Embed Size (px)
Citation preview
News from the Scottish Plastics and Rubber Association
2006
Newsletter Contents 2006 April 2006 Page Fibre Optic Communication System 2 Waste Tyres: A Valuable resource? 3 Microbial Devulcanisation and Recycling of Rubber 3 Civil Engineering Applications of Waste Tyres 4 SPRA Dinner Dance 2006 4 Opportunities to Work in Scotland 6 June 2006 Vascutek win Prince Philip Award (Polymers in the Service of Mankind) 7 SPRA meeting: Artificial Sports Surfaces 8 Ticona Roadshow: engineering thermoplastics and applications 9 SPRA contribute to DVD on Workplace Learning 10 SPRA Annual General Meeting 2006 11 Cogent SSC: Skills Needs Assessment for the polymer sector 11 September 2006 Polymer Study Tour 2006: residential course for teachers 12 History and Design of Plastics 13 Faraday Plastics Partnership absorbed into Materials KTN 14 Polymer Employer Network: challenges facing the polymer sector 15 ‘Radikal’: new initiative to bring SMEs and academia together 15 ‘White Magic’: educational resource box from EPS Group at BPF 16 Congratulations 16 Polymer Engineering Graduates from Napier University 16 Apprenticeship in Management awards at Carclo Technical Plastics 17 Colin Hindle’s perspective on UK Plastics Trade Shows 17 December 2006 SPRA meeting: Plastics in Packaging 18 Plastics Films from Vitasheet Group 18 PET and Glass Bottles: an end user’s perspective 19 SPRA meeting: Manufacture in Low Cost Economies 20 The Czech Experience: Carclo set up plants in the Czech Republic 20 The China Evolution: Hoover’s experiences in setting up in China 21 SPRA meeting: Advances in Polymer Processing 22 Billion UK: Process Innovation for Efficiency and Profit 22 Mitutoyo: Measurement Technology for plastics and tooling 23 IOM3 Accreditation for Napier University Polymer Engineering Programmes 24 Scottish Parliament drops Plastic Bag Tax 25 Report on Euromould Exhibition, Frankfurt 25 Cogent’s successful bid to establish a National Skills Academy 26 Polymer Study Tour 2007 26
News from the
Scottish Plastics and Rubber Association
April 2006
Features in this issue: Fibre Optics Waste Tyres Microbial Devulcanisation Civil Engineering Applications Dinner Dance 2006 Opportunities to Work
FIBRE OPTIC COMMUNICATION SYSTEMS
At the first SPRA meeting in 2006, Phil Clayton, Technical Manager at Emtelle in Hawick, provided a fascinating insight into the world of fibre optics communication systems. Compared to copper cables, glass fibre optical systems can handle communications much more effectively with speeds of 110 Mbps and, through multiplexing, a single fibre can carry 1 million conversations at the same time.
top: glass
bottom: copper
blow head
Concentrating on Fibre To The Home systems, Phil demonstrated how optical fibre can be blown through polyethylene tubes for distances up to 1 km, direct from the cabinet in the street to the consumer lead in box in the home. The optical fibre is uncoiled from a pan (with a force of less than 5 gf) and fed into the tube using rubber drive rolls. Compressed air is also fed in at a pressure of 10 bar (decaying to 1 bar at the other end) to carry the fibre, with a metal bead on the end, along the tube at a speed of 30 m/min.
The polyethylene tubes vary from 3 mm to 12 mm diameter, either singly or in bundles of up to 24 tubes in an outer sheath. The inner tubes are mostly extruded medium density polyethylene (MDPE) and outer sheaths of high density polyethylene (HDPE) (for direct burial), polyamide 12 (for termite resistance), flexible PVC (for inside homes) and halogen free, low smoke grades for low fire hazard.
The systems have been carefully designed to facilitate connections
at minimum cost. Once the ducting is in place, additional fibres can be readily installed at a later date to cope with increased demand. As a measure of the extent of this technology, Emtelle use 40,000 tonnes of polyethylene per year.
Phil Clayton (left) in discussion with SPRA members
01450 364000
www.emtelle.com
WASTE TYRES -- A VALUABLE RESOURCE?
The SPRA meeting on 16 March in Livingston explored diverse aspects of the problem of disposal of end-of-life tyres.
Fact File 3
WASTE TYRE DISPOSAL OPTIONS
Fact File 1
Annual tyre disposal in Scotland: 4 million tyres
(38000 tonnes)
In 1999 Landfill 45% Export 42%
Reuse in Scotland 13%
2003: whole tyres banned from landfill 2006: shredded tyres banned from landfill
Re-use
Recycle
Energy Recovery
Retread Landfill engineering Coastal Defence Lightweight fills Drainage beds Roads, paths, surfaces Reclaim Devulcanisation Pyrolysis Tyres for Fuel ( Cement Kilns)
Fact File 2
Waste Tyre Recovery Rate
UK 70% Germany 92% Sweden 98%
Netherlands 100%
(l to r) Dr Mike Kenny (Univesity of Strathclyde), Colin Hindle (Napier University), Dr Dan Kirkwood (Univesity of Strathclyde).
MICROBIAL DEVULCANISATION
Colin Hindle, deputising for Prof Nick Christofi (both from Napier University), described the DART project (Microbial Devulcanisation and Recycling of Rubber from Used Tyres).
Natural bacteria have been harnessed to remove sulphur crosslinks from finely ground tyres (crumb). Devulcanisation occurs only at the surface but this is sufficient to convert the crumb from the role of a diluent filler in fresh rubber mixes to a more integrated phase as a result of crosslinking onto the surface of the crumb. Not only does this maximise the physical properties of the resulting vulvcanised rubber (tensile strength, tear resistance and abrasion resistance) but processability is also improved (mixing, form stability, degassing and mould release). Outlets for the treated crumb would include all major rubber sectors (tyres, hose, belting and general rubber goods). Compared to other attempts to devulcanise rubber using bacteria, the DART method is faster, cheaper and operates at low temperatures. Over 10% of the sulphur can be removed from the crumb over a period of 6 days, with no chemical disposal problems. Plans have been drawn up for a full-scale plant to process rubber crumb.
Tyre crumb 0.5 - 5.0 mm
Prof Christofi 0131 455 2490 [email protected]
Napier University
www.lifesciences.napier.ac.uk/research/ambres1.htm
British patent application 0304574.7 International (PCT) Patent Application No PCT/GB2004/000827
CIVIL ENGINEERING APPLICATIONS OF WASTE TYRES
Dr Dan Kirkwood (Centre for Advanced Structural Materials, Dept of Mechanical Engineering, University of Strathclyde) reviewed the use of whole tyres, shredded tyres and rubber crumb as civil engineering materials and described project work and research in this field. Bales are typically produced by stacking 100 - 130 car tyres in a herring bone pattern and compressing into a compact structure of 1.5 m3, weighing just under 1 tonne. Because of the air pockets the bulk density is around 0.6 tonnes/m3. When constructed the bales have security wires but the bales retain their shape even when the wires are removed at a later stage.
Photographs courtesy of Northern Tyre
The low density bales (30% weight reduction compared to aggregate) have been successfully used to build roads on soft subgrades, such as the B871 in Sutherland which crosses a peat bog. Whole tyres have also been encased in concrete to produce lightweight building blocks. Dr Mike Kenny (Dept of Civil Engineering, also of Strathclyde University) described tests he has been using to quantify the engineering properties of tyre bales as a road building material. Under cyclic load, deformation does not exceed 5 mm and the bales recover their shape within 24 hours.
