What's new over there that you can use over here.

The triennial plastics mega-show in Germany next month will offer a look at the latest processing technology from European and other suppliers. Much of what's new will arrive on our shores in a matter of months. From the news revealed before the show, our editors have selected the developments most relevant to North American processors.

INJECTION MOLDING 

After next month's K'95 show, molders will have plenty of brand-new machines to choose In fact, freedom of choice seems to be the theme behind several new lines of modular presses scheduled for introduction at the show. Also on hand will be bigger and better all-electric models and improved multi-component systems. New hot runners and other tooling products will also appear in force.

MODULAR IS POPULAR

Ferromatik Milacron (subsidiary of Cincinnati Milacron, Batavia, Ohio) will roll out four new modular hydraulic machines ranging from 40 to 110 tons. With their integrated hydraulic tank/pump combination and one-third fewer parts than the company's other hydraulic models, these new K Series machines will cost about 30% less than comparable CM hydraulic presses. K Series machines will come in two versions: The E Model is an economy machine intended for low energy consumption. The S Model, which has a bigger control memory, supports parallel ejection, core pull, and other simultaneous operations. Both K machines come with adjustable, variable-delivery hydraulic systems.

Battenfeld (U.S. office in West Warwick, R.I.) will introduce a brand-new HM ("Hydraulic Modular") series of machines from 550 to 1430 tons. They have a new two-stage hydrome-chanical clamping system that applies force via a pressure column and sliding lock-up mechanism. This new system also permits opening forces as great as 10% of the clamping force - compared with around 5% or less in the past. Other HM features include variable-flow pumps, dual ejector pistons, and linear roller bearings to guide platen movements. Also new is a redesigned CDC Series machine, a 220-ton model with new maintenance-saving features.

Netstal (Fitchburg, Mass.) will introduce a new line of modular machines called Synergy that will ultimately replace the HP line. Synergy machines (66 to 385 tons) have a 25% smaller footprint than the HP, larger tiebar spacing, and upgraded DSP controllers that incorporate new ease-of-use features. The machines also feature provisions for fast changeovers and easy maintenance, such as pivoting hoppers and a quick-release plasticating unit. Even the nozzle heaters now have quick-release electrical connections.

Arburg (Newington, Conn.) will introduce the new Allrounder S Series modular machines that allow users to specify the control, hydraulic, clamp, and injection units they want.

ALL-ELECTRICS HUM

Electric-machine aficionados will see a brand-new machine and some new sizes:

* Krauss-Maffei (Florence, Ky.) will show a "hybrid" machine that marries an electric-driven injection unit with a hydraulic clamp. This 165-ton machine is the first in the company's new CE Series.

* Battenfeld has extended the size of its all-electric machines from 155 up to 220 tons.

* Ferromatik Milacron will introduce the largest ever all-electric machine - 725 tons.

MULTI-COLOR MACHINES

Several machine makers will bring new or redesigned multi-component machines to the show:

* Engel (Guelph, Ont.) will show a new injection unit for coinjection and other types of multi-material molding. Intended for small machines and for regrind applications, this unit features a simplified nozzle that can accommodate injection units in a horizontal/vertical configuration. The new unit can work with a hot-runner system that combines two melt streams just before the valve gate, preventing premature mixing.

* Krauss-Maffei will introduce a new multi-component machine based on its smaller C Series. Previously, K-M offered multi-component capabilities only on its larger B Series. A 72-ton C Series model will be shown.

* Battenfeld will show a new coinjection system with a redesigned nozzle. This new nozzle joins the two melt streams just before the nozzle exit.

* Ferromatik Milacron will demonstrate a for-license multi-shot injection molding process that works on a standard machine (see Technology Newsfocus section).

* Mannesmann Demag (in the U.S., Van Dorn Demag Corp., Strongsville, Ohio) will show the new Ergotech 150 S, a high-speed multi-component machine with a vertical injection unit.

* Husky Injection Molding Systems, Bolton, Ont., will show a 1250-ton rotary-platen, multi-material model with four injection units.

* Netstal has a new two-color system with features suitable for molding PET preforms (see Technology Newsfocus).

