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SEPTEMBER 2022 IN-PERSON EVENT IS FIRST IN 1,185 DAYS K 2022 TO PROMOTE SOCIAL NEEDS AT ANNIVERSARY EXPO Sustainability and circular economy will be prominent in Düsseldorf PLUSINSIDE PLASTICS ENGINEERING VOLUME 78 NUMBER 8 SEPTEMBER 2022 14 K 2022 EYES SOCIETAL NEEDS The giant trade fair is emphasizing climate protection and the circular economy as well as new products. 22 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 FACE-TO-FACE: COVER STORY 2022 TRENDY Awards Most Improved Magazine www.plasticsengineering.org | SEPTEMBER 2022 | PLASTICS ENGINEERING | 15 | Reader Feedback Pittsburg State has had a great plastics program for 50-plus years. 47 | Calendar 48 | Ad/Editorial Index INSIDE PLASTICS ENGINEERING VOLUME 78 NUMBER 8 SEPTEMBER 2022 44 | DEI Dialogues 30 6 | Set Point Plastics Omnium buys HBPO; Stratasys adds AM business; Alpek acquires Octal. 40 | New Product News PROTECTING THE PROTECTORS Graphene nanoplatelets extend performance levels in primers, paints and coatings. 28 SURE SHOTS Innovations in injection molding technology yield greater control over materials selection and part quality. 32 MORE UPTIME, BETTER EFFICIENCY Innovative machine monitoring unit is designed to make it easy, fast and affordable to escape Excel hell. 12 | Data Points Polymer markets show strength. SUSTAINABLE VINYL The latest efforts to make PVC even greener will be a focus of upcoming VinylTec conference. 26 ALL ONBOARD ReFocus summit highlights industry efforts to increase recycling and sustainability. 36 13 | The Legal Angle California law targets plastics. 2 | PLASTICS ENGINEERING | SEPTEMBER 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 | SEPTEMBER 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 S eptember is a great month. Autumn is approaching, bringing with it spectacular scenery as trees change color; shifting temperatures, which become progressively colder in most areas but are exhilarating for many people; and the realization that we are in the final third of the calendar and facing the prospect of another year that’s soon to be a memory, whether good, bad or indifferent. September in most countries is also when colleges and universities shift into high for the academic year. However, amidst all the activities and offerings on major campuses, one question looms— in fact grows every year: Is all the time and investment in higher education really worth it? For many students, especially those in Generation Z, the answer is no. Their skepticism is understandable: according to figures from the federal government and other sources, 48 million Americans owe $1.7 trillion for their college and university education—$412 billion more than the total amount of U.S. auto loan debt. In exchange for this indebtedness—which will take years for many to pay off— colleges and universities provide exactly zero assurance of any payback in terms of career potential and lifetime earnings. No surprise, then, that many in Gen Z (born 1997 to 2012) seriously question the value of a traditional four-year college education. According to a report in the Aug. 1 issue of Spectator magazine by Rikki Schlott, a former New York University student who left college to pursue a passion she has for journalism, the number of high school students who planned to pursue a four-year degree declined 28 percent from 2020 to 2022. Not surprisingly, 60 percent of Gen Z students worry about how to pay for college and 68 percent say the cost of tuition is an important factor in determining their education path. And how expensive has college become? Between 1980 and 2019, the average tuition bill increased 169 percent, Schlottwrites, based on data from VICE television and the Education Credit Management Corp. Wages for workers in their twenties, meanwhile, are only up 19 percent in the same period. Little wonder, then, that 62 percent of teens want to make their own educational path and one-half of those believe they can be successful without a four-year degree. There are, of course, degrees that virtually guarantee employment, a good wage to start after graduation and opportunities for career advancement. At the college level these include polymer engineering and polymer science and related courses. For students interested in hands-on work with machinery, molds and dies, and other manufacturing operations including plant management, some four-year and many two-year colleges include these studies in their curricula. And for high school students looking to join the workforce directly after school, there are a growing number of apprenticeship programs in the U.S. that will hire and train capable and committed teens and older candidates in aspects of machine operation, setup, assembly and other needs. Some of this comes at a cost, of