Issue 04 October 2013 www.plastribution.co.uk the magazine Supporting UK Plastics 0845 34 54 560 In this issue Delivering excellence 06 Granic ® expansion 10 Carbon black magic 22 Metal replacement 26 Did you know... Plastic and plastics products exported Companies in the plastics industry 7,500 MILLION TONNES Material Processed People employed BILLION Value of exports Issue 04 – October 2013 Welcome to know-how Mike Boswell Plastribution Limited Managing Director PO Box 7743 5 Ashby Park CEVA House Ashby-de-la-Zouch Leicestershire LE65 1XY Tel: +44 (0) 1530 560560 Fax: +44 (0) 1530 560303 Email: sales@plastribution.co.uk www.plastribution.co.uk Welcome to the fourth edition Back to this edition. You will read in customers. Even the much of know-how magazine and we the following pages how we continue beleaguered construction sector, hope that you continue to enjoy to increase the range of products and which has benefited little from this publication as a valuable source services available to our customers, exchange rates, looks to be facing of information. and make a further commitment to better prospects as in particular the providing technical resources that private housing sector starts to recover. Understandably, many will question the rationale behind producing a magazine in this ‘always on’ age and in particular the justification of printing hard copy alongside publishing an In Momentum In this issue have the capability to support increasingly sophisticated products which offer even greater scope in terms off applications and efficiency. to the continuous development of our expertise through training and You will also see that from June, I have development. It is also due to the that the internet has significantly been elected as President of the British encouragement of our employees to impacted on speed, quantity and Plastics Federation and expect to innovate improved services, and the availability of information, but it serve a two-year term in this voluntary investment in robust processes. In this appears that readers are becoming position. This is the first time in its 80-year magazine you will see evidence of this more discerning in their choice of history that the president has come through activities such as our internal media platforms. In fact the expected from the distribution sector, and is clear training programmes, continuous demise of printed text books has simply recognition of how significant this part improvement projects and investment not happened. Consumers continue of the industry has become in recent in IT infrastructure. to display a preference for the printed years. Having started my career in the medium, and there has been a plastics industry over 30 years ago, and marked increase in the sales of weekly having spent 25 years at Plastribution review magazines as consumers it is a great honour to be of service struggle with ‘information overload’. and in this role represent the whole UK Finally we see that paperbacks plastics industry. You can gain a remain highly popular despite the greater insight into what I hope to Please contact me or any member convenience offered by e-readers. achieve during my term in office in a of the Plastribution team to discuss more detailed article within this edition how we can support your business of know-how magazine. success. 02 Granic ® in film 04 Little Hearts Matter Charity 04 Delivering excellence 06 Sarah Minshaw 06 Dear Dan 08 A sustainable plastics industry 08 Granic ® expansion 10 Richard Cudd 12 Technical support for film 12 Here come the girls 14 Briefing governments on plastics 14 25 years at Plastribution 16 Carmel new grades 16 New IT platform 18 New Plexiglas ® brochure 17 Your mission... 20 Nail Buddy 18 Our vision and values 20 UK Plastics – The enabler of manufacturing and distribution 20 Plastribution is on the move 22 Carbon black magic 22 In response to these changes we Iupital F20-EW 24 plan to take a more hybrid approach Enzymoplast new grade 25 by distributing topical articles more From a business perspective these are Metal replacement 26 quickly through the use of electronic interesting times. There is no doubt that Product list 30 media and industry press. We also plan high polymer prices are a significant to compile relevant information into challenge, but a more competitive an annual edition of know-how exchange rate coupled with a magazine incorporating our annual pro-manufacturing agenda from Product Portfolio. That way we hope government appear to have put you will enjoy the ‘best of both worlds’ many sectors of the industry on a from the end of this year when we stronger footing, and we note the launch our hybrid publication. bullish attitude of many of our Design: voice www.realworldthinking.co enjoy strong growth. This is largely due electronic edition. There is no doubt Knowledge is everything This magazine is printed using vegetable oil based inks on paper that contains fibre from sustainably managed forests. Here at Plastribution we continue to We hope that you will enjoy this latest edition of know-how and through its pages learn more about how the products and services that Plastribution offer can benefit your business. Regards, Mike Boswell 3 Issue 04 – October 2013 Issue 04 – October 2013 Technical fillers for cost reduction in film extrusion Unfortunately, due to the complexities It has long been recognised that adding fillers to plastic can act in a reinforcing manner, that is to say that physical properties can be improved leading to either a better quality product, or to cost reduction by down gauging to maintain existing property levels. in production of these master batches, the industry has been lacking the right quality of product to enable these avenues to be fully explored in extrusion processing. Film producers have tried adding large (+10%) addition rates of typical anti-block type master batches, and have found that rather than obtaining a reinforcing benefit, film properties are - disproportionately negatively affected, and processing becomes incredibly difficult or impossible. There are, however, very specific reasons for this. These are: Technical Fillers for cost reduction in film extrusion Granic Calcium Carbonate master batches ® Due to the bespoke processing method employed by Gestora, production of Granic ® is able to utilise very low melt flow polymers, the standard film grade being based on a MFI 1.1 LLDPE. This means that at higher loadings the carrier resin will not adversely affect processing or physicals properties. Moreover, a very high quality C8 LLDPE is used. This highly elastic resin compensates for the lack of elasticity in calcium carbonate, and further boosts properties. Gestora also use a highly controlled, ultra-fine grade of calcium carbonate, The very high melt flow of the limit the maximum particle size and carrier resin starts to adversely publish this data on their data sheets. affect the processing and physical This ensures that all the particles properties at higher loadings. included are of the right size to act The average particle size of the filler used is too large to act in a reinforcing manner. The maximum particle size is never published. Essentially these large particles act as contaminants and sites of weakness in the film. In thin gauge films these can also cause ‘fish eyes’ or similar. in a reinforcing manner and that there are no large particles to reduce properties and cause processing issues in thin film. These particles are also treated with a heat stable coating. This improves the affinity between the particle and the polymer and eliminates any moisture absorption, further boosting properties. The grade of calcium carbonate The surface of the particle has little used is also very pure, enabling a high affinity for polymer. level of whiteness to be achieved The filler absorbs moisture – at higher doses and this can cause issues. The filler used is often highly and allowing approval for food use. Granic in use Carbon footprint ® For initial trialling of Granic ®, it is To fully optimise potential material A further benefit of using Granic ® recommended that the quantity of savings using Granic , it is is that the carbon footprint of the master batch be gradually increased recommended to reduce the film material has been independently so that the operator gets a better gauge after increase in addition rate assessed and verified by TUV, understanding of how the new blend to bring the weight per metre of the Germany. This enables carbon behaves in processing. Typically as the film back to the original level. Further footprint values to be accurately percentage Granic ® increases, the testing of the film will show the physical assigned to Granic ®. With values stability of the bubble will improve properties stay constant when keeping of approximately 25% of standard resulting in the possibility of faster the section weight constant. polymers, the use of Granic ® can machine speeds. The film will also become more uniform and the weight will increase at the same gauge. ® Blow ratios should be kept above 1:1.8 to produce film with good biaxial properties. Less than this and significantly reduce the carbon footprint of the end product whilst achieving cost reduction. Therefore it is recommended to start the film will have very high strength in Specific approved logos are at a 10% addition rate, and increase transverse direction (TD) and very easy available for incorporation into the this in 10% stages, up to a maximum tear in machine direction (MD). product, along with the TUV stamp of 60%. The material should ideally be added by a gravimetric system directly above the extruder. For trial purposes material can be remotely mixed but separation is a When the desired filler loading is chosen, further savings can usually be of certification and the specific carbon saving obtained. achieved through the reduction in For further information on the full barrel temperatures. This is normally Granic ® range of products, please o found to be approximately 10 C. contact Plastribution on 01530 560 560. possibility if a vacuum system is used to convey the blend due to the difference in densities. contaminated by iron oxide and dirt (causing discolouration). 4 5 Issue 04 – October 2013 Issue 04 – October 2013 Delivering excellence Improving on-time delivery performance OTIF is an acronym for on-time and The subsequent corrective and in-full and measures a business’s preventative actions ensure that performance in getting customers the situation is put right and steps what they want when promised. are taken to ensure the same issues Getting it right first time drives down do not repeat. costs and improves customer The introduction of the OTIF measure satisfaction and as today’s margin and identifying the causes of failures pressure forces business improvements has enabled us to consistently achieve across the board, there is a renewed excellent results, with our rolling 1-year emphasis on service. average currently standing at 99.0%. At Plastribution, we understand that whilst every penny matters and pricing has to be competitive, service can be an order winner. If we can get the right product to the right place at the right time in the right condition, the reputation for reliability can give us a competitive edge. We hold the OTIF measurement with such importance as it is not purely a delivery scorecard. It measures our entire organisation – sourcing, receiving, storing, the sales order, picking, loading So what does this mean to our customers? With fewer picking errors, accurate inventory and higher order fill rates we can meet expectations and give outstanding customer service. “We want to set the benchmark for where service levels in our industry should be. Our challenge is to ensure our resources and expertise are always on hand, exactly where they need to be to meet customers’ expectations.” – Craig Share and delivery. Each aspect of this supply chain has to be right to achieve the commitment given to our customer and on the occasions we do fail, we can pinpoint which part of the process caused the breakdown and address the root causes. 