MORE NEW PRESSES

Krauss-Maffei will show a 44-ton hydraulic C Series press running a high-speed closure mold - an unusual application for such a small machine. Also, the new KM 650 MCM incorporates features of the company's C Series - energy efficiency, reduced cost, and smaller footprint - into a 715-tonner. In the past, C Series features were found only on presses up to 220 tons.

Sandretto (Cedarville, N.J.) will roll out a new high-speed packaging machine called the Metalmeccanica MACH. Available in sizes from 60 to 410 tons, the new closed-loop machine is aimed at thin-wall packaging and technical applications. Features include a beefed-up hydraulic system with servo-accumulators, bigger pumps, and high-capacity valves.

On the high-tonnage end, Cincinnati Milacron has a 3600-ton Vista hydraulic machine. And new from Mannesmann Demag are larger Demag Ergotech models - 420, 500, 650, and 800 tons.

LOW-PRESSURE MOLDING

Hettinga Technologies Inc. of Des Moines, Iowa, will demonstrate "Controlled Density Molding," a new process for producing large, flat panels consisting of a smooth outer skin over a foamed core.

TOOLING NEWS

Husky will show a new 96-cavity PET preform mold capable of running 1870 lb/hr or 21,000 preforms/hr. Also, Husky will show a new multi-cavity Rotating Ratchet Ring ("3R") mold for unscrewing closures. This design eschews rotating cores in favor of stationary cores, which can be cooled more efficiently and require less maintenance. (Arburg will show a 12-cavity Husky 3R mold on a 100-ton machine making HDPE dairy caps.)

Hettinga will exhibit molds made from "Cunial," a copper-nickel-aluminum alloy suitable for casting and machining.

HOT RUNNERS

Mold-Masters Ltd. of Georgetown, Ont., will unveil several developments: A new micro-sized nozzle, the Dura Femto-Shot, will be shown for the first time. Thanks to a tiny new 220-v heating element, this nozzle can squeeze into centerline spacings of less than 1 in. In the past, Mold-Masters had nozzles this small but only in 24-v, which required a special low-voltage controller.

Mold-Masters will also introduce its own simplified flow-analysis software in conjunction with an unnamed filling-simulation software vendor.

Kona Corp. of Gloucester, Mass., will show a newly developed valve gate for large single-cavity molds.

Incoe Corp. of Troy, Mich., will introduce an intermediate series of bushings and valve gates to cover applications between its 5000 and 7000 Series. Also, the company will show off some new applications for its valve-gate systems, including a new stack mold with a single actuator for both halves.

CONTROLS NEWS

Here's just a taste of new sensor and control developments to be on hand:

* Kistler Instruments (Amherst, N.Y.) has incorporated its cavity-pressure-based quality-control system on a chip suitable for use in a variety of OEM controllers (see p. 31). In addition, the company will roll out a new piezoelectric pressure transducer sized to fit in an injection nozzle.

* Schlaepfer Measuring Technique of Hagenbuch, Switzerland, a maker of clamp-force sensors, will show new alignment software that can generate reports according to ISO 9000 or Euromap protocols. SMT sells a line of "strain rings" that can be mounted on the tiebar with just a torque wrench.

* BoyCim, a proprietary network for up to 48 Boy injection machines, will be shown for the first time by Dr. Boy GmbH (in the U.S., Boy Machines, Inc., Exton, Pa.).

* Arburg will have on hand a new control system, dubbed Selogica, which has shot-to-shot fault detection prior to mold opening. - Joseph Ogando

EXTRUSION

Extrusion equipment makers are rallying around the die as the big attraction at this year's show. Die adjustment and control technology for blown and cast film, sheet, pipe, and profile will be featured prominently, along with 3-D die flow-analysis software. Meanwhile, new air-profiling systems are being exhibited, as are a new fully automated sheet line and new extruders for PE pipe.

BLOWN FILM: DIES, IBC 

Brampton Engineering, Brampton, Ont., will introduce the Dial-A-Gap die-gap adjustment system. It has a variable gap range of 0.5 to 3 mm and allows gaps to be changed during processing, eliminating a die-lip change. The company will also show a new Windows version of its Integrated Temperature and Line Yield Control System (ITALYCS), which provides a direct link to process databases for report generation.

