CW February 2013

February 2013
THERMAL COMPOUNDS HIT THE ROAD
THE LATEST ADDITIVES FOR POLYOLEFINS
PRACTICAL TIPS FOR MANAGING COSTS
MORE EFFICIENT MATERIALS HANDLING

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contents
05 Industry news
The latest compounding industry news including international acquisitions and
PAGE 5
alliances, plus new investments and plant openings.
17 Sustainability unites additives for polyolefins

Peter Mapleston reviews developments in polyolefin additives, including
antioxidants, stabilizers, antifogging agents, clarifiers and reinforcements.
PAGE 17
27 Developing heat-conductive thermoplastics

Thermally conductive compounds could play an important role in electric and
hybrid vehicles say Dirk Schmiederer and Maximilian Bader of Robert Bosch.
33 What’s new in thermally-conductive compounds

We examine the latest developments in thermally-conductive additives and
compounds from DSM, ESK, PolyOne, RTP, Sabic and Timcal.
PAGE 27
41 Don’t labour over managing costs

Plastics business management expert Dr Robin Kent discusses the critical
difference between cost management and cost cutting.
47 EU moves to simplify patents

PAGE 33
After three decades of discussion, the EU is to implement a unitary patent system

intended to cut the cost and complexity of the process.
51 Materials handling: maintaining the flow

Compounders need to shift and control hard-to-handle materials. Mikell Knights
looks at the latest systems designed to tame those tricky ingredients.
PAGE 41
58 Compounder of the month: Epsan plastic
60 Dates for your diary
coming next issue

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www.compoundingworld.com February 2013 | COMPOUNDING WORLD 3

news
Lehmann & Voss and SPI hits

degradable
Techmer PM end JV additives
Techmer PM of the US and & Voss has formed a new expertise and tailor-made The Bioplastics Council, a
Lehmann & Voss of Germany company – Lehvoss North products much faster and with special interest group of the
have ended their North America – and it is setting up the dedicated support our US plastics industry trade
American engineering its own compounding plant at customers require”. association SPI, has
compounding joint venture, Pawcatuck, Connecticut, USA. Speaking about its acquisi- published an updated
which was called Techmer This will initially feature four tion of Lehmann & Voss’s position paper questioning
Lehvoss Compounds (TLC). compounding lines and will interest in their joint venture, the scientific validity of
Techmer PM has acquired produce the company’s Techmer PM’s CEO John degradable additives.
the interests of Lehmann & Luvocom high-performance Manuck said: “The full It says that the use of
Voss in the joint venture, which compounds to the same integration of the former TLC terms without reference to
was formed in 2004 and specifications and quality as its business will enable us to existing acceptable standard
operates from Techmer’s European plants. leverage the Techmer PM specifications is misleading,
manufacturing site in Clinton, Alfred Bartkiewicz, manag- North American manufactur- and they are not reproduc-
Tennessee. The acquisition ing director of Lehvoss North ing footprint and global service ible and verifiable. The
includes all the assets and America, said: “This is a strong capabilities. For example, our organisations adds that the
existing business of TLC with commitment to our customers California plant is qualified to terms “degradable”,
the exception of the Luvocom and is a major step forward to produce a full range of colour, “oxo-degradable” and
product line. The business is making sure customers have additive and reinforced “oxo-biodegradable” are not
being renamed Techmer full access to our solution engineering compounds”. supported by any recog-
Engineered Solutions. based products and services. ❙ www.techmerpm.com nized industry certifications
At the same time, Lehmann We are now able to deliver our ❙ www.lehvoss.de/luvocom/llc or third-party peer reviewed
scientific data.
Puma selects API bioplastic for

“We felt it was important
to update our 2010 position
paper because new
the soles of InCycle trainers terminology is now being

used in the marketplace
and new studies have
Italian compounder API is shredded and composted. become available,” said
supplying its Apinat Bio Reiner Hengstmann, global Melissa Hockstad, SPI vice
bioplastics to sporting director of Puma Safe, president, science,
goods company Puma said: “The InCycle technology and regulatory
for the manufacture of Basket [trainers] and affairs. “The 2013 version
shoe soles. The biodegrad- Basket Tee Biodegrad- also includes updated
able elastomer is being used able [T-shirts] have information about stan-
in Puma’s Basket training been analysed as part dards and certification
shoe which is part of its of Puma’s first Product programs, as well as a new
InCycle Spring/Summer 2013 Environmental Profit and section on ‘Guidance on
collection that goes on sale in Puma’s InCycle Basket shoes Loss Account published in Marketing Claims for
March. feature biodegradable soles October 2012 and the results Biodegradation.’”
InCycle is Puma‘s first speak for themselves, showing Bioplastics Council
closed-loop collection of entirely biodegradable or that these two products members include PolyOne,
footwear, apparel and acces- recyclable. The upper of the impacted the environment by a Teknor Apex and BASF.
sories, all of which have been Puma Basket trainer is made third less than their conven- The full 10-page position
given the “Cradle to Cradle from a mix of organic cotton tional counterparts”. paper can be read at
Certified Basic” classification. and linen, while the biodegrad- ❙ www.apiplastic.com http://bit.ly/SPIBC.
The products in the range are able plastic sole can be ❙ www.puma.com ❙ www.bioplasticscouncil.org

news
Advanced Composites expands

Advanced Composites will be boosted by two major Mitsui Chemicals and Prime two investments will take
expansions this year Polymer have announced Advanced Composites’ total PP
plans to add an additional compounding capacity to
14,000 tons/year of PP 268,000 tons/year.
compounding capacity at their Advanced Composites is
Advanced Composites venture owned by Mitsui Chemicals
in the USA. Due on stream in America (59.8%), Prime
Q4 2013, the expansion is Polymer (3%) and others
aimed at meeting growing (37.2%). It operates plants in
automotive industry demand. Ohio and Tennessee. Mitsui
This latest expansion is on also produces PP compounds
top of the previously an- in Japan, Mexico, Brazil,
nounced 28,000 tons/year Europe, India, Thailand and
increase in capacity which is China.
due on stream in Q3 2013. The ❙ www.advcmp1.com
PMC buys UK recycles one million PVC

additives window frames per year
businesses More than one million PVC
PMC has completed the post-consumer window frames
acquisition of Dow Chemi- are being recycled in the UK
cal’s global methyl tin every year through Recovinyl,
stabilizers and solid the PVC industry’s recycling
lubricants businesses. scheme.
The deal includes The latest audited figures
organotin and heavy-metal- show that end-of-life windows
free organic polymer and profiles comprised 25,480
stabilizers, polymer tonnes (52%) of the total
lubricants and multi-com- 48,544 tonnes of waste PVC
ponent package product recycled in 2011. Other
lines. These are sold under materials collected and
brand names including recycled through the Recovinyl
Advastab, Adavalube, programme included pipes and
Advawax and Advapak. The fittings, cables, flexible PVC
transaction also includes a and rigid PVC films.
world-scale manufacturing Recovinyl estimates that
facility for these products in this windows and profiles Recovinyl recycled more than one million PVC window frames in
Cincinnati, Ohio, USA. fraction, which doesn’t include the UK in 2011, according to the latest data
In October 2012, PMC doors, would equate to roughly
acquired Arkema’s 1.25 million frames. as well as the on-going industry voluntary commitment of the
organotin and organophos- “These figures are an commitment to more sustain- European PVC industry, which
phine-based polymer impressive achievement and able practices,” said Jane has set targets of 800,000
stabilizers, catalysts and clearly demonstrate the Gardner of Axion Consulting, tonnes/year of PVC to be
fine chemicals businesses sustainability credentials of PVC Recovinyl’s UK agents. re-used in all European
in the Americas and Europe. as a building material that can Recovinyl is an initiative of countries by 2020.
❙ www.pmc-group.com be easily recycled and re-used, VinylPlus, the 10-year ❙ www.recovinyl.com
6 compounding world | February 2013 www.compoundingworld.com

news
Clariant reveals its ColorForward

plastics colour forecasts for 2014
Clariant has published its connection with the products with old ideas and waste. They everyone. One of the colours in
ColorForward 2014 colour they buy. Norzihan Aziz, head are now enthused about this theme, One Time Zone,
forecasting guide for the global of ColorWorks Asia Pacific repurposing the old into new. gets its deep, dark colour
plastics industry. Now in its Region says: “The colour “The colours are a visualisation inspiration from the city late at
eighth year, the guide is palette plays off of this new of thinking outside of the box, night. “The blackness recalls a
designed to help manufactur- form of power. One of the of morphing discarded city by night; the red sparkles
ers of plastics products by colours, Genuine, represents products into new-generation represent individual persons
giving them a head start in transparency and honesty. It’s identities,” explains Simon all over the world, digitally
using colour to influence interconnected, sharing their
consumer decisions. experiences, thoughts, and
The predictions are ideas,” says Judith van Vliet,
produced by Clariant’s designer at ColorWorks
ColorWorks team based on Europe/IMEA.
research of the most influen- Vamos Jogar Bola: The true
tial societal trends around the spirit of Brazil is what defines
world. Additional input is this theme. One of the colours,
provided by trend-watchers Tapirapé Splash Green, gets its
and colour experts from the inspiration from the lush green
architecture, textiles, house- Amazonian forests of Brazil.
wares, automotive and fashion “The colour is very predomi-
industries. nant in the country’s flag,
Next year’s colour palette is natural surroundings, and of
based on four outstanding Clariant’s ColorForward 2014 course, the soccer grass,” says
societal trends that the predictions are inspired by four global trends Antonio Rollo, regional key
ColorWorks team expect to account manager for Latin
have a key impact in the near grounded and a mindful colour, Clarke, packaging market America.
future: reminiscent of the authentic segment manager, Asia Pacific. For more information
Keep It Real: Consumers are feel/taste of an olive.” There to Share: We are living including an interactive video
overwhelmed with brands and Re|use|full: Having survived in the age of digital informa- presentation of the 20 colours,
bored with me-too products, the current recession, the tion and mobile devices where visit: http://bit.ly/CF2014.
and they are seeking to feel a public is tired and disappointed information is accessible to ❙ www.clariant.com
RTP signs Santoprene license agreement

RTP Company has licensed technology. The RTP 6091 technical polymers and this because their addition will
manufacturing rights from grades will provide similar addition of Santoprene TPV expand our bondable TPE
ExxonMobil Chemical for its performance to the Santo- based nylon-bonding technol- product line and give us a
patented Santoprene TPV prene TPV nylon-bonding ogy will nicely complement the definite advantage by having
nylon-bondable thermoplastic products previously manufac- choice they offer to customers.” the highest performance
elastomer (TPE) product line. tured by ExxonMobil. Scott Mumm, strategic materials in the nylon-bond-
Under the agreement, Reinhart Papen, global accounts and alliances at RTP able arena.”
ExxonMobil will supply marketing manager at added: “We are excited about When over-moulded, the
Santoprene TPV feedstock to ExxonMobil, said: “In addition this opportunity to take over RTP 6091 Series compounds
RTP for the manufacture of to its compounding capability, production of ExxonMobil offer excellent bond strength
RTP branded nylon-bonding RTP Company has a strategic Chemical’s nylon-bondable with rigid nylon substrates.
products using the licensed focus on high-performance Santoprene TPV products ❙ www.rtpcompany.com
8 COMPOUNDING WORLD | February 2013 www.compoundingworld.com

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news
Lanxess expands in China Addmaster

