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Innovative Chemical Recycling Research at Utrecht University Powered by Twin-Screw Extruder

Abhijit Simon
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Innovative Chemical Recycling Research at Utrecht University Powered by Twin-Screw Extruder

Innovative Chemical Recycling Research at Utrecht University Powered by Twin-Screw Extruder

A Coperion STS 25 Mc11 twin screw extruder has been selected by the University of Utrecht for a study on chemical plastics recycling. The mechanical-chemical conversion of mixed plastic trash employing catalysts will be thoroughly investigated by a research team led by Assistant Professor Dr. Ina Vollmer. The Coperion STS twin screw extruder will play a key role in this exciting and mostly uncharted field because of its intense mixing effect and effective energy intake.

At the K trade show (8-15 October 2025, Dusseldorf, Germany) Coperion, together with Herbold Meckesheim, will present their entire repertoire of technology for plastics recycling at Booth 9B34 in Hall 9 as well as in the Open Area in pavilion FGCE07.

Efficient conversion of plastic waste using catalysts

In addition to established methods for recycling mechanical plastics, Coperion also has chemical plastics recycling operations. By repurposing plastic trash into premium raw materials, this technology may enable limitless recycling. The procedure is currently energy-intensive and does not always produce high-quality goods. Catalyst use may be crucial to the ongoing enhancement of process effectiveness and final product quality.

The University of Utrecht’s research project is dedicated to precisely this challenge. The STS 25 Mc11 twin screw extruder, being installed there to carry out the experiments, processes waste plastic, shredded or compacted, with two co-rotating screws in a closed process section. Together, intensive dispersion and high shear introduce a great deal of mechanical energy into the material. The plastic is energy-efficiently melted – an advantage that is particularly important in chemical recycling. Moreover, the extruder achieves a very high mixing effect with its twin screws. The catalysts being implemented in this research project are distributed absolutely homogeneously throughout the plastic melt and can fully develop their intended effect.

In conventional pyrolytic processes, the hot plastic melt is prepared within the twin screw extruder for the next step in chemical processing: pyrolysis. There, in an oxygen-free environment, the plastic is broken down to its chemical building blocks. The temperature of the pyrolysis can be lowered thanks to the efficient use of catalysts, as Vollmer’s team has shown in preliminary work.

Said Dr. Ina Vollmer regarding her research assignment: “Using the extruder, we can achieve an efficient use of the catalyst. Still, our vision is to allow pyrolysis to take place even in the extruder. We can achieve this by exploiting the mechanical-chemical reaction that occurs within the twin screw extruder, and specifically convert the polymer at lower temperatures than have previously been necessary for pyrolysis. Mixing with high shear in the extruder has a very positive effect on the use of catalysts. We are convinced that we can direct the chemical recycling process more precisely using lower temperatures, and this will lead to purer products while at the same time having the potential to revolutionize the chemical plastics recycling process sequence and save energy. “

Should the use of catalysts in the chemical recycling process prove its worth, the results of this research will easily be transferable to larger throughput ranges.

“Following Dr. Ina Vollmer’s scientific approach, we will glean systematically researched results and draw conclusions for chemical plastics recycling from which we can all profit – recyclers and processors as well as end users,” noted Leonid Liber, Sales Engineer at Coperion. “We are proud that our STS twin screw extruder is part of this promising research project, and we wish Dr. Ina Vollmer much success. We look forward to continued collaboration.”

www.coperion.com

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K 2025 to Feature Envalior’s Advanced Safe Smart and Sustainable Developments

Abhijit Simon
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K 2025 to Feature Envalior’s Advanced Safe Smart and Sustainable Developments

K 2025 to Feature Envalior’s Advanced Safe Smart and Sustainable Developments

Envalior will debut from October 8 to 15 at K 2025, the world’s leading trade show for rubber and plastics, held at Messe Düsseldorf. The multinational materials manufacturer will showcase its portfolio of high-performance and sustainable engineering materials for the consumer goods, electrical and electronic, and mobility sectors. Applications derived from recycled or bio-based materials will be on exhibit, with a focus on minimizing the impact on the environment. Envalior is located in Hall 6, Booth B11. At every step of the design and production process, experts will be on hand to discuss how the company uses co-development to accelerate innovation.