Chipped tyres, as replacement aggregate in concrete blocks, offer improved impact resistance, better freeze-thaw resistance and interesting thermal properties. However rubber chips can be up to 10 times more expensive than conventional aggregate. In contrast tyre bales, in cost per unit volume, are less expensive than aggregate in road building and offer a cost-effective solution in civil engineering applications.
Tyre chips 10 - 30 mm
Dr D Kirkwood Dr M Kenny
[email protected] [email protected]
SPRA DINNER DANCE 2006
For the past 31 years the polymer community in Scotland has held its annual Dinner Dance in Glasgow but this year it was held at the Sheraton Hotel in the heart of Edinburgh. SPRA President Ralph McNeill and his team of organisers, particularly June and Avril at Safeglass, are to be congratulated on putting on another hugely enjoyable
(right to left): Dr Charlie Geddes, Mrs Sheena Geddes, Robbie Glen, Ralph McNeill,
Mrs Christine McNeill, John Adams, Mrs Halina Adams.
event.
SPRA Presidents (from left to right) Stephen Learney (1998-2000), Hugh Smith
(2000-2003), Ralph McNeill (2005 - ), Colin Hindle (2003-2005), John Adams (1993-1995).
Guests sat down to a meal with the traditional Scottish flavour, including the "Address to the Haggis" delivered by the piper who also piped in the top table guests. This year's event was graced by the presence of four SPRA Past Presidents. John Adams, the first President back in 1993 and recently retired as General Manager of Carclo Technical Plastics, was the chief guest at the top table, accompanied by his wife, Halina.
After the meal the cares and woes of the polymer sector were dispelled by the highly entertaining speaker, Robbie Glen. The evening was also marked by the presentation of SPRA scholarships to three students from Napier University, Andrew Blemings and Nikunj Jariwala (BEng Polymer Engineering) and Lauren Bowen (BSc Product Design Engineering). A Fellowship of the SPRA was presented to Dr Charlie Geddes for his contribution to polymer education in Scotland and for his service to the SPRA.
Robbie Glen
Andrew Blemings
Nikunj Jariwala
Charlie Geddes
Guests then crowded the dance floor to the music of Obsession while less energetic guests renewed acquaintances in the bar, enjoying their last cigarette at such a function and avoiding enthusiastic Tombola ticket sellers. After several years of declining numbers it was encouraging to note that this year's turnout matched last year. At least two companies who were forced to miss out this year have promised to return in 2007.
Lauren Bowen
Charlotte Morgenthal (2nd left)
at the Council table
One of the students attending the Dinner Dance was Charlotte Morgenthal, a Journalism student at Napier University from Dortmund, Germany. Charlotte, a partner to one of the Polymer Engineering students, has written the following account of the event from her perspective as an overseas "outsider" student.
Table hosted by SPRA Council Members
"You are the 'Cinderellas and Prince Charmings' that are going to the ball on Friday." O.K. I have to admit I knew everything from the above statement except that I will be a Cinderella on Friday. Colin Hindle's email concerning the 2006 SPRA Dinner Dance - in fact my first one!! - starts interestingly. A list of all the participating companies follows. I am studying journalism at Napier University and have promised my flatmate to go with her. That's why I nearly fall asleep reading the list. Ah, its getting interesting again: Colin is telling us what to wear… uhm.. a detailed description of what a 'black tie' means follows with what the man of the day can go to the dinner dance wearing - from kilt and what (or I should rather say what not to) wear underneath it - to a conventional but suitable suit. "For the ladies - well you choose; we gentlemen would never presume to tell you what to wear." Aha… I close the email even more confused than before (what shall I wear, what will happen there??) To find answers to the last questions we simply have to go. One could not miss the group of SPRA black ties in the Sheraton this evening. To be fair I should say that in between the black landscape we saw some very nice dresses and, not to be forgotten, some highland kilts as well. This was very new for me, coming from the 'Continent'… I didn't know what was still to come. It sounds foolish to write too much about the dinner and the food, but even that was an event. The chef and the piper honoured the Haggis with words of Robert Burns. Even though not understandable … it was, I suppose, very nice and it would be wrong not to mention at this point the culinary brilliancy we were allowed to witness! The evening did not come to an end then. It was time for the important people to raise their voices. I have to admit that I thought this would be the part where I could rest a little bit… taking my mind off all these new impressions. I was proved wrong. One entertaining speech followed the other. OK some not so funny jokes for the people from the 'Continent'. The dance floor was opened. Well, I thought NOW I can rest, letting all the old people onto the dance floor with some - probably even older traditional Scottish dances - tell you what? I was proved wrong again! The live band played music even for foreigners!! Finally we (my flatmate and I) couldn't sit still on our chairs anymore. Maybe that was the most embarrassing part of the evening for me, after fighting so bravely through the three different pairs of forks and knives on the dinner table! But after some spirits I couldn't think of another place in the whole wide world I would rather be than on the dance floor at the Sheraton!! A little bit disappointing was the Tombola that followed, especially as a student watching the 'business men' buying thousands of tickets!! I nearly forgot to mention that I was probably the only 'poor student' at the dinner dance, even tempted to consider studying plastics, because of all the generous awards which you can get and which were given to some students this night! I did not win either an award or a prize.. but YES in fact I won something… and I will never ever give it away nor swap it… it is the very intense memory of an evening which I spent with very nice, friendly and warm, welcoming people who I normally would not meet.. Or… the more I think about it.. in a few years time… writing for the Financial Times, maybe? Now I know… we may really have been lucky Cinderella's this evening and I really have to be careful not to think that I perhaps just dreamed? But then there is still Colin's email in my mailbox….
OPPORTUNITIES TO WORK IN SCOTLAND
The SPRA accepted an invitation through Cogent SSC to address a meeting of students in Glasgow on 9 March in conjunction with the Scottish Executive Fresh Talent Initiative, which aims to promote Scotland as a source of job opportunities for foreign students studying in Scotland. Charlie Geddes gave an overview of the polymer sector and Dr Eric Boinard, an SPRA Member, described his experiences in finding employment after carrying out polymer research at the University of Strathclyde. Having started as a Materials Engineer at Polaroid UK in Dumbarton, Eric is now Technical Manager in the Polaroid Eyeware Division. After the talks, the SPRA team fielded questions about the polymer sector from students of different nationalities, mostly studying mechanical engineering and product design engineering.
Charlie Geddes (SPRA Hon Sec) addressing the
students
Eric Boinard explaining
opportunities to students from
Spain
Click here for more details of the Fresh Talent: Working in Scotland Scheme
see also www.scotlandistheplace.com
News from the
Scottish Plastics and Rubber Association
June 2006
Features in this issue: Vascutek: Prince Philip Award Artificial Sports Surfaces Ticona Roadshow Workplace Learning SPRA AGM 2006 Skills Needs Assessment
VASCUTEK WINS PRINCE PHILIP AWARD
The Institute of Materials Minerals and Mining has announced that the Prince Philip Award (for polymers in the service of mankind) for 2006 has been awarded to Vascutek Ltd, Inchinnan, an SPRA Corporate member and the SPRA nomination.
Citation
Vascutek, a Scottish based manufacturer of products used by cardiovascular surgeons throughout the world, has made a significant contribution to healthcare through development of expanded polyetrafluoroethylene (ePTFE) vascular prosthetic grafts. The ePTFE polymer is notoriously difficult to process but Vascutek engineers have successfully overcome the challenges. SEALPTFE™ was introduced in 1999 as the world's only gelatin sealed ePTFE graft. The external gelatin coating minimises suture line bleeding and 'sweating'w during implant, cutting total operation time and reducing the patient's risk exposure time. The unique gelatin coating acts as a reservoir for antibiotics, thereby helping in the fight against graft infection. Rapidax™, a self-sealing ePTFE graft specifically designed to be used immediately with dialysis patients, removes the need for temporary
central lines and drastically reduces the incidence of infection and other complications. Vascutek's computer controlled manufacturing and monitoring systems ensure an exacting level of consistency and quality of product. Vascutek has an extensive range of ePTFE products in the pipeline. The company is committed to the development of new and innovative ePTFE products that offer real benefits to surgeons and their patients worldwide. Since their introduction, Vascutek ePTFE products have saved countless lives and limbs of patients around the world.