Lanxess is investing €55 million
scoops
in a new inorganic pigment
plant in Ningbo, China. It will
UK award
produce Bayferrox premium UK additive masterbatch
iron oxide red pigments and maker Addmaster has won
will have an initial capacity of the People’s Choice prize at
25,000 tonnes/year. the first Made in Britain
A total of 150 new jobs will Lanxess is expanding its production capacity for Bayferrox awards. The award was
be created at the site in the pigments with a new plant in China voted for by readers of the
Ningbo Chemical Park on the Mail on Sunday newspaper
Chinese East Coast. Construc- innovative production process, one of China’s largest and who had to choose between
tion will begin in the second we are raising the bar for the most modern plants for iron eight shortlisted manufac-
quarter of 2013 and production production of iron oxide oxide pigments in Jinshan, turing companies.
start-up is scheduled for the pigments worldwide, especially Shanghai. This plant has an Addmaster was
first quarter of 2015. in terms of water treatment, annual capacity of 38,000 congratulated for its
The yellow shaded red waste gas cleaning and energy tonnes of yellow and black international expansion and
pigments will be produced consumption,” said Joerg pigments. The company also the strong growth in sales
using an improved and highly Hellwig, head of the inorganic produces inorganic pigments of its Biomaster range of
sustainable Penniman process. pigments business unit. in Germany and Brazil. antimicrobial additives.
“With our advanced and Lanxess already operates ❙ www.lanxess.com ❙ www.addmaster.co.uk
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PLASTICS 2013
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options for end of life plastics
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news
REACH review
draws criticism
The European Commission has disappointment with the review.
published a positive five-year Its director of chemicals policy,
review of the implementation Dr Joanne Lloyd said: “This
of REACH chemicals legisla- five-year review has fallen far
tion, concluding that it short of providing the neces-
“functions well and delivers on sary clarity. We urgently need
all objectives that at present the Commission to tackle the
can be assessed”. regulatory minefield so that we
The review also claims that can all be clear on what the law
the use of chemicals in Europe is. This will have a disastrous
has become considerably safer effect on smaller companies
since the REACH regulation who will be hit by the next
entered force. However, it round of REACH implementa-
concedes that there is a need tion which assess chemicals
to reduce the impact of REACH produced and imported in
on SMEs (small and medium smaller quantities”.
sized enterprises). Professor Lucas Bergkamp,
CEFIC, the European Chem- a Brussels-based legal expert
istry Industry Council, points on chemicals and REACH,
out that the review only covers said: “The Commission’s
the first of three phases of report is no great surprise.
REACH, mostly involving larger There is some wisdom in not
companies. During the next changing a law that has only
phases, SMEs not familiar with recently been adopted. On the
the legislation will face other hand, there is a whole
challenges complying with it. host of amendments that could
Hubert Mandery, CEFIC’s be made to eliminate ambigu-
director general, said: “The ity, and improve the effective-
jury is still out on whether ness and efficiency of the
REACH succeeds in its goal of various REACH regimes.”
enhancing competitiveness Bergkamp also raised
and innovation for the industry. concerns about the impact of
It’s clear that companies REACH on innovation, citing a
operating in Europe get hit report that shows resources
twice on the competitiveness have been diverted from R&D
front, as they are paying the to regulatory affairs, and he
whole cost of dossiers, which called for further analysis of
the rest of the globe can then this key area.
access for free.” The EC’s full 15-page
The UK’s Chemical Indus- REACH review can be read at
tries Association expressed http://bit.ly/REACH13.
www.compoundingworld.com
news
People on the move – new appointments

Berstorff role from Dr Hans the PVC additives company heads Elantas Electrical
Ulrich Golz who is now that was spun off from Insulation. The latter’s previous
president of KraussMaffei’s Chemtura. He previously held president, Dr Wolfgang Schütt
injection moulding machinery a similar role with ISP/Ashland is now managing Eckart Effect
business. and he has also worked as Pigments, whose former
❙ www.kraussmaffei.com R&D director at Genovique. In president Dr Christoph
his new post at Galata, he will Schlünken has taken over
Leistritz Extrusionstechnik develop business for Drapex management of BYK Additives
William Murray has appointed Jürgen Sauer Alpha, the company’s new & Instruments.
as its new head of service, non-phthalate, bio-based ❙ www.altana.com
Teknor Apex has appointed based at the twin-screw plasticizer.
William Murray as its new extruder maker’s head office in ❙ www.galatachemicals.com
president, responsible for its Nuremberg, Germany. He was
worldwide compounding previously with Extricom. In PSI-Polymer Systems has
business. He success Jonathan addition, Gregory Quek has named Don Macnamara as its
Fain, who remains CEO and been made the company’s new general manager. He was
becomes chairman of the previously with ancillary
board. Murray joined the equipment company Conair
company in 1978 as a project focusing on film and sheet
engineer and has been markets. PSI supplies melt
executive vice president since filtration systems, gear pumps Mary Rhinehart
2006. In a separate move, and other equipment for
Teknor Apex has recruited Eric extrusion lines. Mary Rhinehart has been
Williams as a senior market ❙ www.psi-polymersystems.com promoted to become the new
manager for TPEs in North president and CEO of Johns
America. He was previously The specialty chemicals group Manville. Previously the
Jürgen Sauer
with A. Schulman and in his Altana has reorganised its company’s senior VP and CFO,
new role he will be responsible service manager for Asia, management team, rotating she takes over from Todd Raba
for sales and market develop- based in Singapore. He’s been key roles. Dr Roland Peter, who has left the company.
ment in the electrical, packag- with Leistritz for 13 years. who was previously president Johns Manville is a Berkshire
ing and distribution sectors. ❙ www.leistritz-extrusion.com of BYK Additives & Instru- Hathaway company that
❙ www.teknorapex.com ments, has taken over the produces building products
Dr Mak Joshi has been management of Actega and glass fibre reinforcements
Wolfgang Siegel has been appointed director of new busi- Coatings & Sealants from Dr for plastics.
appointed as the new CEO of ness development at Galata, Guido Forstbach, who now ❙ www.jm.com
Ter Hell Plastic. He joins the
European distributor and Songwon has appointed Doris
compounder from EMS-Che- Peters to the new position of
mie where he most recently global director of marketing
led the EMS Grivory Europe and business analysis. She
high-performance plastics joins the polymer stabilizer
business unit. producer from Wacker
❙ www.terhell.de Chemie where she has held
senior posts covering the
KraussMaffei has recruited solar and automotive
Peter Roos as the new industries. Her career has
Doris Peters Elena Scaltritti
president of its Berstorff also included positions with
extruder division. The mechan- Chemtura and Great Lakes. Europe. She has been leading from Dieter Morath who
ical engineering expert was Songwon has also promoted European main accounts continues as Songwon’s
previously CEO at Maillefer Elena Scaltritti to be its new since joining the company in executive vice president sales.
Extrusion. He takes over the director of sales for Greater 2011, and takes over the role ❙ www.songwon.com

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Additives for polyolefins | materials feature
Peter Mapleston examines the latest developments in additives

for polyolefins, including antioxidants, stabilizers, antifogging
agents, clarifiers and reinforcements
Among all oil-based thermoplastics, polyolefins are

arguably the most sustainable. Polymerisation
processes are relatively low cost, the polymers process
Sustainability
unites additives
at low temperatures, applications are extremely wide
ranging, and finished products can often be recycled
cost-effectively.
for polyolefins
Sustainability is also what increasingly governs the
development and use of additives used in polyolefins.
Whether they are supplying antifogs, processing
stabilizers or UV absorbers, additive producers are
looking for more efficient ways to make their materials
and incorporate them into compounds, while extending art technology stemming from Additive Technologies
the performance spectrum and lifetime of the polymers Greiz (ATG), a German company that Songwon acquired
they enhance. in late 2011, and which is now called Songwon ATG. Last
Sustainability can also be seen as a driving force in year, it doubled OPS production capacity to 14,000
various business developments. Some additive tonnes/year, and it is now at an advanced stage of
producers are modifying product portfolios in the establishing manufacturing operations in the Middle
search for increased efficiencies, others are extending East and United States.
their production networks to be closer to customers. Songwon ATG is now part of Songwon Additive
There is considerable business activity among stabilizer Technologies, a joint venture established last October
producers, with important developments from at least by Songwon, together with Pan Gulf Holdings of Saudi
three major suppliers in recent month. Arabia and Polysys Industries of Abu Dhabi. Sabo has
Maurizio Butti, Songwon’s COO, reveals that the increased
Stable growth company will soon have a global network with regional Sabostab UV
Songwon Industrial, which offers a wide range of OPS manufacturing units. Songwon Additive Technolo- 119 HALS
antioxidants and UV stabilizers in various physical gies will build an OPS unit at Songwon’s site in the capacity to
forms, continues to extend its reach. In particular, it is Houston area for start-up this March 2013. Last meet growing
building up its presence in ‘OPS’ one-pack systems. It November, Songwon Additive Technologies and Polysys demand in
describes its Songnox OPS as a “fusion of world class Industries said that they would establish a new markets such
antioxidants and UV stabilizers” based on state of the company Polysys Additive Technologies ME, which will as artificial turf

materials feature | Additives for polyolefins
Sabostab UV 119 HALS. The expansion is scheduled to

come on-stream during the second quarter of this year.
The capacity increase is being driven by growing demand
for the product in applications such as PE based
agricultural films, PE tapes for artificial turf, PP fibres,
and PP and TPO automotive parts. Sabostab UV 119 is a
high performance product designed for reduced
interaction with agricultural chemicals, fillers, pigments,
and other additives as compared to conventional HALS.
BASF is also stepping up its production of anti-oxi-
dant one-packs, which it names customer specific
Songwon is build an OPS manufacturing plant in Kizad, Abu Dhabi. blends (CSB). In December, it started production at its
expanding its The new plant, which is set to be completed towards the new plant in Bahrain, which it says is the largest facility
production of end of this year, will have an initial capacity of approxi- of its kind worldwide.
one pack mately 7,000 tonnes/year. The plant, which uses proprietary CSB technology,
systems with Butti also says that Songwon has a long-term will provide local supply and services to the fast growing
new plants in strategic ambition to be a leading supplier of polymer polymer market in the Middle East. Its production is in
Abu Dhabi and stabilizer solutions. Last October, it agreed a long-term addition to BASF’s existing CSB manufacturing
the USA distribution arrangement with Sabo, a leading producer agreement with Astra Polymer in Saudi Arabia, which
of monomeric and polymeric HALS (Hindered Amine was extended earlier this year.
Light Stabilizer) based in Levate, Italy. Chemtura, meanwhile, is selling its antioxidant and
Songwon now distributes Sabo’s HALS product range UV stabilizer business to SK Capital Partners for
of light stabilizers on a global basis, and will closely approximately US$200 million. The transaction is
cooperate with Sabo on the regional HALS markets expected to be completed in the first quarter of 2013.
outside Europe where both of them see big potential for SK Capital says that the acquisition fits with its current
growth. In Europe, the two companies will act strictly portfolio of companies in the polymers and additives
independent from each other. sectors. Three years ago, in fact, it tried to buy Chemtu-
Last July, Sabo said it would double capacity for its ra’s PVC additives business, which eventually went to
The importance of keeping it pure

Challenges in the use of polyolefin and develop products less sensitive to Left: Residues of Metilox (in ppm) found
stabilizers were addressed by Svein hydrolysis and thermal degradation to in AO-1010 antioxidant from various
Jamtvedt, principal researcher at Norner, meet tougher future requirements,” he suppliers. Right: Residues of 2,4-DTBP
the Norwegian research group, at a concluded. (in ppm) found in P-168 antioxidant from
recent IHS conference on polyolefins ❙ www.norner.no various suppliers
(PEPP 2012). In his presentation, he said
non-intentionally added substances
(NIAS) that can develop during the
storage and use of certain polyolefin com-
pound may affect their suitability for food
contact applications.
Norner has tested the purity of
AO-1010 (hindered phenolic) and P-168
antioxidants from various suppliers, and
found considerable variations in the levels
of impurities, some of which can leach
out of compounds during their lifetimes.
“Additive suppliers should focus on
minimising impurity level in antioxidants