Strategically positioned for global-to-local customer support

Choosing the best suppliers and materials has never been more important to preserving competitive advantages given the geopolitical and commercial issues that businesses in the consumer goods, automotive, and electrical and electronics sectors are currently confronting. Envalior, a prominent global-to-local provider of engineering materials, offers customized application support, R&D know-how, and compounding services by fusing a robust worldwide organization and portfolio with a committed local presence. Its dedication to servicing clients where they operate is further demonstrated by its continuous investments in regional compounding capacity, such as the new Xytron PPS compounding facility being built in Uerdingen, Germany.

Latest innovation applications to be unveiled at K 2025

K 2025 will be an opportunity to explore many of the company’s applications, materials, and services. Some highlights at K 2025 are outlined below:

Mobility

  • New Pocan PBT grade designed to meet the demanding requirements of future high-voltage connectors in Mobility as well as next-generation E&E components, supporting the upcoming transition of AI data centers to 800V HVDC power supplies.
  • High-pressure Type IV hydrogen storage vessels made entirely from thermoplastics with blow-molded, injection-molded, or even rotomolded Durethan and Akulon PA6 liners combined with high-strength UDea thermoplastic composite tapes.
  • E-powertrain components made with Xytron PPS such as invertor/convertor busbars and terminal blocks. Xytron solutions are also available for IGBT boards, delivering a CTI value of 600 to meet the increasing electrical insulation and tracking requirements of new mobility applications.
  • Inverter mounting frame for mild hybrid vehicles, constructed using Pocan PBT, delivering significant gains in hydrolysis resistance and thermal shock stability.
  • New PFAS-free Stanyl PA46 grade for wear and friction applications in gears (including xEV) and a thermoplastic composite tape solution for lightweight EV motor brackets.

E&E

  • Sustainable drop-in alternatives to fossil-derived grades for miniature circuit breakers (MCBs), switches and connectors, including Durethan ECO (30% recycled content) and Durethan BLUE (30% pre-consumer recycled content and 56% bio-based content) – halogen-free, flame-retardant PA6 grades.
  • Ultrathin e-motor stator insulation made with Stanyl PA46, allowing for enhanced power and efficiency without increasing the e-motor’s outer dimensions – and enabling some of the industry’s thinnest thermoplastic stator insulation.

Consumer goods

  • New Arnitel thermoplastic copolyester (TPC) foaming grades for the production of high-performance athletic shoe midsoles, enabling performance improvements and compatibility with different foaming technologies, as well as bio-based alternatives.
  • Xytron PPS solutions for household appliances, enabling safer and longer-lasting applications such as components for coffee machines, water heaters, air fryers, and hair dryers.

Bio- and recycled-based solutions

  • Envalior aims to offer a full range of sustainable alternatives across its portfolio by 2030, and many innovative materials will be on display – made from bio- and recycled-based sources such as used fishing nets, cooking oil, and industrial glass fiber waste.
  • Key solutions include Envalior’s PA6 product range, made with circular and bio-circular caprolactam, and its bio-based Stanyl PA46 material, which is certified according to the ISCC PLUS mass balance method.
  • A range of PFAS-free materials to help ensure future regulatory compliance and improve consumer safety while maintaining exceptional mechanical properties.

Engineering Services

  • Envalior will launch its full suite of integrated Engineering Services, enabling customers to save time, reduce risk, and increase cost-efficiency through a unique combination of materials science, deep application expertise, CAE modeling capabilities, and advanced AI-powered tools.

www.envalior.com

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EUROMAP Appoints Tobias Baur as President and Alessandro Grassi as Vice President to Enhance Leadership

Abhijit Simon
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EUROMAP Appoints Tobias Baur as President and Alessandro Grassi as Vice President to Enhance Leadership

EUROMAP Appoints Tobias Baur as President and Alessandro Grassi as Vice President to Enhance Leadership

On the occasion of the EUROMAP General Assembly held in Stuttgart, Germany, the European plastics and rubber machinery manufacturers have elected new leadership to guide the industry through a period of significant transition. Tobias Baur, Chief Sales Officer of the German injection moulding specialist ARBURG GmbH & Co KG, has been named the new President of EUROMAP, the European umbrella organization representing plastics and rubber machinery manufacturers. Joining him is Alessandro Grassi, Shareholder and CEO of the Italian temperature control equipment manufacturer FRIGOSYSTEM S.R.L., who will serve as Vice President. Together, they succeed Luciano Anceschi of TRIA S.p.A. and Michael Baumeister of the Brückner Group, both of whom retired from their roles last year.