Addex Inc., Boston, has a new Internal Gauge Control (IGC) system said to reduce gauge variance by more than 50% by profiling the air from an IBC. IGC consists of a sensor, computer, and modified IBC "pancakes." Bubble gauge data from the sensor is sent via a stand-alone computer to a servo-motor-driven actuator located within the pancake. The actuator travels around the pancake, causing 1/8-in.- wide movable teeth to move up or down, thus creating a profile of the IBC air. The computer can store profiles, including ones for thick/thin films.

Alpine (U.S. offices in Natick, Mass.) will show a new five-layer coex die in operation at its technical center in Augsburg, Germany. The modular die head uses spiral flow channels arranged horizontally rather than vertically for fast exchange of layers.

A three- to five-layer side-fed modular die from Black Clawson-Sano, Amelia, Ohio, is called the Serpentine system. Its interchangeable disk-like modules are separated by air gaps and heater bands for independent temperature control of each layer. The die's design requires half as many bolts as competitive dies, though each module handles up to 7500 psi. The distribution and spiral-flow technology reduce polymer residence time, allowing thermally sensitive materials like EVA to be run.

A new three-layer die will be shown by Davis-Standard, Pawcatuck, Conn.

BLOWN FILM: EXTRUDERS

Reifenhauser (Peabody, Mass.) will show its new and largest 100-mm blown film extruder for HMW-HDPE (see PT, March '95, p. 57). It will run T-shirt bags 4-up at up to 1000 lb/hr. During the show, Reifenhauser will also run four lines at its new 40,000-sq-ft blown film laboratory at its Troisdorf, Germany, facility. Perhaps most interesting is a small line for running HDPE and LLDPE trash-can liners 1-up. Reifenhauser is offering it for only $200,000 complete with a 50-mm extruder, die, sizing cage, tower, collapsing frame, slitting knives, and surface winder.

Signaling its entry into the market for monolayer LDPE and LLDPE films, Alpine will run two such lines at the show.

BLOWN FILM: AUXILIARIES

Battenfeld Gloucester Engineering Co., Gloucester, Mass., will demonstrate its first gravimetric blending system for film and sheet lines. The hopper is stainless steel, but the cost is competitive with blenders using mild steel. The blender is available in a batch, continuous, or feedthroat design.

Kiefel (Wrentham, Mass.) will introduce the new PA series fully automatic surface winder.

Windmoeller & Hoelscher (Lincoln, R.I.) will show its Varex system with a new oscillating haul-off that consists of 25 modular components. It will also show a revised gauge-measurement system.

CAST FILM & SHEET: DIES

Extrusion Dies, Inc. (EDI), Chippewa Falls, Wis., will show its first 3-D die flow-analysis software, which animates polymer particle paths, velocity profiles, and vector plots. The software will be used by EDI to analyze flow in its dies and will not be offered for sale.

Sencorp Systems Inc., Hyannis, Mass., has developed a sheet die-profile system that controls polymer thickness by die temperature. Thickness variations can be controlled to [+ or -]3% across the die.

CAST FILM & SHEET: EXTRUDERS

Davis-Standard will exhibit a new hands-off sheet line featuring the new EPIC III controller, which makes automatic die, roll-gap, and flex-control adjustments.

Windmoeller & Hoelscher will demonstrate a new-generation cast film line that will produce a three-layer coex A-B-A structure.

CAST FILM & SHEET: AUXILIARIES

Extrusion of PET sheet without predrying will be showcased by Welex Inc., Blue Bell, Pa. Welex updated its screw design and vacuum technology to remove moisture during extrusion. The new technology will be shown on a Welex World Standard V-PET line. The line will be fitted with a new Mark III gearbox, which has double the torque capacity of the Mark II. The line will also have the latest simplified Ultima III microprocessor controls, which now automatically adjust the die and roll stack to operator-selected angles. Previous models were positioned by the operator using button controls.

Reifenhauser will also show a vacuum venting sheet extruder that runs TP polyester without predrying.

PIPE & PROFILE: EXTRUDERS

Reifenhauser will introduce the Bitruder BT3800 conical twin-screw, which runs PVC at up to 1210 lb/hr. In addition, the company will show off new die heads for polyolefin gas and water pipes. The heads have a spiral mandrel that reduces pressure but allows high output at low melt temperatures - even for small-diameter pipe.

