D.R. Joseph Reveals Auto-Gauge Air Ring with Innovative Approach on Lower Lip Control and Component Modularity

The TDK-500 is the new automatic gauge control air ring introduced by D.R. Joseph Inc, world leaders in Internal Bubble Cooling and air flow control systems. The new air ring, now available to blown film producers is designed to be used with the company’s InstaGauge auto thickness control system which also will be introduced this fall. The unique design equips the TDK-500 with a host of innovative features which boost versatility and provide a faster control response with higher resolution than current offerings.
The TDK-500 air ring is a result of six years of development which drew from DR Joseph’s 30+ years of internal bubble cooling (IBC) controls design experience, 30+ years of air ring design experience from Techflow Design of Mississauga, Canada, and 30+ years thickness measurement experience from Kündig Control Systems of Ruti, Switzerland. The combined experiences created innovations which focused on making an auto gauge control air ring easier to install, easier to operate efficiently and much easier to modify and maintain.

The new dual-lip TDK-500 has four important innovations while retaining the high performance expected from dual lip air rings:
1) Instant setting lower lip adjustment technology (patent pending Tech flow) which completely eliminates the traditional threaded mechanism. Operators can find and secure the perfect lower lip adjustment in a matter of seconds. The adjustment includes a scaled indicator for SOP purposes. This intuitive design eliminates the intimidation factor of managing bubble stability because operators can quickly “test” the entire setting range within 10 seconds. Anyone who has struggled with the endless rotating of the lower lip adjustment can appreciate the instant nature of this setting.
2) Affecting change to the film for consistent gauge control is made more difficult when high performance is also a requirement. The TDK-500 isolates the primary lip cooling from the gauge control adjustments made using the secondary lip cooling air streams.
This keeps the bubble locked consistently to the forming cone for all conditions. The innovated part of this design is the constrained zone design (patent pending Tech flow). The air flow from each control zone constrained in an independent channel that extends to just before the secondary lip exit. This eliminates zone cross mixing and provides a more direct and effective control response to the film.
3) Instant access for cleaning the lower lip exit technology (patent pending DRJ) allows the operator to release the locking feature without tools and safely lift the secondary and cooling collar assembly to a designed cleaning position within the air ring in less than 60 seconds. IBC hardware need not be removed. Optional weight reduction is available for easier lifting is available from a 3D printed polycarbonate cooling collar (patent pending). Additional 3D printed components are still under development.

4) Instant lip set swapping technology (patent pending DRJ) allows the primary and secondary lips to be removed and replaced without tools and without lifting the entire air ring off of the die. A time and cost saving measure which expands the versatility of the air ring. For instance, an operator can change the lower lip geometry to provide a custom air flow impingement angle or to handle lower blow-up ratios within 5 minutes (excluding the time required to remove the IBC exhaust stack).
Again, the TDK-500 is a high performance dual-lip design established from years of experience for the widest range of materials including ultra-low melt strength materials.

https://www.drjosephinc.com/

#modernplasticsindia #modernplasticsasia #modernplastics #plasticsnews #plasticsplanet #modernrecyclingindia #modernplasticsglobal #modernplasticsworld #plasticstalk #modernplasticsgermany #modernplasticsnetwork #plasticdevelopment

Digitalisation And Automation Hand In Hand: Efficient, Traceable Part Production

• Fully automated: a turnkey system with a hanging-mounted six-axis robot
• Compact: vertical Allrounder overmoulds inserts
• Seamless: ATCM for 100 percent traceable part quality and R-Cycle information

At Fakuma 2024, Arburg (Halle A3, Stand 3101) will be demonstrating how digitalisation and automation work hand in hand to produce plastic parts efficiently and with 100 percent traceability and recyclability, using a turnkey system centred around a vertical Allrounder 375 V. Vacuum housings are manufactured and installed in Multilift robotic systems. The accompanying six-axis robot is suspended and therefore requires very little space. The SCADA system Arburg Turnkey Control Module (ATCM) makes it possible to link material and process data. The fully automated application is also an application example of the R-Cycle initiative.

The compact turnkey system for the automated overmoulding of inserts and traceable part production is a sophisticated manufacturing solution with high autonomy. The consistent use of digitalisation solutions allows the individual process steps to be linked via a continuous data and information chain, enabling seamless tracking of part quality and output.

