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JUNE 2022 BRIGHT FUTURE BECKONS POLYMER GRADS NEW HELMET DESIGN BOOSTS HEAD PROTECTION 3D cushion liner resists concussive injuries caused by linear impact PLUSHIFILL N functional mineral filler for plastics and elastomers offers superior weatherability versus other mineral fillers.INSIDE PLASTICS ENGINEERING VOLUME 78 NUMBER 6 JUNE 2022 14 Design Notes HEADS UP WaveCel helmet technology seeks to reduce the ‘silent epidemic’ of concussive brain trauma. 20 GET YOUR OWN! Plastics Engineering keeps plastics industry professionals informed of the latest news and in-depth reporting on state-of-the-art and emerging technologies that impact the R&D and processing of plastics products. This is the magazine every plastics industry professional NEEDS to read. 4spe.org/Subscribe 4 LETTER FROM THE EDITOR THE GRADE Polymer technology degrees lay a vital foundation for aspiring plastics engineers. COVER STORY 2022 TRENDY Awards Most Improved Magazine www.plasticsengineering.org | JUNE 2022 | PLASTICS ENGINEERING | 19 | Reader Feedback Accurate numbers matter even if they conflict with talking points. 11 | Data Points Never too late to learn: How Ford designers flunked the Edsel driving test. 47 | Calendar 48 | Ad/Editorial Index INSIDE PLASTICS ENGINEERING VOLUME 78 NUMBER 6 JUNE 2022 43 | New Product News 30 5 | Set Point New PIA chief stresses advocacy; Plastic Omnium seals lighting deal. 42 | SPE News COME TOGETHER European thermoforming conference highlights cooperative paths to process and regulatory challenges. 26 MEETING SUSTAINABILITY NEEDS WITH PCR Dow researchers note benefits in adding high loadings of post- consumer recyclate to shrink film structures. 34 As I See It FOURSQUARE 4OCEAN CEO Alex Schulze talks trash in oceans and 4ocean’s commitment to remove it. 10 | The Legal Angle New column looks at relevant issues: ‘Vague’ UN plastics resolution looms. 12 | Infographic CARBON REINFORCEMENTS AS ART Aesthetic appeal of carbon fibers enhances luxury Apple watch case. 2 | PLASTICS ENGINEERING | JUNE 2022 | www.plasticsengineering.orgPatrick Toensmeier Editor-in-Chief (203) 777-1474 ptoensmeier@4spe.org Michael Greskiewicz Director, Sales & Advertising (203) 740-5411 mgreskiewicz@4spe.org Ryan Foster Art Director (203) 740-5410 rfoster@4spe.org Sue Wojnicki Director of Communications (203) 740-5420 swojnicki@4spe.org Editorial & Publishing Staff President Jason Lyons CEO Patrick Farrey President-Elect Bruce Mulholland Vice President – Chapters & Secretary ScottEastman Vice President – Business & Finance / Treasurer James Waddell Vice President – Professional Development Pavan Valavala Vice President – Sustainability Conor Carlin Vice President – Member Engagement Lynzie Nebel Vice President – Publications Raymond Pearson Vice President at Large Paul Martin Past President Jaime Gómez SPE 2021-2022 Executive Board Contributing Editors NANCY D. LAMONTAGNE ndlamontagne@gmail.com Nancy D. Lamontagne reports on science, technology and engineering. Topics she covers for Plastics Engineering include thermoforming, blow molding, medical plastics, packaging, and education and career development. ROBERT GRACE bob@rcgrace.com Robert Grace has been in B2B journalism since 1980. He covers design and business for Plastics Engineering and is editor of SPE’s Journal of Blow Molding. Professional memberships include the Industrial Designers Society of America. JENNIFER MARKARIAN technicalwritingsolutions@comcast.net Jennifer Markarian has been reporting on the plastics industry for more than 20 years, covering a range of technology topics. She is also the newsletter editor for SPE’s Palisades-MidAtlantic Chapter. CATHY NESTRICK Cathy Nestrick is the former vice president and general counsel of Berry Global Group Inc., a Fortune 500 manufacturer and marketer of plastics packaging and engineered materials. She is the founder and co-host of Parity Podcast, which focuses on accelerating gender equality. ERIC F. GREENBERG Eric Greenberg focuses on food and drug law, packaging law and commercial litigation. Work includes regulatory counseling, label and claims review, product development, GRAS, food contact materials evaluations and clearances, and related areas. www.plasticsengineering.org | JUNE 2022 | PLASTICS ENGINEERING | 3 PEGGY MALNATI peggy@malnatiandassociates.com Peggy Malnati has over 30 years’ experience covering