Thorsten Kühmann, Secretary General of EUROMAP, Tobias Baur, EUROMAP President, and Alessandro Grassi EUROMAP Vice President

This leadership shift occurs at a particularly pivotal moment, as Europe and its plastics sector face an intricate situation defined by growing environmental restrictions, international competition, and the pressing necessity of moving toward a circular economy. The new presidency underscores the need for increased cooperation throughout the industry on a European scale. According to them, successful transition in the industry depends not only on ambitious initiatives but also on full involvement of all parties. A concerted effort will be central in making sure that transformation towards a more circular and sustainable plastics economy becomes both effective and inclusive.

Under the guidance of Baur and Grassi, EUROMAP plans to continue advancing key initiatives such as standardization through EUROMAP standards, the improvement of data collection and exchange systems, and stronger trade fair cooperation. These efforts are designed to promote innovation, efficiency, and global competitiveness across the European plastics machinery sector. The new leadership is committed to consistently building on the successful work accomplished in recent years, ensuring continuity while fostering progress.

EUROMAP also took the opportunity to express its deep gratitude to Luciano Anceschi, who has played a pivotal role in shaping the association’s direction over the past two decades—first as Vice President and then, for the last 13 years, as President. Anceschi was recognized for his steadfast leadership, his clear focus on the priorities of European machinery manufacturers, and his enthusiasm for pursuing common goals. His legacy includes significant strides in aligning the industry with evolving technical standards, international collaboration, and strategic planning.

With Tobias Baur and Alessandro Grassi starting their presidency, they have rich industry experience and leadership knowledge to share. Their election marks a welcome move to further entrench EUROMAP’s position as a leader in spearheading the European plastics and rubber machinery industry into an age of technological innovation and eco-friendliness. The organization sends its warmest wishes to the new presidency for continued prosperity and firm leadership in the coming years.

https://www.euromap.org/

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Kisuma Adds Setogem RD to Lineup a Two-in-One Additive for Polypropylene Efficiency

Abhijit Simon
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Kisuma Adds Setogem RD to Lineup a Two-in-One Additive for Polypropylene Efficiency

Kisuma Adds Setogem RD to Lineup a Two-in-One Additive for Polypropylene Efficiency

A number of new additive solutions have been introduced by Kisuma Chemicals, a world leader in magnesium-based additives, with the goal of broadening the company’s diverse product line and improving the sustainability, performance, and efficiency of plastics. Kisuma will launch Setogem RD, a cutting-edge dual-purpose nucleating and acid scavenging agent for polypropylenes (PP), as part of this significant project.

“We are very proud to offer this unique new molecule to our customers in the plastics industry,” says Samir El Khoury, regional business manager Middle East & Africa and Global Product Line Manager Polyolefin Additives at Kisuma Chemicals. “As a two-in-one product, Setogem RD combines a superior balance of properties in one single environmentally friendly and cost-efficient solution that minimizes the complexity of PP formulations, enables faster processing and maximizes final part quality.”

The excellent nucleation performance of Setogem RD helps resin producers promote and control the formation of crystals within the polymer, which results in PP materials with outstanding stiffness, impact strength and isotropic shrinkage. Moreover, it provides excellent heat deflection temperature and low creep deformation. At the same time, acid scavenging is an integral property of the product’s composition, offering non-migratory performance even atlow use levels. This contributes to a substantial reduction in blooming and migration—critical for medical and food contact applications facing strict regulatory demands—while ensuring corrosion protection for processing equipment and preserving the function of additives essential to long-term polymer stability.

Setogem RD is zinc-free and reduces the need for tallow or palm oil derivatives. It also allows customers to reduce the loading levels compared to other, less sustainable additives, such as talc and sodium benzoate (NaBz), from several kilograms per ton of PP to only 200 or 300 ppm. In addition, the innovative new dual-function molecule has a very low Scope 1 and 2 carbon footprint. For instance, a major customer has initiated the replacement of talc by Setogem RD for one million tons of PP produced per year at one site, eliminating the exposure of employees to talc in their process and resulting in a CO2 emission reduction of over 2 kilotons per year.

Talc contains high amounts of hazardous substances which led the European Chemicals Agency (ECHA) in 2024 to classify it as a health hazard.

Available worldwide, Setogem RD has previously obtained full food contact approvals in the EU, Switzerland, Brazil, and Japan. The FDA is anticipated to approve it by the end of the year.

www.kisuma.com

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Research Shows British Consumers Confused About Packaging Recycling Despite EPR

Abhijit Simon
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Research Shows British Consumers Confused About Packaging Recycling Despite EPR

Research Shows British Consumers Confused About Packaging Recycling Despite EPR

New research 1 from Aquapak, which specialises in developing high performance, environmentally safe materials to reduce plastic pollution and improve recycling, shows that the majority (70%) of British consumers admit they are confused by what packaging can and can’t be recycled.