Davis-Standard will show a new 3.5-in., 30:1 grooved-feed extruder for PE pipe that combines its technology with that of Repiquet - the French company it acquired this year. The new unit, the first of a series, has output rates of 880-1100 lb/hr and uses less feed pressure than other grooved-feed extruders.

Rollepaal (Columbia, Md.) completes its line of high-output, parallel twin-screw extruders for PVC pipe with the introduction of the R2-91-25D machine, which has an output range of 440 to 2200 lb/hr. The company will also introduce a new generation of extrusion die heads that will permit quick changes of pipe diameters. The flow-line design of the die head is said to reduce waviness in pipe while increasing output. Rollepaal has a new scanner that measures pipe wall thickness just beyond the extrusion head. Use of two transducers doubles the number of points measured.

Francis Shaw & Co. Ltd. (Warwick, R.I.) will exhibit one in a new range of high-output single-screw extruders for PE pipe. This 90-mm extruder has a rated output of 1320 lb/hr and a new barrier screw and grooved-feed section.

PIPE & PROFILE: DOWNSTREAM

Davis-Standard will exhibit equipment from newly acquired Killion Extruders, Cedar Grove, N.J. A new line of heavy-duty cutters will be shown, along with larger versions of Killion Versa belt pullers (now in 6 in. and 8 in. models).

Rollepaal will introduce a new series of cutting and chamfering machines with automatic settings for pipe diameter and wall thickness. The automatic settings reduce change-over time to 3 min. Settings can be stored for repeatability. - Mikell Knights

BLOW MOLDING

Several new developments for blow molding industrial parts emphasize speed and versatility. Other news includes a stretch-blow molder for PEN and an all-electric machine.

LARGE AND COMPLEX PARTS

Two new industrial blow molding machines will be introduced by Bekum (U.S. offices in Williamston, Mich.). A large BA-120 unit, for producing drums up to 150 liters, is capable of high mold closing speeds. Decentralized clamping force is applied by four outboard hydraulic cylinders. Also, a new compact unit for production of canisters up to 30 liters will be shown.

Battenfeld Blowmolding (Boonton, N.J.) has a new die head for its Type 2-30T machine that permits sequential molding of different materials in a "hard-soft-hard" pattern - for example, olefinic TPEs and glass-reinforced PP.

Battenfeld will demonstrate at its nearby Troisdorf facility the 3-D suction blow molding process it licensed from Sumitomo Tools. Also running will be a new machine for producing fuel tanks and containers up to 2000 liters. It has a 300-ton clamp, two 150-mm extruders, and a 150-liter melt accumulator.

STRETCH-BLOWING PET & PEN

Stretch-blow molding of PEN will be demonstrated by Aoki Manufacturing Co. (distributed here by Formex, Inc., Dayton, Ohio). Aoki will show a machine optimized for PEN (polyethylene naphthalate). It molds PEN/PET in various blending ratios, and reportedly is able to meet the special temperature-control requirements of these materials.

A new generation of stretch-blow machines for PET beverage bottles will be shown by Krupp Corpoplast (Edison, N.J.). Outputs range from 2000 to 30,000 bottles/hr. Krupp will demonstrate molding 0.5-liter PET bottles with improved C[O.sub.2] barrier properties. Key features include a heat wheel that permits installation of 30% more heating capacity for heavy PET preforms used to make refillable or hot-fillable bottles. More-efficient heat-reflector systems improve energy efficiency up to 20%. New compact blowing stations are mechanically driven and mounted on a single main shaft for easy maintenance. Process speed in the closed blow mold has been increased by up to 20%.

A new injection stretch-blow machine for PET, PP, and PC bottles of up to 3 liters will be introduced by Krupp Kautex (Edison, N.J.). Using two injection stations and one blowing station, the new machine's extruder operates continually to provide gentle plastication.

REACHING FOR HIGHER OUTPUTS

Two new single-station blow molders will be exhibited by Stahl Blasformtechnik (distributed here by Battenfeld Blowmolding). The HK453 includes a 45-mm extruder with interchangeable bushings that can be adapted to different kinds of plastics. Various center distances are available for double and triple heads. Blow pins are pre-mounted outside the machine and can be quickly adjusted to the required center distance via a grid system. An "open" design offers various options for article removal.

In addition, a new long-stroke Stahl machine is available with strokes of 500 or 560 mm for making hollow articles up to 5 liters.