course, especially at the college and university level. But the price of tuition is generally much less than at most state and private schools and the curricula highly focused on a student’s needs and interests. (See also July/August Plastics Engineering, p. 10.) All these opportunities are brought to aspiring students by the plastics industry, a STEM business that is large, diverse, global and entirely capable of solving the key issues of our time such as sustainability, the circular economy, reducing carbon emissions and other social concerns. Gen Z students would do well to consider investing their time, energy, focus and creativity in a plastics career that will let them be part of an ongoing effort to improve the quality of life for people everywhere. It would, in fact, be like investing in a winning lottery ticket that has a guaranteed lifetime payout. And no one would complain about that. PAT TOENSMEIER Editor-in-Chief ptoensmeier@4spe.org LIFETIME WINNINGS 4 | PLASTICS ENGINEERING | SEPTEMBER 2022 | www.plasticsengineering.orgTo the Editor: I was reading the June issue of Plastics Engineering magazine and was taken aback by the article titled “Making the Grade (p. 14).” What concerned me is that the Plastics Engineering Technology program at Pittsburg State University (PSU) was not even mentioned in this article. The article was well written, and I appreciated the content. Everything you stated is true. In fact, PSU’s plastics program has been at the forefront of everything you mentioned in the article since 1970. Within the past five years our enrollment has ranged from 75 to 95 students, and we have graduated 20 to 25 in the past few years. Our curriculum covers material characterization, part and mold design, testing and coverage of all major processes in the industry. Our students receive industry experience via internships and interactions with our Plastics Engineering Technology Advisory Council members. Our graduates enjoy 100 percent placement with average starting salaries of $65,000 to $75,000 at prestigious plastics companies all over the country. We also conduct workshops, community outreach and have a thriving SPE student chapter. I am an alumnus of this program and worked for Tyco Electronics and other plastics companies for several years. My daughter graduated from the program and is in her second year at iMFLUX (a Procter & Gamble Corp. subsidiary; see p. 31 of this issue). I am hopeful that our omission from your article was purely by accident, but you can see how this would upset our many alumni, faculty, current students and industry partners. It is also a lost marketing opportunity for our program and university. This email is not meant to be a complaint, but a reminder that we are here and doing quite well for the plastics community. The article was on point but left out a thriving 50-plus-year plastics program. If there is ever an opportunity for a story, or if you need to find out more about our amazing program, please do not hesitate to contact me. Thank you. Regards, Greg Murray Professor, Chair Engineering Technology Pittsburg State University Pittsburg, Kan. FEEDBACK LETTERS, COMMENTS, OPINIONS (PRO AND CON) AND INSIGHTS FROM READERS Dear Prof. Murray, Thank you for your letter, and for giving readers—and our writers—information about the PSU Plastics Engineering Technology program. The omission of PSU from the article was, indeed, unintentional. I am aware of the university and its fine curriculum of plastics technology and should have seen that PSU was missing from the story when I reviewed it. Apologies. PSU is, in fact, on track to become even more influential in plastics education and product development. The university announced in August the receipt of a federal grant for $3 million, which will go toward the establishment of a Center for Commercialization on campus. The center, which will include a polymer chemistry initiative, will be charged with developing sustainable materials for commercial use. Pittsburg State is a shining light on the plains of southeast Kansas (or in the middle of a four-state region, as some prefer to say) and a great place to go to college, especially for students interested in polymer science and engineering. It is also unique in that it is the only U.S. university— and probably the only one in the world—with a gorilla as its mascot. This goes back to 1920 when a group of students, seeking to bolster school spirit, promoted the simian as a rough-and-ready choice. Back then, gorilla was also slang for “roughneck,” which added to the animal’s allure. By 1925, “Gus the Gorilla” had replaced “Manualite” (that’s another story) as PSU’s mascot, and the rest, so they say, is history. So, for a great education in plastics and, coincidentally, if you’re weary of mascots named after predictable land