Extrusion of ePTFE
Vascutek, based at Inchinnan, is a leading manufacturer of vascular prostheses, which are used worldwide by vascular and
cardiovascular surgeons in the treatment of aneurysmal or occlusive arterial disease. Established in 1982 from a joint venture involving Coats Paton, Glasgow Royal Infirmary and the Bioengineering Unit at Strathclyde University, Vascutek initially produced vascular grafts from knitted polyester. In 1999 they introduced vascular prostheses constructed from expanded PTFE (ePTFE). Today, at Inchinnan, Vascutek employ 270 in research, design, development and manufacture and has operations in 80 countries. Over 90% of its production is exported and the company has won 5 Queen's Awards (4 for export and one for technological achievement).
www.vascutek.com
Vascutek
0141 812 5555
ARTIFICIAL SPORTS SURFACES
The SPRA April meeting on Artificial Sports Surfaces, held at McDiarmid Park in Perth, home of St Johnstone FC, attracted a broad audience, ranging from students of sports technology to sports organisations and companies installing and maintaining sports surfaces as well as SPRA members interested in extending their knowledge of applications of polymers. Artificial sports surfaces have come a long way since the early Astroturf, which was not far removed from a domestic carpet.
Today's Third Generation surfaces are now tailor
made for different sports and typically consist of yarns tufted onto a woven backing and filled with a mixture of silica sand and rubber crumb. The yarn contributes to properties of resilience, durability, abrasion, ball roll, colour and weatherability while the sand controls drainage and the rubber affects bounce.
Frans Harmeling, Product and Development Manager at Bonar Yarns and Fabrics, explained in detail the development of yarns to meet the balanced requirements of artificial sports surfaces. Fibres are selected from one of three polymer families. Polyamides (PA) give good durability, resilience and recovery but mechanical properties are susceptible to moisture and the abrasive properties are unsuitable for sports such as football where players contact the surface. Consequently polyamides are found mostly in surfaces for hockey and golf. Polypropylene (PP) is a cost effective alternative, with good resilience, durability, weathering resistance and unaffected by moisture. Polyethylene (PE) offers a softer playing surface, more suited to player contact and with better uv resistance than PP but resilience is poorer.
Monofilament yarns consist of 6 - 8 monofilaments (extruded through a spinneret) twisted together. Monotape yarns consist of 6-8 tapes (rectangular cross-section, cut from an extruded film). Fibrillated yarns are also produced from extruded film, which is slit, heat stretched and then partially split (fibrillated) before twisting into yarn. Hybrid yarns are produced by fibrillation but behave more like monotape yarns. Mixtures of fibrillated and monofilament yarns are used on special projects.
Monofilament yarn
Fibrillated Yarn
Durability of yarns is assessed by the Lisport Test, which consists of a studded roller under 40 kg load, rotating on the surface with a friction ratio. 5000 cycles is equated to a 5 year use. The resilience or stand-up memory is affected by the tendency of the fibre to post fibrillate. Ball roll tests have to be carried out using a specified standard football. The abrasive nature of the surface is assessed using a foam panel pulled across the surface at different speeds and under varying loads, measured as foam weight loss. Weathering resistance and colourfastness are evaluated using standard accelerated tests associated with plastics. High temperature weathering tests are important to simulate the heating caused by the light absorbed by the black rubber crumb.
During discussion, Frans answered many questions relating to the effect of low temperatures (PE totally unaffected), moisture (PE, PP unaffected but PA sensitive to moisture) and the effect of fibre cross-section. Eric O'Donnell (Sports Labs Ltd) described the battery of test required by bodies such as FIFA. Artificial sports surfaces are often assumed to be maintenance free but it was stressed that these surfaces need regular maintenance, including clearing debris, tackling weeds and moss and replacing the infill materials (sand and rubber). After the formal meeting and an excellent buffet, delegates had the opportunity to inspect the FieldTurf installation at St Johnstone's training ground. After 8 years hard use this surface looked as good as new apart from some slight wear in the goal areas. It was generally agreed that professional footballers' resistance to artificial surfaces, based on earlier surfaces, is probably a generation phenomenon. Future footballers brought up on modern surfaces should have no such prejudices.
Bonar Yarns & Fabrics, Dundee
01382 227 346 [email protected] www.bonaryarns.com
TICONA ROADSHOW
Following the well tested formula of a series of rapid fire presentations and case studies, the Ticona team of Peter Burke, Barry Steptoe, Bryan Deacon, Mervyn Cox and David Almond, covered a wide range of engineering thermoplastics and their applications in their 2006 Roadshow, entitled "Your Bridge to the Future".
Peter Burke introducing the Roadshow
with his Ticona colleagues, Mervyn Cox, Bryan Deacon and David Almond.
Information on Ticona materials included new grades of Fortron (polyphenylene sulphide, PPS) for fibre, thermoformable sheet and medical applications and easy flow grades of Vectra (liquid crystalline polymer, LCP) and high heat grades of Vectra for lead-free soldering applications. An injection moulding grade of GUR (ultrahigh molecular weight polyethylene) has been introduced. Fast crystallising grades of Impet (thermoplastic polyester) provide smooth glossy surfaces, while the Riteflex (thermoplastic elastomer, TPE-E) range has been extended with medical grades. Flame retarded (FR) grades of most Ticona materials are available as non-halogen versions to comply with new legislation, particularly for End of Life Vehicle recovery requirements.
Several case studies were used to illustrate how Ticona engineers work with customers in selecting engineering thermoplastics for particular applications. The selection process requires a clear specification of the properties required, followed by comparison of properties of potential materials, based on data sheets and techniques such as spidergraphs, and a generous helping of expertise accumulated over the years by Ticona staff.
Inhaler mouldings
Hostaform (POM)
in call centre headsets
Fortron (PPS) replaces aluminium in Airbus 380 wing components
Case studies covered such diverse areas as call centre headsets, composites for the Airbus A380, swivelling car headlamps for better illumination on bends, lifetime fuel filter modules in cars, car doors, washing machine load sensor, dose-control inhalers for asthma and other medical conditions, telemedication devices, water tank for a steam cooker and a water meter. The case studies also brought out developments in outsert moulding, and laser welding as well as sound design principles. It was emphasised that addition of pigments, particularly in universal masterbatch format, can have an adverse effect on the mechanical properties of engineering thermoplastics.
Car door: outsert moulding
Vectra (LCP) in swivelling car headlamp
Questions and discussion time covered a vast ground - from assembly techniques, fibre reinforcement and environmental stress cracking to polymer coatings on steel and new chemistry polymers.
Photographs cortesy of Ticona UK
Ticona defended the perceived over-use of the word "excellent" by stating that absolute engineering properties would be supplied if available but the term was appropriate if the material property was the best available. After a generous meal, all delegates left with contact details, Ticona publications and a better understanding of engineering thermoplastics and their applications.
