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Welcome to the Summer edition

Message of the Chair

The European Thermoforming industry’s main even of the year, the 8th European Thermoforming Conference, was recently held in Venice and the two days of expert presentations and workshops managed to attract many of the industry’s experts to attend

The biennial conferences are proving to be the most important platform for leading business decision makers, suppliers and technologists to meet, network and to discuss the latest developments within the thermoforming industry. It is agreed that they are fast becoming the major international forums for technological advancement within our sector.

The unique and beautiful City of Venice provided an outstanding venue for the event, which attracted nearly 200 attendees.

A combination of excellent technical presentations, discussion workshops and an exhibition of associated technologies which ran in parallel, all contributed to ensure the event was relevant and informative to the international participants. This year’s subjects presented by industry experts were again comprehensive and all-encompassing, covering advancements in terms of the materials and processes technology.

The discussion workshops focussed on the subjects of “Transformation within Plastics Packaging”, “Handle the Output of Thin Wall Production” and “Mechanical Fixation / New Bonding Techniques in Thick Gauge Applications”.

The Thermoforming Parts Competition attracted a diverse range of entries which offered the visitors a unique insight of how innovative product design combined with modern materials and processes can produce inspirational structural, cosmetic and highly functional parts. There were several examples of how thermoformed parts can support demands in completely new market sectors.

Daniele Versolato, Chair ETD 2012-2014

The next European Thermoforming Conferenceis scheduled to take place in April 2014.

NewsLetterA publication of SPE European Thermoforming Divisionwww.e-t-d.org

Summer 2012

Table of Content ETD Chair message – page 1

Report Parts competition – page 2Conference 2012 Sponsors – page 3

Latest developments – page 4 ETD board – page 7

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The winners of this year’s Parts Competition:The Thermoforming Parts Competition Award goes to outstanding and innovative designs or processes in the field of thermoformed components.

Heavy Gauge Automotive Part: Window for Renault Twizy - polycarbonate lateral glazing

Winner: Company Walter Pack (Spain)

Jury´s motivation: “Winner due to processing highly complex polycarbonate sheet material free from mois-ture and dust contamination on an industrial scale which requires high level of processing control, careful logistic management and well designed tooling. A light weight innovative product in a demanding environ-ment”.

Heavy Gauge Non-AutomotivePart: Long Chair “Avus”single and polyurethane filled twin-sheet thermoformed chair designed by Konstan-tin Grcic

Winner: Company Solera Thermoform Group (Italy)

Jury´s motivation: “Winner due to originality of design, clever use of cosmetic materials, and an excellent example of a high per-forming light weight structure produced us-ing the twin sheet processing technology”.

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Thin Gauge Part: Paint Tray multi-layerthe 5 layers consist of a rigid base and four peelable and rechargeable PVC/PE films

Winner: Company Generation Tech (France)

Jury´s motivation: “Winner due to thermo-forming 5 layers simultaneously, also using recycled material; the product is not only environmentally friendly, but also potential-ly opens up new application areas for the thermoforming industry.

2012 Conference Sponsors

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Latest developments in Thermoforming: EcoForm single-station machines with a modular design

The completely newly developed generation of FRIMO EcoForm thermoforming machines features numerous technical improvements, the most significant being the modular design. This means that an EcoForm machine can be configured from different modules to optimally meet the specific requirements of the customer. The basic version is a classic single-station machine for films and sheets with a pre-blowing box and an upper table. The first of the possible add-on modules could be a chain rail for conveying soft films or, alternatively, a sheet conveyor. The EcoForm can be enhanced with a pre-heating section for both thermoforming of sheet material and thermoforming of films. Another possible add-on module is a second upper table, e.g. for use in vacuum laminating.

Improved energy efficiency for economical operationFRIMO has been implementing a number of features to develop and improve the energy efficiency of its thermoforming machines.

