Plastic Material News

Sun Protection for Greenhouses

June 30, 2010 - Basel, Switzerland -  According to United Nations estimates, over 9 billion people will be living on Earth by the year 2050. The amount of arable land needed to feed them, however, will not increase at the same rate. Inexpensive greenhouses made from plastic film represent one way to solve this problem: With the aid of such greenhouses, the output per hectare can be increased considerably. A new light stabilizer that BASF will launch at the K show after six years of development can help improve these greenhouses and make them even more effective: Tinuvin® XT 200 protects film made from thermoplastic resins against overly fast degradation when exposed to UV light. This economical additive ensures the efficacy of these films over a longer period of time even in the presence of severe concentrations of agricultural chemicals like elemental sulfur. Thus Tinuvin XT 200 fills a gap in the BASF portfolio of light stabilizers for resins used in agriculture.

 

An important market – in several respects
As a result of urban growth, but also because of increased erosion and climate change, the amount of arable land is decreasing. The challenge is how to increase the intensity of agricultural activity while keeping the products affordable. Greenhouses that can be erected very inexpensively through the use of plastic film are one possible way out of this dilemma: They provide an ideal environment for plants, protect vegetables from the effects of frost, wind and rain, ensure uniformly high quality and help fruit ripen faster. In this way, several crops can be harvested in one year. Moreover, modern plastic film can be tailored specifically to the unique light and temperature requirements of many field-grown fruits. At the same time, they help to use water more economically – a resource that has to be looked after even more closely in the coming years.

The benefits of greenhouse production are so convincing that vegetables such as tomatoes, peppers, cucumbers and eggplants are already being cultivated largely under polyolefin roofs. In 2009, about 900,000 tons of plastic film for greenhouses were produced worldwide, covering about 800,000 hectares of arable land. This corresponds approximately to the total area covered by the cities of Tokyo, Mexico City, Madrid, Johannesburg, Rome, Moscow and Berlin together. At the same time, the demand for agricultural film for use in greenhouses is foreseen to grow at an annual rate of about four percent. The most important markets are found in the Mediterranean region. Other fast growing greenhouse areas in the world are Asia, South America and Eastern Africa.

Agriculture has special requirements
Optimized agriculture also includes carefully considered use of agricultural chemicals to prevent harvests from attack by pests or mold. Environmentally friendly solutions are advancing on this front as well. The use of sulfur, for instance, being approved for application on organic produce even in highly regulated German agriculture, is recording noteworthy growth. However, the use of elemental sulfur and other agricultural chemicals places special demands on the film used in greenhouses.

The reason for this lies in the sensitivity of thermoplastic films to UV light. This energy-rich radiation causes plastics to become brittle over the course of time via a complex, multi-step chemical mechanism. Low-cost, thin film in particular, can become useless after only a few weeks of exposure to the open sky as a result of this effect. Polymer chemistry has, of course, already developed additives that can slow this degradation reaction. However, their suitability for use in agricultural film is rather limited, since their effectiveness is reduced considerably by sulfur and acids stemming from the wooden or iron construction of greenhouses. Halogen-containing chemicals can also contribute to the deactivation of common UV stabilizers.

Special products withstand agricultural chemicals
There are, however, already alternatives in the BASF light stabilizer portfolio, specifically for the agricultural sector. Light stabilizers recommended depending on the amount of agricultural chemicals used are, for example, Tinuvin NOR 371, a powerful high-end product on the market since 2001, but also Tinuvin 494, Tinuvin 111 as well as Chimassorb® 2020 and 944.  The new Tinuvin XT 200 operates in a range that for technical reasons cannot be served by Tinuvin 494 and for economic reasons cannot be served by Tinuvin NOR 371. This gap in the BASF-line of additives is now filled.

Economical production assured
Through use of Tinuvin XT 200 it is possible to produce in a very economical manner LDPE (Low-density polyethylene) films that withstand severe agricultural chemicals levels and also assure a service life of two and more years even under intense sunlight. The performance of such stabilized films is also very good when in contact with wood and metal greenhouse structures. Without a light stabilizer, they would not last even one growing cycle.

The capabilities of the new UV stabilizer were verified by extensive testing at Ciba/BASF over several years. This testing involved not only highly specialized laboratories but also experimental greenhouses at the large BASF development center for light stabilizers for agricultural plastics in Bologna, Italy. After the aging characteristics of the stabilized film were investigated in detail in the laboratory, they also had to prove themselves in extended field tests in Italy and Spain. Now the new stabilizer has the opportunity to grow along with a dynamic market.

