Machinery & Production

Machinery and equipment are not only at the heart of K, but also form a key part of K-Mag. Our articles offer fascinating insights into innovative production processes and the workings of pioneering machines that are taking efficiency and quality in the industry to new heights.

Nahaufnahme eines runden Metallgehäuses mit kupferfarbener, gezackter Innenstruktur vor unscharfem Zickzack-Hintergrund.

Results (51)

  • ENGEL St. Valentin wins production contest

    Copyright: ENGEL 19.01.2024 In the production contest organized by Fraunhofer Austria and the Industriemagazin, our large-tonnage machine plant in St. Valentin won the title of "Factory of the Year 2023" and was thus named the best production company in Austria. Together with the other ENGEL production sites, the plant forms a global and high-performance network for manufacturing at the cutting edge of technology. As part of the factory conference held in Bludenz (Vorarlberg) in autumn, ENGEL St. Valentin was awarded both the overall prize and the "Efficient Factory" category. "The winning work by ENGEL is characterised by very good or excellent results across all competition categories," said the jury. Key success factors were the consistent sustainability strategy and the pioneering role in the field of digitalization. Outstanding assembly principle In addition, the well-thought-out manufacturing process contributed to the award. "The right layouts and the right transport routes are of particular importance for our part weights of up to 150 tons. The implementation of this must be clean and coordinated," explains plant manager Martin Weger. One project that takes this approach into account was the expansion and redesign of the flow assembly. The assembly principle, in which the closing and clamping unites of the machine are initially manufactured and assembled separately from each other, is outstanding in the field of special machine construction. With the recently implemented optimizations, the plant's performance limit has been increased by 15 percent and throughput times have been reduced by 65 percent. Exhibitors & products around machinery & equipment Machinery and plant for processing Post processing machines & downstream equipment Machinery & plant for finishing, decorating, printing and marking Welding machines Process automation To all exhibitors in this category Efficiency thanks to Automation The jury saw the intelligent C-parts management as another highlight. This is the automated reordering of consumables, such as screws. The use of the automated guided vehicles for tool dispensing and the highly automated milling centers were also convincing. "Thanks to these measures, our specialists can take on more demanding and complex tasks," reports Martin Weger. In 2024, the competition will host its final in St. Valentin. Source ENGEL AUSTRIA GmbH More around Machinery & Plants

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  • Digital meets material: a software transforms additive manufacturing

    Interview with Lukas Pelzer, Research Associate at the Institute of Plastics Processing (IKV), RWTH Aachen University Exclusively for K-MAG Copyright: IKV/Fröls 17.08.2023 ADAM could redefine the rules of the game in plastics manufacturing. A big claim, but not without reason: Behind the acronym ADAM is a piece of software called "Advanced Dimension Additive Manufacturing," which attracted not only curiosity but real attention at K 2022. The impressive result of this software in action? A powerful screw extruder controlled by an agile jointed-arm robot. In this interview with K-MAG, Lukas Pelzer, one of the brains behind the technology, delves deeper into the world of ADAM. He explains how this software is revolutionizing the production of plastic components and why it could be a milestone for sustainable and innovative manufacturing methods. A look into the future landscape of the plastics industry, which ADAM could significantly shape. Lukas Pelzer. Copyright: IKV What is ADAM? How can we picture the production method of ADAM? Lukas Pelzer: ADAM is a software solution for the optimal calculation of webs for material-extruding additive manufacturing. Instead of the conventional layered construction method, ADAM enables three-dimensional, non-planar deposition of individual strands and layers that precisely follows the contours of the component. This results in higher-quality surfaces without visible steps. ADAM also addresses the challenge of anisotropic component properties: Specific strand alignment along load paths can increase strength and stiffness and create isotropic components when needed, especially when using fiber-filled plastics. The process also allows customization of existing parts by printing directly onto their surfaces, combining the benefits of mass production with the freedom of additive manufacturing. Best of all, ADAM is suitable for a wide range of machines, from simple 3D printers to industrial equipment. What types of plastic can be processed with ADAM? Pelzer: The ADAM software is not limited to a specific type of plastic. It was developed to support additive manufacturing using screw extrusion – a process that has been under research at the Institute of Plastics Processing at RWTH Aachen University since 2015. With our specially developed screw extruders, we can process a wide range of thermoplastics in pellet form. These include common materials such as polylactide (PLA) and acrylonitrile butadiene styrene (ABS), but also polyamide (PA), polypropylene (PP) and thermoplastic elastomers (TPE) with low Shore hardness. Even polymers with high filler content, such as 30 wt% carbon or 50 wt% long glass fibers, can be processed. Our latest screw extruder version, weighing less than 10 kg and with a discharge of up to 4 kg/h, is particularly suitable for jointed-arm robots. Due to their rotational axes, these offer additional degrees of freedom, which are optimally utilized by the ADAM process. ADAM can be used, for example, to produce stools from wood-fiber-filled biopolymer. Such a fully biodegradable stool can be produced in just two hours. Copyright: IKV For a long time, the technology was only used to create prototypes: What steps did you have to take so that final components can now also be produced? Pelzer: Three aspects are crucial for the successful production of final components: optimal surface quality with minimal post-processing good mechanical component properties such as strength and stiffness short production times The combination of an articulated-arm robot with a screw extruder specially designed for additive manufacturing enables significantly faster manufacturing processes than with filament-based systems. By creating a deposition strategy suitable for the component using the ADAM process, the required high surface quality can be achieved. At the same time, strength and stiffness are matched to the load case that occurs. Exhibitors & products around digitalisation CAD systems Simulation software Quality assurance software (SPC/SQC) Maintenance software Equipment & software for manufacturing execution system (MES) What are the advantages of 3D printing like ADAM's over the conventional production of plastic components? Pelzer: Above all, it is always important to choose the right manufacturing process for the application at hand. Additive manufacturing or 3D printing is becoming more and more common due to the rapid development of the technology and is already being used successfully for small to medium-sized production runs. Advantages of the technology include: Flexibility: 3D printing allows the production of virtually any geometry, including complex internal structures, without special setups. Agility: companies can respond quickly to market changes because additive processes do not require part-specific tooling. Product adaptations or revisions can be implemented directly and without additional costs. Efficiency: 3D printing minimizes production waste because material is deposited only where it is needed. The ability to produce complex parts in one step and the suitability for decentralized manufacturing reduce storage requirements and transportation, resulting in time and emissions savings. How do you see the future of ADAM: How do you think companies will use the technology? Pelzer: The future of ADAM lies in further unlocking the potential of additive manufacturing. We are convinced that software like ADAM will unleash the full potential of both small desktop systems and industrial robotic systems. Therefore, we are launching the spin-off of the institute "Layer Performance", which specializes in software development for path planning and control of additive manufacturing systems. Current inquiries range from prototype production to series production. ADAM attracted many visitors at K 2022. Copyright: IKV/Fröls With ADAM, you were present at K 2022 – What could visitors see at your booth? Pelzer: During K 2022, we presented our latest manufacturing cell. It combines our advanced screw extruder with an articulated arm robot from Stäubli and a heatable build platform. The highlight was a stool made of wood fiber-filled biopolymer manufactured using the ADAM process, which visitors were able to test on site. This stood out due to its load-compatible design, material-efficient and fast production (2 hours) and sustainability (fully biodegradable). What feedback did you receive at the trade show? Pelzer: The feedback during and after the trade show was consistently positive. The ADAM technology and its advantages, especially the utilization of the spatial degrees of freedom, were met with particular interest by the booth guests and opened up many in-depth discussions. Personally, I always find it particularly exciting to hear about the visitors' special use cases. Often, new areas of application for the technologies on display emerge in such discussions that go beyond the use cases envisioned during development. Nastassja Lotz (Editorial team K-MAG) More around Additive Manufacturing

