Digitization with a human touch: Eschbach strengthens Shiftconnector processing plant support in Europe

Demand for the interactive management platform has increased significantly since experience from handling the COVID-19 pandemic highlighted the advantages of digital communication among manufacturing teams. In line with this, Eschbach is strengthening its regional application and technical teams to step up its local presence and software customization capabilities.

“24/7 plant operations rely on people, and digital support for teams has helped them to sustain manufacturing processes, manage issues and maintain quality in abnormal situations during the crisis. And it continues to provide valuable support as they move forward with in-person, remote, and hybrid working,” comments Andreas Eschbach, CEO.

Alongside the existing trend to increase digitization and automation in process manufacturing, the Plant Process Management software encourages human-centric, transparent communication involving everyone from the shop floor up. It is unique in capturing and sharing compliance and asset performance data between all levels of personnel, from equipment operators to shift managers and corporate functions. Reporting can be tailored to the needs of each plant and its work centers, giving a comprehensive, easy-to-review picture of routine actions, flagged events, and status.

Andreas Eschbach continues: “We’re very proud to hear from customers that our solution is engaging the essential, frontline plant workers in easily sharing their knowledge, as this is vital for ensuring a safer, more productive environment. No one wants information to be missed that could cause otherwise avoidable issues at a later stage. Our Shiftconnector connects every person of the shift crew and we’re very excited to be extending its availability and support with further implementation partners in Europe.”

Plants operated by major process manufacturers in 21 countries are already using Shiftconnector as a means of improving inter-team communication, creating a seamless handover process. Key clients report greater information transparency, insightful asset performance reports, and smoother handovers, all of which can contribute ultimately towards managing workplace safety and optimizing quality and performance.

The Plant Process Management platform can also be used in conjunction with Eschbach’s io. Performance solution which offers effective and transparent real-time Overall Equipment Effectiveness (OEE) analysis, supporting continuous improvement in production processes.

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Joint venture between ALPLA and Coca-Cola FEMSA to boost the circular economy

With the aim of boosting the circular economy in the states of southeast Mexico, a cornerstone ceremony was held to mark the start of construction of the new PLANETA recycling plant in the municipality of Cunduacán in the State of Tabasco. 

The project is the result of a joint venture between ALPLA, a global leader in the development and production of sustainable plastic packaging solutions and bottle-to-bottle recycling, and Coca-Cola FEMSA, the largest bottler of Coca-Cola products in the world.

With an investment of more than 60 million dollars, the recycling plant Planta Nueva Ecología de Tabasco – better known as PLANETA – will be equipped with the most modern technology available worldwide. It will have the capacity to process 50,000 tonnes of post-consumer PET bottles per year, which will result in 35,000 tonnes of recycled PET material ready for reuse.

The cornerstone ceremony was led by Guillermo Arturo del Rivero León, secretary of the government of Tabasco, and was attended by renowned figures such as Carlos Torres Ballesteros, ALPLA managing director for Mexico, Central America, and the Caribbean; John Santa Maria, chief executive officer of Coca-Cola FEMSA; Abraham Cano, mayor of Cunduacán; and José Friedrich García Mallitz, secretary for the economic development and competitiveness of Tabasco.

Development node for south-east Mexico
The construction and operation of the PLANETA recycling plant are expected to generate more than 20,000 direct and indirect jobs and will thus make a key contribution to the objectives of the Mexican government headed by President Andrés Manuel López Obrador to promote development and employment in south-east Mexico.

Its strategic location in the region with the greatest potential for solid waste recycling will also make it an important development node that will integrate 18 collection centers throughout south and southeast Mexico. In addition to offering an environmental service, it will boost the region’s economy.

Reduce, reuse, recycle
ALPLA and Coca-Cola FEMSA are embracing their position as leading companies to promote and implement effective measures to reduce pollution, reuse plastic waste and reinforce the collection and recycling chain.

