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How granular data is revolutionizing milling

How granular data is revolutionizing milling

The idea of building one of the most advanced flour mill’s conceivable has been a shared ambition for both Bühler and the UK’s largest flour miller Whitworth Bros. Ltd. Today, that ambition is a reality. The gleaming profile of the Mill E3 sits just off one of the main arteries of the UK’s motorway network on which Whitworth’s distinctive yellow bulk tankers fan out daily delivering flour to its customers.

Sitting on a six-acre site at Whitley Bridge in Yorkshire, the flour mill is the culmination of years of planning. But it was the moment the first consignment of wheat arrived for milling in early 2021 that the Mill E3 truly evolved from vision to reality. This futuristic plant was designed to become a testbed for the milling industry. What is being learned and developed here has the potential to transform milling practices globally. “The Mill E3 is a step change from the traditional way of operating a flour mill. It allows us to challenge the boundaries and continue moving forward with the SmartMill technology to really expand the opportunities within milling,” explains Mike Peters, Managing Director of Whitworth Bros. 

At the heart of this voyage of discovery lies digital data and at the heart of digitalization lie sensors, and the automation system that provides the data. Fifteen thousand data points monitor every aspect of the production from raw material delivery to the sealing of flour-laden trucks ready for delivery to clients. Every five seconds sensors feed data to Mercury MES to facilitate control of every aspect of the mill’s internal workings and to Bühler Insights where algorithms compare past and present production parameters to ensure the mill is always operating at optimal efficiency. 

“This is an incredibly exciting project for us. We launched it at our Networking Days IpackIma in Milan in 2018 and now, here at Whitworth, it is a reality,” says Roman Sonderegger, Bühler Head of Wheat and Rye. “This mill allows us to gather and analyze amounts of data that we have never had the opportunity to collect before. It means we will be finding out things about the milling process that we have never even thought of, enabling us to come up with ideas and new services that we can turn into a reality for all our customers.”

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Bühler strengthens market positions in 2021

Bühler strengthens market positions in 2021

The key markets of Bühler in the food, feed, and mobility sectors underwent fundamental transitions driven by changing consumer requirements and enabled by new technologies. As a result, the demand for sustainable solutions has clearly increased. As part of the long-term innovation strategy of Bühler, spending on R&D over the last 3 years including the “coronavirus years” increased to more than CHF 400 million (2021: CHF 141 million, 5.2% of turnover). Bühler has positioned itself as a key enabler and partner for its customers, supported by collaborations with key partners in industry and science.

New drivetrains and new designs dominated the automotive industry. The new processing technologies of Bühler’s Die Casting business area with high locking force production cells resulted in accelerated growth in this market; the Grinding & Dispersing business area, which established its market segment Battery Solutions a decade ago, experienced a record order intake in 2021, attributable to the boom in lithium-ion batteries for e-mobility. Similar positive market demand was noticeable in Bühler’s food and feed businesses, for example, processing solutions for plant-based proteins or for dairy alternatives were in high demand and contributed to growth in Bühler’s Value Nutrition business.

New types of chocolates, pralines, and various confectionery and snack products required new applications which the Bühler Consumer Foods segment (which includes the technologies of the former Haas business acquired in 2018) created. Also, Bühler’s Milling Solutions business grew in the wheat and rye and specialty segments, with processing solutions for high-capacity plants as well as for special applications for local niche markets. Digitalization and cloud-based services acted as key enablers to improve the performances of existing assets of customers all over the world, and this also addressed the need for improved sustainability and CO2 emission reductions.

Strong order intake

On the Group level, order intake increased by 16% to CHF 3 billion. Because of the time gap in the plant business between order entry and turnover, the upward trend on orders is not yet visible in turnover, which remained stable at CHF 2.7 billion. The same is true for profitability, which amounted to CHF 146 million, reflecting an EBIT margin of 5.4%.

Net profit amounted to CHF 113 million, also slightly better than last year. Orders on hand by year-end 2021 increased strongly by 27.2% to CHF 1.9 billion. “Our innovations, both for plants and services led to growth in our order book. Our strategy to position ourselves as an innovative solution provider for material transformation has been paying off,” says Stefan Scheiber.