Galata Chemicals. One analyst says that despite Chemtu- our existing portfolio of specialty solid phosphites, such
ra’s best efforts, margins in the antioxidant and stabilizers as Ultranox 626 and Weston 618,” says Irfaan Foster,
unit were below the company’s average, reflecting very commercial manager for specialty antioxidants. It is
strong competition from Songwon and also BASF. available both as a neat product as well as in Chemtu-
Nevertheless, Chemtura has been continuing to ra’s proprietary Anox NDB stabilizer blend technology.
develop new products. It recently launched Alkanox P-EPQ, the basic chemistry for which was originally
P-EPQ to complement its existing portfolio of specialty developed by Sandoz, is now available in various guises
high-performance phosphites. This is a hydrolytically and from various suppliers. For example, Clariant,
stable organic phosphonite that prevents polymer which was spun off from Sandoz in 1995, has a version
degradation and discoloration during polymer process- called Hostanox P-EPQ. Speaking at AMI’s Polyolefin
ing and downstream use. Key benefits for customers Additives 2012 conference, Clariant’s business develop-
are said to include low volatility, excellent initial colour, ment manager for polyolefin additives Hartmut Siebert
and very high compatibility with the resin. described Hostanox P-EPQ as “a high performance
“Alkanox P-EPQ phosphonite is a natural addition to stabilizer with new benefits”. It is the result of in-situ
synthesis of a phosphite with four different types of
P-EPQ: mono P-EPQ; 4,4’- P-EPQ; 3,3’- P-EPQ; and,
4,3’- P-EPQ.
Pure benefits
Siebert emphasizes the high purity and low residues of
Hostanox P-EPQ, which has an important role in making
it such a potent product. It has high protection power
sustaining initial polymer properties, a low softening
temperature providing early stage protection in
extrusion processes, high solubility in the polymer,
virtually eliminating haze and blooming. It is particu-
larly good at suppressing yellowing (Figure 1) and has
“outstanding” capabilities for cleaning extrusion lines.
“For commodity applications, P-168 [tris-(2,4-di-
tert-butyl-phenyl)-phosphite, sold by several companies
not including Clariant] can be sufficient, “ says Siebert,
Figure 1: Clariant’s Hostanox P-EPQ is particularly good at suppressing
“but Hostanox P-EPQ really scores in high performance
yellowing even at half concentration. Results show colour stability of PPR
applications, for example in BOPP where retention of
(BOPP) processed at 230oC – stabilisation is with 0.1% Ca-stearate and 0.05%
AO 1010 the long chain molecules is important.” He also points
out that, because it is so effective and can therefore be
used in small doses, it helps processors making auto
interior parts conform to strict requirements on
fogging, while low migration levels are also important
for packaging coming into contact with food.
The rapid growth and adoption of polymer-based
materials for construction applications has heightened
the requirement for long-term weathering performance
from 15 to 30 years or more, says Cytec. “Outdoor
durability is increasingly important for construction
markets applications, such as TPO roofing, polyolefin
roofing tiles and shakes, solar shingles, siding, and
shutters,” it says. Cyasorb Cynergy Solutions B877 light
stabilizer was developed to support the ability of polyole-
fin-based materials to achieve these requirements.
Figure 2: A trial TPO containing new Cytec light absorber performs
Andrea Landuzzi, Cytec’s global marketing manager
significantly better than two commercial offerings - the breaking strength
for polymer additives, says the new product is in fact a
retention of low flex modulus TPO is shown after 8,000 and 10,000 hours
under Florida expsoure conditions (ASTM G-155) package of additives that includes several hindered amine
light stabilizers (HALS) as well as other undisclosed

especially homopolymer, as its higher crystallinity (with

respect to polyethylene) impedes migration. Using lower
molecular weight additives is not the answer, since
higher processing temperatures used with PP cause
smoking and deposits on the equipment, Maltby says.
This is why Croda developed its Atmer 7373 additive
concentrate specifically for PP. It contains one additive
that migrates very well in PP to accentuate the
migration of a second additive. Atmer 7373 is designed
to deliver high anti-fog performance in both hot and
cold plus flexible and rigid food packaging. It has no
observable effect on haze.
“We have not seen any other product on the market
that delivers such effective performance in both hot and
cold fogging environments”, Maltby claims. “As a highly
loaded concentrate [40%], it is particularly useful for
Croda’s Atmer chemicals. “Performance is exceptional,” he claims. converters who can easily handle its pellet form. It is
7373 provides In a study (Figure 2), two commercial low flex modulus also useful for masterbatch producers who either
very good TPO roofing membrane samples were compared with a cannot or do not wish to handle soft and pasty raw
antifogging sample containing the new additive. After 10,000 hours of materials.”
performance in simulated exposure to the Florida sun (ASTMG155), the Among offerings in this field is PolyOne’s OnCap
rigid and two commercial samples failed, retaining less than 35% Antifog, which the company says improves film quality
flexible PP of their original breaking strength, while the sample and eliminates production steps, since films containing
packaging containing B877 retained 85%. the additive have no need to be corona treated before
Clariant has also been busy with development of a printing. PolyOne also says that OnCap is one of the few
new HALS additive. It says it is “supporting a step antifog additives available with both EC and FDA
forward in effective crop protection” with the launch of food-contact compliance, “enabling customers to
Hostavin Now customised polymeric amino-ether HALS choose a consistent solution across geographic
stabilization solutions to improve the durability of regions.” Finally, PolyOne says laboratory tests indicate
greenhouse films. that OnCap Antifog produces antifog properties slightly
The service life of greenhouse films is severely faster than existing additive solutions. It is available as
impacted by the combined aggressive effects from a masterbatch or as a component of a PolyOne specialty
intensive solar radiation exposure and increasing use of compound.
agrochemicals. Light stabilizers based on amino-ether
HALS outperform standard HALS in terms of resistance Clear choices
to such agrochemicals as sulphur and halogenated Haze is a critical factor in food and non-food packaging,
chemicals, enabling superior UV protection and targeted by clarifying agents. This May, some European
extending the lifetime of the greenhouse film, according patents owned by Milliken covering the acetal sorbitol
to the company. chemistry behind its Millad 3988 clarifying agent run
out. Other companies are ready to jump into the market,
Antifogs provide food for thought one of them being New Japan Chemical Company,
Croda emphasizes the importance of good antifogging which owns RiKA International and RiKAmerica, and
additives for greenhouse films. The world needs more which is actually the inventor of acetal sorbitol clarifiers
food, polytunnels allow food to be grown more effec- (as well as non-pigmenting beta nucleators).
tively, and antifogs increase the efficiency of the tunnels The first generation of acetal sorbitol clarifiers was
by improving light transmission and increasing yields, based on dibenzylidene sorbitol, DBS. But the clarity
says applications manager Adam Maltby. Fogging on they achieved, while better than you could get with talc
the tunnels can cut light transmission by 50% or more, or sodium benzoate, was not that great, and they
he says. suffered from plate-out at higher temperatures. Second
When the food is in its packaging, antifogs help the generation methyl-dibenzylidene sorbitol, MDBS, was
food retain its fresh appearance, Maltby notes. But two steps forward (better haze, higher melting point)
classical antifogs, often based on glycerol monooleate, and one step back (poorer organoleptics). Third
GMO, tend not to perform so well in polypropylene, generation 3,4 dimethyl-dibenzylidene sorbitol, DMDBS,

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Milliken says improved on the organoleptics, but had a narrow

that Millad processing window, and in addition is a non-free-
NX8000 has flowing powder.
rapidly taken Milliken is now into the fourth generation with
over from its Millad NX8000, the nature of which it does not
Millad 3988 as divulge publicly. This is claimed to combine all the
the clarifier of plus points of second and third generation types,
choice together with additional benefits. It delivers even better
clarity, which can be achieved at lower temperatures (as
low as 190°C) owing to its higher solubility in PP, and it
is also stable at high temperatures (although such
stability is unlikely to be called upon). Milliken continues
to sell its Millad 3988 DMDBS, but all its marketing
effort is on NX8000.
Over the past year, says Milliken, Millad NX8000 “has that increase the stiffness and scratch resistance of PP
rapidly taken over Millad 3988 as the clarifier of choice,” injection mouldings, such as automotive parts, without
thanks to the very high, virtually glass-like clarity it adding as much weight as talc does.
provides in PP while maintaining the polymer’s inherent Weight minimisation in PP auto parts is critical, as
properties. “Although it is true that some IP on Millad the polymer is used for more and more components in
3988 is expiring, Milliken still owns a wide variety of IP car interiors, exteriors and engine
around its Millad products several years out,” a company PP is of course valued for its low density, but if it can
representative says. “The reality today though is that be made even less dense, the weight savings per car
more than 200 Millad NX8000 clarified polypropylene can be notable. Lower weight means lower emissions,
grades across a range of melt flows are commercial and lower emissions mean lower taxes. In collaboration
globally, a lot of them replacing Millad 3988.” with PP compounder Inno-Comp and auto part producer
Mecaplast, Milliken has demonstrated that pillar trim
Seeking clarity parts can be made 7% lighter using a combination of
RiKA, meanwhile, has opted to improve the third talc and Hyperform HPR while offering excellent
generation formula with its own Gel All Advanced stiffness and impact strength and considerably
Technology. It says that excellent haze levels in PP improving scratch resistance. The companies are also
containing its additive change little across a processing eyeing larger parts, such as instrument panels.
temperature range from 190°C to 230°C, so on paper at Hyperform HPR-803i fibres are slightly less dense
least they look to be similar to what NX8000 achieves. than talc (2.3 vs. 2.7 g/cm3), but 2.5 times harder (Mohs
Clarity is similar to MDBS, and organoleptics are better. hardness). Their effect on stiffness is much more
It is supplied as a free-flowing powder. dramatic (Figure 3).
Milliken is also reporting increasing success with its
Hyperform HPR mineral-based fibre reinforcing agents More information
AMI’s next Polyolefin Additives conference takes place
in Düsseldorf, Germany, on 10-12 September 2013. For
details, visit http://bit.ly/PAdd13.
Click on the links for more information:

❙ www.songwon.com
❙ www.basf.com
❙ www.sabo.com
❙ www.chemtura.com
❙ www.clariant.com
❙ www.cytec.com
❙ www.croda.com
❙ www.polyone.com
❙ www.milliken.com
Figure 3: These results from Milliken show how different filler types for PP ❙ www.nj-chem.co.jp/en
have very different effects on modulus
❙ www.rikaltd.com

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June 13-14, 2013

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Thermal conductivity | materials feature
Developing heat-conductive
thermoplastic compounds
Lightweight construction, miniaturization, and cost

reduction are current megatrends in the automotive Thermally conductive, electrically
industry. On one hand, they are driven by legal require-
ments. On the other hand, these megatrends play an insulating thermoplastic compounds
important role in being able to fulfil the high expecta-
tions and customer requirements in electric mobility
could play an important role in
and electric vehicles. electric vehicles. Dirk Schmiederer
In this context, many technical aspects need to be
optimized, as only by increasing the range and signifi- and Maximilian Bader of Robert
cantly reducing the cost of electric vehicles can an
improvement in customer acceptance levels be
Bosch examine the technology
achieved. Light construction and costs therefore
represent two major innovation directions for the future components, possible fields of application include the BMW is a
of electric mobility, a fact that is made clear by the replacement of hybrid composite components. partner in
current, global focus of research and development work. ProSysEasy
As a result of this, as far as the use of plastics in Properties of heat conductive plastics examining the
automobiles is concerned, injection moulded, off-tool The integration of filler materials is a common method potential of
components made from heat-conductive, electrically of influencing the property profile of a polymer material heat-conduc-
insulating thermoplastics show great potential for the in line with its usage purposes with respect to mechani- tive compounds
future. This is due to the fact that the functions of “heat cal, electrical, thermal, and processing technology in electric
conduction” and “electrical insulation” can be integrat- properties. vehicles, such
ed into one and the same material. This material can Using a compounding process, the desired property as its i3
then be processed at a favourable cost in large quanti- profile is created from the total of the properties of the concept car
ties using injection moulding, with a high level of design filler material and the matrix. In so doing, in the case of
freedom. the twin-screw extruder, different filler materials are
In addition to the classic substitution of metal and incorporated into a thermoplastic matrix: by adding
expansion of utilization limits for thermoplastic glass fibres, for example, the mechanical stability of the

materials feature | Thermal conductivity
example, this can be described using the heat flow Q

