SOMOS NEWS Efficient technologies in plastics processing 1/12 From the content Schoeller Plast Industries: Since 1 st of May ProTec Polymer Processing is a member of the Schoeller Plast Industries group of companies +++ Page 2 Focus on Technology: Expanded product range for the processing of PET post-condensation and decontamination +++ Page 6 Report: FWB is processing materials, manufactured into EPS components in a cleanroom, on a latest generation SOMOS D drying system +++ Page 4 Moisture content [ppm] Know-how: Bioplastics, which like PLA are regarded as distinctively susceptible to hydrolysis, must always be dried carefully +++ Page 7 ProTec Polymer Processing
EDITORIAL SCHOELLER PLAST INDUSTRIES Dear Customers and Business Partners, On May 1, 2012, ProTec Polymer Processing GmbH began business operations. In doing so, we implemented the previously announced fusion of MANN+HUMMEL ProTec GmbH and OHL Engineering GmbH. With ProTec Polymer Processing, we are combining the internationally renowned brands SOMOS, synonymous for efficient system solutions for the material handling of all plastic processing methods used today, and OHL, plants for the post-condensation of solid matter and for the drying of plastics as well as turnkey plants for the bottle-to-bottle recycling of PET. With this fusion, we are strengthening the previous activities of both companies as well as simultaneously creating the basis for an expansion of our ranges of services. In our network, we can now, for example, offer you significantly more know-how and equipment technology from a single source in order to optimize the material properties of PET. SOMOS systems and services in regard to drying, conveying and dosing of loose material in the plastics industry will of course remain main areas of focus of our business activities, as will the OHL complete systems for plastics handling and recycling. The previous ProTec location in Bensheim is the headquarters of our company. With the fusion, ProTec Polymer Processing is now a company within the Schoeller Plast Industries Group, however it operates as an independent business under this Group umbrella. The group of companies with manufacturing locations in Germany, Denmark and Brazil as well as sales offices and representatives in, among other locations, China, Russia and Spain is a worldwide recognized industry partner with reusable packaging systems, sealing caps for beverage bottles, the processing and recycling of plastics and now with equipment and systems for material handling in the plastics industry. This inclusion in the global Schoeller Group network offers us the best prerequisites for the intensification and expansion of customer service at an international level, especially in the Asian-Pacific economic region. Now more soundly positioned, ProTec Polymer Processing will continue to accompany you as a reliable partner in order to find and realize solutions for your processing jobs. Since May 1, 2012, the ProTec Polymer Processing GmbH is a member of the Schoeller Plast Industries (www.schoeller-plast.com) group of companies. This group bundles long-term experience in the field of plastics; from the development of efficient processes and systems for the treatment of plastics to the increasingly important recycling, in particular in the PET market. It also includes the development of series production of packaging and transport systems primarily for the food and beverage industries. Schoeller Plast Industries is made up of five companies: Schoeller Plast Enterprise in Regstrup/Denmark, Schoeller Cap Systems in Schwerin/Germany, Schoeller Plast do Brasil in Sao Paulo/Brazil, PET Kunststoff-Recycling in Beselich/Germany and up until now as an individual brand OHL Engineering in Limburg/Germany. Through the merger of OHL and MANN+HUMMEL ProTec, now ProTec Polymer Processing headquartered in Bensheim/Germany takes over this position. Development Recycling Production Schoeller Plast Industries an Overview Sincerely, Alfred Kimpel and Arnold Jahn Managing Directors Cover photo: A visit to FWB (Report on page 4) The headquarters of ProTec Polymer Prosessing in Bensheim. 2 SOMOS NEWS 1/2012
