At K 2022, the major themes of circular economy, digitalization and climate protection promise to be in evidence everywhere.
As sustainability moves from being a far-off "maybe" to a more immediate "must," companies throughout the plastics industry are responding with new products, processes and developments to advance in this area. Recycling Extruder Machine
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At K, Evonik (Hall 6, Stand B28) is introducing a new drop-in sustainable high-performance thermoplastic to its eCO line of plastic products. In the new nylon 12 elastomer Vestamid eCO E40, 50 percent of the fossil-based raw materials used in its production have been replaced with an alternative material obtained from chemical recycling of used tires.
A member of the polyether block amide family (PEBA), the new molding compound is well-suited for applications such as sports shoe soles. The soles exhibit excellent low-temperature impact strength, chemical resistance and high elasticity, and they are easy to color, process and overmold.
The company uses only renewable energy sources for production of the material, reducing its carbon footprint by 42 percent. The new Vestamid eCO E40 and other sustainable plastic materials will be on display at the K fair under the motto "Next generation plastic solutions."
The team from the Centre for Circular Plastics Solutions also will be on-site with new ways for an efficient circular economy.
Sabic (Hall 6, Stand D42), will focus on "Making the change real." It is launching, among others, its Bluehero program, a new strategic initiative designed to support the shift to product electrification.
The initial focus will be on the automotive industry. With electrification becoming a megatrend, the company's starting point with Bluehero is to support the automotive industry's mission to create better, safer and more efficient electric vehicles, with an emphasis on improving structural battery components.
With road transport making up a significant share of total global CO2 emissions, the program will build upon the company's established materials and capabilities to help the automotive value chain transition to a world with zero tailpipe emissions.
The core of the Bluehero ecosystem are Sabic's global team of engineers, research fellows and scientists. As part of its work, the team collaborates with customers, development partners and others across the value chain, from OEMs and tiers to tooling suppliers and testing agencies. As the initiative develops, Sabic anticipates expanding the focus and scope to help support efforts in other sectors. Those could potentially include energy storage, charging infrastructure, other modes of transport and industrial and consumer equipment.
Under the motto "Quality Works," specialty chemicals company Lanxess (Hall 6, Stand C76-78) is presenting material developments, new processes and technologies, and sustainable products and system solutions for the rubber and polyurethane industries as well as colorants and intermediates for the polymer sector at K 2022.
The focus topics for this year are electromobility and sustainability. The High-Performance Materials business unit is highlighting sustainable materials and lightweight solutions for the electromobility market, such as lightweight structural components based on the continuous fiber-reinforced composites of the Tepex brand for passenger car batteries, as well as Tepex composites based on recyclates or bio-based raw materials. Another focus is on tailored solutions for the stringent requirements in, for example, the powertrain or charging infrastructure of electric vehicles.
The Urethane Systems business unit is presenting products designed to increase sustainability along the entire value chain, from Low Free (LF) monomer technology and innovative Adiprene Green-brand prepolymers with a high bio-based content to novel hot-cast and cold-cure systems that can be processed with reduced energy input.
UniteChem Group (Hall 8A, Stand E33), the world's leading supplier of light stabilizers for plastics in a broad range of high-end industrial applications, will showcase the expanded service and product offering following the company's ongoing expansion plans and investments both in global production capacity with new plants in China and local customer support in Europe, where the company is seeking to grow its presence.
After establishing a major warehouse in Antwerp, Belgium, and opening a sales office in Düsseldorf, Germany, the next steps will be to double its workforce, bringing its technical support even closer to local customers and expansion into another European country.
DuPont Mobility & Materials will showcase new Hytrel foam and other novel solutions and technology innovations in Hall 6, Stand C43, including the new Hytrel Eco grades. Based on a biomass balance approach, these newest Hytrel TPC-ET thermoplastic elastomer grades are true drop-in replacements with no need to requalify products or retool. One customer recently launched patented, foldable swim fins to consumers, thanks to an upgrade from Hytrel ECO B.