(Equation 1). The heat transfer coefficient α, the
thermal conductivity k, and the wall thickness s are
taken into consideration in the overall heat transfer
coefficient U (Equation 2) [1].
The temperature in components can be lowered by

an increased heat flow. This can be adjusted, according
to equations (1) and (2), for example, by an increased
FIGURE 1: DEPENDENCE OF SELECTED MATERIAL PROPERTIES ON THE heat transfer coefficient, a lower wall thickness, or a
FILLER CONTENT higher thermal conductivity. To take these material and
system properties into consideration when designing
the component, the use of simulation software is often
material is increased, while graphite is used to increase inevitable.
both the electrical and the thermal conductivity. The use Although pure thermoplastics have a comparatively low
of hexagonal boron nitride as filler material makes it thermal conductivity (0.15 to 0.5 Wm-1K-1), by adding filler
possible to retain the electrical insulation of the materials in commercial compounds, values up to double
thermoplastic matrix while increasing the thermal digits can be achieved, and these are often sufficient for
conductivity. the cooling of electronic components [2]. As the thermal
Table 1 shows standard filler materials and their conductivity shows a volume effect, high filler levels are
properties that are used to increase the thermal necessary to achieve such values, see Figure 1 [3].
conductivity of thermoplastics. Note that the intrinsic With a high filler content, however, there is more
thermal conductivity of the filler material varies greatly, likelihood of the plastic being brittle, which leads to a
which should be taken into consideration when reduction in the elongation at break and the impact
selecting the compound recipe. While, for example, strength, as particle solids in the boundary layer cause
graphite and boron nitride in their primary crystalline stress concentrations. Furthermore, the flowability is
form have a directional dependent (anisotropic) thermal greatly influenced and the processing conditions in the
conductivity, aluminium oxide’s thermal conductivity is injection moulding process deteriorate. As good heat
isotropic. Graphite and boron nitride can also be conductive filler materials are more expensive than
obtained as agglomerated types that demonstrate a technical thermoplastics [4], the compound costs
more balanced range of properties. increase as the level of filler increases, which is relevant
For optimal and target-oriented design of compo- for the developers and designers in economic terms.
nents made from heat conductive thermoplastics, it is
also necessary to know the thermal conditions in use, in The consortium
addition to the heat conduction material parameter, in In order to meet the automotive requirements placed on
order to guarantee efficient thermal performance. For heat-conductive thermoplastic compounds, in particular
with respect to the properties of thermal conductivity,
mechanics, processability, and costs, intensive research
Table 1: Heat conduction and other general properties of
activities are required. In view of the great potential that
selected filler materials
“heat-conductive thermoplastics” technology has with
Filler material Heat conduction [Wm-1K-1] Other properties
respect to simplifying the process and system of the
Glass fibre 1 Mechanical strengthening
electric vehicle, where high voltages and currents must
400 (in plane) Electrical and thermal conduction be handled safely, which also leads to heat loss, the
Graphite
2 (perpendicular to plane)
public-funded “ProSysEasy” project started on July 1,
Hexagonal 400 (in plane) Thermal conduction,
2011. This three-year project, under the consortium
boron nitride 2 (perpendicular to plane) electrical insulation
leadership of Robert Bosch, is sponsored by the German
Thermal conduction,
Aluminium oxide 20-40 Ministry of Education and Research (BMBF) within the
electrical insulation
framework of the “Key technologies for electric mobility”

BORONID FILLER ®
The new ESK BORONID® Boron Nitride filler enables
highly thermal conductive and electric insulating polymers
without any compromise for processing and tool life.
ESK Ceramics GmbH & Co. KG

Max-Schaidhauf-Straße 25
87437 Kempten, Germany
www.esk.com, [email protected]
materials feature | Thermal conductivity
mercially, for use in vehicles these materials must fulfil

photo: BMW
a very demanding property profile in the intersection of

many different requirements. In the ProSysEasy project,
optimal material properties for processing and use will
be achieved by researching new concepts for the
modification and appropriately adapted incorporation of
filler materials in a thermoplastic matrix.
The aim here is the detailed analysis and modelling of
different innovative approaches for optimizing the filler
material or surface properties. Only in the targeted
combination of different optimization approaches can a
target-oriented improvement in the material properties
be expected. The task is therefore to work out approach-
es for the direct evaluation of effects, the modelling of
Heat-conduc- publication (STROM) in the topic field “Material and mechanisms, and hence a possible forecast of syner-
tive plastics process-oriented key technologies for electric mobility”, gisms. Furthermore, by referring back to the results of
could play a and is supervised by project executing organisation the investigation, material and process models and
critical role in Jülich (PtJ) (funding code 03X4625). design guidelines for component design will be created.
making electric The project consortium is made up of the following These will be used to design a functional demonstrator
vehicles more institutes and companies: and validated by checks under conditions of use.
efficient l A. Schulman (Kerpen)
l BMW (Munich) Outlook
l ESK Ceramics (Kempten) To date, heat-conductive thermoplastics have only been
l Leibniz Institute of Polymer Research Dresden (IPF) used in a few niche applications in mass production,
l Robert Bosch (Waiblingen) mainly as heat sinks for LEDs. The material properties
l University of Erlangen-Nuremberg, Institute of targeted by the project consortium will enable the
Polymer Technology (LKT) establishment of the “heat-conductive thermoplastic”
l University of Tübingen, Department of Geosciences, technology in automotive applications. However, the
Applied Mineralogy (IFG) technology of heat-conductive thermoplastic compounds
The consortium therefore covers the whole value- can also find applications in other industrial sectors
added chain from the filler material to the vehicle itself. alongside the automotive sector. In the aircraft industry,
ESK is investigating new approaches for filler materials this technology is also of interest as it has great
and filler material modifications based on hexagonal potential for heat dissipation solutions with low weight.
Boron Nitride, while the incorporation of this into the
thermoplastic matrix is being looked at in turn by A. About the authors
Schulman. The processability using injection moulding Dr.-Ing. Dirk Schmiederer and Dipl.-Wirtsch.-Ing.
and the resulting component properties are in the Maximilian Bader are with the Corporate Sector
foreground of the work being carried out by Robert Research and Advance Engineering department of
Bosch, while BMW is looking at the component Robert Bosch in Waiblingen, Germany
behaviour in the vehicle.
For the specialist areas relevant to the project, the References
leading research institutes in Germany have been [1] Hering, E.; Martin, R.; Stohrer, M.: Physik für Ingenieure.
10th edit. Berlin, Heidelberg, New York: Springer Verlag,
integrated as partners and ensure the successful
2008. (Available in German only)
research of complex scientific questions. The overall aim
[2] Schmiederer, D; Tüchert, C.; Bader, M.; Weiss, C.: Wärmel-
of the consortium is to pursue a unified approach over eitfähige Thermoplaste – Ein heißes Eisen? emobility tec 1
the whole product creation chain in order to achieve a (2012) 1, Hüthig Verlag. (Available in German only)
maximum benefit of synergy effects. By taking innovative [3] Heinle, C.; Ehrenstein, G.W.: Wärmeleitfähig modifizierte
approaches to adapting the material properties to both Kunststoffe-Teil1: experimentelle Analyse und Modellbes-
manufacturing and processing requirements, as well as chreibung einer bauteil- und prozessabhängigen Materialei-
genschaft. Kunststofftechnik [Journal of Plastics Technology]
requirements for use, a maximum utilization of the
6 (2009) 4, Carl Hanser Verlag. (Available in German only)
material’s potential is possible.
[4] Kayser, A: Raising thermal conductivity with hexagonal
Although electrically insulating heat-conductive boron nitride. Compounding World (2012) 2, AMI Plastics.
thermoplastic compounds are already available com- (Read it at http://bit.ly/eskpaper)

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Thermal conductivity | materials round-up
PolyOne targets LED applications

PolyOne has developed its lamps, while Europe is leading Kruunutekniikka’s Coolics
Therma-Tech thermally the demand, therefore we are technology places the heat
conductive grades for light- launching our new Therma- generating circuit boards
emitting diode (LED) lighting Tech thermally conductive within the casing during the
applications. The compounds plastics for LED lighting injection moulding process,
are designed to replace metal applications first in these two eliminating the need for
heat sinks, enabling part regions,” said Eng Guan Soh, traditional heat sinks.
consolidation and providing general manger, PolyOne “These metal-replacement
better management of hot Engineered Materials Asia. solutions manage heat while
spots. The company says that One European company also providing the design
these properties result in that is already using Therma- flexibility, reduced weight and
longer LED lifetimes, reduced Tech grades is the Finnish LED processing ease of conven-
weight, lower manufacturing lighting specialist Kruunutek- tional thermoplastics,” says
costs and improved in-service niikka. It has replaced Holger Kronimus, PolyOne’s
performance. aluminium with the thermal vice president, Europe and
The new grades were management polymers in its general manager, Engineered
launched at last year’s recently patented Coolics Materials Europe.
Chinaplas exhibition. “China is range of LED light fittings ❙ www.polyone.com
the leading producer of LED (pictured right). ❙ www.coolics.fi
Timcal touts the benefits of graphite

Timcal is promoting the moulded parts is evident in the
benefits of using graphite to graph, where graphite
make polymers thermally compounds show good
conductive. It says that the thermal conductivity even at
additive is the ideal choice in low loadings and excellent
markets such as LED lamps thermal conductivity (up to 10
and geothermal pipes. W/m.K) at higher loadings. In
Due to its particular particular, the results show
structure, graphite’s thermal that very high thermal
conductivity is different in the conductivity can be achieved
different directions of the with low loadings of Timcal’s
crystal, moreover its flaky C-Therm specialty graphite,
morphology contributes to the offering weight saving benefits.
overall anisotropic behaviour In-plane thermal conductivity of injection moulded 2-mm sheets of Through-plane conductivity
HDPE loaded with C-Therm and graphite.
of the final compound. was measured for these tests
Due to the graphite in-plane conductivity but moulding are more thermally using laser flash (ASTM E1461)
anisotropy, the resulting reducing the through-plane conductive. This difference is methods, while in-plane
thermal conductivity of a thermal conductivity. less important at higher measurements were steady
finished part is also a function Through-plane thermal loadings above 40%, where state (internal method).
of the processing technique conductivity achieved with high through-plane thermal We published a technical
used, as the latter will graphite loadings below 40% is conductivity (up to 5 w/m.K) paper from Timcal on the use
influence the orientation of the quite low (usually less than 1 can also be reached via of graphite in geothermal
graphite particles. For W/m.K) when the material is injection moulding. pipes in the Feb 2012 edition of
example, injection moulding is injection moulded (high The higher in-plane Compounding World. Read it
known to orient flaky particles orientation) while samples thermal conductivity (versus here: http://bit.ly/Timcal.
along the plane, enhancing the processed via compression through-plane) of injection ❙ www.timcal.com

