use – twice that of Nordson<br />

Xaloy’s own X200 inlay and greater than the standard<br />

alloy in Europe, says the company. The new inlay also<br />

has greater hardness: 64 to 69 on the Rockwell HRC<br />

scale, versus 58 to 65 for the X200.<br />

In acid immersion tests of sample weight loss, X220<br />

alloy exhibited a 55% improvement over other European<br />

alloys in sulphuric acid and a 44% improvement in<br />

hydrochloric acid.<br />

“The new X220 inlay improves productivity and<br />

product quality through better screw-to-barrel fit,<br />

reduces downtime, and prolongs the working life of the<br />

barrel,” according to David Hotchkiss, global product<br />

manager.<br />

A bimetallic inlay is a high-hardness alloy that lines<br />

the inner wall of the barrel. As general-purpose inlays,<br />

the iron-based X200 and the iron-chromium-based X220<br />

can be used with a wide range of polyolefin, styrenic,<br />

and other resins at filler loadings up to 15%. For vinyls,<br />

certain fluoropolymers, and other potentially corrosive<br />

resins, Nordson Xaloy supplies the X306 nickel-cobalt<br />

alloy. The tungsten carbide/nickel-based alloy X800<br />

provides high wear and corrosion resistance for highly<br />

filled resins and high-temperature engineering<br />

polymers.<br />

Expanded output<br />

US-based Reiloy Westland – part of Germany’s<br />

Reifenhäuser since 2012 – is in the process of building a<br />

new facility to help it increase output of screws and barrels.<br />

The new plant, in Maize, Kansas, is eight miles<br />

from the company’s existing facility in Wichita and – at<br />

55,000 sq ft – more than twice its size.<br />

The company has already ordered a Weingärtner<br />

MPMC 600-6000 – a 5-axis, multi-purpose machining<br />

centre that will be used to make both screws and<br />

barrels.<br />

It will be delivered in July this year, by which time<br />

the new plant is expected to be ready.<br />

“It increases the dimensional capacity of the<br />

products we can manufacture,” the company said.<br />

The company intends to be very active at this<br />

year’s NPE, with a number of new products and<br />

concepts on show. For starters, it will introduce its<br />

new patent-pending mixing screw. Based on the<br />

Eagle mixing screw, which the company first<br />

introduced in 1991, it has undergone multiple<br />

redesigns over its history.<br />

s<br />

A new mixer<br />

screw from<br />

Reiloy Westland<br />

is based<br />

on its earlier<br />

Eagle screw<br />

Reiloy<br />

Westland’s<br />

NPE app will<br />

help visitors<br />

negotiate the<br />

show<br />

www.pipeandprofile.com <br />

<strong>March</strong> <strong>2015</strong> | PIPE & PROFILE EXTRUSION<br />

19


machinery feature | Screws & barrels<br />

KraussMaffei<br />

Berstorff’s Eco-<br />

Line microwave<br />

channels have<br />

helped<br />

Trelleborg<br />

reduce energy<br />

costs<br />

The low-shear mixer – which Reiloy Westland sees<br />

as being appropriate to all types of plastics processing<br />

applications, including extrusion – provides both<br />

dispersive and distributive mixing, improves isothermal<br />

melt quality and increases throughput. The new concept<br />

will be seen at the show.<br />

“The projected quality mixing obtained, without<br />

introducing excessive shear, will offer improved<br />

profitability,” said the company.<br />

Another new concept is a special ‘NPE app’, which<br />

will allow visitors to make their visit to the event easier.<br />

As well as advice on travelling to Orlando and a guide to<br />

the city, users can register their attendance at the show<br />

and book appointments with the company.<br />

The app also includes the latest edition of the<br />

company’s Barrel and Screw Handbook.<br />

Microwave seal<br />

Sometimes, special applications dictate that the<br />

traditional approach of plasticising using a screw alone<br />

is not appropriate. This was the case with Trelleborg, a<br />

Swedish producer of sealing profiles for the automotive<br />

and building industries – which has begun using two<br />

EcoLine microwave channels from KraussMaffei<br />

Berstorff.<br />

Trelleborg first saw the technology in action at a<br />

KraussMaffei open house event, and signed the<br />

purchase order for the two lines at K2013. The reason<br />

for the investment was to reduce operating costs in the<br />

energy-intensive vulcanization process.<br />

“In view of the results – in terms of productivity and<br />

quality – we decided to opt for this solution to further<br />

increase our productivity,” said Joakim Hansson,<br />

purchasing manager at Trelleborg.<br />

Four microwave channel modules are each equipped<br />

with a generator of 6kW magnetron power. A circulator<br />

integrated into the energy supply transfers any energy<br />

not absorbed by the product to the connected water<br />

load, to improve magnetron service life.<br />

The channel has a total installed magnetron power<br />

of 24kW. The microwave generators are arranged above<br />

and below the conveyor belt. The microwave coupling<br />

system is designed to ensure a homogeneous field<br />

distribution. Both the microwave power and conveyor<br />

belt speed can be continuously adjusted. The microwave<br />

channel has an effective cross-section of 280mm width<br />

and 150mm height.<br />

A central control panel ensures that system settings<br />

can be selected with ease. A process-oriented user<br />

interface helps to reduce set-up times during material<br />

changes.<br />

“Special features of the EcoLine microwave channel<br />

are reduced waste gas losses and the energy-optimised<br />

switched-mode power supplies,” said Helmut Lüders,<br />

product manager for rubber profile production lines at<br />

KraussMaffei Berstorff.<br />

“Closed circulation of the process air provides<br />

maximum cost savings, as 90% of the energy-intensive<br />

hot air remains in the system.”<br />

Another new feature is improved thermal insulation<br />

of the process chambers, he said.<br />

Nordson Xaloy’s bimetallic barrel alloy shows high resistance to acid<br />

immersion<br />

Click on the links for more information:<br />

❙ http://reiloyusa.com<br />

❙ www.nordsonpolymerprocessing.com<br />

❙ www.kraussmaffeiberstorff.com<br />

20<br />

PIPE & PROFILE EXTRUSION | <strong>March</strong> <strong>2015</strong><br />

www.pipeandprofile.com


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PVC Formulation <strong>2015</strong><br />

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Mixers for PVC | machinery feature<br />

Creating a stir with<br />

the latest mixers<br />

Pat Toensmeier reports<br />

on recent developments in<br />

continuous and batch mixers, including<br />

improvements in rotor and machine designs<br />

Suppliers of batch and continuous mixers are developing<br />

improved machine designs to meet compounders’<br />

changing demands to produce the latest materials<br />

formulations more efficiently. These requirements<br />

include:<br />

l Material versatility and innovation: Compounders are<br />

running more specialty resins and ingredients, and in the<br />

process dealing with formulations that need fine-tuning<br />

to achieve the required properties. Mixers are being<br />

upgraded with special equipment and capabilities that<br />

allow process tailoring for creating innovative materials.<br />

l Higher throughput: Increased productivity means an<br />

improved return on investment, but only if materials<br />

meet quality standards. Mixing systems are being<br />

engineered for high throughputs, notably in screw, rotor<br />

and mixing-blade designs that boost output with no<br />

trade-offs in quality.<br />

l Energy efficiency: Cost savings go right to the bottom<br />

line. In some countries, reductions in energy also<br />

satisfy regulatory standards.<br />

l Automation: Reducing manual input saves money and<br />

assures consistent quality in batch and continuous<br />

machines.<br />

l Profitability: Many high-tech compounds go into<br />

commodity applications, putting downward pressure on<br />

production prices. The ability of mixing to improve<br />

margins is an important tactic in a strategy aimed at<br />

increasing profitability.<br />

Over the following pages we review recent continuous<br />

and batch mixer developments from Farrel Pomini,<br />

TPEI, Ajax Equipment, B&P Process Equipment, Mixaco,<br />

Promixon and Marion Mixers.<br />

Continuous improvements<br />

Recent developments at Farrel Pomini include the<br />

extension of the CP (Compact Processor) Series II range<br />

of continuous mixers. Launched this year, the CP4000<br />

achieves a nominal throughput of 4,000 kg/hour (8,800<br />

lb/hr) and bridges the gap between modular continuous<br />

mixers that are integrated into a unitized frame, and the<br />

company’s higher-output non-unitized designs that can<br />

process materials at rates above 6,000 kg/hour.<br />

The CP4000 is the seventh and final model in the<br />

line, says Paul Lloyd, business unit director at Farrel in<br />

the US. This is because the unitized frame of the<br />

modular series cannot be duplicated for higher output<br />

mixers. “Any mixer with throughput above 4,000 kg/hour<br />

will require different construction,” he explains. “The<br />

Farrel Pomini’s<br />

new CP4000<br />

mixer has a<br />

number of<br />

process<br />

variables that<br />

improve mixing<br />

and throughput<br />

www.pipeandprofile.com <strong>March</strong> <strong>2015</strong> | PIPE & PROFILE EXTRUSION 23