plastics, composites and automotive. She has organized technical conferences for SPE and served as board member and communications chair for SPE’s Automotive Division. GEOFF GIORDANO geoffgio@verizon.net Geoff Giordano has been a contributor to Plastics Engineering since 2009, covering a range of topics, including additives, infrastructure, flexible electronics, design software, 3D printing and nanotechnology. FROM THE T he writer and humorist Mark Twain observed that “Clothes make the man. Naked people have little or no influence in society.” Twain was speaking in the 19th century. In the 21st century, a similar thought can be expressed about numbers, especially statistics, which activists recite on cue when promoting causes like plastics regulation or bans. The ability to recite numbers about the volume of plastics production, the tally of plastics in products, the number of disposable packages in circulation, the plastics trash that ends up in landfills or as litter and the lack of recycling infrastructure is the sine qua non of regulatory arguments. It’s almost like saying people without numbers have little or no influence on society. Statistics, of course, can be an important first step in identifying issues, challenges and objectives. Most people in the industry know that only 9 percent of all plastics worldwide are recycled every year, and even less in the U.S.; and 80 percent of ocean plastics pollution begins with improper disposal of waste on land. These numbers are unacceptable and cause for concern. But statistics can also be irrelevant, especially when presented without context. In March, a USA Today columnist wrote that “Humans have produced 18.2 trillion pounds of plastics—the equivalent of 1 billion elephants (emphasis mine)—since large-scale production began in the early 1950s.” 18.2 trillion pounds is quite a number; inconceivable, in fact, to many people, but perhaps not so overwhelming if expressed as a more manageable 9.1 billion tons, or better yet 9.1 x 109. The number, no matter how one expresses it, also reflects the availability, application versatility, economy and benefits of one of the 20th century’s miracle materials, one that has driven advances in markets as diverse as packaging, medical, automotive and electronics, and which continues to improve the standard of living for most of the world’s 8 billion people. A world without plastics is not unimaginable; it’s undesirable. Numbers like these, moreover, never convey the gains that the industry makes in confronting issues of recycling, sustainability and creation of a circular plastics economy. In April, the month set aside for Earth Day, the journal Nature published a research paper that showed promising results in efforts to create a fast-acting hydrolase for enzymatic depolymerization of polyethylene terephthalate containers and bottles. PET is considered one of the “problem plastics” by activists, owing to its widespread use in single-service containers and prevalence in waste streams and ocean pollution. The paper is titled “Machine learning-aided engineering of hydrolases for PET depolymerization.” Research was conducted at the University of Texas, Austin. Contributors to the project included ExxonMobil Research and Engineering Co. (funding), the National Institutes of Health (a grant) and the Texas Advanced Computing Center in Austin. The researchers formulated a “robust and active PET hydrolase” they named FAST-PETase (functional, active, stable and tolerant). The hydrolase was developed with a machine-learning algorithm that produced a biochemical catalyst with superior PET-hydrolytic activity. The FAST-PETase enzyme was effective at almost completely degrading thermoformed trays with varying pH levels in one week, at process temperatures of 30 to 50°C (86 to 122°F). The algorithm established five mutations needed in the enzyme to rapidly degrade PET. FAST-PETase also depolymerized amorphous portions of a commercial water bottle and an entire thermally pretreated water bottle at 50°C. The researchers described a closed-loop process akin to advanced or chemical recycling, in which FAST-PETase depolymerizes PET and resynthesis of the constituent monomers occurs. As promising as this and other research into recycling and sustainability is, activists will never cite it as an example of the industry’s commitment to improving the environmental footprint of plastics. This