materials round-up | Thermal conductivity
DSM steps up its activities in

thermal management plastics
DSM continues to be very
active in the thermally
conductive compounds arena,
announcing new grades and
applications.
Its latest launch is Arnite
PET XL-T, a thermally
conductive thermoplastic
polyester developed for
automotive lighting and
electronics components. Thermal load infrared scans from Automotive Lighting showing Arnite PET XL-T (left) and PPA
Target applications include GF30 (right). The former has better thermal distribution and its thermal peak is reduced by 25˚C.
fog-lamp housings, lens
holders and adaptive forward current automotive design fog-lamp housings made in the with existing fixtures and
lighting frames. trends, where improved new material as well as in rival sockets.
The new grade is based on comfort and safety need to be thermoplastics, and we see a Shanghai-based Baleno
Arnite PET-XL, which DSM achieved alongside improved clear improvement in thermal worked closely with DSM’s
introduced in 2009. It offers the fuel economy. “Electronics are distribution as well as peak lighting team in China on the
additional benefits of thermal key to managing these temperature levels.” design of the lamps. The
conductivity through the use of ambitious goals, especially DSM also reports good styling of its Revolution range
a proprietary filler: in-plane when hybrid and electric progress with its existing differs from that of other LED
conductivity is 1.65 W/m.K. vehicles are gaining more Stanyl TC thermally conductive retrofit lamps thanks to the
“Car makers and Tier Ones importance,” he says. “The polyamide grades, particularly use of Stanyl TC.
working on lighting and main driver for electronics is in LED applications. The Bas Bergmans, commercial
electronic applications are miniaturization in combination company claims that the director at Baleno, says that
under constant pressure to with increased electrical benefits of Stanyl TC have now the plastic compound was
save costs,” says Richard content. This makes proper been recognized by “almost all chosen for a number of
Frissen, business development heat management more and top lighting players”, with the reasons: “We selected the
manager for automotive more of a challenge. Die-cast material being used in Stanyl TC grade above several
electronics at DSM, add- aluminium is not always an products such as reflector other premium alternatives,
ing: “They need materials with option, due to weight and cost lamps (MR16, GU10 and PAR), because after testing we
good mechanical perfor- restraints, as well as electrical conventional bulbs (A lamps) recognized its unique thermal
mance, low outgassing or insulation issues, while tra- and LED modules. management characteristics
fogging characteris- ditional thermoplas- One company that is taking that resulted in a longer life
tics, and low tics, with their good advantage of the material’s span of our LEDs thus creating
moisture uptake, insulating properties is Baleno, a better lamps. At the same
while staying properties, can’t high-end LED lighting time, the material allowed us
price competitive provide the right manufacturer based in China. to make the lamp safer by
with existing HHR level of thermal It has selected Stanyl TC for its excluding the risk of electrical
[high heat dissipation.” complete range of LED retrofit conductivity; improve the
resistance] These factors lamps (pictured left). These design freedom inside the
solutions. With have driven the are designed to provide lamp; reduce the cost; shorten
Arnite PET XL-T, we development of Arnite high-efficiency and long-lifes- production lead time; and
reckon we have PET XL-T, says pan replacements for tradi- improve the overall perfor-
ticked all the boxes.” Frissen. “We have for tional incandescent lamps and mance of heat dissipation,
Frissen points to the example carried out halogen spotlights. The new dimmability and light output”.
potential conflicts in long-term tests on Baleno lamps are compatible ❙ www.dsm.com

Sabic Innovative Plastics stays cool

Sabic Innovative and PBT families up to Europe, says: “LED lighting providing the best combination
Plastics says that high-end resins offers huge potential to reduce of performance, design
its LNP Konduit such as PPS, LCP energy usage, leading to flexibility, aesthetics and
grades were the and PEEK. Sabic environmental benefits and production efficiency.”
first thermally is also actively cost savings, and with our Compared to metals,
conductive developing engineering plastics, we thermally conductive com-
compounds Konduit believe we can help turn that pounds have lower coefficients
available compounds based potential into reality”. of thermal expansion which
commercially. These on amorphous Gur identifies heat sinks as reduces stresses from
filled compounds resins. a key area where LNP Konduit differential expansion.
combine high thermal The company has compounds can improve the “Thermally conductive
conductivity with already expanded its performance of LED lamps. compounds are also better
electrical isolation Konduit range to include “Effective thermal manage- suited to high volume produc-
properties, and the white grades that coordi- ment is a key factor in tion than metal heat sinks,
amount and type of filler nate with white and ensuring a long lifespan and which require time-consuming
can be adjusted to meet coloured bulbs. For low energy usage of LEDs. As secondary operations, “ says
different application require- example, Leedarson Lighting LEDs become brighter and Gur. “We believe that Konduit
ments. Small amounts of glass of Xiamen, China, is using one more powerful, new thermal will do more than simply and
fibre can also be added to of these white Konduit management materials and effectively dissipate heat - it
improve the strength of the compounds based on PA 6 to designs are needed to handle will open all doors for visionar-
materials. mould heat sinks for retrofit increasing heat. We believe ies and designers to create a
The Konduit product line LED lamps (pictured above). that high performance whole new world of LED
broadly covers crystalline Ilknur Gur, Sabic’s general thermoplastic compounds can lighting.”
resins from PP through the PA manager specialty resins replace traditional metals, ❙ www.sabic-ip.com
ESK gets REACH approval for hBN

ESK Ceramics has success- melamine and boric acid.
fully registered hexagonal ESK says that its Boronid
boron nitride (hBN) under TCP15-100 hBN additive can
REACH. The company acted as be used to increase the
the lead registrant for the thermal conductivity of a range
additive which can be used to of plastics including PA, PBT,
increase the thermal conduc- PPS, PEEK, TPE, PET and PP.
tivity of thermoplastics without To assist compounding, ESK
increasing their electrical supplies the material as
conductivity. easy-to-process, free flowing
The completed dossier was agglomerates. It recommends Left: ESK supplies its hBN thermally conductive additive as free-
successfully submitted to the the use of high-torque flowing agglomerates. Right: The platelet structure of hBN
European Chemicals Agency in twin-screw extruders with high helps lift its thermal conductivity performance in plastics
November 2012, so all of ESK’s Do/Di ratios, such as the
boron nitride containing Leistritz ZSE Maxx, to produce addition, its platelet structure Kayser of ESK Ceramics on the
products are now fully the best conductivity results. delivers much higher thermal use of hBN in thermally
compliant with the require- Unlike some other ceramic conductivities than are conductive compounds in the
ments of REACH. The material fillers, hBN is not abrasive and predicted by theoretical February 2012 edition of
is synthesized from readily therefore does not cause wear models like Lewis-Nielsen. Compounding World. Read it
available boron- and nitride- problems in processing We published a four-page here: http://bit.ly/eskpaper.
rich pre-cursors, such as machinery, says ESK. In technical paper by Armin ❙ www.esk.com

RTP adds thermal compounds

for car and LED applications
RTP has launched two ranges over incandescent and
of thermally conductive fluorescent lighting. “However,
compounds in the past 12 LED luminaires must include
months – one targeted at proper thermal management
light-weight automotive or the life of the LED is
applications and the other dramatically reduced,”
aimed at LED lighting systems. explains Hardwick.
In the automotive sector, Thermally conductive
the global compounder is compounds offer many
focusing on replacing metal benefits over aluminium in
components in heating and LED heat sink applications.
cooling systems. The new The thermoplastics reduce
products have been specially weight by up to 50%, while
formulated to increase the injection moulding processing
thermal management design simplifies and lowers manu-
options available to automotive RTP is aiming for automotive and LED lighting applications with facturing costs.
industry engineers as they its thermally conductive compounds In addition, inherent colour
strive to reduce vehicle weight eliminates the need for
to improve fuel efficiency. They achieved using a variety of LED lighting sector. It has painting or secondary
can be based on a range of additives and the compounds introduced a line of materials operations, and heat sink life
resins, including PP, PE, PBT, can be either electrically for replacing metal heat sinks is increased in wet or aggres-
PA, PPS and PPA. insulating or electrically and housings in such applica- sive environments due to
Neil Hardwick, conductive conductive. tions. They have been formu- plastics’ corrosion resistance.
products marketing manager Thermally conductive lated to increase the design RTP can modify thermally
for RTP, says that the ther- compounds offer many options available for LED conductive compounds to meet
mally conductive compounds benefits over aluminium or lighting as it expands into a the performance requirements
“give engineers the opportu- stainless steel for vehicles. broader range of end-use of specific LED lighting
nity to redesign heating and These include: the ability to markets, including automotive, applications. A variety of
cooling systems in ways that provide electrical isolation; industrial, retail, and consum- additives achieve in-plane
have never before been reductions in part weight by up er goods. thermal conductivity up to 35
possible.” to 50%; lower manufacturing “The lighting market is W/m.K and allow the com-
Automobile systems that costs and simplified produc- undergoing a dramatic shift pounds to be either electrically
are ideal candidates for such tion using injection moulding; from incandescent to LED light insulative or conductive.
redesigns include both plus longer system lifecycles sources,” says Hardwick. Additionally, UL94 flame
air-cooled and liquid-cooled by eliminating corrosion. “LEDs currently comprise less retardance, white colours with
systems for batteries, Some thermally conductive than 10% of the overall lighting reflectivity greater than 95%,
emissions control, lighting compounds can also provide market, but their share is and UV resistance can be
modules, and electric vehicle EMI shielding properties. This predicted to rise to 80% over included to optimize each
thermal management. can be a crucial feature for a the next five years. To achieve formulation.
“RTP Company’s newest replacement material in that growth, new lighting A variety of resin systems
thermally conductive com- automotive systems where designs will be necessary and are offered in this range,
pounds actually provide metals have been used in a RTP Company’s thermally including PA 6, PA 66, PPS and
thermal conductivity values dual role as both an EMI shield conductive compounds will PC. Data sheets for RTP’s full
that exceed that of stainless and a heat sink. make those designs possible.” range of thermally conductive
steel,” claims Hardwick. The other market that RTP Reduced energy consump- compounds can be found at
In-plane thermal conductivity is targeting with thermally- tion and longer service life are http://bit.ly/RTPtherm.
values up to 35 W/(m.K) can be conductive compounds is the some of the benefits of LEDs ❙ www.rtpcompany.com

Polymers
Conductive Carbon Black Graphite & Coke

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For electronic packaging, fuel hoses, For seals, water-meters, heat sinks, geothermal
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Cost management | business
Plastics business management expert Dr Robin Kent, author of

“Cost Management in Plastics Processing”, discusses the
critical difference between cost management and cost
cutting and the inexplicable focus on labour content
Don’t labour over managing costs

Cost management is a vital subject for everybody in the ● Why do we justify machinery purchases on the labour
plastics processing industry but many people confuse we save and yet rarely analyse how much labour we
cost management with cost cutting - they are not the actually have saved?
same thing. ● Why do managers know exactly how many staff they
Cost cutting will not make your company a world control and how much material they have used but
leader or even an also-ran; it will eventually destroy not know how much capital equipment they control,
your business. Too many companies have carried out how much energy they use or how much of the
crude cost cutting without any real attempt at managing overheads they control?
the process. The results are frequently tragic for the ● Why do we think: ‘Overheads are part of the business.
staff, the company and eventually for the management They are central, unmanageable and unavoidable’
who embarked on the cost cutting process. and then ignore them or assume they are somebody
This confusion is primarily due to a continuing else’s problem?
fascination with the cost of labour. Ask yourself: We should ask ourselves: Are we really serious about
● Why do we think that if we want to reduce costs then managing costs or are we just playing at it? Trying to
we must start with direct labour costs? manage what we don’t understand is a recipe for failure
● Why do we have Human Resources Departments and and is one of the reasons that cost cutting programmes
Purchasing Departments but ignore any attempt at fail and risk bringing the company down with them.
Overhead Management or Energy Management? Realistic cost management is not achieved by
● Why do we get upset if we see an idle worker and yet ignoring large costs (such as overheads) but is achieved
unthinkingly accept unrealistic overhead allocations by understanding what we are really doing. It is not
and/or walk past machines that are running but not simply about low labour cost, but about reducing all the
producing any product? costs and taking effective action to survive in an

business | Cost management
FIGURE 1:
ANALYSIS OF
COST AND
MANAGEMENT
EFFORT IN A
TYPICAL
PLASTICS
PROCESSING
PLANT
increasingly perilous world. concentrated on the staff (or labour) element of

