Today's KNOWLEDGE Share : Core defects leads to catastrophic results

Today's KNOWLEDGE Share

Based on consulting requests, I realize that a lot of people forget that huge forces are developed during the molding process, as a result of pressure levels exceeding often 1000 bar/100MPa.

That amounts to 1 metric Ton of equivalent force applied to each square cm of tool surface.That is why clamp tonnage numbers are what they are of course.

But, no matter how good your steel or tool design is, metal will bend significantly when subjected to huge unbalanced forces.

And, even more surprisingly, for balanced forces, the cavity will expand by "compressing" the steel by quite a few microns !

You can run a quick FEA to check that, by applying 1000-2000 bar on a piece of steel.

Of course tubular shaped parts will readily see significant core shift problems as soon as flow is slightly unbalanced, since a differential of a few Tons-force can quickly appear if flow is not perfectly balanced. The problem here is, of course, that the more the core deflects, the more the unbalance grows. So it is a bad case of positive feedback leading to catastrophic results (unexpected weldlines in the thinned side towards which the core has been bent/pushed).

Don't underestimate the importance of these effects in molding.

While coupling Flow Analysis with stress analysis on the steel structure can supposedly model this, it is very challenging to describe the complex tool assembly. And such coupled approaches can be very challenging numerically. So, while core-shifting predictions are now quite standard, full tool deflections are usually neglected in simulations. And the clear tendency of steel compressibility to lead to overpack is never accounted for.

source:Vito leo

Today's KNOWLEDGE Share : Cupra Born VZ driving sustainability with Bcomp’s natural fibre materials

Today's KNOWLEDGE Share

Cupra announces the use of Bcomp’s innovative natural fibre composite solutions for the new CUP Bucket seats in the Cupra Born VZ electric vehicles, the latest addition to the Spanish brand’s vehicle line-up.  

Cupra focuses on innovation and sustainability to redefine the automotive industry. This approach is exemplified by the Cupra Born VZ, which combines powerful performance with eco-friendly design, aiming to inspire a new generation of drivers with its progressive and responsible engineering.

For the car’s interior design, Cupra’s collaboration with Bcomp and Sabelt, renowned for their expertise in high-performance automotive seats, has resulted in the creation of the first full natural fibre CUP Bucket seats in the Cupra vehicle line-up. By replacing the seatbacks currently made from carbon and glass fibres, the new all-natural fibre seatbacks offer significant reductions in emissions. Indeed, the use of Bcomp’s proprietary ampliTex™ technical material reduces CO2 emissions by 49% compared to the hybrid version, while also offering end-of-life options. The incorporation of natural fibres offers other significant benefits including enhanced vibration damping and increased safety, providing an optimal blend of sustainability and high performance.

The close collaboration between Cupra and Bcomp also reflects the ability to rapidly integrate these natural materials into the production car manufacturing process. With a shared commitment to improving environmental responsibility without compromising performance, the transition from traditional materials to innovative sustainable materials has been remarkably swift. The ampliTex™ natural fibre provides both the structural layer and a visual surface that introduces an elegant natural appearance and higher level of comfort for drivers and occupants.

The resulting fully natural fibre-based CUP Bucket seats are available exclusively for the most powerful electric Cupra. The Cupra Born VZ delivers impressive performance with 322 horsepower and a massive instant torque of 545 Newton-meters, allowing the vehicle to accelerate from 0 to 100km/h in just 5.7 seconds and reach a top speed of 200km/h while offering a thrilling and dynamic driving experience for anyone seated comfortably in the supportive bucket seat.

By adopting advanced eco-friendly materials, Cupra not only enhances the sustainability of its vehicles but also sets a new benchmark for the automotive industry. We are changing the sporty aesthetics to incorporate a functional part made of flax fibre in the interior of a car”.

source: Bcomp/jeccomposites.com

New Energy Blue and ARCO/Murray partner to build biomass refineries to produce sustainable fuels and chemicals

New Energy Blue, the clean-energy developer whose technology converts agricultural waste into lowest-carbon biofuels and biochemicals, and ARCO/Murray, one of America's largest, most experienced, and fastest-growing construction firms, today announce a partnership to build out the New Energy Biomass Refinery designed platform across the American Midwest. 

