Biofibix launches high-performance isotropic flax reinforcements

Developed by materials expert Gilles Koolen, former coordinator of the Alliance’s Scientific Council, and Vanacker, a 3rd generation flax grower and scutcher, Hypermat directly addresses the economic and processing challenges that have limited the adoption of yarn-based flax fabrics in composites. Their innovation aligns with the Alliance’s commitment to advancing sustainable, European-grown natural fibres in industrial markets.

Hypermat is produced in-house from controlled flax sources and manufactured on a high-capacity line capable of up to 2 t per day. The materials offer consistent availability and tailored formats, with nominal weights from 300 to 1,200 gsm and widths ranging from 25 mm to 2,300 mm.

Hypermat delivers notable mechanical improvements, including double the flexural stiffness and a 25% weight reduction compared to quadriaxial glass reinforcements. Hypermat materials outperform glass fibre in specific bending stiffness tests and deliver exceptional comfort, safety and quietness to the end user.

Boosting performance and sustainability:

Biofibix’s proprietary treatment process improves the flax fibres’ moisture resistance and reduces resin uptake, increasing performance in humid or load-bearing environments while also supporting higher fibre volume fractions. The improved resin economy further enhances the sustainability profile of the composite, with each kilogram of Hypermat-based composite storing approximately 0.75 kg of CO₂ and all manufacturing conducted within a 150 km supply radius.

Available in stock weights of 300, 500 and 600 gsm, with custom formats also available, Hypermat is already being trialled by industry partners in the sporting goods, marine and infrastructure industries. With a balance of affordability, performance and environmental benefit, Biofibix Hypermat is positioned to expand the practical use of flax fibre reinforcements across high-volume applications.

“Cost-effective nonwoven manufacturing, combined with our unique Biofibix fibre treatment, has created a powerful solution for low impact composites across a host of applications,” said Gilles Koolen. “We’ve reengineered our reinforcement in response to market needs, enabling Hypermat to offer cost effective and comparable performance to quadriaxial flax non-crimps and quasi-isotropic lay-ups.

Cover photo: Hypermat/Biofibix

Today's KNOWLEDGE Share : Circular Dent on the plastic milk Jug

Today's KNOWLEDGE Share

This dent isn’t there for decoration or by mistake it’s an intentional design feature that helps the jug manage pressure, stay strong during transport, reduce plastic usage, and make recycling easier.

When the jug is filled, the liquid inside creates pressure. The dent works like a flex point that can expand or contract slightly to prevent the jug from cracking or becoming misshapen, especially during stacking or when temperatures change.

It also allows the jug to absorb some impact if dropped, which helps prevent spills or breakage. From a manufacturing perspective, the dent strengthens the jug’s structure without needing extra plastic, which cuts down on material costs and waste. This makes it both economical and more environmentally friendly.

Additionally, the design makes the jug easier to crush for recycling, saving space and making the recycling process more efficient. Some brands even use the dent for visual appeal or branding by adding logos to the indented area. While many people mistakenly think the dent is a flaw, it’s actually a smart solution that makes milk jugs safer, cheaper to produce, and more sustainable. This tiny detail shows how thoughtful design can have a big impact on everyday products.

source: Garnik Gary K

Today's KNOWLEDGE Share : New Ferroelectric Polymer Eliminates Need for ‘Forever Chemical’ in Wearables

Today's KNOWLEDGE Share 

New Ferroelectric Polymer Eliminates Need for ‘Forever Chemical’ in Wearables

The polymer developed at Case Western Reserve University is described as an alternative to PVDF, which contains fluorine, typically used in wearable electronics.

A ferroelectric polymer made without fluorine, a so-called forever chemical that can take centuries to break down in nature, has been developed by researchers at Case Western Reserve University. The material may represent a more environmentally friendly substitute for poly(vinylidene fluoride), or PVDF, which is typically used in wearable electronic devices, sensors, and other electrical applications.

Ferroelectricity refers to certain materials exhibiting “spontaneous polarization" that can be reversed by applying an electric field, similar to an on-off switch. Ferroelectric materials allow for the development of smaller, more-efficient electronic devices, reducing reliance on traditional energy sources.

Polymer with on/off switch

The polymer developed at Case Western and described in its newsletter, The Daily, combines flexibility, essential in wearable applications, and has tunable electronic properties that can be switched on and off.

Although the researchers are still working to improve the material's electric and elastic properties, its flexibility and eco-friendly structure offer tremendous potential in wearable technology, according to researchers at Case Western in Cleveland, OH. (The university was named by PlasticsToday recently as one of the best US colleges for plastics engineering degrees.)