machinery feature | Mixers for PVC<br />

Farrel Pomini’s CP4000 bridges the gap<br />

between standard continuous mixers<br />

and non-unitized, high-output<br />

models<br />

CP4000 is the maximum size for this platform concept.”<br />

Two CP4000 mixers have been sold to undisclosed<br />

compounders in Europe, Lloyd reports. The new larger<br />

model is more expensive than previous sizes, as you’d<br />

expect, but is claimed to deliver a better return-oninvestment.<br />

“Volume helps [the bottom line] in our<br />

business. Customers can expect lower cost per<br />

kilogram and better ROI with the CP4000,” he says.<br />

CP Series II sizes range from 125 to 4,000 kg/hour<br />

– the number of each machine denotes nominal<br />

throughput in kilograms. Each system has an integrated<br />

mixer and extruder, as well as a controller that<br />

regulates upstream and downstream equipment.<br />

Systems are wired, piped, pre-tested and shipped ready<br />

for installation.<br />

The mixer mounts on top of the frame and accepts<br />

multiple feed systems and material types. It has a<br />

gravity chute through which processed material<br />

FR rotors from discharges to a hot-feed extruder below. This is<br />

TPEI are equipped with a pumping screw (to minimize heat<br />

installed with build-up), screen-changer and pelletizing system.<br />

couplings, so Each mixer is equipped with twin-lobe, elliptic,<br />

the driveshaft counter-rotating, non-intermeshing rotors that produce<br />

bearing block distributive mixing while maintaining short residence<br />

doesn’t need to time and, consequently, a low heat history in materials<br />

be accessed and lower-than-average energy use.<br />

Two rotor versions are available for the mixers: the<br />

standard FCM (48 to 203.2 mm in<br />

diameter), and a CPXL or extra-long<br />

version optimized for high<br />

filler loadings, temperaturesensitive<br />

materials and<br />

reduced energy use. The FCM<br />

rotors have 6:1 L/D ratios,<br />

while CPXL versions have two<br />

stages and 10:1 ratios.<br />

The mixers handle diverse<br />

materials. These include: highly filled and pigmented<br />

polyolefins, PVC, styrenics, polyamides, polyesters,<br />

polycarbonate and thermoplastic elastomers (TPEs);<br />

calcium carbonate, titanium dioxide, carbon black and<br />

colorant masterbatches; flame-retardant compounds;<br />

recyclates; and biopolymers.<br />

Self alignment<br />

An important feature of the CP machines is their<br />

modularity, and Farrel Pomini has been adding<br />

components to optimize processing. The latest is the<br />

Self-Aligning Seal (SAS), which was developed by R&D<br />

manager Stuart Sardinskas based on customer<br />

feedback. The device provides a solid mechanical seal<br />

that keeps pellets and powders within the feed section<br />

of the mixing chamber.<br />

The SAS uses an air cushion to automatically align<br />

with the outer-diameter clearance of the rotor shafts.<br />

This maintains an impervious seal that prevents<br />

material migration. Lloyd says that although the CP<br />

mixers are designed for starve-feeding, they sometimes<br />

back up, which is when the seal is especially useful.<br />

The device is available on new machines and as a<br />

retrofit.<br />

Other components allow compounders to fine-tune<br />

processing. Farrel Pomini has long maintained that by<br />

adjusting a handful of process variables – feed rate,<br />

rotor speed, chamber temperature and the throttle gate<br />

output – its continuous mixers can produce a range of<br />

compounds without changing their hardware.<br />

Adjustable mixing-dam assemblies, for example, can<br />

be raised or lowered as necessary to restrict flow and<br />

thereby increase energy and shear during mixing,<br />

rather than wait until material reaches the orifice,<br />

which regulates discharge to the extruder. They can<br />

also be configured to accept ports for additives.<br />

A vent plunger regulated by a timer can be added at<br />

the end of the mixer to automatically vent moisture and<br />

other volatiles while enhancing throughput rates. Lloyd<br />

says the device is more efficient than conventional<br />

stationary vents, which may clog during operation and<br />

require immediate cleaning.<br />

▲<br />

24<br />

PIPE & PROFILE EXTRUSION | <strong>March</strong> <strong>2015</strong><br />

www.pipeandprofile.com


You make<br />

great things.<br />

We make great<br />

things happen.<br />

In <strong>March</strong> <strong>2015</strong>, more than 60,000 professionals from every aspect of the<br />

plastics industry and its vertical and end-user markets will assemble in<br />

Orlando, Florida for the largest, most influential plastics event of the year.<br />

Expect great things.<br />

Register for free today at www.npeguestpass.org/<strong>Pipe</strong>2<br />

NPE<strong>2015</strong>: THE INTERNATIONAL PLASTICS SHOWCASE<br />

<strong>March</strong> 23-27, <strong>2015</strong><br />

Orange County Convention Center<br />

Orlando, Florida USA<br />

Face-To-Face, NPE2012


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Mixers for PVC | machinery feature<br />

The orifice is adjustable to control melt<br />

residence time. The device opens to<br />

whatever degree is necessary to<br />

increase or decrease work to the<br />

material prior to discharge.<br />

Free rotor<br />

Another supplier of continuous<br />

mixers, Technical<br />

Process & Engineering Inc<br />

(TPEI) continues to upgrade<br />

and expand a design it<br />

commercialized several years<br />

ago – its Free Rotor (FR)<br />

machines.<br />

FR rotors are three-piece<br />

constructions that are installed<br />

without opening a machine’s driveshaft<br />

bearing block. This is possible because<br />

the rotor shafts are separate from the rotor body. The<br />

rotor itself is installed with couplings, says engineer<br />

Jim Hower. This facilitates installation and doesn’t<br />

expose bearings to contaminants.<br />

FR models also come in extended FRE versions,<br />

which lengthen the rotor body by 1 L/D. Hower says this<br />

permits an extension of the feed chamber, which<br />

improves the feeding and processing of lightweight and<br />

other hard-to-feed materials such as recyclate.<br />

Eight models of the FR and FRE mixers are available<br />

– two in FR configurations and six in FRE versions.<br />

Hower points out that TPEI’s rotors evenly disperse<br />

highly loaded materials such as colour concentrates.<br />

Some formulations have an 85/15 ratio of concentrate<br />

and base material.<br />

One continuous mixer that utilizes innovative<br />

technology to optimize process capabilities is the<br />

TriVolution line of single-screw machines from B&P<br />

Process Equipment. The system achieves dispersive<br />

and distributive mixing. It also allows controlled shear<br />

mixing with high surface area regeneration for devolatization<br />

and reactive processing of materials.<br />

The unit performs these and other capabilities by<br />

blending the mixing features of a reciprocating kneader<br />

with those of a twin-screw extruder, says Michael<br />

Lazorchak, global product manager for mixing systems.<br />

But there is a twist. Whereas reciprocating kneaders<br />

allow one stroke (a forward and backward movement)<br />

per screw revolution, the TriVolution mixer generates<br />

three stokes for every 360˚ revolution of the screw, to<br />

broaden mixing flexibility.<br />

The screw can be configured with up to 12 intermeshing<br />

flights to modify mixing. Stationary pins<br />

inside the barrel create what Lazorchak describes as a<br />

“slalom effect” on the melt as it undergoes<br />

shearing, decompression, folding and<br />

elongational mixing.<br />

“The stroke of the machine is not<br />

adjustable, but the geometry is,” he<br />

explains. A compounder tailors<br />

mixing parameters by adjusting<br />

elements on the screw. “You can<br />

configure units according to<br />

the process you run.”<br />

Moreover, kneading and<br />

splitting of the melt, caused<br />

by the screw and stationary<br />

pins as it travels down the<br />

barrel, opens and exposes<br />

material to grafts and reactive<br />

processing. It also facilitates venting<br />

moisture and volatile gases. This is useful<br />

for compounds that contain natural fibres,<br />

which typically have high moisture content.<br />

In addition to producing a high-quality melt, the<br />

process minimizes the heat and energy in mixing. As<br />

B&P explains, the mechanical energy used for melting<br />

and mixing does not come from aggressive shear-inducing<br />

devices but from elongational mixing that takes place<br />

in the intermeshing areas between the stationary pins<br />

and reciprocating screw flights. There is, as a result, less<br />

material degradation, as well as cost savings.<br />

Six models are in the TriVolution line, with screw<br />

diameters of 30 to 160 mm and L/D ratios of 12, 16 and<br />

20:1 for each.<br />

Batch benefits<br />

Promixon of Italy reports developments in equipment<br />

and product distribution. The company has made a<br />

number of upgrades to its batch mixing systems and<br />

components, and in September inaugurated a venture<br />

with US-based Exline to distribute custom mixing<br />

B&P says that<br />

its TriVolution<br />

combines the<br />

mixing features<br />

of a reciprocating<br />

kneader<br />

with those of a<br />

twin-screw<br />

machine<br />

Promixon has<br />

upgraded<br />

mixing tools to<br />

improve<br />

material<br />

distribution,<br />

reduce wear<br />

and save energy<br />

www.pipeandprofile.com <strong>March</strong> <strong>2015</strong> | PIPE & PROFILE EXTRUSION 27


