Choosing a Contract Manufacturer That Supports Your Vision

For any medical device OEM, selecting a contract manufacturing organization (CMO) is not a decision to take lightly. In fact, it’s often compared to dating — because the long-term implications of the partnership are just as significant. With stringent FDA and EMA regulatory requirements, long product lifecycles, and intricate product development timelines, switching CMOs mid-stream can be prohibitively expensive and risky. That’s why the first match must be the right one.

At Accumold — a global leader in micro molding — the success of an OEM-CMO partnership hinges on more than just technical capabilities. It’s about finding alignment in values, vision, and capabilities that go beyond part production. It’s about ensuring that the people who will come into contact with your product every day care about it as much as you do. And it’s about choosing a partner with proven capability, scalability, and sustainability to see your project through — from the first prototype to millions of units, delivered with consistency and confidence.

So how should OEMs approach the challenge of finding the right contract manufacturing partner? And what does the ideal CMO relationship look like? Let’s explore those questions through their approach to micro molding and customer collaboration.

UNDERSTANDING THE HUMAN FACTOR IN MANUFACTURING

It’s easy to get caught up in the numbers — cycle times, tolerances, cost-per-part — but those don’t tell the full story. Ultimately, it’s people who make products. And when you’re outsourcing the manufacture of critical components, particularly in regulated fields like medical devices, you’re entrusting your product — and your reputation — to those people.

This is why OEMs should pay attention to the workplace culture, energy, and employee satisfaction at potential CMOs. At Accumold, there’s an emphasis on understanding who is on the floor, assembling, molding, and inspecting your parts. Are they engaged? Do they take pride in their work? Do they collaborate and communicate well?

They answers these questions with transparency. With over 350 employees operating in a state-of-the-art, 130,000 square foot facility that runs 24/7, the company fosters a culture of excellence and accountability. Long-term employment is common — a testament to employee satisfaction and company stability. Visitors often comment on the high energy of the production floor and the cleanliness and organization of employee spaces. These aren’t superficial markers, but instead they reflect a company-wide dedication to quality, order, and doing the right thing — for the customer, and for each other.

MORE THAN JUST MOLDING

Precision micro molding isn’t merely about making small plastic parts — it’s a discipline that demands mastery across design, tooling, material science, molding, and metrology. Their deep capabilities across all these domains set it apart.

From the outset, they emphasize Design for Micro Molding (DfMM), working collaboratively with OEMs to refine their product designs for manufacturability. The company’s in-house tooling team builds molds that can meet micron-level tolerances. This is not common. In fact, only a small group of companies globally can claim to consistently achieve the precision they deliver.

And it doesn’t stop there. With integrated metrology and validation systems, plus the adoption of micro additive manufacturing (micro-AM) for prototyping and complex geometries, they ensures that even the most advanced parts can be manufactured consistently.

When assessing a CMO, OEMs should ask, “Does this partner have the right technology for our product? Do they have experience in our market? Can they handle the complexity our components demand?”

In their case, the answer is a confident yes. The company’s team doesn’t just make parts — it engineers solutions.

READY FOR GROWTH

A common pitfall for OEMs is selecting a CMO that can make a prototype — but can’t scale. When early-stage development is smooth but volume production falters, programs stall, deadlines slip, and reputations suffer. This is where scalability becomes mission-critical.

Their manufacturing infrastructure is specifically designed for scale. The company runs dedicated high-volume production cells with automation, process control, and repeatable quality baked into every step. Whether the production requirement is in the thousands, millions, or even billions, they have proven it can deliver. This is especially crucial for medical and telecom applications, where demand is sustained and long-term.

Moreover, scalability at Accumold isn’t just physical — it’s also financial. The company’s long-standing operational stability and financial independence means it’s prepared for the long haul. Economic fluctuations, supply chain disruptions, and market volatility are less likely to derail your program when your CMO is well-capitalized and deeply experienced.