Also on display will be a 3-in-1 Solution for EV batteries: A patent-pending concept to increase energy density that combines three elements into one modular unit to decrease range anxiety, increase passenger room, improve cooling and integrate components; a sustainable polymer portfolio for e-bike applications; as well as the company's patented chemical bonding technology enabling direct nylon and aluminum joining that produces higher bond strength. In addition, the DuPont stand will feature numerous commercial applications in the consumer space, from running shoes to espresso machines; developments in the industrial and electrical space and what might be the only thermoplastic solution that can pass requirements for the high-temperature dip soldering process: a Zytel grade able to replace phenolic parts that is bio-based, recyclable and NHFR at V0.
From Ascend (Hall 6, Stand A07) came the news of its public commitment across a broad range of sustainability goals, including the reduction of its greenhouse gas emissions by 80 percent by 2030. The company will also begin using bio-based feedstock and by 2023 and will offer bio-based acrylonitrile, hexamethylene diamine and nylon.
At K 2022, the company will showcase a new technology platform of high-temperature, high-ductile nylon 6/6 for fasteners called Vydyne Thermaplus, which has been designed as a smarter replacement for nylon 4/6. Also on display: Vydyne AVS, a new engineered material effective at dampening high-frequency vibrations at the motor, which translates into a 80 percent reduction in cabin sound pressure. EV motors produce vibrations at 10 times the frequency of internal combustion engines, making standard automotive under-the-hood dampening materials less effective.
Other highlights include the company's Starflam flame-retardant nylons designed to meet a variety of performance requirements and its HiDura portfolio of long-chain nylons for consumer goods and connectors, as well as copolymers for films that make packaging more durable.
At K 2022, in Hall 6, Stand A75, Covestro will present new products and materials for many key areas that support the circular economy and climate neutrality. The company has developed the "CQ" brand suffix, which stands for "Circular Intelligence." Products tagged have at least a 25 percent alternative raw material base.
One of the first is Desmodur CQ, a polyurethane foam used in upholstered furniture, mattresses and thermal insulation. Covestro said it is increasingly moving away from fossil resources, in the direction of mass-balanced, renewable precursors and plastic waste as alternative raw materials. Renewable energy and green electricity are other focuses, while the company is also looking at the future supply of "green" hydrogen and the development of innovative recycling technologies. In the long term, Covestro aims to offer all of its products in a climate-neutral version. By 2030, the company plans to invest around 1 billion euros in circular economy projects.
Brüggemann (Hall 8A, Stand D08) is presenting a range of performance-enhancing additive solutions at the K fair this year. These run the gamut from electrically neutral heat stabilizers for nylon in electrical and electronic applications, including e-mobility, that do not corrode metallic components, such as overmolded sensors, and have no impact on the polymer's electrical properties, to high-performance stabilizers for exposure to moderate to very high temperatures and additives for stabilizing recycled polyolefins. A further focus is on efficiency-boosting flow enhancers, which enable shorter cycle times and low wall thicknesses for components made of nylons and PBT.
Brüggemann will also be showcasing the new developments in its range of additives for recycling featuring specially developed technology to repair defects in the molecular chains that arise during the processing and use of polyolefins, and degrade quality. As a result, recycled polymers are obtained with improved mechanical properties that do not require the addition of virgin material.
ExxonMobil (North Entrance/11) will demonstrate how it is "Advancing Sustainable Solutions. Together" at the booths of industry-leading machine manufacturers and distributors at K 2022. These include solutions made with certified circular polymers using Exxtend technology for the chemical recycling of plastic waste as well as solutions that enable the use of higher percentages of mechanically recycled content, and monomaterial solutions, such as polyethylene/PE laminates, which are designed for recyclability by reducing the number of components, including those often considered more difficult to recycle.
At K 2022, injection molding machine manufacturers from around the globe will be displaying a host of developments and improvements targeted at sustainability. From energy-saving innovations to intelligent modules that enable better processing using recycled and bio-based materials, here, too, the topics of digitalization, climate protection and circular economy are top-of-mind issues.