machinery feature | Mixers for PVC<br />

Batch unit from<br />

Marion Mixers<br />

uses WaveMix<br />

microwave<br />

heating system,<br />

which is fast,<br />

thorough and<br />

energy efficient<br />

Promixon’s TRX<br />

container mixer<br />

is designed for<br />

a range of<br />

materials<br />

including<br />

masterbatches,<br />

additives and<br />

polymers<br />

plants and spare parts in<br />

America. CEO Marco Marinello<br />

also says that the company will<br />

soon add “an innovative on-line<br />

service for spare parts<br />

management and technical<br />

support.”<br />

Developments that back up<br />

these initiatives include mixing<br />

tools with enhanced performance,<br />

25% increased cooling<br />

efficiency in the CMX cooling<br />

system, and greater energy<br />

savings in all mixing equipment.<br />

Marinello also says<br />

Promixon has added to its<br />

range of machines to meet<br />

the “enormous variety of<br />

mixing requirements” from customers.<br />

The company has increased the coating, thickness<br />

and incidence angle of the bottom blade of its mixing<br />

tool. This permits mixing at lower speeds when<br />

necessary, reduces wear to the tool and mixing tank,<br />

and reportedly assures optimum material distribution<br />

and dispersion. Promixon has also developed wearresistant<br />

coatings to extend mixer life. Engineers have<br />

also increased discharge diameters to raise throughput<br />

speed and batch productivity.<br />

One important development has been engineering<br />

mixers for greater reliability. Marinello says that as a<br />

result, customers will have “minimal maintenance<br />

costs in the first five years of use.”<br />

Mixers can be used with a range of thermoplastics,<br />

additives, masterbatches, colorants, bio-based composites<br />

and recyclate. Promixon’s best-selling models are<br />

the Problend-TC dry-blending system for PVC, with<br />

throughput of 400 to 9,000 kg/hr, and the TRX container<br />

mixer, for colour masterbatches and additives,<br />

with output of 60 to 1,000 kg/batch.<br />

The Problend-TC is said to be efficient and<br />

low cost to operate, while the TRX mixer<br />

affords easy cleaning and fast changeover.<br />

Alternative heating<br />

Marion Mixers produces batch and continuous<br />

machines and components<br />

to improve process operations.<br />

One notable technique<br />

the company promotes for<br />

horizontal mixers processing<br />

free-flowing materials is<br />

microwave (MW) heating.<br />

Called WaveMix technology,<br />

the process replaces conventional<br />

jacketed heating elements, says Nick<br />

Burkle, WaveMix specialist, and is<br />

reportedly faster and more effective than standard<br />

mixer heat systems, while consuming less energy.<br />

The company licensed the process from the<br />

University of Northern Iowa in the US two years ago.<br />

Burkle says an installation uses a 75- to 400-kW<br />

microwave transmitter operating at 915 MHz in a<br />

stainless steel vessel specially designed by Marion for<br />

safety. The process, which is scalable, yields even<br />

heating across the material.<br />

In a test carried out earlier this year, Marion reported<br />

that microwave-assisted drying was tested on 500 lb<br />

(230 kg) of agricultural-grade limestone powder, using a<br />

75-kW, 915-MHz transmitter in a 10-ft 3 batch mixer. The<br />

MW heat achieved moisture content of less than 0.05%<br />

(500 ppm) at 171°F (77.2°C) in less than 30 minutes.<br />

More information<br />

Michael Lazorchak of B&P Process Equipment and Jim<br />

Preston of Rhetech gave a presentation on “Putting the<br />

TriVolution mixer through its paces” at the Compounding<br />

World Forum 2014, which took place on 9-10<br />

December in Philadelphia, PA, USA. A selection of<br />

leading mixer suppliers were also exhibiting at the<br />

event, including B&P, Farrel Pomini, Mixaco, Promixon<br />

and TPEI. For conference proceedings, contact Kelly<br />

Cressman (kc@amiplastics-na.com).<br />

Click on the links for more information:<br />

❙ www.farrel-pomini.com<br />

❙ www.tpei.com<br />

❙ www.bpprocess.com<br />

❙ www.promixon.com<br />

❙ www.exline-inc.com<br />

❙ www.marionmixers.com<br />

28<br />

PIPE & PROFILE EXTRUSION | <strong>March</strong> <strong>2015</strong><br />

www.pipeandprofile.com


AMI at NPE <strong>2015</strong><br />

Stand W8283<br />

Orange County Convention Center, Orlando from 23-27 <strong>March</strong><br />

Stop by to find out more about our conferences,<br />

publications and free magazines<br />

Contact Matt Wherlock, mjw@amiplastics.com<br />

for more information


NPE <strong>2015</strong><br />

| show preview<br />

The leading US<br />

plastics exhibition<br />

kicks of this month.<br />

We look at why NPE<br />

<strong>2015</strong> is shaping up<br />

to be huge success,<br />

and preview a<br />

selection of new<br />

products that will<br />

be on show<br />

NPE: lifting off in Florida<br />

NPE <strong>2015</strong>, which takes place on 23-27 <strong>March</strong> in<br />

Orlando, Florida, is likely to be the largest US plastics<br />

exhibition ever. More than 60,000 visitors are expected<br />

to view displays by some 2,000 exhibitors over more<br />

than 106,000m 2 of exhibition space. And according to<br />

show organiser, the US Society of the Plastics Industry<br />

(SPI), more than 400 of those exhibitors will have<br />

equipment running on their stands.<br />

“With so many exhibitors operating equipment, the<br />

show floor will be a dynamic panorama of manufacturing<br />

in action,” said Gene Sanders, SPI’s senior vice<br />

president of trade shows and conferences.<br />

NPE 2012 took place as the US economy began its<br />

recovery from the downturn. Exhibitor mood was<br />

optimistic then and is, perhaps, even better now as the<br />

US economy is performing well. While the IMF recently<br />

downgraded its forecast for global growth for <strong>2015</strong> to<br />

3.5%, the US was the sole major world economy to see<br />

its economic performance expectation lifted (from 3.1%<br />

to 3.6%).<br />

The most recent data from the SPI’s Committee on<br />

Equipment Statistics (CES) shows that US quarterly<br />

plastics machinery shipments have been running at<br />

near record levels now for close to three years. In the<br />

third quarter of last year, shipments of primary<br />

processing equipment totalled US$304.1 million. That<br />

was only 2% below the 10-year record result for the<br />

same period in 2013 and 6% ahead of the second<br />

quarter 2014 figures. Sales of twin-screw extruders in<br />

the US grew particularly strongly last year – they were<br />

35% higher during the first three quarters of 2014<br />

compared to the same period in 2013.<br />

More evidence of growth in the US plastics market<br />

can be found in the latest data from Germany’s<br />

machinery association, the VDMA. It reports that<br />

German exports of plastics and rubber processing<br />

machinery to the US grew 15.5% in 2013 to reach<br />

€630.4 million. This was the fourth consecutive year of<br />

strong growth since the downturn of 2009.<br />

Total world exports of plastics and rubber processing<br />

machinery to the US reached €2,020.4 million in 2013, up<br />

8.6% compared to 2012, according to statistics compiled<br />

by the VDMA using export figures from national statistical<br />

offices in 52 countries. Germany had the largest share of<br />

this market at 31.2%, followed by Canada (18.0%), Japan<br />

(14.6%), France (8.0%), China (5.4%), and Italy (5.2%).<br />

Over the following pages, we take a look at some of<br />

the materials, machinery and equipment relevant to pipe<br />

and profile extruders. If you’re at the exhibition yourself,<br />

please visit us at the Applied Market Information stand<br />

(W8283). We will also be touring the halls and tweeting<br />

news live from the show via our @PlasticsWorld Twitter<br />

feed.<br />

More details about visiting NPE <strong>2015</strong>, including<br />

opening times, advanced registration, travel information<br />

and accommodation booking, can be found on the<br />

exhibition website:<br />

❙ www.npe.org<br />

▲<br />

More than<br />

60,000 visitors<br />

are expected to<br />

view displays<br />

from 2,000<br />

exhibitors at<br />

NPE <strong>2015</strong><br />

www.pipeandprofile.com <strong>March</strong> <strong>2015</strong> | PIPE & PROFILE EXTRUSION 31


