Color precision meets high performance
 
    

Blankenhain/ Kirn – SIMONA AG and GRAFE Polymer Solutions GmbH are linked by a successful and lasting partnership that is reflected in the implementation of many challenging projects in the public transportation sector and other areas.

GRAFE not only brings in-depth expertise in plastic finishing and coloring to this collaboration, but also positions itself as a technological driving force for the coloring of sophisticated plastic applications: The focus of this project with SIMONA AG is the development of technically high-performance, visually convincing and sustainable solutions. These range from precisely colored, flame-retardant polycarbonate sheets for thermoformed components in bus and rail projects to customer-specific material concepts for complex mobility applications.

GRAFE’s color expertise goes far beyond mere coloring: As a specialist in the coloring of plastics, GRAFE advises on color effects, stylish texture design and sophisticated surface aesthetics, from the initial idea to process-reliable implementation. The color granules are created in tailor-made formulations that meet the highest quality and safety requirements and are aesthetically pleasing at the same time.

Strictest safety standards: Certification in accordance with EN 45545-2

Compliance with the European fire safety standard EN 45545-2, which regulates the fire behavior of materials and components in rail vehicles, was a key criterion in the joint application projects. The standard defines specific requirements with regard to flame propagation, smoke development and toxicity, with the aim of ensuring maximum safety for passengers and staff in the event of a fire.

Meeting the hazard levels (Hazard Levels 1-3) posed a particular challenge. The classifications are intended for applications where there are high risks in the event of an emergency, such as in tunnels or densely frequented urban areas. According to this standard, materials must be self-extinguishing, low-smoke and toxicologically harmless.

With SIMORAIL sheets for thermoformed components in customer-specific formats, SIMONA provides , which meet precisely these stringent requirements. This not only provides the technical basis for a certified solution, but also a reliable and sustainable choice of material that is characterized by excellent processing properties and high mechanical strength.

These properties have also been decisive in the realization of two pioneering projects: the interior fittings for an all-electric metro bus system in Brisbane and the development of large-scale components for the new generation of streetcars in Europe. In both cases, the complex task of adapting the color of the flame-retardant polycarbonate material precisely to the specifications of the fire protection standard and the thermoforming properties was undertaken. The areas of application of the components are also very different: from armrests and window panels to large components of ceiling elements and entire partition walls, the requirements are placed on the thermoformed components.

Technical challenges in the coloring of PC – GRAFE provides the solution

The coloring of engineering plastics, such as in this case flame-retardant polycarbonate, is one of the most challenging tasks in masterbatch development. SIMORAIL from SIMONA has an intense inherent color, which makes the exact color definition of light or neutral shades in the end product particularly challenging. In addition, the materials must fully meet all safety and mechanical requirements even when colored.

GRAFE integrates its comprehensive color and material expertise – from pigment selection and the development of tailor-made masterbatches to process-safe implementation during processing. The visual requirements of those responsible for the design as well as the functional requirements of fire protection, UV resistance, thermal and mechanical resilience and surface structure must be taken into account.

Specifically, GRAFE developed two color variants for these special projects, which were precisely matched to the respective requirements: a deep, technical anthracite grey and a clear, modern light blue. The challenge was to ensure that both colors could be precisely reproduced visually on the respective surfaces – despite the intense inherent color of the raw material.

“Coloring PC with high flame retardancy is a challenge, especially in combination with textured surfaces. The material only has a low tolerance for deviations in color stability. Colors often show a stronger color effect on grained surfaces and appear inconsistent. Precise coordination of pigmentation and material viscosity is always required to ensure a harmonious appearance in the visible area – and that across large thermoformed component surfaces. For this reason, it was crucial to maintain close cooperation with SIMONA at every stage of the project,” explains Team Leader D-A-CH, Steffen Schubert, adding: “The aim of these projects was to harmonize technical excellence and visual quality. The close collaboration between SIMONA and GRAFE led to a tangible result: perfectly coordinated design and functional components that are now installed in the interiors of two innovative mobility projects worldwide.”

The project partnership between SIMONA and GRAFE demonstrates how innovative materials and color technology expertise can be combined to create sustainable solutions for the mobility of tomorrow. Together, the project partners are setting new standards in the design of interior components in public transport. Whether in the interior cladding of an all-electric metro bus system or in the new generation of modern streetcars: The result is a future-proof overall concept that is technically efficient, visually convincing and precisely tailored to the requirements of public transport.

SIMONA – Global Thermoplastic Solutions 

SIMONA AG is one of the leading manufacturers and development partners for thermoplastic products with international production and sales locations. The product range includes semi-finished plastics (sheets, rods, profiles, welding rods), pipes and fittings. SIMONA employs over 1.880 people worldwide. 35.000 items are manufactured in Germany and abroad, offering optimum solutions for a wide range of applications in industry, infrastructure, mobility, construction, advertising and aquaculture. SIMONA AG is listed in the General Standard. The company is headquartered in Kirn, Rhineland-Palatinate. Further information can be found at www.simona.de. Information on our sustainability goals and measures can be found at https://sustainability.simona.de/