R&D Thermoformer Tek Pak Takes Concepts to Production-Ready Parts in Record Time
54 How to Make World-Class Stretch Film 62
Get Your Robot Sized Right
66 Three Components Critical to Feeder Performance
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OCTOBER 2015
No- 10
VOL 61
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VOLUME 61 • NUMBER 10
On-Site R&D Thermoformer: Tek Pak Is Launch Pad For New Products Toolmaker and thermoformer takes concepts to production-ready parts in record time. By Matthew H. Naitove, Executive Editor
4 FROM THE EDITOR 8 STARTING UP
CLOSE-UP 14 Injection Molding 20 Predictive Maintenance 24 Sustainability
KNOW HOW
46
28 Materials
Tips and Techniques
54
Here’s What You Need to Know To Make World-Class Stretch Film Advances in materials, feedblock/die technologies, and winding can help processors develop more sophisticated cast-stretch products. By Trudy Iaccino, ExxonMobil Chemical Co. Peter F. Cloeren, Cloeren Incorporated Dr. Frank Hoffmann, Windmoeller & Hoelscher
34 Injection Molding 38 Extrusion 42 Tooling
KEEPING UP WITH TECHNOLOGY 70 Injection Molding 72 Extrusion 72 Compounding
Tips and Techniques
62
Spec’ing a Robot? Match It To Your Press Size & Project Where is your business today? What might tomorrow’s molding projects look like? These are among the questions you need to answer when deciding what style robot is best for you. By Jason Long, Wittmann Battenfeld USA
72 Thermoforming 72 Feeding 74 Material Handling 74 Testing/Measuring 74 Size Reduction 75 Materials 78 Tooling
Tips and Techniques
66
To Improve Feeder Performance, Start by Understanding Three Key Components These are the screw trough, agitator, and the screw itself. It’s crucial to understand the diferent types and the advantages/disadvantages of each. By Walt Folkl & Andy Kovats, Brabender Technologie Inc.
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YOUR BUSINESS 79 Resin Pricing Analysis 81 Processors’ Business Index 82 Market Watch 83 Marketplace 88 Processor’s Edge
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Busted! This company’s QA program AND reputation Like Humpty Dumpty, it is hard to put the pieces back together once a real world product quality disaster strikes. The ultimate cost of a recall will be far, far greater than any savings from cutting corners or not investing in a quality assurance program in the first place. With our broad spectrum of physical testing machines, software, and technical support, Tinius Olsen can help you assure quality from material to end product. To international standards and your toughest specifications. Reputations (yours and ours) depend on it.
@plastechmag
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From The Editor
Don’t Waste Any More Time: Register Now for the Extrusion 2015 Conference Don’t miss out on the technical event of the year in extrusion. The clock is ticking and seats (and hotel rooms) are flling up. Have you checked out Plastics Technology’s upcoming Extrusion 2015 Conference? If not, do it now (a twopage advertisement on p. 32-33 of this issue will give you the skinny). It’s going to be held Nov. 2-3 in Charlotte, N.C., at the Omni Charlotte Hotel in the downtown section of the city. This two-day event is packed with presentations from more than 60 technical experts, covering a wide range of Jim Callari Editorial Director
Source: Davis-Standard
subject areas. The morning sessions on each day will include presentations on general extrusion topics. During each
afternoon there will be three concurrent breakout sessions that hone in on your particular process: flm/sheet; pipe/profle/
Source: Davis-Standard
tubing; and compounding. If you extrude sheet or flm, these two afternoon sessions
conveying systems, new developments in fltration and melt-pump
will give you the opportunity to learn more about best practices
technologies, how to make more efcient use of reclaim, new
in winding, drying, purging, product changeovers, and trouble-
approaches to foaming, and more.
shooting nettlesome issues such as gels and black specs, as well as new developments in no-dry systems for PET, and much more. If you extrude pipe, profle or tubing, these two afternoon
In addition to the technical program, there will be ample opportunity for you to mingle with the more than 40 companies that will be exhibiting at this event.
sessions are an opportunity to learn more about best practices
You can log on to PTonline.com to download a copy of the entire
in quick changeovers, drying, downstream systems for sizing,
program, see a list of all of the companies that are exhibiting, learn
pulling and
Don’t sleep in, because there is plenty on the agenda each morning for you.
cutting,
about pricing details, and register. In terms of accommodations, once again it’s best to act
and even
quickly. The Omni is the show hotel, but has sold out. As a result,
“direct”
we have negotiated a similar discounted rate with the Aloft
extrusion
Charlotte, which is nearby.
technology that combines compounding with pipe processing. And if you’re involved in compounding you’ll have access to presentations on running flled compounds, conveying dusty
We at Plastics Technology believe the Extrusion 2015 Conference is the event of the year for extrusion processors of all kinds. Don’t miss it. We hope to see you there.
materials like TiO2, new developments in pelletizing, breakthroughs in single-screw compounding, plus troubleshooting tips on venting, dust removal, and a range of other topics. But don’t sleep in, because there is plenty on the agenda
FOLLOW US @plastechmag
each morning for you, too: screw-design basics, troubleshooting 4
Plastics Technology
OCTOBER 2015
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T ECHNOLOG Y A ND INDUS T RY NE W S
Star ting Up
Trexel Adds Chemical Foaming Agent to Its Product Line Trexel, Inc., Wilmington, Mass., a long-time proponent
with MuCell) and 30-35% in accumulator blow molding.
of physical foaming with its MuCell direct gas-injection
TecoCell reacts at 200-280 C (392-536 F), suiting it mainly
process, has now added chemical foaming to its micro-
to PE and PP, whereas MuCell is also used with higher-
cellular technology portfolio. Trexel has partnered with
temperature engineering resins. TecoCell also works well
masterbatch producer Polyfl Corp., Rockaway, N.J., which
with unflled resins, whereas MuCell is generally used with
has offered EcoCell
flled or reinforced
blowing-agent
materials.
concentrates since
Trexel says MuCell
2009. Polyfl’s
and TecoCell are
patented technology
complimentary
uses 0.08-micron
rather than compet-
nanoparticles of
ing technologies.
calcium carbonate
TecoCell requires
in an endothermic
no equipment
reaction that yields
modifcation, unlike
only carbon dioxide,
MuCell, which needs
water, and citric
a modifed screw
salts, whereas most
and barrel. That
endothermic chemi-
gives TecoCell an
cal foaming agents
economic advantage
(CFAs) reportedly also produce soda
for low-volume jobs
TecoCell in PP
using unflled or
ash, which can cause plateout and corrosion. Besides being
talc-flled PE and PP. But once the equipment investment
a “cleaner” reaction, EcoCell is said to produce smaller cell
for MuCell is made, the ongoing costs of MuCell nitrogen
sizes and more uniform cell distribution. Trexel describes it
injection are lower—typically less than 1¢/part vs. 3-9¢/lb
as a microcellular cell structure of 20-80 microns.
added cost for 1-3% use levels of TecoCell. Because nitro-
While Polyfl will contine to market its EcoCell CFA
gen is a more effcient foaming agent than CO2, MuCell
for extrusion, Trexel will now offer it under the TecoCell
will generally produce higher foaming levels and density
name for injection molding and automotive blow molding
reduction, according to Trexel. MuCell is also said to be
of products like ducts. Weight reductions with TecoCell
superior in reducing warpage, but TecoCell may produce
are typically 7-10% in injection molding (compared with
better surface fnish—although not Class A.
more than 20% density reductions commonly achieved
(800) 733-2946 • trexel.com; (866) 765-9345 • polyflcorp.com
Purging Compound Developed For FDM 3D Printers In collaboration with 3Dom USA, Fargo, N.D., Schuman Plastics’ Dyna-Purge Div., Depew, N.Y., has introduced a new grade of non-abrasive, non-chemical, FDA-compliant thermoplastic purging compound specially formulated for FDM (Fused Deposition Modeling) 3D printers. FDM printers extrude a fne thread of
8
Plastics Technology
OCTOBER 2015
molten plastic, which is deposited in layers to build up a part. Dyna-Purge 3D Clean is suited to 3D printing applications that require multiple color and resin changes. The new compound is designed to purge all resins used in 3D printing. It is reportedly easy to use before or after printing a
part, for color or resin changes (especially involving composite materials such as glass-flled nylons), and for preventive machine maintenance. It has a wide processing-temperature range, from 320 to 575 F. It comes in 8-in.-long strands of 1.75- or 2.85-mm diam. (716) 685-2121 • dynapurge.com
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T ECHNOLOG Y A ND INDUS T RY NE W S
Star ting Up
RTP Offers Tribology Data for Medical Material Selection An innovative friction test that predicts sliding behavior in plastic singleuse drug-delivery devices has been developed by RTP Company, Winona, Minn. Molders, designers, and OEMs are keenly aware of how stick-slip phenomena, or “stiction,” can affect the performance of devices such as auto-injectors, injection pens, stop cocks, and safety syringes. Until recently, RTP says, there were no established industry tests that accurately predicted friction behavior (tribology) in such devices, making material selection diffcult. Using the new test method, RTP characterized the tribology of PC, acetal, ABS, PC/ABS, HDPE, and PBT. These resins were tested in a variety of combinations with friction-reducing additives including PTFE, PFPE (perfuoropoly-
ether) oil, and a selection of silicones, along with RTP’s own All Polymeric Wear Alloy (APWA Plus). RTP measured the static and dynamic coeffcients of friction of various combinations of resins and friction-reducing additives. The threshold representing the smallest delta between the two measurements has been dubbed by RTP tribologists the “Glide Factor.” Tests showed that the optimal friction pairings exhibited low static coeffcient of friction (≤ 0.15) and a Glide Factor of ≤ 0.015. RTP is making data from these tests available to help choose the correct low-friction thermoplastics for medical applications so that single-use devices will perform more consistently without the need for external lubrication. (507) 454-6900 • rtpcompany.com
BOPP Tailored for Thermoforming IML A new flm designed specifcally for in-mold labeling in thermoforming is said to deliver a look and feel comparable to injection molded products. Developed by Treofan in Raunheim, Germany (treofan.com), the flm is a biaxially oriented polypropylene (BOPP) with a special surface layer that enables the thermoformed part and label flm to fuse together at comparatively low temperatures and pressures. Before this flm innovation, BOPP could only be attached to thermoformed containers in a separate step, says Joachim Jung, product and business development manager. The surface of the new Treofan EPT flm utilizes an undisclosed PP coextrusion. Treofan commercialized the flm following a comprehensive series of tests with Illig, the thermoforming machinery maker. Unlike the paper and cardboard labels commonly used in thermoforming, this BOPP can decorate the container on all fve sides (all four lateral areas plus the bottom).
