Environmentally Friendly Corrosion Protection For Machines: Good Cooling Water Quality Without Chemicals

For good production results and low service costs, a permanently high water quality is required. Users must ensure that their machines do not allow bacteria to form in their circuits, which are disturbed by biofilms, for example – or where corrosion often gnaws at steel moulds. Corrosive or bacterially contaminated cooling water damages machines and plants, especially in plastics processing companies.

Chemicals are often used to regulate the pH value and biocides to prevent the formation of biofilms to prevent or at least reduce corrosion in the plants. However, the use of these agents is also maintenance- and cost-intensive. A chemical-free solution is therefore ideal for maintaining the quality of the cooling water, which is not only associated with lower costs but also protects the environment.

A typical example is companies that use injection moulding systems, writes Christian Barth, Country Manager at Enwa AS in Hennef in the trade journal 'Plastverarbeiter'. There, he says, cooling circuits are used in which oxygen and CO2 always penetrate the water and reduce the pH value. The treatment of the tools can also subsequently deteriorate an initially good water quality in the cooling circuit. This happens when passivation is carried out with phosphoric acid and the rest of the highly concentrated acid is not properly rinsed out of the mould before the next use. When the mould is put into operation, this residue is then returned to the large circuit and harm  the water quality, but in practice, the situation is usually different for users of chemicals.

If chemical corrosion protection agents are added to the system to counteract corrosion, it is not uncommon for the biology in the storage tank to virtually explode. As a result, biocides are necessary to remove the bacteria – a vicious circle, so to speak.

A Solution Without Chemicals For Clean System Water In Cooling Circuits.

The consistent use of minerals means that no food source for bacteria can be created in the first place. The permanently high pH value, once set, in combination with the minerals, represents an effective bacterial barrier.

The corrosion protection is achieved by the adjusted pH value, which forms a stable protective layer on the base metals. The pH-value is self-regulating and enables maintenance intervals of twelve months for the operator.

The expert recommends the use of a pressurised, closed system for a new system to be planned. This would not automatically solve all the challenges of open systems, but the boundary conditions would be easier to control. However, this water is not bacteria-free - just as drinking water cannot be. And, corrosion often remains an issue, as many of the systems are made of steel.

Improve Quality: Metallic Impurities In Plastic Granulates

Even the smallest metallic impurities in plastic pellets can cause considerable problems in plastics production and processing. In contrast, the industry has high-quality requirements (and associated strict standards) for materials and the resulting products, making it clear that the detection of metallic impurities and continuous monitoring during the production process is extremely important. A new quality control system combines X-ray technology with automatic offline inspection and analysis.

Almost always a high level of effort is required to avoid errors and an even greater effort to eliminate them. The dismantling of injection moulds alone, the replacement of hot runner systems or the reworking/repair of cavities are both time and cost intensive. Rebecca Zachau from Sikora presents in an article for the trade journal ‘Plastverarbeiter’ a new system which should significantly improve this situation.

With the help of X-ray technology, a non-destructive view into or through the plastic granulate is possible. In addition, there is an equally advantageous differentiation between different materials such as the granulate and the metal particles in question. Thus, chippings trapped in the raw material can be detected - and as the X-ray unit is hermetically sealed from the environment, no radiation escapes to the outside, so that the requirements of the Radiation Protection Act and the Radiation Protection Ordinance are fulfilled.

How Are The Impurities In The Plastic Analysed?

The substrate is guided through the inspection area equipped with an X-ray camera on a sample carrier. Within 30 seconds the inspection and evaluation takes place, whereby a projector directly marks contaminated material in colour. At the same time, the monitor displays the size and area of the contamination. The X-ray images automatically detect, visualise and evaluate metallic contamination from 50 μm upwards on the surface as well as within non-transparent, coloured and transparent plastic granulate.

 In addition to individual tests, the system's software also permits series tests and thus valuable comparisons throughout the whole manufacturing process. Moreover, the system does not work in isolation in the operating process - it can be connected to the company network via a LAN interface and the collected data can be exported for further processing. The whole unit is a mobile offline testing device on wheels, which can be used for spot checks outside the production process in the laboratory or directly next to the production line.

Waste Prevention In Composite Materials: Additives Optimise Sustainability And Efficiency

Improving recycling rates and thus improving the consumption of resources is one of the outstanding tasks in the development and production of composite materials today. To this end, waste must be reduced and production residues returned to the manufacturing process, which is an important factor in reducing costs and increasing efficiency in plastics processing.

For example, newly developed polymer stabilizers enable a significant increase in the proportion of recycled materials in the production process and make it possible to operate at high speed. Film damage is avoided, and a consistent, uninterrupted production is guaranteed. Tests with a 30 percent recycled content and the use of the polymer stabiliser have shown a reduction of film stippling by up to 25 percent.

