Luxus Celebrates Success As The Hycolene Commercialisation Project Completes

KAM_4746 Peter Atterby sml

Technical compounder Luxus celebrated yesterday the completion of its €1.4m Recyclite project, co-funded by the EU’s Eco-Innovation initiative, at the Brackenborough Hotel, Louth, Lincolnshire. The three year project to help commercialise its environmentally positive, advanced lightweight, scratch resistant thermoplastics range for Class ‘A’ auto interiors will come to an end later this month. (www.recyclite.eu)

Luxus along with its fellow project partners – Tier 1 moulder International Automotive Components (IAC), major auto manufacturer Jaguar Land Rover and bespoke twin screw manufacturer Coperion have helped support the development of the Hycolene™ thermoplastics range through a series of technical trials – proving the technology’s potential at full commercial scale.

Underlining the need for eco-innovation entrepreneurism in Europe on the day was guest speaker Didier Gambier, head of department, Department B – LIFE and H2020, Energy, Environment, Resources, The Executive Agency for Small and Medium Sized Enterprises, The European Commission. While Matt Croucher, environment manager, The Society of Motor Manufacturers and Traders (SMMT ) focused on the UK market with highlights from its ‘2016 New Car CO2 and Automotive Sustainability’ reports, confirming that new car emissions had hit their lowest ever levels.

Launched in 2008 the Eco-innovation initiative was part of the EU’s Entrepreneurship and Innovation Programme (EIP), set up to support innovation among SMEs and to improve their competitiveness. It helped to bridge the ‘gap’ between research and the market.

Luxus technical director, Dr Christel Croft explains, “We’re pleased that the commercial potential for Hycolene™ was recognised by the EU and our fellow project partners three years ago. This crucial investment and the dedicated industry expertise it required, has enabled us to make a fundamental step change in our technology, as we have replaced filled compounds with ‘next generation’ reinforcing additives.

“Offering excellent tensile properties these additives do not detract from the appearance of a moulded compound, yet their adoption reduces weight by up to 12 per cent per part and significantly improves scratch resistance too, satisfying stringent industry standards.

“Hycolene 16818 offers a much lower density than currently provided, while still delivering up to 60 per cent recycled content with the option for prime grades too. The result is that the material satisfies the rapid cycle times now set by OEMs and Tier 1 manufacturers whilst having significant Co2 reduction.”

Rob Crow, materials innovation manager, Jaguar Land Rover. ‘Through our involvement in the Recyclite project, Jaguar Land Rover has demonstrated first hand that Hycolene™ 16818 can meet our key structural requirements for use in Class ‘A’ interior applications, whilst delivering a significant improvement in scratch performance over conventional talc filled polypropylenes.’

Looking ahead Luxus will be developing additional Hycolene™ grades, including an even higher impact version with excellent scratch resistance and further colour options. Its capacity to produce the new compounds will be helped in the future by working in close partnership with both local and global sources to access (PP) recyclate – the same lightweight performance can be achieved too in prime grades.

Luxus managing director, Peter Atterby said: “This project has enabled us to become a true ‘Eco-innovator’, Hycolene™ produces 26 per cent less CO2 per tonne over the life cycle of the vehicle compared to virgin compounds for example. By helping to also preserve limited natural resources, we are reducing the vehicle’s carbon footprint and contributing to automakers vehicle ‘life cycle analysis’ requirements. As we inevitably move towards a future legislative regime that will include more than simply tailpipe emissions alone.

“Beyond its ‘green’ credentials, we have engineered what we believe is the next generation in performance leading polymers. Hycolene™ has exceeded expectations offering an enhanced surface finish where it matters most – in the auto cockpit and cabin.”

“Our advanced thermoplastics technology, developed for Europe’s auto interior applications is of benefit to many diverse global markets too. We’re developing an extrusion grade to bring the advantages of Hycolene™ to the heavy equipment industry, such as earth moving machinery manufacture to coaches, buses and HGVs for example.

“We’re also investigating cosmetic packaging, particularly black bottles where improved scratch resistance at the point of sale is required. We intend to incorporate a near infrared (NIR) detectable version to enable effective post-consumer recycling, as it will contain no carbon black – this is just the beginning of what Hycolene™ can achieve. Without the support however, of this EU initiative and our expert partners, we as an SME wouldn’t have been able to bring to market this innovative new compound.”