It’s important for OEMs to assess whether their CMO has the infrastructure and financial resilience to grow with them. At Accumold, scalability is not an aspiration — it’s the reality, proven every day in production.

SUSTAINABILITY BUILT INTO THE BUSINESS

The word “sustainability” gets thrown around a lot. At Accumold, it’s more than a buzzword — it’s an operating principle. And it’s not just about environmental responsibility, though, that’s certainly part of it.

From an environmental perspective, they minimize waste through precise material usage, energy-efficient practices, and optimized production flows. These efforts not only lower environmental impact, but they also support customer goals for responsible sourcing and lifecycle stewardship.

But sustainability also refers to business sustainability — the ability to remain a trusted, capable partner for the entire product lifecycle, no matter how long. This is especially vital in medical device manufacturing, where product lifespans often exceed 10 years. Having to transfer production mid-cycle due to supplier instability can mean new tooling, revalidation, and regulatory delays. Their 4 decades-long presence and continued investment in people, technology, and infrastructure provide confidence that they’ll be there from day one through year ten and beyond.

As an OEM, you should ask, “Is this CMO built to last? Are they growing sustainably? Do they have a track record of continuity?”

At Accumold, the answers to these questions align with the company’s foundational commitment to long-term, value-driven partnerships.

FIT, ALIGNMENT, AND REALISM

Finally, there’s the matter of “fit”. Not every OEM is right for every CMO — and vice versa. They approach this candidly, evaluating whether a new partnership makes sense early on. Startups, for instance, often come with big ideas but less clarity around manufacturing realities. They invests time upfront to determine whether its services align with the OEM’s needs — and whether both sides are ready for the road ahead.

This approach avoids costly misalignments and sets realistic expectations from the beginning. You want to ask, does the CMO have the technology types that we’re looking at getting into? Do they have experience with the relevant types of products?

The OEM should also consider cultural alignment. Are the people at this CMO driven to do the right thing? Do they have a customer-first mindset? Do they treat each other — and the OEM team — with respect and collaboration?

At Accumold, these qualities are part of the DNA. The team isn’t just skilled — they’re motivated, curious, and committed to innovation on behalf of their customers.

A PARTNERSHIP THAT SCALES

Choosing the right contract manufacturing partner is not just a procurement decision — it’s a strategic investment in the future of your product. And in the high-stakes world of micro molding for medical and high-tech industries, that decision must be guided by more than capabilities alone.

It must encompass an organization’s ability to scale with you, to operate sustainably, and to maintain a team that is not just competent, but collaborative and committed. Accumold exemplifies this model, offering OEMs a partner that is technically equipped, operationally ready, and culturally aligned for long-term success.

In the end, it’s not just about who can mold the part. It’s about who you want molding it — day in and day out — for years to come.

www.accu-mold.com

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Industry at the Crossroads: Plastics and Circular Strategies

K 2025 from 8 to 15 October in Düsseldorf has set itself the goal of addressing the central issues of our times. One of its three Hot Topics reads “Shaping the Circular Economy”. Reason enough to shed some light on the current state of affairs in terms of circularity six months ahead of the world-leading trade fair of the plastics and rubber industry.

The global raw material dilemma is a result of the fact that over 90% of the 100 billion tons of raw materials used each year are not recycled. A concerning ratio that the European Investment Bank (EIB) has identified. Companies are under increased pressure to manage resources more carefully due to rising CO₂ costs, unstable raw material prices, and geopolitical insecurities.

Circularity is considered the decisive lever for achieving a sustainable future. An analysis by management consultancy Material Economics shows that Europe could save 450 million tons of CO₂ equivalents through closed material cycles by 2030 – this corresponds to 8% of the current emissions. In the long term, the Ellen MacArthur Foundation forecasts that up to 45% of emissions could be avoided by a closed-loop circular economy.