ARCO/Murray will construct the flagship New Energy Freedom biomass refinery in Mason City, Iowa, to sustainably process corn stalks into second-generation fuel ethanol and clean lignin at large commercial capacity. The partners have agreed to a $650 million construction contract. In 2023, New Energy Blue completed the design engineering, obtained local permits to proceed, and conducted field trials of new harvesting methods and machinery; in 2024, the project entered the final investment decision (FID) phase. The partners plan to break ground later this year and start up the refinery in 2026.  

The significant economic impact anticipated is comparable to that typically seen with first-generation ethanol facilities. In Iowa, the state responsible for approximately one-quarter of U.S. production, the industry contributes about $8 billion to household incomes annually and 100,000 indirect and induced jobs. The construction of the Freedom refinery in Mason City is projected to generate between 400 and 500 high-paying construction positions over a 20-month period. Refinery operators and feedstock suppliers from New Energy Farmers aggregation team will hold about 70 permanent jobs carrying an annual payroll of $7 million. The economic ripple effects will likely support another 5,000 jobs. Local corn growers stand to benefit by not only selling their excess corn stalks to the refinery but also participating in profit-sharing through the New Energy Farmers business unit. 

Patrick Hidder, Executive Vice President of ARCO/Murray's Green Infrastructure team, says, "We are excited to partner with New Energy Blue on this groundbreaking biomass refining project, reflecting our shared commitment to sustainability and innovation in the renewable energy sector. We welcome the opportunity to help launch a nascent industry dedicated to decarbonizing this country's fuel and chemicals." 

James Foster, Vice President of Construction for New Energy Blue, says the selection of ARCO/Murray as engineering, procurement, and construction (EPC) contractor "has paid off immediately. Their involvement is letting us accelerate the project schedule, manage costs, and provide the necessary bonding capacity needed to satisfy finance. ARCO/Murray's expertise in process piping, water treatment, anaerobic digestion, and power solutions has already added significant value."  

source:New Energy Blue/ prnewswire.com

Today's KNOWLEDGE Share :Microplastic fibres released from cleaning sponge

Today's KNOWLEDGE Share

Commonly used cleaning product releases millions of microplastic fibres

A study has demonstrated that one single sponge can release millions of microplastic fibres that could end up inside the body.

Researchers from the School of Energy and Environment at Southeast University, China, have analysed how much microplastic a specific and common type of cleaning product releases. The result was 1.5+ trillion particles a month on a global scale.

Researchers: trillions of fibres released from cleaning sponge

The popular melamine sponge was the subject of the researchers' study.

They examined sponges from different brands and rubbed them against the same surface.

In doing so, they determined that one single sponge released approximately 6.5 million fibres for every g they were worn down.

To calculate how many microplastic fibres are shed globally every month, the researchers estimated that all sponges wear down by an average of 10 %.

This data, combined with sales figures from global online retailer Amazon, prompted the researchers to conclude that 1.55 trillion fibres could potentially be released from melamine sponges every month.

Why it can be harmful to your health

Science Illustrated has previously described how microplastics find their way into the human body - either through the air or via what we eat and drink.

When a melamine sponge is used or rubbed against a surface, it eventually breaks down into smaller pieces that release microplastics.

The microplastics can then be flushed into the sewage system and eventually ingested by fish or other animals, which is how the fibres enter the food chain. This could ultimately affect humans who eat fish or other foods, absorbing the microplastics.

However, the researchers' results also indicated that dense sponges both decomposed more slowly and released fewer fibres than sponges whose foam was less dense.

Their advice is to use dense sponges or natural cleaning products, of which there are many on the market, to avoid too much microplastic ending up in nature.

The study has been published in ACS Journals.

source:scienceillustrated.com

Ineos Styrolution and Edge Solutions sign exclusive supply agreement:

Ineos Styrolution has announced today that the Scottish wind energy specialist Edge Solutions has signed a ten-year exclusive supply agreement for an ultra-tough Luran SC thermoplastic product, designed specifically for wind turbine blades.

Edge Solutions, based in Edinburgh has developed a patented system, called Armour Edge, which repairs and protects the leading edge of wind turbine blades from erosion - a significant issue for operational onshore and offshore windfarms. Their product is a custom-fitted modular shield which uses a bespoke version of an ultra-tough Luran SC thermoplastic product, designed specifically for wind turbine blades.