The Schoeller Plast Industries companies are internationally recognized partners of the most renowned corporations in the food, beverage, cosmetics, automobile and fiber industry. The scope of activities includes everything from the concept of tailor-made systems for plastics treatment to recycling (in particular PET) as well as the series production of packaging, means of transportation and screw caps for beverage containers. Development... The core competence of OHL Engineering now integrated in ProTec Polymer Processing is the planning, design and realization of systems for the drying and mixing of granulate and powdery bulk substances as well as the post-condensation of plastics, supplemented by complete systems for the recycling of PET bottle flakes. At the heart of the drying and mixing systems are vacuum rotary reactors, either as a tumble dryer or double cone dryer version (also see page 6 of this SOMOS NEWS). They are used as a dryer for chemical semifinished and finished goods, granulates and powder, as well as for highly sensitive materials. Beyond this, they serve in the manufacturing of antibiotics and pharmaceutical ingredients. Through batch operations, the entire content in the reactor has exactly the same retention time, which leads to reproducible, consistent product characteristics. Beyond this, the vacuum reactors are also suitable for post-condensation (increase in molecular weight) of synthetic granulates such as polyamides (PA6, PA66, among others) and polyesters (PET, PBT, PEN, among others). In accordance with the patented OHL process, this solid-phase post-condensation plays an important role in the recycling of PET bottle flakes. The result is an R-PET that is as good as a new product, approved for the direct contact with foodstuffs.... Recycling... Development Recycling Production those are the three pillars in the areas of activity of Schoeller Plast Industries companies. quality PET flakes from used PET bottles that either flow directly back into the PET processing or are treated to R-PET granulate in new-product quality through the OHL process.... Production Three other Schoeller Plast Industries companies located in Denmark, Brazil and Germany have, combined with efficient development and construction, enormous production capacities that meet the latest technological standards in the injection molding segment. Schoeller Plast Enterprise A/S, as one of the first companies, introduced plastic beverage containers for beer and soft drinks to the market and in Denmark the company is still one of the largest producers in this segment. Beyond this, the company now manufactures numerous further technical items from trays and transport containers for the food retail sector to stadium seats and much more. Schoeller Plast do Brasil is specialized in the development and production of plastics packaging and, in particular, in large plastics transport pallets for the food and beverage industry. Schwerin-based Schoeller Cap Systems GmbH is an expert for all types of screw caps for glass as well as PET bottles, including additional printing. Worldwide Network The Schoeller Plast Industries Group itself is integrated in Schoeller Industries (www.schoeller.org), Pullach, which also includes Schoeller Renewables and the globally operating packaging specialist Schoeller Arca Systems. Globally, the company has over 1,800 employees. ProTec Polymer Processing has access to a worldwide network and is therefore able to provide its customers with the latest technology and best possible local service. 1 2 3 4 5 PET Flakes Pre-drying Extrusion Melt Filtration Granulation With the OHL process, Beselicher PET Verwaltungs GmbH treats PET flakes to high-quality R-PET in large volumes. It is used for the renewed production of PET preforms (output stage for PET bottles), foodstuffs packaging, fibers and much more. PET Kunststoffrecycling GmbH, a sister company based at the same location, extracts high- 6 7 8 9 10 Crystallisation Weighing Silo Post-condensation Cooling Silo Big Bag Filling With OHL systems technology, used PET bottles are turned into high-quality PET granulate that is approved for contact with foodstuffs. Recycling saves large amounts of PET new products, protects resources, saves energy and carbon emissions and, by doing so, protects our environment. SOMOS NEWS 1/2012 3
REPORT As a company based in Pirmasens, having a history in the shoe industry belongs to the fabric of the region. Even if the glory days of shoe manufacturing faded in the early 1970s, the city situated on the western edge of the Palatinate Forest remains known as the city in which shoe expertise is at home (www.pirmasens.de). However, in Pirmasens, the current job market is no longer dominated by the shoe industry. From a shoe industry supplier to an automotive industry supplier FWB Kunststofftechnik GmbH (www.fwbgmbh.de), located in Pirmasens since 1980, has also undergone a change in its area of activity. Founded as a mould and tool construction company, FWB initially focused on the manufacturing of accessories such as heels, toe caps and counters for the shoe industry. By the end of the 1980s, however, a shift to the injection moulding of technical plastics for the household appliances industry had already taken place. From the mid- 1990s on, the first series production 2K parts for the automotive industry were added. Today, the name FWB stands for innovative development work and technical expertise in plastic injection moulding technology. Providing