Embed Size (px)
Citation preview
News from the Scottish Plastics and Rubber Association
2001
CONTENTS
April 2001 Page The Annual SPRA Dinner Dance at Hilton Hotel, Glasgow 2 Branson Ultrasonics explain assembly of plastics components by ultrasonic welding 3 Moldflow Plastics Xpert (MPX) software for moulding simulation 4 Rapid Prototyping and Rapid Tooling for plastics moulding 6 Setting up an Employer Learning Network for the Polymer Sector in Scotland 7 SPRA Corporate Membership 8
August 2001 SPRA President, Hugh Smith, reviews his first year in office 9 Debate on Managing Polymer Waste 10 ‘Closing the Gaps’ – Approach to Quality in the Polymer Industry 11 Employer Learning Network discusses Training Needs Analysis (TNA) 12 Polymer Study Tour 2001 - residential course for teachers 13 Scottish Materials Exchange II 14 SPRA Annual General Meeting 2001 14 Schools competition winners – model yacht 15 Congratulations 15 SPRA Corporate Membership 15 December 2001 ‘Hard Times’ - a tough year for the plastics and rubber industry in Scotland 17 Tie-barless Injection Moulding Machines – lecture from Billion UK 17 Robotics for injection moulding – presentation by Sepro 18 Fire Performance Development: testing, additives, base polymer 19 Laser welding of plastics by Herfurth 20 Real time monitoring of polymer processes by Mattec 20 K 2001: report on the International Plastics Exhibition 21 Employer Learning Network: Managing Change 22 Scottish Materials Exchange III: Biomaterials 23 Expanded Polystyrene Recycling 23 SPRA becomes and Affiliate of the British Plastics Federation 23 Congratulations 24 School groups visit Napier University polymer facilities 24
News from the Scottish Plastics and Rubber
Association
April 2001
Features in this issue: Dinner Dance 2001 Ultrasonic Assembly Moldflow MPX Rapid Prototyping Employer Learning Network Corporate Membership Latest News
DINNER DANCE 2001
The annual SPRA Dinner Dance at the Hilton Hotel, Glasgow on Friday 16 March again attracted record numbers. A Scottish flavour permeated the evening, with the traditional piper, the address to the haggis, the menu and, of course rigorous sampling of the national beverage. The main speaker, John Morgan, resplendent in the kilt, entertained the guests with typical Glasgow humour.
Mr Hugh Smith, SPRA President,
with his top table guests
Mr Hugh Smith, SPRA President, introduced his top table guests, who included Dr Malcolm Hall (Polymer NTO) and Nick Edwards (Editor of PRW), before announcing that SPRA membership continued to flourish. Corporate Membership has been successfully introduced and web pages for each company are now live on the SPRA website. Hugh also presented SPRA prizes to two students and thanked CTP Silleck for generously donating Dinner tickets for three students. The future for the industry according to Hugh "will be challenging but there will always be a place for companies offering innovation, quality and service; companies that remain lean, abreast of developments and alert to change; companies who not only listen to but also respond to customers' ever changing needs."
By midnight there was general agreement amongst the revellers that, in contrast to the current unfavourable trading position, this had been one of the best Dinners.
Tracey Douglas presented with the SPRA prize for her performance in Polymer modules on the BSc Applied Chemistry course at Napier University, Edinburgh
ULTRASONIC ASSEMBLY
The ultrasonic process is a proven technique for plastics assembly, providing a fast, repeatable, high quality method of plastic joining, eliminating the need for adhesives and mechanical fixings. However, for successful use, due consideration must be given to the requirements of the ultrasonic process in terms of the polymer selected, part geometry and joint design. Ultrasonic welding uses frictional heat generated at the joint interface to melt the surfaces so that a homogenous bond can be formed. For this to happen the two parts to be welded must have the same melt characteristics so that a simultaneous melt can be generated. It is possible to weld different polymers together that meet this requirement such as ABS to acrylic but in general terms like-to-like polymers give the strongest results. Energy transmission abilities are also a key consideration when considering the process.
The vibratory energy is generated by converting mains frequency to 20,30 or 40 kHz using a solid state power supply. Electrical energy at one of these ultrasonic frequencies is fed into a converter which contains a number of polarized piezoelectric discs which grow and diminish in size as the polarity is reversed.
Attached to the converter are booster and work horns, which modify the amplitude of vibration to the appropriate value for the resin to be welded. Both horn and booster are tuned to resonate at the required amplitude and frequency. The work horn must contact the part directly above the joint line over a sufficiently large area to ensure energy transmission without marking the part. The horn is applied to the part using a pneumatic actuator. A suitable joint design must be incorporated so that a small initial contact area and self-location of the part is provided.
In addition a means of controlling the flash is needed if good appearance is required. There are two basic types of joint depending on the resin to be welded and joint specification required. Amorphous materials require an energy director type of design whilst semi-crystalline polymers need a shear joint to generate a full hermetic seal since these types of materials have a sharp melt point which inhibits free flow of resin in the joint area.
The key considerations for ultrasonic assembly are:
horn contact area
energy transmission properties and amplitude requirements of polymer
suitable horn design
welded assembly appearance
joint specification and design
Should the application present aspects that are not compatible with the ultrasonic process then such alternatives as Linear/Orbital Vibration,Hot Plate and Spin Welding should be considered.
Branson Ultrasonics, Middlesex
Tel: 020 8561 4422 E-mail: [email protected] www.Branson-PlasticsJoin.com
MOLDFLOW MPX
The SPRA meeting "Removing the Black from the Art of Moulding" on Tuesday 20 Feb at SAMC, Livingston, attracted an audience of 44, from 18 companies, all eager to evaluate Moldflow's latest product, Moldflow Plastics Xpert (MPX).