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Peter Atterby, Managing Director, Luxus

 

Hycolene™ achieves accelerated material performance requirements

26th October 2016

Advanced lightweight scratch-resistant thermoplastics (PP) range Hycolene™ engineered by Lincolnshire based technical compounder Luxus, has recently satisfied rigorous accelerated materials performance trials with Tier 1 moulder IAC*. These latest trials conclude the material validation process required for Hycolene as part of the €1.4m Eco-innovation funded Recyclite commercialisation project (www.recyclite.eu).

The aim was to provide a theoretical equivalent of real-time ‘vehicle life’ for Hycolene (grade 16818), to satisfy fellow project member, Jaguar Land Rover’s engineering standard. The materials trials followed previous positive performance, delivering high scratch-resistance; lightweight benefits and a rapid cycle time in the spring of this year.

The chosen ‘A’ class interior test component for this latest trials was a current Jaguar Land Rover instrument panel (IP), which was exposed to in market service temperatures expected for IP assemblies, for several weeks ending in June 2016. The tests were managed by IAC’s laboratory and an independent test house which compared the results against an industry standard thermoplastics grade.

Accelerated material tests were completed as auto manufacturers require all interior plastics components to be more resistant to sunlight and heat as part of an overall goal of achieving a 10 year vehicle life. Weathering requirements have also become more severe as larger, aerodynamic windshield designs for example, have increased the sunlight exposure of many vehicle interiors today.

Luxus technical director Dr Christel Croft explains the trial process: “Firstly, we took panel gap measurements both pre and post-tests to determine if there was any degree of component movement. UV resistance was also critical, with only minor fade allowed and no other colour tone change. A non-uniform colour change was unacceptable in these trials – Hycolene 16818 passed all the agreed criteria.

“Any occurrence of tackiness; grain loss; blistering; distortion; cracking; crazing; fibre deterioration; wrinkling; waviness; milking or spotting would have led to a rejection. We along with our Recyclite project partners are satisfied that Hycolene has once again exceeded expectations.”

Peter Middleton, CBU director at IAC, adds: “We are pleased that Hycolene has proved to be a fully developed and durable composite able to meet the requirements of this trial. We believe this composite now has the potential to be successful at full commercial scale for auto manufacturers that demand advanced lightweight and scratch performance in either sustainable recycle content or virgin grades for the vehicle’s life.”

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Dr-Christel-Croft-Project-Manager-LuxusDr Christel Croft, Technical Director, Luxus

For further information please visit www.recyclite.eu or www.luxus.co.uk

*International Automotive Components (IAC)

Supporting image – Dr Christel Croft, Technical Director, Luxus

Luxus Ltd        

UK leading independent technical plastics recycling and compounding company Luxus has been developing highly specified thermoplastics compounds based on prime and recycled feedstocks for over 50 years. Luxus is a key supplier to the major names in the global auto industry and it was the first and still is the only UK business to achieve approval for its recycled grades in car interior trims.

Luxus also offers specialist ‘closed loop’ and ‘open loop’ recycling services to manage ‘end of life’ post industrial and consumer waste for the retail transit packaging, construction and local authority wheel bin markets.

 

 

Hycolene proves it is up to scratch for auto interior surface pioneer RocTool

20th May 2016

Technical compounder Luxus and RocTool the ‘Heat&Cool’ technology specialists, have announced a new joint collaboration ahead of the Plastics Design and Moulding (PDM) exhibition, Telford, 14th-15th June 2016. (Luxus stand, DO10).

The Luxus Hycolene™ grade 16818 has been selected as RocTool’s preferred high performance PP resin for use with its rapid inductive heating technology. This decision followed extensive lab trials of Hycolene™ versus a standard prime material. These took place at RocTool’s French headquarters last year and subsequently at Luxus’ in-house Technical Centre in March 2016.

RocTool is a pioneer in the very latest in high gloss effects and 3D textures producing a finish that is both premium and unique to satisfy the latest ‘A’ Class surface trends. It therefore required a PP resin that could offer high scratch performance.

Terry Burton, technical manager at Luxus explains: “We found in the lab trials that when RocTool’s induction technology is turned to the higher temperatures it requires; the scratch is far more exaggerated on the resulting moulded part with the standard talc filled material compared to our Hycolene™ product.”

Calypso Beloli, material engineer at RocTool comments: “We’re really enthusiastic to obtain this kind of quality surface with PP. Scratch resistance on a moulded part has been a challenge, but with the selection of the right compound together with our induction system technology means that we can develop new markets.”