This transformation also holds enormous economic potential: according to estimates by consulting group EY, the use of secondary raw materials reduces energy consumption by 20% to 90%, saves large amounts of water and could save European firms up to EUR 465 billion in material costs per year. The International Labor Organization (ILO) also expects seven to eight million new jobs to be created worldwide by the transition to a circular economy by 2030. More and more use cases show that circularity makes not only ecological but also economic sense. For instance, the German Cabka Group annually produces pallets and crates from some 150,000 tons of recycled plastics by their own accounts – proving thereby how waste can be turned into valuable products.

Plastics industry: a key sector with catching up to do

The plastics industry plays a pivotal role in this transformation. In 2023 413.8 million tons of plastics were produced worldwide, according to Plastics Europe, but the share of recycled materials continues to be low: only 8.7% of plastics were recycled – most of them by mechanical recycling – whereas the lion’s share was incinerated or landfilled. This is happening even though recyclates hold an enormous potential. Their production requires markedly less energy than the production of new products from fossil raw materials, thereby substantially reducing CO₂ emissions. On top of this, their use increases supply security – a factor of rising importance in times of geopolitical crises.

However, recycling is technically demanding – and often more expensive than producing new plastics. After all, post-consumer plastics have to be sorted, cleaned and prepared with great effort. In addition, the legal requirements are strict, high-quality recyclates scarce and many processes energy-intensive – all resulting in higher production costs compared to new plastics. “But nobody wants to pay higher costs,” stresses Ulrich Reifenhäuser, Chairman of the K Advisory Board. “Plastics are so successful because they are so much better than other materials. But the transition to the circular economy costs money. This cost issue will not be overcome without regulatory requirements.”

However, the responses to the question of how the transition to a functioning circular economy will work vary from country to country.

Europe looks to regulation

While other nations focus on voluntary commitments and market-oriented solutions, Europe regulates by law. Strategies such as the “Circular Economy Action Plan” (CEAP) and regulations such as the Packaging and Packaging Waste Regulation (PPWR) and the Single-Use Packaging Directive (SUPD) drive the transition to circularity by means of recycling rate, mandatory recyclate content and Extended Producer Responsibility (EPR). The PPWR shows how this works: since 2025 single-use PET bottles have to contain a minimum of 25% recycled plastic and this percentage will go up 30% by 2030. For manufacturers such as Coca-Cola or Nestlé this means rebuilding their supply chains, sourcing high-quality recyclates, adapting production – otherwise they run the risk of a sales ban. The SUPD is also having an impact: in Lithuania the return rate of PET bottles shot up from 34% to 92% after the introduction of a deposit system – in as little as two years. Companies face major challenges in the process: the limited availability of high-quality recyclates, the technical complexity of changing over to a recycling-friendly design – not forgetting the short deadlines set for complying with these often-complex requirements.

Chemical ingredients are also increasingly moving into the focus of the EU. Especially disputed is the handling of PFAS since a ban could make recycling considerably more difficult – because plenty of waste plastics would then be classified as contaminated and eliminated from the circular economy. Wolfgang Große Entrup, Director General of VCI, therefore warns against a blanket ban: “With each individual substance banned in the EU the risk grows that more of our industry players move to less regulated regions. This, however, does not solve the original problem.”

Asia: between advances and structural deficits

Accounting for 53% of global plastics production Asia is the main player – and the main source of plastic waste. While some countries pursue ambitious recycling strategies, others lack the basic infrastructure.

China’s circularity offensive: centrally controlled, consistently implemented

For a long time, China was the biggest importer of plastic waste, now the country is recharting its course. By adopting its “National Sword Policy” the country has stopped the imports of unsorted plastic waste and is now driving the expansion of own recycling structures. The 14th 5-year plan focuses on modern collection and sorting systems and promotes both mechanical and chemical recycling. By 2035 the industry aims to be largely decarbonized and have transited to closed material cycles. This strategy is accompanied by the “Circular Economy Promotion Law”, which obliges companies to take back and safely dispose of specific products, and the establishment of the state-owned “China Resources Recycling Group” with the aim of centrally controlling the transformation.