6 7 Issue 04 – October 2013 Iss Issue ssue ss ue 04 – October Octo cto t ber err 2 2013 013 3 Dear Dan Q1 Q4 Dan Jarvis I am trying to mould a component products shrinkage values. In fact I hope you can help – I am currently Technical Manager with PMMA but even though I think the end products shrinkage will vary designing a bracket component that I am drying the material thoroughly, across the part and also when the will be used in a blast furnace. It has I am still getting visual defects. measurements are taken. There to withstand peak temperatures of Can you offer any advice? is a small but not insubstantial post 1000 oC whilst holding a load of up mould shrinkage for polypropylene to 25 kg. I would like the manufacturing which is a particularly significant for and component costs to be as low close tolerance mouldings. I hope as possible and so I would like to use this helps to answer your question. that cheap plastic I hear so much “Plastics are amazing materials and can be used in many very demanding applications, often at a lower weight and manufacturing costs and should not be underestimated.” This is a common issue with PMMA. Even though on the face of it the material seems dry it can often not be at the required maximum residual moisture content to produce visually perfect parts. As a rule of thumb for optical parts or thick walled mouldings, the residual moisture content should be no more than 0.04%. The best way of ensuring the material is dry is to use the highest possible temperature to remove the moisture as quickly as possible – typically the Vicat softening point of the grade in question minus 20oC for 2 to 4 hours. If possible also use a dry-air drying system. Q2 I have been trawling the internet and have rung several suppliers in an about. Can you recommend Q3 I have just started to mould a new job and I am having problems with inconsistent shrinkage. The parts like components which are can be used in many very demanding masterbatched in several colours applications, often at a lower weight including white, black, red, yellow and manufacturing costs and should green and blue. The only two colours not be underestimated. I seem to be having a problem with are the green and blue which are giving me different shrinkage values compared to the other colours. Is there anything that I can do to supplier a call and ask if the green getting various answers. Can you and blue formulations contain help at all? phthalocyanine pigments. If they do, your question. Shrinkage rates are influenced by many factors which is why you are generally given a range to work with. Processing temperature, mould temperature, tool design, MFI and injection speed and pressure all However, sometimes other more traditional materials are still more suitable and in your case I would certainly use metal! resolve this issue? value for polypropylene but keep for as there is no definitive answer to for you – Steel! Plastics are amazing materials and My advice is to give your masterbatch you cannot find what you are looking I certainly can recommend a material I am moulding are small HDPE cap attempt to get a definitive shrinkage Yes I can. I am not at all surprised that a material for me? then ask if it is possible to reformulate the green and blue without them. Phthalocyanine pigments have a nucleating effect on HDPE and PP which will cause differential shrinkage when compared to your other colours (which do not contain them). I am fairly confident that this will be the case. play a significant role in the final 8 9 Issue 04 – October 2013 Issue 04 – October 2013 GCR Group expansion GCR Group is the new company name for the producer of the Granic ® range of masterbatch. The company formerly known as largest source of high quality plastic processing. This surface treatment fillers as an antiblock are often range that covers the film, pipe, sheet Gestora de Catalana de Residuos grade calcium carbonate (7km). also significantly reduces abrasivity surprised to find that they can utilise and automotive industries. These started production in 2001 locally In addition the world’s largest talc and gives a product which is no the Granic ® material in much higher products have been produced to recycling PE and PP. The company mine is less than 200km away. more abrasive than virgin HDPE. dosages than 5%. In fact addition exacting standards with the express This is an important consideration rates in film of up to 60% have been purpose of replacing virgin polymer when processing polymers with achieved successfully. and has recently gained a lot of had three distinct business areas namely Granic , Ciclic and Irtion and ® the name change brings them all under the GCR Group. of the plastics converters regarding plastic reinforcement, oil based high levels of mineral fillers. Production is highly automated with interest from the automotive sector. polymer replacement, lowered Probably one of the most important closed loop operation enabling the Irtion is the technological unit of the Granic is the largest producer environmental impact, carbon differences from Granic materials and Granic products to be produced to GCR group where a patented new of filler masterbatches in Europe. footprint reduction (through others on the market is the grading of the highest specification. Extensive way of mixing, drying and coating With a compounding capacity certification), reduced energy the calcium carbonate. Granic pay post blending is carried out to ensure materials is giving the company the of 110 000mT the company will consumption and help converters close attention to the quality and that each batch is completely ability to improve the quality of the have doubled this to 220 000mT achieve a reduction in the cost grade of calcium carbonate used in consistent and product is regularly environmentally friendly plastics by the end of the year. By the end of their finished goods” comments the production of their masterbatch. sampled to ensure that moisture, top that Granic ® and Ciclic produce. of Q2 2013 Granic will start up their Victor Oliva the commercial Average particle size (top cut) cut, average particle size, loading, The company is currently looking 3rd compounding line with its own director at GCR. distribution is absolutely paramount colour and specific gravity are all for strategic partners for this when producing a filler that will not within tolerance. technology. ® ® Irtion technology. 10 “Granic’s aim is to fulfil the needs The extremely pure, ultra-fine calcium ® ® compromise mechanical properties. ® This will be further complemented carbonate that is used in production by a 4th line in early 2014 and this of Granic materials is surface treated is expected to be at full capacity and carries certification to that effect. by the summer. The plant, which is This ensures that these products do not ideally situated locally to its polymer absorb moisture and therefore require Due to the differences documented the petrochemical industry and feed stock supplier (20km) and the no drying and provide trouble free above many producers who use converters. Ciclic have a product ® In fact in many cases it actively improves certain mechanical properties. Ciclic is the recycling arm of GCR business. Today Ciclic have a recycling capacity of 35 000mT and it specialises in PE and PP post industrial waste from “Environmentally friendly plastics solutions” 11 Issue 04 – October 2013 Issue 04 – October 2013 Technical support for film During the time I have spent in the polyethylene film industry, the emergence of metallocene-catalysed polyethylene has led to significant advances in film performance, particularly with regards to mechanical properties, sealing performance and optical properties. Whilst the first generation of attractive, offering the same or Richard Cudd metallocene grades were difficult better performance as thicker film Technical Executive to extrude, advances in catalyst and the potential for promoting and process technology has given more sustainable products based on rise to metallocenes which combine reduced packaging weight and film the high mechanical strength of consumption. Additional advantages LLDPE with near-LDPE extrudability. along the supply chain could be Understanding how these high performance materials can be lower costs of raw material inventory holding, delivery and disposal. exploited whilst keeping blend costs My role within Plastribution is to under control can be a challenge, offer our customers the technical particularly for companies with limited support they need to develop technical or marketing resources. and improve their film products. The key is to determine what the Plastribution supplies a wide main drivers are along each particular range of polyethylene grades value chain, i.e. what are the most for film extrusion, including Exceed important performance criteria for and Enable metallocenes from the end-user, how can metallocene ExxonMobil, C4-LLDPE from Sumitomo products be used to improve this and autoclave LDPE from Carmel. performance and how can the Also available for film extrusion value of this improvement be shared. are Vistamaxx propylene-based Reducing film thickness whilst maintaining (or even improving on) existing mechanical properties, increasing seal strength to allow for lower sealing temperatures and/or elastomers for polymer modification, high quality Granic ® calcium carbonate masterbatches for blend cost reduction and a range of functional additives from Kafrit. higher line speeds, increasing clarity Being able to offer our own, and gloss to improve film aesthetics dedicated technical support, are all benefits of using metallocene. means Plastribution can provide Downgauging can sometimes be a difficult concept to promote, particularly where extruders sell their film by weight; reducing film thickness will mean more metres of film per reel if reel weight is kept constant and therefore the end-user will re-order less frequently. If, however, end-users can be persuaded to buy film by the “My role within Plastribution is to offer our customers the technical support they need to develop and improve their film products.” a faster response to technical enquiries, help with day-to-day problem solving, recommend the most suitable product for a specific application and have someone on site to support trials of new products, ensuring the optimum processing conditions are used to maximise the benefits of the product. metre, then downgauging becomes 12 13 Issue 04 – October 2013 Issue 04 – October 2013 Briefing governments on plastics Plastribution’s Managing Director, Mike Boswell, recently met Michael Fallon MP, Minster of State for Business and Enterprise, and impressed upon him the importance of the UK plastics industry to the UK economy and society. This was in Mike’s role as President £19 billion. Most settlements in the of the British Plastic Federation (BPF) UK and certainly