These two companies have been working in tandem for many years1 and the new exclusivity agreement extends Edge Solutions’ sole global rights to use Luran SC in leading edge protection (LEP) applications for the next decade, and on a rolling annual basis thereafter.

"This agreement cements our position as a significant player in the LEP market and underlines the strength of our long-term partnership with Ineos Styrolution," says Edge Solutions’ Managing Director David Urch.

"Edge Solutions was launched commercially in 2020. We now have a growing Armour Edge order book worldwide, with repeat orders from early customers, including RWE, and the German offshore wind farm Riffgat, with a number of our clients now looking to increase the amount of coverage per blade. We are delighted to continue our successful collaboration with Ineos Styrolution, and we look forward to announcing more significant customer orders in the months ahead," Urch concludes.

Andreas Kolf, Business Development Manager at Ineos Styrolution adds: "We are very excited to work with the very motivated and ambitious team at Edge Solutions. The fact that our material contributes to the production of renewable energy adds a new facet to our own commitment to sustainability."

About Luran SC:

The Luran SC product line comprises blends of ASA with PC. Luran SC provides a very high heat resistance and improved impact strength at enhanced stiffness compared to ASA. Luran SC is very stable towards oxidation and keeps its outstanding mechanical properties also outdoors. Therefore, a main field of use are demanding applications in automotive interiors and exteriors. Within this product line, Ineos Styrolution also offers a flame-retardant grade that meets UL 94 test standards at V0.

source:plastech.biz

Dow Launches New Recycled Plastic Resins with Up to 100% PCR for Shrink Film

Dow has announced the development and launch of its innovative REVOLOOP recycled plastic resin family. The launch marks a milestone in Dow’s commitment to advancing circularity and waste diversion.

 

By 2030, Dow aims to achieve waste diversion and commercialize 3 million tons of circular and renewable solutions per year. To achieve this goal, Dow is increasing its efforts to advance circular and sustainable packaging. To achieve these sustainability goals, the launch of REVOLOOP plastic resins brings a new commitment to unlock more value from plastic waste for customers and partners.

 

Two new grades of REVOLOOP plastic resins are launched and approved for non-food contact packaging applications. One contains 100% post-consumer recycled content (PCR) and the other is a formulated grade containing up to 85% PCR from household waste.

 

“With the launch of our new grades of REVOLOOP recycled plastic resins, we continue to expand our sustainable portfolio, working with brands, converters and recyclers to devise new ways to reduce the amount of plastic in packaging and ensure that used plastics are fully recyclable,” said Fabrice Digonnet, head of plastics machinery recycling strategy for EMEA at Dow Packaging & Specialty Plastics.

 

“Our launch of REVOLOOP is an exciting step forward in our recycling history, enabling us to achieve new circularity and low-carbon goals.”

 

By combining Dow’s material science expertise with RKW’s extrusion and printing expertise, they are maximizing the value of recycled plastic household waste for the most demanding applications in history. “This collaboration will bring a whole new class of shrink films to the market,” said Konrad Noniewicz, RKW Group Director of R&D and Application Engineering.

 

“By combining REVOLOOP 100% PCR and REVOLOOP containing recycled plastic household waste with virgin material, we have created a flexible packaging solution that meets the requirements for mechanical recyclability, ensures compatibility with existing recycling processes and helps the transition to a circular economy.” The end product is a collation shrink film containing PCR, partly derived from recycled plastic household waste, which meets the high requirements of well-known global brand owners.

source:echemi.com/Dow

Ampacet Expands ELTech™ Range to Include Color Masterbatches for Optical Fiber Cable

Ampacet, a global masterbatch leader, has expanded its ELTech™ portfolio to include a range of high performance color masterbatches based on a Polybutylene Terephthalate (PBT) carrier resin and specifically designed for optical fiber cable PBT jacketing.

Optical fiber cable jacketing is often made of Polybutylene Terephthalate (PBT) to benefit from its mechanical properties such as high strength and stiffness as well as resistance to heat and chemicals. PBT jacketing is often selected for indoor optical fiber cables used in building and construction as well as in data centers. For ease of installation, optical fiber cable manufacturers use a color-coding system such as the RAL system to identify individual optical fibers.

