From time to time, we share insights into the advantages our customers and partners gain from using additives from the bFI product family. These findings are based on applications and trials, often sparking ideas for additional use cases where, for instance, the bFI A 3745 provides the necessary solution.

Wide Range of Application Opportunities

Originally developed on an acrylate basis, the flow enhancers of the bFI product family were initially intended for use primarily in acrylic glass, polycarbonate, and polystyrene. However, as described elsewhere, the compatibility of these polymeric additives extends well beyond this scope. They can be applied across all common plastic variants, including both thermoplastics and thermosets, effectively addressing a wide range of viscosity challenges.

In addition to our research findings, validated in collaboration with partners, positive feedback from customers and documented case studies further confirm the efficacy, reproducibility, and stability of our polymeric additives.

What advantages does the bFI product family offer you?

We observe a range of benefits in both the processing phase and the additive-enhanced material, which consistently appear across applications.

Here is a brief selection:

• Reduction in viscosity (significant increase in MFR or MVR)
• Increased productivity through shorter cycle times
• Lower processing pressures and temperatures
• Potential energy savings, thus reducing the CO2 footprint
• Greater flexibility in choosing injection molding machines, extruders, etc.
• Enhanced flexibility in raw material selection, whether polymers or additional components (e.g., regranulates, temperature-sensitive additives)

Our customers, well-acquainted with their own processes, can often quickly identify secondary advantages from these points. This success is often achieved in the form of thin-walled components made from specialized materials that would not have been feasible without the bFI additive.

Current Findings

Understandably, we cannot discuss many of our shared successes with customers. However, here’s what we’ve learned in recent months: Biomaterials also pose no issue for polymeric additives like the bFI A 3745. Their processing temperature range can be significantly expanded. We will provide more detailed information on this elsewhere.

It is also possible to process regranulates, even from post-consumer sources, consistently and at an injection molding material level. Alongside rPMMA and rPET, rPP can also be optimized for flowability, standardizing the quality of purchased materials.

Both points offer real added value for our customers in times of changing raw material cycles and increasing sustainability demands. Let’s tackle it together!

For an innovative company, it is crucial to remain curious and open to new developments. Therefore, the trending topic of Artificial Intelligence, or "AI" for short, has naturally not passed by Polytives unnoticed. We have read reports, examined use cases, and even witnessed firsthand how the impact of AI must be considered when implemented in the production process. We have also participated in various webinars and events on the subject, such as those offered by the Chemistry Cluster Bavaria or the TITK in our neighborhood. Below, we would like to provide an overview of what we have learned so far, with a focus on AI in research and development.

Experiment design, data analysis, documentation

An unbeatable advantage of AI is the simplified experiment design, which supports statistical experimental design methods. This can save a great deal of time when analysing different variables and parameters. Experiments can also be automated and carried out by AI-controlled robots.

The amount of data generated in this way can then be analysed - here, AI recognises patterns, trends and complex relationships and dependencies, allowing new synthesis routes to be identified and implemented more quickly and easily. When it comes to molecular modelling and simulation in particular, AI is making major contributions to research and development. The aim is to change molecular structures in such a way that desired properties are specifically adapted - an important means of developing medicines or, for example in the industrial sector, investigating material properties such as strength or thermal stability.

AI in research and development can also touch on an area that is rarely considered outside of academia: The publication of results. The publication of scientific articles is an elementary component of the accumulation and dissemination of knowledge. Here, AI can help not only with literature research, but also with the publication of articles in general. Even if people are sceptical about direct publishing, there are already promising reports that AI-supported text structuring facilitates the scientific analysis and peer review of manuscripts.

Transfer to industry

In order to transfer the fields of application of AI in research and development to industrial issues, partners are currently needed who generate a large amount of data and test and evaluate the processes derived from it. Irrespective of this, applications in the areas of quality assurance, process control, etc. have of course already emerged. But AI can be a possible basis for linking academic research fields and industrial expertise - this has not yet been done to this extent. However, we are sure that innovative ideas will always seek ways and means to reach the world and would not be surprised if there is significant progress in this area in the coming years.

We will definitely stay on top of it and test, wherever possible and practical, how the positive effects of AI tools can support our daily and not-so-daily challenges. An example outside of AI in research and development is the use of AI in marketing. For instance, ChatGPT is quite useful for illustrating a blog post.