all Parliamentary and the encounter took place on constituencies will have at least July 22nd at the special exhibition one plastics operation within their on the industry mounted by the boundaries, a fact, which significantly BPF in the foyer of the Department assists the BPF’s lobbying power. of Business Innovation and Skills on Mike explained to Mr Fallon that it London’s Victoria Street, very close to was the UK which had launched Westminister. Mike spent thirty minutes the commercial plastics industry giving Mr Fallon a tour of the exhibition with the introduction of ‘Parkesine’ and was able to explain the role of in 1862. The contribution of the UK plastics in supporting the business and to the industry since that date was profitability of a wide range of sectors documented on the BPF’s Time-Line not just in manufacturing but also in which was on prominent display retail, distribution and healthcare. at the exhibition. Key landmarks The BPF exhibition made the point that the industry is a significant employer of some 180,000 workers and has a sales turnover of approximately of included the UK’s role in the discovery of ‘Polyethylene’ by ICI in 1933, the The Museum of Design and Plastics, a already evidence of civil servants early exploitation of the PET bottle part of the University of Bournemouth, having digested the messages in the late 70’s and the preparation had curated display cabinets for and using them in their work.” of PEEK, again by ICI, in 1977. the BPF adorned with iconic plastics products made in the UK and which illustrated some of the key benefits of using plastics such as their ability to be recycled. The BPF also designed a number of street- facing images, focusing on the theme of ‘Fantastic Plastic’, illustrating how the materials can help ‘keep food fresher for longer’ and how they reduce vehicle weight and hence fuel consumption when used as components in cars. “The exhibition”, said Mike, “was the combination of a whole series of contacts made by the BPF and its members over the previous year and we had Vince Cable’s video message of congratulations to the BPF on its 80th Anniversary playing continuously alongside the display. Taken together “The BPF exhibition made the point that the industry is a significant employer of some 180,000 workers and has a sales turnover of approximately of £19 billion.”– Phillip Law with David Cameron’s more recent letter of congratulations, this is a terrific governmental endorsement of the UK plastics industry. As the Prime The exhibition was visible to the Minister said, the plastics industry many civil servants who were passing ‘is contributing enormously to our through the foyer, many of them transition to a green economy’ and policy-makers on issues affecting our exhibition at the Department of the industry, and passers by on their Business Innovation and Skills showed way to the tourist sites close by. exactly how we are doing this.” Mike said “The feedback was very positive indeed and that there is 14 15 Issue 04 – October 2013 Carmel new grades Exciting new grades from Carmel Olefins. A batch of four new speciality polymer Carmel Olefins Ltd. manufactures products has been developed and sells 165kTPA of Low Density and released by Carmel Olefins Polyethylene (LDPE) under the and is now available to processors name Ipethene®. A broad range in the UK through Plastribution. of Ipethene® products have been TP50V is a very high flow heterophasic copolymer with exceptional impact properties. It has been designed for injection moulding applications with thin walls, complex design or long flow lengths. This grade will also be of interest to compounders or other produced since 1964 (formerly by Israel Petrochemical Enterprises Ltd.), and there are now four lines consisting of high pressure autoclave reactors. The technology was originally licensed from ICI Ltd. – the inventors of high pressure LDPE technology. converters using reprocessed or Carmel Olefins Ltd. also manufactures recycled materials to enhance the and sells 450 kTPA Polypropylene mechanical performance of the (PP) under the name Capilene®. The overall product or allow increased range of Capilene® PP products are incorporation of recyclate. manufactured in two production lines Carmel has also introduced a unique range of transparent impact based on Spheripol and Spherizone technology under license from Basell. copolymers which are intended to Carmel Olefins is committed to solve the traditional Polypropylene developing and extending its trade off between impact and product range by extending the clarity, and also offer excellent property window of available resistance to stress whitening. polymers and providing solutions CT80A – MFR (25) and CU80AV – to today’s plastics processor. High MFR (35) are intended for the Plastribution’s technical resources, injection moulding of thin walled in the form of Dan Jarvis (please packaging, clear containers for see inside back page spread) are deep-freezer storage, caps and available to help processors select and closures, pails and crates or any work with these new Carmel grades. applications where both clarity and impact properties are required. The final addition to the range is Capilene U12EV a polypropylene hompolymer with a high MFR (37) intended for Non-Woven applications. Please contact your Plastribution sales representative for more details. Evonik Industries new PLEXIGLAS® brochure It is specifically aimed at helping with the processing of Plexiglas ® and Evonik have produced a new brochure which details all aspects of injection moulding with PLEXIGLAS PMMA. contains detailed information on: Product range Physical properties Technical requirements including the moulded part, the moulding process, the mould and moulding machine 16 Processing Injection moulding defects, causes and remedies Product handling Issue 04 – October 2013 Nail Buddy – a recipe for success Take a young beauty therapist with a clever concept, combine some good old fashioned product development expertise with lashings of collaboration, add the effective use of complementary materials and you have the hallmarks of a Dragon’s Den success story. Nail Buddy is, seemingly, every The material selection for the main girls’ best friend. The product is body of Nail Buddy required a high a professional, handy and new gloss, durable finish, capable of portable fashion accessory, looking fashionable whilst maintaining designed to hold nail polish bottles functionality. With its high rigid, securely, leaving both hands free medium impact strength, Plastribution to apply nail polish and achieve recommended ABS Polylac® PA-757 professional looking results whether ABS, which provided an ideal balance at home or on the move. of properties combined with ease of Developed on the back of requests from professionals and customers alike, processing, and the ability to be coloured using masterbatch. Nail Buddy is designed to sit perfectly And to keep nail varnish bottles of between your knees or on any flat all shapes and sizes secure, a rubber surface. And by being able to hold cage was developed that sits inside all shapes and sizes of bottle, Nail the main body of the product. Buddy is simple to use and effective. A variety of grades of thermoplastic Nail Buddy has recently entered vulcanizates (TPVs) were trialled, the fashion and beauty markets with Santoprene™ offering the and is currently enjoying a positive best performance, together with its reception. The product currently inherent manufacturing flexibility, retails at £9.99 and is available ease of processing and consistent in two fashionable shades – durability. A non slip rubber base Honeysuckle Rose or Silver Peony. completed the design. The initial concept for Nail Buddy In production, the moulding, assembly provides an excellent example of and pack-out of the product was product development synergy. carried out by Dugdale Plastics. The three ‘players’ in this product’s development included Ramsgate based Dugdale Plastics, UK based offshore manufacturing and injection moulding tooling project management specialists, Protek and materials supplier, Plastribution. Both Dugdale Plastics and Protek created aesthetic and functional 3D designs, from which prototype tooling was manufactured and assessed to check form, fit and function. With support from Plastribution, varying Nail Buddy was launched exclusively into Boots UK in December 2012 through High Street TV. The product is currently on sale through other major retailers, distributors, shopping channels and airlines. To further promote Nail Buddy, a company known as Majique Ltd was formed in November 2012 to market and distribute the product, along with a range of beauty products and gift sets. grades of materials were also trialled, with the emphasis being on balancing cost with performance. 19 Issue 04 – October 2013 Issue 04 – October 2013 UK plastics UK plastics industry: Key facts The enabler of manufacturing and distribution The plastics industry is an industry that employs more than 180,000 people. This is more than the pharmaceutical We all recognise modern life would industry, oil and gas industry, nuclear not be possible without plastics. It is industry, video game industry and essential that both the government the film industry combined. and banking sector fully understand Yet the size and importance of the industry is difficult for many to comprehend as the first image that often springs to mind is the sector as the producer of toys and bags. The the vital role our industry plays in the ongoing recovery of our economy and the need to rebalance our priorities BILLION Companies in the plastics industry 7,500 Value of exports to reduce the current dependence on retail and service sectors. MILLION TONNES full range of applications and the industry’s role in supporting almost 19 every branch of the economy is frequently overlooked. In considering the full range of applications, plastics is an essential, enabling industry for almost every sector of our economy, including: 4.8 Plastics materials produced Plastics industry turnover MILLION TONNES Food & agriculture Infrastructure Medical & healthcare Manufacturing Transport Electrical & electronics Material processed People employed Plastic and plastics products exported Sport & leisure 13.1 Number of primary processors Processorover sales turn 20 21 Issue 04 – October 2013 Issue 04 – October 2013 Carbon black magic Turning electrically conductive plastics into products Carbon black magic This is the first instalment in a series of articles on the processing of Premix’s electrically conductive plastics. The series kicks off with a look at the key element of conductive compounds – carbon black – and how it is used for creating the perfect compound mix. Conductive carbon black is the most reliable and cost-efficient choice for conductivity: black type for the purpose branched chains. Such a structure technique is ideal for conductive compounds Small particle size: smaller used in countless processing methods conductivity. If the particles are and final applications. The role of small and relatively uniform in the compounder is to ensure that shape, their surface area is larger above factors are executed correctly than otherwise. Extra conductive and to help the customer take full carbon blacks, with the smallest advantage of the compound in the particle size, provide the highest manufacturing process. Together, electrical conductivity. Step 1: Picking the right carbon black Carbon black comes in many