Japan and South Korea: driving technology systematically

Japan and South Korea are among the pioneers in circular economy – not least due to clear political objectives and early-adopted legislation. In Japan the “Container and Packaging Recycling Act” has already obliged companies since the 1990s to participate in return and recycling systems. This is supported by the “Plastic Resource Circulation Act” adopted in 2022, which promotes recyclate use and prescribes detailed recycling plans for plastic products.

South Korea pursues a systemic, technology-driven approach via its new “Act for Promotion of Transition to a Circular Economy Society” (APTCES):  binding recycling rates, clear requirements for sustainable product design as well as targeted regulation for hard-to-recycle products. In addition, companies wanting to place new recycling technologies on the market, are temporarily exempted from restrictions.

Unlike Europe, these two countries are banking on clear responsibilities, hands-on implementation and targeted innovation funding rather than detailed regulation. This approach is supported by high social acceptance and responsibility assumed across the board when it comes to waste separation and saving resources, for example.

From India to Indonesia: why the circular economy is faltering

In India the “Plastic Waste Management Rules” (PWMR) oblige companies to take back plastic waste. Despite this important step insufficient infrastructure and the varying regional applications of the rules remain a major challenge for a nation-wide implementation. Similar problems exist in Vietnam, where an EPR law was introduced in 2022.  It holds manufacturers and importers accountable for seeing to the recyclability of their products.

In Thailand the “Plastic Waste Management Roadmap 2030” pursues the aim of recycling or energetically using 100% of plastic waste by 2027. There are local initiatives in Indonesia but there is no comprehensive national strategy. One objective is to drastically reduce the plastic waste that ends up in the sea by 2040.

Despite the progress made in these countries the regional fragmentation of waste management and the lack of infrastructure continue to pose a major challenge. Raising people’s awareness and stronger industry involvement will make or break the success of these measures.

North America: a patchwork of strategies

In North America circularity strategies are heavily fragmented. The US is pursuing an approach that comprises both state initiatives and private business measures. 33 US states have established EPR programmes, which oblige manufacturers of single-use packaging to financially participate in waste management. By 2032 100% of packaging is to be recyclable or compostable, and 65% of one-way packaging be recycled. Other states, however, lag behind. There is also another reason why plastic recycling in the USA only has a low uptake compared to the rest of the world, despite modern recycling technologies: “There is neither a national nor a state-wide recycling programme that would cover at least a complete federal state. Instead, individual cities and municipalities decide whether, how and which waste they collect and sort,” explains the German federal economic promotion agency, Germany Trade & Invest (GTAI).

Canada pursues a more comprehensive approach to promote the circular economy. The government has introduced the “Federal Plastics Registry”, a national registry for plastics to collect data about the production, use and disposal of plastics. It is designed to increase transparency and make for more effective plastic management. The “Action Plan on Zero Plastic Waste” aims to reduce plastic waste and establish a circular economy for plastics. It includes measures for reducing single-use plastics and promoting reuse and recycling. Beyond this, a gradual approach is pursued to reduce plastic waste by banning single-use plastic products and introducing EPR.

South America has a long way to go

In South America the circular economy is still in its infancy – some 90% of waste ends up at landfills and recycling is only of secondary importance. Chile, Colombia and Brazil have national return and circularity schemes such as Chile’s “Ley REP”, Colombia’s “Basura Cero” initiative or voluntary industry solutions in Brazil. Uruguay banks on consistent waste management with its Integrated Waste Management Act (Ley 19.829) and promotes packaging recycling. Despite various advances and initiatives, however, infrastructure remains insufficient in many South American regions and success will depend on further state investment, international cooperation and stronger awareness raising among the population.

https://www.k-online.com/

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STADLER’s Tech Powers New Republic Services Recycling Facility in Indiana

In addition to strengthening Republic Services’ vertically integrated plastics recycling operations, the new Indianapolis Polymer Center expands on the success of the Las Vegas site. The plant’s purpose is to recover PET and PO from pre-sorted plastics that Republic Services collects. It will supply premium, food-grade recycled plastics that may be used again to make new bottles, jugs, and containers.