KEY POINT: If you don’t understand where your costs overheads and ‘delayered’ (another word for ‘made
are coming from it is futile to try to manage them. redundant’) the middle management. This meant there
was nobody left to do any of the work that could really
Target cost management effort save the company money. Meanwhile, production staff
The cost model that many processors have been using were frantically trying to meet the ever increasing
was largely developed in the first half of the 20th century production targets, to complete new initiatives started
when direct labour was a high proportion of the costs. by the upper management (the latest set of manage-
Increased investment in machinery and services has ment fad initiatives) while the real cost contributors
reduced direct labour costs and simultaneously were left unchallenged and out of control.
increased overhead costs but the cost model remains This misdirected effort continues to cost money and
the same. waste resources throughout the industry. Our efforts
Figure 1 presents the broad cost distribution and the are badly or incorrectly focused because we continue to
effort spent on cost management within a typical operate with a model that is now out of date and sends
plastics processing operation. It shows that most of the us in the wrong direction when we try to manage costs.
effort is spent in managing direct labour when this is We spend most of our time and effort on the
actually one of the smallest components of the total smallest component of the cost and largely ignore the
Direct labour is cost. Are we determined to get it wrong? other costs. Reducing overheads by only 10% translates
no longer a big In fact, this problem is getting worse as time goes by. into a product cost reduction of about 3.5% - the same
cost contribu- Direct labour costs continue to shrink and overhead as a labour cost reduction of 35%. Logic should tell us
tor but it costs continue to rise. The cost basis for most manufac- that if we want to make reductions then we should start
remains the turing industry has changed yet direct labour continues with the big numbers because that is where we will
prime focus for to be the focus for cost management. The model we make the big savings. Yet this is not where we start and
many plastics have all grown used to is no longer valid. we wonder why our cost reduction efforts are not as
processors In the past, even when we did look at ‘overheads’ we effective as we would like them to be.
KEY POINT: Managing costs can make you a low-cost
producer, simply cutting labour costs will not.
Control material costs

Plastics processing rarely adds much to the product in
terms of additional items and is basically a ‘conversion
industry’. This means that direct materials are inevita-
bly one of the largest cost elements of the finished
product, yet it is one of the least attacked.
Depending on the product, the raw materials cost
element will vary from 45% (technical products) to 80%
(mass produced products). In many processing
companies there are few formal attempts to manage
the materials cost. Attempts generally involve simply
reporting ‘variances to standard’ without any real

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Cost management | business
attempt to reduce absolute use.

Concentrating on materials costs will give a rapid
and significant payback. So who is really responsible for
materials costs? The general process can be described
as follows:
l Design/technical staff produce a product design and
specify the materials. They take the basic decisions
on the shape and design of the product and these
‘simple and obvious’ decisions effectively define the
overall cost of the product. Once the length, width,
height, wall thickness and material type has been
decided, up to 80% of the product cost is already
fixed!
l Purchasing staff negotiate a price for the specified
material and volume requirements.
l Production staff make the part and attempt to keep
waste to a minimum. Manage your energy use Effective
It is clear that in such a process chain nobody is Energy usage is a variable and controllable overhead accounting
really in charge so everybody blames somebody else for but most companies do little to actually manage their is the key to
high materials costs. This needs to change. use of energy – many still regard it as a fixed and realising
Set up a Materials Team (to include Sales, Design, uncontrollable cost when nothing could be further from significant
Purchasing, Production and Accounts staff) to ensure the truth. Energy use is often ignored and thought of as material cost
that all materials are used cost-effectively. Consider being a minor cost that can be signed off by the savings
that a 1% reduction in purchasing spend has the same accounts department alone. However, this area can be
effect on profit as a 10% increase in sales volume. So managed to reduce costs significantly with no ill effects
give the Materials Team aggressive targets for materi- on product quality or output.
als reduction – taking 10% off the total materials bill Reduction in energy use is not only beneficial in
should force them to think radically. terms of cost management but also reduces the
KEY POINT: Effective accounting and availability of environmental impact of a company. Many of the
detailed accounting information holds the key to materi- techniques used in waste minimisation can also be used
als cost reduction. as part of an ISO 14001 Environmental Management
system. This has a double benefit - turning the bottom
Understand overhead costs line black while turning the company green is good for
Without effective overhead management, any attempt at both finances and reputation.
cost management is bound to be both partial and KEY POINT: Managers should be responsible for, and
ineffective. Effective cost management depends on the evaluated on, the energy costs under their control.
measurement and improvement of overhead productiv-
ity and will be one of the keys to success in the future. About the author:
To manage overheads, managers first have to accept Dr Robin Kent is an independent expert
that these costs are under their control and that they specialising in plastics processing
are not simply there to be allocated away and disappear. technology and business management.
Overheads are part of a manager’s responsibility and Founder and managing director of plastics
every manager must be provided with the incentive and consultancy firm Tangram Technology, he
the information to drive down the costs. has published more than 400 technical
Overheads need to be examined in every area of the papers and articles and written two books
business. This is not simply about the number of staff, it on plastics processing covering strategies
is about the processes and assumptions that we make. for energy and cost management.
Do not simply think about manufacturing, although this The third edition of his book “Cost
is often fertile ground for improvement. Consider other Management in Plastics Processing:
areas such as stock and inventory costs, quality costs Strategies, Targets, Techniques and Tools” was published at the end of last
and staff overhead costs and processes. year. Providing a clear and well-structured route map comprised of clearly
KEY POINT: Managers should be responsible for, and defined tasks and achievable goals, this revised and expanded edition is
evaluated on, overhead costs that are under their control. available now from the Plastics Information Direct bookstore here.
www.compoundingworld.com February 2013 | compounding world 45

PVC Formulation 2013
Market trends and technical developments in PVC additives and compounding
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12-14 March 2013

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Intellectual property | product development
After three decades

of discussion, the
EU is to implement
a unitary patent
system intended
to cut the cost and
complexity of
the process.
Compounding
World considers
the implications
EU moves to simplify patents

Members of the European Parliament voted in Decem- enters into force, whichever is the later.
ber last year on a package of proposals that will finally The new patent process will be less costly than the
lead to the creation of a unitary patent structure. The current system and is intended to provide more effective
package of reforms is the culmination of some 30 years protection. It should eventually reduce the cost of a
of discussion within the European Union and aims to patent to €4,725 from a current typical cost of around
reduce the cost of the patent system for individuals and €36,000, according to the European Commission.
smaller companies and make the patent system more Under the new rules, any inventor will be able to
competitive compared with the Japanese and US apply to the European Patent Organisation for an EU
systems. unitary patent that will be valid in all 25 participating
Aside from the establishment of a unitary patent, the member states. Patents will be made available in
package of measures passed by the European Parlia- English, German and French; applications must be
ment also addresses the issue of the high cost of made in either English, German or French or in any
translation into the national languages of the EU and other EU language accompanied by a translation into
sets up a unified patent court. one of these three languages.
MEP Raffaele Baldassare - the Italian MEP and “Today’s vote is good news for the EU economy and
Christian Democrat European People’s Party member especially for European small and medium enterprises
who lead the discussions on the patent translation (SMEs)”, said Bernhard Rapkay, a German MEP and
regime - has described the current European patent member of the parliament’s Progressive Alliance of
system as a “tax on innovation”. He said the European Socialists and Democrats who lead the regulation
Parliament hoped to minimise this burden through a setting up the unitary patent protection scheme.
series of specific measures enabling SMEs to fully “Intellectual property must not stop at borders. The
reimburse translation costs. path towards the introduction of the EU patent was long
The international agreement creating the unified and troubled, but ultimately it has been worth the
patent court come will come into effect from 1 January effort,” he said immediately after the vote.
2014, or when the UK, Germany and France plus at European Patent Office president Benoît Battistelli
least 10 other signatory states have ratified it. The other sees the vote finally clearing the way for a long awaited
two acts will come into effect either from the beginning unified European patent system that will particularly
of 2014 or from the date the international agreement benefit European researchers. “Cutting the cost of

product development | Intellectual property
patenting inventions in Europe will However, these will become alternatives: it will not be
strongly benefit European possible to obtain, for example, both an EP(UK) patent
enterprises, especially and a unitary patent, but only one or the other,” he says
research centres and in a discussion document (which can be read in full
SMEs. The vision of the here http://bit.ly/V6TUrt).
founding fathers of the Robinson also points out that the European Patent
EPO to equip the Office is not an EU institution and includes non-EU
European economy member states such as Norway and Switzerland. If an
with a truly supra- applicant requires protection in those countries it will
national patent system be necessary to make applications separately in these
can now become a countries. That will also apply to Spain and Italy if they
reality, strengthening decide to remain outside of the unitary system.
Europe’s competitive-
ness,” he says. Complicated court structures
The new measures have However, Robinson points out that the most complex
been given a cautious welcome by aspect of the package lies in the establishment of the
Will Cook, a partner at UK-based intellectual Unified Patent Court (UPC), which will in fact be
property law firm Marks & Clerk Solicitors. “Despite the comprised of a system of local, regional and central
technical concerns of many lawyers around Europe, the divisions across the EU. Cases will at first instance be
new unified patent and unitary court has a very real held in the state where the defendant is based with the
chance of reducing costs and complexity of enforcing language of proceedings normally being those of the
patents,” he says. patent, says Robinson. Where the defendant is not
The challenge, he warns, will be in the implementa- EU-based or has no EU local subsidiary, actions will go
tion. Whether the new patent enforcement landscape direct to the Central Division, which will operate from
ultimately proves to be cheaper, simpler and more Paris, London or Munich according to the nature of the
effective than the current highly fragmented system will case. The system will also include a court of appeal in
depend not on the politicians but on the lawyers around Luxembourg and arbitration and mediation centres in
Europe that service the system, according to Cook. Portugal and Slovenia.
“Technology-driven industry will welcome a system “A layer of complexity is added by the fact that the
with straightforward, reliable and cost-effective applicable law relating to infringement and validity will
procedures. But will we get one? That will surely be be that of the state where the patentee is based.
down to how the judges run the court: With strong Questions remain regarding whether referrals to the
leadership from an experienced judiciary, we will get Court of Justice of the EU may be possible, which would
there,” says Cook. threaten to cause significant delays and increases in
He adds that while the current proposals are not cost during litigation,” he says.
perfect, if the judges are selected with care and are Robinson also sees at least one potential disincen-
effectively supported then the system should be robust tive to using the unitary scheme. While it should provide
enough to work as intended. a less costly means of obtaining and maintaining
patents across the EU – and should also reduce the cost
Obstacles to implementation of litigation – applicants should keep in mind, he says,
There remain some potential obstacles to implementa- that revocation of a unitary patent will take effect across
tion of the new scheme. Spain and Italy are currently Europe.
not participating in the unitary patent scheme and could “Even non-unitary European patents will ultimately
mount a challenge to its implementation. But Cook says fall under the jurisdiction of the new courts and an
while the Court of Justice could issue a ruling that as-yet untested legal system. Applicants may therefore
blocks the unitary patent plans, it would have to wish to take the precaution of filing multiple national
contradict the opinion of the EU Advocate General, who patent applications if the prospect of UPC jurisdiction
has already ruled the implementation process correct. raises concern,” he says.
According to Alex Robinson, who is a technical
assistant at international patent and trademark Click on the links for more information:
attorneys Dehns, there are also potential pitfalls within ❙ www.epo.org
the system. “The existing country-by-country validation ❙ www.marks-clerk.com
route will continue to exist alongside the unitary patent. ❙ www.dehns.com