Trex Launches Recycled LLDPE Compounds Trex Company, Winchester, Va., maker of wood-plastic composite decking and railing and one of the largest recyclers of post-consumer and post-industrial polyethylene, has begun selling recycled plastics compounds. The company is using its excess recycled raw material to produce LLDPE pellets as a new business venture. Says Dave Heglas, sr. dir. of material resources, “We envision numerous applications for our recycled pellets,” such as trash bags and other bags, as well as molded products such as bins, totes, and even kayaks. He also sees considerable potential in the manufacture of both rigid and fexible tubing, such as agricultural drip tape. Trex already has four lines dedicated to recycled pellet production, making it one of the country’s largest producers of recycled LLDPE, and has plans to add several more lines. (800) 289-8739 • trex.com 10
Plastics Technology
OCTOBER 2015
High-Moisture-Barrier HDPE Gains In Flexible Food Packaging A bimodal homopolymer HDPE that features up to 50% higher moisture barrier than standard resins has gained signifcant ground as a barrier layer in multilayer fexible food packaging, particularly in easy-open cereal and cracker packages. Surpass HPs167-AB, a 1.2 MI, 0.966 g/cc resin for blown flm from Nova Chemicals, Moon Township, Pa., is one of the high-barrier materials made with Nova’s Advanced Sclairtech dual-reactor process and single-site catalyst. Referred to as sHDPE, HPs167-AB material has seen signifcant growth in commercial packaging applications in the last two years. Typical dry-goods packages are threelayer coextruded blown flms with a peelable seal layer and an HDPE core layer. According to Dan Falla, Nova technicalservice specialist, the thickness of the HDPE typically determines the moisturevapor transmission rate (MVTR) of the
flm. “Traditionally, the HDPE layer was conventional HDPE. The HPs167-AB resin is quickly becoming the resin of choice for a PE moisture barrier.” In many cases, it is desirable to use the sHDPE together with EVOH, as the sHDPE protects the EVOH from having its barrier properties weakened by moisture. Falla says the sHDPE is stiffer than typical HDPEs for multilayer packaging flms, so it enables downgauging without making the flm too soft to run easily through vertical form/fll/seal machines. His fndings are contained in a paper, “Sealable Seal Films with Enhanced Moisture Barrier Properties for Flexible Packaging Applications,” presented at the SPE ANTEC in Orlando in March. (412) 490-4000 • novachem.com PTonline.com
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T ECHNOLOG Y A ND INDUS T RY NE W S
Star ting Up
Davis-Standard Buys Gloucester Engineering Davis-Standard LLC, Pawcatuck, Conn., recently announced it had purchased Gloucester Engineering, Gloucester, Mass., from investment frm Blue Wolf Capital. Until the early 1990s, Gloucester was perhaps most recognized as a supplier of machinery for commodity flm and bagmaking. It then evolved into supplying more sophisticated lines for coextruded barrier systems, at one point dominating that market. It then became a major supplier of high-tech lines for cast stretch flm as well. More recently, Gloucester has narrowed its focus to blown flm, mainly on aftermarket services. To support this strategy, in 2012 it purchased Pearl Technologies, Savannah, N.Y., which makes sizing cages, collapsing canopies, and other products for blown flm and bagmaking; and Future Design, Mississauga, Ont., which specializes in air rings. “We’re excited about combining the strengths and market reach of Davis-Standard and Gloucester,” says Jim Murphy, D-S president and CEO. “Gloucester has always been a strong company, so bringing their technology and engineering expertise to our operation is signifcant for our combined
THE KEY TO YOUR PROCESS COOLING NEEDS
customer base. It also supports our ongoing goal of continuing to provide equipment and service that improves process effciency and proftability.” Murphy adds, “The acquisition includes all of their designs and technology: blown flm, cast flm, sheet, and foam sheet—all areas where Gloucester Engineering has had a market presence over the last several decades. We will be incorporating these into the Davis-Standard product lines and focus Gloucester primarily on its strongest area of blown flm. We will continue to support the installed base of all Gloucester Engineering equipment.” States Carl Johnson, Gloucester’s v.p. of sales, “The alignment of our companies leverages our sizable base of installed equipment with the industry’s best resources for sales, engineering, and service. Both companies have a reputation for strong people and strong brands.” Johnson referred to the D-SGloucester combination as a “game changer in the global blown flm market.” (860) 599-1010 • davis-standard.com
T ECHNOLOG Y A ND INDUS T RY NE W S
Chinese TPE Compounder Reshores To Chicago Area Here’s an interesting and novel spin on reshoring: A brandnew TPE compounder in the Midwest has been launched by a Chinese-born U.S. citizen who already was running a successful compounding operation in his ancestral homeland. PolymaxTPE began production in the U.S. in February from a 42,000 ft² facility in Waukegan, Ill. The company currently has capacity for 9 million lb/yr of TPEs on a twin-screw extrusion system from Leistritz, Somerville, N.J., with an underwater pelletizer from Gala Industries, Eagle Rock, Va. The plant also has a pilot line for testing and small production runs, as well as a fully equipped laboratory. PolymaxTPE was co-founded by Dr. Martin Lu. Born in China, Dr. Lu graduated from Stevens Institute of Technology in Hoboken, N.J., obtained his MBA from the University of Chicago, gained his U.S. citizenship, and married and started a family in the Chicago area. About 10 years ago, after serving as director of development and production for Xerox, Lu cofounded Nantong Polymax Elastomer Technology Co., Ltd. in China. It has about 25 million lb/yr of TPE capacity and ranks among the largest Chinese TPE suppliers. It has also been designated the TPE Research and Development Center for Jiangsu Province. The two sister companies operate independently. Nantong Polymax serves the Asian market, including some processors that are satellites of U.S. operations. PolymaxTPE will focus
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on North America, the world’s second largest market for TPEs. Lu says, “Polymax now can provide the same premium quality products and services, with the added value of shorter delivery lead time and better cost control for our customers from the two continents.” PolymaxTPE makes a broad range of TPE products for consumer, packaging, automotive, healthcare, and electronics uses. The company specializes in providing FDA-grade, “sensoryneutral” materials that have low odor and low extractables. One niche is liner flm for caps and closures, where Lu says the material offers low compression set for good sealing and can replace TPVs. Polymax TPEs are also said to offer a unique combination of exceptionally low gel content, outstanding organoleptics, and easy processing in thin-flm packaging. Polymax products were distributed since 2010 by APS Elastomers, Romulus, Mich. (847) 316-9900 • polymaxtpe.com
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INJ EC T I O N M O L D IN G
Close-Up On Technolog y
New Sensor Technology Monitors State of the Melt During Molding Detect ‘true’ melt temperature, viscosity variations, melt density, and much more, throughout the molding cycle. “Injection press controls today measure parameters like the
Durina is president of Md
forward speed of the screw or plunger, the pressure applied, the
Plastics Inc., Columbiana, Ohio,
torque to run the screw, percentage ‘on’ time of the heater bands,
a frm that makes plasticating
By Matt Naitove Executive Editor
and so forth. Those are all machine variables.
components for injection
What they don’t measure is the state of the
molding (mdplastics.com). He
plastic itself.” According to Michael F. Durina,
is the exclusive manufac-
At last, a solution to ‘the mystery of melt temperature’ in an injection machine.
that’s the key factor limiting molders’ ability to know in real time
turer and marketer of sensors invented by Fred Buja, owner of
whether they are producing good or bad parts. It would be much
FJB PlasTechnology, Rochester, N.Y. The sensors, trade named
more useful, in his view, to measure such factors as the melt
Temp-Tek, frst appeared at NPE 2012. Since then, Durina has been
temperature, viscosity, melt density, and total energy input to
working with Buja (formerly of Eastman Kodak) and a number of
the melt during each cycle. The good news, Durina says, is that
molders and machinery OEMs to develop the technology for prac-
technology has arrived to do just that.
tical use. Md Plastics developed improved mounting hardware for the sensors and has just released new monitoring software designed to make them easy to use.
SENSING TOTAL ENERGY INPUT The business end of this patented “thermoelastic”
(Mold Filled) Pack/Hold Starts
sensor is a spherical bead of two metals, one magnetic and one nonmagnetic, that expands and con-
Cooling
A Setting Filling
tracts under the infuence of both temperature and pressure. According to Buja, the key principles are that a temperature increase causes a volume increase in the sensor bead, while a pressure increase on the
Screw Rotate
bead decreases its volume, which raises its internal temperature (pressure x volume = temperature).
Screw Idle
Temperature
Durina demonstrates the sensor’s behavior in a video on the frm’s website, in which he inserts a sensor through a puncture in a tennis ball. When he squeezes the ball, the sensor readings rise. Likewise,
One example of a molding cycle recorded by a Temp-Tek nozzle sensor. The area under the curve for Pf calculation is variable by the user. The Te peak indicates when the mold is totally flled. The low point marked “Temperature” is where the screw is idle and the reading corresponds most closely to “pure” melt temperature, without the effect of pressure on the sensor.