show preview | NPE <strong>2015</strong><br />

Coperion<br />

K-Tron’s dual<br />

blower rail<br />

unload system<br />

transfers<br />

powders,<br />

granules or<br />

pellets<br />

E-Plus dryers<br />

from Dri-Air<br />

Industries offer<br />

faster, more<br />

complete<br />

drying of<br />

plastics<br />

Ancillaries<br />

Coperion K-Tron will show a range of bulk<br />

materials handling systems at NPE this month, ranging<br />

from unloading, feeding and pelletising equipment<br />

through to packaging and loading systems.<br />

Its dual-blower Rail Unload<br />

System pneumatically transfers<br />

pellets, powders and granular<br />

materials from railcars at rates<br />

in excess of 120,000 lb/<br />

hour (54,000 kg/hour).<br />

Using separate vacuum<br />

and pressure blowers,<br />

the system is designed<br />

to unload<br />

materials from the<br />

railcar at higher conveying<br />

rates and for longer conveying distances.<br />

Coperion K-Tron’s modular loss-in-weight<br />

(LIW) feeders are designed for materials with<br />

varying bulk density and for automated materials<br />

handling. The S100 single-screw LIW feeder offers feed<br />

rates from 0.4 to 560 ft³/hour (10 to 15,800 dm³/hour)<br />

and can handle free-flowing powders, granules, and<br />

pellets. The T35 twin-screw LIW Feeder offers feed<br />

rates from 0.04 to 88.0 ft³/hour (1.25 to 2,500 dm³/hour)<br />

and is designed to cope with floodable powders and<br />

more difficult, sticky or hard-to-flow materials.<br />

❙ www.ktron.com<br />

E-Plus dryers from Dri-Air Industries<br />

claim to offer faster, more complete<br />

drying of plastics, with high energy<br />

efficiency. Their parabolic tower design,<br />

special heater configuration and optimised<br />

air flow maximize moisture pickup for<br />

ultra-low dew points, faster drying, and<br />

reduced regeneration energy usage, says<br />

the company. Greater hopper insulation<br />

further improves their efficiency, even<br />

with the most challenging, hard-to-dry<br />

plastics. They are available in three sizes,<br />

with capacities of 25, 50, or 100lbs/hour.<br />

❙ www.dri-air.com<br />

FB Balzanelli is to exhibit its TR1200C<br />

automatic coiler, which is highly flexible and<br />

suitable for coiling a variety of pipes. Most commonly<br />

used for corrugated pipes, PE gas and pressure<br />

pipes and PEX pipes up to 1in, the TR1200C has a<br />

compact design, user friendly functions and interface,<br />

and fully automated real time adjustment.<br />

Highlights include: quick installation, thanks to its<br />

compact design; 12in touch screen with diagnostic<br />

alarms; precision pipe guide to ensure a compact coil,<br />

saving on transport costs; a third-generation pneumatic<br />

strapping head design, for high reliability and efficiency;<br />

minimal maintenance; and, short payback time.<br />

❙ www.fb-balzanelli.it<br />

Herbold Meckesheim has redesigned its SMS<br />

Series granulators to cope with the most demanding<br />

heavy-duty size reduction applications in a single step.<br />

The machines are made with rotor widths ranging from<br />

23.5 to 78.75in, and with drive capacities of 60-420HP.<br />

The knife design is segmental, ensuring a quick and<br />

easy exchange of the cutting tools.<br />

SMS Granulators are equipped with a third bed knife<br />

called a deflection wedge. When the deflection wedge is<br />

removed larger, bulky items can be easily accommodated.<br />

Typical applications for these granulators are: heavy,<br />

thick-walled semi-finished products in PE, PP, POM and<br />

PA; pipes with high wall thicknesses; and large<br />

purgings.<br />

❙ www.herboldusa.com<br />

Test equipment supplier Instron will exhibit its new<br />

Advanced Video Extensometer (AVE 2), which conforms<br />

to the rigorous ISO 527-2 and ASTM D638 standards. It<br />

is a fully-integrated device that adapts to the<br />

normal fluctuations of environmental<br />

conditions in the lab and is easily<br />

adapted to any testing machine<br />

that uses a ±10V analogue input<br />

(performance depends on the<br />

system). Designed to reduce<br />

errors from thermal and lighting<br />

variations that are common in<br />

most labs, it is the only device on<br />

the market to use the real-time<br />

490Hz data rate while achieving a 1<br />

micron accuracy, says Instron.<br />

NPE visitors will also see<br />

Instron’s AutoX Automatic Contacting<br />

Extensometer that offers faster,<br />

more reliable and more accurate<br />

materials testing routines. Its high<br />

accuracy and travel make it ideal for tensile<br />

and flexure testing of plastics. Meeting the<br />

requirements of ISO 527-2, it is used to determine a<br />

variety of calculations including modulus, offset yield<br />

and plastic (non-proportional) elongation to failure.<br />

❙ www.instron.com<br />

s<br />

32<br />

PIPE & PROFILE EXTRUSION | <strong>March</strong> <strong>2015</strong><br />

www.pipeandprofile.com


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NPE <strong>2015</strong><br />

