Teko-plastic, a family-owned company based in Preding near Weiz, Austria, has adopted sustainability and energy efficiency as its guiding principles. In addition to using recycled materials in production and investing in renewable energy, the company installed a machine of the EcoPower series from WITTMANN BATTENFELD this February and has carried out energy measurements with this machine.

The company Teko-plastic Kunststoffwerk E. Schröck GmbH, now managed by Theo Koblischek in the third generation, was founded by Erich Schröck und Theo Koblischek in 1961. Today’s 18,000 m² production facility in Preding near Weiz, Styria, was built in 1971. Since the beginning of the 1980s, Teko-plastic has specialized in the production of household goods made of plastic. With its takeover of BEKAFORM Kunststoffproduktion GmbH, Teko-plastic successfully entered the German market.

More than 80 % of the company’s sales are realized with its own products, such as bowls, household and kitchen aids, baskets, tubs, boxes, buckets, canisters, fresh food boxes and much more. Just under 20 % are contributed by job order production for Austrian industrial customers. Apart from its main markets Austria and Germany, Teko-plastic also supplies its products to customers in Switzerland, the Netherlands, Belgium, Slovenia, the Czech Republic, Sweden and France.

To make its products, the company with a workforce of 48 employees uses 12 BATTENFELD injection molding machines ranging from 1,000 to 8,000 kN in clamping force. The raw materials used are polypropylene and polyethylene, with 25% of the materials processed consisting of regrind. The latter is mostly purchased in Austria and Germany, but sprue and faulty parts are also recycled in-house and mixed in with the virgin materials.

However, Theo Koblischek’s ecological commitment goes far beyond just using recycled materials in production. Investments are also being made into improving the company’s energy balance, with moves such as energy recovery from waste heat utilization and use of solar energy. Currently, 6,000 m² of roof area are being covered with solar cells designed for a total annual output of 850,000 kWh. Teko-plastic expects to use 550,000 kWh of this for its own energy requirements, the rest will be fed into the public electricity network.

With energy costs making up an increasing share of the total production costs, it was natural for Theo Koblischek to take a closer look at the injection molding machines, too. “The energy costs have more or less doubled over the last year”, says Theo Koblischek, “so the issue of energy efficiency is now highly relevant for us.” In February this year, a machine from the all-electric EcoPower series with 4,500 kN clamping force was installed at Teko-plastic. The machines of the EcoPower series stand out by their extremely high level of energy efficiency, due on the one hand to the use of ultra-modern servo motors and on the other hand to the machine’s KERS (Kinetic Energy Recovery System) technology.

Theo Koblischek wanted to evaluate as precisely as possible the ultimate benefit gained from using state-of-the-art WITTMAN BATTENFELD technology, so he carried out the relevant energy consumption measurements on the new EcoPower 450 equipped with an 85 mm screw. He subsequently compared the measurement results with those achieved with a BATTENFELD TM 4500 injection molding machine installed in 2001 and fitted with a 100 mm screw. On both machines, a bucket with a volume of 10 liters was produced. The difference between the two machines’ energy consumption rates turned out to be enormous. Over an eight-hour measurement period, an energy consumption of 68 kWh with a cycle time of 16 seconds was measured on the TM, while the consumption shown for the new EcoPower was a mere 24 kWh with a cycle time of about 13 seconds. Theo Koblischek comments: “Our measurements have shown that by comparison with the TM, an output of 115% has been made possible with an energy input of only 35 %. If both machines were equipped with screws of the same diameter, the difference in energy requirements for both machines in favor of the EcoPower would be even greater. Moreover, the EcoPower’s water consumption is also considerably lower.”

Theo Koblischek has now measured the electricity consumption of all machines previously used on the company’s production floor and compared the readings to the consumption data of comparable new machines from WITTMANN BATTENFELD. The option of replacing all machines with up to 4,500 kN clamping force with all-electric machines opens up an enormous savings potential of more than 60% for these machine sizes. But for larger machines, too, energy savings of around 40 % can still be achieved. Theo Koblischek concludes: “If the electricity price remains at the current level, an exchange of our total range of machinery could be fully amortized within 10 years. Due to the particularly high savings potential for the smaller high-speed machines, we will replace these with new ones first. “

Concerning the installation of the EcoPower 450 delivered in February 2022, Theo Koblischek further remarks, that in addition to the machine itself, he also has come to greatly appreciate the customer support provided by the WITTMANN BATTENFELD service team.