New fully automatic single- and twin-station machines will be shown by the new B&W subsidiary of Johnson Controls, Manchester, Mich. (B&W of Germany was formerly represented here by FGH Systems.) The single-station BW1000E has a max. capacity of 1-liter bottles; the dual-station BW6000E can produce 10-liter containers.

Bekum will show two additions to the new BM-04 series of shuttle machines. The twin-station BM-704D is a high-output model capable of 10 cavities on 110-mm centers. A BM-504 machine will demonstrate two-cavity production of 2-liter handled containers.

Jomar Corp., Pleasantville, N.J., will show a larger model in its new extrusion blow line. The EBM 6.0-S will mold 3-liter PP handleware in a two-cavity mold. This machine can also run HDPE, PVC, and PC. The tiebarless clamp system enables easy mold changes.

Battenfeld will exhibit an energy-efficient all-electric blow molding machine from Tahara of Japan (represented in the U.S. by Kanematsu USA Inc., Arlington Heights, Ill.). Features include a 7-ton clamp and touchscreen control.

At Battenfeld's Troisdorf facility, a new-generation controller will be demonstrated on a new single-station machine, model BFB 1-4. Available for all machines after mid-1996, the S7 controller is a lower cost replacement for the current Blowlog system. It will offer LCD display of temperature and wall thickness. - John De Gaspari

THERMOFORMING

Twin-sheet thermoforming machines will be showcased by at least two exhibitors in Dusseldorf. New thermoforming systems on display have become more modular or more flexible, expanding either the range of materials that can be processed or trimming the processing time. A quick-change tooling system can be seen at the show as well.

TWIN-SHEET STARS

Twin-sheet thermoforming will be demonstrated by Brown Machine Div. of John Brown Inc., Beaverton, Mich. An R244-ETS machine will be making HDPE pallets in less than 3-min cycles.

Cannon Shelley of the U.K. (represented in the U.S. by Cannon U.S.A., Cranbury Township, Pa.) will for the first time show a special version of its Powerform machine designed for twin-sheet forming of ABS or polycarbonate.

Twin-sheet forming is one potential application for the new UA 150 K modular machine from Adolf Illig (represented by a number of U.S. companies). The pneumatically driven forming table can handle part heights up to 600 mm and has a forming area of 950 x 1450 mm. The unit features a new clamping-frame system and CRT control panel, as well as automatic tool change.

Paul Kiefel GmbH (Succasunna, N.J.) will exhibit a new electric-drive pressure former, the KMD 70 FS. It combines the cut-in-place feature of Kiefel's BFS line with the matched-metal punch-out station of its older KMD line.

QUICK TOOL CHANGE

Sencorp Systems, Hyannis, Mass., will display its new Quick Tool Change Apparatus and PC-based tool-change software on a Series 2000 machine. Tool changes can take less than 30 min. The software provides a step-by-step check list for the operator. - Mikell Knights

COMPOUNDING

New screw designs for corotating and counterrotating twin-screw extruders lead the news in compounding. A new series and new sizes of extruders are also being shown, along with developments in pelletizers.

NEW SIZES, NEW MODELS

Werner & Pfleiderer (U.S. office in Ramsey, N.J.) will introduce two new giant sizes in its twin-screw extruder line, a ZSK 250 and ZSK 320, which have throughput rates of 33,000-44,000 lb/hr and 66,000-88,000 lb/hr, respectively. W&P has also upgraded its ZS-B series of side feeders and has introduced two new sizes. The new feeders have a compact design, higher power rating, and higher speeds.

Berstorff (Charlotte, N.C.) will exhibit the first in a new series of corotating twin-screw extruders, the ZE 110-A (118 mm), which is a new size for the company. Berstorff beefed up the gearbox and redesigned the barrel of these machines, offering screw-segment lengths of 4 and 6 D. The new machine has a max. output rate of 6600 lb/hr.

The company redesigned its ZE 25 lab extruder with improved controls and co- or counterrotating screw options. Output rates from under 5 lb/hr to 100 lb/hr are possible.

Berstorff will introduce the "Schaumex Profile" TPE foam line, which uses water as a blowing agent to make profiles for automotive and construction uses.

Leistritz (in the U.S., American Leistritz Extruder Corp., Somerville, N.J.) will display new 60-mm and 75-mm sizes in its ZSE twin-screw line.