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Becky Merriott – Conference Manager [email protected] Tel: +44(0)117 924 9442 Fax: +44(0)117 311 1534
Materials handling | processing feature
Compounding typically involves shifting

and controlling hard-to-handle
materials. Mikell Knights looks
at the latest material
handling systems designed
to tame those tricky ingredients
Maintaining
the flow
Dispensing and controlling hard-to-handle feed-stocks “The MaxiBatch line for the first time allows Maguire Special devices
in a compounding plant, such as low bulk density to offer a product capable of handling powders as a on Maguire’s
powder or flake or low melt temperature additives, is major ingredient in a formulation,” adds Smith. Users MaxiBatch
being addressed with several hardware and software can mount one or several hoppers, each with its own blender (shown
developments. These enhancements target gravimetric dispense mechanism, on top of the blender. MaxiBatch here with
metering systems and seek to eliminate material flow accommodates up to 12 removable hoppers and blends company owner
issues in the hopper, improve product conveying, up to 12 ingredients at throughputs up to 12,000 lb/hour Steve Maguire)
optimize formulations for cost savings, and connect (5,500 kg/hour). Each component in the MaxiBatch simplify the
feeder control to a plant-wide system. system is sold as an off-the-shelf module. handling of
Maguire is one company that has been refining its After developing a blender for dispensing wood flour powders,
tried and tested systems to handle low bulk density composites 10 years ago, Maguire tweaked its design flakes, regrind,
materials. It says that its MaxiBatch Gravimetric for use as a powder feeder, giving rise to the MaxiBatch. additives or
blender line is designed to accurately dispense powder, Four additional dispense valves were developed after wood flour
wood flour, flake, regrind or pellets into a weigh the wood flour blender valve, including two designs for
chamber at rates up to 12,000 lb/hour (5,500 kg/hour). low bulk density powders and flake: the High Flow
The model line, which grew out of Maguire’s initial Corner Valve, and the Small Capacity Powder Feeder.
efforts to handle higher percentages of wood flour in a Maguire’s High Flow Corner Valve is a 7 in x 7 in (18
formulation, features a selection of five proprietary cm x 18 cm) pneumatically operated slide gate that is
dispensing devices, each developed to handle different positioned in a back corner of the hopper, designed for
material types. use with flake or powder. When actuated the valve
“Any material above 25 lb/ft3 [400 kg/m3]can be creates a large opening for low bulk density materials
metered and dispensed with a standard discharge valve, to flow through.
because it is free-flowing and easy to dispense. To ensure flow through the opening, Maguire
However, material from 18 to 25 lb/ft3 [290 to 400 kg/m3] developed its Bridge Breaker, a bar-like device with
tends to be light, fluffy and poorly flowing. The hard-to- paddles installed in the hopper that pulses up and down
handle nature of these types of materials requires to continually encourage material to flood the bottom of
specialized dispensing,” says Pat Smith, Maguire’s vice the hopper. Pulsing the vertically mounted bridge
president, marketing and sales. breaker encourages flow of flake or powder through the

processing feature | Materials handling
corner valve. Encour- flow easily through an oversized opening at the base to
aging flow minimizes a horizontal auger that positively conveys it to the
bridging or hang-up of mixing chamber.
material. Where high volume throughputs have to be accom-
The Small Capacity modated, the company uses lift augers positioned at an
Powder Feeder angle in a corner of the regrind bin. Instead of forcing
dispensing device is a the material into the base of the bin, these lift it to avoid
smaller throughput option. compaction in the feed zone.
The hoppers can dispatch TrueBlend units are available to handle throughputs
powder or flake to conveying of less than 23 kg/hour on the smallest TB45 unit up to
augers designed to move powder or 5,455 kg/hour on the largest TB3500 models. They can
flake, or directly to the weigh bin. be supplied with up to 12 ingredient bins.
In addition to physical devices
created for hard-to-handle materials, Taking control
Maguire is focusing on software Other specialists in the handling of difficult materials
improvements that will help users have been busy developing improved control systems.
process extremely poorly flowing For example, Brabender Technologie has rolled out two
materials, such as long-glass fibres. new fully digital control and regulation modules that
“Despite the use of the most forgiving allow direct control of its gravimetric feeders through a
valve or dispense mechanism, processor’s plant- or system-wide controls. The new
tough-to-flow materials like long glass Intelligent Signal Conditioner (ISC) modules rely on
Conair’s fibre pellets can tangle, causing discharge amounts to ethernet or field bus interconnections to link with a
TB2500 fitted vary widely. You might want 1,000 g but only get 50 g the broad range of interfaces used by system-wide
with fluidizing first time the valve opens, then 500 g the second time, automation systems.
augers is one then 30 g the next,” says Smith. Brabender offers the ISC-CM plus (feeder control
of two designs Maguire has enhanced the control software of its module) and the ISC-FC plus (speed control module
developed to gravimetric blender to build the batch around the with frequency converter. The advantage of the ISC
handle difficult amount of material received. “The key is to dispense modules is the all actual weigh feeder control and regu-
materials the difficult flowing material first, then weigh what is lation tasks are taken over by the supplier’s control
received, then automatically adjust the ratio of the other electronics.
components to match the dispense of the hard-flowing For feeder operation without central automation
material.” The trade-off is the potential of lower systems, Brabender offers a variety of touch screen
throughput rates or at least a slowing down of the operating and display units for up to 32 feeders,
process. Smith says operators can dispense multiple depending on the respective model.
shots of the tough flowing material before adjusting the Schenck AccuRate is another leading supplier of
ratio of other ingredients in the batch as a means to ingredient handling systems that is focusing on control
keep throughput near target. system updates. It is in the
Updated Conair has also been focusing on process of upgrading its
controls will improving the handling of flake Disocont control electronics,
enhance recipe recyclate and other difficult-to-feed which are used throughout its
management regrind materials with new developments Mechatron line of gravimetric
on Schenck’s for its TrueBlend blending systems. The feeders. More user-friendly,
Mechatron company is adopting two different intuitive functionality,
systems approaches to overcome feeding additional I/O and improved
problems depending on integration are key features of
the volume throughput. the new platform, says Mike
For smaller through- Karas, marketing communica-
put quantities, the units tions manager at the company.
are fitted with side Schenck AccuRate’s
feeders with steeply Mechatron Coni-Flex line of
angled sides that help screw feeders feature
prevent regrind from hanging or flexible-walled conical mass
bridging. The material can then flow feed hoppers, the Disocont

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All prices are correct at the time of publication but may be subject to change.
Please check the Plastics Information Direct website for current prices and shipping charges.
WOOD-PLASTIC
COMPOSITES 2013
The international business conference & exhibition for
the wood-plastic composites industry
HEADLINE SPONSOR
25-27 February 2013

Austria Trend Savoyen Hotel, Vienna, Austria
Images courtesy of: battenfeld-cincinnati Austria GmbH, Beologic, TimberTech and Trex Company

Organised by: Also sponsored by: Media supporters:
Applied Market
Information Ltd.
Maud Lassara – Conference Organiser [email protected] Ph: +44 117 924 9442 Fax: +44(0)117 311 1534
Materials handling | processing feature
control, and are offered as a low range LC model,

mid-range MC unit, or high throughput HC series. The
Mechatron Coni-Flex series allows for disassembly,
cleaning, reconfiguring or service of the feed screw,
motor or internal feed hopper from the non-process
side, which eliminates the need to remove upper
extension hoppers, bins or bulk bags.
Two years ago, Schenck AccuRate’s parent company,
Schenck Process purchased Mac Process, a manufac-
turer of custom pneumatic conveying equipment and
filtration devices based in Kansas City, Missouri, USA.
The company is now integrating Mac Process into
Schenck Accurate. Merging the two businesses is part
of a company-wide effort to slowly transition all its
material handling equipment under a single Schenck
Process name, says Karas. sensor that detects any vacuum leaks within the Motan-
pipeline, eliminating time-consuming visual control Colortonic’s
Keep it quiet checks of the piping. Motan-Colortronic says that the double-walled
Shifting large volumes of materials can be a noisy double-wall construction ensures that conveying SilentLine
business. At last year’s Fakuma show, Motan-Colorton- continues even if a vacuum leak is detected. system
ic introduced a new double-walled stainless steel feed Motan-Colortronic has also upgraded its Gravinet GP dampens
conveying line system that is claimed to dampen control system with a larger touch screen and the ability conveying noise
conveying noise by at least 12 dBA. The new SilentLine to control virtually unlimited number of dosing mod- and offers
features an inner material feed-line surrounded by an ules. At least four process lines can be monitored and other benefits
external pipe. controlled. The system is designed to continuously
An air buffer between the two pipes helps reduce regulate up to eight material combinations.
noise levels for a quieter working environment, and it is
said that the air buffer reduces heat loss from the Click on the links for more information:
pipeline to its surroundings, which can eliminate a local ❙ www.brabender-technologie.de
drier when conveying dried material. SilentLine can be ❙ www.conairgroup.com
combined with conventional pipelines from Motan- ❙ www.maguire.com
Colortonic. ❙ www.motan-colortronic.com
The system offers a special externally applied flow ❙ www.schenckprocess.com
AMI Strategy Seminars

These one-day seminars are given by an AMI director and provide
invaluable insights into market trends and industry strategies.
They are held in small groups and provide ample
opportunities for questions and discussions.
21 March 2013: Singapore

14 May 2013: Vienna, Austria
Contact: Katy Cheng

[email protected], +44 117 924 9442
www.amiplastics.com/seminars
This month’s free
brochure downloads
Simply click on the brochure cover or link to download a PDF of the full publication
Entek: WPC lines Coperion: ZSK Mc18 extruder

Extrusion Solutions for This brochure covers This brochure has the full
Wood-Plastic Composites
Entek’s complete turn-key story on Coperion’s latest
extrusion lines for the ZSK Mc18 twin-screw
production of wood-plastic extruder which offers
composite (WPC) decking. market-leading specific
The lines are built around torque levels of 18 Nm/cm3
the company’s E-MAX leading to higher maximum
twin-screw extruders. throughputs.
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Leistritz: ZSE Maxx extruders Struktol: additives for plastics

This 12-page brochure This brochure from Struktol
Get To Know Struktol
Quick Guides covers Leistritz’s state-of-

Struktol’s vast polymer additive experience is translated into the most
intelligent solutions available anywhere. Each of our additives are tested and
retested to insure maximum product quality and performance consistency.
Struktol Company of America
Struktol Company of America is a member of the Schill & Seilacher family of companies, with representation in
over 100 countries around the world. A global organization with over a century of specialty chemical expertise,
covers its wide range of
the-art ZSE MAXX twin- additives for thermoplastics,
Struktol manufactures a complete line of additives that function individually Schill & Seilacher markets most of their polymer processing products under the brand name STRUKTOL® – a name
or in combination as adhesives, lubricants and surfactants, all accompanied that has become synonymous with both quality and performance. Struktol manufactures chemicals for the plastics
by a wide range of benefits. and rubber industry, foam inhibitors, polydispersions, silicone emulsions, products used in latex processing, and
POLYDIS®, a line of epoxy prepolymers and flame retardants.
screw extruders in great including products for

The Struktol approach to the rubber and plastic additives business is by no means typical or ordinary. Chemistry
is at the heart of everything we do. Providing Intelligent Additive Solutions, Struktol products are designed to
Case Studies meet the challenges and exacting demands of our customers. Our technical specialists, R&D chemists and
Improved Processing compound laboratory are dedicated to creating innovative solutions for the ever-changing polymer industry –
detail. These high-torque, superior viscosity control,