Sustainable Products - Just a Mouse Click Away

New online tool for easy calculation of the ecological footprint

June 30, 2010 - Ludwigshafen, Germany -  When does it make sense to use biodegradable plastics? Packaging industry, consumers and policy makers are more and more confronted with this question during discussions about climate and the environment. Up to now, anyone who wanted to base a decision on a solid foundation had to turn to extensive individual eco-efficiency analyses or other life cycle assessments (LCA) that scrutinize the consumption of resources during the manufacture, use and disposal phases of a plastic product. A new BASF online tool, the so-called Ecovio® Eco-Efficiency Compass (E³C), will make this decision much easier in the future.

The software compiles all of the relevant data for the production and disposal of selected products – the findings of many exhaustive Eco-Efficiency Analyses – in a single user-friendly interface. Various parameters that are crucial for the ecological evaluation of a given product can be quickly checked, revealing their impact on the product’s eco-efficiency right away. The uncomplicated comparison of the ecological footprint of various approaches allows the user to quickly ascertain whether, in the final analysis, a biodegradable plastic is actually more environmentally friendly.

Biodegradable is not necessarily eco-efficient
It has been more than ten years since biodegradable plastics have entered the awareness of consumers and the industry, and they continue to enjoy a growing interest on the part of the market and the public at large. A number of BASF products have contributed to this development, too. Ecovio® F Film is commonly found in compostable shopping bags. At the end of 2009, BASF’s Ecovio product line was expanded by two new types, namely, Ecovio FS Paper, which is suitable for the production of coated paper cups and cardboard boxes, and Ecovio FS Shrink Film, which was developed explicitly with an eye towards the manufacture of shrink films.

Biodegradable plastics, however, do not automatically solve environmental problems simply because they can be composted. Their use only makes sense if they are more sustainable than non-biodegradable materials at a performance level that is the same or even better. The biodegradability is supposed to create added value, for instance, by allowing organic waste to be composted rather than incinerated. After all, organic waste consists primarily of water, which makes thermal utilization very inefficient. In contrast, if the film can be composted along with its contents, this can have a positive effect on the environment.

Comprehensive life cycle assessments like the Eco-Efficiency Analysis developed by BASF have already been helping people for many years to make the right choice among different product and process alternatives. Towards this end, such analyses thoroughly and quantitatively investigate and evaluate the consumption of resources, the environmental impact and the economic effects during the production, use and end-of-life phases of a material in a given application. However, all of this makes these studies complex: a comprehensive Eco-Efficiency Analysis has to be performed by LCA experts and takes several months. Such individual studies do not lend themselves to being combined and specific scenarios must be prepared separately. This again affords the experts’ support. Thus it is not possible to make flexible and quick decisions from among several material alternatives.

User interface with clear layout
This is where the new Eco-Efficiency Compass springs into action. A web-based interface with an input mask is provided so that users can combine numerous parameters with each other that are of relevance for the ecological profile of their envisaged product such as, for instance, a shopping bag. These parameters include not only the selection of the packaging material – if necessary all the way down to the monomer level – but also the weight of the bag and the type of disposal technology. Thus, the entire life cycle of the product is depicted, from the selection of the raw material all the way to disposal.

The software bases its calculations on several Eco-Efficiency Analyses and control parameters describing materials, applications and disposal scenarios. For the sake of clarity, however, they stay in the background. Moreover, some of the variables have been pre-set to appropriate values. Experience has shown, for example, that, when seen over the entire life cycle of the product, the energy consumption during the production of the film only has a relatively small impact on the eco-efficiency of a film bag.

Simple presentation of complex systems
Users first receive the analysis results in the form of a radar and portfolio diagram that clearly and logically shows the eco-efficiency of the approaches being compared. This already shows where a product variant has advantages or disadvantages, for example, in terms of its consumption of resources or its emissions.

If so desired, users can receive assistance from BASF experts who will provide them with individual diagrams showing valid and reproducible estimates of the energy and material streams involved in the production, transportation, use and final disposal. The environmentally relevant effects of the material selection and naturally also the costs of the chosen approach are provided.