The new Polymer Center was inaugurated with an official ceremony that included remarks by Jon Vander Ark, Republic Services President and CEO; Tim Oudman, Republic Services Senior Vice President, Sustainability Innovation; and Chris Nie, Republic Services Area President, and attended by Willi Stadler, CEO of the STADLER Group; Mat Everhart, CEO of Stadler America LLC; and Jürgen Berger, Head of International Sales at STADLER Anlagenbau GmbH.

“This new facility represents another major step forward in our plans for a nationwide network to close the loop on plastics recycling and help customers achieve a true plastics circular economy,” said Pete Keller, Republic Services Vice President, Recycling and Sustainability. “With the addition of a second Polymer Center we are expanding our processing capacity to produce high-quality recycled resins, contributing to a more sustainable future for packaging in the U.S.”

“The new Indianapolis Polymer Center is a testament to STADLER’s commitment to innovation and excellence in the U.S. recycling industry, contributing to the development of a plastics circular economy,” stated Jürgen Berger. “We are proud of the trust that Republic Services have placed in our company and in our collaborative efforts to drive positive change in the PET and Polyolefins markets in this country,” added Willi Stadler.

A State-of-the-art recycling process to close the plastics circular economy loop

The Republic Services Polymer Center in Indianapolis incorporates a cutting-edge dual-line system designed by them. Bales of mixed plastics are opened using their WireX machine for fully automated wire removal. The materials are fed into the facility and processed separately on two dedicated lines: one for PET and one for mixed plastics, with capacities of 5.5 and 5 tons per hour, respectively.

The process on the PET line begins with mechanical separation and cleaning to remove ferrous particles. A STADLER STT2000 ballistic separator then sorts materials into rigid, flexible, and fines fractions, which undergo near-infrared (NIR) sorting to further separate caps, rings, and labels. The 3D fractions go on to be processed through their Label Remover and Label Separation Hood. Clear PET, caps, and rings are directed to the washing line for granulation and cleaning for reuse, while color PET is compacted into bales.

On the mixed plastics line, materials are first sorted into fines and sieve overflow. The heavier fractions from the overflow are then separated into four polyethylene (PE) fractions –Natural, White, Red/Orange/Yellow, and Other/Color – and two polypropylenes (PP) fractions – Natural/White and Other/Color. PET is recovered from this stream and redirected to the PET line for further processing. The final sorted products are stored in dedicated bunkers before being baled for market distribution.

The linear flow of the plant’s design enhances operational efficiency by improving access to all areas, simplifying maintenance, and incorporating a fully enclosed pre-sort area and a control room with a comprehensive view of material flow and baler operations. The facility also prioritizes workplace quality, offering an open, well-lit environment.

“The Indianapolis Polymer Center is amazing; it might be the nicest looking build-out I’ve ever seen in any plastics plant in the world. The whole installation has a light and airy feel to it, making it a great environment to work in,” said Mat Everhart at STADLER America.

A Growing Partnership for a Circular Economy

Republic Services selected STADLER for the Indianapolis Polymer Center following the successful collaboration on the Las Vegas facility and STADLER’s proven expertise in delivering high-performance recycling solutions. The expansion of Republic Services’ Polymer Centers underscores the growing demand for high-quality recycled plastics in the U.S., driven by both regulatory requirements and consumer preference for sustainable packaging.

This new facility also incorporates additional processing steps to provide Republic Services with greater flexibility in selecting markets for their recycled materials and expanding the range of accepted inputs.