QUESTIONS ABOUT INJECTION MOLDING?
he says, a sensor simply lying in the open on a desktop will record a change in reading if the atmospheric pressure changes. The thermoelastic strain on the sensor bead from both temperature and pressure is converted to a temperature output reading, though it should more properly be interpreted as a dimensionless unit of total energy input from both heat and pressure. Durina notes that under conditions in which the melt is under little or no pressure—such as
Visit the Injection Molding Zone 14
Plastics Technology
OCTOBER 2015
at the end of holding pressure before screw recovery
starts—the PTonline.com
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INJ EC T I O N M O L D IN G
Close-Up On Technolog y
reading correlates most closely
much more than melt tempera-
with just melt temperature.
ture. It can measure the total amount of “work” (energy input)
That was the experience of Wayne Staupe, Technology
imparted by the machine to
Center manager at Evco
the melt throughout the whole
Plastics in De Forest, Wis.
molding cycle. Durina reports
His group tested one of the
that a study at Tech Molded
sensors in the nozzle of a
Plastics in Meadville, Pa., showed
machine and compared the
that the shape of the “total work”
sensor readings at the end
curve from the Temp-Tek sensor
of holding pressure—where,
over the course of a cycle very closely matched that of the
Staupe saw that sensor Once a mold is producing good parts, the user can press the “Template” button to store that thermal energy curve as a quality standard. Users can also set tolerance bands around key points on the curve
output stabilized before screw recovery—and found they were consistently at the center of the range of manual
relative-viscosity output from an RJG eDart system, which calculated “efective viscosity” for the same cycle from injection speed, pressure, and screw diameter.
readings from a temperature probe in a purged shot taken by a group of technicians. “It was
(RJG Inc. is in Traverse City, Mich., rjginc.com). With appropriate
pretty darn good,” Staupe concluded.
scaling, the two curves can be overlaid almost exactly.
SOLVE THE ‘MYSTERY’ OF MELT TEMPERATURE
a Temp-Tek nozzle sensor as an in-process quality check to detect
Staupe would be the frst to agree that there has been no econom-
viscosity changes that would occur if there were a change in the blend
ical way to accurately measure melt temperature in the injection
ratio of long-glass compound and unreinforced pellets being fed to a
barrel or nozzle. A conventional sensor embedded in either loca-
4000-ton press. Otherwise, parts could be produced with insufcient
tion would be infuenced by the surrounding steel temperature,
strength but no visible signs of the change in reinforcement loading.
and a sensor projecting into the melt stream would be too suscep-
Dennis Quinby, injection molding process engineering supervisor,
tible to wear or damage. Durina adds that conventional thermo-
says the Temp-Tek sensor “works well and is very cost-efective for
couples are relatively slow to react. (A newly available, fush-
what we’re trying to do.” He is also exploring the potential of the
mounted infrared sensor is another alternative that may ofer
sensor to indicate screw wear through a change in the thermal profle.
Draexlmaier Automotive of America in Duncan, S.C., is using
fewer limitations—see Keeping Up section.) “The only practical way to measure melt temperature today is by manually sticking a probe into a purge,” says Staupe. “That’s too
the sensors in the nozzle, mold vents, and hot-runner manifold
inaccurate because it’s subject to a large number of measurement
on the same machine. And, like other molders interviewed for this
variables.”
Detect changes in melt viscosity or signs of screw/barrel wear.
Durina thinks the
article, the thermal sensor is being used together with cavity-pressure sensors. A senior molding manager at the company, who has
Temp-Tek sensor can fnally
30 years of experience and is a certifed expert in Scientifc Molding,
“solve the mystery of melt
says the combined use of diferent sensors is enabling advances in
temperature.” Staupe agrees:
process monitoring: “We’re doing things no one else has done,” he
“It’s the best thing I’ve seen for
says, though he could not go into much detail. He did say, however,
measuring melt temperature inline.” Evco has just purchased two
that the Temp-Tek sensors provided an unprecedented capability
more Temp-Tek sensors for evaluation at the tech center.
for “dynamic” thermal monitoring: “We can see things happen over
The stainless-steel-bodied sensor is typically mounted in a 1.5 mm (0.063 in.) diam. hole in the injection nozzle. Md Plastics devel-
every phase of the cycle.” Durina says the sensor can be used to detect changes in the
oped a compression ftting for the sensor with a PTFE thermal barrier.
process caused by screw/barrel wear or batch-to-batch variations in
It screws into the mounting hole and withstands high internal barrel
resin quality or moisture content. Durina’s new PC software makes
pressures. The sensor is mounted tangent to the melt stream, with
it easy to use the shape of the total-energy curve and the area under
only the very tip directly exposed to the melt, and is covered by a flm
the curve as QC tools. The software can run on a standard laptop.
of melt thinner than a human hair, which protects the sensor from
It takes signals from a module into which up to 16 sensors can be
abrasion by the melt stream, fllers, etc.
plugged, along with a 24V signal from the press at the start of injec-
According to Durina and Buja, the Temp-Tek sensor can reveal 16
Another molder, which did not wish to be identifed, has been using 16 Temp-Tek sensors in extensive development work. It uses
Plastics Technology
OCTOBER 2015
tion. For startup of a new mold, the user would run until a good PTonline.com
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Close-Up On Technolog y
shot is produced consistently, and then hit a button marked “Create
He also notes that an advantage of Temp-Tek sensors over
Template.” This stores a sensor output curve for a good shot based on
conventional in-mold sensors is that they can be placed anywhere
75 readings/sec. (Higher sample rates can be provided as an option.)
in the tool—at the parting line or even inside a slide or a pin. A
After running several good shots, the user can go to the new
lower-cost solution, uniquely available with Temp-Tek sensors, is
software’s Statistics page and examine the minimum, maximum,
that they can be located in the vents with little or no mold modif-
and average values for two key parameters—the maximum point
cation. There, they can measure the temperature of the vent gases
in the cycle curve (Te) and the Power Factor (Pf), or area under the
on each shot as a proxy for melt temperature.
curve. The user can then set
The new sensor can be placed anywhere in the mold—in a vent at the parting line or even inside a slide or a pin.
Md Plastics has sold more than 20 sensors so far to a small
alarm limits for those factors,
handful of molders. Nozzle sensors cost about $379 apiece, and
but knowing where those
in-mold sensors under $300. Modules that send data to a PC come
limits should be set requires
with capacity to plug in up to 16 sensors. Price is under $7000 for
empirical data on how much
the module plus one nozzle sensor and monitoring software.
variation in those values will
Md Plastics also recently signed its frst license with a machinery
produce a bad shot. Durina
OEM to integrate its Temp-Tek monitoring software with the injec-
says the Temp-Tek output
tion press controls. PASL Windtech (P) Ltd. in Ahmedabad, India,
curves can show the instantaneous results on total energy input of
recently introduced its HM Series of servo toggle and hydromechanical
changes in backpressure, barrel temperature, screw speed, injec-
presses from 160 to 880 tons (pwsl.in). According to managing director
tion velocity, and melt decompression.
Abhishek Javeri, the Temp-Tek sensor is “something that has not been
In complex, multicavity molds, Durina recommends putting a
ofered before in the ability to measure actual melt temperature at the
sensor in both the nozzle and in the last cavity to fll, which can be
nozzle. We hope to ofer customers the ability to develop a thermal
established via short shots. Sensor output gives an indication of melt
template for a good part and then compare each subsequent part
density in the cavity, which Durina says is “the best variable that can
to know if it is good or bad. We hope to ofer the nozzle sensor and
be used to determine injection-pressure transfer from pack to hold.”
control software as a standard feature across our machine range.”
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PREDIC PREDICTTIV IVEE M MAAINT INTEN ENAANCE NCE
Close-Up Close-Up On On Technolog Technologyy
‘Wearable’ Machine Sensors Extended to Power Factor & Retrofts As is often the case with a new technology, customers are dictating how predictive-maintenance sensors will be applied and where they might be headed next. Shown at NPE2015 for the frst time, new technology that uses wireless Cloud-computing sensors to analyze and predict equipment failure garnered an overwhelming, and at times, surprising, By Tony Deligio Senior Editor
response (see February and May Close Ups). In short, almost everyone who sat through the demo of new predictive-maintenance technology at
Novatec’s booth was interested, but not everyone was as keen to purchase new auxiliary equipment to avail themselves of it. “We had so many people at our booth who said, ‘Well gee, I have all these problems you’re describing, but what can I do about them?’” says Conrad Bessemer, president of Baltimore-based Novatec (novatec.com). “‘You can’t help me other than I’m going to have to replace all my equipment.’” To support processors interested in the technology but who might not be in the market for all-new auxiliaries, Novatec and its partner on the project, Prophecy Sensorlytics, Columbia, Md. (prophecysensorlytics.com), have developed a retrofttable product that can be added to machinery already in the feld, including non-Novatec products. Novatec says the new ESP Sensorlytics will detect specifc issues that are typical with vacuum pumps, including problems like worn bearings, which can cause a heaving friction and lead to overheating of the motor, as well as poor oil viscosity or unsafe
Prophecy sensors can be installed on any type of industrial equipment to determine overall power factor as well as sag, surge, swallow, and crest factor, so defciencies can be identifed and corrected.
pump operation. The so-called Pump Lite does this in the same
“Our focus is really on power, air, and water, which are what drive or complement most machinery.”
manner as the original Prophecy tech-
testing, the new ESP Sensorlytics will apply a Cloud-based “deep
nology being deployed on new Novatec
learning” technique to understand the physics of the maintenance
equipment: by detecting anomalies in
condition automatically. The software will also have a feld-learning
vibration and magnetic feld.
mode in which a user will be able to set the maintenance gauge
Where it will difer from the tech-
according to his/her best experience. In the self-learning mode,
nology shown at NPE2015 is the use of
Novatec said the system tries to ft data with physics of a known
what the company calls self-learning
anomaly; while in the reinforced-learning mode, a user trains the
and reinforced learning. At its R&D lab,
system on what to show on the Predictive Maintenance Gauge.
Novatec has studied its own pumps and dryers, learning about their failure
20
Novatec notes that an ESP Sensorlytics beta version will be available around November or December for selected customers.
modes and feeding that information into Prophecy’s algorithm so
The company’s ESP Sensorlytics Plus, which is a full pump predic-
that it knows what a low-oil vibration feels like, for instance.
tive-maintenance system will be available on the new Novatec
To provide the same predictive maintenance for equipment
Silencer and VPDB positive-displacement vacuum pumps. With
made by other OEMs, which has not been put through the same
ESP Sensorlytics Plus, users can check flter condition, oil level,
Plastics Technology
OCTOBER 2015
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PREDIC T IV E M A INT EN A NCE
Close-Up On Technolog y
and belt tension in addition to bearing condition, oil viscosity,
POWER, AIR AND WATER
and unsafe operation.