vision of plastics contradicts the restrictive outcome many activists want. The technology is also difficult to explain in debates and less compelling as a call to action than beaches and oceans littered with waste. The plastics industry should aggressively promote such research, commercialize it as soon as possible, and show consumers and regulators that plastics are not a burden on the future, but a necessary and positive means of maintaining progress in numerous aspects of life. Remember: Bad news sells. USA Today on Earth Day this year published another column on plastics that included this quote from one activist: “Most of all, plastic waste isn’t safely recyclable, and it is wrecking the recycling system.” PAT TOENSMEIER Editor-in-Chief ptoensmeier@4spe.org MAKING SENSE OF NUMBERS 4 | PLASTICS ENGINEERING | JUNE 2022 | www.plasticsengineering.orgMattSeaholm has a long to-do list as it relates to his newly assumed role atop the Plastics Industry Association (PIA). His first priority: Fill the group’s senior communications role that has stood vacant since July 2021. The Washington, D.C.-based trade association in late April elevated Seaholm to the posts of president and chief executive officer, replacing Tony Radoszewski, who was relieved of his duties just a month earlier (May Plastics Engineering, p. 5). At the same time, the board also promoted plastics machinery industry veteran Glenn Anderson to chief operating officer from his previous role as vice president of member engagement. A native of Wisconsin, Seaholm joined the association in December 2016, initially as executive director of the American Recyclable Plastic Bag Alliance, a self-funded division of PIA. Then, in April 2020 he assumed the role of vice president of government affairs, leading advocacy efforts on behalf of PIA at all levels of government. Prior to that he served for 18 months as vice president of public affairs in Washington for Edelman, the global public relations firm. A veteran of political and policy campaigns, he graduated from the University of Wisconsin, Madison, with a bachelor’s degree in political science and government and also attended the Accelerated Management Program at the Yale School of Management. In a May 5 interview with Robert Grace, Seaholm said: “When the chairman of the board, Tad McGwire, made the call [to offer me the job], he said, ‘Make no mistake about it, this is an indication of the level of importance that the board wants to put on advocacy and communication.” Seaholm has specialized in those two areas for his entire career. “I’ve now spent the last six-and-a-half years working on plastics policy of some sort, as well as communication ... and [this new role] feels like a pretty darn good fit,” he said. He added that it was a strategic move on the part of the board to elevate both him and Anderson at the same time. “With all of Glenn’s relationships, institutional knowledge and managerial experience, it really does make for a heckuva one-two punch.” Seaholm added, “I’ve made it very clear that the number one hire is the vice president of communications.” That post has been vacant since Brendan Thomas departed the group last summer, and “it absolutely has to be filled. ... It’s just too darn important to be sitting there and not saying things on the communication front, both internally and externally.” The fact that this position was open for so long was a point of frustration for the PIA board, he acknowledged. To underscore his point, Seaholm noted that his first day on the job was April 27, and the very next day he was on the phone to the recruiter, seeking some great candidates for that role and to get someone on board as soon as possible. He said he is looking for someone who is media savvy and who can develop great relationships with reporters who cover plastics-related issues. “There is so much misinformation that is put out there, and our members expect us to be a voice of the industry, and some of that is simply correcting the record when we see these falsehoods being put out there. “ Seaholm noted that the PIA website also is undergoing a major revamp and should be relaunched in the next few months. As for other priorities, he remarked: “We’re going to continue to put additional emphasis and investment on sustainability because, there’s no doubt about it, the industry needs leadership on the sustainability front,” and that