Space-saving automation

A vertical Allrounder 375 V with a clamping force of 500 kN is at the centre of the production cell, equipped with a single-cavity mould from Arburg. The hanging-mounted automation does require not any additional space. The six-axis robot first transfers two metal bushings, which are provided via vibratory conveyors, to the mould where they are overmoulded with glass-fibre-reinforced polyamide PA6 (GF30). The “aXw Control ReferencePilot” ensures homogeneous material preparation and consistently high product quality. This pilot function in the control system precisely regulates the pressure profile in the mould and compensates for fluctuations in viscosity. The cycle time is around 30 seconds, and the weight of the moulded part is 58.5 grams. After removal from the mould, the injection moulded parts are marked with two QR codes by a laser station for part-specific traceability and for reading R-Cycle information. The housings are finally discharged from the production cell via a conveyor belt.

100 percent traceable

The SCADA system ATCM is the key technology for linking and tracing material and process data. At the exhibit at Fakuma, the part-specific data from the injection moulding process and the automation will be collected and linked with the results of the visual inspection of the insert. The component ID ensures that each individual product is clearly identified and that the part quality is seamlessly documented.

On the other hand, the application is a practical example of R-Cycle and digital product passports: the ATCM passes on data relevant to processing and recycling over a defined production period during the manufacturing phase. This is done using a so-called GS1 barcode standard (in accordance with the German guideline “Circular Plastics Traceability”). R-Cycle enables standardised data exchange across company boundaries. The data is stored in digital product passports. In this way, information relevant to recycling can be viewed and utilised across the entire value chain, e.g. by subsequent processors, end users and recycling companies. This forms the basis for recyclable processes and the best possible reuse.

visit : www.arburg.com

#modernplasticsindia #modernplasticsasia #plasticsislife #plasticstalk #modernplastics #modernplasticsworld #plasticsnews #plasticsisgood #plasticsplanet #plasticsrecycling

Frigel Introduces the Latest Developments in Advanced Mold Temperature Control Units and Adiabatic Cooling Solutions at FAKUMA 2024 (Hall A5-5123)

Frigel Group will participate in Fakuma 2024, the International Trade Fair for Plastics Processing, in Friedrichshafen (Germany) from 15 to 19 October, presenting the latest process cooling solutions, designed. especially for the following Plastics fields: automotive, packaging, medical, household and technical molding.

Frigel is a Global Solutions Provider for cooling and temperature control applications, with more than 10.000 customers worldwide. Our innovation and expertise offer uniquem systes, designed to match the specific needs of each industrial process.

Our innovative solutions are focused on:
• Maximizing productivity through highly innovative mold cooling technologies
• Reducing overall operating costs, through significant energy and water savings
• Highest sustainability standards, with the lowest environmental footprint in the market.

Visit us and meet our engineers, as they will be able to show you the best solutions for your precise industrial process. Learn about our important innovations:

• New Turbogel B4: a new generation of Mold Temperature Control Units, specifically designed for cycle-time reduction for all injection molding and packaging applications achieving up to 40% increased productivity
• New Microgel™ RSY: Unique Mold temperature Unit with patented SYNCRO Variotherm Technology, provides unprecedented increase in productivity of high-quality technical molding parts – up to 60%
• Ecodry Adiabatic Cooler 4DK: centralized closed-circuit adiabatic cooling systems designed to replace the old cooling tower technology
• 3PR 4.0 control system: complete real-time control of the entire cooling system (parameters, functions, alarms, etc.)
• Thermogel TDK Series: High precision Single Zone pressurized water TCUs
• A wide range of Microgel RSM/RSD provides an optimized mechanical design, increased reliability and a wide range of options. Powerful pumps and precise temperature control up to 90°C ensure long-term high performance and product quality improvement with minimal cycle cooling time.

NEW TURBOGEL B4 Series – The unique “Profit Booster TCU”

Frigel launches for the first time in market history, a New Generation of Mold Temperature Control Units, specifically designed for cycle cooling time reduction. The advantages for the customer are easily understood, increased productivity and profitability of a single production cell, against an investment with an average payback time of few weeks.
The unprecedented performance of these units guarantees a significant reduction of the cycle time by increasing the heat transfer efficiency between recirculating water flow and mold cavities, thus drastically reducing the cooling time of the actual cycles, over traditional TCUs.