comprehensive service and consulting which includes everything from the idea, to the design, and to the manufacturing of precision injection moulding tools individual customer requests can be implemented in moulded parts that possess the highest manufacturing quality. The focus is on the multi-component injection moulding and moulded parts, which, in some cases, contain very complex insertion parts, all manufactured in fully automated manufacturing areas. The customer base includes, among others, well known, globally operating system suppliers to both domestic and international automotive manufacturers. The technical equipment includes over 30 highly modern injection moulding machines with clamping forces ranging from 300 to 4,200 kn, as well as individual components and 2K machines powered hydraulically, as a hybrid, and even fully electric. The machines are all fitted with linear robots for all tasks related to loading and unloading. Complex assembly processes in the manufacturing areas are adopted by bending robots. The spectrum of the realized weights for moulded parts ranges from 2 grams to about 650 grams. All standard engineering plastics, often reinforced with glass fibers and FWB uses SOMOS dryer technology Flexible, reliable & efficient FWB is now processing materials, which are manufactured into electric power steering components in a cleanroom, on a module drying hopper system and a latest generation SOMOS D dry air generator. One of the many advantages: Upon an expansion of the drying system, only one new drying hopper is connected via standard interfaces the dryer control unit automatically recognizes the new hopper and the system is operational. partially equipped with long glass fibers, are processed. Newly designed cleanroom with its own material treatment area In the finishing, a new cleanroom in accordance with VDA 19, part 2 is currently located in Pirmasens. Here FWB is planning on manufacturing components for electric power steering (EPS) on up to seven injection moulding machines. For this cleanroom, we require our own material processing with a centralized drying system outside of the manufacturing area. To work with auxiliary dryers at the injection moulding machines would principally not work because of the particle emissions, reports Anton Paternoster, who is responsible for the entire material processing and therefore is a decision maker in system procurement. Both parties are apparently very satisfied with the solution: Anton Paternoster, FWB (at left) and Manfred Horsch, Sales Manager at ProTec Polymer Processing, who is always available to assist and provide FWB with input and who, from the onset, also cooperatively contributed to the system design. 4 SOMOS NEWS 1/2012
In the end, the SOMOS technology by ProTec Polymer Processing was selected. There were several reasons that persuaded us. In particular, it is the advantage of being able to flexibly operate the new D dryer in a large throughput area. For any future expansion, this is clearly an advantage, Anton Paternoster mentions and adds: The possibility of changing a desiccant pot during ongoing operations if necessary must also be emphasized. Since we manufacture 24-hours a day, this saves us from having to interrupt our manufacturing operations as opposed to shutting down our manufacturing operations for several hours. And with the rotary principle, the created dry air has a constant dew point temperature at all times, which is very important for the verification of the process consistency. The drying system is constructed on a pedestal in front of the cleanroom. It consists of a dry air generator of the SOMOS D500 frame size five connected drying hoppers, three with a volume of 200 liters each and two with 300 liters each as well as a blower station with central filter for dust removal. The materials to be dried are prepared in octabins located underneath the pedestal; the transportation of the dried material to the injection moulding machine is performed using dry air. Each conveying process concludes with a complete emptying of the conveyor line. This is also performed using dry air. Even the suction process just as the entire drying and conveying line works trouble free, reflects Anton Paternoster contently. Two examples from the wide range of FWB products: a light-controlled LED with lens for the illustration of complex images for a bicycle light, StVZO (road traffic licensing authority) approval since 2010, and an accelerator with overmoulded electronics board (at right). SOMOS D Series modularly structured, flexibly expandable SOMOS D, the new generation of material drying systems is modularly structured and consists of the dry air generator and the so-called modular hoppers, which can be attached to it. All hoppers have their own control unit, which, aside from the regulation of the