different varieties. The carbon black that works perfectly in truck tyres is not the right choice for conductive compounds. Selecting the carbon black with just the right features is the first important step towards a successful end product. Strong bonds between primary particles Agglomerate <102 ohm.cm CB Loading (W%) Size: >0.1mm Weak bonds between aggregates reached with lower loading levels. size means higher electrical are met successfully. Size: 0.1 -0.5 microns – the required conductivity can be Electrically conductive plastics are desired goals for the end products High Structure Aggregate means that the carbon black agglomerates form long and Optimising the compounding 108 ohm.cm High structure: high structure Selecting the optimal carbon Formulating the compound 1014 -1018 ohm.cm Size - 0.01 microns plastic compounds. The secret behind lies in three important factors: Primary Particles conductive compound. Factors that improve electrical the perfect carbon black compound Volume Resistivity(ohm.cm) electrical behaviour of the electrically producing electrically conductive these measures guarantee that the Low Structure porosity also have an impact on the Premix’s R&D specialists can select The carbon black content and the The Premix compounding lines have just the optimum carbon black load production process require careful been optimised for the production needed to achieve the required control and monitoring. of electrically conductive plastics. electrical properties. Finding the correct loading level is extremely important: too high a carbon black load has a negative impact on the compound’s mechanical properties. It also increases viscosity, causing High porosity: higher particle problems in the injection moulding porosity enables better process, for example. electrical conductivity. Step 2: Formulating the right mix The percolation curve illustrates the relationship between the quantity of added carbon black (CB load) and the achieved electrical resistivity. After exceeding a certain loading Note the narrow threshold in which level, carbon black changes the the electrical resistivity dramatically electrically insulating base polymer drops. After this threshold level, into electrically conductive plastic. increasing carbon black will no longer The decrease in electrical volume improve the electrical properties. resistivity due to the increased amount of carbon black can be described using a percolation model. The most important factor affecting The percolation behaviour of carbon the electrical performance of carbon black depends on the qualities black is its structure. Particle size and mentioned in step 1: particle size, structure and porosity. Usually the steepest part of the curve hits the static dissipative resistance levels (106–109ohms). This makes the development and production of dissipative carbon black compounds very challenging. Choosing the right carbon black also depends on how the material will be processed. For example, during the injection moulding process, the compound is subjected to different For each formulation and base polymer, our processing engineers select the right machinery with optimal screw geometry and granulation technology. processing conditions than during the Carefully defined processing extrusion process. For each process, parameters ensure that the shear roughly speaking, there is a matching forces and process temperatures type of carbon black. are at the ideal level. In optimal Premix has accumulated 30 years of expertise in formulating and manufacturing electrically conductive compounds. Based on our research, experience and years of product development, we have found the perfect mix for any requirement. conditions, the carbon black agglomerates are separated into aggregates which are then dispersed and distributed evenly within the compound. This is done without breaking the carbon black’s structure. Continuous quality control throughout the process and seamless Step 3: Optimised compounding process The final piece of the puzzle for creating a perfect electrically cooperation between the production and quality assurance departments are the final checkpoints on the way to the perfect outcome. conductive compound is finding the optimal technique for dispersing the carbon black to the base polymer. 22 23 Issue 04 – October 2013 Issue 04 – October 2013 Enzymoplast™ new grade Mitsubishi Engineering Plastics Corporation Mitsubishi Engineering Plastics Corporation launches new grade of POM for water fitting applications. MEP have announced a new grade Iupital POM has good mechanical Advanced Enzyme Science Ltd is flexible and industrial packaging and of acetal, Iupital F20-EW, which is a properties as well as: proud to announce an addition to agricultural films including mulch and their range of additive master batches silage. All products will also retain US which biodegrade polyethylene. FDA approval. Enzymoplast ENZO0900 AESL’s master-batches can be easily Biodegradable uses similar incorporated into standard PE film enzyme based bio-technology to production lines with only minor that which is used in the original changes to settings. ENZO0900 has ENZO0001 Compostable grade, been independently tested by a albeit with modifications to better reputable European Laboratory in suit environments where industrial accordance with ISO 14855-1:2005. composting facilities are not available The product is certified aerobically or applicable, or in developing biodegradable within a defined period markets or where there is no end 1-3 years at end of its life, depending of life solution other than landfill. on prevailing environmental modified version of F20-03 and meets all the requirements for potable water High fatigue resistance uses in various European countries. Excellent anti-creep properties Iupital F20-EW is a general purpose Excellent low friction and POM copolymer suitable for all anti-wear properties water fitting applications and meets the approval requirements in various countries as follows: UK – WRAS (BS 6920, for use with water up to 85°C) USA / Canada – NSF 14 (NSF 61) Germany – KTW (23°C and 60°C) France – ACS (XP P 41 250) Wide range of operating temperatures High oil and organic chemical resistance Excellent thermal stability in moulding Natural, black, coloured and glass filled grades available AESL- Enzymoplast announces the launch of its new technological innovation in biodegradable PE formulation ENZO0900. Products incorporating ENZO0900 conditions. exhibit excellent mechanical Of course, like all polyethylene film properties, and have been found treated with AESL master batches, the to increase film tensile strength in the finished product is 100% recyclable final product by approximately 2-3%. and will not adversely affect the ENZO0900 technology has also been recycling stream. targeted to reduce cost compared to other degradation systems, such as those containing metal ions, therefore making it a more affordable proposition with nominal cost. A further The active ingredients in ENZO0900 come from renewable sources and do not adversely affect or rely on the food supply chain. benefit when compared to these other For further information please visit: systems is, just like ENZO0001, ENZO0900 www.enzymoplast.com leaves no contaminants in the soil after degradation. The product applications are many and varied, and the master-batch may be added into the production of all types of polyethylene flexible film where single use of the end product is normal such as disposable bags, 24 25 Issue 04 – October 2013 Issue 04 – October 2013 Metal replacement Plastribution are proud to announce the introduction of a brochure detailing their metal replacement range of thermoplastics, along with the creation of a website designed to help to guide designers and engineers through the complex choices to select the best material for their desired applications. The manufacturing benefits of using polymers from the industry’s leading plastics instead of metals have long producers, we are able to offer been recognised, however the realistic and workable solutions to technical capabilities of products most metal replacement issues.” have not been able to match environmental demands. With weight reduction, performance enhancement and cost reduction all major drivers in today’s markets, particularly in the automotive sector, metal replacement has never been so high a priority. Engine downsizing and fuel efficiency, reduced under bonnet space and longer vehicle life time requirements are providing increasing demands on existing and historically acceptable solutions to part designs. of the world’s largest producers of means that higher productivities can be achieved, along with improving properties of weld line resistance. Underlining their commitment to environmental concerns, Radici Group are proud to have developed backwards integrated producer makes it the ideal choice for metal Radilon D, a new family of PA610 of both PA 6 and PA 6,6. This replacement where impact strength engineering plastics for injection and Developed by Idemitsu, XAREC, integration allows them the scope and vibration resistance are key extrusion moulding, produced in with a melting point of 270oC, and diversity to be the world’s factors. Such areas include engine part using polymer from renewable demonstrates an exceptional level of most dynamic and inventive mountings, oil pans and seat frames. sources. Compared to petroleum- high heat resistance and is therefore producer of nylon resins. Several suitable for many lead free soldering new developments are targeted applications. Also, thanks to its low at high end engineering plastic density, it can represent a part applications for metal replacement weight saving against other high and automotive environments. XAREC SPS: Syndiotactic Polystyrene from Idemitsu temperature plastics such as PPS. built with not only straight metal excellent resistance to a wide replacement in mind though. With range of chemicals and oils very high modulus, high temperature including automotive under bonnet resistance and ultra-low fogging fluids, and show a very high hydrolytic properties as examples, another stability, low water absorption (0.01%) key target area is performance coupled with excellent electrical enhancement of products properties. It is easy flowing and shows already produced in polymers. high weld stability even at elevated temperatures in water and glycol. Radilon A RV500RW and Radilon S URV: High glass fibre and high flow nylon based products, these materials Radilon HHR PA 6,6 for high temperature applications Radilon HHR has been developed for blow moulding and injection moulding applications to produce, o can not only reduce dependency on fossil resources but also lower greenhouse gas emissions and energy consumption in production processes. Radilon® D materials show reduced at a continuous operation of 210 C moisture uptake and a smaller in air, the best performing material loss of tensile strength and tensile in its class. Due to the original heat modulus under wet conditions. Radici Group’s highly filled range protection technology employed of nylons offer higher stiffness, by Radici group in their HHR resins, deformation at break, weld line a high retention of tensile strength strength and impact resistance and impact properties after heat when compared with standard ageing at 210oC means these grades of PA 6,6 50% GF. These grades are aimed at areas of enhanced product families also metal replacement and property have comparable tensile strength improvement. They can also Manager at Plastribution said This blend of properties makes at break compared with light metal often replace special polymers “We have worked tirelessly to XAREC an ideal choice for today’s alloys and demonstrate much better such as PPA, PPS and PA 4,6. ensure we are able to offer a modern high temperature and fatigue behaviour. These product comprehensive range of materials pressure engine environments benefits come at a lower density to cover most applications. including, amongst others, control than light metal alloys, allowing for units, housings, fuse links, lamp performance increases at a reduced sockets, connectors (including PCB’s), part weight, so aiding fuel efficiencies. range of high end engineering Radilon D: Eco sustainable PA6.10 This unique balance of properties Parts made in XAREC offer We feel that, with our current product 26 Based in Italy, Radici Group are one The ease of processing these resins nylon, and they are the only fully Plastribution’s portfolio has been Peter Tillin, Engineering Product Radilon: Specialist nylon grades from Radici Typical applications include charge air coolers, resonators and turbo air ducts. Furthermore, PA610 products have better chemical resistance in contact with zinc chloride and calcium chloride solutions and better glycol resistance. Compared to PA11 and PA12, the new Radilon® D products have improved thermal resistance and reduced hydrocarbon permeability Typical applications include injection moulded components, vapour, fuel and brake lines, pneumatic pipes, connectors, high stiffness parts, pipe fittings and monofilaments. antennas and high voltage parts. 