This year, Haitian International (Hall 15, Stand A57) has a bigger booth, more exhibits and more room for smart solutions, the company said. With a total of five exhibits, including two European machine premieres — one of which is the Haitian Mars K Series — Haitian International will be exhibiting intelligent machine functions for the first time that enable plastics processors to achieve additional energy savings and more efficient processes. The goal: to offer smart features as a standard feature at no extra charge. Recognizing the importance of flexible connectiveness, several system partners will be integrated into the machine concepts shown at K 2022. In the MES (manufacturing execution systems) area, in addition to Haitian Smart Solutions' own "GoFactory," another MES partner will be presented specifically for the European market. All five exhibits will be connected to both systems.
Next to introducing its precisionMolding and powerMolding injection molding machine series — already available in Asia — to its customers in Europe and North America, KraussMaffei (Hall 15, Stand C15/C24-D24) will be showcasing new digital solutions designed to achieve a more energy-efficient production — important in an era where energy prices are soaring.
Visitors to the stand will also see a complete circular economy circuit in action. An all-electric PX 200-1400 in clean room design will be manufacturing caps for insulin pens under clean room conditions, in short cycle times. These will then be shredded, fed into a ZE 28 BluePower twin-screw extruder with a variety of additives, such as bonding agent and liquid dye, blended and homogenized. The recycled compound is then processed on the new powerMolding 1300-11900 with a clamping force of 13,000 kN into an automotive front-end carrier made of 100 percent recycled material.
The company has also announced its entry into the additive manufacturing market with new technology that will be unveiled at K 2022.
Engel Austria (Hall 15, Stand C58; the Circular Economy Forum) has developed a new process that enables ground plastic flakes to be used in injection molding, thus eliminating the pelletization step from the recycling process and significantly improving its energy and cost efficiency.
To be able to process flakes in injection molding, the recycling process breaks plasticizing and injection down into two process steps. In the first, the plastic flakes derived from post-consumer or post-industrial collection are melted in a conventional plasticizing screw. The melt is transferred to a second screw for injection into the cavity. Depending on the material and application, a melt filter and a degassing unit can be integrated into the process between the plasticizing and injection units. This means that high-quality products can be created — even from contaminated plastic waste. Processing plastic flakes directly significantly improves the energy footprint of the product by up to 30 percent, the company said.
At K 2022, Engel is presenting the new, two-stage process for the first time as a live exhibit at a trade fair, producing dolly pallets at the stand in the Circular Economy Forum in the open-air area between halls 11 and 16. A blend of polyolefins from a post-industrial collection is being processed on an Engel duo 12060H/80Z/900 injection molding machine.
Sumitomo (SHI) Demag, exhibiting in Hall 15, Stand D22, is further growing its all-electric IntElect platform. First launched with smaller tonnages — 50 to 180 tons — the company in 2019 expanded the range from 220 to 500 tons. Basic machines are available in the full range, with higher-speed versions launched in 2018 from 50 to 80 tons.
At K 2022, they will offer those IntElect S versions to 450 tons. In addition, the company will introduce the high-speed PAC-E line of machines, initially targeting packaging and currently available in the medium tonnage range. Described as a fusion of the El-Exis hybrid platform and IntElect all-electric series, the line features a brand-new injection unit developed specifically for high-speed packaging. At K, the PAC-E line will debut with an all-electric 350-ton model running a 72-cavity cap mold, illustrating that the electrified press can achieve the same cycle time as the El-Exis.
At the show, the company is also showcasing its web-based myConnect software, which can provide critical data and decision-making information in real time. In the future, all new machines will be equipped with this platform and its range of networked support services, which has been extended to include condition monitoring.
A true highlight at Netstal (Hall 15, Stand D24) is the redesigned Elios 4500, which now features a fully electric clamp unit. At K, it will mold a thin-wall, 150-milliliter, in-mold label-decorated yogurt cup from certified renewable polypropylene from Sabic based on tall oil.