Ticona hotline
Tel : 01952 213 456 Fax: 01952 213 423
Email: [email protected] Website: www.ticona.co.uk
WORKPLACE LEARNING
With funding from the Scottish Executive and the European Social Fund, the 21 Sector Skills Councils, operating across all sectors of industry, have collaborated to produce an interactive DVD aimed at increasing the awareness of the contribution that workplace learning makes to successful business. Cogent SSC asked the SPRA to organise the production of a video sequence on workplace learning in the polymer sector for inclusion in the DVD. SPRA Corporate Member, Carclo Technical Plastics kindly agreed to have the filming done at Harthill. The video sequence features technicians Evelyn McGhee and Chris Docherty and Operations Manager, Andy Brady. Recording and editing was carried out by Rae Manger of the St Andrew's Multimedia Youth Project, Bo'ness. The DVD, which also contains a Workplace Learning Evaluation Tool, was launched at Napier University on 22 June.
stills from the DVD
Evelyn McGhee and Chris Docherty
Andy Brady
www.pwl.org.uk
www.cogent-ssc.com
www.carclo-ctp.co.uk
SPRA AGM 2006
At the SPRA Annual General Meeting in April, President Ralph McNeill reported on another busy year, including a programme of 7 technical meetings and a successful Dinner Dance. The SPRA confirmed its commitment to support teaching of polymers in schools through sponsorship of 2 teachers on the Polymer Study Tour and running a one-day course for technical teachers. The interests of members (both Individual and Corporate) were served through links with other bodies, including the Institute of Materials, Minerals and Mining and the British Plastics Federation. SPRA has also been working with Cogent SSC to ensure that the education and training needs of the polymer sector in Scotland are recognised and that appropriate provision is made to satisfy the requirements. There is also a commitment to develop the Polymer Employer Network to help companies remain competitive. After several years of declining membership, the trend has been reversed. New members include schoolteachers and students. Two long standing SPRA members have joined the Council, Dr Graham Bonner, Commercial Developments Manager at Ineos in Grangemouth and David Barlow, R&D Engineer at Lab901 in Loanhead. The Council wish retiring member, Colin Wilson (ex NMT), success in his new post at Terex Powertrain in Peterhead.
SPRA Council 2006-07
(from left to right) David Barlow (Lab 901), Les Rose (Impact Labs), Richard Donnell, Mike Barker (Napier University), Colin Hindle (Napier University), Ralph McNeill (Safeglass), Charlie Geddes, Sheena Geddes, Tom Campbell (Plastech Mouldings), Hugh Smith (Albyn), Graham Bonner (INEOS)
SKILLS NEEDS ASSESSMENT
In the informative and lively workshop in May, the Cogent team presented the results of the Skills Needs Assessment exercise, aimed at identifying the skills that companies need to remain competitive and the action plan to provide and fund the development of skills for the different industrial sectors within the Cogent footprint. The three critical areas requiring action are: Innovation and R&D; Management and Leadership; Supervisors and Technicians. Cogent is looking at setting up a National Skills Academy as part of the action plan. This concept would not be another new build but a virtual academy co-ordinating current and future skills providers.
Break-out groups then discussed issues including: productivity; competence assurance; technician upskilling; job benchmarking; contractor passports; industry image; FE/HE not meeting needs; poor understanding of career paths. It was concluded that the problems were common to the various industries but the solutions will need to be very different for each industry.
www.cogent-ssc.com
For the full Cogent report on Skills Needs Assesment click here
For the summary of Skills Needs Assessment for the Polymer Sector click here
News from the
Scottish Plastics and Rubber Association
September 2006
Features in this issue: Polymer Study Tour 2006 History and Design of Plastics Knowledge Transfer Network Polymer Employer Network
Radikal EPS - White Magic Congratulations UK Plastics Trade Shows
POLYMER STUDY TOUR 2006
Colin Hindle and his team at Napier University are to be congratulated on organising and running yet another successful residential course on polymer science and technology for teachers of science, design and technology, from schools across the UK. The 4-day course made teachers more aware of the science and technology of polymers and the career opportunities in the plastics and rubber sector, through a series of lectures, hands-on practical work and visits to local companies.
Napier University
The usual race for rocket cars, constructed by teams from coke bottles, thermoformed chassis and injection moulded wheels, resulted in some disappointing times, particularly after a promising practice session, but less controversy than previous years. On the Monday evening SPRA members joined the teachers for an entertaining and informative talk on the history of plastics design, given by Colin Williamson.
Teachers at the premises of Bausch & Lomb,
manufacturers of contact lenses
The practical sessions, in which the teachers had hands-on experience of mill mixing, compression and injection moulding, thermoforming, extrusion, mechanical testing and plastics identification, were attacked with great enthusiasm.
Mill mixing
Vacuum Forming
Teachers were also impressed by the visits to Vita
Thermoplastic Sheet, Bausch & Lomb and Formould where they experienced a range of processes and products. The course dinner gave teachers further opportunities to meet SPRA members and find out more about the industry, while the main speaker, Michael Hart, Renter Warden of the Worshipful Company of Horners, talked about this ancient Guild, which is now the main sponsor of the Polymer Study Tour.
Michael Hart
Rocket Car Race Winners of booby prize
This year the SPRA again sponsored two teachers, Kerryanne McMahon, Chemistry teacher at Kirkland High School in Methil and William Sawers, Design and Technology teacher at St Luke's High School in Barrhead. SPRA Corporate member, Polaroid UK, sponsored Julie Curtis, Chemistry & Science teacher from Vale of Leven Academy. Companies can sponsor teachers from their local school for as little as £600. The SPRA recommends this modest investment for 2007 to help future recruitment and create fruitful relations with schools.
For further details of
enrolling on Polymer Study Tour 2007 or sponsoring a teacher
contact Colin Hindle 0131 455 2622 [email protected]
HISTORY AND DESIGN OF PLASTICS
For the June meeting, SPRA members joined with teachers on the Polymer Study Tour for a fascinating journey through the history of plastics and design. Colin Williamson, managing Director of Smile Plastics and well known plastician (an enthusiast for plastics) took the audience on an entertaining and informative journey from thermoforming of horn in the 16th century up to modern household items, illustrated with numerous slides.
In the 1830s entrepreneurs capitalised on the demand for jet mourning jewellery by mass producing brooches in moulded horn that was dyed black. In the 1870s beautiful boxes were made from horn and inlaid with mother of pearl. Lac resin mixed with woodflour or ground limestone, proved an alternative moulding material, as was ebonite, a thermoplastic material made from natural rubber and high levels of sulphur. Alexander Parkes was responsible for the big breakthrough when he used cellulose nitrate plasticized with castor oil to manufacture buttons and other items in a wide range of colours. In America, the Hyatt brothers found camphor to be a better plasticizer and moulding of celluloid was improved with the invention of the injection moulding machine. Celluloid was responsible for dramatic social changes such as pre-recorded sound, photographic film and inexpensive toys.
The early 1900s saw the introduction of cast phenolic for cutlery handles but this material was eventually overtaken by true phenolic moulding materials developed by Leo Baekeland. His Bakelite materials found applications in electrical equipment, radios and of course the telephone handset. The 1930s saw the appearance of thermoplastics such as nylon, "Perspex" and polyethylene, each making a contribution to shortening World War 2. Post war expansion of plastics enabled not just domestic artefacts but fashion jewellery and furniture. As an avid collector of interesting plastics items, Colin was not only able to show slides of the items but add the important historic interest. By the end of the evening, the audience were in no doubt that Colin had earned the title of plastician.
Plastics Historical Society
www.plastiquarian.com
Smile Plastics www.smile-plastics.co.uk [email protected] 01743 850267
KNOWLEDGE TRANSFER NETWORK
Faraday Plastics Partnership, formerly administered by Rapra Technology (before it changed ownership), is now fully absorbed into the Materials Knowledge Transfer Partnership (KTP), which is managed by the Institute of Materials, Minerals and Mining. Knowledge Transfer Partnerships were set up by the Department of Trade and Industry (DTI) to stimulate innovation in the UK's key technology sectors by promoting collaboration, best practice and knowledge sharing between industry and academia.