Mark Dingwall opened the evening with an interactive session to establish the main objectives in setting a new mould, validating the process and monitoring production: optimised cycle time, consistent quality, minimal scrap, a stable process. Richard Perry then looked at the principles and operation of MPX. The hardware, which can be retrofitted to most machines, assists setters in systematically altering machine conditions, using Setup Xpert until a "good" moulding is produced.
l to r: Mark Dingwall (Moldflow), Colin Hindle (Napier University),
Richard Perry (Moldflow)
Optimise Xpert systematically examines the process window and alters process conditions to establish a robust process, capable of producing quality parts consistently. Production Xpert monitors production and adapts to changing external variables (material rheology, ambient temperature, etc) to maintain quality output.
The evening was illustrated with numerous case studies in which the application of MPX had demonstrated significant financial benefits. In the cases where a return on investment was as short as 6 weeks the cynics in the audience felt that they showed up some very poor setter qualities in the first place. The overall impression was that Moldflow have made big strides with MPX from its previous Smart Mold product but the sceptics felt there was still some way to go to provide true optimised adaptive production.
Contact: Mark Dingwall, Moldflow (Europe) Ltd tel: 01928 589718; mobile: 07768 863399 www.moldflow.com
RAPID PROTOTYPING
At the Stirling Management Centre on 13 March an audience of 34, drawn from 23 organisations, enjoyed a lively meeting on rapid prototyping and rapid tooling.
Clark Campbell, from CA Models, described how the company he had set up in 1983 had developed from a traditional modelmaker, relying mainly on manual skills, to the present high-tech company, employing 26 staff and applying the latest 3-D software, 3 Stereolithography (SLA) machines, a Selective Layer Sintering (SLS) machine and CNC equipment. CA Models, as a result of investment in equipment, software and staff, has cultivated a wide customer base in Scotland and beyond. To maintain that progress Clark is investing in a new fast SLA machine, a large SLS machine and is experimenting with new materials for prototypes. Although prototypes can be produced in a matter of hours, quality prototypes still require meticulous preparation and finishing, all of which takes time
Clark Campbell CA Models Ltd, Stirling
Philip Strachan, a design engineer from Stoneridge Elecronics in Dundee, gave a review of the options in applying rapid tooling, the topic of his prize winning Project as part of his MSc (with Distinction) in Plastics Moulding Technology at Napier University. In his talk Philip concentrated on the techniques driven by the same software as prototyping. The methods can be classified as Direct, in which the cores and cavities are produced directly from the software, and Indirect, in which moulds are produced from SLA masters.
Philip Strachan (left) in conversation with Andy Page (SPRA member)
DIRECT ACES Injection Moulding Direct Metal Laser Sintering Copper-Polyamide Mould Inserts R.T. via Fused Deposition Modelling Laminated Object Manufacture Tooling
INDIRECT 3D Keltool LaserForm ST-100 (RapidSteel 1.0 & 2.0) Spray Metal Tooling Nickel Bridge Tooling ProMetal System Polysteel Powder Metal Forging Foundry Shell Sand Moulding
The relative advantages and disadvantages of the techniques were presented, with particular reference to detail, dimensional accuracy, strength, lead time and cost. Rapid tooling is at its best if it can provide mouldings that are not just in the design-intent material but have the same properties as mouldings from full production tooling. In particular this requires the same pressures and heat transfer experienced in filling, packing and cooling. Philip proceeded to demonstrate the possible shortcomings of some rapid tooling systems arising from their thermal properties.
Discussion centred on the increasing expectations of customers regarding shortened time scales to produce models and mouldings from prototype tooling and the high charges for mouldings produced from rapid tooling. Considerable interest was also shown in the exhibitions on prototype modelling from the RDM Centre and the Q-drive rapid mould system currently being used by CTP Davall for small mouldings.
Philip Strachan (r) discussing the Q-drive system with Lee Dodd (CTP Davall)
CA Models tel: 01786 464 434
E-mail: [email protected]
P.Strachan tel: 01382 834 239 E-mail: [email protected]
RDM Centre tel: 0141 548 3486
CTP Davall tel: 01501 751447
EMPLOYER LEARNING NETWORK
The launch of this joint Polymer NTO / SPRA initiative took place at the Westerwood Hotel in Cumbernauld on 31 January 2001. Of the 60 companies invited over 30 expressed interest but a number were unable to be present. The 16 companies that were represented reflected a broad spread of interests from moulding, extrusion and blow moulding to rubber manufacturers and OEMs. Gill Doyle, Polymer NTO, outlined the origins and operation of an employer learning network in Lincolnshire. The network, consisting of a group of companies and other organisations, can:
l to r: Gill Doyle (PolymerNTO); Hugh Smith (SPRA President); Neil McLaren (SPRA Hon Treasurer)
ensure provision of existing and future support for companies
assist with grant support bids
develop the local training provision
share good business practise and experience in training and recruitment
support schools liaison and the promotion of careers
provide events for the sector.
Dougie Somner, Scottish Enterprise Renfrewshire, explained the support and training schemes available to the network.
Dougie Somner (left) with Dr John Wilcox (IOM Representative)
From subsequent discussions a number of issues were identified as concerns within the companies present:
Poor access of companies to existing training provision, since this is available only in selected colleges throughout Scotland. This has led to some companies taking SVQ training in-house.
A continuing decline in the current training provision in Scotland threatens to
reduce this access still further
The need for training to deliver specific business benefits to companies rather than qualifications for employees
Difficulties of recruiting operatives with a knowledge of the industry. As a result, companies are trying to recruit school leavers and train them, but this has its own difficulties.