Just one in five (21%) say they always read the recycling instructions on product packaging; this increases to almost one in three (31%) in the 25 – 34 age group but drops to 17% for those aged 65 and over. However, almost one in ten (9%) say they never bother reading whether the packaging they have bought can be recycled.

The survey also points to a problem with the recycling instructions producers are using on their packaging. Only 10% of Brits say they always find instructions on how to dispose of packaging easy to understand, over half 52% describing them as “sometimes” understandable and just 29% saying they are “often” easy to understand. When asked which every-day packaging is the easiest to dispose of and recycle, over half (53%) stated paper; followed by glass (18%), plastic (13%), mixed materials (9%) and metal (e.g. aluminium) (7%).

The findings highlight the enormous challenge the Government faces when it comes to the 12 million tonnes of packaging waste thrown away in the UK annually 2 , a significant proportion of which is plastic or complex flexible packaging using conventional plastic which is difficult to sort and recycle. To tackle the problem, the Government introduced Extended Producer Responsibility (EPR) on 1 January 2025, which is intended to shift the responsibility from consumers to producers, incentivizing them to create recyclable packaging and providing clearer guidance to consumers, ultimately leading to a more straightforward and less confusing recycling process.

EPR mandates the use of universally understandable labels on packaging, indicating whether an item is recyclable or not, simplifying the process for consumers.  By making producers financially responsible for the collection and recycling of their packaging, EPR encourages them to design products and packaging that are easier to recycle and reuse, reducing the amount of difficult-to- recycle material on the market.  EPR also aims to fund improvements in recycling infrastructure and education, further supporting easier and more efficient recycling practices.

However, Aquapak is calling on the Government to ensure that legislation underpinning the EPR enables producers to use new materials if they are to decrease the total environmental impact of their products by moving away for hard to recycle conventional plastics.

Dr John Williams, Chief Technical Officer at Aquapak, comments: “Our research findings suggest that there is a very long way to go when it comes to making packaging recyclability in the UK easy to understand for the consumer, particularly as so much of it contains hard to recycle plastic material. There needs to be a significant shift away from the status quo for packaging. New legislation should support faster adoption of innovation that is specifically developed to retain packaging functionality, support recyclability and offer safe end of life options if optimal waste management processes are not available.

“We would also argue that if the target of EPR is to ensure that producers actively engage in sustainable practices and decrease the total environmental impact from their products and packaging, we can’t keep using the same tools and materials to fix the problem. Extended responsibility must also mean an extension to include the use of proven new materials to help producers recycle more effectively without compromising the integrity of their products.”

Aquapak has developed a marine-safe, non-toxic polymer technology called Hydropol, which breaks down harmlessly in all existing recycling streams. When used in place of conventional plastic in crisp and snack wrappers it makes unrecyclable packaging fully recyclable because the Hydropol layer is formulated to dissolve or biodegrades completely. If it does escape into the environment, it is easily broken down by micro-organisms without forming harmful microplastics. Nothing is left behind except CO2, water and biomass that can even be used in renewable energy plants. This means that consumers can put packaging and wrappers made with Hydropol in their kerbside collections where it is recycled alongside paper, plastic, metal or food without any risk of contamination, where it disappears without a trace.

Garment bags made with Hydropol present zero end-of-life issues for consumers and brands. They can be disposed of in existing domestic waste streams without contaminating other recyclable products or they can be dissolved immediately in hot water at home without producing dangerous micro-plastics. They also degrade harmlessly on land or in the ocean.

https://www.aquapakpolymers.com/

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Modernizing Pelletizers: Bay Plastics Offers Gearless Belt Drive for Upper Feed Rolls

Abhijit Simon
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Modernizing Pelletizers: Bay Plastics Offers Gearless Belt Drive for Upper Feed Rolls

Modernizing Pelletizers: Bay Plastics Offers Gearless Belt Drive for Upper Feed Rolls

A new belt system for driving upper feed rollers (UFR) without a gearbox has been announced by pelletizer provider Bay Plastics Machinery.

The new option can be readily installed on existing pelletizers or purchased with new Bay pelletizers, eliminating the noise and maintenance associated with a gearbox.

The UFR belt drive is designed to be installed on single- and dual-drive pelletizers or retrofitted to existing pelletizers of multiple configurations. Similar to a normal feedroll serpentine, the UFR belt is detensioned for quick pelletizer access when the chamber cover is opened. And, new machinery can be narrower than the width previously required when using a gearbox – in fact, the same width as a standard, non-gearbox design.