NEW SCREW GEOMETRY

Leistritz has developed new geometries for counterrotating intermeshing twin screws. These "Counterflight" geometries permit counterrotating models to match the screw speeds of corotating types. Counterflight geometries abandon the calender-gap mixing used in traditional counterrotation, so screw deflection is minimal, allowing for higher extruder rpm's and horsepower. Available in bilobal through hexalobal geometries, Counterflight reportedly can provide better dispersive mixing than corotating screws at a lower rpm.

PELLETIZING NEWS

Berstorff will show an updated version of its UWG 10 underwater pelletizer with a knife-to-die alignment optimized for PP and metallocene-based polyolefins. An updated WRG 20 water-ring pelletizer with improved flow channels and a new design for easier disassembly also will be exhibited.

W&P will introduce a new low-pressure pelletizing die plate, the UG 500. It is made from a special wear-resistant alloy and has polymer flow channels designed to reduce pressure build-up in the pelletizing head while ensuring high output rates. The patented die-plate design has an increased number of holes - boosting throughput per unit of area - and creates space for heating channels between the die holes. - Mikell Knights

COMPOSITES

Versatility will be the theme of new composites molding equipment at K'95. New low-pressure presses are suitable for both cold and hot molding, and new modular presses for the auto industry can be configured for SMC and/or GMT.

A new generation of vacuum presses from Merva Systems of Germany (with offices in Burlington, Ont.) is suitable for both cold-press and hot-press molding of low-pressure molding compounds (LPMC). The new presses are said to meet demand for flexible production of low to high volumes at reduced cost. For low volumes, cold-press molding and cost-effective polyester or epoxy molds can be used. Hot-press molding is suited to medium and larger volumes. Switching from cold- to hot-press molding requires only a heatable metal mold.

The new DY series of compression presses from Dieffenbacher (represented in the U.S. by Girard Associates, Middleburg Heights, Ohio) is designed for the automotive industry. The modular series is available for SMC, GMT, or both. - John De Gaspari

RIM & URETHANES

Two suppliers will bring out new high- and low-pressure metering systems for urethanes. In addition, a new technology uses liquid C[O.sub.2] as a low-cost blowing agent for flexible molded foam.

LOW-PRESSURE MACHINES

For polyurethane molding, Cannon (U.S. offices in Cranbury Township, Pa.) has developed the Cannon b2G Plus metering unit for very low outputs. It is aimed specifically at molding gaskets for electrical control-panel doors, sealed ' lamps, and automotive filters.

HIGH-PRESSURE SYSTEMS

Gusmer, Lakewood, N.J., is launching the Model H-7 hydraulic metering unit designed for outputs of up to 31 lb/min at 2000 psi and 18 lb/min at 3000 psi. The positive-displacement double-acting piston pump has externally accessible ball checks.

LIQUID C[O.sub.2] FOR MOLDED FOAMS

Cannon is featuring a new method for using C[O.sub.2] as the blowing agent in molded PUR foams. Called CannOxide, this technology is similar to the company's CarDio technology for adding liquid C[O.sub.2] to flexible slabstock. CannOxide reduces cost of existing foam formulations by replacing other blowing agents. - Lilli Manolis Sherman

MATERIALS

Metallocene catalysts will make news in both engineering and commodity resins. Other news includes lower-cost grades of PAEK, halogen-free flame-resistant nylons, and a host of new extrudable engineering resins.

A slew of new PP materials will be featured, as well as several new TPUs and a styrene-butadiene block copolymer with potential to replace PVC in transparent film packaging.

CYCLO-OLEFIN DEBUTS

New metallocene catalyst technology for polyolefins will be the focal point of the exhibit of Hoechst AG (in the U.S., Hoechst Celanese Corp., Summit, N.J.). A particular highlight will be the introduction of Toplas - a transparent cyclo-olefin engineering resin with potential applications in optical storage media and electronics (see PT, July '95, p. 13).

HALOGEN-FREE FR MATERIALS

A new generation of halogen-free, flame-resistant nylon will be introduced by BASF (Mt. Olive, N.J.). Ultramid KR 4450 and KR 4455 have high creep resistance and can be dyed in light colors - both important factors in the electrical industry. The flame retardant used is magnesium hydroxide. KR 4450 has passed the glow wire test at 1760 F, and KR 4455 has received UL 94V-0.