The poor work skills of young people leaving school, and the difficulty of retaining them in the industry
The difficulties of recruiting technically qualified staff with higher qualifications in polymer technology
Opportunities for the network to influence this were identified:
To identify generic training needs for the industry (including an appreciation of business issues) that can be delivered efficiently by training providers
To plan and arrange for the training required by the industry.
To support existing training provision, thereby encouraging its retention
To influence training providers and ensure training delivers real benefits to the industry.
At the second meeting, 29 March, the results of a questionnaire revealed that the main concerns were indeed: (a) poor access to a declining training provision in Scotland, (b) problems in recruiting technically qualified staff and (c) the need for training to deliver specific business benefits. It was proposed that network members should share information on sources of suitable training. Although training was the main issue discussed, the network could help in solving other problems such as benchmarking pay rates, identifying good suppliers of tooling and non-technical training.
At the next meeting (15 May) two companies agreed to give presentations on their approach to identifying
training needs.
CORPORATE MEMBERSHIP
THe SPRA is delighted to announce that the following companies have become Corporate Members of the Scottish Plastics and Rubber Association:
Albyn of Stonehaven Krauss-Maffei UK Rosti (Scotland) CTP Silleck Scotland
Billion UK Brand-Rex ARC Euro Polaroid UK
Each company has received a Certificate and now has its own web page on this website, with appropriate contact details and weblinks to its own web site. For further details of the benefits of Corporate Membership see Corporate Membership or contact Sheena Geddes, Membership Secretary
LATE NEWS STOWE-WOODWARD APPOINTMENT With effect from 1 June 2001, the Glenrothes based rubber roll manufacturer, Stowe-Woodward BTR, have appointed SPRA member, Graeme Noble, as Director/General Manager. Graeme, a product of the successful Polymer Technicians Award scheme, started his career in the rubber industry with Stowe-Woodward and rejoined them as Technical Manager after a spell with Day International in Dundee. Graeme graduated with an MSc in Materials Technology from Napier University in 1999.
IAN JOBLING JOINS OMEGA PLASTICS (UK) LTD Gateshead based Rapid Tooling manufacturer, Omega Plastics, has recently employed SPRA member Ian Jobling as Business Development Manager for Scotland. Ian has worked for 16 years in the Plastics industry and was awarded a Graduateship of the Plastics & Rubber Institute in 1992. Ian spent a number of years with WAVIN Plastics, DYNISCO Hot Runner Systems, and for the last 4 years he held the position of Sales Manager with the Austrian machine manufacturer, ENGEL.
News from the Scottish Plastics and Rubber
Association
August 2001
Features in this issue: President's Report Managing Polymer Waste Closing The Gaps Employer Learning Network Polymer Study Tour Scottish Materials Exchange III SPRA AGM 2001
Model Yacht Winners Congratulations Corporate Membership
THAT WAS THE YEAR THAT WAS * - PRESIDENT'S REPORT
The year that was - interesting, challenging, exciting, demanding, amusing, rewarding, disappointing, gratifying, congenial and always enjoyable.
The year when:
Membership growth greatly exceeded our year on year target of 10%.
Corporate Membership was successfully launched.
In conjunction with Polymer NTO, Scotland's first Employers Learning Network was established. It is hoped that the network will provide us with a better understanding of the industry's needs, threats and opportunities.
SPRA set an example to industry by sponsoring a teacher on the Polymer Study Tour and providing IOM Affiliate membership for 10 schools.
Communication with individual members was greatly improved by the increasing use of E-mail.
Website development was taken in-house, ensuring that the site was updated both regularly and timeously. The website has also enabled us to develop an unabridged, cost-effective newsletter.
There was near record attendance at the Dinner Dance held this year in the Glasgow Hilton - feedback suggests that bookings for next year's dance (March 15) will be extremely high - don't be disappointed, BOOK EARLY
On your behalf, I would like to thank the small band of Council members whose enthusiasm and commitment, time and talent ensured last year's success and will ensure that we can face the current year's ambitious programme with confidence.
Hugh Smith (SPRA President)
*Ask a senior citizen if the title doesn't make sense!
MANAGING POLYMER WASTE
An audience of 48, including 24 teachers on the Polymer Study Tour 2001, enjoyed a lively debate on
"Managing Polymer Waste" on Monday 15 June at Napier University, Edinburgh.
John Stewart, SEPA, set the scene with some facts and figures on polymer waste in Scotland before tracing the relevant legislation and outlining the implementation of the National Waste Strategy in which each of the 11 areas in Scotland has to evaluate the various waste disposal options. Landfill is becoming less attractive with increasing costs (£100 per tonne in Ireland) and the introduction of the Landfill tax at £35 per tonne.He fuelled the debate by ending with a number of questions such as "Can the industry use fewer polymers in packaging?", "Can we find more markets for mixed waste recyclate?" "Can industry influence the expectations of customers?".
It is noticeable that in recent years, in the UK, there has been a shift from the over-emphasis on mechanical recycling to composting and energy from waste, as practiced by our European neighbours. The economic barriers to recycling arise mainly through the cost of collection and sorting of mixed waste and the cost of cleaning. Agricultural film recovered from farms for recycling by Dumfries Plastics Recycling contains 30% non-polymeric material. Lance Hamer (DPR) also explained that the levy scheme for agricultural film had broken down because of the intervention of free-loaders but it was hope that the scheme could be resurrected.
The value of energy from waste polymers was ably demonstrated by Steve Dodd of Blue Circle Cement, which has the capacity to use waste tyres for 10% of the fuel requirements in the cement kilns at Dunbar. He described the venture as win-win in that there was also a decrease in gaseous emissions from the plant. Les Slater illustrated how implementation of a waste plan at UCP had not only taken care of the polymeric and non-polymeric waste from the plant but had reduced the total by 30% since 1998.