All three business segments of Bühler contributed to this positive development. Grains & Food grew orders by 12% to CHF 1.8 billion, Consumer Foods by 6% to CHF 584 million; and Advanced Materials showed the strongest growth of 37% to CHF 620 million. The business areas with the highest growth rates were Die Casting, Grinding & Dispersing Grain Quality & Supply, and Milling Solutions. From a regional perspective, the Americas, Europe, Middle East & Africa, and India experienced the strongest upswing. China represented the single largest market for Bühler in 2021.

Global network, and passionate people key to success

The global network of Bühler with 30 factories, 103 services stations, and 24 Application & Training Centers across the globe was key to being successful in a very dynamic business environment. This allowed Bühler to secure on-time deliveries, also in times when supply-markets were difficult and logistic chains partly interrupted. In 2021, the company executed over 2,000 customer projects, and as part of this Bühler produced and delivered around 50,000 machines and key components. This was only possible thanks to the expertise and dedication of Bühler’s employees, and their focus on customer success.

In 2021, Bühler continued to prioritize the safety and wellbeing of all employees, while maintaining our focus on training and education. With nearly 12,500 staff across the globe, flexibility and resilience became key success factors in response to public health challenges and all related limitations. Bühler continued its commitment to its global apprenticeship program and to the development of employees on all levels. The same was true for the training of personnel of customers, both in Bühler schools as well as in dedicated training centers.

Bühler Service portfolio in growing demand

It has long been Bühler’s strategy to be in the region for the region with our global Services & Sales organization. This strategy was key to our ability to continue important service offerings at all times for our customers globally. Having experts present in all key markets proved yet again to be a key success factor. Understanding the challenges our customers were facing in the different countries and continents has allowed Bühler to make decisive steps towards providing an even more customer-centric approach in its service offering.

The recently renewed and expanded services portfolio – including new digital services and Service Level Agreements – grew in orders by 15% to CHF 746 million. Combined with Bühler’s Single Machine business, the Service business represents about one-third of the overall turnover. Orders on the online platform “myBühler” grew by 50% to CHF 90 million; nearly 100 customer sites are now connected to the Bühler Insights platform; and RemoteCare contracts, of which customers make use of online support functions, have increased by a factor of 6 to nearly 400. Nearly 160,000 service orders were carried out.

“It is not only that we grew volume, but that we changed the character of our Service business to specific value additions for our customers, enabling them to improve the performance of existing and new assets. This, at the same time, is a key contributor to improved sustainability in the value chains of our customers,” says CEO Scheiber.

Further strengthening of financial position

Despite the stable turnover volume, Bühler managed to further improve its financial position. Driven by a strong operating cash flow which stood at CHF 256 million at year-end, net liquidity more than doubled to CHF 329 million. Consequently, the equity ratio rose to a strong 47.2%. “Our balance sheet is stronger than before the coronavirus crisis,” says CFO Mark Macus. “This financial strength gives our customers and stakeholders security in a volatile economic environment and enables us to continue executing our strategy, including strategic investments into assets and innovation. We are a reliable partner for our customers – in critical times, this is more important than ever.”

Accelerated impact in 2022

Political tensions, climate change, supply chain issues, and rising inflation continue to be key factors impacting the economic climate, and it is unlikely that these issues will change in the foreseeable future. At the same time, new market opportunities continue to emerge. Bühler considers itself well-positioned to continue a growth path in the running year and beyond.

“During the past two years of coronavirus crisis, we have learned to master the demanding environment with a strong purpose and value orientation, with a positive mindset, and a focus on innovation and on people,” says Stefan Scheiber. The upcoming Bühler Networking Days, which are planned to take place end of June 2022, underpin this positive mindset. “We look forward to again bringing decision-makers and partners from the global food, feed, and mobility industries together. We would like to create a positive, accelerated, and sustainable impact together with our partners.”