goes far beyond just recycling. The little things matter, he said he stressed to his staff on day one. “I said that our members expect a lot from us. We’ve got to raise the level of expectation in everything we do. We’ve got to think bigger, and we’ve got to do bigger things, because our members are counting on us. You’ve got to do the little things well to make the big things possible. “We’re going to improve our member communication. We’re going to make sure our members know what we’re doing and why we’re doing it.” He stressed that PIA’s new communication strategy and vision “has to be more than just the nuts and bolts of the process of what we’re doing, but it’s about who we’re fighting for, who we’re representing. It’s the hundreds of thousands of workers who rely on us to be their voice. We just haven’t done it well enough, and we’ve got to do better.” His predecessor, the Texas-based Radoszewski, ruffled a few feathers with his overt support of Donald Trump. Seaholm noted: “I’ve been advocating on behalf of the industry with Republicans and Democrats for years. You certainly have to understand the bipartisan nature of advocating on behalf of an industry and not for your own personal beliefs.” He says that throughout his time working on behalf of the industry, his focus has always been on “maintaining a free market and letting plastics compete, because in most applications, plastics win.” SET POINT NEW PIA CHIEF STRESSES COMMUNICATION, ADVOCACY MattSeaholm www.plasticsengineering.org | JUNE 2022 | PLASTICS ENGINEERING | 5It’s been a busy second quarter for automotive supplier Plastic Omnium. The company, based in Levallois Cedex, France (U.S. subsidiary is Plastic Omnium Auto Inergy of Troy, Mich.), signed a partnership agreement to supply high-pressure hydrogen vessels to green mobility specialist Hyliko for use with its decarbonization process in heavy trucks. Plastic Omnium also agreed to acquire Varroc Lighting Systems (VLS) from automotive supplier Varroc Engineering Ltd., of Aurangabad, Maharashtra, India, in a €600 million ($630 million) deal. The moves reflect Plastic Omnium’s strategic business plans which are proceeding despite mixed financial results in the first quarter. Economic revenue was €2.09 billion (about $2.2 billion), which it described as a “limited decline of 5.5 percent” from year- ago results. The company attributes this to a “particularly disrupted environment” created by the continuing shortage of semiconductors and Russia’s invasion of Ukraine and war of attrition there. Plastic Omnium’s joint ventures, however, primarily automotive body parts production in Asia, posted a 14.1 percent increase from the same period in 2021. The first phase of the Hyliko partnership covers an order for 315 high-pressure hydrogen vessels which will be used to equip 45 trucks by the end of 2024. The partners plan to work together to develop hydrogen storage systems that increase truck range to more than 750 km (466 miles), a boost of almost 60 percent from current hydrogen systems. Hyliko provides transporters and logistics operators with an all-in-one decarbonization approach, which includes leasing and maintenance of hydrogen-powered trucks, supply of hydrogen produced from biomass residues and managing the carbon footprints of fleets. By 2030, Hyliko aims to eliminate 1.5 million tons of CO 2 emissions from European roads and highways, equip 10 percent of the continent’s hydrogen truck market (around 15,000 vehicles) and deploy 100 hydrogen production and storage stations in Europe. Plastic Omnium has been active in hydrogen mobility since 2015. Its New Energies Division develops and produces comprehensive hydrogen systems for all forms of mobility, ranging from storage to management systems including fuel cell modules. The company is committed to growing the use of hydrogen fuel systems in vehicles. It recently signed a deal to deliver hydrogen storage systems for the Staria, a new multipurpose vehicle with a futuristic appearance and iconic design from Hyundai of South Korea. The storage systems can be housed in the vehicle’s floor architecture. They offer the flexibility to integrate, on one architecture, either hydrogen storage vessels or batteries. VLS, with annual revenues of €800 million ($840 PLASTIC OMNIUM MAKES HYDROGEN DEAL, LIGHTING BUY SET POINT Gurit Holding AG of Wattwil, Switzerland, has sold its aerospace business to