Ian Logie of CTP Silleck and Andrew Brady of CTP Davall echoed the benefits of a well-conceived waste plan. Keith Charlton described how Mainetti handles the vast numbers of returned garment hangers. Some are re-used while others are reground for incorporation into the daily output of a million hangers. Removal of paper labels and metal hooks provide the main challenge. Professor Jim Baird, Glasgow Caledonian University, urged the industry to get involved with the REMADE project which is exploring markets for recycled materials.
The consensus from the evening was that the industry is concerned with minimising waste but there are still many problems to be solved in achieving the targets set for managing waste from packaging, electrical and electronic goods and the automotive industry.
John Stewart Steve Dodd Jim Baird Les Slater Lance Hamer
(SEPA) 0141 945 6350 [email protected] (Blue Circle Cement) 01368 861 1260 [email protected] (REMADE) 0141 404 8890 [email protected] (UCP) 01786 833 613 [email protected] (DPR) 01387 247 110
CLOSING THE GAPS
The word 'quality' can mean different things to different people. It can refer to the composition of a material or product, the compliance with a specification or perhaps simply excellence. It can also be seen as 'fitness for use'. Whatever interpretation may be current flavour of the month, an undeniable fact is that it is the customer's interpretation that will affect your business.
A customer will have an expectation for the product or service that you are to provide. This will be influenced by factors which include what your competitors can supply, current technology in the marketplace, past dealings with you and of course the use to which the product or service will be applied.
Peter J Warren, Chief Chemist with James Walker & Co Ltd, Cockermouth, Cumbria, delivered a talk on Quality at an SPRA meeting on 26 April
Quality as seen by your customer will be how your offering is perceived to match up with this expectation. If the gap is positive, or your offering exceeds expectation it will be seen as 'excellent'. If it matches it will simply be seen as 'good'. If the gap is negative, and doesn't measure up it will be seen as 'poor'. The magnitude and direction of this gap is the sum of 4 antecedent gaps within your business, after Zeithaml (1).
How well does your management understand this customer expectation?
How well has this been transferred onto your manufacturing / service standards?
How good are you at delivering against these standards?
What do you tell the customer-does it reinforce your credibility?
Be honest with yourselves, where are the widest gaps?
Customers evaluate product quality via measures, which include performance, features, reliability, conformance with specification and durability. For service these will include the reliability and responsiveness of the offering, and the confidence inspired by the staff. The emphasis and requirements of customers will vary. Customers with similar needs can be aggregated into market segments, or even more specific groups known as niches. Broadly speaking, these will be for 'commodity' or 'engineered' offerings with differing lead times. The sensitivity of price will of course vary, with the more attractive margins normally resting with the 'engineered' segments. Are you aiming for the most lucrative markets?
A contingent approach to quality improvement will start with knowledge of what the target customer's expectations are. It will take into account the environment within which the business operates both externally and internally including its resources, and focus activities on closing the widest gaps. SPC and factorial experiments are powerful tools for reducing variation, but they are of little value if the product is wrong!
None of this is new and it is not the intention to teach you to suck eggs, though it is perhaps a different approach. 1. Zeithaml et.al, "Delivering Quality Service-Balancing Customer Perceptions and Expectations", The Free Press [1990]. Want to know more? Contact: Peter Warren, James Walker & Son, Cockermouth, Cumbria E-mail: [email protected]
EMPLOYERS LEARNING NETWORK
At the third meeting of the Scottish Employers Learning Network at the Westerwood Hotel in Cumbernauld on 15 May, the main items on the agenda were presentations on Technical Training Needs Analysis from Lirrie Craig (McKechnie Plastics Components, Beith) and Gillian Buchan (Birkbys, Glenrothes).
McKechnie, with 95 employees at Beith, have implemented a formal procedure:
1. Establishment of the basic objectives at all levels --- ( company, department, shift, individual), with emphasis on anticipating change
2.
Assessment of current skills and competences, related to individual roles and responsibilities; emphasis is on establishing underperformance skills, looking for areas for development and how training will be applied.
3.
Construction of a Training Matrix covering different areas (processing, maintenance, toolmaking etc)
using a 4-point scale (highly skilled, competent, basic, requires training).
4.
Application of training , where necessary, through internal tutors, external set courses and specially designed courses.
At all stages the process is carefully recorded and evaluated. A matrix is constructed to identify existing skills levels and to highlight where additional training is required. Attention is also given to the needs of highly rated personnel in order to keep them in the company.
Lirrie also outlined the operation of a development team approach to tackling specific problems, such as reducing scrap rate on a particular moulding run.
At Birkbys the approach is similar, with structured meetings to carry out gap analysis and establishing priorities. Identifying growth opportunities has equal importance as identifying shortcomings. Birkbys use computer based training for injection moulding. Both speakers emphasised that, for success, everyone in the company must be convinced of the value of the process. The success of the Training Needs Analysis at McKechnie is reflected by the recent decision to ring-fence the Training Budget.
Hot Issues: The meeting was able to provide answers for some of the hot issues identified by members.
o
o
o
o
Conversion from ISO 9002 to 9001/2001: courses are available Publicising the industry in schools: this is being tackled through the Polymer Study Tour and the Institute of Materials Schools Affiliate scheme. Enterprise Company contacts: a list of contacts in specific areas will be circulated. Employee concerns about changes in working practices: it was suggested that this could be minimised by arranging visits to other companies.