According to the company, switching to all-electric mold closing allows for a 0.1-second faster dry cycle and a 7kW reduction in average power consumption. The machine is also 450 millimeters shorter. One cup weighs just 6.5 grams. The 12-cavity mold, like the handling system, comes from IML Solutions. The cycle time will be around 5 seconds. Combining digitization and circular economy, the in-mold labels from Verstraete will also feature digital watermarks from the Holy Grail 2.0 initiative.
As always, the Wittmann Group's machinery presentation is broad and comprehensive, with applications on display at Wittmann Battenfeld (Hall 15, Stand C06), at the VDMA Circular Economy Forum in the outdoor area, and more equipment presented at the booth of Wittmann Technology.
The show highlight, however, is an EcoPower equipped with the new B8X control system and operating with direct current generated from sources of renewable energy. Wittmann Battenfeld, together with its customer WAGO, has developed technology — and applied for a joint patent — that enables the continuous current generated by solar cells to be used directly for driving injection molding lines, without loss by first passing through inverters, transformers and high-voltage power lines. On an EcoPower 180/750+ operating with direct current, a part for the customer's "basic clamp" is produced from flame-retardant nylon with a 24-cavity mold supplied by WAGO.
The parts are removed by a modified WX142 robot from Wittmann in a DC version powered directly via the intermediate DC circuit of the EcoPower and also returns any excess energy set free by axis deceleration to the intermediate circuit. This concept not only enables energy costs to be kept down by direct use of solar electricity, but direct current is also easy to store in conventional batteries, thus providing an excellent way to handle current peaks. If necessary, the machine can be changed over to AC operation.
Nissei and Negri Bossi will be exhibiting together (Hall 15, Stand B22) for the first time at a major event since the Italian machinery manufacturer joined the Nissei Group in January 2020. That move added large-tonnage injection molding machines and a greater geographic reach to Nissei's product line and allowed the businesses to share supply chains and production bases.
Nissei will debut an all-new all-electric machine, intended as a flagship model, to be sold in Europe. The companies also plan to expand on the polylactic acid bioresin molding package introduced at K 2019, where Nissei molded long-stemmed thin-wall transparent PLA champagne flutes, and exhibit a solution to meet the rapidly shifting demands relating to electric vehicles.
Arburg, whose motto at K this year is "There is only a Plan A," is emphasizing its commitment to addressing the fundamental and critical issues of sustainability, the circular economy and carbon reduction. At its stand (Hall 13, Stand A13-1) and the arburgGREENworld pavilion in the VDMA Circular Economy Forum, the company is demonstrating how highly networked, digitalized manufacturing helps to conserve resources and increase production efficiency.
The arburgGREENworld pavilion offers insights both into Arburg's own efforts, within the company to conserve resources, and into what its products do for customers. Here, an electric Allrounder 370 A with recyclate package will produce "Greenline" plugs from Fischer.
The main stand will showcase Arburg technologies that enable sustainable, efficient manufacturing. Exhibits will include solutions with a small footprint, process control and networked peripherals, as well as completely new technologies, configurations with compact automation or the series production of mass-produced articles. A total of eight hydraulic, hybrid and electric Allrounders with a clamping force of between 350 and 6,500 kN and two Freeformers for industrial additive manufacturing will be on show. All injection molding machines will be automated with robotic systems, in some cases integrated into complex turnkey systems and connected to the "arburgXworld" customer portal.
Extrusion highlights this year include energy-efficient technologies from Coperion and Coperion K-Tron (Hall 14, Stand B19) for processing, and a dedicated area for plastics recycling developments.