Example – shopping bag with double benefit
The calculational comparison between a shopping bag made of paper and one made of Ecovio, both of which offer double benefit since they can be used for shopping and for biowaste disposal, shows: under the boundaries chosen the Ecovio bag is more eco-efficient than the paper bag, because the latter has to be considerably thicker in order to perform equally well. Generally speaking, this parameter plays a crucial role. Together with trained BASF employees, users can experiment with these parameters.

Expandable concept
At the present time, the new Ecovio Eco-Efficiency Compass is still tailor-made for estimating the eco-efficiency of shopping bags and foam trays of the type found everywhere in the retail sector. Other product groups, however, can be added. Major developments on the market can be promptly incorporated; an example of this is polyethylene made of “bio-ethanol”.

At the moment, experts are implementing models for paper coatings as well as for shrink films. These will help BASF customers to ascertain the eco-efficiency of paper cups and beverage packaging – and also to ensure that, in these sectors, biodegradable plastics are only employed where they are indeed more sustainable while performing at least equally well.

PolyMedex Introduces Custom Bone Growth Formulations for Orthopedic Implants

June 30, 2010 - Putnam, CT - PolyMedex Discovery Group has expanded its range of services for implantable polymers to include a range of clean room blending of bone growth additives in polymers.  The company has invested in state-of-the-art twin screw extrusion technology to allow for small scale development batches that are scalable to full production. 

PolyMedex blends bioactive fillers such as tricalcium phosphate (TCP), hydroxyapatite (HA), and biphasic calciumphosphate (BCP) to make them osteoconductive, meaning that bone will grow on and bond to the polymer.  Implantable polymers such as polyetheretherketone (PEEK) are used in permanent implants, often in high stress applications.  Bioresorbable polymers such as polycaprolactone (PCL), polylactide (PLA) and polyglycolide (PGA) are used in implants for temporary support while the body heals and ultimately replaces the implant with natural bone.  For optimum implant device performance, PolyMedex customizes bioresorbable polymers for absoption ranges from 1 to 36 months and flexural modulus (stiffness) from 30,000 psi (200 MPa) to over 1,000,000 psi (6,900 MPa).

PolyMedex processes implantable polymers in 100,000 class (ISO 8) cGMP certified clean room conditions to minimize contamination.  Pharmaceutical grade twin screw extruders are used for precision metering and fine filler dispersion that is required for high surface quality and consistent implant performance.  Process records of all process parameters are meticulously maintained during development and manufacturing trials.  All manufacturing components are calibrated and equipment is cleaned per GMP standards.

PolyMedex Discovery Group offers its implantable polymers in multiple delivery forms for use in a variety of applications.  Simple implant components can be precision cut from extruded film and fiber.  Innovative implant designs are possible with implantable polymers in the form of coextruded and multi-lumen tubing.  Injection molding is by far the most common process for fabricating implantable devices. PolyMedex’s custom formulations are available in a variety of pellet sizes for processing in standard or micromolding equipment.

For more information please call (860) 774-1559  x116 or visit www.polymedexgroup.com.

GMD Inc. Launches First Reusable Trocar With Thermoplastic Handle to Replace Metal

June 30, 2010 - Alpharetta, GA – Medical Instrument Uses Udel® Polysulfone from Solvay Advanced Polymers for Chemical Resistance, Autoclavability, and Major Cost Reduction - The medical industry’s first reusable trocar with a thermoplastic handle has been introduced by GMD Inc., Gig Harbor, Wash., a leading supplier of high-quality, cost-effective medical devices for standard of care procedures. The medical instrument, which is used to implant GMD’s Universal SlingTM for the treatment of female stress urinary incontinence, is made of 20% glass-filled Udel® GF-120 polysulfone (PSU) resin from Solvay Advanced Polymers, LLC for strong chemical resistance, low shrinkage, and excellent autoclave resistance (a minimum of 50 cycles). The plastic-handled trocar also reduces cost by 75% over the previous all-metal version.

 

The PSU-handled instrument replaces the all-metal trocar which was prohibitively more expensive and more complicated to manufacture and assemble. “Solvay delivered the enabling material technology that made this a game-changer for us,” said Shawn Lunney, GMD’s vice president, sales and marketing. “We were able to meet strict industry standards and deliver a high-performance, cost-effective equivalent.” For certain procedures including the implanting of GMD’s Female Universal Urinary Incontinence Sling, providers can now opt for GMD’s reusable trocar to lower overall cost per procedure, explained Lunney.

