Page 56 - Plastics News February 2024

PRODUCT NEWS

that includes the configuration of the solutions from a technological point easily be recycled in the traditional
neck and cap, and the structure of the of view, which are capable of inter- PET chain. A high-performance solu-
bottle itself once it has been blown, cepting new market trends is an im- tion in terms of sustainability that has
right up to the design of the moulds, portant part of SACMI Beverage's already attracted the attention of ma-
which is also carried out using ad- activities. One interesting proposal is jor customers.
vanced simulation techniques such as the development of PET-In-Box, i.e. It is important to note that the ap-
finite element analysis (FEM analysis). the replacement of the traditional BIB plication developed does not require
In all cases, the result is not limited 'bag', which is difficult to recycle, with the production of special preforms:
to a paper copy; it is prototyped and a PET bottle blown from a super-light in fact, the lightest preform already
industrially tested either using test preform. available on the market was used to
benches and simulators or using an- The advantage is twofold, a net saving make a standard 41/48 mm neck, with
thropomorphic robots that simulate on material which – taking the stand- the possibility of improving weight re-
the behaviour of the actual machine. ard 5, 8 or 10 litre formats as an ex- duction even further depending on
The PET-In-Box Opportunity ample – is more than 50% (from 125- the application requested and the
Research and development into new 130 g to just 69 g). The container can availability of ultra-light preforms.

Broadway’s Innovative Endothermic Blowing for Moulding Processes

of course offers obvious advantages in
a variety of applications.
MasterFoam is an endothermic blow-
ing agent. Endothermic blowing
agents absorb energy during the reac-
tion process, so the reaction is easy
to control. They typically only release
carbon dioxide and water upon de-
composition. Broadway states that
this is a much safer product than
widely available exothermic blowing
agents.
What are the benefits?
roadway is an ISO certified, UK reaction which creates a foaming ef-
Bmanufacturer of colour and addi- fect whilst the material is in a liquefied MasterFoam offers many benefits.
tive masterbatches and compounds. state during the moulding process. The application, polymer type and
Their new blowing agent masterbatch The foam expands as the thermoplas- moulding conditions will determine
was extensively trialled throughout tic cools in the mould. This process which are achievable, and to what ex-
2023. The material – developed by offsets the tendency for the moulded tent in each moulding.
Broadway’s in house technical team, part to shrink whilst cooling, thus re- Following successful trials, an indus-
is now marketed as MasterFoam. ducing sink marks. try partner of Broadway suggest they
Moulders already using the additive As the material hardens, a fine, regular could save 105 tonnes of polymer
have achieved notable reductions in foam structure forms within it, reduc- over a five year period in just two
polymer usage, cycle times and costs, ing its density. This means less poly- small packaging components, mould-
as well as light-weighting their com- mer is needed to fill the mould cavity, ed for a leading multinational consum-
ponents. therefore less material is required to er goods company. They state this
How does it work? complete the production run, reduc- would result in a saving of £110,000
on material costs alone. For packaging
Broadway’s MasterFoam is a chemical ing material costs by almost 10% components subject to the UK Plastic
foaming agent (also known as a blow- in many instances. As a result, the Packaging Tax (the rate of which is due
ing agent). MasterFoam instigates a moulded component is lighter, which

58 PLASTICS NEWS February 2024