A compounder of flame retarded polypropylene was solutions that keep you ahead of your competition with increased productivity, better quality parts and lower
unable to efficiently mold their compound due to the high overall cost. In addition to premium product performance, Struktol Customer Service initiatives have become
temperatures and pressures required during processing. the industry benchmark.
The molding conditions caused problems with the flame
high-volume machines have improved mixing and filler

retardant system. By adding 1% of STRUKTOL® TR 251
the customer was able reduce the process temperature
by 20°C and reduce the pressures required to completely
fill the mold.
been developed to deliver dispersion, plus reduced

Improved Performance
Struktol Company of America
A compounder of polycarbonate resin was able to 201 E. Steels Corners Road
P.O. Box 1649
reduce the viscosity of his product by 25% using 1%
Stow, OH 44224-0649
of STRUKTOL® TR 044W without sacrificing any clarity 330-928-5188
800-327-8649
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due to the additive. This viscosity reduction led to a Fax: 330-928-0013
corresponding reduction in molded-in stress which Email: [email protected]
improved the mechanical performance of the material. www.4struktol.com

In addition the additive provided improved mold filling
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Cost Reduction
A rigid PVC profile extruder was able to increase the
addition level of regrind into his product by adding a
costabilizing STRUKTOL® V Series product. The additive
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maintained the heat stability of the compound resulting in
substantial cost per part savings due to the increased level
of regrind added. No performance reduction was seen.
Many Struktol Intelligent Additive Solutions are the result of a partnering effort
between our customer and our sales and technical staff. If we don’t have the
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exceeds your requirements.
TEB0047/2012
Today’s Thermoplastic Industry
Steer: SPL40 turn-key lines PlasMec: PVC mixing/cooling

This eight-page brochure This brochure covers
covers Steer Engineering’s PlasMec’s HEC High
new SPL40 compounding Efficiency Horizontal Cooler
pelletizing systems that for the production of rigid or
include feeders, extruders, plasticized PVC dry-blend.
strand die heads, water Available in sizes up to 8,000
troughs, air knives, litres, it delivers high levels
pelletizers and classifiers. of efficiency, throughput and
quality.
If you would like your brochure to be included on this page, please contact
Claire Bishop. [email protected]. Tel: +44 (0)20 8686 8139
Download the programmes for
these forthcoming conferences
Simply click on the brochure cover or link to download a PDF of the full publication
Green Polymer Chemistry Pipes in Infrastructure

The second international AMI is holding the Pipes in
GREEN POLYMER Pipes in 2013
CHEMISTRY 2013 conference on manufactur- I n f r a s t r u c t u re Infrastructure 2013
International conference on manufacturing conventional plastics
ing conventional plastics Market trends, new products and technical developments in plastic pipes
conference in Düsseldorf,
from sustainable sources for infrastructure applications
from sustainable sources is Germany, on 9-11 April.

being held on 19-21 March Check out the programme
in Cologne, Germany. This which covers market trends
brochure has all the details. and technical developments
Images courtesy of: Wavin GmbH and Hobas Rohre GmbH

in plastic pipes for
infrastructure applications.
19-21 March 2013
Maritim Hotel, 9-11 April 2013
Cologne, Germany Hotel Nikko, Düsseldorf
* + 19% German VAT
Germany * + 19% German VAT
Image courtesy of: Shutterstock
SPECIAL OFFER: Save €140* if you register before 15th February 2013 SPECIAL OFFER: Save €100* if you register before 8th March 2013
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o +44 (0)117 311 1534 Fax back to +44 (0)117 311 1534
Stretch & Shrink Film Polymers in Photovoltaics

AMI’s 10th international POLYMERS AMI’s international
STRETCH & SHRINK
FILM 2013 conference on Stretch & in
Photovoltaics
2013
conference on polymer
The business conference & exhibition for
the stretch & shrink film industry Shrink Film will take place International industry conference on polymer components in photovoltaic systems
components in photovoltaic
in Berlin, Germany, on 16-18 systems is taking place in
April 2013. The programme Cologne, Germany, on 16-18
10
ANNIVERSARY
CONFERENCE
th
includes detailed market April. Check out the

The 10th anniversary
analyses, plus the latest programme that covers new

Images courtesy of: Ray Colby of Sundial Solar and SBM Solar Inc. USA
conference will be
a celebration of the
success of the stretch &
materials, processing and developments in this

shrink film industry over
the past ten years
application developments. exciting market.

16-18 April 2013 16-18 April 2013
InterContinental Hotel, Maritim Hotel,
Berlin, Germany Cologne, Germany
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Plastic Closure Innovations Polymer Sourcing

Taking place in Cologne on AMI’s ninth Polymer
PLASTIC CLOSURE POLYMER SOURCING
INNOVATIONS 2013 23-25 April, this conference Sourcing conference will be
2013
will examine market and New sources, optimising customer relations and maintaining profitability
held in Vienna, Austria, on
Trends and technical developments in the international closures industry
technical developments in 14-16 May. This essential

the global caps and closures event covers the European
industry. Download the polymer supply chain from
programme which features production through
key players from throughout HEADLINE SPONSOR distributors and traders to
the supply chain. purchasers and specifiers.
14-16 May 2013
23-25 April 2013 Imperial Riding School Renaissance Hotel,
Maritim Hotel, Cologne, Germany
Vienna, Austria
* + 19% German VAT
Hartley’s image and Vosene image courtesy of: GCS
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o +44 (0)117 311 1534 Fax back to +44 (0)117 311 1534
To see our full line-up of more than 25 plastics industry events

over the next 12 months, please visit www.amiconferences.com
compounder of the month
Epsan Plastic
Head office location: Bursa, Turkey
Date founded: 1976
CEO: Atila Efe
Ownership: Privately owned
No. of employees: 100
Plant locations: Bursa and Gemlik, Turkey
Production 2012: 13,000 Tonnes
Profile: Epsan Plastic was founded in 1976 as a plastic trading firm. In 1998 it
established its first manufacturing plant for high-performance polyamide
compounds. The company now has two production plants in Turkey and it added
its fifth Coperion compounding line towards the end of last year. This takes its
total compounding capacity to 22,000 tonnes/year. Epsan distributes its PA 6 and
6.6 compounds to Europe and North Africa under the Eplamid, Eplon and Epimix
brandnames. It has held the ISO 9001:2000 quality certification since 2003.
Product line: Epsan specializes in PA 6 and 6.6 compounds produced to customers’

requirements. These include flame retardant, mineral-filled, glass-fibre-
reinforced and carbon-fibre-reinforced grades of the engineering thermoplastic.
The company also offers coloured and lubricated formulations, plus UV and
heat stabilized compounds. Its main target markets are the automotive and the
electrical & electronic sectors.
Product strengths: Epsan offers customized high-performance compounds internationally. With its
UL approval and high quality standards, its compounds are used by high-profile
global OEMs.
Forthcoming features
The next issues of Compounding World magazine will have special reports on the following subjects:
March April
Additives for PET 50th issue – celebration special
Twin-screw extruders Anti-oxidants
Natural fibres and fillers Wire and cable applications
Editorial submissions should be sent to Andy Beevers: [email protected]

For information on advertising in these issues, please contact
Claire Bishop: [email protected] Tel: +44 (0)20 8686 8139
Catch up on our recent
issues for FREE
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Compounding World – Jan Compounding World – Dec
The January edition of Compounding World’s December
Compounding World covers edition covers the processing of
developments in foaming high-temperature plastics,
additives and the formulation developments in lab-scale
of polyolefin foams. It also compounding, the selection of
takes a look at coupling agent flame retardants for polyamides,
innovations and pelletizing and trends in renewable
technology. polymers and additives.
➤ Click here to view ➤ Click here to view
Injection World – Jan/Feb Injection World - Nov/Dec

This edition of Injection World The November/December
covers automotive composites, edition of Injection World has
IML developments, reinforcing in-depth features on machine
fibres and additive setting procedures, automotive
manufacturing, plus it has applications, machinery
three practical features on market trends, renewable
cost management, developing polymers, and hot runner
multi-shot products and developments.
understanding moulding
variables. ➤ Click here to view
➤ Click here to view
Film and Sheet – Dec/Jan Pipe and Profile – Jan/Feb

The December/January issue The January/February issue of
of film and Sheet Extrusion Pipe and Profile Extrusion
has special articles on melt contains articles on additives
filtration systems, recycling and colorants, screenchangers,
machinery, bag-making and PVC stabilizers, corrugated
converting equipment, plus pipes, and the use of
new markets for sheet composites and engineering
extruders. plastics in high-performance
pipes and profiles.
Take out your own FREE subscriptions to any of the magazines.

Click on the logos below to simply register on-line.
dates for your diary
Global exhibition guide

6-7 March Plastec South, Orlando, FL, USA www.plastecsouth.com
6-8 March Plast Bulgaria, Sofia, Bulgaria www.plast.bg
12-15 March Plastimagen, Mexico City, Mexico www.plastimagen.com.mx
12-15 March Pro-Plas Expo, Johannesburg, South Africa www.proplasafrica.co.za
3-5 April Plastex Uzbekistan, Tashkent, Uzbekistan www.plastex.ite-uzbekistan.uz
3-6 April Tiprex, Bangkok, Thailand www.tiprex.com
10-11 April PlastTeknik, Malmo, Sweden www.easyfairs.com
10-12 April Plastic Japan, Tokyo, Japan www.plas.jp/en
7-10 May PlastPol, Kielce, Poland www.plastpol.com
14-16 May Plast-Ex, Toronto, Canada www.plast-ex.org
20-23 May Chinaplas, Guangzhou, China www.chinaplasonline.com
20-24 May Feiplastic, Sao Paolo, Brazil www.feiplastic.com.br
6-8 June Plastics Printing Packaging Tanzania www.pppexpo.expogr.com
18-19 June PDM, Telford, UK www.pdmevent.com
18-20 June Plastec East, Philadelphia, USA www.plasteceast.com
16-23 October K 2013, Düsseldorf, Germany www.k-online.de
AMI conferences
25-27 February Wood-Plastic Composites, Vienna, Austria
5-7 March Cables, Cologne, Germany
12-14 March PVC Formulation, Düsseldorf, Germany
18-20 March Masterbatch Asia, Singapore For information on all
19-21 March Green Polymer Chemistry, Cologne, Germany these events and other
7-8 May Bioplastics Compounding & Processing, Miami, FL, USA conferences on film,
14-15 May Polymers in Cables, Miami, FL, USA sheet, pipe and
14-16 May Polymer Sourcing, Vienna, Austria packaging applications, see
3-5 June Masterbatch, Frankfurt, Germany
4-6 June End of Life Plastics, Cologne, Germany www.amiplastics.com
13-14 June Fire Retardants in Plastics, Denver, CO, USA
10-12 September Polyolefin Additives
17-18 September Medical Grade Polymers
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February 2013

THERMAL COMPOUNDS HIT THE ROAD

THE LATEST ADDITIVES FOR POLYOLEFINS

PRACTICAL TIPS FOR MANAGING COSTS

MORE EFFICIENT MATERIALS HANDLING

on the iPad, iPhone and

ANDROID VERSIONS NOW AVAILABLE

alliances, plus new investments and plant openings.

17 Sustainability unites additives for polyolefins

27 Developing heat-conductive thermoplastics

33 What’s new in thermally-conductive compounds

41 Don’t labour over managing costs

47 EU moves to simplify patents

After three decades of discussion, the EU is to implement a unitary patent system

51 Materials handling: maintaining the flow

58 Compounder of the month: Epsan plastic

60 Dates for your diary

coming next issue

www.compoundingworld.com February 2013 | COMPOUNDING WORLD 3

Lehmann & Voss and SPI hits

Puma selects API bioplastic for

the soles of InCycle trainers terminology is now being

www.compoundingworld.com February 2013 | COMPOUNDING WORLD 5

Advanced Composites expands

PMC buys UK recycles one million PVC

6 compounding world | February 2013 www.compoundingworld.com

Clariant reveals its ColorForward

RTP signs Santoprene license agreement

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Peter Mapleston examines the latest developments in additives

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