“Our partnership with Republic Services goes beyond constructing state-of-the-art recycling facilities,” concluded Mat Everhart. “It’s about shaping the future of plastics recycling in North America. The success of the Indianapolis plant marks another milestone in our commitment to supporting a more circular economy through advanced sorting technology and strategic collaboration.”

As Republic Services continues to expand its network to close the loop on plastics recycling, they remain a key partner in designing and delivering world-class recycling infrastructure. The Indianapolis facility is expected to make a significant contribution to increasing the availability of high-quality recycled plastics, reinforcing the industry’s transition to a more sustainable future.

https://w-stadler.de/

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Virgin PET Outsells R-PET by Wide Margin in Europe

Since cost-cutting is still crucial in 2025, several firms are reducing the usage of recycled content due to spreads of about €600/ton between virgin PET, food-grade pellet (FGP), and recycled polyethylene terephthalate (R-PET).
With improvements in the free delivered (FD) colorless (C) bale and flake pricing in March, ahead of the start of the peak preform manufacturing season in Q2, the R-PET market has turned bullish in Q1, which might further boost demand for the product.
Meanwhile, PET costs have been rising, but they are gradually being driven down by low-cost imports, which might cause the gap between virgin and recycled materials to expand even more.

Freely negotiated FGP prices for material available on the open market are currently between €1,600-1,680/ton FD NWE, while contact prices – prices linked to feedstock bale and/or flake and usually subject to a formula calculation – have been heard at well over €1,800/ton in some parts of Europe.

This is in stark contrast to the current price of virgin PET which still represents a significant cost saving in comparison to R-PET flakes and pellets.

Several participants in the R-PET market, including beverage brands, have said some brands and fast-moving consumer goods companies (FMCGs) are cutting back their use of R-PET to the minimum contracted volumes, which for beverage bottles is often between 25-30%. This is either to meet the mandatory recycled content target for beverage bottles as set out in the Single Use Plastics Directive (SUPD), which came into effect on 1 January 2025, or in line with internal company targets.

The Coca-Cola Company announced in December 2024 significant changes to its 2030 sustainability goals, in some cases delaying and minimizing targets – which has led to comments from European R-PET market participants that some brands now feel more emboldened to reduce previously announced R-PET content targets, often set anywhere between 50-100%, to a more manageable, and more cost-efficient level.

Many brands went big on R-PET content targets at the start of the 2020s after the SUPD was passed in 2019, as shown in the chart below. The spread between R-PET FGP and virgin PET rose significantly from 2019 onwards showing an increased level of demand for R-PET, and though the market has been volatile in recent years, the spread between R-PET and PET remains higher than before the Directive was passed.

Prices peaked in June 2022 but the cost-of-living crisis in 2023 and 2024 saw a much sharper focus on cost savings, and recyclers started to come under much more pressure to try and make R-PET more competitive as consumers in parts of Europe focused more on the money in their wallet than the amount of R-PET in their beverage bottle.

PET buyers entering into the R-PET market for the first time sometimes struggle to understand the relationships between feedstock bale and flake and the R-PET FGP they want to use in their preforms or bottles, with some approaching price discussions based purely on where PET prices are rather than taking into account the cost of production through the R-PET chain.

Member states have yet to put in place any significant financial or economic penalties for non-compliance for brands not hitting the SUPD’s 25% target, leading some PET bottle producers and brands to continue to use the minimum R-PET content, or are even stick with 100% PET until forced to make the change.

This is particularly true of small and medium-sized brands, and particularly in parts of central and eastern Europe, though it has also been noted in other parts of Europe too.

Put simply, many brands do not want to pay high prices for recycled material made from post-consumer plastic waste when they can get prime virgin material at lower prices.

The chart below shows the spread between the midpoint of the FD Europe PET bottle grade resin price and the FD NWE food-grade pellet price, which currently stands at €590/ton.