ELTech masterbatches for optical fiber cable preserve high-performance signal transmission and feature excellent opacity at a low addition rate, high resistance to heat and color fading and include 16 colors that comply with RAL color references. Additional shades using custom colors or color-coding systems such as RAL or Pantone can be developed upon request.

“The significant increase in consumer and business demand for high-speed internet has resulted in dramatic growth in the fiber optic cable market, ,” says François Thibeau, Ampacet Strategic Business Manager E&E. “We have responded to customer needs by expanding our ELTech range to include color masterbatches for optical fiber cable.”

The ELTech product range also includes masterbatches combining color with functional additives. For proper functionality and operability of E&E applications, Ampacet offers advanced additive masterbatches, including laser marking, metal deactivators, UV stabilizers, flame retardants, antimicrobial, scratch resistance, slip and release, odor absorbers, process stabilizers and processing aids.

source: Ampacet

EVERTIS LAUNCHES EVERCARE™ BRAND FOR THE HEALTHCARE PACKAGING MARKET

Evertis launches Evercare™ brand, set to be a leading provider of specialty and innovative medical-gradefilms designed to provide superior performance and support regulatory compliance to the healthcare market. Evercare™ is built on over 65 years of trusted technical Evertis experience in developing PET and PETG films for regulated applications that meet sustainability credentials, and now compliant in meeting the rigorous needs of the healthcare industry.

Evercare™ sits in avertically integrated Group that delivers a unique value proposition to Healthcare customers in terms of innovation, sustainability and supply chain security. As film converters for packaging, Evertis is integrated with Selenis,a premium supplier of innovative copolyesters resins with solutions specifically developed, and certified for the medical value chain to further support patient safety. As a Group it fully understands and plays its part in circularity whilst reducing the carbon footprint of its products.

Evercare™ PET and PETG drop-in solutions offer performance and sustainability advantages when compared to other materials. Their films facilitate the thermoforming process, provide improved mechanical and optical properties, and have a better resistance to sterilization. Manufactured in strict compliance with GMP standards and support regulatory compliance needs, Evercare™ films are offered with declarations such as ISO10993, USP661.1, ISO11607, as well as change notification.

Gonzalo Lopez-Oleaga, Evertis Europe Deputy CEO said; “This is another key milestone in the journeyof our Group of businesses. As innovators and thought leaders in polyester-based materials we are now positioned to help healthcare companies meet their sustainability packaging goals, now, and into the future. Behind Evercare™ we have made large investments operationally, in technology and most importantly GMP manufacturing supported by full certifications to service this market”.

Similar to other industries, the healthcare packaging industry faces the challenges of improving sustainability. This is why the Evercare product range not only offers plug&play recyclable PET based solutions, but also two other sustainable options: bio-based and chemically recycled materials with up to 50% post-consumer recycled (PCR) content. All of these options take advantage of vertical integration with Selenis, meeting the same quality and regulatory standards and representing a great opportunity to lower carbon footprint.

Casimiro Sacchetti, CSO Evertis Americas said; “It’s an exciting and unique offering for the Healthcare market. It’s the coming together of experience, deep technical knowledge underpinned by a truly integrated, vertical operational set-up from resin production to extrusion of medical-grade films.

source:Evertis

Turning Plastic Waste Into Carbon Nanotubes

Welsh-based startup TrimTabs has developed an innovative process to upcycle waste polymers into a light, super-strong composite material with applications in the energy storage and transmission, automotive, construction, electronics, medical and aerospace industries.

Trim Tabs leadership team: David Ryan and Professor Alvin Orbaek White

Plastic waste is a growing global challenge, with millions of tonnes disposed of every year. It is perhaps the most totemic waste problem of our age. Despite increasing efforts to improve recycling rates, many types of plastic remain difficult or uneconomical to recycle, demanding innovative solutions.

One company taking a novel approach to this is TrimTabs, a UK-based startup that has developed a process to turn plastic waste into high-value carbon nanotubes. By harnessing the inherent value in discarded plastics, TrimTabs aims to commercialise a new option for the circular economy, addressing the environmental burden of some waste plastics.

The potential applications using carbon nanotubes are vast, from enhancing the performance of lithium-ion batteries to creating stronger, lighter composites for industries like aerospace and automotive. The use of nanotubes in electronic components, solar cells, and water filtration systems also holds significant promise.