The reusable trocar consists of a stainless steel needle and inner handle that is overmolded with Udel PSU. The overmolded instrument offers the weight and feel of metal, along with the reusability and cost effectiveness of plastic. Initial testing of other polymers including glass-filled polycarbonate showed cracking due to residual stress or poor autoclave resistance and poor surface finish. Glass-filled Udel GF-120 provided lower shrinkage to reduce stress over the metal insert. Other key features include strong chemical resistance and excellent steam autoclavability. Solvay provided several recommendations to reduce residual stress and improve the appearance of the finished part.

The injection molded trocars will be commercially available in June.
 
About GMD Inc.
GMD Inc., based in Gig Harbor, Wash., is a developer and marketer of medical instruments that are equivalent to currently available products at a substantially lower cost. GMD’S mission is to improve the lives of patients, families, and health-care providers by offering high quality, cost-effective medical devices for standard of care procedures. GMD is initially focused on soft tissue repair products and products used in soft tissue repair procedures. For information is available at www.gmd-us.com.

About Solvay Advanced Polymers
Solvay Advanced Polymers, LLC produces more plastics with more performance than any other company in the world. This gives design engineers worldwide more ways to solve top design challenges in automotive, medical, electronics, aerospace and other demanding industries. Learn more at www.solvayadvancedpolymers.com.

Solvay is an international industrial Group active in Chemistry. It offers a broad range of products and solutions that contribute to improving quality of life. The Group is headquartered in Brussels and its companies employ about 19,000 people in 50 countries. In 2009, its consolidated sales amounted to €8.45 billion. Solvay is listed on the NYSE Euronext stock exchange in Brussels (NYSE Euronext: SOLB.BE - Bloomberg: SOLB.BB - Reuters: SOLBt.BR). Details are available at www.solvay.com.

DSM Announces Breakthrough in Technology for Second Generation Biofuels

June 30, 2010 - Royal DSM N.V., the global Life Sciences and Materials Sciences company headquartered in the Netherlands, today announces a major breakthrough in the technology to produce second generation biofuels. This breakthrough will help second generation biofuels to become more cost effective and to become a viable alternative to both first generation biofuels and conventional fossil fuels.
 
Second generation biofuels are manufactured from agricultural residues or specially cultivated energy crops that do not compete with the food chain because they can be grown on land that is deemed less suitable for food production. By enabling second generation processes the biofuels industry will be able to greatly improve its sustainability as it continues to grow and replace fossil based fuels.
 
DSM's breakthrough comes as a result of two separate innovations, the first of which relates to its enzyme technology. By focusing its research on a fungal organism that typically thrives in compost heaps or on fallen trees, the company has identified enzymes that are able to break down biomass into its constituent sugars much more efficiently compared to products and prototype formulations available in the market today.
 
The advantage of these new enzymes lies not only in their ability to break down biomass into sugars more effectively than conventional enzymes, but also in the fact that they are able to function at higher temperatures. These unique properties enable a lower enzyme dosage, better contamination control during fermentation, increased feedstock loading, reduced energy consumption and shorter processing time.
 
DSM's second innovation lies in its new advanced yeast technology. Microorganisms such as yeasts or bacteria are essential to the biofuel production process as they are needed to convert the fermentable sugars generated from the biomass into ethanol, today's most widely used biofuel. There are two primary classes of fermentable sugars that are liberated from cellulosic biomass during hydrolysis, six carbon sugars and five carbon sugars. Typically these microorganisms only consume six carbon sugars resulting in significantly reduced levels of efficiency in second generation processes.
 
Through classical strain improvement combined with metabolic engineering DSM has developed an advanced yeast strain that is capable of converting all the major sugar components found in biomass (both six carbon and five carbon sugars) to ethanol. It has been estimated that, taking a mixed sugar fermentation as an example, the overall ethanol yield using DSM's advanced yeast can be improved by up to 100% as compared to the yield of standard yeasts used today.
 
The combination of these two innovations will result in greatly improved process economics and productivity for second generation biofuel producers coupled with the sustainability benefits derived from the use of second generation feedstocks. The investment bank UBS recently estimated that second generation bioethanol will become the main transportation fuel over the coming decade, with a market valued at US$80 billion annually by 2022.
 