Coperion will be exhibiting an entire production line for recycling PET at the VDMA's Circular Economy Forum (CE09) as well as its expertise in numerous plastics recycling processes such as chemical recycling, multilayer film recycling and upcycling. Its ZS-B MEGAfeed side feeder that enables plastic film and flake recycling in very high throughput dimensions will be featured in the system, which is built around a ZSK 58 Mc18 twin-screw extruder configured for manufacturing high-quality PET based on recycled materials. Conventional technologies for recycling PET require pre-drying and crystallization of flakes and fibers before they can be reprocessed. Using Coperion's technological process solution, PET recyclate can be introduced directly into the ZSK extruder.
The MEGAfeed enables plastic recyclate with a bulk density under 200 kg/m³ to be fed in large quantities into the ZSK twin screw extruder. Melting, intensive devolatilization and complete homogenization occur in the process section of the ZSK 58 Mc18; the material stream is then transferred via a gear pump and filter with an automatic screen pack changer to an underwater pelletizer for pellet production, and then condensed in the SSP (Solid State Polycondensation) reactor. The high quality of recycled PET manufactured using this innovative Coperion process was approved by the FDA for direct contact with food (letter of nonobjection).
One eye-catcher at the Coperion booth (Hall 14, Stand B19) will be the high-performance ZSK Mc18 extruder with a 70 mm screw diameter. With its high specific torque of 18 Nm/cm3, it is especially suited for efficient compounding of plastics at very high throughput rates and with comparatively low energy consumption.
Davis-Standard will exhibit machinery and process solutions that highlight the company's commitment to "value, innovation and sustainability" (Hall 16, Stand A43). Technology will be displayed from the Davis-Standard family of companies, including Davis-Standard, Maillefer, Brampton Engineering, Deacro and Thermoforming Systems LLC (TSL), focused on a circular economy, energy efficiency, reduced power consumption and minimized waste. A live demonstration of smart factory connectivity is included. One highlight is the space-saving SHO Extruder (3.5-inch, 90mm) offering outputs of at least 20 percent higher vs. existing groove feed models, engineered with a new gearbox, an optimized feed section and high-performance, energy-efficient DSB barrier screw for high-viscosity high density PE applications such as pipe extrusion.
Other exhibits include Maillefer's new MXD series high-performance extruders that will be on display in 45mm and 80mm sizes; and Extrusion Die 510A for packaging, cup stock, board and paper, foil and film applications offering improved safety and reduced waste.
Expertise is the main focus at the stand of Leistritz Extrusionstechnik GmbH (Hall 16, Stand F22), where extrusion specialists will demonstrate their know-how and problem-solving skills based on successfully concluded customer projects. In addition, visitors will be able to learn about modern twin-screw extrusion technology and solutions for the recycling industry with intelligent control systems. A ZSE 60 iMAXX extruder, the newest member of the iMAXX range, will be on display. The series is known for its flexibility and modularity. It covers a wide range of applications in plastics extrusion and in recycling. Because of the high specific torque of up to 15.0 Nm/cm³ in combination with a high free volume (Da/Di = 1.66), the ZSE MAXX machines are among the world's most powerful co-rotating twin-screw extruders.
Windmöller & Hölscher's response to challenges to create a circular economy, new opportunities through digitalization and the constant pressure to make production more efficient is succinctly expressed in its K 2022 theme of "Get in the Loop," illustrated with the infinity symbol. The focus is on demanding applications, such as barrier films or packaging with an increased percentage of post-industrial and post-consumer recycled plastics, the company said. Automation and digital systems for improving efficiency, such as the RUBY IoT system, will also be highlighted, with live demonstrations run on the VAREX II blown film line on the stand (Hall 17, Stand A57).
W&H is also inviting visitors to the four-day EXPO at its headquarters in Lengerich, Germany. More than 10 machines covering extrusion, printing and converting will be running live demonstrations several times a day. Visitors can register at the W&H booth at K to join.
KraussMaffei (Hall 15, Stand C15/C24-D24) will be showing its DCIM (direct compounding injection molding) system that enables different recycled materials, with different viscosities, to be economically processed — using a single-screw extruder — into a homogeneous melt that can subsequently be injected molded into products.