Exact Metrology: A Division of In-Place Machining Company and a comprehensive 3D metrology service provider and hardware sales company, now offers the newest version of its Artec Micro scanner. This new model distinguishes itself through its professional ultra-high precision industrial desktop 3D scanner, designed to deliver industrial-quality scans in just one click.

With a 2-year warranty, features of the Artec Micro include up to 10 microns accuracy and is perfect for quality testing and reverse engineering. It produces metrology-grade scans suitable for quality control, while removing the need for targets on the scanned object.

Artec Micro’s advanced twin color cameras and blue LED lights are synchronized with the scanner’s dual-axis rotation system to create a digital copy of your object with a minimum of frames captured. In addition, the Smart Scanning mode captures every surface of the object in the least amount of time, using an ideal number of frames. A minimum amount of training is required with Micro, as the scanner is user-friendly and ready to set up quickly. The scanner integrates with Artec Studio for real-time digital capture.

Delivering highly accurate scans, not only can Micro “see” well below the human visibility threshold of 40 microns, but its 3D measurements are among the best in today’s cutting edge scanners, making it a perfect choice for inspection and much more. Reverse engineering is completed with Artec Micro’s precise 3D measurement to digitally fit together legacy parts with those customers create, capturing even the smallest details that most scanners miss.

In minutes, Artec Micro transforms intricate items into CAD/CAM data for design, modification, 3D printing and casting. As a result, this saves hours of time in the design and production of complex pieces. The scanner also creates highly-detailed 3D models.

https://www.exactmetrology.com/

Unique recycling technology helps the industry close the loop on PVDC- coated PET films

Solvay and Carbios successfully demonstrated that multi-layer PET1 films coated with Diofan® PVDC2 high- barrier polymer are fully compatible for enzymatic depolymerization – Carbios’ innovative recycling process. Results show that the PET is fully depolymerized, whereas the PVDC remains intact.

Carbios is the first company to have developed enzymatic processes dedicated to the end-of-life of plastics and fibers. The collaboration builds upon the results of an earlier proof of concept by Solvay which has confirmed that waste from packaging or other applications using bi-oriented PVDC multi-layer film can efficiently be recycled without compromising the outstanding barrier performance of the polymer. It aligns with Solvay One Planet’s sustainability ambition to preserve resources and contribute to safer, cleaner and more sustainable products.

“OEMs and brand owners are under tremendous pressure to increase the sustainability of their products,” says Guruprasad Sivakumar, Head of Marketing for Consumer, Healthcare and Environment at Solvay. “While PVDC has long been used for coating flexible PET films e.g. in food packaging, where it delivers impressive barrier properties, these multi-layer structures have been challenged regarding their recyclability. This is where Carbios’ unique recycling technology comes as a real game changer. By providing a feasible and sustainable end-of-life management solution, it can help the industry close the loop on PVDC-coated PET films and extend the value proposition of our high-barrier specialty polymers to further markets, such as the packaging of pharmaceutical products.”

The patented recycling process developed by Carbios works with specific enzymes to break down the PET molecules back into their constituent monomers. The technology uses moderate temperatures, which is ideal in the presence of PVDC, and can be applied to recycle post-industrial as well as post-consumer waste. The resulting monomers could be purified for reuse in the production of a new PET polymer of the same quality as those derived from virgin petrochemical feedstock. Notably, the joint study by Solvay and Carbios has demonstrated that PVDC does not jeopardize the depolymerization of PET.

“Our enzymatic approach overcomes the limitations of other recycling processes,” explains Alain Marty, Chief Scientific Officer at Carbios. “Conventional thermo-mechanical routes require clean-mono-material grade waste, and high-heat chemical or pyrolytic recycling cannot be used to regain the material value still present in many end-of-life applications. As the industry’s first solution for the recycling of complex multi-layer structures such as PVDC coated PET films, our enzymatic biological recycling makes a significant contribution to help the plastics economy become more circular. The joint study with Solvay also shows what can be achieved by collaborating towards a common goal – to the benefit of all players along the value chain.”

Solvay’s Diofan® and Ixan® high-barrier polymers have a track record of proven food packaging applications from fresh and processed meat to fish, poultry and cheese. They provide a superior barrier against the permeation of both water vapor and oxygen – most existing alternatives only meet one or the other purpose – as well as to odors and loss of aroma or flavor.

New multi-year license and supply agreement builds on successful joint development of biobased coatings for paper and board products using sustainable biopolymer

Danimer Scientific, Inc. and Kemira announced a multi-year license and supply agreement, exclusive in Kemira’s core markets, to commercialize biobased barrier coatings for paper and board products. The companies will introduce the newly developed coatings for food and beverage industry applications within North and South America, Europe, the Middle East and Africa in the coming years. The relevant dispersion barrier market size is currently around EUR 500 million and is expected to grow around 10% per annum.