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  • From the 3D printer to the dishwasher: researchers develop biodegradable support material

    Interview with Lars Schmohl and Frederik Gutbrod, Research Associates, Institute of Polymer Technology, University of Stuttgart Copyright: leungchopan 27.09.2023 In the world of additive manufacturing, innovations are constantly revolutionising the possibilities. Despite the progress, there is one major challenge: the need for support structures. They prevent material layers from sagging – but removing them after printing can have environmentally damaging consequences. In the AquaLoes project, the Institute for Polymer Technology at the University of Stuttgart is tackling this challenge. Lars Schmohl. Copyright: IKT In an interview with K-MAG, Lars Schmohl and Frederik Gutbrod talk about the newly developed water-soluble and fully biodegradable support material, the process of their research and what a dishwasher has to do with it all. You have developed a support material for 3D printing. What inspired you to do this and what is special about it? Lars Schmohl and Frederik Gutbrod: Additive manufacturing enjoys great popularity in industry and home applications due to its almost infinite freedom in design possibilities and simple production of components. In the strand delivery process, also known as fused filament fabrication (FFF), support structures are required when printing complex structures (undercuts and overhangs, etc.) so that subsequent material layers are secured against sagging. Since these support structures have to be removed again after printing, the use of soluble materials has now become established for this purpose. By dissolving them with an appropriate solvent, e.g. water, after printing, a high-quality surface finish of the 3D component can be achieved. Of course, the material of the component does not correspond to the material of the support structures. However, these support structures dissolved in water then often end up as individual dissolved polymer chains in the waste water and thus inevitably in the environment. Therefore, our goal was to develop a plastic that is both water-soluble and completely biodegradable in water. Frederik Gutbrod; Copyright: IKT What is the composition of the material? What was the development process and the challenges in selecting the appropriate compound? Schmohl and Gutbrod: The support structure material is currently made up of a mixture of three components. A polyhydroxybutyrate-co-valerate (PHBV) was used as the base polymer. PHBV is a bio-based polymer and is also fully biodegradable in environments with low bacterial activity such as seawater. Due to its low elongation capacity, a short-chain polyethylene glycol (PEG) was additionally compounded in as a plasticiser, which can also be biodegraded. In order to achieve a rapid release of the support structure from the component, a very fine table salt was also used. More than 30 different formulations were developed for the pressure and dissolution tests. The aim was to achieve a high salt content in order to achieve the fastest possible dissolution process. However, with the increase in salt content, the stretchability and thus the processability of the filament also suffers. So it was always necessary to weigh up these two points in order to achieve a suitable mixture. Furthermore, strong crystallisation occurs with the base polymer PHBV, which can lead to warping of the component even during printing. Finished print with support structures. Copyright: IKT Surface of the component after the dissolving process. Copyright: IKT What is the detachment process like for the developed material? What options have you tested here? Schmohl and Gutbrod: The detachment process is somewhat different from other conventional water-soluble support structures (such as PVA). In our case, the entire support structure material does not dissolve, but only the salt, which fragments the support structures in a first step. When the 3D-printed component is removed from the water bath, any remaining residue can be removed without leaving any residue by light mechanical action. Filament roll. Copyright: IKT The removal process for the developed material takes longer than for conventional materials. How do you plan to tackle this challenge in the future? Schmohl and Gutbrod: In our tests, the printed component was placed in demineralised water in each case. As expected, with an increase in temperature, the time after which the support structures could be removed without residue dropped from 24 to 4 hours. The use of a commercially available dishwasher was also successfully tested. To close this gap, one approach would be to test higher dissolving temperatures depending on the material pairings (component material to support structure material) or the use of a type of washing line. Furthermore, it could be possible that a higher elongation capacity of the compound allows a higher salt content and thus a faster dissolving process. The support structures consist of 40 % PHBV, 10 % PEG and 50 % ultrafine table salt. Copyright: IKT The issue of microplastics plays a major role when it comes to the contact of plastics with water. How do you solve this problem in your development? Schmohl and Gutbrod: This issue also plays a major role for us in this project. The components were chosen in such a way that there is no permanent entry of microplastics into the environment. The PHBV and the PEG are completely biodegradable even in seawater. You are currently looking for industrial partners. What do you hope to gain from such a partnership and what kind of companies or experts are you looking for? Schmohl and Gutbrod: We would like to develop the material mixture, which is not yet ready for the market, into a product suitable for industrial use. Here, companies from the most diverse directions can contribute to the commercialisation of the product. Both material suppliers and filament manufacturers might be interested in working with us. You have applied for a patent for the 3D printing support material. What are the next steps to bring this product to market? Schmohl and Gutbrod: The next important steps will deal with increasing the stretchability and scaling up the support structure production, both in terms of other 3D printing processes and in terms of the achievable component size. These issues will be crucial for a market launch. Elena Blume (Editorial team K-MAG) More around Additive Manufacturing