temperature and the required dry air volume dependant on the throughput, also controls the respective hopper of the allocated conveyor. Among other things, this independent method of operation simplifies the expansion of the module system through the addition of one or more drying hoppers. In combination, the new constructive, process and technical control features lead to a significantly expanded area of application. In this fashion, the technical control of the dry air throughput in the D500 frame size employed by FWB can be expanded from 200 m³/h up to 500 m³/h. With this flexibility, the reliable dry material throughput can be increased variably without the need to make any constructional alterations to the dry air generator. A high level of energy efficiency is ensured through the tried-and-tested control mechanisms used in the SOMOS dryers: ALAV for the automatic adjustment of the dry air volume on the material flow rate and Super-SOMOS for adjusting the desiccant regeneration to the adsorbent s actual moisture content in each case. At the same time, the new process control of the dryer s rotary desiccant container means that a much shorter time is needed to regenerate the drying agent, so that the energy required for this can be used more effectively With the new D Series, on average about 30% of the energy required for the previous generation of dryers can be saved. The SOMOS drying system at FWB (left) contains five drying hoppers; the company plans to expand it up to seven hoppers. The dried materials are conveyed through the machine supply line in a dust-free manner to the injection moulding machines in the cleanroom (pictured at right). Since abrasive granulates are also processed, the redirection of the lines transporting the materials until the connection with the injection moulding machine (section of image) are made of hardened glass. Photo: GerhardGiebener@pixelio SOMOS NEWS 1/2012 5
FOCUS ON TECHNOLOGY SOMOS crystallizers are available in different frame sizes (pictured at left is the frame size K200 for throughputs of up to 300 kg/h in the operation mode out of thermal equilibrium). The crystallizers are operated with warm air and have a tilt mixer (pictured at right) that prohibits the particles from sticking together while passing through the transition temperature. A crystallizer type, which can exclusively be filled with amorphous material, is the compact, batch-wise operating SOMOS eddy current crystallizer. By supplying air, heated up to 140 C, the material is warmed up in a crystallization hopper and simultaneously intensively swirled so that the granulates do not stick together when the glass transition temperature is reached. The eddy current crystallizer is dimensioned for a usable volume of around 5 kg per batch. Since PET crystallization occurs within only a few minutes, throughputs of up to 50 kg/h can be realized. This design has, in particular, proven its worth in the manufacturing of PET master batches when a dissimilar polyolefin does not serve as a substrate, but as the directly processed PET base material itself. Even batch doses, which often occur in the manufacturing of master batches, can often be quickly and easily realized. Crystallizing and post-condensation of PET Crystallizers for various tasks PET in an amorphous state, whether as virgin granulate, regranulate or mill base must always be crystallized before it is dried. This transition from the amorphous into the partly crystalline state occurs in a crystallizer at temperatures starting at about 120 C. Here, SOMOS crystallizers work according to two processes: in the thermal equilibrium operation mode (TG) or out of the thermal equilibrium operation mode (ATG). In the thermal equilibrium operation mode, the material is crystallized by batch (discontinuously). The TG process is used for PET granulate and mill base with a bulk density of 0.65 to 0.9 g/cm 3. On the other hand, out of the thermal equilibrium operation mode is only useful for a continuous mode of operation a controllable cell wheel lock ensures the continuous removal. The ATG process is primarily employed for the crystallization of free flowing mill base from films with a bulk density of 0.2 g/cm 3. The common denominator of both processes is that they require a partial filling with crystalline material in order to start up. Otherwise, through the sticking together of the material during the pass through into the glass transitional phase (at approx. 80 C for PET), the crystallizer s tilt mixer would be subject to too much force. With an expanded product range, ProTec Polymer Processing now offers expanded, new solutions for the processing of PET. In this fashion, the OHL tumble reactors have joined the SOMOS crystallizers as part of a product range with which PET, among other products, can be very efficiently post-condensated and decontaminated. Tumble reactors for PET treatment and finishing The OHL tumble reactor is a solid-state (SSP) batch reactor. It consists of a double shell and is heated to the required reaction temperature of the product (< 230 C) using heat transfer oil, or it is cooled in accordance with the process requirements; in addition, steam plates can be installed inside the reactor. The reactor is set in an inclined position to the horizontal rotational axis. The result- OHL tumble reactor employed in a recycling plant for decontamination and post-condensation (increase of the IV value) of R-PET granulate. Frame sizes are available with a volume of up to 44 m³. 6 SOMOS NEWS 1/2012