To use this system with current pelletizers, customers just have to order new extended- shaft upper and lower feed rolls with a conversion parts kit containing bracketry, belt, idlers and a tensioner; then install the parts and put on the drive belt, explained Bay’s President Jason Forgash.

“Customers will only have to drill and tap a couple of mounting holes to retrofit their existing units, if the holes are not already there” Forgash said. “We’ve been including the mounting holes with every new pelletizer delivered for some time now, the entire conversion only takes a few moments.”

Benefits of Bay’s belt-driven upper feed roll system include:

  • A controlled gap between rolls when running steel upper and lower feed rolls.
  • Greatly improved ease of startup when running a gap between rolls.
  • More consistent pulling force with difficult-to-pull material.

Additionally, operators can run a steel upper feed roll when running high-temperature materials. The system saves money by using readily available components, not costly custom gearbox parts and U-joints – many with lengthy lead times.

https://bayplasticsmachinery.com/

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Maximise Labelling Efficiency with Sidel’s 18-Reel CoboREEL Powered by Intelligent Cobots

Abhijit Simon
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Maximise Labelling Efficiency with Sidel’s 18-Reel CoboREEL Powered by Intelligent Cobots

Maximise Labelling Efficiency with Sidel’s 18-Reel CoboREEL Powered by Intelligent Cobots

Sidel presents CoboREEL, an automated reel loading solution for beverage packaging labels with three times the reel capacity of any other solution on the market.

CoboREEL’s exceptional 18-reel capacity guarantees 100% accuracy, maximizes efficiency, promotes productivity, and boosts profitability by integrating cobots to automate the reel loading process.

According to forecasts, the world’s demand for packaged water will have increased by 3.5% to over 350 billion liters by 2029. This increase is primarily due to the growing scarcity of clean drinking water in many regions, as well as increased tourism and on-the-go consumption, even though many countries have implemented strict regulations on single-use plastic. Since sustainability and health are predicted to be key trends in the category, carbonate volumes are also anticipated to have increased by 2.2% by 2029. These are just two of the primary beverage categories that are anticipated to expand; other PET packaging sectors are following suit.

As cutting costs and improving efficiency are essential in such high-volume segments, packaging leader Sidel has created CoboREEL, an innovative solution to boost the labelling step.

By automating this simple, repetitive task with integrated cobots, manufacturers achieve 100% accuracy and maximum precision—minimising errors, delays, and misplacements that can lead to unexpected downtime and lost productivity. It also eliminates the need for manual label reel changes, further reducing disruption to operations.

“Our customers are looking for ways to work smarter, with fewer resources and in a more efficient and intelligent way,” explains Antonio Mancino, Product Manager – Labelling, at Sidel. “Thanks to our five decades of packaging expertise at Sidel, we are constantly developing easy-to-use solutions that reduce costs, speed up daily operations, and require minimal training. With CoboREEL, automating reel uploading not only frees workers from repetitive tasks but also allows them to focus on value-added activities where their input is critical.”

Optimising workforce efficiency

CoboREEL enhances production efficiency by automating the reel loading task for labelling equipment, removing the need for operator intervention or reel replacement for the whole duration of the shift. After feeding the CoboREEL at the beginning of the work shift, workers are freed from the repetitive task of manually loading the reels. This allows them to focus on more complex, interesting tasks which in turn improves focus and productivity.

With 18-reel autonomy, the highest reel capacity on the market, CoboREEL not only ensures a full coverage throughout the entire production cycle, but it also handles different label types and designs in total autonomy, without the need of manual changes.

This innovative solution is designed to be intuitive and easy to use, with no maintenance requirements and minimal need for technical expertise, ensuring the lowest total cost of ownership (TCO). With frequent staff turnover, CoboREEL provides businesses with a tool that anyone can operate quickly, without the need for specialised skills or long onboarding.

Boosting productivity and profitability 

With CoboREEL, Sidel has developed accurate and innovative cobot technology that eliminates the risk of manual errors and prevents unplanned machine stops due to uploading delays or misplacements. Coupled with its ability to work independently from the production line, operators can continue working on CoboREEL to load reels for the next cycle even if the line is temporarily stopped. This reduces inefficiencies, which in turn increases profitability and leads to a fast and measurable return on investment.

Flexibility through mobility

CoboREEL works as a standalone unit which can be easily moved and deployed across different modules as required. As it can be interchanged among the labellers, producers benefit from greater flexibility and can utilise equipment efficiently across the plant.