John Monks, Business Director Bio-Conversion Solutions at DSM commented: "By leveraging our century-long heritage in industrial biotechnology, we have been able to develop highly innovative conversion solutions for the emerging second generation biofuels industry. DSM holds a unique position in this field, and among our industry peers, based upon our ability to creatively combine enzyme and yeast technologies in an integrated way. This places DSM firmly at the forefront of new technologies that will enable the sustainable production of second generation biofuels, which will likely become the default transportation fuel of the future. I'm extremely proud of DSM's achievements to date in this field and look forward to being able to announce further innovations from our programs that support future generations of bioethanol."
 
DSM's approach to market development and business model for second generation biofuels is also innovative. Rather than opting for the classic industry model of remotely producing and bulk selling enzymes and yeasts, DSM is working with customers and partners to develop more localized, on-site production. The company views this approach as the most sustainable in the long run, because it bypasses long and expensive global supply chains and to truly integrate conversion technology into the biofuel process itself.
 
DSM - the Life Sciences and Materials Sciences Company
Royal DSM N.V. creates solutions that nourish, protect and improve performance. Its end markets include human and animal nutrition and health, personal care, pharmaceuticals, automotive, coatings and paint, electrical and electronics, life protection and housing. DSM manages its business with a focus on the triple bottom line of economic performance, environmental quality and social responsibility, which it pursues simultaneously and in parallel. DSM has annual net sales of about €8 billion and employs some 22,700 people worldwide. The company is headquartered in the Netherlands, with locations on five continents. DSM is listed on Euronext Amsterdam. More information: www.dsm.com

Hydrolysis-Resistant Polyurethane for Hydrants

Thermoplastic polyurethane (TPU) is not only abrasion resistant, wear resistant, and resistant to tear propagation, it is also hydrolysis resistant, which means that it can safely be used with drinking water. The Swiss hydrant manufacturer Hinni makes the most of these numerous advantages by developing an innovative control system for drinking water networks.
 
Hydrolysis-resistant thermoplastic polyurethane boasts a fascinating range of outstanding material properties such as: very good wear resistance; high tensile strength and elongation at break; hardness that can be adjusted over a wide range; high ozone resistance and oxidation resistance; excellent damping behaviour in dynamic applications, and high resistance to cracking and crack propagation.

 

Simrit is the only supplier in the world to offer its customers hydrolysis-resistant TPU that has all the necessary approvals for drinking water (KTW and W270). Hydrolysis-resistant TPU is now used for drinking water applications instead of the more traditional NBR and EPDM sealing materials.
 
Hinni AG, the Swiss hydrant expert, uses these outstanding material advantages for an innovative control system for drinking water networks. A hydrophone in the main hydrant valve picks up and evaluates sound waves from the pipelines. A specially developed precision molding made of hydrolysis-resistant TPU connects the closing cone in the main hydrant valve with the hydrophone, thereby making the measurements possible. This precision molding can roll up to follow the movement of the double shut-off in the hydrant. The geometry of the molding cap has been optimised to ensure that it rolls up smoothly.

 

Hinni also uses specially developed seals made of this hydrolysis-resistant TPU for the main valve and draining seals in its hydrants. The outstanding advantage of this material for customers of the Swiss hydrant specialist is the considerable extension of service intervals. In this way, the hydrant manufacturer helps water supply companies to reduce operating costs significantly.
 
As illustrated by the Hinni application, this material opens the door to customized solutions that are specially adapted to meet individual application requirements, including a variety of technical and material-specific variants. The color of the new hydrolysis-resistant TPU can even be adapted to meet individual needs.
 
Moreover, standard seals and precision moldings made of this hydrolysis-resistant TPU are available and can be used for valves, fittings, sliders, meters, sprinklers, faucets, and mixing faucets, and to seal pipe connections. Because of the high dimensional stability of hydrolysis-resistant TPU, O-rings made of this material can safely and reliably be used and installed over thread courses and side drilled holes. The fact that this material is extrusion proof and nondeformable, means that additional support rings are not needed for high-pressure applications. These seals are also capable of bridging larger gaps and allow for greater production tolerance and, therefore, lower costs in production.
 
For more information, visit www.freudenberg.com

First Tough-Elastic Foam with the Benefits of Styropor

June 29, 2010 - Ludwigshafen, Germany -  Polymer foams are a success story for BASF. This story began in 1952 with the invention of Styropor® (EPS: expandable polystyrene). Today, following the successful development of the extruded polystyrene rigid foam panels Styrodur® (XPS), the tough-elastic polyolefin range Neopolen®, the melamine resin foam Basotect®, and the advanced version of EPS for thermal insulation Neopor®, BASF has a broad portfolio and unique know-how when it comes to particle and extrusion foams. Continuous research and the launch of new products on the market open up new applications in a lot of industry sectors: the automotive industry as well as aviation, but also solar technology, construction and of course the packaging industry.