In the course of developing Prophecy, and in the time since its
Prophecy Sensorlytics likes to refer to its technology as
launch, Novatec and Sensorlytics have honed in on specifc areas to
“machine-wearable” by analogy with wearable pulse monitors
apply the technology. “Our focus is really on power, air, and water,”
for athletes—and also as a way of emphasizing that its sensors
Bessemer explains, “and if you think about it, that’s what drives or
are externally mounted (via magnets) and their built-in
complements most machinery. Any machine that uses those types of
Internet communications do not have to be tied into the
processes is really eligible for Prophecy.”
machine controls.
One of the factors the company tested as it developed its
Novatec says it will supply an installation kit of machine-
Prophecy sensors was power—both the quality of incoming power
wearable sensors and a data hub, allowing the user to access the
to the equipment and the equipment’s power consumption.
predictive-maintenance condition of fve pumps. In time, the
Unimpressed by the current power-meter oferings and knowing that inconsistent and/or poor-quality power supply are a major source of main-
Processors just install snap-split-core sensors from Prophecy in their three-phase lines going into their machines and then a Prophecy data hub will collect all the data from the sensors in a wireless network.
Extruder #1
Extruder #2
tenance for equipment, Novatec and Sensorlytics decided to create their own power-quality monitoring system using what it calls power-factor sensors. According to Novatec, power quality has become a major industrial issue with the widespread use of sensitive electronic equipment, making manufacturers much more aware of power anomalies. Varying
Hopper #4
internal loads within the plants from sources such as variable-speed drives, microprocessor-based devices, lighting,
Hopper #3 100m for Zigbee
Hopper #2
10m for Bluetooth
and battery chargers also contribute to the quality of electric power in a circuit, causing poor power factor, harmonics, and power-quality events such as sags, swells, and transients.
Hopper #1
Novatec noted that plastics processors today can either apply power-factor sensors connected to an industrial bus network, with data analyzed by licensed
Dryer #2
software, or they can use a stand-alone power meter to record voltage and current. Novatec and Sensorlytics will ofer a
Dryer #1
third option: a power-quality monitoring system that uses an Internet-based architecture for 24-7 power-quality tracking of
Pump #2
all the machines in a factory. Micro-controller Zigbee
Pump #1
Bluetooth
By applying sensor-on-chip (SoC) technology, plus a wireless network and a new distributed computational technique, the company says it has been able to reduce the cost of such systems by 90%. Whereas in
22
company said that limit will be raised to 20 pumps and will cover
the past, power-quality tracking would require an industrial bus system,
a distance of 300 ft. Pump Prime will automatically establish base-
additional I/O, and several layers of additional software licensing,
lines on new pumps, so anomalies will be clearly displayed when
Novatec says Prophecy power-quality monitoring systems use a single
operational issues develop in the future.
silicon chip, open-source networking, and Cloud-based software to keep
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OCTOBER 2015
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P R ED I C T I V E M A IN T EN A N C E
costs within the reach of small manufacturers like plastics processors. With Prophecy, power-factor sensors provide automatic 24-7 tracking of all power issues, including harmonic distortion, swallow, sag, surge, interruptions, and
working and I have to reset it. How did that happen?’ It’s usually power-related.” In addition to tracking electrical consumption, the system will continuously track power-quality metrics like sag, surge, swallow, and crest factor, helping processors better understand a process variable with a huge impact on their operations.
QUESTIONS ABOUT PREDICTIVE MAINTENANCE?
power factor. No PLCs or additional equipment are required; processors just install snap-split-core sensors from Prophecy
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in the three-phase lines going into their machines, and then a Prophecy data-hub will collect all the data from the sensors in a wireless network. That data will be pushed to a Cloud server, from which a processor will be able get a summary of all the issues in all the three phase-lines going into individual machines in real time. This data will
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be available on any smart phone or tablet registered with the application. “The electrical power-factor instrument industry is well established,” Bessemer notes, “but I would guess that fewer than 10% of our customers have such an instrument, because it can cost $5000 to $15,000 by the time you buy all the software and everything else to do it efectively, and maybe you still need an electrical engineer to sort out for you what’s being recorded. Our intention is to
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THE SILENT PRODUCTIVITY KILLER In the western world, high-quality electrical power, much like clean drinking water, is assumed, but perhaps it shouldn’t be. Says Bessemer, “With power quality,
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23
S U S TA IN A B IL I T Y
Close-Up On Technolog y
Achieving Zero Waste: Two Processors Prove It’s Possible Working with an Ohio-based recycler, two flm and sheet processors go landfll-free. There are three things certain in life: death, taxes, and waste. In 2013,
landfll-free program has started at a facility, the company recom-
Americans generated about 254 million tons of trash, according to the
mends an end date to ensure the program is completed.
By Heather Caliendo Senior Editor
most recent statistics from the Environmental
Green Innovations handles a variety of waste streams, including
Protection Agency (EPA). About 30% of that is
facility debris, single-stream
recycled. If you take a glass-half-full approach,
recyclables, and food waste. The
the only way to go is up when it comes to recycling rates, right?
company ofers solutions for all
Industrial recycler Green Innovations (green-innovate.com)
waste generated at an industrial
takes the optimism one step further, envisioning a world where
level, specifcally plastic scrap
zero waste to landfll is the norm. The company believes its
and leftover raw materials, as well
business model brings a realistic and cost-efective approach to
as cardboard, consumer waste,
recycling the waste that is generated at manufacturing plants.
and other waste headed to a landfll. For products that are customarily
“When we came up with the landfll-free concept, we actually
non-recyclable, Green Innovations says that its partnerships allow
got laughed at. No one believed it was a possibility,” says David
it to process these materials and keep them from the landfll. The
Sweeney, partner and sales manager for Green Innovations,
company says non-traditional materials can be turned into environ-
Solon, Ohio. “Fast-forward to today, and now other companies
mentally friendly fuel for use by other industries.
are copying our business model.” Achieving zero waste to landfll sounds like an environmen-
Once a facility has achieved landfll-free status, Green Innovations will certify the location as 100% landfll-free. Plastics Technology
talist’s dream, but it is happening—not because the company
checked in with two processors that are currently working toward
found some magic solution to eliminating trash, but by helping
landfll-fee status to learn more about the process.
processors implement a three-step program that requires a multi-faceted approach and accountability, Sweeney says.
TIME-INTENSIVE Headquartered in Atlanta, Printpack is a privately held manufacturer of fexible and specialty flm and sheet for packaging. The company (printpack.com) operates 22 manufacturing facilities in the U.S., Mexico, and China. Camilo Cruz, senior environmental specialist, said the company tries to reduce waste going to landfll by recycling whenever possible, but saw a need to expand its waste-minimization initiatives. Printpack started to work with Green Innovations, and the plan is to fully implement the landfll-free program at its New Castle, Del., facility in 2016, with the goal to achieve a landfll-free status that year as well. Cruz said that the main challenge to achieving that landfll-free status is the resources required to implement the program. This
David Sweeney (left) and Don Resh are partners in Green Innovations, an Ohio-based company that helps processors develop zero-waste strategies.
includes the funds, personnel time, and planning to ensure the required changes can happen efectively at the plant level. In addition, the process of going landfll-free includes fnding options for waste streams that have little value from a recycling
24
For instance, Green Innovations will start with an audit at the
standpoint—for example, composting cafeteria wastes, utilizing
facility to review what is being collected as well as the landfll,
low-value flm waste as engineered fuel, or incinerating plant
compactor, and hauling costs. Sweeney says that as soon as the
wastes for energy recovery.
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S U S TA IN A B IL I T Y
Close-Up On Technolog y
“Money investments in the landfll-free program will not be
so the company began working with Green Innovations in early 2015.
substantial, although signifcant time will be required to modify
There are several reasons Fredman Bag decided to aim for zero landfll:
plant work fows so that wastes can be segregated and collected in
It’s good for the environment; many of its customers see it as value
preparation for ofsite management,” Cruz states.
added; it provides cost savings; and “as an organization, we felt it was the responsible thing to do,” Globke notes.
He said that sending no waste to landfll will provide cost savings as well as supporting the company’s sustainability goals. Printpack plans to implement the landfll-free initiative eventually at all its facilities.
‘PAINLESS’ PROCESS
Going landfll-free includes fnding options for waste streams that have little value from a recycling standpoint.
Since the company already had a comprehensive recycling program in place, the employees didn’t run into any problems in working toward a landfll-free plant, he said. “The process of going landfll-free was quite painless,” says Globke. “Other than a few planning meetings and discussions, we
Peter Globke, shipping and warehouse manager at Fredman Bag, a Milwaukee-based printer and converter of
changed out a few trash bins with recycling bins and did a few short
fexible packaging flms, said the company follows the standard
training sessions with our employees. Green Innovations provided
“Reduce, reuse, and recycle” model. First, the company (fredma-
us with all of the bins and supplies we needed and even helped with
nbag.com) works to reduce the usage of materials that may add to
the training, so the only investment we made was time.” In August, Fredman Bag began the fnal stage of the program and
its waste stream. Secondarily, employees try to reuse as many materials as possible. Everything from simply reusing pallets or excess raw materials for other purposes, to recapturing spent resources and materials, can make a diference to the environment and the company’s
is no longer sending any of its waste to landfll, Globke says. The company expects to be fully certifed as landfll-free this year.
QUESTIONS ABOUT SUSTAINABILITY?
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Know How
MATERIALS Impact Testing: The Problems With Single-Point Data
PART FIVE
Knowledge of test conditions and graphical data showing the course of the impact event can help provide engineers and designers with the information they need to make informed choices about material toughness. As we have discussed in preceding columns, the tests most com-
FIG 1
monly used to characterize impact performance in plastics involve a very narrow range of the parameters that infuence the test result—temperature and
ations are typically limited to tests conducted at room temperature (73 F/23 C). Occasionally, one or perhaps two subBy Mike Sepe
ambient conditions are used. Frequently, there is a dramatic decline in impact strength at the lower temperatures.
This indicates that the material being evaluated has a ductileto-brittle transition temperature somewhere between the test temperatures, but we cannot be sure exactly where this occurs. We
4.0
35.0
3.0
28.0
2.0
21.0
1.0
14.0
0.0
7.0
-1.0 -3.0
-1.5
0.0 1.5 Time, msec
Energy, J
publication on the data sheet, impact evalu-
Load, kN
strain rate. As with most tests performed for
Impact Test Result on PVC at High Velocity
0.0 4.5
3.0
This instrumented impact test on PVC shows results characteristic of brittle failure.
do know, however, that this transition takes place over a relatively narrow temperature range. The other shortcoming of these tests is
This is important, since impact resistance is a function of strain rate,
the general inability to control velocity. Finally, while it is possible
as we have already established. Inside the tup is a transducer that
to instrument the pendulum test apparatus in order to create a
monitors the force generated by the tup on the sample and feeds
graphical output of the impact event, this enhancement is seldom
several thousand data points characterizing the event to a computer.