Reducing the environmental impact

The unique, safety-first cobot design of CoboREEL is compact and flexible, with embedded traceability, able to manage different label types and designs autonomously. Its low energy consumption (<0.5 kWh) helps manufacturers reduce their environmental footprint.

“With an unmatched reel autonomy of up to 18 reels, Sidel’s CoboREEL sets a new standard in the industry,” concludes Antonio Mancino. “As the beverage market grows, Sidel will continue to innovate and offer new packaging technologies and solutions that guarantee accuracy, optimise efficiency, boost productivity and increase profitability for our customers.”

https://www.sidel.com/en

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Trusted Globally, Engineered in India: Shibaura Machine’s Decades of Molding Expertise

Abhijit Simon
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Trusted Globally, Engineered in India: Shibaura Machine’s Decades of Molding Expertise

Trusted Globally, Engineered in India: Shibaura Machine’s Decades of Molding Expertise

How has Shibaura Machine India adapted its technology and product offerings to meet the evolving demands of the Indian plastics industry?

Shibaura Machine India (SMI) has continually evolved its technology and product offerings to meet the dynamic demands of the Indian plastics industry. With a strong focus on innovation and customer-centric solutions, SMI has integrated advanced automation, energy efficiency, and precision engineering into its injection molding machines. We have introduced a range of high-performance machines designed to cater to diverse sectors such as automotive, packaging, medical, and consumer goods, ensuring flexibility and adaptability to various industry needs.

In response to the growing demand for sustainable solutions, Shibaura Machine India has developed energy-efficient molding machines that reduce power consumption while maintaining high output, contributing to both cost savings and environmental benefits. The company has also embraced Industry 4.0, incorporating IoT-enabled smart technologies into its machines for real-time monitoring, predictive maintenance, and data-driven insights, enhancing production efficiency and reducing downtime for customers.

Additionally, SMI has focused on improving the customization of its products to better align with the specific requirements of the Indian market. This includes offering localized technical support, training, and tailored solutions that cater to regional manufacturing challenges. By staying at the forefront of technological advancements and responding to market trends, Shibaura Machine India continues to provide cutting-edge solutions that drive growth and innovation in India’s rapidly expanding plastics industry.

Can you explain how the integration of Industry 4.0 technologies in your All Electric Injection Molding Machines enhances automation, monitoring, and overall operational efficiency for customers?

The integration of Industry 4.0 technologies in Shibaura Machine India‘s All Electric Injection Molding Machines brings substantial improvements across multiple areas, including:

Reduction in Rejection Rates: With realtime data monitoring and advanced sensors, the machines can detect any inconsistencies during the molding process. This early detection helps in making instant adjustments, minimizing defects, and ensuring higher product quality, ultimately reducing rejection rates.

Reduction in Cycle Time: Industry 4.0 features, such as automation and predictive analytics, optimize machine performance by continuously adjusting the molding parameters for maximum efficiency. This reduces cycle times, increasing throughput and enabling faster production without compromising on quality.

Low Running Costs: The All Electric Injection Molding Machines are designed with energy efficiency in mind. They consume less power than traditional hydraulic machines, leading to lower operational costs over time. Additionally, automation minimizes the need for manual intervention, further reducing labor costs.

Low Utility Costs: These machines require fewer utilities, such as water and compressed air, compared to our hydraulic counterparts. This reduces the overall utility expenses for manufacturers, making them more cost effective to operate.

Enhanced Product Quality: The precision offered by the All Electric machines ensures that each molding cycle produces consistent and high-quality parts. With the integration of real-time monitoring, adjustments can be made instantly, resulting in fewer defects and more reliable product outcomes.

What aspects of Japanese manufacturing culture and Shibaura Machine’s own legacy influence its approach to modern challenges like sustainability and automation in today’s global market?

Japanese manufacturing culture, characterized by precision, efficiency, and a strong emphasis on quality, has significantly influenced Shibaura Machine’s approach to modern challenges. Japanese manufacturing culture, with its emphasis on precision, quality, and continuous improvement (Kaizen), deeply influences Shibaura Machine’s approach to modern challenges like sustainability and automation. Shibaura Machine’s legacy of innovation aligns with Japan’s commitment to technological advancement, driving the development of energy-efficient, automated solutions that meet global standards for eco-friendliness and productivity. This focus on meticulous craftsmanship and environmental responsibility allows Shibaura Machine to address evolving market needs while upholding the trusted quality associated with Japanese engineering on a global scale. The Japanese work ethic is characterized by dedication, discipline, and a strong sense of teamwork. This fosters a collaborative environment where employees work together to achieve common goals.

