Page 63 - Plastics News July 2018

produCt news

Borealis launches new packaging Servo-electric FLEXflow hot

solution produced entirely with runner systems support the

PCR material large-series production

orealis, a leading provider of innovative solutions he production of a lightweight center armrest for
Bin the fields of polyolefins, base chemicals and Tthe automotive interior is one of the latest examples
fertilizers, has successfully launched a new packaging of the use of the innovative FLEXflow technology from
solution produced entirely with post- Italian hot runner specialist, HRSflow. The multi-step
consumer recycled (PCR) material. process combines the thermoforming of a composite
Developed in close collaboration with sheet with the injection molding of two different
the German consumer and industrial thermoplastics. Development partners in the successful
goods company Henkel and two implementation of the project includedinjection
additional value chain partners, this molding machine manufacturer,KraussMaffei,as well
is truly sustainable packaging solution asUS mold manufacturer, ProperTooling.The load-
The launch of this new packaging bearing structure of the center armrest was created
solution provides further evidence with the aid of the FiberForm process developed by
that plastic recyclate is indeed KraussMaffei in which a thin-wall, fiber-reinforced
suitable for a variety of demanding composite sheet is heated, inserted into the mold
packaging applications, in this case and thermoformed. The two subsequent injection
a popular adhesive brand marketed molding processes are carried out according to the
by Henkel. In 2016, Borealis acquired principle of the swivel-platen technique simultaneously
leading German recycler mtm plastics in two opposite parts of the same mold. In one step,
GmbH, which is now a member of the the carrier is first encapsulated with polypropylene
Borealis Group. By leveraging their (PP). This results in the near-final geometry of the
respective areas of expertise and decades of experience as
a virgin polyolefins producer and “upcycler”, respectively,
Borealis and mtm plastics are exploring new growth
opportunities with joint forces.A success story originating
from this exploration is a recently completed pilot project
with Henkel, the global leader for adhesives, sealants
and functional coatings. The companies have worked
to develop a new packaging solution based on recycled
material for the Made-at-Home all-purpose glue bottle
and cap, which Henkel is marketing under its well-known
Pattex brand.
The aim was to replace the virgin plastic material
traditionally used for this packaging with a recyclate- part, including the elements needed for subsequent
based resin. After extensive and joint application assembly. This PP structure is then overmolded with a
development, a new bottle was developed with Borealis’ thermoplastic elastomer (TPV) in the opposite section
proprietary product brand Purpolen® PE, a high-quality of the mold. This produces the flexible visible surface
polyethylene regranulate produced by mtm at its with the fine grain that is later responsible for the high
facilities in Niedergebra, Germany. For the three separate optical and tactile quality of the center armrest. With
components of the adjustable applicator nozzle, which is both injection molding steps, a FLEXflow hot runner
used for both filigree and wide-area gluing, high-quality system is used, with two or three hot runner nozzles.
Purpolen polypropylene regranulate produced by mtm Their servo-electric, individually controlled valve pins
was identified as the ideal solution. It was launched on ensure optimum filling of the cavities in each case, and
the European market in 2018. they also contribute to the reliability and economic
viability of the process.

63 July 2018 Plastics News