Materials KTN members will have access to the latest developments in materials technology. They will be guided to the best UK scientific and manufacturing facilities to research and apply new materials developments, and find funding. Members will be able to debate, online, the future of materials technology in a secure forum with like-minded people.
The DTI is providing £11 million over the next 3 years to support the Materials Knowledge Transfer Network because the £200 billion sector contributes 15 per cent to the UK's GDP and directly employs 1.5 million people and supports another 4 million jobs.
Materials KTN embraces 8 individual initiatives:
www.materialsktn.net
NCN (composites) NAMTEC (metals) SmartMat (smart materials)
and 5 materials Faraday Partnerships:
Advance (materials for transport) Packaging Plastics Powdermatrix (ceramics and metal) TechniTex (technical textiles)
Faraday Plastics Partnership focuses on three main strands: new polymers, polymers for solving environmental problems and novel methods of processing
New Polymer Materials
Nanotechnology - polymer based nanocomposites Conductive polymers Biodegradable polymers Materials from sustainable resources Smart materials; self repairing composites
Polymers in Environmental Solutions
Sustainable Polymers Low energy processing Recyclate characterisation and mapping Markets for recyclate polymers
Innovative Polymer Processing
Low energy processing Gas and liquid assisted processing Fibre oriented processing Process modelling Energy efficient tooling
This summer there has been a series of roadshows throughout the UK to launch the Materials Knowledge Transfer Network and refocus the Faraday Plastics Partnership.. Unfortunately the double event scheduled for 20 July at Strathclyde University in Glasgow and Napier University in Edinburgh had to be cancelled at the last minute.
POLYMER EMPLOYER NETWORK
The Scottish Polymer Employer Network meeting in June was the venue for the launch, by Cogent SSC, of a DVD on Workplace Learning. The DVD, produced by a number of Sector Skills Councils in Scotland and featuring Carclo Technical Plastics, is intended to raise the awareness of workplace learning among employers, as an effective contribution to the success of companies. Following presentations on the state of the UK plastics industry and on the recently published reports on Skills Needs Assessment and Current Provision of skills development opportunities for the plastics and rubber sectors, a healthy turnout of Network members discussed the challenges facing the sector in Scotland and how to remain competitive. The Network is currently expanding its contact list to a range of job functions within companies so that it can deliver a series of more focussed events over the next 12 months.
For information on the Network and copies of the presentations, contact Charlie Geddes: 01592 651 269; [email protected] For information on the DVD on Workplace Learning, contact Walter Williamson; [email protected]
RADIKAL
A project has been launched to bridge the gap between the research and development requirements of Scottish small and medium sized enterprises (SMEs) and the cutting edge research going on at Heriot-Watt University, Edinburgh. RADIKAL aims to bring industry and academia closer together to solve common problems and share resources such as costly facilities. The project funds three industry associates and an administrator to work with companies, to identify industry problems and propose realistic solutions. The tools used include:
• Identification of funding opportunities and introduction to possible partners/collaborators. • Transfer and introduction of new technologies to and from companies. • Feasibility studies for potential new products. • Strategic technology roadmapping for clusters and larger companies.
RADIKAL works closely with the Scottish Manufacturing Institute, a £4.2million EPSRC-funded innovative research centre in the School of Engineering and Physical Sciences at Heriot-Watt and is joint funded by the Scottish Executive's SEEKIT fund and ERDF's East of Scotland European Partnership. One of the main themes of the centre is digital tools for manufacture. The aim of the group is to exploit emerging digital technologies to create pioneering computer-based tools for design and manufacturing processes and provide efficient solutions. The group is also conducting research into controlling the density of polyurethane foams using ultrasonics.
Polymer research at Heriot-Watt covers a large field of topics including; polymer blends, miscibility, physical ageing, crystallinity, modified silica fillers, polyolefins, biopolymers and shape memory polymers.
The Galashiels campus is the home of the School of Textiles and also hosts:
• The Research Institute for Flexible Materials • The Biomedical Textiles Research Centre • Textile and Colour Science and Technology Research Group • Textile Design and Clothing Research Group
So far the RADIKAL project has achieved some great results, having interacted with over 120 companies and enabled £130,000 of funding to assist companies. Collaborations can vary in duration and scope, depending on the particular needs of the company.
For more information on RADIKAL, click here
or contact Dr Iain McEwan 0131 451 4300 [email protected]
For details of materials analysis equipment, textiles and design facilities click here
RADIKAL team
EPS - WHITE MAGIC
The Expanded Polystyrene Packaging Group of the British Plastics Federation (BPF) has developed an education box to assist the teaching of science in schools.
The White Magic box contains a steamer, a blender, a mould and a supply of raw material to allow teachers and pupils the hands-on experience of moulding an expanded polystyrene ball and testing the conductivity of different materials. The box, which is already on sale in England and Wales for £45, also contains a teachers' information CD. In October, the EPS Packaging Group is organising a demonstration of the White Magic Box at the premises of Styropack UK in Glasgow.
EPS Packaging Group
0207 457 5022
www.eps.co.uk
CONGRATULATIONS
POLYMER ENGINEERING GRADUATES At Napier University's summer Graduation Ceremony held at the Festival Theatre on Friday 14th July there were 9 Polymer Engineering graduates. Although this was the largest number graduating at one time for a few years now, most were graduating with the ordinary degree and hence a small honours year is inevitable next session. Included in the photograph are SPRA scholarship winners Nikunj Jariwala (2nd left) and Andrew Blemings (2nd right) who both achieved First Class Honours degrees.
Some of the graduates in Polymer Engineering
with Programme Leader, Colin Hindle (centre front)
Nikunj is returning to India to work for his father's company - Sumilon Industries Limited. The company mainly manufactures metallic yarn (Lurex). Nikunj will be working at Gandhidham where the company produces BOPET film, metallised & coated film, intermediate lacquers, epoxy & melamine formaldehyde resins and metallic yarn. His responsibilities will include production and planning of the BOPET film plant, plant upgrading & maintenance, quality control and research activities.
Andrew has accepted a design engineer position in the International Projects Group at Rosti and will be moving to London to take up the post. He will be designing / modifying products on CAD as well as carrying out Finite Element and Moldflow analysis. The job will involve travel to various Rosti manufacturing sites, which include Poland, China, USA, Mexico and Larkhall.
APPRENTICESHIP IN MANAGEMENT Congratulations to Kenneth Angell (Shift supervisor) and Robert Brown (Toolroom Manager) both from Carclo Technical Plastics in Harthill on completing the "Apprenticeship in Management" at East Kilbride Group Training Association.
Kenny and Bobby are the first of 8 CTP employees to complete the accreditation, which incorporates the Institute of Leadership and Management's (ILM) Introduction to Supervisory Management and NVQ Level III in Management qualifications.
From l to r
Robert Brown, Brian Boyle (EKGTA), Kenneth Angell
UK PLASTICS TRADE SHOWS
The sequel to: "How many trade shows does it take to destroy an industry?" SPRA News December 2005
The latest entrant to plug the obvious gap in the supply of trade shows for the UK plastics industry, following the switch of Interplas back to the more sensible September 2008 date, will be easyFairs. Their "Plastics Innovations" exhibition will be held at the Ricoh Arena, Coventry on 22 & 23 May 2007. If you can't get to Telford for PDM this month, then the good news is there is another one along in just 8 months time, and another only 4 months later. A potential advantage is that Coventry is easier to access than Telford being just a short train ride from Birmingham International (which of course is the long standing home of our own long standing Interplas).