Frequently, there is a dramatic decline in impact strength at lower temperatures.
employed and the results are not
Software reports a number of parameters associated with the test,
published even on those rare
including the velocity at impact, duration of the test, sample defec-
occasions when it is done.
tion, and energy required to produce failure of the sample.
The ability to control velocity and provide graphical results
graphical output of load and energy plotted as a function of time.
comes from more sophisticated
The results of this type of impact test can be found on some data
pieces of equipment known as
sheets, and they are often provided at room temperature and a
instrumented falling-dart impact testers. These employ a tower,
sub-ambient condition such as -20 C or -40 C. These tests are typi-
and the crosshead is raised to a specifc height so that when it is
cally only performed on very ductile materials that produce excel-
dropped it achieves the desired velocity as it strikes the sample. The
lent values such as polycarbonate and related alloys such as PC/
sample is either a disk or a plaque that sits fat on a platform and
ABS and PC/polyester. But the result is given only in terms of total
is impacted by a cylindrical object called a tup. The tup can vary in
energy, and no insight is provided into how the event unfolded.
diameter and has a radiused end that contacts the sample. This apparatus is modeled after the Gardner impact test;
KNOW HOW MATERIALS
however these devices employ an energy much higher than what
Learn more at PTonline.com
is required to make the test specimen fail. This ensures that the
Get more insights on Materials from our expert author: short.ptonline.com/materialsKH
velocity of the tup does not change appreciably during the test. 28
But the real value of this method is the fact that it produces a
Plastics Technology
OCTOBER 2015
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M AT ER I A L S
Know How
Figure 1 shows the graph associated with an instrumented
FIG 2
impact test. This test was performed on a PVC material and the total energy collected at the conclusion of the test is shown as 21 joules, or approximately 15.4 ft-lb. This is the only infor-
In this case, the load builds up rapidly once the moment of impact has occurred. Once the maximum value is achieved, the
Load, kN
reported on a data sheet. But the curves tell us so much more.
load declines rapidly and the test is completed in approximately 3 milliseconds. Even visually we can determine that the majority of the total energy was collected before maximum load was reached and this behavior characterized what would be consid-
4.0
35.0
3.0
28.0
2.0
21.0
1.0
14.0
0.0
7.0
-1.0 -10.0
0.0
ered a brittle failure. Some materials exhibit an even more brittle response than this material, and in that case the load curve may exhibit multiple peaks and some noise as the various layers of the sample fail in a rapid sequence that produces total energies as low as 2-3 ft-lb. Sample thickness will obviously infuence the result, and the total energy can be divided by this thickness to
10.0 20.0 Time, msec
30.0
Energy, J
mation that would be provided if the test result were to be
Impact Test Result on PVC at Lower Velocity
0.0 40.0
This impact test performed on a specimen of the same PVC material shows very different results from those in Fig. 1. First, the total energy collected is approximately 50% greater. The test duration is also longer. But the most signifcant difference is the change in the failure mode from brittle to ductile.
normalize the results to ft-lb/in., although this is rarely done. Figure 2 shows an impact test performed on a specimen of the same PVC material that looks very diferent from the results shown in Fig. 1. First, the total energy collected is approximately 50% greater at 32.5 joules or 23.9 ft-lb. The test duration is also
longer, a little over 20 millisec as opposed to 3 millisec. But the most signifcant diference is the change in the failure mode. The load curve, rather than dropping abruptly after the achievement of maximum load, tails of gradually and the peak of the load
速
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curve is rounded rather than sharp. The energy collected up to
for this material at 73 F (23 C) is 8 ft-lb/in., a value associated with
the point of maximum load comprises only about half of the total
a ductile material. However, this supplier had also provided a data
energy required to produce complete failure. These features are
point for 0 F (-18 C). At this lower temperature the result was only
characteristics of a ductile response, and the signifcant amount
1 ft-lb/in., a value characteristic of a brittle material. The fact that
of energy expended to complete the failure after the point of
this material exhibited a ductile-to-brittle transition temperature
maximum load is referred to as energy management. True tough-
somewhere between these two temperatures led us to expect that it
ness is captured after maximum load; the energy required to reach
might also display a ductile-to-brittle transition strain rate if we did
maximum load is more
not change the temperature. The test result confrmed this and also
attributable to rigidity,
helped to solve a performance problem that had been blamed on
not ductility.
the material but actually was due to a change in the way the molded
A performance problem that had been blamed on the material actually was due to a change in the way the molded parts were being assembled.
So what aspect of
parts were being assembled.
the test conditions
So as with the properties of strength and modulus we have
distinguishes the
again demonstrated the importance of test conditions and the
results shown in Figs. 1
ability to provide graphical data in order to give engineers and
and 2? While a change
designers the information they need to make informed choices
in temperature could
about material performance. Next month, we will extend this
certainly account for this, the temperature of both tests was the same.
discussion to include thermal properties.
However, the velocity associated with the test result in Fig. 1 was 15 ft/ sec (4.57 m/sec) while the test result shown in Fig. 2 was obtained at a velocity of 5 ft/sec (1.52 m/sec). The faster speed produced a result that would be more typical of a test performed at a lower temperature. Ironically, it was the data sheet that led us to perform this experiment in the frst place. The notched Izod impact strength
ABOUT THE AUTHOR Mike Sepe is an independent, global materials and processing consultant whose company, Michael P. Sepe, LLC, is based in Sedona, Ariz. He has more than 35 years of experience in the plastics industry and assists clients with material selection, designing for manufacturability, process optimization, troubleshooting, and failure analysis. Contact: (928) 203-0408 • mike@thematerialanalyst.com.
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Extrusion 2015
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Photos courtesy of: Teel Plastics (background); Davis Standard, Dow Chemical Co., Getty Images/iStockphoto (this page, top to bottom); Getty Images/iStockphoto, Processing Technologies International LLC., Getty Images/iStockphoto (facing page, top to bottom)
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SCHEDULED PRESENTERS
RE G I S TE R TO DAY ! If your company is involved in extrusion—be it film, sheet, pipe, profile, tubing, or compounding, or some combination thereof—The Extrusion 2015 Conference is for you!
We look forward to having you join us at The Extrusion 2015 Conference… the one and only conference you’ll need to attend this year.
LEARN! More than 60 presenters at Extrusion 2015 will give you unprecedented access to new technology, tips and techniques, and best practices aimed at helping you boost effciencies at your operation.
NETWORK! Make invaluable contacts with the top minds and innovators in the feld of extrusion as you network with not only with presenters, but with the more than 35 suppliers to the extrusion processing market who are exhibiting at Extrusion 2015!
For up-to-date agenda & abstracts, please visit:
ExtrusionConference.com
Extrusion 2015
ACS Group Addex Addivant American Kuhne Asaclean Bohler-Uddeholm Brampton Engineering Castle Associates / Dow Chemical Century Extrusion Cloeren Incorporated Compuplast Conair Coperion Coperion K-Tron CPM Century Extrusion C.W. Brabender Davis-Standard DR Joseph Dri-Air Industries Edison Technical Services (Allan Griff) ENMOUNT Technologies Entek Gloucester Engineering Gneuss Guill Tool IQMS JSW America Key Filters Krauss-Maffei Corp. Kuhne Group Leistritz Macro Engineering & Technology Mucell Extrusion Nordson EDI Nordson Xaloy Novatec NDC Pelletron Piovan Processing Technologues LLC (PTi) PSI – Polymer Systems, Inc. Randcastle Extrusion Rauwendaal Extrusion Engineering Reduction Engineering Scheer Riverdale Global Siemens Teel Plastics TWWomer & Associates Universal Dynamics Vecoplan VAC-U-MAX Windmoeller & Hoelscher Corp. Schedule and presentations subject to change.
Know How
INJECTION MOLDING
Partially Melted Pellets in a Part
Why Pellet Size and Shape Are Important Uniformity is needed to help ensure melt quality.
Partially Melted
FIG 1
Variation in pellet size and geometry infuences solid-bed breakup and is the source of partially melted pellets in your parts.
There are hundreds of details in the injection molding process and
through the cleanout window. If the pellets up against the window
in evaluating them I can get rather “picky.” This month I’m picking
do not slide down into the feed throat, you have a problem. My bet:
on the pellets. Regardless of the resin type or manufacturer, you as a molder want
By John Bozzelli
95% of the time, those pellets stay there for the entire run. So how do you ensure mass fow? Check the hopper angle; for
your pellets to be uniform in size and
mass fow: It should be angled 60°. Single-shot hoppers are fne,
shape. But pellets vary in size and shape.
provided you do not see fuidizing of the pellets (dancing in an air
In the case of regrind they can range from
stream) when it calls for resin. If fuidizing occurs during screw
fnes to larger chunks. Bottom line, you
rotation, you can guarantee the next shot will be a diferent part,
need all the pellets to be uniformly melted
because the fuidizing keeps some pellets from settling into the
at the proper temperature. If your pellets
intake screw fights. This is a process variation. If you do have
range in size and geometry, this won’t
fuidizing in single-shot hoppers, fx the air leak at the junction
happen. Non-uniformly melted resin will
of the feed throat with a good high-temperature silicone gasket.
not yield uniformly good or identical
Once you’ve established mass fow, make sure your feed throat
parts…period. (By pure coincidence, Jim Frankland discusses this
is clean, unobstructed with big chunks, fnes, or streamers, and is
very subject in his Extrusion Know How column this month.)