KNOW-HOW: BIOPLASTICS PLA...... hygroscopic & susceptible to hydrolysis Hygroscopic plastics must always be dried carefully in order to, among other things, prohibit the material degeneration in the processing machine through hydrolysis. Special focus must be placed on bioplastics, which like PLA are regarded as distinctively susceptible to hydrolysis. The batch-wise operating SOMOS eddy current crystallizer can exclusively be loaded with amorphous material. Moisture content [ppm] Time [h] ing tumbling rotation leads to a permanent, gentle and homogenous mixing of the granulate-shaped, free flowing packaged goods. The steam plates promote the circulation and consistency of the product s temperature distribution. The inner, product-contacting reactor shell is made of highly corrosionresistant stainless steel and can be evacuated to <1 mbar (absolute). With the precision control of the temperature, vacuum and time parameters, granulates new materials or recyclates can be individually brought to meet the required quality, depending on the technical prerequisites and customer demands, with or without the selected addition of additives. At the same time, the desired IV value (IV: intrinsic viscosity) is calibrated. Through the regulated batch process one always receives reproducible, consistent product characteristics (material viscosity, cleanness). Decontamination and post-condensation are significant process steps necessary in order to attain R-PET from the used PET bottles. The R-PET is approved for the direct contact with foodstuffs. An IV value of 0.78 to 0.82 dl/g is required for the production of, for example, preforms as a pre-product for the manufacturing of PET bottles. The treatment in the OHL tumble reactor leads to an R-PET with material properties like virgin PET and an acetaldehyde content of 1 ppm. For special applications, the reactor can be used to even attain IV values 1.20 dl/g for polyesters (for example, required for technical applications). Pictured at left: Moisture absorption of PLA (type Ingeo 3251D): at 20.5 C, 34 % relative humidity (r. h.) and 37 ppm initial material moisture (A) as well as 21.5 C, 37 % r. h. and 18 ppm initial moisture (B). Pictured at right: Step threads, injection molded from PLA with varying granulate moisture: Residual moisture 20 ppm (1), 2300 ppm (2) and 4400 ppm (3). Optically, no difference can be determined between the steps the MVR values, however, vary significantly from one another. Regarding the PLA water absorption process, systematic examinations of a dried injection mold (type Ingeo 3251D) under controlled environment conditions is carried out[1]. The results show the correlation between humidity and water absorption of the granulate (see illustration): In the consistently higher water absorption of the test series B, the absolute humidity and therefore the driving concentration difference for the humidity exchange between air and granulate was about 15 % higher than for the test series A. In the process, the 37 % relative humidity of the air was not even that high. 50 % relative humidity is considered comfortable interior climate and is easily attained in the production environment, often times even significantly exceeded. 50 % instead of 37 % relative humidity (as with test series B) signifies a further plus of about 35 % of absolute moisture content in the air that the granulate is subjected to at the same temperature. On the other hand, the significant increase in the moisture absorption at the outset shows that PLA is very hygroscopic in a dry condition: Under the test conditions, the re-humidification rate initially was up to about 500 ppm/h. This also means that the threshold value of the maximum of 100 ppm required for injection molding processing had, after approximately 10 minutes, already been exceeded (at higher humidity levels in an even shorter period of time). The influence of the material moisture was tested during the processing of injection-molded step threads. In doing so, the process parameters of the injection-molding machine were in accordance with the material manufacturers recommendations for especially gentle material stressing. From the injection molded step threads, the final stage with a strength of 1 mm was sheared, dried and the MVR (melt volume-flow rate) was determined. The MVR values of the dried granulate and the resulting injection-molded step threads (test sample 1) were almost identical. The significantly higher volume flow rates of the test samples 2 and 3 and indeed all the more higher the greater the material moisture unequivocally show the hydrolytic breakdown of the material occurring in the injection molding machine. [1] All results of this test in: P. Heidemeyer, C. Helm et al.: Home and dry? Kunststoffe International 4/2012, p. 48 SOMOS NEWS 1/2012 7