The front page of PRW (25 August 2006), headed "All roads lead to Telford", shows that it takes 4H 50M from Glasgow and 5H 15M from Edinburgh. Somewhere under the header it might say that it takes over 7 hours from Aberdeen.
Following my own advice I have been saving up for K-2007, and I have just booked my flight to Frankfurt for Euromold 2006. At just £102.50 return for the 2 hour direct flight by Lufthansa from Edinburgh this is certainly faster and cheaper than attending a small exhibition in Telford or Coventry. Of course it remains to be seen if it is better. I will let you know my views in due course, but really only you can judge for yourself. Why not give it a try?
Colin Hindle, SPRA Past President
News from the
Scottish Plastics and Rubber Association
December 2006
Features in this issue: Plastics in Packaging Plastics Films PET v Glass Bottles Manufacture in Low Cost Economies The Czech Experience The China Evolution Advances in Polymer Processing Process Innovation for Profit Measurement Technology
Napier Accreditation Plastic Bag Tax EuroMold 2006 National Skills Academy Polymer Study Tour
PLASTICS IN PACKAGING
The opening meeting of the SPRA 2006-7 programme in September at the Stirling Management Centre, "Plastics in Packaging", was the first joint meeting between the SPRA and the Scottish Packaging Society, recently formed following the merger of the Institute of Packaging and the Institute of Materials, Minerals and Mining.
PLASTICS FILMS
In the first presentation, Graeme Smith, Head of Product Development for the VitasheetGroup, explained how thin plastics sheet can solve packaging problems by careful selection of the type of thermoplastic and an innovative approach to design. For low cost packaging, high impact polystyrene has much to offer. It is relatively easy to extrude, thermoform, fabricate and print. Surface finish can be either matt or gloss and a recent innovation of a co-extruded thermoplastic elastomer provides a soft touch surface, which prevents product moving in packaging during transport.
Clear polystyrene is ideal for in-shelf marketing and can be made pliable by blending with olefinic additives. In the polyolefin range, high density polyethylene (HDPE) is expensive at the moment but polypropylene (PP), homopolymer or copolymer, offers many exciting packaging solutions. Nucleated grades of PP have excellent clarity, although difficult to vacuum form.
Twin-wall PP provides an alternative to cardboard for box applications. Printability is the main challenge when working with PP packaging.
The excellent clarity, mechanical properties and chemical resistance of polyethyleneterephthalate (PET), both amorphous and crystalline grades, lead to applications in medical and cosmetics packaging and blister packs. However its poor tactile properties make it less appealing than PP, which also has the benefits of ease of cutting and creasing.
When selecting a particular thermoplastic for a packaging application, cost is still the most important factor. Properties such as clarity, printability, anti-block characteristics and aesthetics also come into the equation. Behaviour in secondary processes (cutting, folding, printing and adhesive assembly) must also be considered. Increasingly packaging manufacturers have to look at niche markets and added value, where the packaging design infers a quality perception to the consumer.
Looking to the future, Graeme saw continuing 'cost-down' pressure in which nobody really wins. A more attractive approach is to invest in design and development and 'sell on properties'. Graeme also predicted that agropolymers would make significant inroads into the packaging market. Agropolymers cover a range of polymers produced from renewable resources, which are attracting attention because of claims of disposal through biodegradability and compostability. Supermarkets saw an opportunity to increase sales by inferring that these materials are more environmentally friendly. In a robust discussion, polymer technologists in the audience pointed out that these materials would act as unwelcome contaminants in the recycling of mainstream plastics packaging. Claims of 'environmentally friendliness' need to be examined in relation to by-products in their manufacture, production of greenhouse gases in the biodegradation and energy consumption associated with the packaging having to be chilled in transport and storage. It was reluctantly accepted that, with politicians promoting agropolymers, their appearance in packaging was probably inevitable.
www.vitasheetgroup.com
PET v GLASS BOTTLES
The second speaker at the Plastics in Packaging meeting, Duncan Bond, Packaging Technologist at Chivas Brothers, in his presentation entitled PET and Glass bottles: an end users perspective explained that the materials of choice for alcoholic beverages varies depending on the type of alcoholic drink and from country to country. Glass bottles, the traditional material for wines, spirits and beer, are usually associated with quality and have the reputation of being 'green' (60-70 % recyclable). However the high energy consumption inherent in the bottle manufacturing process and in transport of bottles (both empty and full) is making glass less attractive. Polyethyleneterephthalate (PET) bottle production is less energy intensive, more suited to short run manufacture, the bottles are 10-20% of the weight of glass bottles and are virtually unbreakable.
For carbonated beverages, the gas permeability of PET has been steadily reduced, firstly with latex coating back in 1984, then with barrier layer materials incorporated in preforms using 5-layer extrusion and more recently by incorporating oxygen scavengers. From the beverage manufacturers' perspective, glass bottles are less pressure sensitive, easier to fill and more suitable for label application. PET offers considerable reduction in transport costs. For glass bottles, a lorry load is 40% glass and only 60% product whereas with PET bottles it is 93% product. Most customers prefer glass bottles, except in the younger generation.
PET has a low penetration of the beer market in Western Europe (7%) but a much higher usage in Eastern Europe. Likewise the UK spirits industry is heavily committed to glass --except for the travel retail market (miniatures) - whereas, in the USA, PET is more accepted, particularly with large volume bottles. EU Packaging Waste Regulations are also having an effect on material selection. In Germany the retailer take-back scheme favours glass while UK supermarkets are trying to rationalise the number of materials used (at the expense of metals). As a result of changing attitudes of customers, energy considerations and waste packaging regulations, Duncan expected that PET would continue to displace glass in most alcoholic beverage markets.
01389 723 139
MANUFACTURING IN LOW COST ECONOMIES
The recurring topic of competition from low cost economies was the theme for a joint meeting between the SPRA and the Scottish Polymer Employer Network in October at West Lothian College, Livingston. Delegates heard from two SPRA Corporate Members (Carclo Technical Plastics and Hoover) that had set up manufacturing operations in low cost regions in order to survive and maintain a base in Scotland.
THE CZECH EXPERIENCE
According to Gary Allan, Managing Director at Carclo Technical Plastics, the main reason for Carclo setting up moulding operations in the Czech Republic in 2001 was to move closer to key customers who had already moved to Eastern Europe. The Czech Republic was selected for the short supply chain, fast response time, reduced transport costs, lower direct labour costs and market growth opportunities. The Czech Republic could offer staff with high technical skills, proficient in English, excellent industrial and environmental ethics and a good track record on quality. Anticipating Czech entry into the EU, problems of duty and product security (copyright) were minimized.
Discussions opened with the relevant authorities in Brno in March 2001, construction of the facility was started in September 2001, completed by December and production started in March 2002. A second factory was built in 2004 and production started in Jan 2005. The two facilities (35 machines, 155 employees, 24/7 production and accreditation to various standards) operate to world class standards, with 6 sigma, 5S, JIT etc.
The strategy for competing in Low Cost Regions (LCR) is:
(i) meeting the challenge of the cost down culture by providing a service and/or product at a price that ensures that both parties return a profit to shareholders. (ii) maximizing the benefits of the region by utilizing the lower cost labour pool and central logistic position in a world class service/product (iii) creating a good team by employing the best staff available in the region (iv) in Carclo's case, utilizing the global resources of training, investment, project management, product development, seamless production transfer, key engineering and technical skills.
The Czech market operates with high standards and offers opportunities mainly in automotive products and the electronic sector. The only downside is that decision makers outside the region are still unsure about the technical capabilities of Czech moulders.