| show preview<br />

Moretto will showcase its enhanced Eureka drying<br />

system at NPE. The system comprises a Flowmatik<br />

airflow management and distribution system, OTX<br />

hopper dryer and the X Max dryer.<br />

Moretto says Eureka is “the most advanced drying<br />

system for engineering thermoplastics” and the only<br />

drying system that can process 10,000-12,000kg/h of<br />

material in compounding, extrusion and PET processing.<br />

Here, the company claims, it has around half the<br />

energy consumption of traditional drying systems.<br />

The core X Max dryer is based on Moretto’s patented<br />

‘X technology’ and incorporates a multibed single<br />

molecular sieve desiccant system providing constant<br />

-65°C to -85°C dew point. Though twice the size of<br />

conventional beds, it works without needing cooling<br />

water or compressed air for the changeover valve, and<br />

also recovers energy by cooling of the bed during<br />

molecular sieve regeneration.<br />

A key enhancement in the latest X Max dryer within<br />

the Eureka system is its multi-stage centrifugal blower,<br />

developed by Moretto in cooperation with nearby Padua<br />

University.<br />

Due to these combined features, the X Max drier is<br />

highly efficient: the X Max 916 model provides each unit<br />

with up to 1,600m³/h drying capacity at 300 mbar<br />

pressure with an electricity consumption of 13.2kWh.<br />

❙ www.moretto.com<br />

NDC Technologies says it has developed the<br />

industry’s first four-axis diameter and ovality gauge for<br />

products up to 12mm. Its Beta LaserMike AccuScan<br />

6012 enables manufacturers to measure product<br />

diameter and ovality with higher accuracy than two- and<br />

three axis gauges.<br />

The company says that manufacturers of medical<br />

tubing, high-performance cable and other extruded<br />

products – who have previously relied on two- and<br />

three-axis diameter and ovality gauges for on-line and<br />

off-line measurement – will benefit from the product,<br />

thanks to its ability to make precise measurements at<br />

increasing production line speeds.<br />

Making an “out-of-tolerance” medical tubing product<br />

can affect the performance of devices such as catheters,<br />

while errors in the diameter or roundness of the<br />

conductor or insulation in Coaxial and twisted-pair LAN<br />

products directly affects the cable’s performance<br />

characteristics – rendering it useless for the designed<br />

application.<br />

“This unusable product winds up being scrapped,<br />

increasing manufacturing costs,” according to the<br />

company.<br />

❙ www.betalasermike.com<br />

The Bessemer series of downstream equipment from<br />

Novatec now includes modular stainless steel<br />

vacuum tanks. These tanks are built in 4ft and 8ft<br />

lengths with 12 x 12in and 8 x 8in cross sections.<br />

Their modularity allows them to be connected<br />

to create whatever length profile<br />

extruders need. In the past, this<br />

type of tank was built-to order,<br />

which resulted in long lead<br />

times and high cost.<br />

These vacuum tanks will be<br />

stocked in the 4ft and 8ft<br />

lengths so they can be shipped<br />

quickly and in reasonable<br />

lengths (to reduce shipping costs)<br />

and easily connected in the<br />

processing plant.<br />

❙ www.novatec.com<br />

OMP, one of the companies in the NPE<br />

Startup Garage, has a mission to help<br />

extruders improve product identification,<br />

using digital colour printing to mark PVC products such<br />

as pipe.<br />

Company founder Jim Vitous previously spent more<br />

than 30 years in the product identification industry. The<br />

company’s name is derived from the phrase ‘One<br />

Moving Part’ – as its technology has a single rotating<br />

component.<br />

“The resulting solution provides an integrated<br />

simplified printing experience that will displace the<br />

cumbersome ink jet technologies currently in place,”<br />

said Vitous. “The consumer’s perceived value will be<br />

raised significantly.”<br />

❙ www.pvcpipeprinter.com<br />

R&B Plastics Machinery will use NPE as the<br />

launchpad for its Max extrusion control system. This<br />

uses an economical Windows CE-based human machine<br />

interface (HMI) system that provides performance<br />

similar to SCADA software systems, according to R&B.<br />

Featuring Allen Bradley and Ifix systems, the Max<br />

control platform can provide integrated line control for<br />

a wide range of extrusion applications, including<br />

compounding and recycling. It provides control of<br />

temperature, speed and pressure with the touch of a<br />

screen. Integration of upstream and downstream<br />

equipment is also available.<br />

The system is customised to meet end-user requirements,<br />

including the selection of hardware suppliers. It<br />

can be retrofitted to all makes of extruders and can also<br />

be used with R&B’s own Max extruder product line.<br />

❙ www.rbplasticsmachinery.com<br />

s<br />

Novatec’s<br />

Bessemer<br />

series of<br />

downstream<br />

equipment now<br />

includes<br />

modular<br />

stainless steel<br />

vacuum tanks<br />

www.pipeandprofile.com <strong>March</strong> <strong>2015</strong> | PIPE & PROFILE EXTRUSION 35


show preview | NPE <strong>2015</strong><br />

Aurora’s<br />

capstock is<br />

designed to<br />

withstand<br />

weathering<br />

over the long<br />

term, even in<br />

dark colours<br />

Materials<br />

Aurora Plastics has introduced a weatherable PVC/<br />

acrylic alloy capstock. The product is designed to<br />

withstand the effects of weathering over the long term,<br />

even in dark colours, offering an attractive alternative<br />

for a variety of demanding applications such as outdoor<br />

trim, windows, decks, siding, fencing, and railing. It<br />

offers superior processing characteristics<br />

that translate into a more<br />

consistent coating, less scrap,<br />

faster startup and a<br />

broader processing<br />

window, says the<br />

company.<br />

“We identified a<br />

need for a more<br />

cost-competitive,<br />

long-lasting solution,” said<br />

Matthew Kuwatch, vice president of marketing and<br />

business development. “There are currently many<br />

options available, but most do not offer the same level<br />

of long-term weatherability and resistance to water<br />

whitening, especially in darker colours.”<br />

❙ www.auroraplastics.com<br />

Kureha America will show a range of KF Polymer<br />

PVDF grades at NPE <strong>2015</strong>.<br />

The material is a versatile fluoropolymer that is<br />

easily melt-processed. It has a long history of use for<br />

extruded and injection moulded piping and liquid<br />

handling components such as fittings and valves.<br />

It is now receiving increasing interest in oil and gas<br />

transport as a piping and lining material, and for water<br />

treatment systems for manufacture of ultrafiltration<br />

media, says Kureha.<br />

Benefits of the material include: chemical inertness;<br />

retention of mechanical properties from 23°C to 150°C;<br />

abrasion resistance; low coefficient of friction; thermal<br />

ageing resistance; resistance to UV and gamma<br />

radiation; and, conformance with CFR 177.2510 for food<br />

contact.<br />

❙ www.kureha.com<br />

Orion Engineered Carbons will showcase new<br />

speciality carbon blacks for pressure pipe, wire and<br />

cable, and conductive products.<br />

Arosperse 5-183a is a soft-beaded furnace black for<br />

use in semi-conductive insulation shields for mediumvoltage<br />

cables. With low sulphur impurities and low<br />

sieve residues, it is a very clean product.<br />

Another application is potable water pipe, which<br />

requires a clean, smooth conductive surface.<br />

Printex Zeta A is designed specially for pressure<br />

piping in gas and water distribution. The high chemical<br />

purity and physical cleanliness minimises taste and<br />

odour effects. Low compound moisture absorption and<br />

excellent microscopic dispersion performance ensure a<br />

smooth, defect-free pipe. It also gives the polymer<br />

excellent UV protection, shielding the pipe from<br />

photo-oxidative degradation. Printex HV is for use in<br />

high-voltage cables<br />

❙ www.orioncarbons.com<br />

Machinery & tooling<br />

Battenfeld-<br />

Cincinnati is a<br />

leader in<br />

large-diameter<br />

pipe extrusion<br />

Battenfeld-Cincinnati USA will present a variety<br />

of technologies at NPE, including co-extrusion options,<br />

high-tech pipe heads for multi-layer applications as<br />

well as twin screws with tailored wear resistance<br />

features.<br />

The parallel twin screw extruder TwinEx range has<br />

been expanded with the industry’s highest-output large<br />

diameter machine, the TwinEx 148-28. It was designed<br />

to meet the growing demand for large diameter PVC<br />

pipe extrusion and high-output profile extrusion in<br />

North America. It also has a Z design gearbox with the<br />

main motor in the back for easy maintenance and can<br />

process both virgin and regrind PVC with output rates of<br />

up to 2,000kg/h (4,400lbs/hr).<br />

The SolEx high-performance single screw extruder<br />

series yields high outputs with low melt temperatures<br />

and homogeneous melt for polyolefin materials. It has<br />

been extended with a new machine, the SolEx 150,<br />

which is particularly suited to the demands of the large<br />

diameter heavy wall PO pipe market. It offers outputs<br />

up to 2,750kg/h (6,000lbs/hr) for HDPE applications.<br />

s<br />

36<br />

PIPE & PROFILE EXTRUSION | <strong>March</strong> <strong>2015</strong><br />

www.pipeandprofile.com


Oil & Gas Polymer<br />

Engineering Texas <strong>2015</strong><br />

Focused industry conference on qualifying and utilizing elastomers,<br />

thermoplastics, composites and coating materials in oilfield applications<br />

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NPE <strong>2015</strong><br />