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  • Breaking boundaries: Delivering gigantic injection molding machines across continents

    Interview with Anders Nybäck, Sales Director Technical Moulding, ENGEL AUSTRIA Exclusively for K-MAG Copyright: ENGEL 03.07.2023 8000 tons in weight, a good 30 meters long – how do you manage to ship such a gigantic injection moulding machine across the big pond? In an industry where logistics and size present special challenges, ENGEL has managed to master them with expertise and a cooperative approach. Anders Nybäck. Copyright: ENGEL In an interview with K-MAG, Anders Nybäck, an expert from ENGEL, sheds light on the successful delivery of two massive 8,000-ton injection molding machines from Austria to the United States. What is the significance of these machines, and how is the future outlook for injection molding machines with such high clamping forces? Mr. Nybäck, ENGEL recently delivered two 8,000-ton injection moulding machines to the USA. How did that happen exactly? And how long did it take from order to handover? Anders Nybäck: ENGEL received the order in November 2020 and the first machine could already be handed over in February 2022. Now, one year later, a second identical machine has been delivered. What must be considered when supplying machines of this size? Nybäck: Logistics is a special challenge. Before delivery, each machine is completely assembled and tested at the ENGEL plant. Such large machines then have to be disassembled again for transport. The weight of the individual components plays a major role in logistics planning. The mould fixing platens for these two 8000-ton machines, for example, were transported on barges on the Danube. Special transporters were used for some of the machine components – here, for example, for a 117-ton fixed clamping platen. Copyright: ENGEL What challenges did you face and how did you overcome them? Nybäck: From the initial idea to completion, the project was a close team effort across company boundaries. Our long collaboration with Infiltrator, mutual trust, and not least the fact that everyone knows what is important to the other were key success factors here. This is the only way to deal with the risks that naturally come with the size of the machines, the degree of innovation and the immense investment volume. We are thrilled to see what we have achieved here together. When we develop solutions together with our customers, we do everything we can to make them even more successful with innovative and forward-looking concepts. What makes injection molding machines with such high clamping forces necessary? Nybäck: Injection molding enables particularly resource-efficient processing of plastics and also a high degree of process integration and automation. As a result, more and more very large components are being produced by injection molding for which other processes were previously used or which were previously assembled from several individual components - for example, large containers and underground tanks, but also more and more large-area vehicle components such as structural components and lightweight body components or glazing. We see a lot of potential in the automotive sector in particular. Hyundai-Kia in Korea, for example, recently took delivery of a particularly large injection molding machine from us. This picture shows the mold room alone. This already suggests the length of the entire machine which amounts to 29.3 meters. Copyright: ENGEL Why did Infiltrator approach ENGEL specifically with its request? What makes your machines special? Nybäck: ENGEL has a great deal of experience and expertise in building large-scale machines and also a global production network, which simplifies logistics, shortens time-to-market and makes the overall project more cost-effective. ENGEL already has a long business relationship with Infiltrator. This was the deciding factor in this particular case. All previous projects for Infiltrator were completed by ENGEL on time, and costs were not exceeded either. Therefore, Infiltrator also placed the necessary trust in us for this particularly challenging project. To what extent does ENGEL contribute to sustainability with these injection molding machines (e.g. in this specific case)? Nybäck: The large machines make it possible to produce components that previously consisted of several individual parts and had to be assembled in a single process step and in one piece. This saves process steps and thus a lot of energy and raw material. Infiltrator also says that with the new machines they can manufacture the products even more cost-effectively and efficiently. Sustainability played a major role in the overall project. Infiltrator produces innovative water management products that have a high percentage of recycling. The company recycles more plastic than any other in North America. How will the demand for injection molding machines with such high clamping forces develop in the future and how is ENGEL preparing for these developments? Nybäck: We see an increasing need and an increasing demand. However, it is important to realize that injection moulding machines with clamping forces of over 5500 tons are a niche market and will remain that way. However, this niche is very interesting for ENGEL because we are one of the injection moulding machine manufacturers with the greatest experience and competence in the field of large machines. Not to forget: With our worldwide production network, we have the capacity to efficiently build and deliver such machines. Exhibitors & products around machinery & equipment Machinery and plant for processing Post processing machines & downstream equipment Machinery & plant for finishing, decorating, printing and marking Welding machines Process automation To all exhibitors in this category Nastassja Lotz (Editorial team K-MAG) More around Machinery & Plants

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  • The VR glove from the 3D printer