How this material generates its electric properties is also fundamentally new," said lead researcher Lei Zhu, a professor of macromolecular science and engineering at the Case School of Engineering. "Unlike current ferroelectric materials, it doesn't have to crystallize to lock in the polarity that gives it electrical properties," he told The Daily.

Applications in wearable technology sensors

The polymer has broad applications in infrared detectors and sensors used in wearable electronics, where materials need to be soft, pliable, and elastic to be compatible with the human body. Conventional ceramic ferroelectric materials are rigid and brittle, according to the researchers.

Ferroelectric polymers also have applications in sensors for ultrasound diagnostic tools because they are acoustically compatible with biological tissues. They are also potentially useful in augmented and virtual reality goggles.

We're still in the development stage of synthesizing small quantities and investigating the properties," Zhu said. "But we're excited about the potential to replace environmentally harmful plastics in sensors and detectors."

The research explaining the discovery was recently published in the journal Science. The new material is patent pending.

source: Plastics Today

Today's KNOWLEDGE Share : Walmart recalls 850,000 water bottles after two consumers suffer vision loss from ejecting caps

Today's KNOWLEDGE Share

Walmart is recalling about 850,000 stainless steel water bottles because the lid can “forcefully eject” and unexpectedly strike consumers resulting in permanent vision loss for two people to date.

The recall covers Walmart’s “Ozark Trail 64 oz Stainless Steel Insulated Water Bottles,” which have been sold at the chain’s stores across the country since 2017. According to a notice published by the U.S. Consumer Product Safety Commission on Thursday, these products pose “serious impact and laceration hazards.

That’s because when a consumer attempts to open the bottles “after food, carbonated beverages or perishable beverages, such as juice or milk, are stored inside over time,” the lid can eject forcefully, the CPSC notes.

As of Thursday’s announcement, Walmart had received three reports of consumers who were injured after being struck in the face by these lids when opening their bottles. And two of those people “suffered permanent vision loss after being struck in the eye,” the CPSC added.

Consumers are urged to stop using the now-recalled Ozark Trail bottles — and contact Walmart for a full refund. Shoppers can also bring the products to their local Walmart store for that compensation.

The health and safety of our customers is always a top priority,” Walmart said in a statement sent to The Associated Press. The company added that it had “fully cooperated” with the CPSC and the manufacturer of the recalled product “to remove it from our stores and notify consumers”

The bottles being recalled can also be identified by their model number, 83-662 which doesn’t appear on the product itself, but would show on packaging. The stainless-steel base is silver and the lid is a black, one-piece screw cap. There is also an Ozark Trail logo embedded on the side of the 64-ounce bottle.

source: AP News

My views on Plastic Caps:

PET bottles do have a proper gas venting system with their caps. All major companies do have passed such a test before launching the bottles into the market. The threads on the plastic bottle caps are well designed to handle such pressure in the bottle. There are some poorly designed caps from the small manufacturer of the plastic bottles that sell such bottles in the market in India. I too have witnessed such a high pressure build up bottle that the cap failed when opening the bottle and made little injury on the hand of the consumer.

When threads are designed to release such a gas vent out mechanism on the caps, such incidents can be avoided and user-friendly plastic bottles are in circulation for the long term in the global market. All plastic bottle manufacturers' caps need to be tested and certified before launching in the market.

Wabtec expands rail automation capabilities

Wabtec Corporation has announced the acquisition of Austria-based Frauscher Sensor Technology from France’s Groupe Delachaux for €675 mln. The transaction is subject to customary closing conditions and regulatory approvals. Only this year, Frauscher is expected to generate approximately €145 mln in revenue.

Founded in 1987, Frauscher is a leading supplier of axle counting systems and wheel detection sensors for rolling stock. The company claims a 45% share of the global axle counting market, having delivered more than 350,000 sensors to over 100 countries worldwide.

#Frauscher’s manufacturing facilities have the capacity to produce up to 50,000 sensors annually. The company employs more than 600 staff across 15 countries on four continents.

This latest acquisition follows #Wabtec’s recent purchase of the inspection technologies division from Evident for nearly $1.8 bln, further strengthening the group’s position in the railway automation and diagnostics sector (see https://lnkd.in/e4wVd4jW for details).