27 Issue 04 – October 2013 Issue 04 – October 2013 Metal replacement Pre-Elec and PRESEAL: Conductive polymer solutions from Premix OY Vaporised fuel and air mix together to form an explosive atmosphere and then in order to make environments safe, all ignition sources must be removed, including static electricity. The best way to control electrostatic Mitsubishi Engineering Plastics have set of advantages. Grades are also injection and extrusion, one of the has enabled Thermofil to replace both resin that is tailored to achieving high further enhanced their acetal (POM) available unfilled and in variety of filler most diverse ranges on the market, metals and higher end engineering quality results with electroplating. range with the development of a loadings, and Plastribution are able to enabling its use in a number of plastics in a variety of applications, The new material - Polylac® PA-726M low formaldehyde emission grade offer all. high performance environments. including engine cooling fans, shrouds, - is intended for use in automotive manifolds, internal automotive door parts and components, particularly parts, pedals and housings. front grilles, and is already approved to combat anti-fogging issues and chemical irritation that can be encountered with standard grades. This is achieved with no reduction in properties from standard acetal. PPS is used extensively in the Typical applications for VESTAKEEP automotive sector and is currently include gears, high rigidity machinery found in alternator parts, power parts, housings, bearings and modules, sensors, electric coils, self-lubricating parts. These can capacitors, connectors, housings, hot generally be found in the medical, build-up in fuel systems is to use In routine automotive emission water systems, pump parts and many film, sheet, cable, automotive conductive plastic materials in tests, standard acetal emitted other applications. and aerospace industries. direct contact with the fuels. approximately 14 times the amount Vestakeep: High performance PEEK from Evonik Thermofil HP: High performance glass filled Polypropylene Premix are the industry leaders on providing solutions to the automotive of formaldehyde compared to the Iupital LF series. Thanks to Sumika’s unique processing for use by some automotive OEMs. Evonik: Plexiglas replaces metal for enhanced surface finish Meeting the high demands of the automotive sector Evonik Industries are the global leader Mitsubishi Engineering Plastics’ in Acrylic (PMMA) materials, offering a comprehensive portfolio of diverse range of speciality PMMA XANTAR polycarbonate and materials for use in the Automotive blends offer new opportunities and Electronics industries. for the automotive industry. The industry in fuel lines. They offer a This makes it ideal for products used unique range of products for both in vehicle interiors and confined Polyether ether ketone, or PEEK, technology, Thermofil HP grades Plexiglas Hi-Gloss NTA-1 offers an extrusion blow moulding and injection spaces, or general acetal mouldings is being produced by Evonik for are able to offer performances not excellent surface finish and a very moulding applications, providing where residual smell from, for example, applications where, historically, previously achievable in glass filled high level of black gloss (class A) significant cost savings in the overall storage in sealed bags, is an issue. the use of plastics struggled due to polypropylene (GF PP). This, along surface finish. It also benefits from its extremes in environment. VESTAKEEP with their improved glass coupling ability to resist scratching, and, where grades demonstrate particularly methods, results in significantly higher damage occurs, its ability to be high rigidity and strength, and with tensile strength, tensile modulus, polished back to its original condition. Vicat softening temperatures of over elongation at break, creep resistance, 300oC, this is coupled with exceptional impact resistance and heat distortion resistance to high temperatures. temperature when compared Also of note is VESTAKEEP’s very low with equivalent standard GF PP. fuel system. And as the materials have a constant electrical conductivity over time, safety is assured. Typical properties include excellent processability and weldability providing lower production costs. Also since the products are high gloss with very smooth surfaces, less fuel turbulence is encountered through the systems. The products are suitable for mono-layer and multi-layer systems and are also bio-fuel compatible. Iupital LF Series: Low formaldehyde emission acetal for excellent antifogging properties Typical products include clips, seat belt guides and trim parts. PPS: Polyphenylene Sulphide for high temperature and stiffness appications PPS is a unique material which water absorption, giving the benefit offers excellent resistance to high of a very high dimensional stability. temperatures, coupled with flame retardancy and excellent electrical properties. This blend of properties makes PPS suitable as both a metal replacement and a thermoset material replacement. PPS is available in Linear and Branched or Cross Linked and Elastomer Modified, with each material offering a distinct 28 developed grades offer solutions for demanding applications such as air conditioning and venting nozzles, steering column claddings, dashboard components and interior lighting. temperature and its excellent mouldability has lead to it being successfully used in a variety of internal and external automotive Other properties include excellent to replace glass filled nylon (GF PA) components. These include external chemical resistance, electrical applications, where their use offers trim parts for Lotus and Jaguar Land properties and hydrolytic stability. higher tensile strength and tensile Rover. This balance in properties makes modulus. When also considering VESTAKEEP and ideal metal the much lower density of Thermofil replacement material. compared to GF PA, significant and filled grades for processing by such as instrument panels. Specially- resistance, good heat deflection the products are finding their way cost savings can be achieved. in automotive interior applications This coupled with good impact The properties are such improved that VETAKEEP offers, with both unfilled materials are predominantly used Chi Mei ABS: Enhanced finish Electroplating Grade Taiwanese plastics producer Chi This unique blend of excellent stiffness, Mei has introduced a new grade of creep resistance and impact resistance ABS (Acrylonitrile Butadiene Styrene) 29 Issue 04 – October 2013 Product list Supplier Material Brand Name Engineering polymers The Plastribution team is always available to provide advice on all aspects of grade selection including design, processing and properties. So please do not hesitate in contacting us to discuss your specific requirements. Please remember that, despite our best efforts to do so, it is almost impossible to cover every request for information on the website or through the new portfolios, particularly as new developments are happening all the time. If you should be unable to find what you require, just get in touch on the phone, email or through the website and, if we really can’t help, we will do our utmost to point you in the right direction. Plastribution Limited PO Box 7743, CEVA House, 5 Ashby Park, Ashby-de-la-Zouch Leicestershire LE65 1XY Tel: +44 (0) 1530 560560 Fax: +44 (0) 1530 560303 Email: sales@plastribution.co.uk www.plastribution.co.uk Material Brand Name Specialities Bioplastic Apinat TPE Megol TPO Apigo TPV Tivilon TPE TPU PP Recycled Aurapene Barrel Blitz Universal Raplan Biohybrid Cardia Biohybrid Apilon 52 Biodegradeable Wonderlite PMMA Plexiglas Cyro XT Clear Polymer Cyro Cyrolite PEEK Vestakeep SPS Xarec Polycarbonate Tarflon PC/ABS Xantar C PC/PET Xantar E POM (Acetal Copolymer) Iupital Polycarbonate Iupilon PBT Ramster PA6.6 Plustek PA6 Prime Plustek PA12 Plustek TPE – Highly Conductive Preseal TPE Thermally Conductive Compounds Pretherm Static Dissipative Compounds Pre-Elec ESD Conductive Pre-Elec TPEE/TPE/TPV Heraflex PETG Raditer E PBT Raditer PBT Radiflam B PA6.6 Prime (Italy) Radilon A PA6.6 Prime (Germany) Radilon A PA6.6 Industrial (Italy) Heramid A Material Brand Name PPRCP Capilene PPHP Capilene PPCP Capilene LDPE Ipethene PPHP Ducor PPCP Ducor Masterbatch – UV Stabilisers Colourtone Masterbatch PPHP ExxonMobil PP Masterbatch – Universal Colourtone Masterbatch PPCP ExxonMobil PP Masterbatch – PVC Colourtone Masterbatch PP Plastomer Vistamaxx Masterbatch – POM Colourtone Masterbatch mPE Exceed Masterbatch – Polycarbonate Colourtone Masterbatch mPE Enable Masterbatch – PBT Colourtone Masterbatch LLDPE ExxonMobil LLD Masterbatch – Nylon Colourtone Masterbatch LLD Plastomer Exact Masterbatch – Blowing Agents Colourtone Masterbatch LDPE ExxonMobil LD Masterbatch – Anti-static Colourtone Masterbatch HDPE ExxonMobil HD Biodegradeable Enzo EVA Escorene EAA Escor Functional Polymers Exxelor PP Compounds Exxtral PP Compounds Thermofil Calcium Carbonate Compounds Granic Masterbatch Slip/Anti-block Kafrit/Constab Masterbatch Masterbatch Colour Universal Kafrit/Constab Masterbatch Masterbatch Anti-block Kafrit/Constab Masterbatch Masterbatch – UV Stabilisers Kafrit/Constab Masterbatch Masterbatch – Slip Agent Kafrit/Constab Masterbatch Masterbatch – Process Aids Kafrit/Constab Masterbatch Masterbatch – Flame Retardant Kafrit/Constab Masterbatch Masterbatch – Blowing Agents Kafrit/Constab Masterbatch Functional Polymers Modic Functional Polymers BondyRam Styrenics PA6.6 FR (Italy) Radiflam A PA6.6 (Industrial) Germany Heramid I/A SAN PA6.10 Radilon D PC/ABS Wonderloy PA6 Prime FR (Italy) Radiflam S BDS Kibiton PA6 Prime (Italy) Radilon S ASA Kibilac PA6 Prime (Germany) Radilon B ABS Polyac Polylac PA6 Industrial (Italy) Heramid S SMMA Acrystex PA6 Industrial (Germany) Heramid I/B SMMA Styrilic PA6 Radilon S PA6 Heramid B Susteel Supplier Polyolefins Purging Agent Polycarbonate PPS 30 Supplier DELTECH CORPORATION Kibisan HIPS FR Total HIPS FR HIPS Alloys Total HIPS Alloys HIPS Total HIPS GPPS Total GPPS PPCP Sumitomo LLDPE Sumitomo HDPE Sumitomo PPRCP Total PP PPHP Total PP PPCP Total PP mPPRCP Lumicene MDPE Total MD LLDPE Total LLD LDPE Total LD HDPE Total HD EVA Total EVA PP Compounds RamOfin Our expertise 0845 34 54 560 www.plastribution.co.uk Plastribution is working hard to evolve materials, the best at identifying new the distribution model to be supportive, markets and the best at managing and sustainable and secure. Our expertise is advising on raw materials and pricing. one of the things allowing us to do so. By delivering reliability, know-how and Expertise is something that all of our true business partnership to the world’s suppliers and customers know they best polymer suppliers and our UK can rely on. Differentiating us as truly customers; our expertise is helping the consultative business partners, industry get better, smarter and faster. making us the best at sourcing Momentum – October 2013 Knowledge is everything At Plastribution we are always looking for new ways to improve the service we offer to our customers and make their experience of dealing with us a positive one. “I found it simple to follow, informative and easy to understand. Which I think was the plan.” “Personally I thought it was fab!” One of the areas that we identified and Specialities) decided to out as clearly and concisely as as an area for improvement was construct a suitable training possible with eight modules in total the general polymer knowledge course. covering such topics as ‘what is of our staff. Although the general level was fairly good, we thought we could make it better. This would not only help us to deal with our customers more effectively but also help stimulate and motivate our staff. Understandably, there is a mix of backgrounds within Plastribution. Some staff have been educated to degree level and beyond in polymer science and engineering, whilst others have not had any formal polymer science training at “I look forward to learning more!” The course was made available to everyone in the company whether or not they were directly involved in the sale of polymers or providing a supporting role. To gain an insight into the overall levels of knowledge, all prospective students completed a test comprising of 30 questions. The results of the test highlighted areas that needed attention, whilst also giving a base line from which to measure future progress. all, particularly the newer members The course content was designed of staff and support staff. To redress to be delivered in short 30 minute that balance and bring everyone’s segments, which could be polymer knowledge up to a similar delivered during a lunch hour standard, Dan Jarvis (Technical (lunch provided of course!) to Manager) and Martin White avoid any disruption to normal (Product Manager for Styrenic’s office cover. The modules were set a thermoplastic’, Amorphous and Crystalline, Compounds and Masterbatch and structure property relationships. To date four modules have been delivered to 25 members of staff. Successive modules will be delivered monthly until the full course of eight modules is complete. It is early days yet, but if the first Plastribution Polymer Course is a success then further instalments will follow. Given the positive comments to date, we should be able to produce some very knowledgeable employees for the future. Watch “It was light-hearted, engaging and very useful – whilst not covering too much at any one time.” this space! 3 Momentum – October 2013 Momentum – October 2013 Plastribution raise over £350 for the Little Hearts Matter charity Plastribution’s social committee ran their second charity food day in aid of the Little Hearts Matter charity. The event produced a mouth watering display of cakes and savouries, which were purchased (and consumed!) by Plastribution staff and other employees from the office complex. All manner of delicacies were A year later William had his Little Hearts Matter offers a on offer, including: Multi-layer second open heart surgery to telephone support line 24/7, cakes, chocolate cakes, lemon boost his growth and appetite. support literature for families meringue pie, chocolate chip The latest surgery will see William and schools. They also help with cookies, Bakewell Tart, Chilli Con continue through to adulthood DLA, dental visits, medications, Carne, Lasagne and Chicken and develop as best he can. The lifestyle choices as well as running Tikka Masala - all produced by surgeries are palliative meaning workshops and trips out from time the talented Plastribution chefs. that these are non-curable to time. More can be found on corrections and William will need their website www.lhm.org.uk Andrew Diamond explains the story behind the charity food day and the Little Hearts Charity We were introduced to Little Hearts is centered on my son, one of Matter who helped and guided a pair of twins, who suffers with us before, during and after surgery. a complex heart condition. They provided us with a cardiac On the 29th July 2008, my wife and I became parents for the first time. We knew we were having twins and the excitement of their impending arrival was, quite liaison nurse who made sense of all the surgical team’s jargon and talk. At each step Little Hearts Matter were there for us. Without them we would have been very lost. literally, the best moment of our The charity, which is based lives. Two weeks later I rushed one in Birmingham, West Midlands, of the twins, William, to Wigan A&E supports parents of children who knowing something terrible was have been diagnosed with a wrong with him. complex heart condition and is It turned out that William was suffering from tricuspids atresia, transposition of the great arteries and ventricular septal defect. funded entirely by donations. It requires a minimum of £250,000 each year to continue to provide an essential support service. In layman’s terms, this means that Williams’s recovery has been the plumbing of his heart is back nothing short of fantastic. Having to front and that oxygenated been discharged within two blood is not pumped around weeks of his last operation, five his body as it should be. weeks later he is out and about That evening, William had the first Andrew Diamond a heart transplant in later life. of three open heart surgeries with “We were introduced to Little Hearts Matter who helped and guided us before, during and after surgery. They provided us with a cardiac liaison nurse who made sense of all the surgical teams jargon and talk. At each step Little Hearts Matter were there for us. Without them we would have been very lost.” – Andrew Diamond on his ‘early rider’ and keeping up with his twin brother Oliver! the sole aim of continuing his life. 4 5 Momentum – October 2013 Momentum – October 2013 Sarah Minshaw Customer Service Representative I decided to return to full time work after my 3rd child turned six, and after spending the last 5 and a half years running my own fitness business. Prior to this I was a technical author for a shop fitting firm, writing operating and maintenance manuals. Family constraints were the catalyst Plastribution look after their staff for the career change and my really well and people seem involvement with fitness training. genuinely happy in their work I studied the theory whilst on and work environment which maternity leave and then went on reflects in how we engage with to pass various courses including customers. I have settled in fitness pilates, kickboxing, hula really quickly and have been hooping, burlesque, zumba and made to feel very welcome. the latest being kettlercise in 2011. I have even appeared in the Mail on Sunday twice with write ups from a drastic change in career! I find the variety of my role at Plastribution very satisfying. Being able to build a rapport and a solid relationship with my customers I still run classes alongside my is very rewarding and with the full time position at Plastribution experience of running a business and enjoy the variety that this myself I can understand their brings to my working life. needs and know how important it I was offered two positions of employment during the same week is having a reliable, dependable, friendly supplier at hand. and I chose to go with Plastribution as I felt it would be a great place to work. Everybody came across as really friendly when I came for “I find the variety of my interviews and it also helped my role at Plastribution very satisfying. Being able to build a rapport and a solid relationship with my customers is very rewarding.” – Sarah Minshaw that I already knew a couple of people that worked here. 6 7 Momentum – October 2013 A sustainable plastics industry A strategic asset in our manufacturing economy “I want to focus on realising our industry’s growth and innovation potential; and securing investment in UK plastics manufacturing....” BPF President, Plastribution’s Mike Boswell, believes these aims are achievable by working to meet the industry’s needs in: finance; energy; skilled staff; and a stimulus for construction Finance – Why is this important? The Governor at the Bank of England, Mark Carney, signalled now look questionable as a result of more realistic exchange rates and rapid inflation in these countries. a change of strategy at the It is vital that the correct economic Monetary Policy Committee conditions persist on a long-term (MPC) meeting on 4 July 2013, basis, thereby ensuring both by providing ‘forward guidance’ the increased availability of on policy including interest competitively priced finance and a rates. Whilst this creates a stable stable situation on exchange rates. environment in terms of base rates, the margin and terms for borrowing are limiting investment. Along with the BPF, I will continue to push for the best financial position for UK plastic processors. As a key enabling industry, plastics, so far, has mainly been able to accommodate increased demand by increased capacity utilisation. However, there is a very real risk that if companies do not have the confidence and ability to invest, there will be strong implications for the wider As his theme for his two year Presidency, he explains all. manufacture to Eastern Europe economy as the availability of key components becomes restricted. Energy – Why is this important? BPF CCA Agreement As you are already aware, the BPF has successfully negotiated a new agreement for the plastics sector with targets that are realistic and achievable. We should remember that the CCA not only provides a tax discount for members of the BPF With exchange rates, sterling is Energy CCA, but is also a tangible 25% cheaper today on a trade- demonstration of our sector’s weighted average basis than it was commitment to reducing energy in 2008. There is little doubt that the consumption and to supporting devaluation of sterling following wider sustainability themes. the banking crisis has been a key factor in enabling the current resurgence in British manufacturing. Reliable, secure and affordable energy supply The BPF has long been pressing Prior to 2008, the UK plastics sector government on the issue of was ravaged by the move to Asia energy supply and, in particular, of the manufacture of products raising concern with regard to containing a high plastic