animals, birds, fish, 18th- century college founders and colors, PSU could be a dynamic choice for a career- shaping education. Pat Toensmeier answers: CORRECTION In the July/August issue on p. 51, the Timeline entry for 1995 states: “SPE launches PlastiVan …” The PlastiVan program, in fact, was started at that time by the National Plastics Center and Museum with a donation from Husky Injection Molding Systems Ltd., Gordon Lankton of Nypro and Stephen Uhlmann of Tech Group Inc. The program was eventually turned over to SPI (now the Plastics Industry Association) and after that came to SPE, which is still successfully operating it. www.plasticsengineering.org | SEPTEMBER 2022 | PLASTICS ENGINEERING | 5Automotive giant Plastic Omnium reports two acquisitions that will expand its role as a supplier to current and developing automotive markets. The company purchased the remaining 33.33 percent of shares of automotive front-end module specialist HBPO GmbH from Hella, a joint venture partner. HBPO is a global leader in the development of complex front-end modules and has strong growth potential due to the increasing electrification of automotive markets. With 2,800 employees at 31 plants in 11 countries, HBPO assembles over 5 million front-end modules every year—one in five worldwide. It generated revenue of €2.2 billion ($2.24 billion) in 2021. Plastic Omnium closed the acquisition of 100 percent of ACTIA Power, a division of the ACTIA Group, for €52.5 million ($53.5 million) in a self-financed transaction. ACTIA Power was consolidated in Plastic Omnium’s accounts on Aug. 1. ACTIA specializes in the design and manufacturing of on-board batteries, power electronics and electrification systems for trucks, buses, trains and construction equipment. Turnover in 2021 was €22 million ($22.4 million). Plastic Omnium said in a statement that the acquisition of the remaining shares in HBPO supports a strategy to increase its value- added content per vehicle, while leveraging the growing demand for electric vehicles. The purchase of the remaining shares will unlock development opportunities and further reinforce the company’s proximity to premium and German automotive OEMs. HBPO’s headquarters are in Lippstadt, Germany, and will remain there. HBPO was founded in 2004 as a joint venture between Plastic Omnium, Hella and Behr. Plastic Omnium held the majority of shares in HBPO since 2018 when it increased its stake to 66.66 percent of the share capital from the 33.33 percent it initially held. Full ownership means that Plastic Omnium is well positioned to develop modules and systems with new lighting capabilities, among other features, in line with the transformation of the market to electric mobility vehicles and customer expectations. Laurent Favre, CEO of Plastic Omnium, which is based in Levallois Cedex, France, said in a statement: “The acquisition … of HBPO will allow Plastic Omnium to implement its growth strategy by broadening the range of modules offered. Thanks to HBPO’s strong relationships with premium customers, Plastic Omnium will … meet demand for more complex modular innovations accompanying the shift towards electric vehicles. The complementarity of … business lines will allow [us] to offer smart and fully integrated solutions to the automotive market as it transitions toward more sustainable and connected mobility.” The transaction is subject to regulatory approval, which is expected in the fourth quarter. ACTIA Power, meanwhile, will create synergies with Plastic Omnium’s hydrogen business in all segments enabling the group to meet the needs of combustion and electric vehicles, whether hybrid, plug-in hybrid, battery or fuel cell. (See also June Plastics Engineering, p. 6.) PLASTIC OMNIUM CLOSES MARKET-GROWING DEALS SET POINT Additive manufacturing (AM) powerhouse Stratasys Ltd., of Eden Prairie, Minn., has signed a definitive agreement to acquire the AM materials business of Covestro, which is based in Leverkusen, Germany. The acquisition is expected to be immediately accretive upon closing. It will include R&D facilities and activities, global development and sales teams across Europe, the U.S. and China, a portfolio of approximately 60 AM materials and an extensive IP portfolio comprised of hundreds of patents and patents pending. The purchase price is approximately €43 million ($43.8 million), plus additional inventory, less certain liabilities. In addition, there is a potential earnout of up to €37 million ($37.7 million) based on the achievement of various performance metrics. Both companies expect the deal to close during the first quarter of 2023, subject to regulatory approvals and other closing conditions. Covestro has been a key part of Stratasys’ third- party materials ecosystem, and the acquisition will benefit customers using multiple Stratasys 3D