Flame-retardant halogen-free grades of Noryl GTX nylon/PPO alloy will be introduced by GE Plastics (Pittsfield, Mass.). Other new Noryls include halogen-free grades for extrusion and a new family of high-flow grades for thin-wall injection molding. A new filled FR grade of Valox TP polyester has improved comparative tracking index.

HIGH HEAT AT LOWER COST

BASF is introducing two new lower cost test grades of its PAEK materials. Glass-reinforced Ultrapek KR4179 and carbon-fiber-reinforced grades reportedly are about 30% less expensive than standard Ultrapek. They offer somewhat better flowability and dimensional stability under heat, but with some compromise in chemical resistance.

NEW EXTRUSION MATERIALS

GE Plastics will launch 10 new extrusion materials. These include a new Lexan PC grade said to have very high transparency without blue or yellow tint. Also, a new high-flow Lexan is tailored for the lighting industry. A new grade of Cycolac ABS for refrigerator liners is said to offer higher gloss and better retention of mechanical properties than competitive materials.

Several new Noryl PPO grades include a Noryl GTX blend for components of powder-coated windows. Also new are extrusion grades of Cycoloy PC/ABS, Valox, Xenoy PBT/PC, and Ultem polyetherimide. In addition, GE Plastics will introduce a new die and calibration technology for extruding engineering thermoplastics.

MEDICAL & INDUSTRIAL GRADES

New Trogamid CX7323 amorphous nylon will be shown by Huls (Piscataway, N.J.). Aimed at medical applications, it has high transparency and impact strength, uv resistance, and steam sterilizability. In addition, new glass-reinforced Trogamid copolyamides for industrial applications are said to have mechanical properties that remain virtually constant in the presence of moisture and high temperatures. Glass content ranges from 30% to 60%, providing high impact strength.

PP COULD STEAL THE SHOW

Belgium-headquartered Montell Polyolefins (Wilmington, Del.) is launching several new materials made with its Catalloy process. They include Adsyl 5 C 37F, a PP film grade with reduced seal-initiation temperature and a haze level of only 1%. Adflex Q 103F is a new Catalloy PP film grade for heavy-duty bags. It features excellent puncture resistance and improved stiffness.

New Adstif T 2 101F PP is for cast films with higher heat resistance. It offers improved stiffness and potential for downgauging.

A new copolymer for thin-wall molding, Moplen EPL 3 1UA, offers high flow with no change in Izod impact strength.

A new blow molding grade, Adflex Q 100F, is designed for warm-feel bottles that are tough and resistant to wear. It exhibits a Shore D hardness of 28 and flex modulus of 11,600 psi.

Also new for rigid packaging are a copolymer for blow molding, a homopolymer for thermoforming, and a random copolymer for injection stretch-blow molding.

Montell is also launching Adstif V-2400G as a replacement for filled PP in garden furniture. Besides stiffness of 290,000 psi, it offers improved abrasion resistance and improved processability.

New Adflex 7149 is designed to replace conventional PP in refrigerated storage containers. This clear grade is said to offer greatly improved low-temperature impact with no loss of stiffness.

Also new from Montell is Higran PP foam, targeted as a replacement for polyurethane in automotive bumper cores, head rests, sun visors, and arm rests. It is said to feature high energy absorption, excellent dynamic cushioning over a broad loading range, high service temperature, low water absorption, and resistance to oil and solvents.

Still more new materials from Montell include a tough, high-flow PP for bumper fascias. Astryn FPA is a specialty PP for landfill liners. It boasts chemical resistance similar to that of PE, but it outperforms PE in mechanical properties, environmental resistance, and ease of installation. It also will compete with PVC in geomembranes.

Montell will also have a new HiFax grade for roofing said to offer equivalent flame retardance to PVC but with 60% better weather resistance and better mechanical properties. A new HiFax grade for wire is said to offer 50% better electrical properties than PVC.

Meanwhile, BASF says it has developed a catalyst system for making high-molecular-weight and highly isotactic PP on an industrial scale. BASF already markets polyethylene made with metallocene catalysts, under the trade name Luflexen.