This complete range of units comes in several versions covering most applications:

Turbogel “S” – for INJECTION MOLDING:
This new generation of temperature control units offers to all molders a unique tool to highly improve productivity and optimize their process keeping high quality of molded parts. As an immediate replacement
of standard TCUs commonly used in the industry, these new units have proven productivity increase of at least 20% in most existing molds and up to 40% in some cases. They are available in single zone (B4SM) and dual zone (B4SD) configurations. Each unit includes a high-performance booster pump per zone, actuated modulating cooling valve, and 6 to 24 kW heater per zone

Turbogel “P” – for PACKAGING:
This unique TCUs are designed for high performance mold cooling in low temperature applications, including packaging molding, closures and thin-walled containers, blow molding, and extrusion applications.
Replacing the direct cooling from Central chillers, these units reduce cooling cycle time of processes running with chilled water by highly increasing the heat transfer efficiency of the mold, obtaining productivity boost between 10 and 20%.

These units are available in single zone and dual zone configurations, including a high-performance booster pump per zone (with or without inverter), actuated modulating cooling valves and cooling capacities capable of servicing the highest throughputs.

NEW MICROGEL™ SYNCRO RSY – A paradigm shift for high-end Technical Molding

“Simply Synchronized Proven Results”
Frigel presents to the market MICROGEL SYNCRO RSY, the most innovative Mold temperature Control Unit featuring patented SYNCROVariotherm Technology, integrated water-cooled chiller and double zone booster pumps.

The new machine-side unit, that revolutionizes the temperature control method for technical injection molding, allows for a drastic reduction of cycle time -up to 60%-, while maintaining the surface quality, dimensional characteristics and mechanical properties of the finished technical products.

The reduction of the total cycle time is obtained thanks to the use of chilled water – provided by the integrated chiller – only during the cooling phase of the cycle, through the digital synchronization with the molding process, that provides the signal for “deep cooling only when it is needed”, obtaining a significant reduction of the cooling time while keeping the cavities warm during injection phase. The Microgel SYNCRO product line features more than 10 models, with cooling capacities from 16 kW to 56 kW and heating capacities from 12 kW to 24 kW.

As an immediate replacement of standard TCUs commonly used, this new technology has the great advantage of not requiring modifications to the mold itself or any of the molding parameters, making the system communicate with the press while remaining completely autonomous and easily implemented by the operators. The advantages for the customer are easily understood increased productivity and profitability of the single production cell, against an investment with an average payback time of few months.

visit  : www.frigel.com

#modernplasticsindia #modernplasticsasia #plasticsislife #plasticstalk #modernplastics #modernplasticsworld #plasticsnews #plasticsisgood #plasticsplanet #plasticsrecycling

PET Bottle-to-bottle Recycling: Ganesha Ecopet’s Powerful way to Mitigate the Effects of Climate Change

The Indian PET recycling specialist ramps up its PET bottle-to-bottle recycling capacities with two Starlinger recycling lines to a total of 42,000 tons per year. It aims to recycle 25 % of India’s PET bottle waste by 2026.

The two new Starlinger recoSTAR PET 165 HC iV + recycling lines are set up at the recycling facility of Ganesha Ecopet Private Ltd. in Warangal, Telangana State. The company, a subsidiary of Indian PET recycling pioneer Ganesha Ecosphere Ltd., already produces recycled PET flakes and pellets for food-grade packaging as well as for filament yarns and fibres on two Starlinger lines installed in 2022. The new recycling lines are in operation since mid-2024 and triple Ganesha Ecopet’s annual production of bottle-grade rPET, raising it from 14,000 tons to a total of 42,000 tons.

EPR and consumers drive demand for sustainable products

The increasing demand for food-safe recycled PET in India has two main reasons. On the one hand, the Indian government has introduced Extended Producer Responsibility (EPR) for importers, brand owners and plastic waste processors as part of its Plastic Waste Management (Amendment) Rules in 2022 to ensure systematic collection of plastic waste. In addition, the rules stipulate that brand owners and producers must include a 30 % share of post-consumer recycled content in PET bottles by 2025, with the share being gradually increased each year to reach 60 % by 2029.