Significant potential savings are offered by reducing waste heat through insulation of the main heating system, which accounts for the lion’s share – around three-quarters – of a thermoforming machine’s energy requirement. During the inactive heating phase, the heating system itself is moved into an insulated or partitioned parking position with reduced power consumption in order to maintain operational readiness.

For many processors, the use of a frequency-controlled vacuum pump is a sensible option. This would mean that a vacuum tank could be dispensed with and the pump performance controlled in a way that is optimally tailored to the process requirements.

The drives for the tables are fitted with high-efficiency energy-saving motors. In addition, use of suitable braking curves makes it possible to recover energy for feeding to the intermediate circuit of the frequency converter.

Energy monitoring could be an important aid in all efforts to save energy. This involves the machine’s energy requirement at a given time being displayed on a control monitor. In order to enhance the informative value of the data, it is possible to create appropriate key indicators (e.g. kWh per section) and link them with the recording of energy and production data.

Further development of the molding cooling system for shorter processing timesTraditionally, cooling of the parts is achieved by fitting around four to eight ventilator fans to the machine frame, which only fan the thermoformed components relatively diffusely and may even interfere with each other, depending on the settings.FRIMO has refined and optimized the cooling air flow in order to make air cooling more effective. An air duct system ensures that the cooling air is directed at the molded part in a much more effective and targeted way. As well as reducing the cycle time, this also means that the pray systems that have frequently been used and need high efforts in maintenance are no longer required.

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Bendable chain guide for complex three-dimen-sional components when using thermoforming in-line machines with a film conveying system

Especially when thermoforming components with strong three-dimensional contours, there are often sharp drawing angles involved, which are liable to cause serious stretching of the grain and the needto use a lot of film. Here the newly developed bendable chain guide helps to achieve much better forming of suchgeometries. After the film is heated, bending of the chain guide ensures that the film is guided to the mold cavity in the forming station in a way that follows the precise contours. This means that the quantity of film can be reduced while at the same time improving the quality. The reduction in the area of film required (and to be heated) also means reduced energy con-sumption. FRIMO has filed a utility patent application for this new development.

FRIMO Group GmbH, Martina Schierholt,Hansaring 1, D-49504 Lotte, Germany,Phone: +49 – 5404 886-157schierholt.m@frimo.com - www.frimo.com

Economical, fast, reliable processing. With innovative FRIMO technology, you set the benchmark in thermoforming. Rely on the competence of the technology specialists.

We assure the optimal shape!

FRIMO Group GmbH | Tel.: +49 (0) 5404 886 - 0 | info@frimo.com

www.frimo.com

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Mission Statement

It is the purpose of the European Thermoforming Division to stimulate and diffuse knowledge of all aspects of the Thermoforming industry.This will be achieved by providing conferences, training seminars and regular topical news bulletins. It will provide a dynamic network platform and encourage and promote technical and scientific participation by its members.

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Advanced Thermoforming: Methods, Machines and Materials, Applications and Automation Introduces the latest innovations in thermoforming materials, processes, and applications bySven Engelmann - Published June 2012 by WileyABOUT THE BOOKAdvanced Thermoforming brings readers fully up to date with the latest standards, processes, materials, and applications. From forming to filling to sealing processes, the author explains everything that can now be accomplished using the most advanced thermoforming technologies available. Emphasizing theapplication of advanced thermoforming for the production of technical parts and packaging,the book:• Draws upon interviews with industry experts• Guides readers through all facets of development, design, and machine and mold technology• Recommends new technologies that offer higher productivity, better quality, and lower costs• Describes common raw materials used in thermoforming, including how specific materials affect the production process• Explains the proper handling of semi-finished products and formed parts• Sets forth the basic principles of extrusion, an essential process underlying thermoforming• Introduces the latest software techniques to simulate the thermoforming of new products.