ALPLA CEO Philipp Lehner says, ‘The big challenge today is the handling of the materials after the consumption phase. We are currently investing worldwide in systems to give plastic packaging a value – because then it is collected and recycled. With strong partners like Coca-Cola FEMSA at our side, we will be able to set up the necessary infrastructure and close the bottle cycle in as many regions as possible.’

John Santa Maria, CEO of Coca-Cola FEMSA, explains, ‘As an environmentally responsible Mexican company dedicated to creating economic, social and environmental value in the communities in which it operates, Coca-Cola FEMSA is permanently committed to caring for the planet. This is why we are implementing a series of measures to promote recycling with the goal of recovering 100% of post-consumer packaging.’

Global recycling initiatives
In collaboration with all of the companies that make up the Coca-Cola Mexican Industry (IMCC), Coca-Cola FEMSA is part of the global World Without Waste initiative launched by the Coca-Cola Company, which aims to make all packaging 100% recyclable by 2025, integrate 50% recycled PET resin into bottles and collect 100% of the packaging by 2030.

ALPLA managing director for Mexico, Central America and the Caribbean, Carlos Torres Ballesteros, stated, ‘This new recycling plant for food-grade PET will be ALPLA’s third recycling plant in Mexico, which makes us a spearhead at a national level and a recycling benchmark for the rest of the world. As part of our commitment to sustainability, ALPLA will invest more than 50 million euros every year between 2021 and 2025 to expand its global recycling capacity.’

In 2018, ALPLA and Coca-Cola FEMSA joined the New Plastics Economy Global Commitment launched by the Ellen MacArthur Foundation in collaboration with the United National Environment Programme. Its goals are to make 100% of its products reusable, recyclable, or compostable by 2025 and to have 25% post-consumer recycled material in total material consumption by that year.

On this occasion, Guillermo Arturo del Rivero León, secretary of the government of Tabasco, highlighted that ‘PLANETA represents Coca-Cola FEMSA and ALPLA’s commitment to sustainability but, at the same time, it is one more step towards a circular economy, which is essential for achieving the Government of Tabasco’s international commitment in the 2030 Agenda under Carlos Merino’s leadership to build stronger and greener economies.’

Post-consumer PET pioneers
Since 2005, ALPLA Mexico, Coca-Cola Mexico, and Coca-Cola FEMSA have united forces to run Industria Mexicana de Reciclaje (IMER), the first food-grade PET recycling plant in Latin America.

Located in the State of Mexico, this facility has a production capacity of 15,000 tonnes of flakes from post-consumer PET per year. Since its foundation, it has processed more than 140,000 tonnes of this material, which has been returned to the production cycle of new bottles. This has saved the same volume of virgin resin, which in turn has reduced the carbon footprint.

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EPBP and RecyClass sign off strategic collaboration

Following the numerous commitments of the industry players to increase uptake of recycled plastics, including the new mandatory target of 25% in PET bottles by 2025, the European PET Bottle Platform (EPBP) and RecyClass decided to join efforts to further support the value chain actors in making the right design decisions in PET bottle production so that its recyclability, and therefore, circularity is guaranteed.

“If we are to make plastics circular the industry players need to speak with one voice”, said Paolo Glerean, RecyClass chairman, “we need also a clear and long-term objective which requires the collaboration, know-how, and endorsement of all the partners”, he added.

“Working together to safeguard food contact rPET with the highest quality in a bottle-to-bottle closed loop will be a key enabler for the industry towards its commitments”, says Philippe Diercxsens, EPBP Board Member representing Natural Mineral Waters Europe (NMWE).

“We believe that this partnership will be very beneficial to support a sustainable PET business and to foster solutions that help create a truly circular economy,” says Antoon Spiessens, EPBP Board Member representing UNESDA Soft Drinks Europe.

Within this partnership, EPBP will be responsible for the governance development and update of the testing protocols while RecyClass will be responsible for the execution and validation of the analysis of the standard package based on EPBP guidelines and protocols. This will include among others, running standard testing, ensuring impartiality, and the highest quality of tests.