Sustainability To ensure the continued development of the Employer Learning Network, additional companies will be encouraged to join. Financial support will be sought from both members and the public sector, including the Scottish Executive. For the remainder of this year reports will continue to be available to non-members.
Next Meeting: The next meeting of the Scottish Employers Network is on Tuesday 28 August at the Westerwood Hotel in Cumbernauld, starting with a buffet lunch at 1.00 pm. In response to one of the 'hot issues' identified by the ELN - 'Managing Change' - Iain Riddle, Organisational Strategy Manager, Alcan Chemicals, Burntisland will give a short presentation to the Network: 'The Alcan Chemicals Business Turnaround ......the background, planning and implementation of a major business turnaround programme involving 400 employees at the Alcan Burntisland site... the people aspects of change' Results of a questionnaire designed to focus on possible issues for a half-day seminar will also be discussed.
POLYMER STUDY TOUR 2001
The change of organisers (now Polymer NTO) and change of format (3 ½ days instead of 5 ½ days) resulted in Napier University acting as host for 24 teachers from across the UK on Polymer Study Tour 2001, compared to 6 last year. The intensive residential course, designed to improve teachers' understanding of the science and technology associated with rubbers and plastics, exposed them to a range of guest speakers, hands-on practical work and visits to local industry (BP Chemicals, Carron Phoenix, Royalite Plastics, Bausch & Lomb and High Pressure Plastics). The SPRA sponsored one of the teachers and the Worshipful Company of Horners, the main sponsor, is now looking for companies to sponsor teachers next year, at an approximate cost of £600 per teacher.
If you are interested in sponsoring a teacher from your local school, provide a visit or a speaker: Contacts: Polymer NTO: tel:01952 587 020 Colin Hindle: Napier University: [email protected]
Visit to Bausch& Lomb Ltd, contact lens manufacturers at Livingston
Mould construction at Carron Phoenix Ltd, Falkirk, cast acrylic sink manufacturers.
SCOTTISH MATERIALS EXCHANGE II
The exhibition comprised a mixture of companies, universities and support/professional organisations offering delegates wide ranging opportunities to make new contacts, identify sources of support and technical assistance. Snapshot presentations during the networking breaks were popular and offered the exhibiting companies the opportunity to inform delegates briefly on their technology/services. SPTN took this opportunity at this event to launch its new website, www.polymernetwork.uk, and ask delegates to visit and give feedback to ensure the future development of the site to meet user requirements. Feedback from the event supports the continuation of the format for future events but more involvement from the business sector is essential to build on this early success. The next Scottish Materials Exchange is on Biomaterials and will take place in early November. In line with the aims of the Materials Foresight Initiative, this event will focus on the developments, challenges and opportunities in all aspects of industry designing, supplying and utilising biomaterials. Hence companies that should attend include medical device manufacturers, wound healing and drug delivery research and development, medical packaging, medical textiles and food manufacturers. Those involved in the research areas related to the study of biomaterials such as biomimetics, biocompatibility, tissue engineering etc will also benefit from attending this next Scottish Materials Exchange event. For further information about speaking, exhibiting and/or sponsoring this event, please contact Carol Scullion ( Event Manager ) at SPTN, [email protected] or visit the web site for details www.polymernetwork.org.uk
SPRA AGM 2001
SPRA President, Mr Hugh Smith, reported that, although the industry is experiencing sluggish demand, threats from the Far East and severe cost-down pressure, the SPRA has made considerable progress, due to the commitment and enthusiasm of Council Members. Individual Membership continues to thrive with a 35% increase from 1999 to 2000, in spite of losing members who have moved out of the industry or out of the area. The aim is to increase membership by 10% year on year. Corporate Membership, launched in 2000 has already yielded 8 founder companies. The priority in 2001 is to increase the Corporate Membership by 75% and introduce a Corporate Members Forum.
Among the partnerships formed by the SPRA has been a venture, with the Polymer NTO, to establish an Employers Learning Network for the rubber and plastics industry in Scotland. SPRA communications have been further enhanced. The regular Newsletter is now well established and the website, introduced in 2000, now has regular updates of news, events and useful web-links, as well as a page for each Corporate Member. Over 75% of the SPRA Membership is now contactable by E-mail.
Attendance at the technical meeting programme for 2000-2001 was up by 50% and the popular Dinner Dance, in its new venue, attracted record numbers once more. Polymer education, at Napier University, Edinburgh and Bell College, Hamilton, continues to suffer from lack of support. A full-time/part-time MSc in Plastics Moulding Technology is being launched at Napier in September and the streamlined Polymer Study Tour for teachers is attracting increased numbers.
The SPRA made a small trading loss in 2000, mainly due to the start up costs associated with the website and the increased costs of servicing the membership. It was agreed that the membership fees for 2002 should be increased to £15 as a first step in ensuring appropriate services to members
The second Scottish Materials Exchange Day on Materials and Design took place on June 5 at the Big Idea Inventor Centre in Irvine. Attended by 45 delegates from business, academia and the public sector, the event was lively and, if the noise level was anything to go by…most successful in provoking discussion and interaction. Presentations covered issues such as the impact of new process technology on industrial design to rapid prototyping and its use in developing and investigating new materials. The business sector was well represented with speakers from Linn Products and BAE Systems giving the industry perspective on the challenges, successes and failures in industrial design.
MODEL YACHT WINNERS
The SPRA's chain of contacts, and its aim to raise the profile of the industry in schools, enabled Dunbar Grammar School to design and build model yachts which landed first, second and fourth prizes in a national competition in Glasgow, winning nine out of the ten races. Phil Roberts, head of the craft, design and technology department at Dunbar Grammar School, contacted McLaren Plastics, Loanhead, who enlisted the help of Colin Hindle at Napier University who in turn arranged with a graduate, Scott Russell of High Pressure Plastics in Livingston, to thermoform the hulls in black ABS extruded by Royalite Plastics at Newbridge. The hulls were then worked on by pupils to complete the prize-winning yachts.