Gary's advice to anyone contemplating moving to a Low Cost Region is to:
(a) understand the market being served; (b) be aware of customers' expectations in cost and logistics; (c) anticipate where their customers are going to be in 5 years; (d) scope the investment fully; (e) determine the full cost of ownership ( costs for employment, construction, legal work, training, business development, accreditation, logistics); (f) work closely with investment Departments in the region and with local authorities; (g) employ the best, most flexible, motivated people; (h) train, train, train --- and train more; the people in these regions have a hunger to learn.
Carclo is looking to expand further in the Czech Republic, China and India but at the same time supporting organic growth in their existing facilities.
www.carclo-ctp.co.uk
THE CHINA EVOLUTION
John Semple, R&D Manager at Hoover Floorcare Division in Cambuslang, gave a presentation on Hoover's experiences in moving manufacture of their range of vacuum cleaners from Cambuslang to China. Hoover Candy primarily services the European floorcare market. Hoover USA is a separate company and China has several indigenous vacuum cleaner manufacturers. Hoover's main products are canisters (less popular in the UK), uprights, sticks, hand-helds (including battery powered), steam & wet, polishers and professional products. Prior to 2003 Hoover Europe was not profitable. The market volume was increasing at 5% pa but value was dropping at 10% pa. To increase margins Hoover had to decrease manufacturing costs. The initial internal solution was to streamline the factory, reduce floor space by 50%, bring warehousing in-house, increase output and concentrate on value-added operations (large mouldings and printing). However the market continued to fall and a 22% cost reduction was required.
A new product was introduced with a lower part count but it would have to be manufactured in a low cost region. For Hoover the choice between Eastern Europe and China favoured China because there was no experience of floorcare manufacture in Eastern Europe whereas China had a thriving floorcare industry. So less training would be required in China. The annual production from vacuum cleaner manufacturers world wide is 90 million units. 60 million are built in China, of which 40 million alone are produced in the city of Suzhou, 2/3 of which are produced in 3 Factories, TEK (7 million), EUP (8 million) and Kingclean (11 million). In 2003 Hoover selected TEK as their first partner, initially with purchased or branded products, but eventually UK designed products were transferred to China for production.
The first decision was either to transfer all tools to China or commission a second set of tools. The advantage of transferring tools was that there would only be one set to maintain but there was a high risk of product shortfall during transition and airfreight costs were prohibitive. Commissioning a new set of tools reduced the risk and softened people issues (redundancy) in the UK but it did mean additional costs and budget problems. In China, Hoover worked with two standards of tool --Type A for automated moulding and lower standard tools, Type B, which would require secondary operations of fettling (deflashing), which is feasible with low labour costs. The higher standard tools could be obtained in China for 60% of the cost in Europe and Type B tools were 10 -20% of the European price. For the canister cleaner, the tool costs were £1 million in Europe but less than £200,000 in China. Transfer to China started in 2003 and Cambuslang manufacture closed in mid 2005. Hoover UK changed from a manufacturing company to a purchasing company. Initially there was no Chinese support. Engineers were flown from Europe and a subcontractor was used as a quality presence. Now a new Enterprise has been established in Suzhou with 12 Engineers (10 Chinese nationals) tasked with new production. The Chinese engineers are well educated but there are still some communication difficulties. Purchasing and Quality functions are also in place along with associated administration. The outcome has been that Hoover is restored to number one position in the European market (based on number of units) and the next objective is to be #1 in value. Future plans are to move production introduction to China and consolidate R&D, Innovation and Product Verification Testing at Cambuslang.
www.hoover.co.uk
ADVANCES IN POLYMER PROCESSING
Process Innovation for Efficiency and Profit
Advances in Measurement Technology
At the November meeting at the James Watt Building on the Scottish Enterprise Technology Park in East Kilbride the first presentation was given by Peter Kirkham, a long term SPRA member and Managing Director of Billion UK Ltd. The original speaker from Mitutoyo UK, David Coughlan, was unable to be present but his colleagues, Graham Bell and Paul Spencer, stood in at the last minute to give the presentation on Measurement Technology.
PROCESS INNOVATION FOR EFFICIENCY AND PROFIT
In addressing the topic of Process Innovation for Efficiency and Profit at the November SPRA meeting in East Kilbride, Peter Kirkham, Managing Director of Billion UK, gave a comprehensive overview of how the basic principles of injection moulding have been developed to make processing more efficient and more innovative. The techniques are particularly appropriate for the Billion range because the machines have been designed on the principle of independent and simultaneous movements. Dosing can be carried out during mould open/close steps and machines can be unlocked during the cooling stage. Using a single pump and accumulator system, each function can be controlled independently for speed and pressure. This is all achieved with a smaller pump and motor at a lower installed power.
In Mould Assembly (IMA) is a unique process for clamshell mouldings, using a rotary mould system. Welding is carried out from a second injection unit at the same time as the moulding cycle for the next pair of clamshells. IMA eliminates secondary (expensive) operations while assembly is achieved cleanly and with perfect alignment.
Peter described a research project that resulted in a screw design for a standard machine that can cope with long fibre reinforced thermoplastics, with less fibre degradation compared to conventional screws and with shorter cycles. For medical applications, Billion provides an alternative to full clean room facilities in the form of a laminar flow cabinet round the mould unit, which can transform a Class 10,000 mould shop into a Class 1000 moulding operation.
The Easy Flow Technique is essentially an injection-compression approach in which the clamp pressure can be varied during injection to allow easy filling and good venting early in the injection cycle and a more uniform packing phase.
A circular base plate, 364 mm diameter, 1.7 mm thick, in ABS, would require a clamp force of 400 tonnes on a conventional machine and a cycle time of 30 s. With the Easy Flow approach, the same component can be moulded on a 260 tonne machine and a 25 s cycle. A more comprehensive injection compression process is also offered, which is ideal for moulding onto fabric and film.
Perhaps the most interesting technique is Autocorrection. By calculating the injection energy in real time, it is possible to maintain the same volume at change over to hold pressure, even when the melt viscosity is varying. Autocorrection offers the opportunity of consistent moulding from lower specification materials and rework.
Billion UK Ltd
01908 223 344
[email protected] www.billion.fr
ADVANCES IN MEASUREMENT TECHNOLOGY
After a general introduction, by Graham Bell (left), to the capabilities of Mitutoyo in providing solutions to measurement problems in the plastics and toolmaking sectors, with 68 Metrology Solution Centres in 38 countries, including 6 in the UK, Paul Spencer (right) described their range of Coordinate Measuring Machines (CMM's).
The CMM range includes manual machines suitable for parts with dimensions up to 700 mm and CNC controlled machines capable of handling components of up to 5000 mm, with accuracies down to 3 micron. In addition to the x, y and z movements, probes with styli down to 300 micron diameter can rotate fully in the x-y plane and 105o in the z axis, to give access to all forms of complex geometry.
CMM software is available in three levels. The first level is designed for basic geometry (prismatic elements) with images to show the measurement points. At level 2 measurements are linked to a CAD model of the part, again with prismatic elements. At the highest level, the software copes with free form surfaces and scanning, operating with patches of points and graphic images to show tolerance maps. The software is designed to interact with a range of standard CAD systems and data is automatically exported to suit different formats for reports.
From l to r: Graham Bell (Mitutoyo UK), Greg Kirkpatrick
(Safeglass Europe), Colin Hindle (Napier University), SPRA President Ralph McNeill (Safeglass Europe)
Laser non-contact systems are also available, although accurate measurement comes at a high cost and problems such as component surface finish need to be overcome before they can compete with the current stylus contact CMM. After the presentations and discussion, the delegates adjourned to the Mitutoyo showroom in East Kilbride for demonstrations of the full range of metrology equipment.