printing platforms, including Origin P3, Neo stereolithography and H350 printers. Stratasys already distributes Covestro’s Somos resins, which are available for Neo and Origin One printers. (See also June Plastics Engineering, p. 44, for information on new Stratasys products.) “Innovative materials are the fuel of additive manufacturing and translate directly into the ability to create use cases for 3D printing, STRATASYS TO ACCELERATE 3DP DEVELOPMENTS WITH COVESTRO BUY continued on p. 10 Plastic Omnium’s acquisition of HBPO expands its work in automotive front-end development for conventional and electric vehicles. Courtesy of Plastic Omnium Covestro’s AM business includes Somos, a global brand of photopolymers. The automotive grille shown on a Stratasys Neo800 stereolithography system was printed with clear Somos WaterShed CX 11122. Courtesy of Covestro 6 | PLASTICS ENGINEERING | SEPTEMBER 2022 | www.plasticsengineering.orgAlpek S.A.B. de C.V., a major producer of chemicals and plastics with headquarters in Monterrey, Mexico, has acquired all the shares of Octal Holding, a manufacturer and supplier of polyethylene terephthalate resin, sheet, packaging and recyclate. Octal, like Alpek, has global operations and is based in Muskat, Oman (U.S. offices are in Cincinnati and Plano, Tex.). The deal is valued at $620 million and is financed by free cash flow from existing businesses and bank loans. Alpek assumed control of Octal’s operations on June 1. The company expects an accretive EBITDA effect of approximately $120 million from the Octal assets through the remainder of 2022, largely based on better-than-expected polyester market conditions in recent months. This would increase Alpek’s comparable EBITDA guidance to $1.37 billion and reported EBITDA guidance to $1.48 billion. Octal is a major producer and developer of PET sheet. With total annual capacity of almost 1 million metric tons, it says it is among the largest global manufacturers of PET resin and sheet at a single site, and the only company in the world with a fully integrated food packaging system from raw material to finished product. Products include DPET sheet, which Octal describes as a cutting edge and sustainable alternative to traditional PET sheet. DPET fabrication technology eliminates five energy intensive stages of conventional PET manufacturing, which the company says makes the product “the most sustainably produced PET sheet on the market.” Sustainability is an important goal for the company. Octal reports that its PET resin uses 63 percent less electricity during manufacture than most competitive versions and that DPET sheet uses 65 percent less electricity. On-site high-efficiency burners consume 20 percent less gas than traditional PET plants and the integrated facility recycles PET waste back into the manufacturing process. Octal, in fact, maintains that DPET sheet has the “smallest carbon footprint of any comparable PET sheet available.” Alpek is a leading petrochemical company operating two business segments: Polyester, which includes PET, rPET and polyester fibers, and Plastics and Chemicals, which covers polypropylene, expandable styrenics and other specialty and industrial chemicals. Alpek is one of the largest rPET producers in the Americas, the third-largest expandable PS manufacturer worldwide and the only PP producer in Mexico. In 2021, Alpek reported revenues of $7.7 billion and comparable EBITDA of $962 million. The company operates 35 plants across North and South America, the U.K., Oman and Saudi Arabia, and employs more than 6,500 people. ALPEK BOOSTS PLASTICS BUSINESS WITH OCTAL ACQUISITION Octal, now owned by Alpek, monitors PET sheet gauge during fabrication. Courtesy of Octal On a future battlefield, soldiers deployed to remote areas will use sophisticated additive manufacturing (AM) printers to print virtually everything they need, from shelter to weapons. The U.S. Army has made AM a priority and DEVCOM (Combat Capabilities Development Command) is supporting the effort with Project Prime, a collaboration with Army Special Forces and an international industry partner. The Project Prime team consists of the Army’s 7th Special Forces Group (Airborne); Combat Capabilities Development Command International Technology Center (ITC)-United Kingdom; the DEVCOM Command, Control, Communications, Computers, Combat systems, Intelligence, Surveillance and Reconnaissance Center (C 5 ISR); and Defend3D, a U.K. company that enables secure transmission of remote 3D printing. Soldiers from the 7th SFG (A) tested INTERFACE SPEEDS ARMY’S 3DP ACCESS IN REMOTE AREAS DEVCOM evaluates high-tech systems for communications and other technology needs of the U.S. warfighter. Photos courtesy of U.S. Army continued on p. 10 www.plasticsengineering.org | SEPTEMBER 2022 | PLASTICS ENGINEERING | 7Next >