Both bodies have expertise in plastic recyclability-related topics.

EPBP has built a strong legacy supporting the industry by developing PET bottle design guidelines for recycling, evaluating beverage PET bottle packaging solutions and technologies, and facilitating the understanding of the effects of new PET bottle innovations on recycling processes and circular economy. The ultimate objective of this initiative is food safety and consumers’ related protection, while EPBP fully supports and is an ambassador towards circular economy working with all stakeholders across Europe.

RecyClass, on the other hand, works with all the actors from the value chain on the development of standard Recyclability Evaluation Protocols and other scientific testing methods for innovative polymer materials for a variety of applications. The test results are incorporated into the Design for Recycling Guidelines and the free RecyClass Online Tool, including the plastic packaging certification delivered by third-party auditors. It supports the industry in redesigning plastic packaging to improve recycled plastic quality, aiming to harmonize the existing methodologies.

EPBP and RecyClass are looking forward to giving a clear direction and one voice to the industry on topics surrounding the recyclability of PET with an overall goal of sustainably improving its production, collection and recycling in Europe.

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INEOS STYROLUTION RECEIVES ISCC PLUS CERTIFICATION IN EUROPE

The certification announced today paves the way for the audited production of recycling- and bio-attributed styrenics materials using a mass balance approach. The ISCC PLUS certificate for Antwerp addresses bio attributed and recycled-attributed ABS1, SBC2, and polystyrene.

The respective certificate for Ludwigshafen addresses bio-attributed and recycled-attributed SMMA3, SAN4, and ABS. This announcement follows a recent announcement for ISCC PLUS certification of several INEOS Styrolution sites in the Americas5. Further certifications for other European INEOS Styrolution production sites are expected soon.

Dr. Eike Jahnke, Vice President Specialties EMEA comments: “We are excited to receive the ISCC PLUS certifications since we will now be able to offer our customers sustainable styrenics solutions that meet all the stringent ISCC requirements. I am looking forward to having sustainable ECO solutions for our broad range of styrenics Specialty products.”

Sven Riechers, Vice President of Standard Products EMEA adds: “Complementing our existing sustainable solutions, I expect INEOS Styrolution’s family of sustainable ECO products to grow rapidly as a result of today’s announcement.”

ISCC is an independent multi-stakeholder organization providing a globally applicable certification system for the sustainability of raw materials and products. It has been developed to meet the high demands regarding the implementation of environmentally, socially, and economically sustainable production.

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PLASTICS Promotes Patrick Krieger to Vice President for Sustainability

WASHINGTON, D.C.—The Plastics Industry Association (PLASTICS) has promoted Patrick Krieger, Senior Director for Materials & Sustainability, to the newly created role of Vice President for Sustainability. 

“As an industry, we intend to be all-in on sustainability, helping to lead the way toward a truly circular economy. Patrick will play an essential role on that journey,” said Tony Radoszewski, President and CEO of PLASTICS. “Patrick’s stellar performance as Senior Director for Materials and Sustainability, which included important work with our Recycling and other Material Supplier committees, made him the obvious choice to lead our sustainability efforts.”  

Krieger’s accomplishments to date include significant roles in guiding New End Market Opportunities (NEMO) projects for PLASTICS, as well as contributing to the growth of Operation Clean Sweep, a program in which companies dedicate themselves to measures aimed at preventing the release of resin into the marine environment. He is also responsible for the creation of Bioplastics Week, a successful online event geared toward educating both industry and consumer audiences about biobased plastic materials. Bioplastics Week gave rise to Plastics Recycling Week in 2021, another popular event that PLASTICS intends to grow this year. 

“I’m looking forward to the opportunity of working with our members to promote and improve the sustainability of the plastics industry,” said Krieger.“Improving recycling and recycling infrastructure, renewable feedstocks, or addressing the problem of marine debris – we are just getting started.” 