Mitutoyo UK Ltd East Kilbride
01355 581170 [email protected]
www.mitutoyo.co.uk
NAPIER UNIVERSITY ACCREDITATION
Following a visit by an accreditation panel from the Institute of Materials, Minerals and Mining back in May 2006, the Accreditation and Professional Development Committee, at its meeting on 19th October, agreed to accredit the "polymer" courses at Napier University, Edinburgh. The 3 year BEng Polymer Engineering programme is now accredited in fulfilment of Incorporated Engineer (IEng) and the 4 year BEng Honours Polymer Engineering is accredited in partial fulfilment of Chartered Engineer (CEng) requirements. A further 1 year MSc Engineering (Polymers) programme is approved as suitable further studies to complete the academic requirements for CEng.
Napier University
This 3 year + 2 year route has been designed to provide a progressive framework within which candidates can climb the ladder to the level appropriate to their needs and abilities. It is entirely compatible with the current Engineering Council UK-SPEC and very much in line with the European model for the education and training of professional engineers. UK-SPEC is a competence-based system, recognising the output standards of courses rather than the input standards (entry qualifications) of the earlier SARTOR scheme. Napier University has been running polymer courses for 40 years but these have not be accredited since the days of the Plastics & Rubber Institute (PRI).
The School of Engineering and the Built Environment at Napier University, whose motto is "Really Useful Engineering", sees the provision for both Incorporated Engineers (IEng) and Chartered Engineers (CEng) as very important and certainly not the former a failed version of the latter. Indeed due to demand from employers, and the financial pressures of being a student, many will leave at the end of the 3rd year with the ordinary degree. However, study can continue in part-time attendance mode and in fact the reverse is also possible. The 3 years + 2 years route is an alternative to the more widespread 5 year MEng provision of other Scottish universities (4 years in England), and is probably the only accredited provision in the UK for Polymer Engineering.
Napier University is one of just a very few centres in the UK offering BEng Hons Polymer Engineering and indeed the only one in Scotland. With its attractive setting in the beautiful city of Edinburgh, excellent access via road, rail and air, and absence of "top up fees" it is well worth considering by both full-time and part-
time students.
Polymer Processing Workshop, Napier University
www.soe.napier.ac.uk/courses/undergrad_courses/polymer_eng.htm
PLASTIC BAG TAX
After intense debate over the last 18 months, with written and oral evidence from over 100 companies, organizations and members of the public, the Environmental and Rural Committee of the Scottish Parliament decided to drop the controversial proposed Environmental Levy on Plastic Bags Bill in September. Although the Committee agreed that the legislation would have raised public awareness on litter, waste and environmental issues, it concluded that the Bill would not achieve the environmental impact that its author had intended. Indeed specialist reports commissioned by the Scottish Parliament concluded that there could even be a negative effect on the environment. The Committee accepted that what appeared initially to be a simple proposal turned out to be more complex. In addition to potential job losses, there was an ambiguity regarding VAT and doubts over the logistics of collecting the levy. The concept of a levy on plastic carrier bags has not been abandoned entirely and may reappear in proposals for a wider waste minimization strategy.
Click here for previous report
The proposed Bill did not appear to anticipate the changing attitudes towards litter, waste and recycling. Retailers have been introducing voluntary schemes to reduce the number of carrier bags. Proponents of the Bill based much of the argument on the apparent success of a similar scheme introduced in the Republic of Ireland in 2002, which claimed an immediate 90% reduction of carrier bags. The reality is more complex because there was a massive increase in sales of other plastic bags and today plastic bag imports in Ireland are higher than ever. There were claims that plastic bags in litter had been reduced from 5% to 0.28% but it now turns out that the 5% figure was an estimate and studies in other parts of the world give figures between 0.1% and 1.0% (without any legislation). Attitudes towards waste are ramping up as local authorities make it easier to recycle waste. For example Fife region collected three times as much plastics for recycling in 2005 compared to 2004 and six times more than in 2001. Education of the public is an important factor in the National Waste Strategy for Scotland
For more details of the Committee Reports and written and oral evidence click here
EUROMOLD 2006
A report from Colin Hindle (Lecturer in Polymer Engineering, Napier University) who visited the 13th EuroMold Exhibition in Frankfurt on 1 & 2 December 2006 with Alias Mohd (research student).
EuroMold - we went, we walked and we were impressed
The direct evening flight from Edinburgh to Frankfurt took less than 2 hours and then it was just a 15 minute train journey to our city centre hotel. The Frankfurt Messe is just 10 minutes walk from our hotel and soon we were in the first of the 4 Halls. To get around the entire exhibition in a single day is just about possible and we proved that on day one, but only by passing over several busy stands with a "we will return tomorrow" resolve. By the time the exhibition closes at the end of our first day we knew we had been around an exhibition. However, we are not finished yet. This is Alias' first trip to Germany, indeed his first time outside the UK since he arrived from Malaysia a year ago - we have to visit the Christmas Market. Wow! - compared to the Christmas markets we have in the UK this is a K-show rather than an Interplas. We resist the temptation of the Gluwein, but the lure of the wooden toys is too much for Alias.
Next morning we are back at the Messe for our second and the final day of Euromold. Being a Saturday it is noticeably quieter and we can get around the stands with time to sit and talk (especially sit). There is no doubt that this is a "world" fair and the large number of foreign exhibitors, and also foreign visitors, is impressive. Compared to 3 years ago when I last visited, the number of exhibitors from China is staggering. 3 years ago there were none - now they have nearly half of a hall. They are not here to sell mouldings, but rather the mould tools, machine tools, and even design services. Its hard to take in … this is Germany! The statistics of this specialist exhibition are impressive: 1,674 exhibitors from 41 countries; 80,050 m² of exhibition area; 60,376 visitors over the 4 days.
"From design to serial production" - EuroMold is the show that PDM would like to be.
Amazingly this show runs every year, but 2007 is a K year and so I, like most of you, will be heading for Dusseldorf. However, I will definitely put EuroMold in my diary for 2009 or even 2008.
Ein sehr glückliches Weihnachten zu allen unseren Lesern.
Colin Hindle
""NATIONAL" SKILLS ACADEMY
A skills provision vacuum has been created in the polymer sector in Scotland as a result of Cogent's successful bid to establish a 'National' Skills Academy for Processing Industries (PINSA) for the chemical and polymer sectors. The virtual academy, coordinating skills development through a network of providers, such as Polymer Training Ltd in Shropshire, will operate initially only in the North and Midlands of England. The Scottish Executive has indicated that the model will not be adopted in Scotland and they seem to favour a collaborative consortia approach involving several Sector Skills Councils rather than the individual sector model (PINSA).
Employers are reminded that Sector Skills Councils are designed to be employer led and an appropriate skills provision system in Scotland will only be achieved if employers in the polymer sector engage in the process and make their aspirations known to Cogent SSC and to the Scottish Executive.
www.cogent-ssc.com
POLYMER STUDY TOUR
Congratulations to Colin Hindle, Lecturer in Polymer Engineering at Napier University and SPRA Past President, who has been appointed Chair of the Polymer Study Tours Committee within the Worshipful Company of Horners after becoming a Liveryman of the Horners Company earlier this year.
The Polymer Study Tours are residential courses for teachers of science, technology and design and will be held in 3 centres (London, Bradford and Edinburgh) in summer 2007.
17 - 20 June 24 - 27 June 08 - 11 July
Napier University London Metropolitan University Bradford University
Through sponsorship (£600) companies are urged to support teachers on these courses, which give a valuable insight into polymer materials and the plastics and rubber industries. If the SPRA can sponsor 2 teachers each year, surely a company can support a teacher from a local school.