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KRAIBURG TPE TO UNVEIL BREAKTHROUGH INDUSTRY INNOVATIONS IN CHINAPLAS 2022

KRAIBURG TPE TO UNVEIL BREAKTHROUGH INDUSTRY INNOVATIONS IN CHINAPLAS 2022

The recognized TPE manufacturer will be showcasing its breakthrough TPE series for automotive interior and exterior applications, and THERMOLAST H TPEs for medical and healthcare devices. Also on show will be its latest TPE series for consumer electronics and food contact packaging applications.
All over the world, the demand for essential goods including automobiles, consumer electronics, packaging, and medical are evolving to meet new trends that focus on sustainability, safety, and functionality. These are further aided by new innovations in materials, designs, and technology. 

KRAIBURG TPE, a global TPE manufacturer of high-quality, innovative, and custom-engineered TPEs is keeping pace with the demand for advanced material solutions, especially for high-growth industries. The company will be exhibiting its latest TPE compounds and applications at the 35th edition of CHINAPLAS 2022. 

Driving material innovation in automotive parts
KRAIBURG TPE’s automotive TPE series fits the criteria for safe, durable, and high-quality automobile parts. For the automotive exterior, the compounds feature superior thermal stability, UV resistance, and good weathering. The compounds exhibit excellent adhesion to a broad range of thermoplastics including PP, PP+30% glass fiber, SAN, ASA, PMMA, PC/ABS, and nylon allowing for design innovation and flexibility of parts processing with multi-component injection molding. 

 For automotive interior applications, the TPE compounds offer many other material advantages, including abrasion, chemical, and scratch-resistance, dry and visually appealing surface with optimized touch as well as vibration-damping. KRAIBURG TPE’s low odor and low emission compounds are also ideal for interior automotive parts as they satisfy automotive interior VOCs and SVOCs market criteria. 

In addition, the selective TPE series’ lightweight properties are ideal for diverse automotive applications. They offer a homogenous surface, provide excellent compression set value, and can be processed cost-effectively using established injection-molding machines and extruders. KRAIBURG TPE’s compounds also meet OEM approvals from major global automotive standards and have passed the Kalahari and Florida testing standard.

Steering towards global sustainability 
Besides driving innovation, KRAIBURG TPE’s compounds are recyclable, driving further support for environmental efforts globally in the automotive industry. 

Healthcare and medical devices
KRAIBURG TPE will be unveiling its new THERMOLAST H product line in CHINAPLAS 2022, targeting healthcare and medical device applications exclusively within the Asia Pacific market.  KRAIBURG TPE’s THERMOLAST H compounds are free from toxic substances and contain neither latex, PVC, phthalates, nor heavy metals. 

Furthermore, the compounds comply with ISO 10993-5, GB/T 16886.5, and other relevant medical standards. KRAIBURG TPE’s THERMOLAST H meets global food regulatory standards such as China GuoBiao (GB) GB4806, FDA-Code of Federal Regulations (CFR) Title 21, and Commission Regulation (EU) No. 10/2011. Moreover, it complies with RoHS and REACH standards and is sterilizable with autoclave 121°C and EtO.

With good adhesion to PP and PE, haptics, and compression set, THERMOLAST H is suitable for applications such as closures, flexible connections, medical tubing, syringe gaskets, catheter connectors, mouthpieces, and more; as well as for applications requiring soft-touch features such as grips, switches, and mats. 

Enhanced ergonomics for consumer electronics and food contact packaging
KRAIBURG TPE’s innovation has also made headway in wearable technology applications such as watch and wrist bands, headphones, ear tips, game consoles, wireless automatic sensors, car phone holders and chargers, virtual reality (VR) devices, remote controls, and more.

The compound series are designed to deliver desired properties such as soft-touch feel, abrasion, oil, and chemical resistance along with skin-safe contact properties.  

KRAIBURG TPE’s compounds provide manufacturers with benefits such as ease of coloring, impact resistance, and the ability to create hard-soft touch combinations to achieve innovative designs or functional elements.

Meanwhile, in consumer food packaging, the compound series offers excellent organoleptic properties to help maintain food and beverage flavor. The low migration feature also makes the compounds the material of choice for all food types including fatty food contact applications, especially for food packaging. Such applications include squeeze bottles, closures, seals, valves, and other food packaging solutions.