Image: Frauscher/ ROLLINGSTOCK

Today's KNOWLEDGE Share : World’s first 4,000-metric-ton (4,440-ton) electric injection molding machine

Today's KNOWLEDGE Share

New 4,400-ton Electric Molding Machine Targets Automotive Applications

The “ultra-large” press is designed to address demand for lightweight parts among makers of electric vehicles.

#JapanSteelWorks Ltd. (JSW) has introduced what it is calling the world’s first 4,000-metric-ton (4,440-ton) #electricinjectionmolding machine. The so-called “ultra-large” press was designed initially to mold lightweight components for #electricvehicles (EVs) to extend range, but also has applications in agricultural and industrial machinery and household appliances, primarily for the US market.

Target products for the machine with a 4,000-tonne clamping force include exterior automotive parts such as bumpers and tailgates, as well as the conversion of #EVbatterycases to #plastic, said JSW. 

Hydraulic presses currently dominate the 4,000-tonne injection molding machine market, said #JSW, but they are saddled with a number of issues:

High operating costs caused by significant power consumption, the use of hydraulic oil, and water cooling requirements;

poor precision, resulting in quality variability;

limitations in mold opening/closing and injection speeds, making it difficult to shorten production cycles.

To address these shortcomings, JSW said it opted for an electric system that optimizes productivity, energy efficiency, and product quality. In addition, a long-life, robust machine design is a differentiator in the injection molding machine market, according to JSW.

The model J4000F-22000H reportedly achieves the fastest dry cycle in the industry, improving productivity by 10% compared with current hydraulic presses. Moreover, power consumption is reduced by as much as 20%, consumption of cooling water is slashed by 50%, and hydraulic oil use is cut by 70%. Annual operating costs can be reduced by 20%, according to JSW, and the machine also lessens CO2 emissions compared with hydraulic presses.

Despite the massive tonnage, the machine’s footprint is only 17.4 meters (57 feet) in length, which JSW claims is the shortest in the industry. The rigid mold platen, similar in design to a car bumper with a short vertical and long horizontal shape, comes with a large-diameter, movable support mechanism that maintains platen precision over extended periods, said JSW.

JSW will exhibit at the K show in Düsseldorf, Germany, in October in hall 13 at booth B77.

source: Plastics Today

Today's KNOWLEDGE Share : Avantium’s PET/PEF multilayer bottle gains full recyclability recognition from RecyClass

Today's KNOWLEDGE Share

RecyClass Validates Avantium’s PET/PEF Bottle as Fully Recyclable in PET Stream

Avantium N.V., a leader in renewable and circular polymer materials, announces that its innovative PET/PEF multilayer bottle has been recognized as fully compatible with the PET recycling stream following an evaluation by RecyClass, the European non-profit initiative dedicated to advancing plastics circularity.  

Avantium’s PEF (#polyethylenefuranoate), branded as releaf®, can be used in fully plant-based monolayer PEF bottles, but also has advantages in combination with PET (polyethylene terephthalate). For example, #PEF can be used in multilayer PET bottles as a barrier material when the required shelf life cannot be guaranteed by a single layer of PET. Currently, many multilayer #PETbottles include nylon as a barrier, which is known to cause issues when recycled within the PET recycling stream. Due to its excellent barrier properties and its close resemblance to PET, a PEF layer is an excellent alternative. 

The RecyClass PET Technical Committee evaluated Avantium’s PET/PEF multilayer bottle - containing 10% PEF releaf® RP90N - through lab tests by PTI-Europe and Plastics Forming Enterprises. Results confirmed full compatibility with PET recycling stream under the conditions outlined in the RecyClass Approval Letter. RecyClass collaborates with the US-based Association of Plastic Recyclers (APR) to harmonize recyclability recommendations and testing procedures. Avantium’s PEF received APR Critical Guidance Recognition in 2023. With both approvals, brand owners can confidently adopt PEF as a recyclable barrier layer. Additionally, RecyClass validation supports favorable acceptance by national producer responsibility organizations (PROs), which oversee compliance with Extended Producer Responsibility (EPR) regulations and determine packaging-related EPR fees. EPR is a policy mechanism that requires producers to, amongst others, pay fees based on recyclability and environmental impact. 

Ingrid Goumans, director Public Affairs at #Avantium, comments: “This recognition by RecyClass clearly demonstrates that PEF can be successfully integrated into the PET recycling stream. By offering a 100% high-barrier polyester solution, the PEF/PET multilayer bottle opens new possibilities for sustainable packaging. It gives brand owners and converters the confidence to adopt PEF as a functional barrier layer in their PET applications.” 

source: Avantium