CONGRATULATIONS
Congratulations to Robert McVey, one of just two graduates this year from the BEng Honours Polymer Engineering programme at Napier University. During his time on the programme Robert spent a full year on supervised work placement with CTP Silleck Ltd, Inchinnan, and subsequently worked part-time at McLaren Plastics, Loanhead. Now that he has graduated, Robert is looking for a job in the industry - any offers? E-mail: [email protected]
Colin Swanton(far left), an enthusiastic supporter of the SPRA, retired, at the end of June, from his post as Managing Director of Billion UK. Colin has spent over 40 years serving the plastics industry (with Turner, Netstal and Billion). The SPRA wishes him a long and happy retirement. Peter Kirkham (right), formerly Technical Director, has taken over as Managing Director
CORPORATE MEMBERSHIP
The SPRA is delighted to announce that the following organisations have become Corporate Members of the Scottish Plastics and Rubber Association:
Omega Plastics (UK) Ltd Polymer NTO Spraymasters Ltd
Each company receives a Certificate and now has its own web page on this website, with appropriate contact details and weblinks to its own web site. For further details of the benefits of Corporate Membership see Corporate Membership or contact Sheena Geddes, Membership Secretary
News from the Scottish Plastics and Rubber
Association
December 2001
Features in this issue: Hard Times Tie-barless Machines Robotics Fire Performance Development Laser Welding Real-time Monitoring K 2001 School News
Employer Learning Net Managing Change Seminar Biomaterials XPS Recycling BPF Affiliate Congratulations
2001 has been a tough year for the plastics and rubber industries in Scotland. The moulding sector has been hit badly with the disappearance of Motorola from Bathgate, the substantial reorganisation of CTP Silleck at Inchinnan, minimisation of the big picture at Polaroid in Dumbarton, and the proposal for Birkbys to pull out of Glenrothes. Elsewhere other companies have felt the ripples from the major players and the continuing effect of global competition. Now BP have decided to distill down their presence in Grangemouth. However, if companies like Fullerton can win back work from the Far East, there is hope for others although Fullerton have had to cut back on total staff numbers as well. On a brighter note, the medical products sector continues to expand and niche market companies, away from the electronics sector, continue to compete. It was also encouraging to see some SPRA members finding new employment quickly, after becoming victims of the troubles. Other SPRA members who find themselves out of work should ensure that the SPRA membership has their updated details so that enquiries for experienced staff can be passed on quickly.
TIE-BARLESS INJECTION MOULDING MACHINES
At the opening meeting of the 2001-2002 season, in Cumbernauld on Tuesday 25 September, sponsored by Billion UK, appropriately a founder SPRA Corporate Member, Peter Kirkham explained the different
approach that Billion had taken in maintaining platen parallelity in their Proxima range of tie-barless injection moulding machines. In most other designs of C-frame machines the stretch at the top of the C-frame is compensated by a ball type coupling behind the moving platen. In the Billion design the top movement is matched using a sleeve in the bottom tie-bar nut, acting like a spring.
Parallelity (0.05 mm) matches conventional Billion machines and is well within the 0.2 mm quoted by EUROMAP. The locking mechanism is of the lock-and-block principle with a chock plate in front of the main piston and behind the small mould closing piston. This design leaves good accessibility for ejection. Another advantage is that mould unlocking takes place during the cooling phase. For technical mouldings there is the option of a two pump system to boost speeds
HARD TIMES
As well as the improved accessibility of tie-barless machines the Proxima range offers significant savings by accommodating large moulds on a smaller machine. One mould from a conventional 165 tonne machine was successfully run on a 50 tonne Proxima machine. The current range covers 40 - 100 tonnes lock but plans are in place to extend the range to a 200 tonne machine next year.
Billion UK Ltd tel: 01908 223 344
H ROBOTICS
To complete the meeting on 25 September, entitled Optimising Injection Moulding, Paul Goodhew outlined the range of robotic options offered by Sepro to optimise the injection moulding process. Manual loading of inserts can result in mould cycle variations of up to 5 seconds and consequent moulding losses of up to 20%. Sepro concentrates on more than just pick-and-place robots, by providing solutions for niche markets such as in-mould labelling, textile overmoulding and palletisation, all with a wide range of grippers and suckers, with automated coupling. Sepro also specialise in axial and gantry systems and designs for low height clearances. The special bearing designs provide high speed options. It is generally reckoned that a robotic installation has a pay-back time of 6 - 9 months.
Sepro tel: 01908 223 116
ARD TIMES
FIRE PERFORMANCE DEVELOPMENT
The evening meeting devoted to Developing Polymeric Materials for Fire Performance, on Tuesday 16 October, in Livingston, had three speakers.
Andrew Green, Fire Testing Technology, opened with a paper on the development of laboratory tests to evaluate the different aspects of fire performance. Some tests concentrate solely on assessing ignitability while others measured flame spread, smoke production and toxic gases, all in separate tests.
The Cone Calorimeter has been developed to quantify all the parameters in one single test. This instrument uses a conical radiant heater to supply a range of heat fluxes typically encountered in fire scenarios. Heat release is measured using the oxygen depletion principle which states that, for most materials, 13.1 MJ is released for every kilogram of oxygen consumed. The evolved gases from the burning specimen are ducted away for smoke measurement, oxygen depletion and toxic gas measurement. Because the specimen sits on a load cell the weight loss can also be measured continuously. The Cone Calorimeter is now featuring in many new fire tests and has a role to play in correlation and modelling studies.