#Breakthrough #ChinaPlas2022  #Manufacturer #Highquality #Automotive

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First plant-based ink from Ricoh enhances graphics and packaging print sustainability

First plant-based ink from Ricoh enhances graphics and packaging print sustainability

Brand owners and printer manufacturers can further reduce their environmental impact with Ricoh’s plant-based ink – the first of its kind for mainstream graphics and packaging print.

The ink is a derivative of the oil-based ink created for the décor printing sector as part of Ricoh’s collaboration with German equipment manufacturer Olbrich. It has been developed to deliver excellent rub resistance and set-off performance for corrugated brown and whiteboards, as well as carton boards.

The plant oil component creates a sustainable and environmentally friendly ink that it is:

  • Quick-drying, as no heat is required to fix or dry the ink. The oil penetrates porous substrates leaving the pigment near the surface. This reduces energy consumption and eliminates the need for the whole drying system.
  • Odour-free with improved food compatibility, as no monomers are used
  • Biodegradable and supports deinking.
  • Not water-based so no biocides are required to keep the ink usable.

The print heads are easier to clean and less likely to clog as ‘open time’ is much longer. This helps enhance jetting reliability, performance, and printhead life. Low ink consumption is also enabled as the same optical density is achievable using 50% less ink.

Graham Kennedy, Director Industrial Printing, Graphic Communications, Ricoh Europe, says: “Brand owners and printer manufacturers are increasingly focused on reducing their environmental impact and applying sustainable practices wherever possible. With our new plant-based ink they can seamlessly introduce positive changes that make a big difference without impacting their high-quality printing results.”

#Richocollaboratewitholbrich #ink  #enivornmentfriendly #sustainableprint

http://www.ricoh-europe.com/

Covestro, Mitsui Chemicals, and Mitsui & Co., Ltd, complete first delivery of certified renewable raw materials in Asia

Covestro, Mitsui Chemicals, and Mitsui & Co., Ltd, complete first delivery of certified renewable raw materials in Asia

Covestro has entered into an agreement with Mitsui Chemicals on the supply of raw materials phenol and acetone from ISCC Plus certified mass-balanced sources. Both components will be used for the production of polycarbonate at Covestro’s Asian sites in Shanghai, China, and Map Ta Phut, Thailand. High-performance plastic is used, for example, in car headlights, LED lights, electronic and medical devices, and automotive glazing. Japan’s Mitsui Chemicals and Mitsui & Co., Ltd are already long-standing suppliers to Covestro.

“With this agreement, Covestro, Mitsui Chemicals, and Mitsui & Co., Ltd are taking their partnership to a new level, with the goal of supplying customers along the process chain with more sustainable raw materials from mass-balanced, renewable sources,” says Sucheta Govil, Chief Commercial Officer of Covestro. “I am very pleased that we are now also gradually converting our production in Asia to products with renewable raw materials. In this way, we are helping customers achieve their sustainability goals and offering them a drop-in solution that they can use immediately without a major changeover.”

Recently, the first shipment of mass-balanced phenol produced by Mitsui Chemicals, Inc., from its Osaka site arrived at the production site of Covestro in Caojing, Shanghai. Further shipments are to follow, also including bio-attributed acetone. Mitsui Chemicals uses bio-feedstock from waste and residues as the raw material basis for its bio-attributed phenol and acetone products.

“We’re pursuing not only plastic recycling but also a switch to biomass with the aim of realizing a circular economy,” said Yoshino Tadashi, Senior Managing Executive Director and President of the Basic Materials Business Sector of Mitsui Chemicals. “So it’s a delight to have been able to make our first shipment and delivery of mass-balanced phenol based on bio-feedstock to Covestro. With our materiality contributing to the realization of a sustainable society, we look forward to working together with everyone to steadily promote the social implementation of biomass.”