    Source: Rimidolove 26.12.2022 Together with EPFL and ETH Zurich colleagues, an Empa team is developing next-generation VR gloves that will make virtual worlds tangible. The glove is to be tailored to each user and capable of being produced largely automatically – using a 3D printing process. 3D Printing with Two Colors in Two Stages The next-generation VR glove will make virtual worlds tangible. Source: Herbert Shea, EPFL Research sometimes needs a sacrifice. Empa researcher Patrick Danner has just made one – and filmed it. "When I applied a good 2000 volts to the sample, it caught fire," he reports drily in the debriefing. The mishap is clearly visible in his cell phone video: First it smokes, then flames erupt from the experimentally created polymer. "Hopefully, you were still able to save a piece of it," counters Dorina Opris, head of the "Functional Polymeric Materials" research group. A piece of evidence is important to learn from the result and draw conclusions. With their research on electroactive polymers, Dorina Opris and Patrick Danner are part of a large-scale project called "Manufhaptics". The goal of the four-year project, led by Herbert Shea of the Soft Transducers Lab at EPFL, is a glove that makes virtual worlds tangible. Crucially, all of the glove's components, which exert various forces on the surface of the hand, are to be producible in a 3D printer. So this is about research into new materials, with the production method being considered from the very start. Exhibitors & products around digitalisation CAD systems Simulation software Quality assurance software (SPC/SQC) Maintenance software Equipment & software for manufacturing execution system (MES) Three types of actuators The desired electroactive polymer should have a consistency similar to hand cream so that the artificial muscles can be produced automatically in a 3D printer. Source: Empa To make virtual surfaces feel real and objects tangible at the right size, the research teams from EPFL, ETH Zurich and Empa want to integrate three different types of actuators into the glove: Underneath the fingers, nubs can grow up to replicate a specific texture of a surface. In the area of the finger joints, electrostatic brakes are mounted that stiffen the glove and block the joints. This simulates larger, solid objects that offer resistance when touched. The third type of actuators that complete the virtual experience are called DEA's (Dielectric Elastomer Actuator). These DEA's are used on the back of the hand; they tighten the outer skin of the glove so that it fits perfectly at all points. During the VR experience, they can also apply pressure to the surface of the hand. The DEA's are Empa's topic. Artificial "muscles" from the 3D printer Source: Herbert Shea, EPFL Dorina Opris, the head of the research group, has years of experience with such electroactive polymers. "They react to electric fields and contract like a muscle," the researcher explains. "But they can also serve as a sensor, absorbing an external force and generating an electrical pulse from it. We're also thinking of using them to harvest energy locally: From movement, electricity can thus be generated anywhere." The Manufhaptics project presents new challenges for Opris and her colleague Patrick Danner. "Until now, we have produced our polymers using solvents through a chemical synthesis," explains Opris. Now everything has to work without solvents: The plan is to superimpose up to 1000 fine layers from the 3D printer, always alternating between the electroactive polymer and a current-conducting layer. "Solvent has to be avoided in such a process" says Opris. Patrick Danner explains the next difficulty: The two inks needed for making the layers must have the exact right consistency to flow out of the 3D printer's nozzle. "Our project partner Jan Vermant from ETH Zurich wants something with similar properties to a hand cream. It should come out of the printer easily and then remain dimensionally stable on the base." And after that, this "creamy" layered structure still needs to crosslink into the appropriate polymer. After a long series of tests, Patrick Danner found a promising formulation – a cream that is liquid enough and at the same time dimensionally stable, and from which electroactive polymers can be created in a single step. His colleague Tazio Pleji at ETH Zurich, a member of Jan Vermont's team, has successfully processed the material in his 3D printer into several layers – always alternating between polymer and electrode material. There are not yet 1,000 layers, but only about 10, and the artificial muscle from the 3D printer does not yet function satisfactorily. The competition is at Harvard But Opris and Danner are confident of mastering the task together with the printing specialists at ETH Zurich – possibly as the first team in the world. The only scientific competitors in this field are based at the renowned Harvard University in Massachusetts. "I know the colleagues there from some congresses," says Dorina Opris. "We watch very closely what they are upt to. And they're certainly watching our work, too." Quelle Empa Mehr Science News

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  • 25 years technology centre at Brückner – expansion in sight