At K, five-piece polyolefin collapsible crates will be produced from PP staple fiber fleece from FFP2 masks, shredded HDPE from logistics packaging goods and HDPE blow molding scraps from toy production, with masterbatch, stabilizer additives and micaceous iron oxide added as fillers.
The extruder, equipped with a specially developed, elongated screw with a ratio of length to diameter of 30 L/D (instead of the normal 17-23 L/D) is installed in a space-saving piggyback position directly over the injection unit of a standard hydraulic machine.
The compounded melt is conveyed into the plasticizing unit in a single heating process, which reduces degradation of the polymer, conserves energy and reduces the CO2 footprint. The extruder and injection molding machine produce in intermittent operation, which means that when the injection volume for the next cycle has been reached, the extruder stops. The system complements the company's well-known IMC technology and, says KraussMaffei, enables material cost savings of up to 50 percent.
Bausano (Hall 16, Stand B70), specialized in the design and production of customized plastics extrusion lines, will be showcasing its Smart Energy System for cylinder induction heating, which helps to significantly reduce energy consumption. The system features forced-cooled induction coils with special openings that allow air to pass through and the temperature sensor to be installed. The coil is wrapped in highly insulating materials to minimize heat loss from the cylinder to the outside.
The cooling airflow is channeled directly onto the plasticizing cylinder for faster cooling. The system allows for an even heat distribution and a lower coil surface temperature, quick heating up to 250°C (482°F) and extremely accurate temperature control thanks to reduced thermal inertia. It will be on display at the stand on a twin-screw extruder from the Nextmover range, demonstrating that with this technology, an overall productivity of 2,000 kg/h can be achieved for PVC pipe diameters from 63 mm to 160 mm, with energy savings of 35 percent.
The system will also be shown on Bausano's new single-screw extruder E-GO R, designed for recycling plastics, which the company is debuting at K and is designed to handle highly contaminated plastics. Some examples are HDPE waste from containers for milk, motor oil, shampoos and conditioners, soap, detergents and bleach. Other applications include PP waste from lunch boxes, yogurt pots, syrup and medicine bottles, caps and low density PE waste from cling film, shopping bags and squeezable bottles.
Promix Solutions (Hall 9, Stand E18) is presenting solutions for the mixing, foaming and cooling of polymer melts that can save raw material costs, reduce the carbon footprint and increase production capacity. Promix Microcell Technology creates a microcellular foam structure in the polymer by adding environmentally friendly atmospheric gases (N2 and CO2). This reduces the product weight by 20-50 percent, which leads to substantial savings in raw materials.
Promix conducted intensive research in the past two years into the further development of physical foam extrusion, leading to an important milestone in terms of cell size. The company showed it was possible on average to halve the previous cell size of 100 microns.
The extremely fine-celled structure yields mechanical values comparable to those of non-foamed trays of the same thickness but with weight savings of around 20 percent. The technology is suitable for use in packaging films, sheets, foam core and corrugated pipes as well as profiles, cable sheathing, blow molding and blown films.
Promix Microcell Technology can be used for almost all raw materials, including for PP, PE, PET, thermoplastic elastomer, thermoplastic polyurethane, nylon, hard and soft PVC and bioplastics. The technology is available both for newly planned extrusion lines and as a retrofit solution.
Kiefel GmbH (Hall 3, Stand E 90, VDMA Circular Economy Forum), specialized in thermoforming and joining technology for plastics and natural fibers, will be presenting machine, tool and automation solutions for processing recyclable materials at this year's K fair, as well as new digital services, solutions for the medical and pharmaceutical industries and research activities on the topic of sustainability.
Among others, the company is offering a demonstration of the KMD 78.2 Speed steel rule machine, illustrating how high-quality, sustainable packaging products are made from recycled film — making a contribution to tray-to-tray recycling. The company is also unveiling the new Kiefel Standard Automation (KSA), a completely modular standard automation solution based on a building block principle for the most common applications.
Kiefel will also demonstrate its successful natural fiber thermoforming technology at the stand. The installed base of the NATUREFORMER KFT 90 machine, which deploys this technology, is growing rapidly worldwide.