Terry Burton, continues: “We’re really pleased to be a RocTool materials partner. The great appeal of Hycolene™ is that is allows manufacturers to satisfy environmental goals thanks to its recycled content (up to 60%) without sacrificing performance – delivering a lighter, stronger and critically a high scratch-resistant finish.”

Hycolene™ is going to feature in RocTool’s future marketing to Tier 1 moulders and manufacturers for the first time through specially tailored 3D holographic High Definition Plastics™ samples later this year.

Ends

 Notes to Editors

For further information please contact: Sasha Stewart at Straight Talk PR,            tel: 07764 346 896 or email: sasha@straighttalkpr.co.uk

Luxus Ltd

UK leading independent technical plastics recycling and compounding company Luxus has been developing highly specified thermoplastics compounds based on prime and recycled feedstocks for over 50 years. Luxus is a key supplier to the major names in the global auto industry and it was the first and still is the only UK business to achieve approval for its recycled grades in car interior trims.

Luxus also offers specialist ‘closed loop’ and ‘open loop’ recycling services to manage ‘end of life’ post industrial and consumer waste for the retail transit packaging, construction and local authority wheel bin markets.

For further information please visit: www.luxus.co.uk

PP conventional and with RocTool technologies

An injected part with Luxus PP resin using RocTool technology.

 About RocTool

Created in 2000, RocTool is a Technology & Manufacturing solutions provider offering Engineering services and systems. RocTool induction process is fully adapted to plastic injection and composite molding, including multiple configurations to fit with tier manufacturers requirements. RocTool’s Research and Development team is constantly adapting the technologies to more materials including metal. As a ‘Heat and Cool’ technology leader, RocTool offers now High Definition Plastics™ capabilities to plastic moulders and Light Induction Tooling™ to composite part suppliers.

The processes developed by RocTool are used in production by major brands in innovative industries such as automotive, aerospace, consumer products and electronics. They hold many advantages including reduced cycle times, surface quality, light – weighting and performance, therefore resulting in an overall cost reduction of the produced parts for manufacturers.

RocTool is listed on the Alternext Paris stock market. Its headquarters and R&D center is situated at Le Bourget du Lac (France). RocTool also has offices and moulding platforms in North America, Japan, Taiwan and Germany.

For further information please visit: www.roctool.com

 

 

Luxus To Present Keynote Speech At Nordic Recycling Conference

5th October 2015

Luxus technical director, Dr Christel Croft has been invited to deliver a keynote speech at the opening of the Competence Centre for Recycling (CCR) Conference at Chalmers University of Technology in Gothenberg, Sweden, on the 17th-18th November 2015.

The presentation ‘lightweight recycled polypropylene for tomorrow’s automotive interiors’ from technical compounder and recycler Luxus, has been selected by the CCR’s organising committee as they believe it offers an excellent example of ‘the circular use of materials’ to share with its members.

This annual recycling conference has been developed to facilitate the co-ordination of R&D collaboration activities within the field of the ‘circular economy’. It will be attended by CCR members who include representatives from Sweden’s major auto manufacturers and academia.

Dr Christel Croft will share with the audience the aims of the Luxus commercialisation project known as Recyclite that is supporting the development of Hycolene™ – the next generation in advanced polymers with up to 60% recycled content for the rigorous class ‘A’ auto interior trim market. (www.recyclite.eu)

Commenting on the event, Dr Christel Croft, technical director at Luxus said: “I’m delighted to have the opportunity to share our progress to date on this important research project with a completely new audience – the eco-conscious Nordic automotive sector.”

Luxus announced earlier this year, that it has as part of a consortium recently secured a €1.4m investment, co-funded by the EU Eco-Innovation initiative, part of the EU’s Entrepreneurship and Innovation Programme (EIP ). Its members are injection moulding company IAC for materials trials, twin screw manufacturer Coperion for technical support and Jaguar Land Rover offering end user guidance.

If you are interested in finding our more about the CCR conference please visit: http://www.chalmers.se/sv/centrum/ccr/Sidor/default.aspx

ENDS

Technical Director, Dr Christel Croft
Technical Director, Dr Christel Croft, Luxus

 

Notes to editors

For further information please contact: Sasha Stewart, Straight Talk PR, tel: 07764 346 896 or email: sasha@straighttalkpr.co.uk

Luxus Ltd        

UK leading independent technical plastics recycling and compounding company Luxus has been developing highly specified thermoplastics compounds based on prime and recycled feedstocks for 50 years. Luxus is a key supplier to the major names in the global auto industry and it was the first and still is the only UK business to achieve approval for its recycled grades in car interior trims.