    Copyright: Brückner Maschinenbau GmbH 06.11.2023 25 years ago in autumn, on the occasion of the leading international plastics trade fair "K 1998", Brückner Maschinenbau inaugurated a technology centre at the Siegsdorf site. It was to house the laboratory equipment already in use as well as a completely new type of pilot line on which films could be stretched simultaneously for the first time with the aid of linear motors. The aim of the technology centre was and is to research and further develop film stretching technologies as a prerequisite for innovative film applications, for example in food packaging as well as in solar modules, capacitors, flexible screens or membranes for lithium-ion batteries. The globally unique facility soon developed into a meeting place for raw material manufacturers, converters, film producers and even brand manufacturers, who can rent the technology centre for their test projects. For Brückner, this was an important milestone on the way to becoming the world market leader. Michael Baumeister, Managing Director CTO: "By bundling development and synchronising the various company divisions, we were able to identify technological trends as well as market opportunities at an early stage and often place our technologies as trendsetters in the global market." The equipment of the technology centre, which has been constantly expanded and modernised over the years, with a pilot plant, laboratory extrusion, laboratory stretching frames as well as a chemistry and film laboratory, enables almost all types of film stretching and the processing of a variety of polymers and biopolymers. All known stretching methods can be used: monoaxial in machine direction (MD) or transverse direction (TD), biaxial sequential or biaxial simultaneous. In this way, raw materials can be tested for their stretchability, new film concepts developed, small series produced for sampling and entire production models run through. The films produced can be immediately tested in the film and chemistry laboratory – for prompt feedback on sample production. Expansion of the technology centre at the site planned Changing framework conditions and ever new areas of application place high demands on the entire film industry. The legally required use of recycled materials and bio plastics, films for energy production and storage, or membrane technologies for water treatment are just a few examples. Brückner Maschinenbau intends to meet these challenges with a significant expansion of its technology centre. The most important innovation besides the modern infrastructure is an additional pilot plant to increase the availability of testing capacities and to reduce waiting times for customers quite significantly. Senior Manager New Business Development Markus Wolfertstetter: "For some of the biggest challenges facing our industry, this expansion of the pilot plant will be of utmost importance. I am thinking, for example, of the linking of new film types with the requirements of digitalisation in the service of the circular economy or CO2-neutral and waste-free film production. Research and development will also become even more important for technical film applications – we are ideally equipped for the future with this expansion." All the necessary steps for the expansion are to be completed by mid-2026. Exhibitors & products around machinery & equipment Machinery and plant for processing Post processing machines & downstream equipment Machinery & plant for finishing, decorating, printing and marking Welding machines Process automation To all exhibitors in this category Some customer voices "It is always a great pleasure working with the full Brückner team in the technology center. We have had a strong collaboration for several years now and the high-quality, professional support, excellent pilot facilities and in-depth technical discussions have been key in advancing our developments in BOPE. We've come a long way from the initial trials we ran together and now it is great to see how this work is being implemented on the new, industrial lines." Martin Hill, Packaging and Specialty Plastics Technical Service and Development, Dow Chemical Ibérica S.L. "It's been our privilege to collaborate with the team at the Brückner Technology Center on many projects over the last 25 years. The team's technical knowledge, experience and creativity have been invaluable inputs on every experiment run, and the efficiency of the lab has made working there a joy. We want to thank you all for your skills, cooperation, professional approach and for your hospitality. Congratulations on 25 years of excellence at Brückner Technology Center and our best wishes for the future." Tom & Cagla DeAngelo, owners Thomas Frank Associates, LLC "Finally, the success of developing HDPE material for BOPE film has been proven at Bruckner's facility. We would like to express our gratitude to Bruckner for their excellent collaboration and for providing their world-class lab facilities here. Congratulation again to your 25 years old anniversary." Kanyanut Narkchamnan, LDPE Research & Development Leader, Thai Polyethylene Co., Ltd. "I would also like to thank you again on behalf of our team for the two very interesting days. The fact that everything went relatively smoothly is certainly thanks to your very well-rehearsed team. I am already looking forward to the next time." Christoph Michel, Research and Development, Taghleef Industries. "Thanks a lot for the complete and detailed trial data. Again, I would like to thank you and the Brückner team for the great support and hospitality provided during these demanding trials." Carlos Rodríguez Giraldo Research and Development Eng., Taghleef Industries. Source Brückner Maschinenbau GmbH More around Machinery & Plants

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  • Oerlikon Polymer Processing Solutions: Sustainable Technologies for Central Asia's Textile Industry

    Innovative machinery solutions supporting energy efficiency and quality in the Uzbek textile market. Caption 2: The WINGS family from Oerlikon Barmag covers almost every process; standard, high-titer or micro yarns, polyester or polyamide, POY or HOY, 10-, 12-, 20- or even 24-thread; Copyright: Oerlikon 16.09.2024 Oerlikon Polymer Processing Solutions is driving sustainable innovations for the growing textile industry in Central Asia. From polycondensation plants to textured yarns, the company offers complete machinery solutions tailored to meet the evolving needs of the Uzbek market. With a focus on energy efficiency and high yarn quality, Oerlikon is set to make a significant impact in the region. Sustainable Textile Solutions for Uzbekistan The revolutionary Oerlikon Neumag EvoSteam staple fiber process is bluesign® verified; Copyright: Oerlikon As Uzbekistan’s textile industry continues to shift from traditional cotton production to synthetic fibers, Oerlikon Polymer Processing Solutions presents a comprehensive portfolio of machinery designed to meet this demand. The company offers complete solutions for polycondensation plants, yarn production, and processing, ensuring a harmonised technology that guarantees high yarn quality. André Wissenberg, Head of Marketing, Corporate Communications and Public Affairs at Oerlikon, comments: "The Uzbek market continues to develop well. The country has been known for decades for very good products in the cotton sector. However, market players are increasingly recognising the advantages and necessity of synthetically produced yarns and fibres." With this transition in mind, Oerlikon is committed to providing solutions that not only meet industrial needs but also contribute to sustainability by improving energy efficiency. POY and FDY Yarn Production: Efficiency and Quality Oerlikon Barmag’s WINGS technology for partially oriented yarn (POY) is a cornerstone of the company’s offering. POY yarn is essential for a range of applications, including fashion, sports, and home textiles. WINGS ensures high yarn quality and productivity with improved energy efficiency. Its unique design reduces yarn deflection, resulting in better yarn tension, evenness, and dyeability. Fully drawn yarn (FDY), processed using Oerlikon Barmag's technology, offers smooth and high-quality surfaces for textiles, used in products requiring smooth gliding properties, such as clothing and upholstery. Exhibitors & products around machinery & equipment Machinery and plant for processing Post processing machines & downstream equipment Machinery & plant for finishing, decorating, printing and marking Welding machines Process automation To all exhibitors in this category DTY Yarns: Flexible Applications for Various Industries For texturized yarn (DTY), Oerlikon offers machines that cater to various industries, from clothing and home textiles to automotive applications. The modular machine designs allow for the efficient and sustainable production of yarns from materials such as polyester, polyamide, and PLA. These machines ensure maximum flexibility, with configurations that meet different industrial requirements. Sustainability at the Core: EvoSteam and BICO BCF Yarn Oerlikon’s EvoSteam process sets a new benchmark for staple fiber production, offering significant savings in energy, water, and raw material consumption. By minimising operational costs (OPEX) and reducing CO2 emissions, EvoSteam supports resource-efficient fiber production. In carpet manufacturing, Oerlikon Neumag’s new bicomponent (BICO) BCF yarn technology enables richer and higher-volume yarns while significantly lowering raw material consumption. This advancement aligns with market demands for sustainable carpet production. The new BICO BCF yarn is characterised by a richer and higher volume while at the same time significantly reducing the consumption of raw materials in carpet production,’ explains Oerlikon Neumag BCF Sales Director for Uzbekistan Arnd Luppold. Oerlikon Polymer Processing Solutions continues to push the boundaries of sustainability and innovation in the textile industry. From efficient POY and FDY production to cutting-edge DTY and BCF yarn technologies, the company provides Uzbekistan’s textile industry with the tools it needs to meet modern demands. Oerlikon’s long-standing commitment to sustainability, showcased by its e-save label, is driving change in an industry where energy efficiency and reduced environmental impact are essential. Source Oerlikon More around Machinery & Plants