This reduction in the use of R-PET FGP in particular has resulted in some higher-than-expected stock levels leading some suppliers to offer FGP below market price in order shift volumes or free up working capital.

There is still hope that 2025 will see better FGP and R-PET demand compared with the previous two years, and the annual Plastics Recyclers Show Europe (PRSE) in Amsterdam on 1-2 April will be a good opportunity to gauge the feeling of the market for Q2 and into the rest of the year.

In the days ahead of the key industry event, while there is optimism in the market right now, it might not be at the levels that some FGP and preform producers would like to see for the time of year, especially with the prospect of even lower virgin PET prices on the horizon.

 www.bcmpublicrelations.com
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HFFR Additives Tailored for Industrial Polypropylene Use

Highly active, halogen-free (HFFR) grades are now part of Tosaf’s range as an alternative to flame retardants based on chlorine or bromine, allowing for more environmentally friendly solutions to meet regulatory standards and client demands. FR8719PP is made especially to satisfy polypropylene’s flame-retardant needs in extrusion and injection molding applications.

High efficiency at low concentration

In applications including construction, automotive, and shipping packaging, FR8719PP helps to stop fires from spreading and satisfies strict fire safety standards without sacrificing effectiveness, even at very low concentrations. For instance, after converting to halogen-free flame retardants, PP pipes maintain their high impact strength, dimensional stability, and chemical resistance without any limitations. FR8719 exhibits no long-term migration of the active components, in contrast to many halogen-based flame retardants, and equivalent PP products provide noticeably greater UV protection.

The very good dispersion of FR8719PP in injection-molded and extruded PP-based products is one reason for the very high efficiency of this HF flame retardant. This not only enables a relatively low dosage and therefore the mechanical properties to be largely retained, but also uniform flame retardancy across the entire product. In addition, the low potential for dye build-up (DBU) offers a considerable processing advantage over other halogen-free solutions available on the market.

Broad portfolio of halogen-free flame retardants

The choice of flame retardant depends largely on which UL94 classification is to be achieved. For example, to fulfil the requirements of class V-2, flame retardants in low concentrations are sufficient to eliminate the free radicals formed by the heat of combustion and thus suppress the fire. Only in higher concentrations do they also prevent burning droplets, as required by the UL94 V-0 classification.

They have developed an extensive portfolio of HFFR grades that differ from each other in their flame-retardant systems and fulfil individual priorities to achieve the optimum balance between effect and concentration. Their dosage is between 3 % and 10 % and depends on the desired classification, the type and melt flow index (MFI) of the PP, the thickness of the part and the simultaneous presence of other additives. In contrast, intumescent halogen-free flame retardants require a dose of over 20 % to achieve similar performance.

Expanding the portfolio of conventional flame-retardant additives

In addition to developing new HFFR grades that do not harm health or the environment, Tosaf also fulfils the continuing need for halogen-based products. They combine high thermal stability with high performance to fulfil stringent fire standards without compromising the properties of the product. For example, the brominated flame retardant FR6413PE is suitable for all types of PP pipes, while chlorinated cost-effective flame retardants such as FR0049 can be used for both PE and PP.

State-of-the-art production plant for flame retardants

To meet the growing demand for flame retardants, they have invested in a state-of-the- art production facility. A high-tech laboratory equipped with a cone calorimeter for complete combustion analysis, among other things, is available for testing according to a variety of fire standards. In addition, the company has set up pilot lines that simulate real production conditions and make it possible to taylor flame retardant additives for specific applications.

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Eliminating Manual Cleaning in PET Recycling with COBRA’s Filtration System

Short filter service lives and labor-intensive cleaning are no longer an issue

Large-area filtration is stigmatized by high maintenance costs, time-consuming cleaning and switching procedures, and other issues. However, as rPET proportions increase, good filtration becomes inevitable. Therefore, BB Engineering has used its decades of extrusion and filtration experience to address these problems. In addition to meeting the rigorous criteria of recycling operations, the new COBRA filter sets a new benchmark for efficiency, usability, and resource conservation by combining continuous and automated large-area filtration with integrated intermediate filter cleaning.