Luxus also offers specialist ‘closed loop’ and ‘open loop’ recycling services to manage ‘end of life’ post industrial and consumer waste for the retail transit packaging, construction and local authority wheel bin markets.

 

PLASTICS PIONEER LUXUS DELIVERS RECYCLITE PROJECT PRESENTATION AT AUTO INTERIORS EXPO

First time exhibitor, technical plastics compounder Luxus delivered a presentation, ‘lightweight recycled polypropylene for tomorrow’s automotive interiors’ last week at the Auto Interiors Expo based in Stuttgart. (www.automotive-interiors-expo.com).

Dr-Christel-Croft-Project-Manager-Luxus
Dr Christel Croft – Project Manager Luxus

The show has become a ‘must-visit’ for Tier 1 and Tier 2 suppliers as well as for interior design teams from automotive manufacturers wanting to keep up with the rapidly changing world of materials, finishes and technologies in the cabin.

As part of the expo’s ‘Interiors Innovation and Design Forum’, Luxus Project Manager, Dr Christel Croft shared with the audience the aims of its new commercialisation project known as Recyclite.

Dr Christel Croft, comments: “The expo has provided a great platform to showcase the Hycolene™ commercialisation project and the sustainable benefits this technology offers with Europe’s key designers, buyers and suppliers in the very home of automotive manufacturing in southern Germany – Stuttgart.”

Luxus has as part of a consortium recently secured a €1.4m investment co-funded by the EU Eco-Innovation initiative. Its members are injection moulding company IAC for materials trials, twin screw manufacturer Coperion for technical support and Jaguar Land Rover offering end user guidance.

The project will enable Luxus to make a step change in the development of its Hycolene™ range of lightweight (PP) compounds, while also encouraging its wider adoption by Europe’s automotive manufacturers.

Luxus Shows Next Generation Sustainable Thermoplastic (PP) Lightweight Materials At Auto Interiors Expo 2015

 

UK based technical compounder and recycler Luxus, will be showing on stand (A5126) the progress it’s made on the road towards delivering next generation lightweight and sustainable materials to drive tomorrow’s auto interior innovation – the result is Hycolene™ a new sustainable lightweight thermoplastic (PP) range.

Luxus has as part of a consortium recently secured €1.4m investment co-funded by the Eco-innovation initiative of the EU for its Recyclite project (www.recyclite.com). The aim is to commercialise the development of its Hycolene range of lightweight (PP) compounds with up to 60 per cent recycled content to target’s Europe’s class ‘A’ automotive interior trim market.

Luxus will be collaborating on the commercialisation project with twin screw manufacturer Coperion to help with complex processing, tier 1 moulding supplier IAC for materials trials and Jaguar Land Rover. The automotive manufacturer will be providing end user guidance on the project to ensure the technical requirements are met, allowing exploitation of this technology across future automotive industry applications.

Robert Crow, Group Leader , Materials Innovation at Jaguar Land Rover described the Recyclite project as, “A ‘double win’ because the use of recycled material and lower weight of the compounds are both beneficial in Jaguar Land Rover’s programme for reducing the environmental impact of its vehicles.”

Project Manager, Dr Christel Croft at Luxus will be presenting a seminar on the Recyclite project as part of the Interiors Innovation and Design Forum, ‘High performance lightweight recycled polypropylene materials for tomorrow’s auto interiors’ at 11.45am, on Thursday 18th June 2015 at the Auto Interiors Expo 2015.

The key technical benefits of the Hycolene range are as follows:

  • Significant weight reduction – up to 12% per part
  • Increased recycled content – up to 60% per part
  • Excellent stiffness/impact balance and improved scratch resistance
  • Similar dimensions – a drop-in solution and colour matching

Peter Atterby, Managing Director, Luxus explains: “We are pleased that the commercial potential of our Hycolene range has been recognised by the EU. This investment has enable us to effectively make a fundamental step change in our technology as we aim to replace our filled compounds with next generation reinforcing additives.

“These additives offer excellent tensile properties that don’t detract from the appearance of the moulded compound, yet their adoption reduces weight by up to 12 per cent per part and significantly improves scratch resistance to meet industry standards.