PID temperature controlled. Erratic water fow in the feed throat is not acceptable; it’s the most important
My guess is that the majority of molders do not give this issue much thought. Admittedly, it’s not the frst thing I check when troubleshooting a problem, but I need to bump it up a few rungs. We assume all is well because we see molten polymer come out of the nozzle when we purge the machine, or because the parts look OK. That’s a bad assumption. To understand
Go out to the shop foor and watch the pellets through the cleanout window. If they do not slide down into the feed throat, you have a problem.
the problems with melting non-uniform pellets, let’s look closer at the melting process. The melting process starts with the hopper, which feeds the
zone of the process. It also should be set at a higher temperature than you think. The feed throat has two jobs: Feed the resin, and —just as importantly—act as a vent for gases escaping from the feed section of the screw. Set it at 55-65 C (130-150 F) to allow volatiles to escape and not condense. Even polypropylene will not get tacky at these temperatures. If you have bridging problems, note
the composition of the bridged material. If all the individual granules are stuck, then the feed throat is too hot. But if there is any
granules into the feed throat. The hopper should be designed
completely melted polymer, or if the bridge is a ball of solid plastic,
to provide mass fow—not funnel fow—so that resin is fed
you do not have a feed-throat temperature problem. More likely
uniformly to the feed throat. There must be no channeling in
your non-return valve is leaking.
the center, which is known as funnel fow (or “rat-holing”). Take a reality check: Go out to the shop foor and watch the pellets
Now let’s turn our attention to the feed section of the screw. As the screw rotates, it picks up the granules from the feed throat and augers them through the feed section of the screw. On a general-purpose
34
KNOW HOW INJECTION MOLDING
screw, the feed section is a whopping 50% of the fight length. The
Learn more at PTonline.com
purpose of the feed section is to compact the pellets and prepare them
Get more insights on Injection Molding from our expert authors: short.ptonline.com/moldingKH
for the transition section (also called the compression zone). Here is
Plastics Technology
OCTOBER 2015
where the fights of the screw pick up the granules, and they have to ft PTonline.com
INJEC T ION MOLDING
into the fight chamber. Pellets falling into the fight are no problem, unless they are either very large or very small (fnes).
Completely Unmelted Pellet in Sprue Unmelted Pellet
If the pellet is so large that it stands
through the feed throat. Somebody will tell you a story of the feed throat burping pellets or, worse, being blown to or through the roof. With compaction comes some pressure,
taller than the fight, it may or may not
but the high pressure (thousands of psi)
be sheared between the fight and sharp
develops within the transition zone. Here
edge of the bottom of the feed throat. This
is where all the melting should happen.
can actually force the screw back, not
The transition section of the screw is where
allowing the fight to fll completely with
the root diameter tapers thicker to the
granules. The screw just augers backward
metering diameter of the screw; this taper
and you do not have a full shot of plastic
FIG 2
in front of the screw. This is common with small-diameter screws and/or use of low backpressures. The result is the next shot has splay, bubbles, shorts, or unmelt.
Variations in pellet size and geometry can cause some materials to pass through the screw completely unmelted.
compresses the plastic against the barrel wall. The ratio of the volume of a feed fight to the volume of a metering fight is known as the “compression ratio.” Here is where the size and geometry of the pellets become driving factors on how
Fines pose a diferent type of problem, lem as they melt much faster and earlier than normal-size pellets, which
and when a pellet or granule melts. Any variation in geometry or
in turn reduces the friction needed to melt the normal pellets.
size will cause diferent degrees of friction, and this in turn provides
Results are unmelt and black and white specks in your parts.
non-uniformity within the polymer melt.
As the granules move through the feed zone, they begin to pick
My bet is that variation in pellet size and geometry infuences
up heat of the rear zone, along with some compaction. This is when
so-called “solid-bed breakup, ”a disruption of uniform conversion of the
your friend Murphy—you remember Murphy’s Law—invites himself
“solid bed” of compacted pellets into a melt pool within the screw fights,
My bet is that variation in pellet size and geometry is the source of partially or completely unmelted pellets in your parts.
to the party.
which is the source of partially melted pellets in your parts (see Fig.
First, you have
1). My guess is that nearly 70% of your parts have this problem.
worry about
Diferent coefcients of friction will generate diferent melting
where the air
patterns as the pellets travel down the screw. And when Murphy is feeling
between the
particularly mischievous, you can get completely unmelted granules
pellets is going
in parts. This is a rare occurrence but it does happen (see Fig. 2).
as the pellets
Bottom line: Non-uniformity in pellet size and geometry
compact. If the melting process starts too early, air gets trapped and
fouls up the melting process and is a source of cosmetic, physical,
pushed through to the nozzle. The air shows up in your part as splay,
chemical, and performance problems.
which you may mistake for moisture. Running the feed throat hot and rear zone at the proper temperature allows the air to escape (vent) out the feed throat, perhaps taking along some moisture and other volatiles. Ask around if you don’t believe moisture and volatiles vent
ABOUT THE AUTHOR: John Bozzelli is the founder of Injection Molding Solutions (Scientifc Molding) in Midland, Mich., a provider of training and consulting services to injection molders, including LIMS, and other specialties. E-mail john@scientifcmolding.com or visit scientifcmolding.com.
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Know How
EXTRUSION Pellet Geometry Can Impact Output A simple angle-of-repose experiment can help you determine how your pellets will feed. Why do some polymers having the same melt fow or I.V. (intrinsic viscosity) sometimes generate diferent specifc outputs on the same
FIG 1
The Mechanics of Solids-Flow Feeding View A
extruder? You may have come across this when changing resin suppliers, and have had to modify established running conditions as a result. This occurs particularly in the case of coextrusion, where close matching of multiple layers is required. When you are running the extruder at full speed, yet the net efect is a reduction in output, that’s a big problem. In fact, even an increase in output can be an issue if the By Jim Frankland
extruder is near its torque limit. Why does this happen? In most cases the
1 2 3 4 5 6 7
Layer Velocity VD1 VD2 VD3 VD4 VD5 VD6 VD7
VD
VBarrel
polymer supplier has likely delivered the correct product, but the pellet geometry may be diferent. Truth is, pellet geometry is often diferent
View B
among suppliers. It may be caused by use of diferent pelletizing equipment or even by a preference on the part of the supplier for a certain pellet geometry to aid in bulk-handling operations. Several years ago, I worked with a
Pellet geometry is often different among suppliers.
polymer supplier that had to make special pellets just for processors that used grooved-feed extruders. This supplier had been furnishing the same pellets for everyone, but processors running with
grooved-feed sections were getting 20% less output than when they ran material with the same I.V. from other suppliers. You can understand why this could happen by knowing the
1 2 3 4 5 6 7
Layer Velocity VD1 VD2 VD3 VD4 VD5 VD6 VD7
VD
VBarrel
mechanics of polymer solids feeding. The force that moves material forward is the drag of the pellets along the barrel inner surface rotating in relation to the screw. Since only the top layer of pellets contact the barrel, the movement of the layers farther down in the channel is dependent on the drag from the layers above. Each succeeding layer has a lower average velocity than the layer above it due to slip between the layers. If the feed channels get deep enough, the layers near the screw root may barely move in the down-
The force that moves the material forward is the drag of the pellets along barrel surface. Only the top layer of pellets contact the barrel, so the movement of the layers beneath depends on drag from the layers above. Highly uniform pellets in View A have a less uniform velocity distribution than with the varying sizes or shapes in View B, so adding some regrind can boost output.
channel direction due to the combination of the slip between layers and the resisting drag of the bottom layer against the screw surface. In View
KNOW HOW EXTRUSION
A of Fig. 1 the pellets are quite layered because of their uniformity. This
Learn more at PTonline.com
is somewhat typical of many “hot-cut” pellets that have a thin, fat wafer
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geometry. If the feed material has some random sizing or varying 38
Plastics Technology
OCTOBER 2015
PTonline.com
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Know How
shapes, the layers interact more, creating a better velocity distribution, as illustrated in View B. This explains
involved in this measurement, so it’s
FIG 2
The Angle of Repose Test
hard to distinguish which of the criteria dominate the resultant angle of repose:
why a small amount of refeed or other
Size, shape, randomness, and friction all
polymer shapes can increase the
play a part. However, for a given polymer,
specifc output.
the higher the angle, the better the
The drag between layers is
solids-conveying efciency in smoothAngle of Repose
determined by the pellet shape, size, randomness of shape, and the
bore extruders. This rule of thumb also applies to grooved-barrel extruders, but
dynamic friction coefcient between
the particle size and shape relative to how
pellets. The drag of the frst layer
they ft in the grooves is actually more
contacting the barrel wall depends on the friction coefcient between the pellets and the barrel material, which may be quite diferent than the pellet-to-pellet friction coeffcient. That pellet-to-barrel friction
This simple test measures the way the polymer piles up when gently poured onto a fat surface. It can be useful to answer some questions about specifc output for polymers of the same type but different suppliers.
coefcient is controlled by heating
critical to their solids-feeding efciency. It should be noted that a higher angle of repose can occasionally have a negative efect on overall feeding efciency, as polymer may not fow as freely into the screw. The angle of repose is not a solidsfow measurement necessarily, but gener-
the barrel, which causes the pellets to “stick” to the barrel.
ally the higher the angle of repose, the poorer the solids fow is in
This whole area of investigation is related to the science of
areas upstream of the screw that depend on gravity—such as hoppers,
tribology. Wikipedia defnes tribology as “the science and engi-
feed tubes, and magnet packs. This issue seldom comes into play
neering of interacting surfaces in relative motion.” There are
except when there is some restriction to entry into the screw, such as a
no hard and fast rules for evaluating a polymer’s tendency to
blocking apparatus over the feed opening, a small feed opening, or no
feed, because the criteria noted—shape, size, and randomness—
column pressure due to bridging or a ledge above the screw.
interact, and frictional force depends on contact area even though
Trying the simple angle-of-repose measurement on your
the friction coefcient remains essentially the same for given
polymers may answer some questions about specifc output for
polymers. A simple test that gives insight into conveying char-
polymers of the same type but diferent manufacturers.
acteristics of your polymers is called the “angle of repose,” and
ABOUT THE AUTHOR: Jim Frankland is a mechanical engineer who has been involved in all types of extrusion processing for more than 40 years. He is now president of Frankland Plastics Consulting, LLC. Contact jim.frankland@comcast.net or (724)651-9196.
it basically measures the way the polymer piles up when gently poured onto a fat surface (see Fig. 2). All the criteria mentioned about the pellet characteristics are
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40
Plastics Technology
OCTOBER 2015
PTonline.com
WEBINAR
Tuesday, October 27th 2:00 PM EST
a feature of PTonline.com
Register for this webinar at: short.gardnerweb.com/wb PRESENTER
How the “Internet of Things” Optimizes Productivity and Decreases Downtime
Christian Glueck Technical Trainer/ Tech Center Manager, Injection Molding Machines
Today, full scale online diagnostics and remote service allows equipment suppliers to help molders: • Reduce down time during troubleshooting • Increase productivity • Increase part quality • Identify defective machine parts before technicians arrive • Monitor machines remotely, and tune machine parameters (service values) to keep equipment running until service arrives with parts
Christian started his career with Wittmann Battenfeld at the Tech Center in Kottingbrunn, Austria in 1985. After 5 years as a process engineer and 25 years doing customer training for Injection Molding Machines in Austria, he has recently relocated to our USA Headquarters, in Torrington, CT, where he manages the Tech Center and molding machine training.