The idea behind TrimTabs originated with founder and CEO Prof. Alvin Orbaek White, whose background spans physics, chemistry, mechanical engineering, and chemical engineering. "I was working on a Ph.D. program in Barcelona, where we were making a device that will go to the moon and turn lunar regolith, moon soil, into solar cells and breathing oxygen," Prof. Orbaek White explains. "In order to do that, in space physics, you really need robust, lightweight materials that have long durability. And there was one critical material that was capable of doing this - carbon nanotubes."

Prof. Orbaek White's fascination with carbon nanotubes led him to Rice University, where he was inspired by the late Professor Richard Smalley, a Nobel laureate for his work on buckminsterfullerene (soccer ball-shaped carbon molecule). Under the supervision of Professor Andrew Baron "I learned to make carbon nanotubes and was just totally enamoured by them," Orbaek White recalls. "They're light like ash but have tensile strength 100 times greater than steel. So I thought to myself, this is a magic material."

It was during a meeting with the Welsh Government about opportunities in India that Orbaek White considered moving forward on his ideas about the potential for using waste plastics as a feedstock to produce carbon nanotubes. "I knew instinctively as a chemist that plastics can be a very viable source of carbon for making carbon nanotubes, but I didn't have the data."

source:Trim Tabs

Today's KNOWLEDGE Share:Biodegradable plastic waste into green energy

Today's KNOWLEDGE Share

New Project to Turn Biodegradable Plastic Waste into Green Energy:

This research project involves AIMPLAS, the Plastics Technology Centre, the Research Institute of Water and Environmental Engineering at the Universitat Politècnica de València (IIAMA-UPV), the CALAGUA Group UPV-UV Mixed Unit, and the companies Global Omnium Medioambiente and Fych Technologies.

Recovery of Bioplastics Through Anaerobic Co-digestion:

Recovering biodegradable plastic waste through anaerobic co-digestion treatment with sludge from sewage treatment plants (STP) to obtain a biogas stream that can be used as an energy vector and a digestate for agriculture.

This is the main objective of VALPLAST (Recovery of bioplastics through anaerobic co-digestion at sewage treatment plants), a strategic project in which a consortium of members participates, including AIMPLAS, the Plastics Technology Centre, the CALAGUA Group UPV-UV Mixed Unit (made up of the Research Institute of Water and Environmental Engineering at the Universitat Politècnica de València and the Department of Chemical Engineering at the Universitat de València), and the companies Global Omnium Medioambiente and Fych Technologies.

The project is financed by the Valencian Institute of Competitiveness and Innovation (IVACE+i) within the framework of the European Union’s 2023 strategic cooperation projects. It seeks to implement an alternative to current management of biodegradable plastic packaging waste that is aligned with circular economy principles.

Evaluating Possible Effects of Additives in Plastic Synthesis:

“The main innovation of the project involves understanding that bioplastics are a resource that can be recovered and transformed into green energy,” according to researchers participating in the project.

The aim will therefore be to study, at laboratory and pilot scale, the degradation of different plastics through biological treatment with sludge from municipal sewage treatment plants under anaerobic conditions. The possible effects of the additives used in the synthesis of plastics (conventional and bioplastics) in the anaerobic treatment process and the subsequent quality of the digested sludge will also be evaluated, given that its main application is agricultural use.

Work will also be done on the development and optimization of pilot plant instrumentation and control systems, as well as the analysis of costs and the life cycle. As consortium members highlighted, “They are essential to be able to evaluate the environmental and economic sustainability of the proposed treatment.”

After the recovery process, analysis will be carried out to measure the presence of microplastics in the sludge. For this analysis, the methodology developed by AIMPLAS in previous projects (MICROPLAST and PREVENPLAST) will be used. This method makes it possible to measure these emerging contaminants in both wastewater and the sludge generated at treatment plants.

This process will be used to develop a methodology for energy recovery from bioplastics at STP digesters for better management of these wastes resulting in greater energy recovery.

Also of note is the previous experience that part of this consortium acquired during implementation of and collaboration on other R&D projects related to the goal of this project, such as AVI MICROPLAST and AVI PREVENPLAST.

source:AIMPLAS/omnexus.specialchem.com