Capscrap Project to Reduce In-Process Scrap Reaches First Anniversary

June 2009 sees the end of the first year of an innovative project entitled CAPSCRAP. The project aims to address concerns hindering scrap reuse in major injection moulding sectors such as packaging, PET bottles, and engineering polymer systems such as PEEK and PPSU.

Modern moulding machines are equipped with temperature & pressure sensors and computer-controlled systems; all developed for easier operation and faster more efficient moulding. However, significant waste during manufacture is still a problem. In recent years the industry has tried to overcome the scrap problem by investing heavily in super-advanced machine controls and process modelling. In applications involving prolonged production runs using dedicated machines, this approach was successful but many manufactures require more flexibility, utilising the same machines for different products & polymer systems. This then, requires alteration of machine settings affecting material characteristics leading to defects and waste.

In process waste is often high quality, clean material yet significant volumes are still being dumped rather than reused. Both moulders and end-user customers are often fearful of reuse due to concerns over degradation of properties. CAPSCAP seeks to provide solid data to eliminate the existing unsupported theories where reuse in many polymer systems still remains un-researched. The literature details many studies concerning the reprocessing of post-consumer recycled material, much of which is not applicable to this situation. The reuse of production scrap is considerably less complicated, where far higher percentages can be reprocessed than current levels. Investigations at the University of Exeter in conjunction with engineering plastics producers AAVF and Algram, has defined the precise relation between material history, processing and final properties that exist in PEEK and PPSU systems, - information with the potential to transform re-use levels in the future.

Similar programmes are also underway in other systems such as PET, ABS, & PE/PP, in conjunction with Esterform Packaging Ltd & Becton Dickinson, Data Plastics, & Robinson Plastic Packaging.

The project wants to go even further and develop a methodology to prevent scrap being created in the first place through closer monitoring of the melt, in the injection moulding process. This will be achieved by employing an in-line monitoring system developed at Exeter in conjunction with Colormatrix Europe Ltd - the project leaders. The system uses two optical fibre probes that continuously monitor material flowing through the injection nozzle. In this way real time spectroscopic information on the condition of the liquid polymer can be collected during the injection process. This will offer a solution to materials-related problems by providing additional process control based on the real-time condition of the material itself, rather than operator judgement.


The European plastics processing sector includes approximately 39,000 companies, mainly SMEs and employs more than one million workers, of this just over 20% are UK based equating to £17.5 billion in turnover (2.1% of the UK GDP) and an estimated 5.9Million Tonnes of product by 2011. It is estimated that 63% of the UK plastic sector could benefit commercially from the CAP-SCRAP developments. Those in the industry contacted were strongly attracted to the potential of an in-line monitoring tool with marker incorporation to help reduce waste.

The project which is 50% funded by the UK Goverments Technology strategy Board is being led by Colormatrix Europe Limited in collaboration with the University of Exeter and will run for a duration of three years. There are 8 other partners working on the project and these include Boots, Algram, Becton Dickinson, Data Plastics, Robinson Plastic Packaging, Esterform Packaging Ltd, AAVF and the British Plastics Federation.

[ENDS]


For further information on this press release, please contact Tim Marsden, British Plastics Federation, 6 Bath Place, Rivington Street, London, EC2A 3JE, tel 020 7457 5017, fax 020 7457 5045, email: [email protected]

Notes for editors:

British Plastics Federation (BPF) is the UK trade association for the plastics industry - representing the whole supply chain including polymer producers, distributors, additives suppliers, machinery manufacturers, processors and recyclers.


Colormatrix Europe Limited
ColorMatrix are innovators of new technologies for the plastics industry. Our advanced liquid colorant, additive and dosing systems are designed to improve manufacturing efficiencies and enhance the performance and aesthetics of plastic products. The ColorMatrix dosing technologies used to deliver our colorants and additives are highly accurate, easy to install and facilitate quick, easy in-line colour changes. This complete package approach makes ColorMatrix the lowest total-cost-in-use supplier in the sectors in which we operate. ColorMatrix liquid technology systems are adaptable to individual customer requirements and are fully supported for processing trials and full scale production start-ups.

University of Exeter
We are a leading UK university with 14,000 students at our campuses in Exeter and Cornwall, research income of £34m a year and a network of 58,000 alumni across 150 countries. In the National Student Survey we have been ranked in the top 10 for student satisfaction for the last three years.

Technology Strategy Board
The Technology Strategy Board is all about driving innovation.

Our role is to stimulate technology-enabled innovation in the areas which offer the greatest scope for boosting UK growth and productivity. We promote, support and invest in technology research, development and commercialisation. We spread knowledge, bringing people together to solve problems or make new advances.

We advise Government on how to remove barriers to innovation and accelerate the exploitation of new technologies. And we work in areas where there is a clear potential business benefit, helping today's emerging technologies become the growth sectors of tomorrow.