Krieger also organizes PLASTICS’ Re|Focus Recycling and Sustainability Summit, a multi-day conference during which industry professionals hear from expert speakers and their peers on solutions that will improve their sustainability efforts. A key feature of the Summit is the annual Sustainability Innovation Award competition, in which companies from both inside and outside the organization can showcase their efforts to contribute in the areas of recycling and sustainability. 

Beginning his career at PLASTICS in 2015 as Assistant Director of Regulatory and Technical Affairs, Krieger became Director of Regulatory and Technical Affairs in 2018, and then Senior Director for Materials and Sustainability in 2020. Before joining PLASTICS, Krieger served as Regulatory Affairs Manager for the Animal Health Institute. He is a 2007 graduate of Texas A&M University with a Bachelor of Science degree in Agricultural Leadership and Development.

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Absolutely clean 3D printed components for recreational vehicles with a fully automatic operation

significant quality improvement of the de-powdering and cleaning operation for 3D printed components at lower costs and shorter cycle times! A leading manufacturer of recreational vehicles is fulfilling this goal with the purchase of the automated post-processing system S1 from AM Solutions – 3D post-processing technology.

With their innovative designs and powerful drive systems the motor homes, caravans and panel trucks of the Knaus Tabbert AG allow safe, comfortable, and sustainable traveling. At its German headquarters in Jandelsbrunn, Bavaria, the company is utilizing its comprehensive experience and know-how to continuously improve the materials and designs of its vehicles.

Naturally, this also includes the employment of new manufacturing technologies such as additive manufacturing (AM). Mario Meszaros, development engineer at Knaus Tabbert explains: „On the one hand we are using the 3D printing technology for creating prototypes. On the other hand, we are also utilizing additive manufacturing for
producing standard components in volume such as the bracket for an alarm system or the hinge mechanism for the swing-out shower stall”.

A challenging post-processing task

To date, the de-powdering and cleaning of PA 12 components, produced by a powder-bed printing system, was done manually in a blast cabinet. Since this post-processing operation required not only a lot of labor and time but also produced highly erratic and inconsistent results, the company was looking for an automated alternative.

Therefore, comprehensive processing trials were run with different components in the Customer Experience Center of AM Solutions – 3D post-processing technology. This division of the Rösler group specializes in post-processing solutions for 3D printed components. After the conclusion of the highly successful processing trials, the customer chose the S1 shot blasting system.

This shot blast machine was specifically developed for the post-processing of plastic components produced with the powder bed printing method. The plug-and-play S1 is the only machine on the market that allows the time-saving and cost-efficient de-powdering as well as surface smoothing and homogenization of 3D printed components in one single machine. All that is required, is a simple change of the blast media, for example, from glass beads to plastic spheres.

The S1, equipped with a basket that rotates during the finishing operation and allows easy, ergonomic loading and unloading of the workpieces, allows fully automatic batch processing. Throughout the entire process, the basket remains in the machine housing. This, combined with a special door sealing system, prevents any powder spillage into the immediate surroundings.

The control panel allows an easy and quick switch to manual operation without any retooling. „More and more companies from different industries are choosing the S1 for post-processing of their 3D printed components. This is a confirmation of our product strategy. It shows that our 3D post-processing products are in full compliance
with the requirements of the market”, adds Manuel Laux, Head of AM Solutions – 3D post-processing technology.

Perfect cleaning results and quick amortization

Mario Meszaros comments: „The fact that after surprisingly short cycle times the components came out of the machine perfectly clean and without any powder residues was very impressive”. He continues: „With the underlying operating data I prepared an ROI calculation. The results quickly convinced our management: Even with only three print jobs per week in the S1, we already achieve a return on investment after roughly two years.
However, it is safe to assume that the quantity of 3D-printed components will increase significantly. This will drastically reduce the amortization period.”

High process stability and operational safety

The benefits of the S1 are not only limited to the excellent processing results and the quick amortization. In its standard version, it also features a system that automatically monitors and records all relevant process parameters. The integrated blast media cleaning and recycling system represent another reason for the high process stability. It ensures that irrespective of the media type the media is always available in perfect condition.