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ETD board Members 2012-2014Daniele Versolato Chair and CouncilorReinhold Plot Past-chairCor Janssen TreasurerYetty Pauwels Secretary and Newsletter EditorHubert Kittelmann Programme Committee ChairGabriel Bernar Programme CommitteeWim De Vos Programme CommitteeMauro Faé Programme CommitteeHans Lauridsen Programme CommitteePeter Lichtherte Programme CommitteeMarek Nikiforov Programme CommitteeJeff Pitt Programme CommitteeHenning Sandal Programme CommitteeDaniele Versolato Programme CommitteeMauro Faé Technology Committee ChairGabriel Bernar Technology CommitteeMarc Ommeslagh Technology CommitteeReinhold Plot PR / Website Committee ChairNiklas Magnusson Parts Committee ChairRay Lewis Parts CommitteeMarek Nikiforov Parts CommitteeCor Janssen Sponsors Committee ChairKen Braney Sponsors CommitteeYetty Pauwels Sponsors CommitteeDaniele Versolato Sponsors CommitteeCor Janssen Social Programme Committee ChairKitty Beijer Social Programme CommitteeMichel Py Social Programme CommitteeCor Janssen Membership ChairManfred Jacob AdvisorKen Braney Advisor 2012-2014Wim De Vos CEO SPE

SPE European Thermoforming Division

Newsletter EditorYetty PauwelsEric Sasselaan 51, BE-2020 Antwerpen, BelgiumTel: +32 3 541 77 55 – Fax: +32 3 541 84 25spe.etd@skynet.be - www.e-t-d.org

16 – 20 Oct. 2012

FriedrichshaFen

22nd Fakuma

International

Trade Fair for

Plastics Processing

Schall makes trade fairs for markets

VERANSTALTER

P. E. Schall GmbH & Co. KG

Gustav-Werner-Straße 6 . D-72636 Frickenhausen

T +49 (0)7025 9206-0 . F +49 (0)7025 9206-620

info@schall-messen.de . www.schall-messen.de

. Injection moulding machines

. Thermoforming technology

. Extrusion equipment

. Tooling systems

. Materials and components

w w w. f a k u m a - m e s s e . d e

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The Conference for the Thermoforming IndustryS E P T E M B E R 2 3 - 2 5 , 2 0 1 2

> Select your choice of over 25 educational sessions and workshops> Presentations will be led by world-renowned and innovative industry leaders > A robust exhibit hall of 100+ projected exhibitors dedicated specifically to

thermoforming products and services> The SPE Thermoforming Division Parts Competition will unveil cutting-edge

thermoformed products> See how it's done: your choice of exclusive plant tours at Allen Extruders and

Formed Solutions or Fabri-Kal allow you to benchmark your practices to othersin the industry (full conference registration only)

> Advance SPE Member full conference registration fee (includes all meals): only $395 USD

> Stay at the Conference Headquarters’ Hotel and network with industrytrendsetters after hours

Why Should You Attend?

ThermoformingDIVISION

Presented by

For more information or to register, visit the website:

www.thermoformingdivision.com

September 23-25, 2012Amway Grand Plaza Hotel | Grand Rapids, Michigan USA

12819L1a_ThermoAd20x14cm_Layout 1 8/3/12 12:15 PM Page 1

Career Summary:Design and Product Development Professional with 20+ years plastics industry experience.

Career Objective:A challenging yet rewarding position withan established company with heavyNational (or International) presence inthe Plastics industry.This ideal company would take seriously their desire to experience steady future growth. Preferably this position would dovetail my highly energetic, positive, and motivated “Team Player” personality with my strongorganization, communication, and relationship

building people skills into a Design Engineering or Market Development/Sales Engineering position. As a “hands-on” individual, I welcome a goodchallenge and find it interesting to coordinate new Developments in Materials and Processes or Techniques with new and yet to be developed advanced Applications. This effort would naturally require heavy involvement with customers, Manufacturing, Corporate Management, and Quality.

Professional affiliations: Society of the PlasticsIndustry (SPI) and Society of Plastics Engineers (SPE)

Contact: Troy Baerwolf, 1009 Ash Street,Baraboo,WI 53913, USA - troyb1@hotmail.com