Large-area fine filtration made for recycling

Recyclers are currently dealing with a dilemma when it comes to filtration. Increasing recycling quotas coupled with insufficient availability mean that lower input qualities are also being considered for recycling, resulting in more challenging contaminants. At the same time, higher-quality applications are being targeted, which further intensifies the requirement for fine filtration. There are systems for large quantities of contaminants, but they do not filter as finely as a candle filter. There are also candle filters that provide excellent filtration but cannot cope with high levels of contamination.

Their new filter can do both. It was specially developed for demanding filtration tasks with high levels of contamination, particularly in PET recycling. Multitasking is the keyword. The filter unites large-area fine filtration with simultaneous, fast and effort-less cleaning, and is therefore able to handle higher contamination rates, which common candle filters would fail on. However, this all-rounder can also be used for other applications, e.g. in synthetic fiber spinning.

Continuity and process stability thanks to automation

As a continuous filter, the COBRA filter has two filter inserts, one of which is always active in production mode and the other either in stand-by mode or in intermediate cleaning. The automated switchover ensures a smooth changeover between the inserts. The status of the filter inserts is constantly checked by the system and, if necessary, their filter automatically initiates the cleaning and changeover process. All the operator has to do is confirm this on the user interface – no further manual intervention is required. The process thus continues to run stably and safely without interruption. Operator-related deviations in the switching process, operating errors or delays, all of which could affect the process, cannot occur.

Effortless inline cleaning – effective and safe

The highlight of their filter is the integration of BBE’s White Filter Cleaning technology (WFC). This process enables absolutely chemical-free and environmentally friendly intermediate cleaning of the filter inserts using hot steam alone and extends the filter’s service life many times over. BBE has already had WFC in its product portfolio as a stand-alone solution for several years. Now, for the first time, the cleaning system is integrated directly into a filter, bringing additional advantages, like cleaning speed and wear-reduction. Production and cleaning become an alternating interaction. Only after multiple operating/cleaning cycles (the ex- act number depends on product and degree of soiling) is it necessary to completely remove the filter insert for a service check and full cleaning. The WFC cleaning process only takes around 10 hours, whereas conventional cleaning takes several days. Filtration and cleaning form a self-contained, automated system that guarantees process and operating safety in equal measure: The operator does not have to handle melt or chemicals.

Development goals: Simplified handling, economic efficiency

BB Engineering pursued clear objectives when developing the filter: in addition to adapting the system to the growing challenges arising from increasing levels of contamination in recycling, BBE focused on simplifying filter changes and cleaning processes through automation as well as significant savings in operating costs.

And that has been successful. Comparing the COBRA filter with other fine filters with a throughput of 2000 kg/h reveals a saving of 40% in pure operating costs. This saving results from various aspects. One significant part of the savings comes from the re-duction of melt loss through backflush-cycles. Another key point is the continuous operation with significantly longer service life thanks to the integrated cleaning with steam. This is linked to reduced use of spare parts and consumables due to the gentle treatment, conversion costs and a lower energy requirement, as no heating and cooling phases and generally lower cleaning temperatures are required. Costs of chemicals are completely eliminated. Automation reduces personnel costs due to the low operating effort and training requirements. In terms of operation, the COBRA filter is also very safe – the closed system of filtration and cleaning without chemicals eliminates many of the risks associated with conventional filters and cleaning methods, such as the risk of injury and fire.

The cost savings are even more far-reaching if you extend the consideration to the downstream processes. The outstanding cleaning performance of COBRA saves a great deal of effort, interruptions and further processing.

The new COBRA filter will be presented to the public for the first time at the PRSE in Amsterdam at the beginning of April.

www.bbeng.de

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