Another plus is the explosion-protected design of the shot blast machine with ATEX compliant motors and valves. Mario Meszaros concludes: „I am absolutely convinced that the simple, effective and efficient post-processing possibilities of the S1 will further promote the use of additive manufacturing in our company”.

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SABIC’s new ISCC+ certified bio-based LNP ELCRIN  copolymer resin helps the consumer electronics industry achieve net-zero carbon emission goals

The prestigious Chinese brand realme chose LNP ELCRIN EXL7414B copolymer resin for the battery cover of its brand-new GT 2 Pro smartphone that launched on Jan. 4, 2022, in China. “Our collaboration with SABIC to successfully incorporate this new bio-based copolymer in our GT 2 series smartphone has helped us achieve competitive differentiation and a stronger sustainability posture,” said Chase Xu, Global Vice President, and Chief Marketing Officer, realme.

“The use of bio-based materials is an important selling point for consumers, who increasingly seek out sustainable products. Further, the adoption of LNP ELCRIN EXL copolymer resin has enabled our company to advance its environmental goals without any compromise in product performance. This application is the latest result of our productive, ongoing relationship with SABIC.”

Realme was the first consumer electronics brand to adopt the incumbent version of this material, LNP ELCRIN EXL7414 resin, which was used to mold the battery cover of its C25 smartphone. Demonstrating its continuing innovation, realme is now one of the first electronics companies to use a bio-based copolymer. The new SABIC copolymer provides the same outstanding properties and processing as its predecessor, enabling a seamless transition for realme.

“The development of bio-based thermoplastics is an important part of SABIC’s overall sustainability strategy, which also encompasses chemical upcycling and mechanical recycling,” said Maureen MacDonald-Stein, Director, Growth OEM, Specialties, SABIC. “We are applying the full scientific and technical resources of the company to create and deliver new materials that can help customers like realme achieve goals such as emissions and energy reductions, plastic waste avoidance, and regulatory compliance.”

Sustainability + High Performance

In addition to lowering carbon footprint by reducing the use of fossil-based feedstocks, SABIC’s LNP ELCRIN EXL7414B copolymer resin delivers exceptional performance for demanding electronics applications. It uses a non-brominated, non-chlorinated flame retardant formulation that meets the UL 94 V0 standard at 0.6 mm.

Both LNP ELCRIN EXL7414 and new LNP ELCRIN EXL7414B copolymer resins help address the harmonized International Electrotechnical Commission’s new IEC 62368-1 standard, which replaced the previous IEC 60065 Audio Video and IEC 60950 IT Equipment standards with stronger safety requirements. For example, this new standard, which took effect in December 2020, requires hazardous energy sources such as lithium-ion batteries to be contained via built-in safeguards to help prevent the energy from transferring to device users.

The excellent processability of the bio-based LNP ELCRIN EXL7414B copolymer resin enables ultra-thin part designs that save weight and space and offers opportunities for shorter cycle times and higher throughput vs. standard PC. The new material also provides excellent low-temperature ductility (-40℃) for impact strength when a device is dropped, and good chemical resistance to withstand ultraviolet (UV)-cured paint.

“Our new bio-based copolymers can be particularly beneficial to the consumer electronics market,” said Joshua Chiaw, Director, Business Management, LNP & NORYL, SABIC. “They combine sustainability with exceptional performance to address key trends for electronic devices, including smaller, thinner designs, increasingly stringent safety regulations, and strong consumer preferences for environmentally responsible products. To further support this important sector and the electrical/electronics industry as a whole, SABIC plans to add new grades to our bio-based LNP ELCRIN EXL family.”