With the increasing demand for specialized applications in industries like medical and electronics, White Goods, Packaging, Medical Equipment, PET Solutions, Agriculture Products how does Shibaura Machine India adapt its molding technologies to meet these specific needs?

At Shibaura Machine India, we continuously adapt our injection molding technologies to cater to the evolving and specialized needs of diverse industries such as medical equipment, electronics, white goods, packaging, agriculture, and PET solutions.

Our machines are engineered for precision, flexibility, and high productivity. For example, in the medical and electronics sectors, features like precise clamping control, optimized screw design, and PID-based temperature stability ensure accuracy and product safety. In packaging, we offer high speed injection systems capable of reaching velocities up to 400 mm/s, meeting the demands of thin-wall part molding. For agriculture and piping, our machines deliver high plasticizing capacity and support long hold times needed for thick parts. In PET preforms, we offer specialized screws, high response drives, and integrated turnkey solutions to ensure high throughput and superior quality at lower cycle times. Across all these sectors, the adaptability of our machines—combined with advanced control systems, energy-efficient servo technology, and support for complex molding operations—ensures we deliver reliable, cost-effective, and application specific solutions to our customers.

How does Shibaura Machine’s die casting technology cater to the needs of industries like automotive and electronics, where strength and dimensional accuracy are critical?

At Shibaura Machine, we understand that industries like automotive and electronics demand not only high strength and dimensional precision but also consistent productivity and sustainability. Our High-Pressure Die Casting (HPDC) machines are engineered to meet these exacting requirements.

Technically, our machines are capable of producing components with superior mechanical properties—high tensile strength, hardness, and wear resistance—which are crucial for critical automotive parts like engine blocks, transmission housings, and structural elements. We ensure tight dimensional tolerances through high-rigidity platens, precision injection systems, and closed-loop control for consistent shot quality—essential for electronic components like connectors and housings.

To enhance performance and reduce energy consumption, we’ve introduced servo hydraulic technology that precisely controls injection pressure, speed profiles, and holding pressure across each cycle. Our electric die closing system, a key innovation, improves cycle time, minimizes hydraulic oil usage, and significantly reduces the machine’s carbon footprint—aligning with our sustainability goals.

Additionally, our machines support high speed casting and are capable of handling complex geometries with thin walls and intricate features, thanks to advanced mold filling simulations and robust clamping mechanisms.

We’ve also integrated IoT-ready platforms into our machines, enabling remote diagnostics, predictive maintenance, and real-time process analytics, which empower our customers to optimize productivity and reduce downtime.

In essence, our die casting solutions are not only designed for high performance but are also future-ready—equipping our customers with the tools to stay competitive in a rapidly evolving manufacturing landscape.

With over 30 years of experience in manufacturing excellence, what core values and practices have been instrumental in Shibaura Machine’s sustained success and growth in the industry?

Shibaura Machine’s sustained success and growth over 30+ years are rooted in core values of quality, innovation, and customer commitment. Dedication to quality ensures that every machine produced adheres to the highest standards, delivering reliable and durable solutions across industries. This focus on quality builds trust with clients who depend on Shibaura machine for critical manufacturing processes.

Rigorous Quality Control: Implementing stringent quality control measures ensures the production of high-quality products that meet or exceed industry standards.

Precision Manufacturing: Advanced manufacturing techniques and precise engineering practices contribute to the production of components with exceptional accuracy and durability.

Global Network: A strong global presence enables Shibaura Machine to serve customers worldwide and collaborate with industry leaders.

Strategic Partnerships: Collaborating with key partners strengthens the company’s market position and accelerates growth.

Shibaura Machine India has a strong commitment to innovation. How does the company’s core vision drive its approach to technological advancements and the development of new solutions for the manufacturing industry?

Shibaura Machine India’s core vision is to be a global leader in providing innovative and reliable manufacturing solutions. This vision drives the company’s commitment to technological advancements and the development of new solutions for the manufacturing industry.