“The new grades will also offer a lower density than is currently provided, while still delivering up to 60 per cent recycled PP. The result of all this is that tier 1 moulding suppliers will be able to produce more parts per tonne of the mineral as they will benefit from a much faster cycle time. This will offset the slightly higher price these new advanced grades will require.”

Luxus is preparing a patent application for the new advanced polymer technology process. Its capacity however, to produce these compounds will be limited by access to local sources of recyclate PP. So in the future it intends to license its IP of formulations and knowledge to other selected compounders in the EU who have access source assured PP recyclate locally.

Ends

Notes to editors

For further information please contact: Sasha Stewart, Straight Talk PR, tel: 07764 346 896 or email: sasha@straighttalkpr.co.uk

 Supporting photography (Photo: http://photos.prnewswire.com/prnh/20150414/739346 )

Image description: The Jaguar XE door trim assembly, an example of where filled Polypropylenes are currently used at Jaguar Land Rover

Luxus sichert EU-Investitionen, um seine hochmoderne nachhaltige Polymertechnologie in Europa voranzutreiben

Der im Vereinigten Königreich ansässige technische Compoundeur Luxus konnte als Teil eines Konsortiums mit Jaguar Land Rover 1,4 Mio. EUR an Investitionen sichern, kofinanziert von der Initiative für Öko-Innovation der Europäischen Union. Ziel ist die Kommerzialisierung seiner Hycolene™-Reihe von leichten Polypropylen(PP)-Compounds aus mehr als 60 % recycelten Inhaltsstoffen für den europäischen Markt für Kfz-Innenausstattung – besuchen Sie http://www.recyclite.eu.
(Photo: http://photos.prnewswire.com/prnh/20150414/739346 )
Diese Investition wird das Verkaufspotenzial für Luxus’ leichte PP-Reihe beträchtlich verbessern und es der Automobilindustrie ermöglichen, ihren Einsatz von Polymeren mit recycelten Inhaltsstoffen auszubauen und so Ziele im Hinblick auf ELV (Richtlinie 2000/53/EG über Altfahrzeuge) und Schadstoffausstoß gleichermaßen zu erreichen.

Luxus arbeitet bei diesem Projekt mit dem Doppelschnecken-Hersteller Coperion zusammen, der mit komplexen Verarbeitungsprozessen helfen wird, sowie mit Formteilanbieter IAC zur Durchführung von Materialversuchen und mit Jaguar Land Rover. Der Autohersteller wird Nutzerführung bereitstellen, um sicherzugehen, dass sämtliche technische Anforderungen erfüllt werden und ein Einsatz dieser Technologie in künftigen Anwendungen möglich sein wird.

Seit Januar 2015 ist die europäische Automobilindustrie dazu verpflichtet, 85 % des Fahrzeuggewichts wiederzuverwerten oder zu recyceln. Gleichzeitig wachsen die Leistungsanforderungen an die Fahrzeuginnenausstattung kontinuierlich. Verbesserte Kratzfestigkeit für hochwertige Oberflächen, größere Steife und ein geringeres Gewicht pro Teil sind Kriterien, die zunehmend gefragt sind.

Dr. Christel Croft, Projektmanagerin bei Luxus, erklärte: “Wir freuen uns sehr, dass die EU das kommerzielle Potenzial unserer Hycolene-Reihe erkannt hat. Diese Investition wird uns einen effektiven Tempowechsel für unsere Technologie ermöglichen; wir haben vor, unsere gefüllten Compounds durch Verstärkeradditive der nächsten Generation zu ersetzen.
Diese Additive bieten hervorragende Zugeigenschaften, die nicht zu Lasten des Erscheinungsbildes der Formteile gehen. Gleichzeitig reduziert ihre Einführung das Gewicht um bis zu 12 % pro Teil und verbessert die Kratzfestigkeit erheblich, wodurch die Einhaltung von Branchenstandards gewährleistet wird.

Eine mögliche Hürde für Luxus bestand bislang darin, seine Hycolene-Sorten mit der vorhandenen Infrastruktur aufzustocken. Infolge der neuen Investition konnte das Unternehmen einen neuen gleichlaufenden Doppelschnecken-Extruder erwerben, um die für dieses Projekt erforderlichen Materialeigenschaften zu optimieren und zur selben Zeit sicherzustellen, dass die erwartete Tonnage erreicht wird.

Wenn die volle Kapazität erreicht ist, rechnet Luxus mit einem Zuwachs von zwei Prozent am EU-Markt für Innenausstattung bis 2016.

SOURCE Luxus Limited