Cone Calorimeter
Andrew Green 01342 323 600
[email protected] www.fire-testing.com
Steve Brown of Alcan Chemicals reviewed the role of fire performance additives used with polymeric materials. Flame retardants can be classified according to whether they function in the solid phase, when the polymer is decomposing, or in the gas phase when the decomposition volatiles undergo combustion. Additives containing chlorine or bromine are cost effective gas phase flame retardants but they have the disadvantage of creating acidic gases that can cause problems with computer installations for example. Halogen additives are also discouraged by environmentalists.
Antimony trioxide is an effective gas phase FR but works through a synergistic action with chlorine containing polymers (eg PVC) or chlorine additives. Alumina trihydrate (ATH) operates in the solid phase and is environmentally friendly although the high loadings required can have an effect on mechanical, electrical and optical properties. Phosphorus and its compounds are finding increasing application in high performance thermoplastics.
Steve Brown 01869 354 161
Steve.Brown/[email protected] www.alcanchemicals.com
Derek Mason, Edlon Ltd, showed that fire performance is also a function of the base polymer. Edlon have produced a number of formulations of fluoropolymers that can be used to coat steel ducting internally to produce chemically resistant ducting with very good fire performance.
Derek Mason 01333 426 222 [email protected] www.edlon.com
LASER WELDING OF PLASTICS
At the SPRA meeting in Glasgow on 20 November, sponsored by Hardie Polymers, Dr Ian Pashby from Herfurth Laser Technology introduced the audience to an alternative method of welding plastics. Diode laser arrays provide high energy beams (5 mm wide) with energies up to 400 W which can be used to weld two plastics together, provided the top layer is transparent to the infra red beam ( wavelength 0.8 to 0.9 microns) and the bottom layer is absorbing, usually by incorporation of fillers. The laser can either be in the form of an enclosed
welding machine or as a tool on a robot creating welds, typically at 100 mm per second. To take full advantage of the technique it will be necessary to develop additives to maximise the process, establish process windows for dissimilar materials and develop joint designs to suit the process. The talk was illustrated by examples of laser welding, such as paint tins, car bumpers,thin film and welding caps on containers full of liquids.
Robotic Laser Welding of Car Bumper
Dr Ian Pashby 02476 323 088
[email protected] www.herfurth-laser.com
REAL-TIME MONITORING
To complete the meeting on 20 November, Andy Jewell, Mattec Ltd, described the application of real-time monitoring systems to a range of production systems. The interface equipment can collect process data ( analogue or digital) in real time (production rates, process machine parameters, energy consumption, operator input, maintenance data etc) and interface with production and planning control systems. Key production data is then more readily accessible to all concerned. The basic system (£7200) can handle 12 inputs but more sophisticated systems are available handling large number of inputs. The SPC system operates on up to 32 parameters. The benefits in real time monitoring are primarily to achieve reduced variability in process systems and product quality . Many customers now insist on real-time monitoring and it conforms to standards such as ISO 9000. For companies seeking process improvement, real-time monitoring provides an accurate base line. Andy Jewell: 01909 561 54 [email protected]
K 2001
The following report was provided by Colin Hindle, SPRA Academic Liaison Officer. Colin is Lecturer in Polymer Engineering at Napier University, Edinburgh.
Held in Dusseldorf every 3 years the legendary K shows provide a meeting place for the worldwide polymer industry. Although the "K" supposedly stands for the German words Kunststoff (plastics) and Kautschuk (rubber) the show is
very much dominated by the plastics industry. Billed modestly as "No. 1 for Plastics + Rubber - worldwide" seeing the entire show is no modest feat, requiring as a minimum 3 full days and a really comfortable pair of shoes. With 17 halls - they have added another since the 1998 show - there is something to suit everyone, but if you are looking for that as yet undiscovered something then there is no alternative but to walk all the aisles. This year's show seemed as cosmopolitan as ever although clearly there were fewer attendees from the USA than normal, I only noticed one US company missing from the exhibitors listed in the catalogue. So what was really new? Perhaps not a great deal as clearly there has been evolution, rather than revolution, over the past 3 years. On the materials front there were: updates from GE Plastics on a number of developments including their polycarbonate glazing for cars; Cargill Dow were promoting their biodegradable polylactic acid (but when asked they admitted it is not yet available commercially)
On the processing side it is difficult to say what was striking. The Netstals and Schottlis of this world did what we have come to expect of them. The hot runner manufacturers were out to impress - but how many PET preforms do you want to make in a single shot? The surprise was how far the Japanese have caught up with European machine design - they all looked the same, and worryingly there were machines there from China that looked like Japanese machines of 9 years ago. Of course the topic of conversation in the many Irish bars of the Altstadt was as it always is, "the ... second cycle time on the ...... machine."
Although this time there was no Scottish group stand, as there was in 1998, there were a number of Scottish Companies with their own stands including: Alcan Chemicals; Flexible Ducting and Silberline. Likewise the Institute of Materials was not present, but the SPE was there in force. For me the most interesting items I saw were the magnesium alloy mouldings displayed on the JSW stand with Thixomold. Although this is definitely not plastic, it is certainly injection moulding and is perhaps the greatest threat (or opportunity?) to the plastics moulding industry.
Colin Hindle:
0131 455 2622
www.napier.ac.uk
EMPLOYER LEARNING NETWORK
MANAGING CHANGE: The main topic of the Employer Learning Network meeting on 25 Aug 2001 was a presentation by Iain Riddle, Organisational Strategy Manager, Alcan Chemicals Europe Ltd, Burntisland.