Sustainable solutions are in demand not only for processors of packaging films, but also for manufacturers of plastic components for the transport or electronics industry, write the authors Dr. Diederik Cioyvaerts and Dr. Christian Battenberg (Global Segment Manager Processors, BL) in the trade journal "Plastverarbeiter 1/20". The focus is not only on the recycling of components, but also on the use of materials that contribute to improved sustainability. As a result, plastics are increasingly being used in transport applications to reduce the weight of the means of transport and their fuel consumption. Fibre-reinforced composites are increasingly being used for sophisticated components. In order to bring their advanced material properties further towards the required target values, various additives such as flame retardants are used. This is essential due to the high carbon and hydrogen content of the underlying plastics and the associated low flammability.

Sustainability Requires Flame Retardants In Fibre Composites

The weight of vehicles can be reduced by using flame-retardant fibre composites, also for structural components. Carbon fibre reinforced composites are used - such as thermoplastics, but especially thermosets, e.g. epoxy resin systems. These weight savings and the resulting increased range are a decisive advantage, especially for the constantly growing electric mobility. It must be taken into account that each individual application has different fire protection standards, which may even differ from country to country.

Flame retardants must therefore be carefully selected and matched to the system in question. According to the Swiss authors, the chemical nature of the flame retardant as well as its decomposition products in case of fire plus their interaction with the plastic influences the mode of action and effectiveness. Therefore, the selection of the appropriate flame retardant is not trivial - on the contrary, it requires a lot of testing, experience and chemical expertise.

As far as flame retardancy is concerned, halogen-free solutions used as additives are the benchmark today for preventing the spread of a fire or the ignition point of plastic components in an environmentally friendly way. In addition to the existing additive flame retardants, the market is showing an increasing demand for additives that are soluble and reactive in the resin. A great advantage is the slightly increased viscosity compared to powdery agents.

Effective Roof Sealing Through Coatings With Latex Impregnated Fleeces

Turning a flat roof into a waterproof roof, and keeping it tight for 20-30 years, is not necessarily an easy task. One of the most common solutions to create a waterproof barrier is to use polymer bitumen roofing membranes. These have been increasingly popular for years and are 'legitimate' successors to roofing felt thanks to their superior long-term performance.

Such roofing membranes essentially consist of two parts: a non-woven polyester fabric impregnated with latex, which is the actual carrier, and a top layer of bitumen for waterproofing. The bitumen also acts as a kind of adhesive to bond the fleece to the unprotected flat roof.

An important component of many of these polyester roofing membrane systems is synthetic latex to impregnate the fleece. The latex impregnation makes the fleece resistant to dimensional changes such as shrinkage and expansion (see DIN standard 18192) – which would otherwise lead to unwanted cracks and could destroy the waterproofing. These forces are caused by fluctuations in temperature, which vary between -40°C and +80°C due to the seasons and day and night cycles. A polymer-impregnated fleece is therefore much less susceptible to these dimensional changes. The latex also prevents water from penetrating the bitumen sheeting and thus prevents the sheeting from becoming delaminated – especially in frosty conditions. The cross-linking agent contained in the latex creates a three-dimensional link between the polymer chains before, during and after the evaporation of the water. This contributes to a balanced ratio of mechanical strength and hardness.

Advantages In Terms Of Environmental Compatibility – Reduction Of Formaldehyde Release

During the impregnation of nonwovens with typical chemical binders available on the market, formaldehyde is released by the cross-linking reaction. However, crosslinking is necessary – tantamount to the use of a polymer-impregnated nonwoven.

The latex also prevents water from penetrating into the bitumen sheeting and thus prevents the sheeting from becoming delaminated - especially in frosty conditions. The cross-linking agent contained in the latex creates a three-dimensional link between the polymer chains before, during and after the evaporation of the water. This contributes to a balanced ratio of mechanical strength and hardness.

Advantages in terms of environmental compatibility - reduction of formaldehyde release

During the impregnation of nonwovens with typical chemical binders available on the market, formaldehyde is released by the cross-linking reaction. However, crosslinking is necessary – as described – to achieve the required resistance and good thermal stability. New latex compounds are ammonia-free and do not contain formaldehyde-releasing crosslinkers.

Measurements show that the emission of the product not only meets the previous requirements of < 20 ppm/m3 exhaust air, but also stricter ones, such as the German Federal and State Working Group on Emission Control with 5 mg/m3 exhaust air (valid since February 2020).

In addition to a formulation that avoids the release of unwanted substances, modern polymers (such as the product 'Litex SkyShield') are also suitable for use as a 1 K system without thermoset resins. This leads to considerable cost savings, such as fewer logistics or reduced warehousing. Another advantage of the new polymer is that it allows the nonwoven to dry at much lower temperatures: The drying air can be reduced from typically 200°C to 170°C during the manufacturing process.

All this represents a significant economic benefit for the end-user compared to conventional technologies.

((From: nonwovens TRENDS 1/2020, authors: Michael Karnop, Andreas Gehr of Synthomer Deutschland GmbH, Marl/Germany))

Weserland can provide hands-on help in this area. We are looking forward to receiving your enquiries.


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