BASF has now succeeded with another innovation: E-por®, a material which is based on a new formulation and is manufactured in a new production process. E-por is the first tough-elastic, crack-resistant foam which can be transported, stored, processed and recycled like traditional Styropor. The material is noted for very good fusion of the surface, excellent resistance to solvents, and an appealing look and feel. Because of its high crack-resistance it is multishock-safe and therefore well-suited to being used as transport packaging for high-quality, shock-sensitive electrical and electronic (E/E) products, such as plasma televisions, laptops, refrigerators or washing machines. Thanks to its special property profile, the new BASF granules offer advantages along the entire value chain for transport packaging – from the converter, the appliance manufacturer and the retailer right to the consumer.

 

Increasing requirements for the packaging of sensitive E/E goods
When it comes to the safe transportation of electrical and electronic devices, the weight and sensitivity to shock of the product are crucial. A protective cardboard packaging is usually adequate for transporting robust and lightweight goods. However, cardboard only absorbs a small amount of energy, so its cushioning effect is limited. This is why cardboard is generally combined with Styropor. Styropor is light and has an excellent cushioning effect. But Styropor is a rigid foam and can break if the packaging is dropped, for example when unloading a truck. Once Styropor has been broken or torn, the cushioning effect diminishes significantly.

As electronic products are becoming lighter and lighter, but electronically more elaborate and thus more sensitive to multiple shocks, the requirements for the packaging are becoming more stringent. This is the reason why valuable and sensitive products are packed in multi-shock safe polyolefin and interpolymer foams. Compared with the standard packaging material Styropor, these foams have a number of disadvantages in processing and are not as easy to recycle as Styropor.

E-por combines the shock resistance and aesthetic appeal of interpolymers with the cost-effective recycling and ease of processing of the standard material Styropor. E-por has a very low blowing agent content of less than 6 percent. Rival products based on interpolymers require a blowing agent content of more than 10 percent. This large amount of blowing agent has to be frozen in the raw material, which means that interpolymers have to be transported and stored in a cold chain. Rival products based on polyolefins have not been capable of containing a blowing agent so far. They are pre-foamed during the production process, which means that it is mainly air that is transported from the raw material producer to the packaging manufacturer. This increases the transport costs considerably.

E-por thus saves transport, storage, and energy costs. It can be transported and stored at room temperature. It is foamed by the packaging manufacturer with a small amount of steam. The material can also be processed on conventional Styropor machines, which is more energy-efficient than processing polyolefins. Ultimately, E-por is the only foam resistant to multiple shocks which can be degased and recycled using Styropor technology: This means that converters do not have to change their machines.

Advantages along the entire value chain
Beyond the converter, E-por offers advantages for the entire value chain right through to the consumer: Appliance manufacturers are provided with a dust-free, flexible packaging material with an appealing look and feel which allows compact packaging with reduced damage and returns, and lower disposal costs. Retailers and consumers can dispose of the reliable transport packaging by the Styropor way, that is cost-efficiently and without additional efforts.

The development of E-por became possible thanks to a new research approach: BASF's researchers no longer regarded foams as a static blend of a polymer and a blowing agent, as is the case with interpolymers, for example. Instead, they developed E-por as a complex formulation of different ingredients which interact both with one another and with the blowing agent pentane. The researchers managed to transfer the concept of the impact-strength modification of polymeric materials to particle foams. This formulation is produced in a new type of BASF process. BASF's direct customer, the converter, is then able to process the granules using conventional Styropor technology. And this produces a foam with a new foam architecture. BASF has been present in the market for almost a year with pilot quantities of E-por. Several customer projects in all regions are running successfully.

Lightweight and Sturdy EuroPallets Thanks to SBC-Polymer

June 29, 2010 - Ludwigshafen, Germany - Whenever goods are transported in large unit loads – be it by sea, land or air – they are usually consolidated on pallets for easier handling. As a rule, products made of wood are used for this purpose. A new generation of transport pallets made of plastic is being launched onto the market by the Hirsch Group, located in Glanegg, Austria. These pallets overcome quite a few of the drawbacks of the conventional models: among other things, they are easier to clean and very sturdy, but first and foremost, they weigh much less than EuroPallets made of wood. The highly elastic BASF styrene butadiene copolymer Styroflex® 2G66 is playing a crucial role in this innovation. Engineers at Hirsch are using Styroflex 2G66 as a toughness modifier for the HIPS film (HIPS: High-impact polystyrene) that protects the lightweight core of the new pallets against damage.