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JURGEN ARTNER APPOINTED AS BOREALIS OPERATIONS MANAGER POLYOLEFINS & LOCATION LEADER SCHWECHAT, MONZA, AND WILDON

Borealis announces the appointment of Jürgen Artner (51) as Operations Manager Polyolefins and Location Leader for Borealis in Schwechat (Austria), Monza (Italy), and Wildon (Austria), effective 1 February 2022. He succeeds Rudolf Sukal, who will retire mid-year.

Jurgen Artner joined Borealis in 2000 and has held various positions since then, including Maintenance Engineer, Head of the Engineering Department, and Production Manager of the Borstar plant in Schwechat. Most recently, he has held the position of Performance Manager responsible for Borealis’ polyethylene plants across Europe.

Jurgen Artner holds a Master’s degree in Mechanical/Process Engineering from the Technical University in Vienna. He is an Austrian citizen, married, and the father of two children.

“I am delighted that Jürgen Artner, who is engaged and experienced in the areas of production, maintenance, and technology, will take responsibility for our Polyolefin Operations in these three locations, as well as the Location Leader’s role,” comments Borealis Vice President Operations Polyolefins, Bob Wullaert.

“At the same time, I would like to thank Rudolf Sukal for his outstanding contribution and commitment to Borealis. He has brought our production facilities to a high level of performance and, more importantly, achieved excellence in safety over the years in Schwechat, Monza, and Wildon.”

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Polymers colour laboratory receives certification from Renault design department

Pre-coloured materials have many advantages in contrast to masterbatch solutions for self-coloring, such as colour stability, colour differences between batches, and risk reduction. ELIX has extensive expertise in developing colours based on OEM requirements, including colours and gloss targets using different surface textures. The ELIX laboratory has several tools, for instance, twin-screw extruders, molds with automotive OEM textures, colorimeters, light cabins, and a Xenotest weathering chamber.

Recently, the ELIX colour laboratory in Tarragona was certified by the Renault design department, which means that ELIX can self-validate new or existing colours with new materials according to Renault specifications and colour approval procedures, instead of requiring an accredited third-party laboratory.

Renault and ELIX have been working together for many years and several products from ELIX were approved in the latest Thermoplastics Renault Materials Panel (PMR). ELIX Polymers also offers Renault technical support at their Tiers where ABS is used for different applications, such as interior trim parts or chrome-plated exterior front grills.

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Omnix ReCycle HPPA demonstrates lower water absorption, improved flowability, and best-in-class surface aspect vs. virgin high-performance polyamides

“As Solvay’s first-ever recycled-based HPPA with 50% glass fiber reinforcement, Omnix  ReCycle is a real
breakthrough in the market of polyamides for household appliances,” says Claire Guerrero, Global Marketing
Manager for Packaging Segment and Sustainability at Solvay. “It combines the outstanding mechanical
properties of virgin semi-aromatic HPPA with better flow, lower water pickup, and best-in-class surface aspect.

In addition, its unique performance and sustainability profile offers an attractive material solution for brand
owners and manufacturers who seek to increase the recycled content in their products without compromising
dimensional stability, high stiffness, impact resistance, and processability.”

The recycled content of Omnix  ReCycle saves resources and results in a significantly lower carbon footprint
compared to virgin HPPA, thus showing a 30% lower global warming potential (GWP). At the same time, it has
an ideal fit for replacing lower-performing polyamides (PA) as well as metals.

In household appliances, for instance, it delivers higher durability than provided by standard PA6 or PA66
polymers. This helps OEMs reduce breakage and damage returns while meeting the growing awareness of
consumers for longevity and lower environmental impact in their product choices.

With its excellent surface appearance, the new recycled-based HPPA can also eliminate the need for painting, which adds to its overall sustainable benefits and facilitates the end-of-life recyclability of applications in an increasingly circular plastics economy. Another target is wearing and tear resistance for lightweight interior components in transportation and automotive.

Solvay’s Omnix  ReCycle can be processed on standard injection molding equipment, including the use of
water-heated molds. Following the successful sampling and approval by selected customers, the new
sustainable HPPA material is commercially available, worldwide.

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