| show preview<br />

The company will also show two examples of<br />

co-extrusion. The ConEx range from 38 to 63mm is<br />

suited to co-extruded pipe and profile applications.<br />

A ConEx 63 from the conical<br />

twin screw series will be<br />

seen in a co-extrusion<br />

set-up on a pedestal<br />

mount with 4-axis<br />

adjustment with the<br />

TwinEx 148-28. This<br />

configuration could be used for foam core,<br />

triple-walled pipe extrusion, PVC fence and siding.<br />

❙ www.battenfeld-cincinnati.com<br />

Beier America is introducing a new high throughput<br />

extruder for polyolefin pipe production. The BRD series<br />

of 38:1 L/D grooved feed throat extruders incorporates<br />

numerous innovative features, including: a feed throat<br />

with a large eccentric feed opening; large surface area,<br />

rectangular grooved feed channels; air gap heat<br />

insulation; and a spiral water cooling system.<br />

The result is high material conveying efficiency – regardless<br />

of back pressure – with low water consumption,<br />

says the company. A BRD60/38 pipe extruder will<br />

be exhibited at the NPE.<br />

The Beier BRD series is designed for efficient polymer<br />

processing with extrusion production pressures up to<br />

455bar. Newly designed components help to separate<br />

plasticising performance from back pressure. The BRD<br />

90/38 has an HDPE throughput rate of 1000kg/h.<br />

❙ www.beieramerica.com<br />

Extrunet America Inc is the North American subsidiary<br />

of a European specialist in energy efficient extrusion<br />

machinery. It claims up to 80% energy savings<br />

compared to conventional calibration tables – with<br />

positive side effects such as reduced noise, automated<br />

extrusion process control and innovative guillotine<br />

cutting technology.<br />

Central Vacuum Technology, as Extrunet calls its<br />

technology, has now been introduced to North America<br />

and more than 100 calibration tables have been<br />

upgraded – helping customers to reduce energy costs.<br />

Extrunet estimates that more than 1,000 profile<br />

downstream lines in North America are ‘coming of age’<br />

– reaching 20-25 years old. Its central vacuum<br />

technology can be retrofitted to most brands of<br />

calibration table.<br />

❙ www.extrunet.com<br />

tubing for the automotive, medical and industrial<br />

applications. The redesigned 800 series produces<br />

flawless extrusion and layer definition of fluoropolymer<br />

and other materials<br />

for fuel line constructions,<br />

multi-layer PEX pipe<br />

and drip irrigation. The<br />

design allows thin layer<br />

combinations of polymers and adhesives<br />

to 0.02mm or less.<br />

❙ www.guill.com<br />

Maillefer has developed a series of innovative<br />

ways of making holes in its PIL micro-drip irrigation<br />

hosing. The company opted for a mechanical drilling<br />

method driven by a high-performance motor in order to<br />

reach very high rates: its lines combine short drip<br />

emitter spacing and high extrusion line speeds, which<br />

translates to 2,000 holes per minute.<br />

Part of the challenge in drilling a hole in a fast-moving<br />

target is knowing where to aim, says Maillefer.<br />

“Our patent-pending emitter detection system helps<br />

us synchronise the movement with laser light precision,”<br />

it said. “Plus, with our auto-tuning algorithm, we<br />

zoom in onto the emitter pool zone quickly and simply.”<br />

❙ www.maillefer.net<br />

Tecnomatic of Italy has teamed up with Puma Plastic<br />

Solutions to bring its extrusion lines to the US. The two<br />

companies will participate at NPE,<br />

It will showcase its L/D 40 Zephyr 90 for pipe<br />

production – which has a throughput of up to 1,700kg/h<br />

– and of its Venus 400 die-head with <strong>Pipe</strong> Air Cooling.<br />

Zephyr boasts an array of technical solutions that is<br />

aimed at pipe producers that need more focused<br />

energy saving machines, with high output performance<br />

at lower melt temperatures. The innovation spans the<br />

entire extruder range and includes new spiral<br />

grooved bush, screw and motors.<br />

❙ www.tecnomaticsrl.net<br />

Guill Tool is<br />

introducing the<br />

latest generation<br />

of its<br />

Series 800<br />

extrusion<br />

tooling<br />

Beier America<br />

will exhibited a<br />

BRD60/38<br />

pipe<br />

extruder<br />

at NPE<br />

Guill Tool is introducing the latest generation of its<br />

Series 800, 2-to-6 layer extrusion tooling designed to<br />

produce high quality and material-efficient 0.125-6in OD<br />

www.pipeandprofile.com <strong>March</strong> <strong>2015</strong> | PIPE & PROFILE EXTRUSION 39


CONDUCTIVE<br />

PLASTICS 2O15<br />

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thermally conductive plastics<br />

CLICK HERE FOR DETAILS<br />

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Kat Langner, Conference Organiser kl@amiplastics.com Ph: +44 117 924 9442 Fax: +44(0)117 311 1534


Materials | technology<br />

etps<br />

IPE introduces speciality products based<br />

on Solvay engineering thermoplastics<br />

International Polymer Engineering (IPE), a<br />

US-based custom extruder of thermoplastic<br />

tubing and profiles, has introduced a<br />

new range of products based on materials<br />

from Solvay Specialty Polymers.<br />

The products include high-precision<br />

microbore tubing, monofilaments and<br />

profiles, and are aimed at applications in<br />

the medical, aerospace, military and<br />

industrial sectors. IPE unveiled the new<br />

line at the Medical Design & Manufacturing<br />

(MD&M) West in February.<br />

IPE has seen growing demand for<br />

extrusions made of high-performance<br />

thermoplastics due to their ease of<br />

manufacturing and strong property<br />

profile. In particular, the company has<br />

seen a major shift toward replacing<br />

metals and thermoset materials with<br />

advanced thermoplastics in medical<br />

applications, according to Jonathan<br />

Jurgaitis, melt extrusion manager for IPE.<br />

“It’s clear that these high-performance<br />

materials have a strong track record, and<br />

the industry is familiar with them as a<br />

viable option for a range of applications,”<br />

he said. “IPE has worked closely with<br />

Solvay to develop custom products that<br />

meet the requirements of demanding<br />

end-use applications.”<br />

IPE chose Solvay’s sulfone polymers<br />

due to their high clarity, stiffness and<br />

steam sterilisability. Specifically, the<br />

company used Solvay’s Udel polysulfone<br />

(PSU) to fabricate 0.02in (0.5mm) monofilaments,<br />

and Radel polyphenylsulfone<br />

(PPSU) to make 0.06in (1.5mm) and 0.11in<br />

(2.8mm) monofilaments. It also used<br />

Radel PPSU to make 0.50in (12.7mm)<br />

microbore tubing with outer diameter (OD)<br />

of 0.012in and inner diameter (ID) of<br />

0.010in (0.3mm OD x 0.25mm ID).<br />

IPE has also used other Solvay grades.<br />

For example, it fabricates microtubes<br />

from KetaSpire Peek resin that deliver<br />

greater strength and rigidity than PTFE<br />

microtubes, and are easier to work with<br />

compared to those made of stainless<br />

steel. These microtubes are used in<br />

medical applications such catheters,<br />

endoscopic working channels, and<br />

laparoscopic instruments.<br />

At the same time, it uses AvaSpire<br />

Paek to extrude 0.06in (1.5mm) monofilaments,<br />

and Torlon polyamide-imide (PAI)<br />

for 0.06in (1.5mm) monofilaments. PAI<br />

offers the highest strength and stiffness<br />

of any thermoplastic up to 275°C (527F),<br />

says the company.<br />

Other monofilaments are made from<br />

PrimoSpire self-reinforced polyphenylene<br />

(SRP), while Halar ECTFE – a partially<br />

fluorinated, melt-processable polymer –<br />

is specified by IPE for 0.06in (1.5mm)<br />

monofilaments due to its high chemical<br />

resistance and lubricity.<br />

❙ www.ipeweb.com<br />

❙ www.solvayspecialtypolymers.com<br />

PBT<br />

Flame-retardant grades for optical fibre jackets<br />

free.<br />

Strict fire safety regulations<br />

for cable material are<br />

increasingly the norm in calls<br />

Evonik’s Vestodur grade for<br />

optical fibre jackets features<br />

excellent flame-retardant<br />

properties, yet is halogenfor<br />

tenders for public construction<br />

projects. This new<br />

halogen-free grade of<br />

polybutylene terephthalate<br />

(PBT) for optical fibre jackets<br />

and wire bundles has high<br />

flame-retardant properties,<br />

says the company.<br />

Vestordur X9426 has a high<br />

limiting oxygen index (LOI) and<br />

low smoke density, and any<br />

smoke gases emitted are of<br />

low toxicity. The extruded<br />

material is also extremely<br />

flexible, kink- and crushresistant<br />

and has good<br />

hydrolysis properties.<br />

Evonik offers a range of<br />

Vestodur PBT and Vestamid<br />

polyamide 12 compounds for<br />

cable extrusion. These are<br />

used both for the safe and<br />

efficient protection of optical<br />

fibres and for wire insulation<br />

and cable protection tubing.<br />

The latest development in PA<br />

12 is a material that meets<br />

the stringent HL3 requirements<br />

for rail vehicles in<br />

accordance with standard EN<br />

45545 – 2:2013.<br />

❙ www.vestodur.com<br />

www.pipeandprofile.com <strong>March</strong> <strong>2015</strong> | PIPE & PROFILE EXTRUSION 41