“Our long-term partnerships with Covestro and Mitsui Chemicals have enabled us to deliver the first renewable Phenol in Asia.” said Takashi Furutani, Chief Operating Officer of the Basic Materials Business Unit of Mitsui & Co. “Mitsui is committed to providing solutions for customers who work towards a circular economy. This is just the beginning of our journey.”

In mass balancing, bio-based raw materials are used at an early stage of production and mathematically allocated to finished products. This saves fossil raw materials and reduces greenhouse gas emissions, while the quality of mass-balanced products remains the same compared to purely fossil-based ones.

ISCC (“International Sustainability and Carbon Certification”) is an internationally recognized system for sustainability certification of biomass and bioenergy, among others. ISCC Plus includes additional certification options e.g. for techno-chemical applications, including biomass-based plastics.

#longtermpatnership #certified #renewablerawmateria #sustainable

https://jp.mitsuichemicals.com/en/

www.mitsui.com.

SABIC collaborates with China’s Dongfeng to produce lightweight truck-mounted toolbox with novel plastic-composite hybrid solution

SABIC collaborates with China’s Dongfeng to produce lightweight truck-mounted toolbox with novel plastic-composite hybrid solution

SABIC, a global leader in the chemical industry, today shared that it has collaborated with Dongfeng Motors, one of the largest truck manufacturers in China, on the development of a novel plastic composite hybrid solution to produce a strong lightweight truck-mounted toolbox. The application is made with a combination of SABIC’s STAMAX  resin, a long glass fiber polypropylene (PP), and continuous glass fiber composite laminate inserts via a single overmolding process. The finished part is lighter by up to 30 percent compared to a similarly designed part in steel, and the use of the solution allows Dongfeng to benefit from resulting production efficiencies.

“This plastic composite solution is a great example of how SABIC helps automotive customers expand design options and simplify production so they can achieve their goals,” said Abdullah Al-Otaibi, general manager, ETP & Market Solutions, SABIC. “By combining two different materials, our solution improves both performance and processability. Now that this composite technology is validated and in mass production with Dongfeng, we see many other automotive applications that could benefit and we are excited to help manufacturers seize those opportunities.”

In addition to truck tool boxes, automotive applications for this hybrid solution with STAMAX resin can potentially include tailgates, seating, front-end modules, and battery housings for electric vehicles.

The use of this plastic composite solution can enable manufacturers to not only reduce weight, but also lower carbon emissions, control costs through production efficiencies, and achieve higher performance.

Design and Performance Optimization

SABIC’s hybrid solution combines STAMAX resin with thermoformed composite inserts made of unidirectional (UD) glass fiber-reinforced PP tape from China-based Qiyi Tech, a company dedicated to the development and production of continuous fiber-reinforced thermoplastic composite materials.

The laminate inserts are pre-heated before being placed in the tool and over-molded with STAMAX resin in a single operation. The inserts add stiffness and strength to critical areas of the part, enabling the use of thin-wall geometries that can reduce weight.

Compared to steel, the conventional material for truck toolbox applications, SABIC’s plastic composite hybrid solution expands design options, enables the consolidation of parts, and avoids secondary operations that can add costs and prevent high-volume production.

The plastic composite solution reduces the weight of the toolbox by approximately 30 percent (4 to 6 kg) without sacrificing the stiffness, toughness, or strength required for this utility application.

STAMAX resins feature 10-25 percent lower density than some competitive materials for weight-out. Their properties include high stiffness and impact strength, excellent structural performance, and easy flow for thin walls.

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Exciting podcast on the topic of Artificial Intelligence (AI)

Exciting podcast on the topic of Artificial Intelligence (AI)

 Arburg goes on air with podcast episode 134 as part of the podcast series “AI in Industry”. The episode entitled, “KI bei Arburg und die Rolle des Basismodells”, looks at the exciting topic of Artificial Intelligence (AI) in mechanical engineering. In the 35-minute German-language podcast, Werner Faulhaber, Development divisional manager at Arburg, talks to moderator, Robert Weber, and provides deep insights into the potential that AI offers the world of injection moulding.