LOTS OF NEW TPUs

BFGoodrich Specialty Chemicals, Cleveland, is launching new Estane TPUs, including rubber-like grades - 58238 (75 Shore A hardness) and 58661 (80 Shore A) - that behave more like traditional thermoset elastomers while maintaining typical TPU processing advantages and physical properties. For use in medical hose and tubing and conveyor belting, they are priced at $3/lb.

New Estane 58237 and 58245 are high-moisture-vapor-transmission TPUs for applications such as wound dressings. They cost $4.50-4.75/lb.

BFG's second generation of non-halogenated FR-TPUs will also be launched. Estane 58243 and 58244 both are V-0 materials that can compete with fluoropolymers and FR polyolefins (PP and crosslinked PE) in mass-transit applications (i.e., coil cords for airplane phones or coated conduit for rail cars). They sell for $4.75/lb.

Also new from BFG are functionalized TPUs for use as binders in polyester audio and video magnetic tape. Based on phosphorus chemistry, they are said to have a greater affinity for dispersing magnetic particles. They also have potential as binders and dispersing agents for color concentrates and carbon black formulations, and can serve as compatibilizers in PC/ABS blends and alloys. They sell for $3/lb.

Also featured by BFG will be new grades of Estaloc glass- and mineral-reinforced TPUs. Estaloc 60155 has received Ford Motor Co.'s worldwide approval for use in exterior body cladding. It has a flex modulus of 55,000 psi and is said to show excellent processability and very few sink marks.

New hydrolytically stable Estaloc grades for injection molding have flex moduli ranging from 100,000 to 300,000 psi. They reportedly feature very high impact and good sound-deadening properties for use in aqueous environments (i.e., valves and pipes).

STYRENIC BLOCK COPOLYMER

BASF is featuring an interesting developmental styrene-butadiene block copolymer that could replace flexible PVC or TP elastomers in transparent film packaging. Elasticity (up to 900% elongation), toughness, and transparency are key features of films made with this resin. The resin's high oxygen permeability is particularly desirable for packaging fresh meat. - John De Gaspari & Lilli Manolis Sherman

ADDITIVES

New stabilizers for polyolefins and several new organic pigments top the list of additives introductions at K. Another interesting entry will be a black liquid colorant for PUR RIM.

ANTIOXIDANTS & UV STABILIZERS

New Tinuvin Performance Plus hindered-amine light stabilizers (HALS) from Ciba Additives (U.S. offices in Tarrytown, N.Y.) cover a broad range of molecular weights, basicities, and functionalities. Tinuvin 783 FB has broad indirect food-contact approvals worldwide. It is designed for low-color applications and is particularly effective in PP fiber, tapes, and filled PP. Its low volatility makes it a candidate for rotomolded parts.

Tinuvin 111FB is said to provide excellent uv stability in polyolefin films and fibers, with outstanding extraction resistance, low gas fading, and low pigment interaction.

Ciba's new Irganox LM ("Low Melt") Blends for polyolefins are combinations of phenolic antioxidants and Irgafos 38, a new phosphite processing stabilizer.

NEW PIGMENTS

Ciba Pigments (Newport, Del.) is featuring additions to its heat-stable DPP (diketo-pyrrolo-pyrrol) pigment line (see PT, July '95, p. 44). Ciba has extended DPP red chemistry into the bluish-red area with new Irgazin DPP Rubine TR for PVC, polyolefins, and engineering plastics. Also new is Irgazin DPP Scarlet EK, a highly saturated shade targeted to replace molybdate orange pigments in PVC. These pigments feature high transparency and color strength, are warp-free in HDPE, and have good resistance to uv and moisture.

Ciba is also introducing Cromophtal Yellow GT-AD, a brilliant yellow anthraquinone for polyolefins. Chromophtal Yellow HRP, a reddish-yellow azo salt for PVC and polyolefins, has excellent heat and light resistance.

Milliken Chemicals, Spartanburg, S.C., is launching a proprietary liquid colorant said to bridge the cost/performance gap between polymeric colorants and pigments for producing black polyurethane automotive parts.

Reactint Black X95A/B is a polyol designed for use with most RIM and semi-rigid PUR parts such as bumpers and door panels. It is said to offer four to six times higher color strength than carbon black dispersions and does not cause equipment wear. It reportedly will not react with catalysts and is very easy to pump due to its low viscosity. - Lilli Manolis Sherman