technology | Machinery<br />

MEASUREMENT<br />

Diameter gauges make 2,500<br />

measurements per second<br />

CONTROL<br />

Easy-to-use extrusion controllers<br />

West Control Solutions has<br />

introduced the PlastX family<br />

of temperature controllers for<br />

plastics and rubber extrusion.<br />

An easy-to-use menu<br />

features pre-populated setup<br />

fields with default parameters<br />

for plastic applications.<br />

This, together with the<br />

removal of unnecessary<br />

options, ensures that<br />

configuration is straightforward<br />

and fast to<br />

implement, says West.<br />

The controllers provide<br />

both ‘heat only’ and ‘heat/<br />

cool’ control in the same<br />

instrument. Units can be<br />

quickly converted to process<br />

indicators, reducing the need<br />

to stock multiple products for<br />

Sikora says that its Laser<br />

Series 6000 diameter<br />

gauges are designed for<br />

customer requirements<br />

that exceed the classic<br />

demands for quality<br />

control in the hose and<br />

tube industry.<br />

The device makes 2,500 measurements<br />

per second, with high single<br />

value precision, allowing for optimum<br />

line control and reliable statistical<br />

data. Sikora offers three gauge head<br />

models for product diameters from 0.2<br />

to 78mm. The Series 6000 can also<br />

handle transparent products.<br />

The devices include an integrated<br />

LCD display with control panel, which<br />

provides the operator with diameter<br />

values at a glance, directly at the<br />

measuring device. At the control<br />

extrusion applications.<br />

PlastX controllers are<br />

available in a compact 1/16 DIN<br />

size (48 x 48mm) and 1/8 DIN<br />

size (48 x 96mm). Standard features<br />

include process and loop<br />

alarms, with LED indicators<br />

for the band and low alarms.<br />

An LED indicator is also<br />

present during auto-tuning.<br />

The controller has one<br />

panel the diameter nominal value can<br />

be entered and the control module<br />

activated. By way of line speed or<br />

extruder rpm, the module automatically<br />

controls the diameter to the<br />

specified value. The high measuring<br />

rate of the diameter devices also<br />

allows the detection of lumps and<br />

neckdowns.<br />

A universal interface module is<br />

directly integrated in the gauge heads<br />

for all connections, such as RS 485, RS<br />

232 and Profibus-DP, or industrial field<br />

buses such as CANopen, Ethernet/IP,<br />

DeviceNet and Profinet IO.<br />

It also has an optional Wi-Fi<br />

interface, which allows a direct<br />

connection to a smartphone or laptop<br />

for diagnostic and quality control<br />

purposes.<br />

❙ www.sikora.net<br />

universal input, multiple<br />

output configurations and<br />

optional Modbus RS485<br />

communications.<br />

❙ www.west-cs.com<br />

TUBE PRODUCTION<br />

Flexible<br />

production<br />

of PBL tube<br />

Breyer has adapted its Topline<br />

and Ecoline tube extrusion<br />

systems to allow flexible, cost<br />

effective production of<br />

cosmetic tubing.<br />

Plastic barrier laminate<br />

(PBL) tubes are made from a<br />

web laminate and have a<br />

visible side seam, in production<br />

runs typically above<br />

100,000 tubes per order.<br />

Laminate film is supplied to<br />

the tube manufacturer. High<br />

speed film lines, side-seamers<br />

and printers allow<br />

economic mass production of<br />

such film but the individual<br />

design for small orders is<br />

often not economical.<br />

Breyer has developed a<br />

special solution for this,<br />

based on its experience of<br />

extrusion systems for flat<br />

film and extruded tubes.<br />

The extrusion line, with a<br />

working width of 1600mm,<br />

800mm, 400mm or less,<br />

allows the production of<br />

slitted flat film with a flexible<br />

configuration of different<br />

layers for different tube<br />

diameters and lengths.<br />

EVOH, PA, PET and COC<br />

barrier layers are all<br />

possible, says Breyer.<br />

Properties like colour and<br />

haptics, which are very<br />

important for the first<br />

impression of the tube<br />

product, can be easily<br />

adapted by using different<br />

polymers such as PET, PP,<br />

PA or PE. An isolated inner<br />

layer even allows the usage<br />

of recycled material.<br />

❙ www.breyer-extr.com<br />

42<br />

PIPE & PROFILE EXTRUSION | <strong>March</strong> <strong>2015</strong><br />

www.pipeandprofile.com


CORRUGATED PLASTIC PIPE<br />

TECHNOLOGY<br />

R<br />

This month’s free<br />

brochure downloads<br />

Simply click on the brochure cover or link to download a PDF of the full publication<br />

Battenfeld-Cincinnati: twinEX<br />

Sica: downstream equipment<br />

twinEX<br />

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This eight-page technical<br />

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If you would like your brochure to be included on this page, please contact<br />

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Global conference on the PVC industry, compounding, recipes and market trends<br />

PVC Formulation <strong>2015</strong> is<br />

taking place on 16-18 <strong>March</strong><br />

in Cologne, Germany. This<br />

global conference on the<br />

PVC industry, compounding,<br />

recipes and market trends<br />

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AMI Strategy Seminars<br />

THE GLOBAL PLASTICS<br />

INDUSTRY SEMINAR<br />

<strong>2015</strong><br />

A strategic review of the prospects<br />

for the global plastics industry<br />

<strong>2015</strong> seminar dates and locations<br />

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Andrew Reynolds is running<br />

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in <strong>2015</strong> with dates set for<br />

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brochure has all the details.<br />

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16-18 <strong>March</strong> <strong>2015</strong><br />

Maritim Hotel,<br />

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in Infrastructure<br />

Trends & developments in design, production, installation and exploitation<br />

of plastic pipes systems for infrastructure<br />

14-16 April <strong>2015</strong><br />

Millennium Gloucester Hotel,<br />

London, United Kingdom<br />

AMI’s third international<br />

conference on plastics pipes<br />

for infrastructure applications<br />

will be held in London<br />

on 14-16 April <strong>2015</strong>.<br />

Download the programme<br />

which covers the latest<br />

design, production and<br />

installation developments.<br />

PolymerFoam<strong>2015</strong><br />

International conference on foam technology and applications in thermoplastic<br />

and elastomeric products<br />

April 14-15, <strong>2015</strong><br />

Renaissance Newark Airport Hotel,<br />

Newark, New Jersey, USA<br />

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elastomeric foam technologies<br />

and applications is<br />

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Compounding World Congress<br />

Fire Retardants in Plastics<br />

Congress <strong>2015</strong><br />

The international conference on business strategies, innovative additives and<br />

process optimisation for thermoplastics compounders<br />

18-20 21-23 February April <strong>2015</strong> 2013<br />

Austria Maritim Trend Hotel Hotel, Savoyen,<br />

Cologne, Vienna, Austria Germany<br />

Following the considerable<br />

success of the Compounding<br />

World Forum in the USA,<br />

Compounding World<br />

magazine and AMI are<br />

launching this new event in<br />

Europe. The programme<br />

features a selection of the<br />

industry’s most influential<br />

leaders.<br />

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FIRE RETARDANTS<br />

IN PLASTICS <strong>2015</strong><br />

Trends and technical developments in the international flame retardant industry<br />

May 12-13, <strong>2015</strong><br />

Grand Hyatt Denver,<br />

Denver, Colorado, USA<br />

5<br />

2<br />

Covering market trends and<br />

technical developments in<br />

the international flame<br />

retardant industry, AMI’s<br />

Fire Retardants in Plastics<br />

conference returns to<br />

Denver, Colorado, USA on<br />

12-13 May. Download the<br />

programme here.<br />

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Polymer Sourcing & Distribution<br />

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POLYMER SOURCING<br />

& DISTRIBUTION <strong>2015</strong><br />

A new era for the polymer supply chain<br />

HEADLINE SPONSOR<br />

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Hamburg, Germany<br />

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Germany on 18-20 May<br />

<strong>2015</strong>. The programme<br />

covers developments in<br />

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includes analysis of polymer<br />

supply and demand trends.<br />

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International business and technology conference for the window,<br />

door, decking, fence and siding profile industry<br />

June 9-10, <strong>2015</strong><br />

Hilton Philadelphia City Avenue,<br />

Philadelphia, Pennsylvania, USA<br />

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9-10 June <strong>2015</strong>. Download<br />

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plus advances in extrusion<br />

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MASTERBATCH<br />

M2 0 1 5<br />

Connecting with downstream customers<br />

9-11 June <strong>2015</strong><br />

Maritim Hotel,<br />

Cologne, Germany<br />

The 28th edition of AMI’s<br />

Masterbatch conference is<br />

being held on 9-11 June<br />

<strong>2015</strong> in Cologne, Germany.<br />

This year’s programme<br />

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Polymers in Cables<br />

Conductive Plastics<br />

Polymers in Cables<br />

<strong>2015</strong><br />

The international conference and exhibition for polymers in cable applications<br />