This commitment to innovation ensures our solutions not only meet current demands but also anticipate future challenges, providing customers with solutions that are adaptable and scalable. For instance, the company’s focus on energy-efficient designs and environmentally friendly.

production methods reflects a broader mission to support sustainability, which is increasingly important in today’s manufacturing landscape. With this Shibaura Machine India continues to deliver high-performance, reliable solutions that empower its clients to achieve operational excellence and competitive advantage in the global market.

www.shibauramachine.co.in

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SML Launches a New Turret Winder for Cast Jumbo Rolls with a Diameter of up to 1,500 mm

Abhijit Simon
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0
SML Launches a New Turret Winder for Cast Jumbo Rolls with a Diameter of up to 1,500 mm

SML Launches a New Turret Winder for Cast Jumbo Rolls with a Diameter of up to 1,500 mm

SML’s brand-new turret winder W1300 comes fully equipped with powerful technical features and functions. Its ability to produce jumbo rolls with a mechanical diameter of 1,500 mm offers numerous benefits to manufacturers in downstream processes.

“Our new W1300 turret winder was designed for the winding of CPP, CPE, mono-oriented and barrier films of absolute premium quality. With winding speeds of up to 450 m/min and end film widths from 2,400 to 3,900 mm, the new winder boasts everything necessary to ensure high-volume production”, Alexander Bruckmüller, the Product Manager at SML, confirms.

Efficiency in subsequent processes

Thanks to the winder’s large mechanical roll diameter of 1,500 mm, the running times of the individual rolls can be extended quite significantly. Extending the production runs primarily leads to a boost in efficiency in subsequent processes, such as printing or metallising. The following example demonstrates quite clearly the tremendous amount of cast film contained in a jumbo roll of 1,500 mm: When cast film with a thickness of 25 µm is wound onto a roll with a diameter of 1,200 mm, this roll contains 45,000 running meters of film. A jumbo roll with a diameter of 1,500 mm has 70,000 running meters of the same film – this is an increase of more than 50 %!

Adjusting the hardness of the film roll

The W1300 winder can be adapted with ease to different production requirements. Two operational modes are available: Depending on the film, the winder either can work in gap mode or in contact mode. Before the film hits the contact roller, it runs over a continuously adjustable satellite roller, to control the air intake between the individual film layers and to adjust the hardness of the film roll. Winding is possible either with or without winding shafts. The inlet section of the winder is prepared for the installation of a post cooling roller.

Roll change with auxiliary contact rollers

Two different cross-cutting units are available for the winder W1300: One is a full-width twisting knife for thinner films and the second one is a flying knife for thicker films and oriented films. During a roll change, driven auxiliary contact rollers are engaged in order to keep the condition of the film at the roll in perfect condition up to the very last layer. A handling system is available both for shaftless winding and for winding with shafts. During shaftless operation, rolls can be also handled with an overhead crane.

Suitable for retrofits

The standalone nature of the winder makes it easy to install it on third-party cast film lines since it comes with its own control system and electrical components.

www.sml.at

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Tosca Builds Out German Operations as Retail Demand Soars

Abhijit Simon
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0
Tosca Builds Out German Operations as Retail Demand Soars

Tosca Builds Out German Operations as Retail Demand Soars

In order to meet the expanding demands of its retail clients throughout Central Europe, Tosca, a world pioneer in reusable packaging and pooling solutions, has announced a major expansion of its operations in Germany. In order to accommodate growing demand and client growth throughout the region, the company has made a strategic infrastructure investment by building a new service center in Salzkotten and expanding its current facility in Frechen.

New Salzkotten Service Centre – Enhancing Capacity and Efficiency

On February 1, 2025, Tosca opened a new service center in Salzkotten to meet the rising demand for its plastic half pallet. Covering 3,300 square meters and offering an annual capacity of 3.1 million trips for half pallets, the facility significantly enhances Tosca’s operational footprint in the region.

The site plays a key role in supporting their reusable plastic half pallet operations, helping to onboard and scale major FMCG opportunities effectively.

Strategic Expansion of Frechen Service Centre – Supporting Growth

In addition to the new opening, they have completed a substantial expansion of its existing service center in Frechen. The facility’s footprint has doubled, enabling approximately 2 million additional half pallet flows per year. This expansion supports anticipated business growth of over 30% in 2025 and ensures Tosca can continue to deliver consistent, high-quality service to customers across Germany.

Strengthening Supply Chain Support for Retailers in Central Europe

These developments reflect their continued focus on strengthening supply chain efficiency and reliability for key players in the FMCG and retail sectors. The investments are tailored to meet the rising operational demands of Tosca’s half pallet business, delivered through a joint programme with several prominent retail chains in Central Europe.

“These strategic investments allow us to keep pace with growing demand while maintaining the high standards of service, reliability, and sustainability expected by our customers,” said Marco Gonzalez, Managing Director for Central Europe. “With enhanced infrastructure in Salzkotten and Frechen, we are well positioned to support our continued growth across Germany.”

https://www.toscaltd.com/

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