content, electricity generating capacity. and thereafter by the manufacture Despite previous denials by of components and sub-assembles Government, on 28th June, a emigrating to Eastern Europe. The statement by Michael Fallon MP economics of decisions to move (Minister of State for Energy), Momentum – October 2013 Momentum – October 2013 confirmed that the government (for example small or thin films), becomes a crisis and the skilled was fully behind a National Grid or availability of secondary market and experienced element of our consultation that could see big (mixed plastics). On this basis, industry workforce retires and businesses being paid to cut Energy from Waste (EfW) clearly cannot be replaced. energy consumption on weekdays, represents the most efficient use between the hours of 4-8pm. of resources. Resource efficiency is This followed a warning by Ofgem that the risk of power cuts has increased in the UK and that spare electricity production capacity could fall to 2% by 2015. This is a matter of grave concern to the UK plastics industry, particularly as many processes cannot easily be interrupted for 4-hour periods. The BPF welcomes the possibility a winning argument and one that the BPF will continue to promote. EfW also has the capability to be brought on-stream quickly, thus helping to reduce pressure on existing generating capacity. By using unrecyclables it saves fossil fuel consumption. Going forward, the government needs to tackle the issue of ‘nimbyism’ to enable EfW to increase momentum. of the UK developing shale gas as both an energy resource and also a feedstock for polymer production. However, it is unlikely that commercial production of shale gas will occur before the end of this decade and should not be used as an excuse for not addressing the critical issues of today. Skilled Staff – Why is this important? The availability of skilled staff for the plastics industry is a matter of grave concern. Almost without exception, all parts of our industry are focussed on securing the resources necessary to meet the needs of their business Whilst plastics is a diverse subject, I do believe that through the BPF we have the capability, the power and the influence to persuade the educational system to deliver what this key industry requires. I especially welcome the initiative put forward by Phillip Watkins, my predecessor, in becoming an active member of the Cogent Board of Directors and would encourage every member “We plan to push the government to invest in new infrastructure The National Infrastructure Plan announced as part of the recent budget offers some cause for celebration, but more needs to done.” – Mike Boswell company to support him in this bold move. We need more people to consider We plan to push the government to: a career in plastics and also export potential has suffered encourage more women to come the effects of the recession most into the sector. As an 18 year-old, severely. Although there are now I was introduced to the plastics promising signs of a recent upturn industry through a holiday job and of activity. The consumption of PVC have gone on to enjoy a career resin, used directly in construction Introduce a 5% VAT rate that has lasted 3 decades so far; for windows, pipes and soffits and on Green Deal Products. I can personally testify that it is indirectly for cables, fell. However a great industry to be part of. the overall image of PVC is Stimulate property buying and building. Invest in new infrastructure - Summary Our goal: To contribute towards building a sustainable plastics industry by being a strategic asset in our manufacturing economy. How: Energy from Waste today and for the future. As far In performance terms, the UK as I am aware, Edinburgh Napier virtually sits at the bottom of the is the only UK University to still Alongside Energy and Finance, European league table in terms run an undergraduate course in HR is a vital pillar for our sector’s of how much energy it generates polymer technology, albeit mainly success. It is vital that we tackle The level of house building is a cause for celebration, but more from waste. studied by overseas students. this issue now, so that our sector matter for real concern given the needs to done. This situation needs to change, Many of us look to our own can continue to realise the increasing population and need for finance, energy, skilled staff, not only because the UK is running induction to the plastics industry, outstanding opportunities ahead. more housing for single and elderly construction stimulus. out of landfill capacity, but for the which typically involved simple reason that we are apprenticeships and part-time squandering a valuable resource. study - the so-called ‘earn-while- Our first priority is to recycle used plastics products but as we are all aware, some elements of plastics waste cannot be beneficially recycled on account of difficulty 10 0 benefiting from the excellent VinylPlus initiative. people. Traditionally, it has been a Construction – Why is this important? you-learn approach’. However, I have chosen to single-out the we should not necessarily take construction sector as a theme for a romantic view of what worked my presidency. There is no doubt in the past should work in the future. that this area of membership But we do need to find a solution feeding into a largely self- for the future before a concern contained market with limited driver for the economy as a whole, pulling through not just building products but also domestic appliances and furnishings. More The National Infrastructure Plan announced as part of the recent budget offers some By realising our growth and innovation potential and investing in UK plastics manufacturing. By working to meet our needs: By continuing to promote the factual benefits of our industry to all the key stakeholders and influences. affordable housing needs to be I look forward to supporting you built, whilst the government should and the UK plastics sector through ensure that buyers are able to my presidency. move onto the property ladder. 11 Momentum – October 2013 “My role will be to work with customers to ensure the best product is selected for their application in order to exploit these benefits fully.” – Richard Cudd Momentum – October 2013 Richard Cudd Technical Executive I joined Plastribution in March this year as Technical Executive in the Direct Sales team. This is a new role created to More recently I held technical provide technical support to management positions at two customers and direct sales staff, of the largest UK blown film particularly in the area of blown extrusion companies, gaining and cast film extrusion. Many of valuable experience in utilising the polymer grades we supply offer a range of polymers to develop specific technical benefits and my new film products. role will be to work with customers to ensure the best product is selected for their application in order to exploit these benefits fully. If you are looking to promote new products for your current customer base or are looking to develop the latest materials to enable you to I have spent the last 15 years enter new markets, then please working in the polyethylene film get in touch with us and we will industry, the first 11 for global do our best to assist wherever petrochemical producers BP & possible. I can also advise on Ineos, providing technical service general process optimisation and to key film customers across Europe offer advice on cost/performance and working on the development ratios to enable you to get the of a range of high performance, very best from your raw materials metallocene-based polymers. and in turn produce the very best products that you can in the most economical manner. 12 Momentum – October 2013 Momentum – October 2013 Here come the girls... Plastribution’s product director, Katherine White, was promoted to commercial director in March this year. The appointment includes Commenting on her appointment the additional focus of the Katherine said: “I am delighted thermoplastics side of the to be taking up the role of business, together with providing commercial director for the a supportive role to the company’s company. We have an exciting senior management team. future ahead of us and I am very With her ‘product management’ hat on, Katherine continues her “I am delighted to be taking up the role of commercial director for the company. We have an exciting future ahead of us and I am very much looking forward to being part of it.”– Katherine White much looking forward to being a part of it.” polyolefin materials responsibilities, In June 2013, the Leicestershire as well as supervising the Mercury spotlighted Plastribution’s company’s Knowledge Transfer significant jump from 74th position Partnership (KTP) supply chain in 2012 to 46th position in 2013 in management project. The project their ‘Leicestershire’s Top 200 was officially completed in August Businesses’ feature. 2012, although there is a strong legacy factor. Katherine was promoted to product director in 2011, a board level position that made her one of a small number of senior women directors within the plastics industry. 15 Momentum – October 2013 Momentum – October 2013 25 Years at Plastribution (and counting)! I have a very clear recollection of joining Plastribution on 19th September 1988 at the age of 24. In the previous year I was studying Plastribution and other players In the 1990’s I moved from external I can say that the time has passed continues to move away from full-time towards my Polymer around at that time were very sales into product management incredibly quickly, and whilst by Western Europe we see increasing Technology qualifications and had much in their infancy. It was and in 1988 was appointed to European standards this would opportunities as a distributor to completed my HNC and the first often difficult to convince the board in the capacity of be viewed as a very long time support UK plastic processors. year of my Grad. PRI (Graduate customers why they would want business development director. to stay in the employment of of the Plastics & Rubber Institute). to buy from what was sometimes Prior to that I had worked in described as a ‘middleman’. various technical, quality and In 2000 I was fortunate to become managing director, and at the end one company, my Japanese colleagues from our parent company who routinely spend The economic situation was also of 2001 instigated the full merger pretty tough. Following the big with Anglo Polymers, which had 1980 recession UK manufacturing been acquired in 1994 and, until When I started my first role at was undergoing massive reform, then, run as a separate entity. It is also worth mentioning that Plastribution as a Technical Sales and the penetration of lower With this combined resource we Veronica Mee ‘Vee’ now has Representative I remember that cost goods from Asia was rapidly pursued a strategy to become one over 26 years service and we the very commercial role came gaining momentum. Also with of the UK’s leading distributors and have a significant number of as quite a shock, and it was not the government’s attempts we were incredibly proud to learn employees who have already until I attended a TACK sales to stay within the ERM, interest from the 2009 AMI European celebrated 20, 15 and 10 years course early the following year rates increased rapidly and Polymer Distribution study, that with the business. We think that that I started to settle into the borrowing costs soared to 15%! Plastribution