Lindner (Hall 9, Stand B17 & B19) is presenting a range of new, efficient all-in-one plastics recycling solutions, As the company points out, the key to recycling success lies in the perfect coordination of the upstream processes of shredding, washing and sorting.
Among others, Lindner is launching its upgraded Jupiter BW series for the first time. The shredder ensures a constant volume flow and homogeneous larger particles, reduces the proportion of fines generated by 50 percent, and thus optimizes the particle size for NIR sorting. Live outdoor demonstrations will be given at the VDMA Circular Economy Forum, where Lindner will show a shredding, washing and drying unit, equipped with a Micromat HP shredder and integrated water treatment, and it will be recycling plastics live several times a day. A definite highlight is the new system solution to directly process post-consumer flakes from rigid plastics in an injection molding process. These pass through Lindner's recycling machine and — without prior extrusion — directly enter the injection molding process.
Gneuss (Hall 9, Stand A22) is showing, among others, its new OMNI recycling machines for the closed-loop recycling of PET, polystyrene and polyolefin post-consumer reclaimed materials, including a complete OMNI recycling machine featuring a new 3C rotary feeder, an MRSjump 70 extruder, a fully automatic RSFgenius 90 melt filtration system and an online viscometer VIS, for the processing of 200 kg/h (450 lbs/h) of undried and uncrystallized polyester (PET) thermoform reclaim.
The new 3C Rotary Feeder makes it possible to use low bulk density materials without any external processing steps. A conveyor belt feeds shredded reclaim material into the hopper, where a fast-rotating disc with knives cuts, compacts and pre-conditions the material. The knives add energy into the material and start the heating and degassing process before the material is automatically fed into the MRSjump extruder.
Samples of polypropylene tubs for food applications made with 30 percent post-consumer PP and PS sheet made from 30 percent post-consumer PS, processed on Gneuss OMNI Recycling Machines with MRS extruders and RSFgenius filtration systems, will be on display.
In parallel, with Gneuss' headquarters only about 200 km from the show, a complete PET sheet extrusion line with an OMNImax Recycling Machine — consisting of an MRSjump 70, Gneuss' deep vacuum system and a fully automatic filtration system RSFgenius 75 — and a sheet downstream with a 500-mm-wide extrusion die will be running in Gneuss' technical center open to visitors.
On a joint stand (Hall 9, Stand C09, and the Erema Circonomic Center) of the Erema Group — consisting of Erema, Pure Loop, Umac, 3S, Keycycle and Plasmac — seven new technological innovations, recycling systems and components will be launched, including technological innovations in the plasticizing unit that have been specially developed for high throughputs with low specific energy consumption, the new Erema 406 laser filter with a 50 percent larger screening area and new digital assistance systems that will be made available on the BluPort customer platform.
Among the apps to be premiered are the PredictOn app, which helps to anticipate and eliminate imminent malfunctions through the continuous measurement and evaluation of machine data. In addition, the company is introducing Chemarema, a new series developed for the mechanical material processing, preparing input streams and ensuring a reliable, continuous and energy-efficient flow of feed material, that is also part of the chemical recycling process. Erema Group subsidiary UMAC is launching ReadyMac, a standardized, prefabricated recycling solution that can be produced from stock, based on proven Erema TVE technology.
Finally, in the in-house recycling segment, Pure Loop and Plasmac will round off the wide range of machines offered by the group of companies with their product portfolio.
At the Circonomic Center located outside on the fairground, Erema will show plastics recycling with live demonstrations in conjunction with cooperation partners. Different waste streams will be processed for this purpose, and applications for the recyclate will be showcased at the Products made of Recyclate exhibition at the center.