Werner Faulhaber explains that combined with a “smart” control system and “Machine Learning”, AI is making injection moulding “more intelligent” step-by-step. He discusses the developments Arburg is working on and how plastic processors can use this technology to create new business models in the future.

“Machine Learning” is changing the world of injection moulding

The podcast discusses why it is not enough to just gather data: you also need the process expertise and domain knowledge. Werner Faulhaber explores the use of AI to develop master models using experience and data collected over the years on the process, material, and machinery. The customer could then sharpen the provided master model “on Edge” and thus optimize their processes.

The in-house development Gestica control system, the Arburg host computer system, and the “arburgXworld” customer portal give Arburg an advantage here. Moreover, the machine will increasingly be able to optimize itself in the future and continue improving by means of so-called “Machine Learning”. Application examples are given in the interview. These include automatic programming of robotic systems, targeted malfunction remedying, and a spare parts system with “intelligent” image processing.

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Borealis and ADNOC Consider Borouge Listing

Borealis and ADNOC Consider Borouge Listing

Borealis AG (Borealis) and Abu Dhabi National Oil Company (ADNOC) are considering a potential initial public offering (IPO) of a minority stake in their joint venture Borouge. Headquartered in Abu Dhabi, Borouge is a leading provider of innovative, value-creating plastics solutions.

Borealis and ADNOC will provide further material updates as and when appropriate.

www.borealisgroup.com
www.borealiseverminds.com
www.adnoc.ae
www.borouge.com

 

Schnitzel surprise at the SeneCura social center in Kirchberg am Wechsel

Schnitzel surprise at the SeneCura social center in Kirchberg am Wechsel

There was a delicious surprise from residents for residents recently at the SeneCura social center in Kirchberg am Wechsel. Some of the seniors quietly and secretly got to work with the SeneCura team to make the other residents and employees happy.

 Early in the morning, the group sneaked into the kitchen to make the others happy with schnitzel and traditional side dishes at lunchtime. For this, the illustrious group first boiled and peeled potatoes and put a pot full of rice on the stove. 

Then it was time for the main ingredient – for the breading, the hobby cooks prepared plates with flour, eggs, and milk, in which the meat was dunked after being beaten flat. zzzsch! With a loud sizzle, they then came into the oil pan. At half-past eleven everything was set and ready. The seniors: inside showed real cooking skills and arranged the wonderfully fragrant schnitzel beautifully on plates.

There was also potato and lamb’s lettuce, as well as rice and cranberries. “Schnitzel is my real favorite food and I like to stand in front of the stove for it. Cooking together was a lot of fun, I hope we can do it again soon,” says Magarete Schitkowitz, resident of the SeneCura social center in Kirchberg am Wechsel.

Schnitzel makes you happy

The excitement in the house was great when the team of amateur chefs served the schnitzel, surprising the other residents and employees: wafer-thin and crispy golden brown – a real treat for the palate! The whole house was happy about this successful surprise and talked about this festive menu all afternoon. “I am delighted that this campaign was so well received. 

We always try to make everyday life as colorful and varied as possible and also incorporate ideas from the residents. So there is something for everyone and in this case for every taste,” says Elisabeth Windbichler, head of the SeneCura social center in Kirchberg am Wechsel.

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Sharing knowledge digitally

Sharing knowledge digitally

Bühler opened the African Milling School (AMS) in Nairobi, Kenya, to train professionals from the region for the region and to reduce dependence on foreign specialists. It’s based on the Swiss vocational system, with a strong emphasis on hands-on training in its school mill and laboratory with a bakery.

When the Covid-19 pandemic forced the school to close in March 2020, the team quickly established e-learnings that apprentices could access on their smartphones back in their home countries while borders were closed. Due to the increased demand for virtual training, the AMS launched a pilot training with TechnoServe on food fortification.

This training is open to quality control managers, millers, and other professionals in the nutrition sector, and drew huge interest in the entire region across Africa and the Middle East. Today, training courses take place on-site again in accordance with local Covid-19 measures, and vital in-person training is in high demand. Online training, however, is here to stay and will continue to accelerate AMS’ impact to build up expert knowledge in the region. 

https://www.africanmillingschool.com.