had grown to become continuity has a great deal to do the largest distributor in the UK. with the success of our business. manufacturing roles in the injection moulding and extrusion sectors. role. I also have fond memories of my first company car - a nordic blue Vauxhall Cavalier 1.6LX! Business for Plastribution was tough and changes in ownership and management were also a This is far from being the end of the story and we maintain very strong business growth as we continue to their whole working life in the company, hardly bat an eyelid. With regard to the future there is still more we want to achieve in terms of Plastics and Distribution, In terms of the market it was challenge. However acquisition an interesting challenge as the of Plastribution by Itochu (then concept of distribution in the know as C.Ito & Co) at the end polymer sector was relatively of 1991 was a clear turning point, As for 25 years at Plastribution, of this exciting and dynamic new, and the activities of and we are grateful to retain the I am often asked if it has felt like business. In particular as the same shareholders 22 years later! a long time, and honestly speaking location of polymer production serve the needs of polymer producers and our UK customers. and I am very much planning to be part of the continuing evolution “As for 25 years at Plastribution, I am often asked if it has felt like a long time, and honestly speaking I can say that the time has passed incredibly quickly.” – Mike Boswell Momentum – October 2013 Momentum – October 2013 Your mission, should you choose to accept it, is.... New IT platform Ensuring the highest levels of service - Investment in IT infrastructure and disaster recovery protection. Over the last 20 years our IT This makes us quite vulnerable; Through recent developments infrastructure has evolved to it is a fragility that has long in server virtualisation and high become an essential part of our been recognised and risks capacity data storage we have, business operations. Not only have been mitigated by using in conjunction with our IT support is modern computing essential ‘back-up’ solutions of varying provider, developed a platform for ever increasing volumes degrees of sophistication. that takes advantage of our two of electronic communication including email, but within Plastribution it enables us to process, analyse and account for a massive volume of complex transactions. However today it is not just a case of having back-up data, the question for more and more companies operating at our level, is in the case of a serious IT system Not being one to shy away from a challenge, Plastribution’s Managing Director, Mike Boswell, embarked on a Top Gear styled driving adventure back in April - all in the name of charity. to put forward a suggestion of an of the list. Mike did exactly that and object that can be photographed ploughed his money into German inside the car - these were then engineering and bought a 1997 E36 entered into a draw with two BMW 323i Auto Touring with 167k being chosen at random. And in miles on the clock. He found it in a true Top Gear fashion, a separate garage in the Scottish border town secret challenge contained in of ’Boswells’ (the name association a sealed envelope was given wasn’t one of the challenges - to every car at the start. shame though, full marks for trying!). On completion of the event Under the event rules and and with all competitors safely regulations, decorating the car returned back to the starting was ‘encouraged’, so Mike wasted point at Blidworth, Mike’s trusty no time in transforming his white beemer apparently never missed ‘beemer’ into a Plastribution a beat throughout the journey. promotional vehicle, complete And due to some highly proactive with logo decals covering all sponsorship efforts, Mike managed body panels, including the roof. to raise a very impressive £3373.27 office locations to create a robust Mike was participating in the failover solution. This effectively Fairview Farm Charity Drive means that should a disaster Challenge, the gist of which With the scene set, Mike and occur, we would have instant involved driving from Nottingham ten other ‘competitors’ in their access to a duplicate system to John O’Groats and back in a £300 budget cars set off on Day and, if necessary, work from a car that was over 15 years old 1 from the village of Blidworth, Having thoroughly enjoyed the temporary office accommodation. and cost no more than £300.00. Nottinghamshire on their journey challenge, Mike commented: Simple enough, but not entirely that to John O’Groats. The various straightforward as the organisers challenges along the way were had added some ‘challenges’ to the main focus for the ‘Days 2 make the task a little more tricky! and 3’ and included: the shortest Points were awarded for each distance covered during the 3 challenge with the eventual winner days (Mike won this!); the closest being the car that accrued the to a Scottish castle (photographic most points over the whole event. evidence required); the egg in a Along with this reliance on PCs, failure - how long would it take to servers, routers, switches and other rebuild the system and become items of technical wizardry comes operational again? Following a Whilst this project involves a the responsibility to plan for the recent review with our IT support significant capital cost the unexpected – a systems failure. providers, we determined that calculated operating costs of And whilst disaster recovery plans a serious systems failure would the solution will result in an overall must be considered in the wider take days rather than hours to cost saving to the business. In context of other essential elements recover; servers would need to summary a better solution at of our business such as buildings be acquired, operating systems a lower cost, providing peace and inventory, the fact is that we built and data reloaded. From of mind to our customers and are, to a large extent, computer this evaluation it became obvious suppliers that in the unlikely event Prior to the event, Mike’s first job dependent. Much of the data that a more robust solution was of a disaster it will be business as was to purchase a car. Now, it’s a contained within our IT system is required to ensure that in the event usual here at Plastribution. known fact that when faced with a unique to us and our operation. of a system failure the business can journey of 1,200 miles and only £300 continue to function normally. to buy a car to travel in, most of us 18 would be placing ‘reliability’ on top bucket challenge (full points for the in support of the Lincolnshire & Nottinghamshire Air Ambulance the event raised over £5000 in total! “The event was great fun and the scenery was epic. I am very grateful to all those who sponsored me on the event - their generosity is much appreciated. We are already thinking about a 2014 event, which possibly will have the theme of plastic cars!” – Mike Boswell egg being intact at the end); the closest to the optimum time set by route planner and lastly the Photo Challenge - each car was asked 19 Momentum – October 2013 Momentum – October 2013 Our vision and values As Plastribution has grown and developed from its humble beginnings over 30 years ago, our staff have been working towards a common goal and demonstrating values and methods of behaviour along the way. This has, by and large, been and “bottle” the Plastribution feel By being easy to do business with, and way of working. The difficult we bring value to our customers, process of trying to verbalise and suppliers and stakeholders, making condense the large amounts of every contact with us a positive data collected then commenced. one. These are all key factors in With a lot of hard work, heated ensuring we are better than our debate and soul searching, a vision competition and an integral part of and set of values eventually our stakeholders’ success. To deliver emerged kicking and screaming this it is vital that we have a strong into the daylight. team, so we work to maintain an So what did we come up with? environment that respects and nurtures the individual, with a focus Vision – what we seek to become on well-being, engagement and Our vision is “to be the UK’s the opportunity to develop through preferred supplier of plastic raw company growth. materials”. In short we want to be the distributor that customers want to use time and time again. We understand that our success will depend on implementing our plans, recognising existing strengths and an organic process and many We aim to deliver exceptional reinforcing them, as well as of our staff have been working customer service through our identifying areas where we need to to unwritten rules and codes unique combination of industry develop and meet challenges. All of behaviour. These have been expertise, innovative approach to employees are aware of how their instrumental to our success in problem solving and processes that individual contribution fits within becoming the UK’s largest polymer are in place to ensure these are their department and the wider distributor and in turn made the delivered on time and in full. This for company goals and as a team we company what it is today. Plastribution will always be a work are committed and determined to in progress as we believe that no deliver success. The management team decided that it was time for this important aspect of our business to be matter how good our service is we will always strive to make it better. Achieving this aim is no easy task but we now have a clear strategy formalised and visible to all of our Values – who we are and vision that we want to share. stake holders whether they are Our values are our Reputation, There is nothing secret to what shareholders, suppliers, industry Value, Competition and Nurture. we’re doing, but just in case, this partners or staff. We strive to protect the name Two teams were tasked with the and reputation of Plastribution at project of articulating our company all times through our behaviours, values and clearly defining our demonstrating professionalism, company strategy. A period of openness and integrity. article will self-destruct in 5, 4, 3, 2, 1 …… consultation was set up with various parties within the company to try 20 21 Momentum – October 2013 Plastribution is on the move! We very much look forward to plans for future growth, new offices providing you with an excellent have been secured on the opposite service from our new home in 2014. side of the road, on the first floor of Clinitron House, Excelsior Road. With double the floor area to that of our existing offices, there will be sufficient space to make further business expansion possible. Following refurbishment work to the new offices, Plastribution will move A511 A5 Contact details will remain ad am Ro y Wa h ting t unchanged apart from any No A42 customers not currently using Premiier Inn the P.O. Box 7743 LE65 1XY postal address. gham Nottin Road Way Smithy Road Since Plastribution moved to its current Ashby-de-la-Zouch headquarters over 9 years ago, the business has expanded rapidly; our current premises on Ashby Park is now completely full. To accommodate our ambitious We will advise of an exact move McD Donalds date nearer the time. A511 in Q1 2104. A date for the move is yet to be confirmed, but rest assured, business will be unaffected during this transition. Exce lsior Ro Cu urrent u bu uilding u Coa lfield Way ad A511 Coa lfield Way McDonalds Lountside A42 N W E S 22