Industry 4.0, the “Internet of Things” and similar technologies take this to another level. They allow the IMM to “talk” to the peripheral equipment and ideally, allow them to be serviced remotely through the IMM. Through live demonstrations we will show that all the above is already reality.
USA Division Manager Injection Molding Machines
PRIMARY TOPICS: > Remote technical service on injection molding equipment > Remote process support on IMMs > Industry 4.0 (intelligent connection of IMMs with peripheral equipment)
Markus Klaus
Markus Klaus is Divisional Manager of Injection Molding Machines for Wittmann Battenfeld, Inc., Torrington, CT. He earned a mechanical engineering degree from the College of Darmstadt (Germany). He has worked in the plastic industry for almost 20 years (Wittmann Germany, Ferromatik Milacron Germany, Toyo Germany) and joined Wittmann Battenfeld in the USA in 2013.
Know How
TOOLING PART 1 OF 2
Having Trouble with Lifters?
Lifters can cause tool maintenance, repair, and processing issues if not designed properly. Here we begin a series on how to avoid all this. Lifters are critical components that impact tool maintenance, repair,
tion. I have had many tools run fawlessly with zero lifter issues
and injection molding. There is a lot to discuss about lifters: design
over millions of cycles. But with other tools I have had nightmares
considerations, materials used, wear sur-
caused by lifters. So the lifter stands out as one component in a
faces; buddy/helper pins, defection, shape
mold design that needs a little extra attention.
(round vs. square), part-sticking issues,
Some of you may be thinking you have no issues with lifters,
ftting/spotting, and timing/preload. In this
but my guess is you are running parts with “lessons learned,” using
column I will discuss the lifter, why it is
low-draft lifters with shallow undercuts. In my arena, I am involved
used, angles/travel, and some design con-
with numerous styles of parts and plastic materials across many
siderations in relation to the angle/travel.
industries, so we run into some challenging issues with lifters.
I manage thousands of preventiveBy Randy Kerkstra
maintenance activities and repairs a year.
LIFTER ANGLE & TRAVEL
These involve a wide variety of mold
It’s fairly simple math to fgure out the angle at which the lifter
designs from all over the world, running
must move. All you need to know is the depth of the undercut on
various materials. In the process I have acquired a lot of knowledge with respect to tool designs and how they can impact
the part and the ejector stroke being used (or FIG 1
available) with the tool or machine. If, for example, your detail or undercut is 0.5 in.
the manufacturing environment with
deep, your lifter would need to travel this
failures and processing issues. I use the
amount plus clearance so the part will remove
term “red fags and sirens” when I want to
freely from the mold without hangups. The
label something as a concern. And if there
amount of clearance needed varies on the size
is one component that jumps out more
of the part, plastic being used, and shrinkage.
than others with respect to tool mainte-
I have seen situations where the clearance
nance and repairs, it’s the lifter.
was indeed part of the design, but because of
When it comes to tool design, most
part shrinkage the lifters were still engaged,
people on the tool-maintenance side
making part-removal very difcult. For example,
prefer slides, if possible. But in cases
if you had a PP part 20 in. long, you could have
where lifters are used, slides are usually
part shrinkage of up to 0.4 in. I stress this
not an option. I mention this because
because it is sometimes overlooked.
there have been cases where slides could
In the example above of the 0.5-in.
have been used instead of lifters in a few
undercut, if we are going to design a 0.1-in.
situations I have encountered.
clearance, our lifter travel would need to
A lifter is a component that travels
be 0.6 in. Let’s also assume we have 4 in.
with the ejection stroke and moves on
of ejector stroke. I use trigonometry when
an angle to slide/pull cavity steel away
calculating this, but there is a less complex
from undercuts or details not in die draw
method: 1 degree will travel approximately
where slides or other mechanics are not an option. There are other names for this component, as well as design variations. The design, angle, and materials used for lifters can have a big impact on tool performance over years of opera42
Plastics Technology
OCTOBER 2015
KNOW HOW TOOLING Critical elements of tool design with lifters are the lifter angle, travel, and supported/ unsupported length.
Learn more at PTonline.com Get more insights on tooling from our expert authors: short.ptonline.com/toolingKH PTonline.com
TOOLING
0.017 in. over 1 in. So over 4 in., 1° will travel 0.068 in. We
FIG 2
need 0.625 in. over 4 in., so just multiply 0.068 by any number to fgure out the angle for our lifter. In this case, we would put the lifter at 9° (9 x 0.068 = 0.612 in. travel). Now that we understand how angles are determined for lifters, let’s discuss how these angles can impact maintenance. From a mechanical viewpoint, the greater the angle, the more concern about mechanical forces contributing to wear and failures. The unsupported length is just as much a concern as the angle. You could have a steep-angled lifter more robust than a shallow-angle lifter with too much unsupported length. This comes down to the unsupported length/diameter ratio along with the angle of the lifter. For lifters on steeper angles, you can add a “buddy” or
Lifter Pin
“helper” guide pin to the lifter slide to prevent defection and keep the slide traveling in the proper position (see Fig. 2). These helper pins are
The greater the lifter angle, the more concern about mechanical forces contributing to wear and failures.
a great option and drastically reduce lifter failures
10.00°
and wear on the rod or shank. I typically would start with at least a 10°
10.00°
angle when considering using a helper pin. But remember that a low-
angle lifter with excessive unsupported length could have defection issues. In one case, we were having problems with fash under the lifter and with the lifter standing above the cavity surface. This lifter had a 0.5-in.-diam. rod at 3° but had excessive unsupported length. The lifter slide in the ejector plates would not make it all the way home, as the lifter rod was not robust enough and defected because of the excessive unsupported length. When this happened, the lifter
Buddy/ Helper Pin A “buddy” or “helper” pin can help prevent defection of lifters set at steep angles, minimizing wear and chances of failure.
head would not seat all the way and would stand above the cavity surface, causing fash underneath. There is really no concrete standard to determine when to use helper pins. I use 10° as a reference point, but some lifters with angles under 10° may need them also. And some lifters with angles greater than 10° may not need them. During tool design, when you determine the lifter angle based on stroke, you need to make sure the unsupported length does not exceed the travel. I have seen many cases where the back plate or mold base is cleared by the lifter rod/shank and the bearing surface is only on the cavity. You should always have a bushing or guide blocks on the back plate or mold base to give the lifter as much support as possible. Lifters can also defect as a result of cavity pressure, causing read-through on the part. In cases where there is no shutof shelf on the lifter, cavity pressure can push it below the cavity surface. Next month, I will get into more specifcs on lifters in wear surfaces, materials used, ftting, timing, and more. ABOUT THE AUTHOR: Randy Kerkstra has been in the plastics industry for more than 26 years, occupied frequently with troubleshooting injection molding. He is currently a tooling manager for a large, multi-plant molding and manufacturing company. Contact: kbmoldingsolutions@gmail.com. @plastechmag
Plastics Technology
43
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On-Site
Tek Pak, Inc. • Batavia, Ill.
By Matthew H. Naitove Executive Editor
R&D Thermoformer: Tek Pak Is Launch Pad For New Products Toolmaker and thermoformer takes concepts to production-ready parts in record time.
The largest machine at Tek Pak is this Kiefel KMD 60 B inline pressure former, used for midvolume production as a “bridge” between prototyping and full production—which usually is performed by another thermoformer.
46
Plastics Technology
When resin maker Eastman Chemical Co., Kingsport, Tenn., and sheet extruder Pacur in Oshkosh, Wis., wanted a thermoformed demonstration part to show of a new three-layer, foam-core PETG sheet, they knew where to go. “We don’t have a lot of competition, because hardly anyone one else does what we do,” declares Tony Beyer, president and founder of Tek Pak, Inc., in Batavia, Ill. (tekpak.com). “We are willing and able to go after new-product development applications, while most big thermoformers want to get in after that stage of the project cycle, when it’s time to make hundreds of thousands of parts. We’ll make tens of parts, if that’s what’s needed.
OCTOBER 2015
PTonline.com
Tek Pak, Inc.
“That’s why Eastman (eastman.com) and Pacur (pacur.com) came
On-Site
it started. Many projects come in as concepts, not full-blown
to us when they wanted someone to design a mold that would
designs.” He cites the example of a surgical tray kit, for which
really challenge Eastman’s new Eastalite material, extruded into
Tek Pak was given only the parts the kit had to contain and a general layout scheme. “They ask, ‘Can
sheet by Pacur. When people see the part we designed (photo on next page), they’ll know that material has good formability.” Seeing interesting potential in the new tri-layer sheet, Tek Pak itself prototyped a medical tray to protect sensitive equipment.
“We got into this business because no one else wanted to mess with prototyping—too much detail, too little volume.”