NEWS CALENDAR We look forward to welcoming you at the following trade fairs / events... We are presenting... Oct 16 20, 2012 Fakuma Friedrichshafen/Germany Hall B3 Stand 3119 Jan 07 10, 2013 Arabplast Dubai/UAE Our Management Systems Team: Hermann Müller (left) and Andreas Seul. Jan 29 Feb 01, 2013 Interplastica Moscow/Russia Forum Welcome to the Management Systems Team Complex, Comprehensive, Proactive The new system should be ramped up on time; upon start-up no defects or even functional errors should occur; on-site service and support should be in case this becomes necessary during ongoing operations quickly available. From a customer perspective, these are all legitimate requests. From a manufacturer s perspective, this wish list must still be added so that the project cycle through to the final commissioning at the customer s facility is realized within the planned timeframe and at costs that enable a competitive price. Now we have reached the area of activity with which our Management Systems Team deals with on a day-today basis. Within the complexity of the processes, links and dependencies in the origination process of products and services, the use of systematic and validated structures and processes are indispensable. For that reason, a quality management system that has been certified in accordance with ISO 9001:2008 and customized to our area of activity has been a cornerstone of our corporate policy for many years. The Management Systems Your contacts The employees in the Management Systems Team can be reached at: +49 6251 77061-EXT and by e-mail at: firstname.surname@sp-protec.com Andreas Seul (Manager) EXT: -270 Hermann Müller EXT: -271 FAX (both) +49 6251 77061-510 Team plays the role of pilot and mentor in the continuous improvement process. In their individual area of responsibility, each employee is integrated into the implementation process; and, of course, our suppliers are as well. That this structured approach is bearing fruit is documented by the evaluation of our customers, who regularly classify us as A suppliers. However, our Management Systems Team doesn t see its cross-sectional job in the company as limited to the QM system. Measures for occupational health and safety as well as active environmental management are integrated on a daily basis. Continuous improvement is targeted at reducing or replacing hazardous chemicals, avoiding waste, protecting natural resources and much more. These actions also have direct repercussions on our products. As a consequence of being aware of our energy consumption, today we only employ the most energy efficient motors and blowers for our conveyor and drying systems. Despite all diligence, mistakes are not always avoidable, especially if complex systems are newly developed. In these types of cases, the so-called 8D method helps us determine the cause of the problem and develop troubleshooting measures. The 8D method is a systematic approach with gapless documentation procedures of the individual solution steps. The fact-based approach ensures that product errors are traced to their roots. This way we can eliminate these errors in the long-term, instead of just covering up the symptoms. Our representations are presenting... Sep 10 14, 2012 MSV Brno/Czech Republik Sep 26 27, 2012 Kunststoffen Veldhoven/Netherlands Diezehal, Stand 88 Representation: Plastima Breda, NL Nov 29 Dec 02, 2012 Plast Eurasia Istanbul/Turkey Representation: Plastteknik, TR Feb 26 Mar 01, 2013 Z 2013 Die Zuliefermesse Leipzig/Germany Representations: Comp. D. Uhlig Comp. IN-KU SOMOS NEWS Publisher: ProTec Polymer Processing GmbH, Stubenwald-Allee 9, 64625 Bensheim/Germany www.sp-protec.com Editors: Grit Feistkorn (responsible), grit.feistkorn@sp-protec.com, Tel.: +49 6251 77061-150, Dr. Georg Krassowski (Konsens) Layout: Konsens PR GmbH & Co. KG, 64823 Groß-Umstadt/Germany www.konsens.de SOMOS NEWS are the customer magazine from ProTec Polymer Processing published regelarly as german and english issue. Reprinting of articles after agreement with the editors and with indication of source permitted. Printed edition on paper produced using environmentally safe process. 8 SOMOS NEWS 1/2012