 

Light weight – low transportation costs
Compared to conventional wooden pallets, weighing 20 to 40 kilograms, or newer metal-reinforced polyethylene pallets, the innovative products from the Hirsch Group offer the advantage of a significantly lower weight: they weigh 50 up to 75 percent less than wooden pallets or solid plastic pallets.

It is hard to estimate how many EuroPallets there are in the global flow of goods. Specialized logistics service providers employ several hundred million such pallets and, year after year, they produce tens of millions of these versatile goods carriers. All in all, the number of pallets roaming the world is probably in the order of magnitude of a few billion: that is how big the potential market is for innovative solutions.

For the purposes of lower transport costs and low carbon dioxide emissions a lightweight pallet represents a decisive environmental advantage – even if only a small part of the enormous quantity of pallets was replaced by the lightweight solution. Even the 5 kilogram pallet, the lightest variant, can handle one ton of payload, that is to say, two hundred times its own weight.

Foamed core wrapped with protective film
In order to minimize the weight of their new plastic pallet, engineers at Hirsch have developed a rigid and strong core made of expanded polystyrene for this standard transport structure. To withstand damage during the rough-and-tumble daily routine of logistical operations this structure has to be protected by a very robust skin. This is why the developers turned to a two-layer film made of BASF’s impact-resistant polystyrene whose layers have Styroflex added to them. The one to two millimeters thick film wraps the pallet tightly.

HIPS made tough by Styroflex
While the special styrene butadiene copolymer serves in other applications in the form of films, in this case it is used as a toughness modifier for impact resistant polystyrene. Even in small amounts, it can considerably boost the basic toughness of HIPS, cost-effectively turning it into a material that can withstand severe mechanical stress. The Charpy notched impact strength of the basic polymer and the energy needed to puncture the product are markedly increased. As a result, the new pallets can withstand all of the jolts, impacts and shear loads normally encountered in routine logistics operations without suffering any appreciable damage.

According to BASF experience, Styroflex 2G66 also makes the material less prone to stress cracking as characterized by the so-called environmental stress cracking resistance, abbreviated ESCR. Furthermore, the addition of Styroflex 2G66 also enhances the compatibility among the materials and creates a non-slip surface. Packaged goods are much less prone to slipping on the HIPS-Styroflex film than on smooth polyethylene.

Sturdy – washable – design-friendly
In actual practice, the combination of the lightweight core with the HIPS skin entails a few more advantages. The pallets are considerably more impervious to changing weather conditions than wood and, unlike the latter, they do not absorb water. This is not only advantageous for the transportation of frozen products, where absorbed moisture unnecessarily consumes cooling capacity, but it also means that the plastic pallets do not have to be extensively treated against mold and rot. As an added bonus, occupational accidents and damage caused by splinters or protruding nails are a thing of the past.

What comes on top are hygiene aspects: the modified HIPS surface can be easily cleaned with regular power washers, which makes it the ideal transportation material for food products. Together with the requisite food contact approvals, the new pallets are also suited for the safe transportation of food. Since all of the materials involved come from the polystyrene family, it is, moreover, much easier to recycle the pallets once they have finally reached the end of their useful life.

Last but not least, from a designer’s standpoint, the plastic version is much more flexible with regard to design parameters than the obdurate wooden variants. For instance, pallets sporting the colors of the customers, and even with molded indentations or printed with company logos, are all conceivable. RFID tags can easily be inserted under the protective film, so that the route traveled by pallets identified in this manner can be continuously tracked all over the world.

Double benefit in logistics
BASF’s styrene butadiene copolymer has already proven itself in other respects of product logistics: In multilayered shrink-wrap or stretch hood films the material helps to effectively secure goods during loading and unloading as well as during handling at the warehouse. For this application films made from pure Styroflex are combined with polyethylene in multiple layers. Here, the product can come up with additional particular properties. Due to its remarkable recovery capacity – even after being stretched by 220 percent – the film once again clings tightly to the items. Pure polyethylene films for industrial use can only be stretched between 20 and 50 percent without loosing their stabilizing function. In the case of stretch hood films made of Styroflex the high puncture resistance together with the high crack resistance of the elastic polymer represents an additional advantage, especially when packaging sharp items.