June 23-24, <strong>2015</strong><br />

Hilton Philadelphia City Avenue,<br />

Philadelphia, Pennsylvania, USA<br />

The American version of<br />

AMI’s conference on<br />

Polymers in Cables applications<br />

is being held in<br />

Philadelphia, PA, USA on<br />

23-24 June. Check out the<br />

programme which covers<br />

interesting materials and<br />

application developments.<br />

CONDUCTIVE<br />

PLASTIC S 2O 15<br />

Developing technologies and applications for electrically and<br />

thermally conductive plastics<br />

29th June – 1st July <strong>2015</strong><br />

Hotel Nikko,<br />

Düsseldorf, Germany<br />

This new conference from<br />

AMI covers thermally- and<br />

electrically-conductive<br />

thermoplastics, examining<br />

materials technology<br />

developments as well as<br />

emerging market opportunities.<br />

It takes place in<br />

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June to 1 July.<br />

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extruder of the month<br />

Tubi<br />

Head office: Paddington, NSW, Australia<br />

CEO:<br />

Founded:<br />

Ownership:<br />

<strong>Profile</strong>:<br />

Product lines:<br />

Factory locations:<br />

Other information:<br />

Marcello Russo<br />

1976 (as Ravcoplast)<br />

Private<br />

Tubi began in Australia in 1976 as Ravcoplast, developing pressure and nonpressure<br />

pipe in HDPE and PVC, as well as extruded film. However, the company<br />

sold its interests in conventional pipe in 2009, and began producing a range of pipe<br />

using its own patented system – the Mobile Modular Extrusion Plant, which allows<br />

production of HDPE pipe in the field.<br />

Using its mobile production units, the company produces a range of pipe, including<br />

conventional HDPE, pressure HDPE (up to 40bar) and corrugated HDPE. The way in<br />

which the pipe is produced helps to the cost of pipe transportation, and guarantees<br />

supply – as the plant is situated at the construction site. The fact that pipe is<br />

produced directly on site means that it can be produced in a single length – reducing<br />

conventional weld joints by around 95%.<br />

The company’s headquarters are in Paddington, in New South Wales, but pipe<br />

production takes place all over the world – wherever the company’s mobile units are<br />

located. It recently commissioned its first Tubi 630 modular mobile plant to make<br />

pipe from 90 to 630mm diameter.<br />

Other Tubi in-house technologies, such as Quick-String, allows large bore reeling<br />

and deployment of up to 4000m of portable pipe, with diameters up to 1200mm.<br />

To be considered for ‘Extruder of the Month’, contact the editor on lou@pipeandprofile.com<br />

Forthcoming features<br />

The next issues of <strong>Pipe</strong> and <strong>Profile</strong> Extrusion magazine will have special reports on the following topics:<br />

April <strong>2015</strong><br />

Control & instrumentation<br />

Laboratory extruders<br />

Computer modelling software<br />

Plast preview issue<br />

May <strong>2015</strong><br />

PVC recycling<br />

<strong>Profile</strong> die developments<br />

Plastic <strong>Pipe</strong>s in Infrastructure report<br />

Chinaplas preview issue<br />

Editorial submissions should be sent to Lou Reade: lou@pipeandprofile.com<br />

For information on advertising in these issues, please contact<br />

Claire Bishop: claire@amimagazines.com Tel: +44 (0) 1732 605976


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<strong>Pipe</strong> and <strong>Profile</strong> - Jan/Feb<br />

The January/February <strong>2015</strong><br />

edition of <strong>Pipe</strong> and <strong>Profile</strong><br />

Extrusion looks at the latest<br />

developments in<br />

screenchangers, trends in the<br />

titanium dioxide market, and<br />

innovation in ETP and<br />

composite pipe.<br />

➤ Click here to view<br />

<strong>Pipe</strong> and <strong>Profile</strong> - Nov/Dec<br />

The November/December<br />

edition visits AMI’s WPCs<br />

conference to find out about the<br />

latest market and technology<br />

trends. Plus, a novel application<br />

for PEX pipe in a US ski resort<br />

and the latest innovations in<br />

materials handling and pipe<br />

joint inspection.<br />

➤ Click here to view<br />

Compounding World – Feb<br />

Compounding World’s February<br />

issue is packed with articles on<br />

thermally conductive plastics,<br />

extrusion simulation software,<br />

new machinery on show at<br />

NPE, materials handling<br />

systems, and the return of<br />

aliphatic polyketones.<br />

➤ Click here to view<br />

<strong>Pipe</strong>line Coating – Feb<br />

The February edition of<br />

<strong>Pipe</strong>line Coating takes an in<br />

depth look at investment in the<br />

African pipeline industry. Plus<br />

the latest oil and gas market<br />

outlook, offshore lining<br />

technology and smart coating<br />

developments.<br />

➤ Click here to view<br />

Injection World – Jan/Feb<br />

This edition of Injection World<br />

magazine is packed full of<br />

features on thin-wall<br />

moulding, thermoplastic<br />

composites, modelling<br />

software, smart factories and<br />

European market trends. Plus<br />

there’s a focused preview of<br />

NPE.<br />

➤ Click here to view<br />

Film and Sheet – Jan/Feb<br />

This edition of Film and Sheet<br />

Extrusion includes reports on<br />

developments in bioplastics,<br />

materials testing technologies,<br />

and new polyolefin grades and<br />

applications. Plus there is a<br />

preview of the NPE <strong>2015</strong><br />

exhibition.<br />

➤ Click here to view<br />

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dates for your diary<br />

Global exhibition guide <strong>2015</strong><br />

10-14 <strong>March</strong> Koplas, Seoul, South Korea www.koplas.com<br />

12-14 <strong>March</strong> 3P Plas Print Pack, Lahore, Pakistan www.plasprintpack.com.pk<br />

23-27 <strong>March</strong> NPE, Orlando, FL, USA www.npe.org<br />

26-28 <strong>March</strong> Eurostampi & Plastixexpo, Parma, Italy www.mecspe.com<br />

2-5 April IPAF, Istanbul, Turkey www.ipaffuarlari.com<br />

8-10 April Plastic Japan, Tokyo, Japan www.plas.jp/en<br />

21-24 April Elmia Polymer, Jönköping, Sweden www.elmia.se/en/polymer<br />

4-8 May Feiplastic, Sao Paulo, Brazil www.feiplastic.com.br<br />

5-9 May Plast, Milan, Italy www.plastonline.org/en<br />

7-9 May PPP Africa, Nairobi, Kenya www.expogr.com<br />

20-23 May Chinaplas, Guangzhou, China www.chinaplasonline.com<br />

23-25 May PPP Africa, Tanzania www.expogr.com<br />

16-17 June PDM & PRE, Telford, UK www.pdmevent.com<br />

16-18 June Plast-Ex, Toronto, Canada www.plast-ex.org<br />

9-12 July Interplas Thailand, Bangkok, Thailand www.interplasthailand.com<br />

26-29 August T-Plas / Tiprex, Bangkok, Thailand www.tplas.com<br />

1-3 September Plasti & Pack, Lahore, Pakistan www.plastipacpakistan.com<br />

22-24 September Composites Europe, Dusseldorf, Germany www.composites-europe.com<br />

13-17 October Fakuma, Friedrichshafen, Germany www.fakuma-messe.de<br />

20-22 October Plastex Uzbekistan, Tashkent www.plastex-events.com<br />

AMI conferences for pipe & profile extruders<br />

3-5 <strong>March</strong> <strong>2015</strong> Cables, Cologne, Germany<br />

16-18 <strong>March</strong> <strong>2015</strong> PVC Formulation, Cologne, Germany<br />

14-16 April <strong>2015</strong> Plastic <strong>Pipe</strong>s in Infrastructure, London, UK<br />

21-23 April <strong>2015</strong> Compounding World Congress, Cologne, Germany<br />

9-10 June <strong>2015</strong> <strong>Profile</strong>s, Philadelphia, USA<br />

9-11 June <strong>2015</strong> Masterbatch, Cologne, Germany<br />

23-24 June <strong>2015</strong> Polymers in Cables, Philadelphia, USA<br />

15-16 September <strong>2015</strong> Medical Grade Polymers, Boston, USA<br />

For information<br />

on all these events<br />

and other conferences on<br />

film, sheet, pipe and<br />

packaging applications, see<br />

www.amiplastics.com<br />

Don’t miss a single issue<br />

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