The plant at Burntisland was established in 1917 to treat raw bauxite ore and supply aluminium smelters in Lochaber and Kinlochleven. By 1970 it had changed to a multi-customer, specialist chemical company with a capacity of 110,000 tonnes per annum of alumina destined for a range of industries, including the increasing use of alumina trihydrate (ATH) as a fire retardant additive for plastics and rubber applications.
By the mid 90s, competition in the oversupplied market suggested that the plant had to change to survive in the specialist chemicals market. Introspection revealed a production-centric operation, with a functional approach, a traditional relationship with the unions and insufficient customer focus. The New Vision was to produce an organisation for the supply of alumina, --a leaner, more effective, fully-integrated business process, sensitive to markets and delivering value ahead of competition.
Planning the change was given high priority. Starting from the prevailing negative attitudes the momentum was built up deliberately in an overt process. A document explaining the changes was circulated to all employees along with a video. Employees who opted out of the new scheme were given support, eg on new business start-up. Training gaps were addressed to develop team leaders and provide cross-skill training for the implementation of a team approach. A new relationship with unions was established and a layer of management removed in the streamlined company structure. In retrospect a few mistakes were made in prioritising the programme of change but the plant is now achieving its objectives with an enhanced performance through a project team approach and an improved employee attitude.
Iain Riddle 01592 411 000
[email protected] www.alcanchemicals.com
SEMINAR
In partnership with the Polymer NTO and as part of the Employer Learning Network, the SPRA is planning a half-day seminar on:
Improving Competitiveness in the Global Market
Tues 5 March 2002
Westerwood Hotel, Cumbernauld
A series of case studies will illustrate how companies, in other geographical areas and in other sectors of industry, have tackled the problems facing the polymer sector in Scotland.
Further details from Charlie Geddes, SPRA Hon Secretary 01592 651 269; [email protected]
SC
SCOTTISH MATERIALS EXCHANGE III
OTTISH MATERIALS EXCHANGE III
At the third in the series of Scottish Materials Exchange events, organised by the Scottish Polymer Technology Network (SPTN) and supported by the SPRA, in the Glasgow Science Centre on 7 November, the day was given over to the theme of Biomaterials.
Presentations covered a wide range of topics from artificial heart valves to smart gels and biomimetics. Delegates also had the benefit of several exhibitors, snapshot presentations and workshops, exploring how to get involved in the diverse field of biomaterial technology. Considering that the Biotechnology field in Scotland now encompasses over 400 organisations and medical device companies constitute 100 of these (employing over 6000) it was surprising that, among the 72 delegates, only 10 biotech companies were represented.
Tri-leaflet Polyurethane Heart Valve from AorTech
The explosive growth rate of biotech companies in Scotland is something that enterprising plastics and rubber companies should keep an eye on.
For further details contact SPTN: 0141 548 2241 [email protected]; www.polymernetwork.org.uk.
E
EXPANDED POLYSTYRENE RECYCLING
XPANDED POLYSTYRENE RECYCLING
On 27 September the BPF Expanded Polystyrene (EPS) Packaging Group organised a seminar in the Glasgow Science Centre attended by a broad cross section of industry and public organisations. Andrew Barnetson (BPF) outlined the benefits from EPS packaging. Although EPS represents only 0.1% by weight in municipal refuse, he urged all sectors to extend the good recycling rate of EPS (15%) by a range of initiatives.
EPS beads provide good aeration in soil. Reprocessors can supply compactors for large users of EPS packaging (supermarkets and electronics companies). The EPS can be recycled into wall insulation, wood substitute products or even back to 'crystal' polystyrene pellets. Gerry Dallimore of Green Waste Recycling Ltd in Gwent described how his company was collecting fish boxes and seed trays from all over the UK and recycle them into products like flower planters and builders buckets. The company has the capacity to recycle 4,000 tonnes per year.
Andrew Barnetson Gerry Dallimore
02074 575 014 01495 313 777
[email protected] www.bpf.co.uk www.green-waste-recycling.co.uk
B BPF AFFILIATE
PF AFFILIATE At the first Corporate Members Forum, on 9 October in Cumbernauld, Hugh Smith, SPRA President, announced that the SPRA had become an Affiliate Member of the British Plastics Federation.
This will allow Corporate Members access, through the SPRA, to many of the benefits of BPF membership: information dissemination, policy guidance, lobbying, business analysis, trade development, technical services. The next Corporate Members Forum will take place in March 2002.
CONGRATULATIONS
CONGRATULATIONS
Congratulations to the following who graduated on 22 November from the Plastics Moulding Technology programme at Napier University:
Advanced Diploma: Postgraduate Diploma: Postgraduate Diploma (with Distinction) MSc (with Distinction)
Arthur Reid (Rosti); Peter Barnes (Oki), Alan Tocher (NCR) : Stan Dunbar (NCR) Billy Rice (NCR) Alan Johnston (Thales)
Alan Johnston also was awarded the GE Plastics prize for his project on "Comparison of Electric and Hydraulic Injection Moulding Machines".
From l to r: Charlie Geddes (tutor), Stan Dunbar (NCR), Alan Tocher (NCR), Colin Hindle (Programme Leader), Alan Johnston (Thales)
SCHOOL NEWS
SCHOOL NEWS The polymer workshop at Napier University has played host to secondary school pupils from Deans Community High School, Livingston and Crieff High School. Both visits were arranged through teachers of Design & Technology who had themselves visited Napier on the Polymer Study Tour held in June. The next Polymer Study Tour is scheduled to run from 23 - 26 June 2002. Colin Hindle: 0131 455 2622 [email protected]
Crieff High School pupils tackling vacuum forming