Isovolta Group, a composites manufacturer based in Austria. The divestment of the business is in line with Gurit’s strategy to focus activities on the wind turbine industry as well as the marine and industrial markets. The aerospace prepreg production site in Kassel, Germany, employs 80. A transitional support agreement is in force to assure a smooth handover. Isovolta Group is an international manufacturer of electrical insulating materials, technical laminates and composites, with a focus on aircraft interiors. The Austrian company employs about 1,500 and has production sites in Austria and the U.S. Factoring in the transaction, Gurit expects 2022 revenue to be around CHF 410 to 450 million ($414 to $454 million) with an operating profit margin between 5.5 and 8.0 percent. Plastic Omnium’s hydrogen fuel deals include storage systems for the Hyundai Staria, a multipurpose vehicle with a futuristic look. Photos courtesy of Plastic Omnium GURIT SELLS AEROSPACE BUSINESS TO ISOVOLTA continued on p. 8 PCS CO. APPOINTS ELSEY PRESIDENT Angela Elsey has been named president of PCS Co., Fraser, Mich., which supplies products and technical support to the injection molding, moldmaking and die casting industries. She succeeds David Cataldi, who is now senior strategic advisor for PCS. Cataldi, who was president since 2017, will retire in July. Elsey served as finance director for PCS since 2019 and was on the Leadership Team. She has been instrumental to the success of the business by streamlining processes, improving financial visibility and oversight, and bringing cross- functional teams together. Prior to joining PCS Co., Elsey held positions continued on p. 8 6 | PLASTICS ENGINEERING | JUNE 2022 | www.plasticsengineering.orgEXTRUSION SPECIALIST NAMES THREE VEEPS Entek, a manufacturer of turnkey extrusion systems, twin-screw extruders and components in Lebanon, Ore., named three vice presidents to serve in key areas of the company: John Burke, manufacturing; Tim Glover, machining; and Marvin Kuenzi, engineering. MOL Group of Budapest, Hungary, has acquired ReMat Zrt., a recycling company with plants in Tiszaújváros and Rakamaz, Hungary, and a logistics hub in Bratislava, Slovakia. ReMat is a major plastics recycler in Hungary, with an annual processing capacity of 25,000 tons and 200 employees. The transaction is part of MOL’s strategy to become a key player in the developing low-carbon circular economy of Central and Eastern Europe. ReMat recycles plastics from community and industrial sources. It repelletizes low-density polyethylene and polypropylene recyclate and other products. With the acquisition, MOL will develop virgin and recycled grades to meet growing demand for circular materials. MOL Group launched its Shape Tomorrow 2030+ Strategy in February, along with a new sustainability strategy. One pillar of the strategy is integrating the circular economy in MOL’s operations. The company will spend $1 billion in the next five years on circular economy and green projects. Waste integration and utilization are key to the approach. MOL continues to look for opportunities to grow the share of recycled materials in its product portfolio. In November 2019, the first step was taken with the acquisition of Aurora Kunststoffe GmbH, a compounder of recycled plastics in Germany. With total combined annual capacity of 40,000 tons from Aurora and ReMat, MOL offers a range of sustainable compounds and repelletized resins for the automotive and packaging industries. MOL also entered a strategic partnership with German company APK, a pioneer in the development of recycling technology, whose solvent-based process produces high-quality polymers from complex plastics waste. Recently, MOL entered another strategic partnership, with Swiss Meraxis, to move ahead with the development and production of polyolefin recompounds. MOL also plans to invest in chemical recycling and further waste-management activities. “Our goal is to become a key player in the low-carbon circular economy in Central and Eastern Europe. This acquisition is a major step towards this goal,” says Gabriel Szabó, executive vice president of MOL Group Downstream. MOL PURCHASES TARGET CIRCULAR ECONOMY Bales of plastics waste arrive at ReMat Zrt. plant in Hungary for recycling. Courtesy of ReMat Zrt. John BurkeTim Glover Marvin Kuenzi www.plasticsengineering.org | JUNE 2022 | PLASTICS ENGINEERING | 7Next >