In Recycling Hall 9, Stand A02, Maag, whose systems play a key role in enabling a more circular economy for plastics, will be showing solutions for mechanical recycling. The company will showcase a range of equipment, from its Ettlinger ERF and ECO series melt filters, capable of handling contamination levels of up to 16 percent, high throughputs of up to 10,000 kg/h and filtration finenesses down to 60 microns; its updated PEARLO underwater pelletizer technology; AMN die plates for underwater pelletizers; and the new extrex recycling pump with more space between the teeth and flatter angles to allow impurities up to a size of 0.6 mm to pass through, making an upstream protective filter in most cases unnecessary. The company is also debuting its new ContiNeo backflush screen changer, combining the advantages of a piston screen changer with those of large-area filtration.
Hellweg Maschinenbau, a manufacturer of advanced granulation machinery, will present extended options around the Smart Control system for its entire granulator range (Hall 11, Stand C39). Also new: a servomotor-driven (enabling optimum control) digital central lubrication unit with Bluetooth data transmission retrofittable to all central granulators together with a new edge trimming system for use in extrusion.
Hellweg has added a hardware module to the Smart Control system table that stores the power consumption data, including power peaks, of the machine it is fitted to over the long term, providing valuable data for analysis and optimizing energy use. The SECURE+ package for the control system adds safety features. As soon as it detects imminent granulator overloads on the basis of motor current and torque values, it counteracts them so that rotor blockages can virtually be avoided.
Hellweg can now also optionally equip all central granulators from the 260 series upwards with a new central lubrication unit. Using a Bluetooth interface, the unit provides the operator with all relevant data, such as battery voltage, temperature, delivered lubricant volume as well as the time since the most recent pump stroke, operating time and number of pump strokes.
The new R 200/20 Servo edge trimming system, a joint development with Breyer Extrusion, complements Hellweg's range of systems of this type, also known as guillotines or chippers. When trimming film webs, it pre-shreds one or two edge strips, which are then fed to a granulator for further processing.
Maguire (Hall 10, Stand C41) is introducing a new gravimetric feeder line that can be configured in any optimal way to accommodate various processing requirements. The new feeder models allow for up to four different size auger feeders, all located on one mounting frame, using a single common touchscreen control.
In addition, the company is introducing a Volumetric Feeder (MVF) option. These new feeder models provide ultimate flexibility for injection molding, extrusion, blow molding and extrusion control applications.
Maguire is also debuting the newest member of the company's line of Weigh Scale Blenders: the new WSB-600 series blender for midrange throughput applications at the show, which precisely dispenses up to 12 materials of widely diverse types and can be configured to dose up to six major ingredients. With a throughput range up to 2,500 lbs/hr, it is suitable for injection, extrusion, blow molding and central blending applications.
At CMG Granulators (Hall 9, Stand C10), the company is showcasing its range of size reduction and recycling equipment solutions, including granulators, shredders, integral feed conveyors and much more. All CMG granulators feature the Adaptive Motor Power (AMP) function, enabling them to autonomously establish the power level needed for the job, while optimizing regrind quality and minimizing power consumption. The return on investment for the AMP is less than 12 months.
CMG provides technologies and solutions designed for the circular economy. Its portfolio features the Evoluzione series super granulators for post-consumer recycling — a solution for the most critical operating conditions, wet or dry granulation, with a granulation capacity from 2,000 to over 5,000 kg/h; high efficiency shredders such as the TRM1500 with patented blade design; and a newly designed granulator series for in-line scrap recycling, suitable for sheet, skeletal sheet and reject parts grinding, comprising four models, suitable for small to medium capacities, to cover applications ranging from 200 through to 1,000 kg/h.
Vecoplan AG (Hall 9, Stand B41; Circular Economy Forum) is highlighting the VAZ 1700, a shredder offering a throughput capacity of 2,000 to 25,000 kg/h and a modular design that creates a host of configuration options, enabling it to tackle a wide range of materials. In addition, the company will be launching another plastics processing step, regarding which no details have yet been disclosed. Visitors to both booths will experience this and more firsthand, with live broadcasts from the Technology Center in the Westerwald and live demonstrations twice a day at the VDMA Circular Economy Forum.
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