Non-Halogenated Flame Retardants for Eco-Conscious PP Parts

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

High efficiency at low concentration

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

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

Broad portfolio of halogen-free flame retardants

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

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

Expanding the portfolio of conventional flame-retardant additives

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

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

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

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Enhancing PET Recycling Productivity with Automated Filtration

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

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

Large-area fine filtration made for recycling

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

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

Continuity and process stability thanks to automation

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

Effortless inline cleaning – effective and safe

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

Development goals: Simplified handling, economic efficiency

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

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

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

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

www.bbeng.de

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EYEgate HRS: Superior Gate Quality for Maximum Performance

The new EYEgate HRS, an improved end ring made for the MULTIflow HRS multi-cavity line, is introduced by Oerlikon HRSflow as industries throughout the world look to maximize productivity and reduce maintenance costs. This creative solution improves performance in a variety of applications and is engineered to provide the best gate quality and longest lifespan.

With a diameter ranging from Ø3.0 to Ø3.5 mm, the new EYEgate HRS ensures a minimal footprint, enabling precise injection point positioning even in complex geometries and hard-to-reach gate locations. A specially designed pin guide system guarantees permanent pin-gate alignment, significantly extending the end ring’s lifespan. Suitable for applications up to 20 g, EYEgate HRS is available for both Sp and Tp nozzle series.

Mold makers can now benefit from a more efficient manufacturing process, as the gate is already integrated into the end ring. This unique geometry simplifies gate area machining, reducing the time required for moldmaking.

Another key advantage of EYEgate HRS is its ease of maintenance. When the gate becomes worn, the end ring can be replaced without re-machining the cavity inserts, significantly reducing maintenance and production downtime costs. This translates to enhanced productivity and operational efficiency.

Designed for industries such as beauty and personal care, beverages, home products, and medical applications, the EYEgate HRS is compatible with a wide range of materials, including: PC, PMMA, PP, PE, ABS, MABS, ASA, SMMA, SAN, thermoplastic elastomers, and most of Sustainable resins.

The streamlined inner profile of the tip enhances color change performance by enabling continuous material flow without stagnation points. This ensures more efficient production processes, particularly in applications where frequent color changes are required.

With its minimal footprint, improved durability, and maintenance-friendly features, the EYEgate HRS defines a new standard for high-performance injection molding solutions, reinforcing Oerlikon HRSflow’s commitment to innovation and efficiency.

www.oerlikon.com/hrsflow

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HASCO’s Cutting-Edge CAD Tools for Modern Mold Engineering

As a reliable systems supplier for standardised high-quality mould units and customised hot runner solutions, HASCO supports its customers from the initial idea to the manufacture of the injection-moulded article. The wide variety of CAD services guarantees efficient design processes and sustainable success.

Web portal with user-friendly tools

The HASCO Web portal offers much more than just an intelligent product search with a convenient ordering service. All the key data for designing the mould are available through corresponding interface to the CAD systems. Starting from the original idea through to the final production, customers are supported by numerous tools. An effective product navigation system with comprehensive full-text search makes it possible, from more than 100,000 standard components, to reliably find the desired items, including all the technical information. With user-friendly tools such as the mould-building assistant and the layout editor, made-to-measure, fully configured moulds can be easily designed.

CAD native databases  

When customers use the HASCO native databases, they benefit from parametric data. The consistent parameterization allows rapid adjustments to be made to the design, and enables the correct identification of the components when generating parts lists. In addition to the component geometry, the installation spaces (take-off units) can also be called up, which leads to major time savings and makes the design of injection moulding tools even easier. Interfaces are available for all common CAD systems and can be downloaded free of charge. Models of the products can be directly imported and exported.

Colour table for the identification of tolerances in 3D models

A standardised colour table for tool and mouldmaking, available on the HASCO website, enables tolerances to be clearly labelled through defined colours. Conventional CAM systems can directly read in 3D models, automatically recognise the colours and derive the tolerance from them. Misinterpretations of 2D drawings are thus effectively avoided.

Standard Engineering Tool

The Standard Engineering Tool, HASCO SET, has been developed specifically to meet the needs of designers in the field of tool and mouldmaking. The offline software program allows access to an extensive product library directly from the CAD workplace without the need for an Internet connection. Through regular updates, users obtain access to all the latest product data.

www.hasco.com 

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