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  • World's First Electrically Heated Steam Cracking Furnace

    BASF, SABIC, and Linde Inaugurated New Demonstration Plant That Aims to Cut CO2 Emissions by 90% BASF, SABIC, and Linde celebrate the start-up of the world's first large-scale electrically heated steam cracking furnace. Copyright: BASF 27.05.2024 Updated on 17.02.2025: We have revised this article to include the latest developments and provide the most up-to-date information. BASF , SABIC , and Linde have inaugurated the world's first large-scale electrically heated steam cracking furnace at BASF's Verbund site in Ludwigshafen, Germany. This demonstration plant, which consumes 6 megawatts of renewable electrical energy, is designed to test the technology's potential to reduce carbon dioxide emissions by at least 90% compared to conventional steam crackers. Electrically Heated Steam Cracking: A Breakthrough in Chemical Production Steam cracking plays a crucial role in the chemical industry, involving the breakdown of hydrocarbons into basic chemicals like olefins and aromatics. Traditionally, this process uses significant energy, with temperatures reaching about 850 degrees Celsius. The new technology allows these temperatures to be achieved using renewable energy sources, marking a significant step towards reducing the chemical industry's carbon footprint. "With the development of electrically operated steam cracking furnace s, we are getting our hands on a key technology that will help to significantly reduce greenhouse gas emissions in the chemical industry," said Dr. Martin Brudermüller, Chairman of the Board of Executive Directors of BASF SE. Dual-Furnace Design: Direct and Indirect Heating The demonstration plant features two separate furnaces, each with a different heating concept. The first uses direct heating, applying electric current directly to the cracking coils, while the second employs indirect heating, with radiative heat from elements surrounding the coils. Together, these furnaces process around 4 tons of hydrocarbon feedstock per hour, indicating the scalability of this technology for industrial use. Exhibitors & products around machinery & equipment Machinery and plant for processing Post processing machines & downstream equipment Machinery & plant for finishing, decorating, printing and marking Welding machines Process automation To all exhibitors in this category Sustainability Innovation: Significant Government Support for Decarbonization The project has received €14.8 million in funding from the German Federal Ministry for Economic Affairs and Climate Action under its "Decarbonization in Industry" program, which supports energy-intensive industries in their efforts to achieve carbon neutrality. "It is our common goal to demonstrate that it is possible to electrify the petrochemical industry and to operate a steam cracker with sustainably generated electricity," said Jürgen Nowicki, CEO of Linde Engineering. "This outstanding joint project is a significant proof of how together we can develop ground-breaking technologies that will advance us on the journey towards net-zero CO 2 emissions and climate-neutral industry." Collaborative Effort and Future Commercialization The demonstration plant results from a joint agreement signed in March 2021 between BASF, SABIC, and Linde to develop and test solutions for electrically heated steam cracking furnaces. Linde was responsible for the plant's engineering, procurement, and construction, while BASF operates it. In the future, Linde plans to commercialize the developed technologies under the new trademark STARBRIDGE™, offering the petrochemical industry a path to decarbonization. "The e-furnace's technology holds huge potential for the sustainability of the global petrochemical industry," stated Abdulrahman Al-Fageeh, CEO of SABIC. CO2 Footprint: Toward a More Sustainable Chemical Industry The newly launched electrically heated steam cracking furnace aims to revolutionize the chemical industry by offering a sustainable solution that could reduce CO 2 emissions by up to 90%. The collaborative effort between BASF, SABIC, and Linde demonstrates the potential of renewable energy in petrochemical production and sets the stage for a more sustainable future. More about the green engine of the industry here Source BASF More around Machinery & Plants

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  • Samsara Eco and NILIT to Establish Nylon 6,6 Recycling Facility