On the other hand, consumer preferences in India are changing, with sustainability being one of the top five factors for purchasing a product. Especially the large number of young consumers —i.e. millennials and generation Z— are increasingly demanding products and packaging that do not harm our planet. Brands respond to that by creating supply chains and packaging that are circular and sustainable. Recycled PET is one of the most convincing options for plastic packaging, given its continuous recyclability and lower carbon footprint compared to other alternatives, while not compromising on production scale, durability or quality.

“Our goal is not only to recycle plastics, but to create premium-quality, sustainable and viable circular solutions for brands,” said Sharad Sharma, Managing Director at Ganesha Ecosphere. “Recycling is not just an environmentally responsible choice; it is a powerful way to reduce CO 2 emissions and mitigate the effects of climate change. Starlinger’s superior food-grade PET recycling technology, combined with the operational expertise we have built up over the last 30 years on the Indian waste recycling market, enables us to push the boundaries of what is possible in PET recycling. Today, we proudly provide the best quality of recycled PET: like-to-like in properties with virgin PET, but with huge environmental savings in carbon emissions and energy. Various global FMCG brands like Coca-Cola have placed their trust in us to make their packaging circular while ensuring utmost safety and quality for the consumers.”

“Ganesha Ecosphere is one of the trailblazers for a circular plastics economy in India,” said Paul Niedl, Commercial Head of Starlinger recycling technology. “With their vast experience in the Indian plastics recycling sector and their willingness to invest in state- of-the-art technology they are able to transform post-consumer scrap into a high-quality secondary raw material for plastic packaging producers. As a technology developer and supplier, we are proud to support Ganesha Ecosphere on their way to ensure a clean, healthy and liveable future for our children.”

Focusing on sustainable production, Ganesha Ecopet also minimized the process-related carbon emissions by recycling and reusing 95 % of the consumed water as well as increasing the use of renewables in plant operations. With a total production capacity of 42,000 tons of food-grade recycled post-consumer PET per year the PET recycling company caters to Indian, US, and European markets. “We are grateful for the partnership with Starlinger and especially applaud their highly advanced, food-safe bottle-to-bottle recycling technology as well as their continuous support that has made this feat possible and circular economy a reality,” Sharad Sharma concluded.

Incentives for improving the Indian waste management sector

Ganesha Ecopet sources post-consumer PET bottles from every possible channel: online, offline, and through more than 300 suppliers and aggregators across India. The Indian government has set a focus on improving the waste management sector. Due to the size and efficiency of the already existing informal waste collection network, through which around 95 % of PET waste —one of the highest rates worldwide— in India is collected and recycled, the main goal is to optimize the current systems. There are various start- ups that are tackling multiple aspects, from piloting deposit return/refund schemes to online scrap marketplaces. The government also plays an important role by setting incentives for better Environmental, Social and Governance (ESG) practices and taxing unsustainable practices.

A pioneer in PET recycling

Ganesha Ecosphere looks back on more than 30 years of experience in the PET recycling business. Founded in 1987, the company started out as a yarn production facility. In 1994, it was among the first companies in India to reprocess PET waste to manufacture recycled polyester staple fibre (RPSF) and recycled polyester spun yarns (RPSY). By today, the group operates six production sites located in the Indian states of Uttar Pradesh, Uttarakhand and Telangana, and one in Nepal. In addition to bottle-grade rPET pellets and flakes, Ganesha Ecosphere produces rPET staple fibre for yarns, nonwovens, flame retardant fabrics, and fibre fillings. Its highest quality rPET products are produced by its subsidiary Ganesha Ecopet and marketed under the brand name “Go Rewise”. With over 2700 employees and exports to more than 18 countries, Ganesha Ecosphere ranks among the largest rPET producers in India, recycling 9.4 billion PET bottles per year.

https://ganeshaecosphere.com/

https://gorewise.com/.

www.recycling.starlinger.com

#recycling.starlinger #gorewise #ganeshaecosphere#modernplasticsindia#modernplasticsasia    #plasticsislife #plasticstalk#modernplastics #modernplasticsworld #pasticsnews #plasticsisgood #plasticsplanet#plasticsrecycling#plasticmagazine #PlasticIndustry#modernplasticsmiddleeast #indianmagazine #innovations #modernplasticsamerica #modernplasticsbangladesh #modernplasticsasia #modernplasticsitaly