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Issue 03/2019

Highlights: Toys Injection Moulding Basics: Microplastics Mind the right terms Captured CO2

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Injection Moulding By: Daniel Ganz, Global Product Manager Bioplastics Sukano Schindeleggi, Switzerland Injection Molding PLA Make the switch today S ukano, a global Masterbatch specialist for polyester and specialty resins, has leveraged its expertise to enable a broader design variety to be injection molded with PLA without major financial investments. One of the key bioplastics, PLA, is currently the second highest consumed bioplastic worldwide by volume, and it offers a broad range of functionalities optimized for each type of application. It can be processed into a vast array of products using conventional plastics processing technologies – in most cases, the process parameters of the processing equipment simply needs to be adjusted to the individual specification of each polymer. Overcoming the barriers in injection molding Currently, polyolefins and polystyrenes resin are the most commonly used materials for injection molding. However, a bigger shift toward PLA in injection molding has been slowed by serious issues. There are several challenges that convertors have faced when processing injection molded PLA parts, especially when using existing equipment and tools, including: • Difficulties to fill cavities due to higher melt viscosity of the carrier, especially for thin wall applications • Additional force required to fill the form, which may lead to shorter lifespan of the tool • Material sticking to the mold surface, making demolding more difficult and increasing the risk of surface defects in the end application Due to these issues, processing PLA was not even possible in many cases – until now. Enabling a broader design variety Formulated to enable a broader design variety to be injection molded with PLA Sukano has developed a mold release additive masterbatch that enables convertors to injection mold PLA – even for thin wall applications – without needing to change the machine or the equipment. Customer cases have demonstrated that the switch from fossil-based plastics to PLA for injection molding is very much possible, all without major financial investments. SUKANO ® Mold Release Masterbatch achieves this by providing the critical barrier between a molding surface and the substrate, facilitating the separation of the cured part from the mold. It acts by migrating to the surface of the final product, which helps to demold the injection molded part from the metal surface of the cavity, therefore reducing the demolding force required. This unique feature can help ensure reduced cycle times, continuous running of production lines, fewer rejects and waste, as well as reduced machine wear out and cleaning. Melt flow increase as an additional effect Sukano Mold Release Masterbatch also has an interesting and very beneficial side effect, as demonstrated in sophisticated spiral flow length trials conducted in an external lab. By reducing the friction between the polymer chains, it creates a lower melt viscosity – and therefore a higher melt flow – without increasing the temperature. This helps to fill the cavities, which can be especially challenging in thin wall applications, and enables a broader design variety to be injection molded with PLA. It essentially eliminates the critical issue of decreased melt flow, often a major barrier to the switch from conventional plastics to bio-based materials in this type of process. Sukano Mold Release Masterbatch helps producers make the switch to PLA while still achieve a consistent high-quality standard of their PLA-based end products, with high clarity, scratch and scuff resistance, improved surface finish, improved material homogenization, and it is food compliant. 1600 — 1500 — 1422 1400 — PLA: Peak demolding force / N Hold pressure: 400 bar, melt temperature: 200°C, mold temperature: 25°C 1300 — 1200 — 1100 — 1000 — 900 — 1213 1075 800 — PLA reference PLA + 1% PLA mr S533 PLA + 3% PLA mr S533 36 bioplastics MAGAZINE [03/19] Vol. 14

Injection Moulding REGISTER NOW & SAVE €300 Sukano – your guide in the move to bioplastics In our highly interconnected world, the general public has become more and more concerned – and engaged – about the planet’s future in the face of increasingly serious environmental challenges. The debate has reached its tipping point, with the European Commission itself stating that “European consumers are more and more prepared to buy goods and services which have a reduced environmental impact.” People are now prepared to participate via their purchase habits and preferences to ensure their impact on the environment are minimized or at least well reduced. To support its customers in making the switch to bioplastics, Sukano has invested in a powerful R&D analytical laboratory and pilot plant. This allows the company to provide industry-leading capabilities to quickly respond to customer’s most urgent demands and flexibility requirements. Together with over 30 years of experience in the field, Sukano is ready and, willing and able to support you to make the switch today. Specific injection pressure in bar 1100% 1050% 1000% 950% 900% 850% Performance of Injection Pressure (MB + Ingeo-PLA 3251D) 800% 0% 1% 3% 5% Dosage of mold release SUKANO mr S533 27/28 June 2019, FrankFurt Messe EXAMINING HOW BIOPLASTICS CAN HELP CREATE A WORLD FREE FROM PLASTIC WASTE applications in Packaging, automotive, textiles & transportation PLUS: Increasing use of recycled Materials & end-of-Life solutions sponsors bioplastics MAGAZINE [03/19] Vol. 14 37

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