    New recycling plant aims to close the loop on nylon 6,6, offering sustainable solutions for textile waste The new plant in Southeast Asia for recycling nylon 6,6 textiles is scheduled to go into operation in 2026. Copyright: Samsara Eco / Nilit 14.10.2024 Samsara Eco, a leader in environmental technology, and NILIT, the world’s top producer of nylon 6,6 for apparel, have announced plans to build a cutting-edge facility in South East Asia to recycle nylon 6,6 textiles. The plant, expected to be operational by late 2026, will enable circularity in the textile industry, offering high-quality recycled polymers for brand use. Textile-to-Textile Recycling: Closing the Loop on Nylon 6,6 Nylon 6,6 is one of the most widely used fibers in the apparel and fashion industry, with approximately 4 million tonnes produced each year. Despite its popularity in performance wear, its recycling has proven difficult—especially when blended with other fibers like spandex. The collaboration between Samsara Eco and NILIT targets this challenge, with the aim of establishing a unique recycling pathway for nylon 6,6 textiles. A New Recycling Facility to Tackle Textile Waste The new facility, scheduled for completion by late 2026, will be capable of recycling textile waste into high-quality nylon 6,6 polymers. This recycled polymer can be integrated seamlessly into supply chains, allowing manufacturers and brands to create new textile fabrics sustainably. According to Paul Riley, CEO and Founder of Samsara Eco, the company's vision is to “deliver climate repair through infinite recycling,” with a focus on creating circular pathways for materials like nylon 6,6. “Discarded clothing made from nylon 6,6, such as activewear, and even products like car interiors, typically end up in landfill or are incinerated at the end of life, which has dire consequences for our planet,” said Riley. Exhibitors & products around machinery & equipment Machinery and plant for processing Post processing machines & downstream equipment Machinery & plant for finishing, decorating, printing and marking Welding machines Process automation To all exhibitors in this category Advancing Circularity and Reducing Waste Sarah Cook, Chief Commercial and Operations Officer of Samsara Eco, highlights the impact of the partnership in achieving textile circularity: “By working with NILIT, we can reverse this trend and give apparel a new life. The MoU agreement is an important step to help brands and the world advance nylon 6,6 circularity and reduce plastic waste.” The collaboration between Samsara Eco and NILIT sets a global precedent for textile-to-textile recycling and is a significant move towards reducing the 92 million tonnes of textile waste that currently end up in landfills annually. The partnership aims to provide the apparel market with premium nylon 6,6 products while lowering environmental impact. “Together, NILIT and Samsara Eco have the potential to produce infinitely recycled nylon 6,6 that delivers outstanding fabric quality and performance while benefitting the planet,” explained Ilan Melamed, NILIT General Manager. EosEco™: Innovative Technology for Infinite Recycling Central to this initiative is EosEco™, the world’s first technology for infinitely recycling nylon 6,6. This technology combines biophysics, chemistry, biology, and computer science (such as AI) to create a family of plastic-eating enzymes. These enzymes break down textile waste made from nylon 6,6 into raw materials that can be reintegrated into manufacturing processes. EosEco™ can process various inputs, including colored and blended textiles like nylon 6,6 mixed with spandex. By working in conjunction with NILIT’s advanced polymerization, spinning, and production technologies, EosEco™ will facilitate the creation of premium-quality recycled nylon 6,6 yarn for global consumption. Source NILIT Samsara Eco More around Machinery & Production

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  • All-Electric Injection Molding: Enhancing Efficiency in Packaging Production

    Heinrich Axmann GmbH Adopts WITTMANN's EcoPower Xpress for Sustainable Solutions The integration of the control system of the injection moulding machine and the robot facilitates the operation of the production cell. Copyright: WITTMANN 08.04.2024 Heinrich Axmann GmbH & Co. KG in Cologne, Germany, has made a significant shift towards sustainability by adopting an all-electric injection molding machine, the EcoPower Xpress, provided by WITTMANN. This move has led to a reduction in energy consumption by over 30% for producing thin-walled packaging, marking a significant step towards eco-friendly production methods. A Leap Towards Energy Efficiency The switch to an all-electric injection molding machine signifies Heinrich Axmann's commitment to reducing energy consumption and enhancing efficiency in the production of sophisticated thin-walled packaging. Compared to hybrid models, the EcoPower Xpress offers substantial energy savings, highlighting the potential for sustainable practices within the industry. Axmann developed a plastic tray that can be opened using a tear-open mechanism at the bottom of the packaging. The edge of the packaging folds back up, the food glides gently onto the plate and looks just as appetising as when freshly prepared and filled into the packaging tray. Copyright: WITTMANN Innovative Packaging Solution Heiner Axmann, CEO of Heinrich Axmann GmbH & Co. KG, has developed a plastic bowl with a unique tear-open mechanism that addresses the common challenge of transferring ready-made meals to a plate without spoiling their appearance. This innovative solution not only improves consumer convenience but also adheres to the highest standards of hygiene, especially beneficial for institutions without their kitchens. Established in 1932, Heinrich Axmann specializes in plastic packaging solutions. The company's vast experience has led to continuous innovation, including the development of the new ready-to-eat food bowl, a product that promises to secure a significant order from the USA. This development underscores the importance of creative solutions in addressing modern packaging challenges. Exhibitors & products around machinery & equipment Machinery and plant for processing Post processing machines & downstream equipment Machinery & plant for finishing, decorating, printing and marking Welding machines Process automation To all exhibitors in this category The high degree of stability shortens the removal time even with extremely fast robot movements. Copyright: WITTMANN Advanced Injection Molding Technology The EcoPower Xpress represents a significant advancement in injection molding technology for Heinrich Axmann. This all-electric machine is capable of handling the stringent requirements of manufacturing thin-walled packaging with varying wall thicknesses. The inclusion of a Sonic high-speed robot further optimizes the production process, ensuring high-speed, reliable movements critical for achieving short cycle times. The trend towards thinner, more material-efficient products is driving the demand for advanced manufacturing technologies. The all-electric drive of the EcoPower Xpress aligns with Heinrich Axmann's sustainability goals, offering a compelling example of how technological innovation can contribute to more energy-efficient and cost-effective production methods. Embracing Renewable Energy Solutions With the new EcoPower Xpress, Heinrich Axmann is entering the all-electric injection molding age. Copyright: WITTMANN In its pursuit of sustainability, Heinrich Axmann has also invested in renewable energy solutions, including extending its photovoltaic system. CEO Heiner Axmann reflects on the company's direction: "Energy efficiency is now the most important criterion whenever we invest in new machines and technologies." Discussions with WITTMANN about adopting DC technology with a battery storage system further demonstrate the company's dedication to minimizing energy consumption across all operations. Source WITTMANN More around Machinery & Plants