Hence, the styrene butadiene copolymer Styroflex offers a double benefit for the transport sector – as a protective skin for new lightweight foam pallets and in stretch hood films for fixing packaged goods on the pallet. This comes all down to the fact that small amounts of a specialty plastic, the knowledge of its potential and the focused cooperation with the customer allow new economic logistics solutions to be realized.

First American Plastics Launches New Website

June 29, 2010 - South Beloit, IL - First American Plastics, a leading value-added manufacturer of custom plastic injection molding solutions to companies all over the United States, has launched its new website, complete with a user-friendly and esthetically pleasing design.

The new website (www.firstamericanplastic.com), discusses First American Plastic’s capabilities, the markets they serve, their certifications, explains their value added services (such as multi-step assembly), and features a blog and visuals.

   

“We revamped the website with a fresh new design, and we support it with up-to-date, relevant content,” said Steve Erickson, a vice president at First American Plastics. “The new site is aimed at providing a more complete representation of First American Plastic’s expertise in plastic molding, value added services, mold takeover, design assistance, tooling repair and assistance.”

Along with the advanced features and functionality, the photo gallery section of the site provides a unique opportunity for prospective customers to have a chance to see a small sample of tools and molds that First American Plastic Molding Enterprise has worked on.

Established in 1993, First American Plastic Molding Enterprise is a Certified Minority Business Enterprise. They have been certified in a variety of industries, including Dairy, NSF, Automotive, Consumer, Medical, and original equipment manufacturing, and have the capability to handle projects in a timely fashion without sacrificing quality.

“We have the level of expertise and attention to detail that you expect,” Erickson said, when asked about First American’s breath of experience in the marketplace. “Our workforce of approximately 150 individuals includes 14 cross-functional management team members who share more than 300 years of molding experience.”

First American operates two facilities in the United States, its headquarters in South Beloit, Illinois, and another plant in Ocean Springs, Miss. These plants are 39,000-sq.-ft. and 22,000 sq. ft., respectively.

About First American Plastics Corporation
First American Plastics Corporation is a provider of thermoplastic molding and custom injection molding services for the food, packaging, automotive, and (non-invasive) medical industries. They have been in business since 1993 and are headquartered is in South Beloit, IL, 75 miles northwest of Chicago.

DuPont Launches Thermoplastic Vehicle Armour Solution at Eurosatory

June 28, 2010 - DuPont has announced the launch of its new thermoplastic vehicle armour solution, Kevlar® ACV (Advanced Composites for Vehicles), at this year’s Eurosatory trade show in Paris.

The new innovation from DuPont, launched at its stand at the show on 16th June, is an extension to its Kevlar® product range and has been designed for the protective vehicle market. The development of this new product has primarily focused on incorporating optimum ballistic properties to ensure maximum protection as well as durability.

The Kevlar® ACV has been developed to be fully compliant with material standards for use in vehicles requiring thermal stability up to 120ºc whilst not compromising the ballistic efficiency for use by the private sector as well as the military. DuPont has developed the solution and will work with manufacturers to produce light-weight ballistic protective elements. The Kevlar® ACV combines various DuPont proprietary technologies including nano-material sciences, to bring a durable protection with high weight efficiency and multi-threat capability.

The new Kevlar® ACV is designed for vehicle applications with a focus on durability, ease of implementation and environmental friendliness as well as ballistic protection efficiency against multi-threats such as bullets and fragments.

DuPont™ Kevlar® is an organic fibre from the aramid family offering an excellent combination of properties: it is lightweight, sturdy and fireproof, affording protection and thermal resistance. Kevlar® is five times stronger than steel at equal weight, thus providing outstanding sturdiness combined with amazingly reliable and durable material performance. Kevlar® armouring systems are less cumbersome, easy-to-model and adaptable to vehicle structure, for simplified, quicker and thus less costly installation. Kevlar® boasts high ballistic performance and can withstand extreme temperatures, remaining relatively lightweight without being too cumbersome. These properties are extremely important to ensure protection whatever the circumstances, whilst maintaining payload performance and vehicle mobility.

For more information on Kevlar® ACV visit DuPont on stand K321 during Eurosatory or visit www.dupont.com