“This new, exclusive agreement is a major step in realizing our biobased strategy to deliver high-quality, sustainable and circular packaging solutions to our customers,” said Antti Matula, SVP, Global Product Lines & Business Development for Kemira Pulp&Paper. “We’re excited to expand our partnership with Danimer to harness the full potential of PHA globally. Together we will bring new biobased and circular products to markets, an important milestone in reaching our biobased growth targets and differentiating from competitors.”

“This expansion of our partnership with Kemira represents several important milestones in Danimer’s mission to reduce plastic waste,” said Stephen E. Croskrey, Chairman and CEO of Danimer Scientific. “First, this successful project reflects the potential for PHA to serve as a sustainable alternative to traditional plastic across multiple categories. Second, this new license and supply agreement establishes a new revenue stream that will further support the global commercialization of this material. We are grateful for Kemira’s continuing partnership and look forward to helping them bring these coatings to market.”

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SABIC, a global leader in the chemical industry, today introduced LNP ™ THERMOCOMP ™ OFC08V compound, a material well suited for 5G base station dipole antennas and other electrical/electronic applications. This new compound can help the industry develop lightweight, cost-effective, all-plastic antenna designs that facilitate deployment of 5G infrastructure. In an era of increasing urbanization and smart cities, broad availability of 5G networking is urgently needed to provide fast, reliable connectivity for millions of residents.

“To help achieve 5G’s promise of faster speeds, increased data loads and ultra-low latency, RF antenna manufacturers are revolutionizing their designs, materials and processes,” said Joshua Chiaw, Director, Business Management, LNP & NORYL, Specialties, SABIC. “We are helping our customers simplify the production of RF antennas, which are used by the hundreds in arrays within active antenna units. Our latest high-performance LNP THERMOCOMP compound not only helps streamline manufacturing by avoiding post processing, but it can also deliver exceptional performance across multiple, critical areas. By continually developing new materials for 5G infrastructure, SABIC aims to accelerate expansion of this next-generation networking technology.”

LNP THERMOCOMP OFC08V compound is a glass fiber-reinforced material based on polyphenylene sulfide (PPS) resin. It features excellent plating performance using laser direct structuring (LDS), strong layer adhesion, good warpage control, high heat resistance, and stable dielectric and radio frequency (RF) performance. This unique combination of properties could enable an injection moldable new dipole antenna design, offering advantages over traditional printed circuit board (PCB) assembly and the selective electroplating of plastic.

Across-the-Board Performance Benefits
The new LNP THERMOCOMP OFC08V compound is formulated for potential use in metal plating using LDS. The material offers a wide laser processing window and both ease of plating and uniformity in plating line width to help ensure stable and consistent antenna performance. Strong adhesion between the plastic and metal layers avoids delamination, even following thermal aging and lead-free reflow soldering. Improved dimensional stability and lower warpage compared to competitive glass-reinforced PPS grades help achieve
smooth fixation of the metal plating during LDS, as well as accurate assembly. Thanks to these attributes, LNP THERMOCOMP OFC08V compound has been listed by LPKF Laser &
Electronics, a German provider of laser manufacturing solutions, as an approved thermoplastic for LDS with the company’s systems.

“All-plastic dipole antennas made with glass-reinforced PPS are replacing traditional designs because they can reduce weight, simplify assembly and deliver higher plating uniformity,” said Jenny Wang, Director, Formulation and Application, APAC, Specialties, SABIC. “However, conventional PPS materials need a complex metallization process. To address this challenge, SABIC developed a new, specialized PPS-based compound with LDS capability and high-strength bonding.”

Compared to the current complex selective electroplating of plastic, which is a widely used process involving multiple steps, LDS-enabled LNP THERMOCOMP OFC08V compound offers greater simplicity and higher productivity. After injection molding of the part, LDS only requires laser structuring and chemical plating. In addition, the new LNP THERMOCOMP OFC08V compound delivers all the performance benefits of glass-filled PPS, including high heat resistance for PCB assembly using surface mount technology, and inherent flame retardancy (UL-94 V0 at 0.8 mm). Low dielectric values (dielectric constant: 4.0; dissipation factor: 0.0045) and stable dielectric performance, together with good RF performance under harsh conditions, help optimize transmission and extend useful life.

“The availability of this advanced LNP THERMOCOMP OFC08V compound can contribute to improved antenna designs and consistent performance in the field, simplify the metallization process and lower system costs for our customers,” Wang added.