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  • Masterbatch Development with New Stretching Machine

    LyondellBasell integrates KARO® 5.0 from Brückner Maschinenbau to boost R&D Capabilities LyondellBasell invests in cutting-edge technology from Brückner Maschinenbau for masterbatch innovation. Copyright: LyondellBasell 26.04.2024 LyondellBasell, a prominent player in the chemical industry, has recently integrated the state-of-the-art KARO® 5.0 laboratory stretching machine from Brückner Maschinenbau into its research and development facilities at the LYB Technical Center in Akron, Ohio. This strategic enhancement is set to significantly advance the company's ability to develop and test masterbatch solutions tailored for various oriented film applications. Advancing Masterbatch Innovation The KARO® 5.0 machine marks a pivotal advancement in LyondellBasell's research capabilities, allowing for more precise and efficient development and testing of masterbatch solutions. "This advanced technology will allow us to accelerate the development of new and improved masterbatch solutions, ultimately helping our customers bring their products to market faster and with greater confidence," stated Tiago Piccoli, LYB Director of APS PAD for Consumer & Industrial Markets in the Americas. Key Features and Benefits of KARO® 5.0 The KARO® 5.0 stretching machine is equipped with multiple cutting-edge features that enhance the testing and development process: Multi-Cast Film Capabilities: Allows testing a broader range of masterbatch materials. Dual Direction Stretch: Provides stretch capabilities in both the machine direction (MD) and transverse direction (TD), closely simulating real-world production conditions. Comprehensive Monitoring: Tracks various material characteristics such as tension, elongation, torque, temperature, and thickness to ensure top performance and quality. Exhibitors & products around machinery & equipment Machinery and plant for processing Post processing machines & downstream equipment Machinery & plant for finishing, decorating, printing and marking Welding machines Process automation To all exhibitors in this category Enhanced Speed-to-Market By enabling a closer match to masterbatch materials used in actual production processes, the KARO® 5.0 significantly reduces the time required to bring new products to market. It enhances LyondellBasell's speed-to-market process, offering customers the ability to rapidly identify and select the optimal masterbatch for their specific needs. Global Impact and Technical Leadership "The addition of the KARO® 5.0 reinforces our technical leadership and commitment to innovation in the masterbatch industry," commented Chuck Hampton, LYB Director of Masterbatch and Colors U.S. & Canada. The new technology not only complements LYB's testing assets in Europe but also extends its advanced R&D capabilities to the Americas, benefiting global customers with innovative masterbatch solutions. Supporting Diverse Applications The KARO® 5.0 supports LYB's Advanced Polymer Solutions (APS) and Olefins and Polyolefins (O&P) business segments by enhancing product development for applications such as protective films and food packaging. Testing with the new equipment is already underway, showcasing LyondellBasell's dedication to creating advanced solutions that cater to a diverse range of industry needs. Source LyondellBasell More around Machinery & Plants

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  • Reifenhäuser Expands Service Capacity in Middle East and Africa

    Enhanced Local Support with New Service Hub for MEA Region This expansion is driven by Reifenhäuser's commitment to being "Close to our customers", a philosophy of the company. Copyright: Reifenhäuser 04.11.2024 The Reifenhäuser Group, a global specialist in extrusion technology, has strengthened its service infrastructure in the Middle East and Africa (MEA) region. By establishing a new Service Hub, Reifenhäuser aims to improve customer proximity and operational efficiency, underlining its commitment to reliable, responsive support. The hub will offer installation, commissioning, and comprehensive on-site service. To address the growing demand for local support, the Reifenhäuser Group has expanded its field service operations in the Middle East and Africa (MEA). This strategic move includes a new Service Hub, focusing on improved accessibility, reduced downtime, and prompt assistance. With this addition, Reifenhäuser continues its philosophy of “Close to our customers,” facilitating better insights into local requirements and enhancing customer satisfaction. Bharath Yalla is Managing Director of Reifenhäuser MEA. Strengthened Local Support and Services The new Service Hub, located in the UAE, is designed to streamline operations by incorporating an on-site service team equipped to deliver a range of field-engineering services. These include: Installation of machinery System commissioning Ongoing service and maintenance support With the infrastructure and expertise now in place, local companies benefit from faster resolution times and enhanced accessibility to Reifenhäuser’s resources. “Our strong dedication to local markets is now embodied in UAE and Lagos. We promised, and we delivered,” states Bharath Yalla, Managing Director of Reifenhäuser MEA. Expanding into High-Growth Markets The MEA region has shown substantial growth in plastics and extrusion technologies, making it a key focus area for Reifenhäuser. The new hub and expanded operations in Lagos highlight Reifenhäuser’s recognition of this potential and commitment to supporting the region's development. “We are committed to building lasting relationships with our customers, ensuring they receive the guidance and support necessary for effortless equipment start-ups and optimal operational efficiency,” comments Bernd Reifenhäuser, CEO of the Reifenhäuser Group. The establishment of the MEA Service Hub reflects Reifenhäuser’s proactive approach to customer service. By fostering close connections with clients, Reifenhäuser can address operational needs with tailored, prompt solutions. This initiative underscores the company's position as a reliable partner in extrusion technology for the MEA region. Exhibitors & products around machinery & equipment Machinery and plant for processing Post processing machines & downstream equipment Machinery & plant for finishing, decorating, printing and marking Welding machines Process automation To all exhibitors in this category Source Reifenhäuser More around Machinery & Production

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Topics covered in K-Mag

Sustainability

Sustainability

Digitalisation

Digitalisation

Machinery & Production

Machinery & Production

Raw materials

Raw materials

Science

Science

People

People

Plastics in Practice

Plastics in Practice

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