In the world of the plastics processing industry, innovative ideas and sustainability in product design are emerging as a guarantee for long-term economic success. We recently met this dual requirement in collaboration with Holzmühle Westerkamp: our flow improver bFI A 3745 was used as a processing aid to optimise the production of fast-food products under the Arweco brand made from PLA, natural fibres, oat husks and other renewable raw materials. The result is a fully organic product which, on the production side, is characterised above all by excellent handling during processing in the hot runner. Of course, this is not the only advantage of this innovative combination of materials.

Our polymer additives are ideal for bio-based polymer composites, as they counteract high processing temperatures, which often lead to material damage and consequently to rejects in the process. Anyone processing PHA or similar materials, for example, may find a new technological approach to previously uninteresting materials. We also recently reported on the potential and challenges of handling PHAs in our blog post.

The temperature-reducing use also has an impact on the energy costs incurred. Savings here lead to more cost-efficient production and, in terms of sustainability, also to a corresponding reduction in the CO2 footprint. This circumstance also helps in the endeavours to become generally more committed to and fit for a circular economic system and to become more resilient in terms of raw material procurement and supply chains.

Conclusion: Better product quality and a more balanced environmental footprint - that sounds like optimisation through bio-based polymer composites. If you are interested in an environmentally friendly addition to any production process, please get in touch with us, because some obstacles are overthrown faster than you can imagine.

The use of recycled materials is an issue for manufacturers of a wide range of products, and not just in the context of the need to reduce CO2 emissions. Replacing virgin material with recycled material wherever possible and, above all, wherever it makes sense, is the declared aim, which is also being pursued by an increasing number of processors due to the standards and specifications that have been set. Unfortunately, it is not as simple as it may sound to the layman. Manufacturers of plastic goods face various challenges, which we would like to briefly discuss here. And also, what solutions might look like.

Quality and consistency

Virgin materials do not have these problems, but unfortunately recycled materials do. They come from different sources and have undergone different processing methods. This can lead to difficulties in the manufacture of consistent products and is critical for the quality assurance of producers.

Contamination and impurities

Returned materials may contain impurities that have not been completely removed during the collection and recycling process. These impurities can affect the mechanical properties of plastic products and make processing more difficult.

Material properties and availability

The properties of recycled materials can sometimes differ greatly from those of virgin materials. This in turn can have an impact on the mechanical, thermal and chemical properties of the plastic products and affect their performance. In addition, the procurement of recycled materials can be relatively expensive due to the collection, sorting and processing required and, depending on the case, the availability of high-quality materials may be unclear.

And yet, in addition to these challenges, there are also clear opportunities. Replacing virgin material with recycled material also means several advantages, which can be seen in the increased demand, among other things.

Resource efficiency, waste prevention and circular economy

By using recycled materials, companies can reduce the need for new virgin resources and thus contribute to the conservation of natural resources. The use of recycled materials supports the idea of the circular economy by reducing waste and integrating reusable materials into the production process.

Cost savings and environmental benefits

In some cases, recycled materials can be more cost-effective overall than virgin materials, especially if they are locally available and the cost of sourcing and processing is lower. The use of recycled materials can lead to a reduction in environmental impact, as less energy and resources are required to produce new materials. At the same time, the amount of plastic waste can be reduced as it is given a second life.

Customer requirements and image

Many consumers and companies value sustainable and environmentally friendly products. The use of recycled materials can therefore help to increase customer satisfaction and improve a company's image. Companies can respond to demand by offering recycled materials and not miss out on the trend towards greater sustainability.

Overall, the use of recycled materials in the plastics sector offers several advantages that consider both ecological and economic aspects and can contribute to the creation of a more sustainable and environmentally friendly industry.

How to overcome these hurdles?

There are various starting points for overcoming the challenges described above. On the one hand, it is worth analysing your own raw materials portfolio as well as the internal possibilities for reusing production waste and the like. This is often already standard practice in most companies today, as it achieves an immediate economic effect.

Furthermore, there is a positive effect if several materials are qualified for a part to be manufactured in order to protect against the sometimes poor availability, as far as this is possible. Of course, customer requirements always play a decisive role here. However, they are naturally also interested in maintaining delivery capability. This can mean, for example, making an ABS product fit for use with an rPET.

In addition, additives and processing aids can be a game changer, such as the flow-improvers from Polytives. These also make it possible to replace ABS with rPET for rather thin-walled or more complex parts, as described above, to name just one example. Inhomogeneous qualities of recycled materials can be matched or plastics that are difficult to process because they are too tough can be made processable. This removes a major obstacle to the goal of replacing virgin material with recycled material.

Get in touch with us if you would like to exchange ideas and give it a try, we would be happy to help!