NOT YOUR TYPICAL THERMOFORMER
you make this?’ For the answer, we rely on our tool kit—our knowledge of tooling and of uncommon materials and how to form, cut, punch, and weld them. A Fortune 500 company came to us after working on a new project for 16 weeks without success. In two months, we had
Beyer’s path to becoming a specialty thermoformer started in the
working samples for them.”
early 1970s as a toolmaker at Plastoflm Industries, Wheaton, Ill.,
This sort of development work can take a lot of itera-
leading custom thermoformer. In those days, Plastoflm had 550
tions. “Medical development can take 18 months of trials and
people in fve locations and was a pioneer in medical thermo-
sometimes up to 16 or more revisions,” says Beyer. “We got into
forming. Beyer rose to plant manager of the home facility, which
this business because no one else wanted to mess with proto-
had 400 employees. After the original owner retired and the frm was sold and resold three times in fve years, Beyer left and started Tek Pak in 1992. His initial focus was on carrier tapes that held components for automated assembly of cellphones. That application started at Plastoflm in 1981, Beyer says, “but the fnance people there said it would never amount to much.” How wrong they were. Carrier-tape business at Beyer’s new frm grew 50% a year for seven years in a row during the 1990s, with Motorola as the leading customer. Tek Pak even opened a plant in Sweden to make carrier tapes for cellphone maker Ericsson in the late ’90s. Then China happened. “It all changed a lot faster than anyone thought possible,” recalls Beyer. In around 2000, 40% of his business moved to China in just six months. He closed the Swedish plant, which is now a sales office. “We went into survival mode and refocused on standard thermoforming, tooling, and prototyping.”
Tek Pak builds a lot of its own forming systems for single-cavity prototyping. Scott Carter, v.p. of R&D stands next to one such system.
Today, Tek Pak has a main ofce and production plant in Batavia with 27,000 ft2, 70 people, fve extru-
typing—too much detail, too little volume. We do 50 prototypes
sion lines for carrier tapes, and 40 thermoforming machines, 35
a month—nobody else even comes close to that.”
of them for carrier tape. In addition, Tek Pak also has a 12,000 ft2
This approach has paid of for Tek Pak. Says Beyer, “We’re not
R&D center 3 miles away in St. Charles, Ill., which houses seven
caught up in commoditization. Most customers realize there’s a
small machines. That separate R&D facility, with a dedicated
cost associated with what we do.” Tek Pak’s biggest market is
staf of 15, is part of what distinguishes Tek Pak from the vast majority of thermoformers. “We work for startup companies and for Fortune 500’s,” says Beyer. “They have an idea and need someone to help them get @plastechmag
QUESTIONS ABOUT THERMOFORMING? Learn more at PTonline.com
Visit the Thermoforming Zone. Plastics Technology
47
On-Site
Tek Pak, Inc.
Carter, a Ph.D. chemical engineer, has at his disposal an analytical lab with an FTIR spectrometer (right) and Dynamic Mechanical Analyzer (left), neither of which would be found at the vast majority of thermoformers.
Tek Pak created this demo part to show off the easy formability of Pacur’s new PETG Foam sheet made with Eastman’s Eastalite. (Photo: Eastman)
electronics, followed by medical and food packaging, as well as
After development and perhaps initial production, Tek Pak
some retail packaging. General thermoforming is only about 20%
usually hands of the job to another thermoformer for full-scale
of its $13 million annual business.
production. “We typically run 10,000 to 100,000 parts. But we
One medical application prototyped
Medical development can take 18 months of trials and sometimes up to 16 or more revisions.
by Tek Pak just received FDA approval after passing a range of tests. It’s a PETG
have made millions of some specialty parts, like carrier tapes or difcult parts that others won’t run. “Telescoping time is our business,” adds Beyer. “Lead time for
tray package for an implantable heart
a design change in carrier tapes is generally three days or less.
pump worth upwards of $100,000.
A food package for Wal-Mart took us three weeks for develop-
Durability and impact protection of the
ment and we had products for them in four weeks.” Tek Pak’s
contents were critical considerations,
speed record is 4 hr to design and build a mold and run sample
Beyer points out.
parts. For its demanding clientele, Tek Pak has to be fast. “We’re
Tek Pak typically helps a customer optimize a product design to ensure
its manufacturability, then builds prototype tooling and forms initial samples. Beyer explains, “We usually start with a single-cavity prototype tool, but it’s built just like a production tool and is suitable for mid- or long-range, low-volume production.” For some customers, Tek Pak also provides initial or “bridge” production to support market development or allow time for a customer to ramp up to full-scale volumes. One resource for bridge production is Tek Pak’s largest continuous former, a Kiefel KDM 60 B pressure former with mold area of 460 x 600 mm (about 18 x 24 in.). On a recent day, the machine was running a blister package for a consumer electronic device using recycled PET (RPET). The blister was running 3-up at 1000 shots/hr. The order called for 60,000 parts over three months. 48
Plastics Technology
OCTOBER 2015
Beyer, who started out as a toolmaker himself, says, “I want to push the limits of what our tooling people think they can do. We live by accomplishing new things, so we have to take risks.” PTonline.com
Tek Pak, Inc.
working on 30 prototypes this month— and it’s a slow month,” exclaims Beyer.
R&D TOOL KIT The “toolkit” that makes this possible
“We have the largest toolroom in the thermforming industry that nobody knows about.”
On-Site
own small-footprint R&D machines with up to 4 x 6 in. forming area and radiant heat top and bottom.” These roll-fed, continuous forming machines are equipped with “gripper chains”—conveying chains with fnger grippers—developed by Tek Pak for
includes knowledge of a broad range of materials, including less common resins like PEEK, Ultem PEI,
thck materials, like 40-mil ABS, and fexible polyolefns as thin as 2
PVDF, TPU, specially formulated conductive/antistatic com-
mil, that can’t be handled efectively with conventional pin chains.
pounds, and even metalized flms. Notes Scott Carter, v.p. of R&D, “Around 30% of our materials are multilayer combinations, which
These R&D machines are designed for small, 1-up prototypes. “Some customers think we should start prototyping with a 12- or
aren’t in any property database.” He cites the example of a PE/
16-up tool,” observes Beyer. “But that just multiplies the difcul-
nylon/PE flm for a medical containment bladder. The nylon layer
ties and burns up more time, money, and material in learning to
adds stifness and puncture resistance. Another example is the three-layer solid/foam/solid sheet developed by Pacur using PETG skins over Eastman’s Eastalite copolyester foam core. It’s a styrene-free alternative to HIPS with faster cycles, greater resilience, lighter weight, more durable living hinges, and excellent cushioning ability. Beyer sees a range of applications potential in protective packaging for medical devices and fragile electronics, and even some consumer packaging. (See August Close-Up for more on Eastalite foam-core sheet.) Carter, a Ph.D. in chemical engineering, has an analytical lab the likes of which you won’t see at many thermoformers. It includes a ThermoScientifc FTIR spectrometer, used to identify unknown materials that customers send in and to validate that incoming materials
With a dozen people and an equal number of CNC machines, Tek Pak’s 6000 ft2 toolroom is “the largest in the thermoforming industry that nobody knows about.”
are what they are supposed to be. There’s also a dynamic mechanical analyzer (DMA) from TA Instruments,
get it right. We start out to make one good part consistently, then
with which Tek Pak can measure the glass-transition temperature
scale it up. And some particularly difcult parts have to run 1-up
(Tg) of unfamiliar materials and determine the optimal preheat
in production, too.”
and forming temperatures. One current task for the lab is analyzing
Another special piece of technology is laser trimming, performed
10 diferent varieties of mineral-flled PP sent in by a customer to
by a pair of LaserSharp LPM Flex 400 machines from LasX Industries,
produce samples of cofee-cup lids that would replace PS.
White Bear Lake, Minn. (lasx.com). “These are great for R&D because
When it comes to detailed design of new products and molds, Tek Pak utilizes two diferent 3D CAD packages and 2D AutoCAD
we don’t have to wait for trim dies to be built,” enthuses Beyer. “Instead of spending $12,000 for a matched-metal punch, the laser
software. While that’s twice as many 3D CAD programs as most
can cut a part in 0.5 sec.” On some special electronic parts, the laser
thermoformers use, “It means we can accept more native CAD
cuts patterns of up to 400 tiny holes (1.2 x 0.6 mm) in about 4 sec.
fles from customers—depending on what they use in-house—
Besides prototypes, Tek Pak manufacturers inserts for Corvette
and that means higher accuracy in translating their geometry,”
hood “badges.” Formerly injection molded, the inserts are thermo-
explains design engineer Kevin Swanson.
formed and laser trimmed at volumes of around 65,000 annually.
Another tool in Tek Pak’s kit is its equipment, much of it
Beyer notes that laser trimming is used by some other thermo-
homemade. “We have adapted commercial machines for proto-
formers, mainly on some heavy-gauge automotive jobs, but those
typing and low-volume work,” says Carter, “and we have built our
are not high-speed models like Tek Pak’s.
@plastechmag
Plastics Technology
49
On-Site
Tek Pak, Inc.
Laser trimming is well suited to development work because it requires no tooling and is fast—for example, punching up to 400 small holes in about 4 sec. Tek Pak thermoforms and laser trims inserts for the Corvette hood badge.
TOOLING SPECIALIST
Most of the molds are aluminum—“It can do millions of
Tek Pak builds all its own tools, and also many for other thermo-
shots,” according to Beyer, who believes steel is nearly obsolete
formers, even for some heavy-gauge jobs. It also machines its
for most thermoforming applications. Most of Tek Pak’s work
plug assists from thermoset syntactic foam. Beyer is understand-
uses cavity inserts that ft into standard mold bases.
ably proud of his 6000 ft2 toolroom with a staf of 12 and a dozen CNC machines with up to 40 x 60 x 15 in. working area. He calls
The toolroom has built 10,000 molds for carrier tapes alone, with six to 12 cavities. “We make 30 to 40 tools a month,” says
it “the largest toolroom in the thermforming industry that
toolmaker Rick Spera. “Our record is 86 carrier-tape molds in
nobody knows about.”
one month.” “We have 250 man-years of experience in our toolroom staf,” says Beyer. “But I want to push the limits of what our tooling people think they can do. We live by accomplishing new things, so we have to take risks. For example, we frequently violate the rules on draw ratios in carrier-tape tools.” He adds, with a sense of irony, “We constantly try out things that don’t work!”
SPECIALIZED PRODUCTION Clearly, a lot of things do work for Tek Pak. Besides its focus on prototyping, the frm has also developed a couple of specialties in commercial production. One that has already been mentioned is carrier tapes for automated electronic assembly. Wound on reels, these tapes are formed with tiny pockets—as small Some of Tek Pak’s carrier tapes are extruded directly over a rotary forming wheel. 50
Plastics Technology
OCTOBER 2015
as 0.1 x 0.15 x 0.1 mm—to hold components that race through assembly stations at speeds up to 75,000 cycles/hr. PTonline.com
Tek Pak, Inc.
On-Site
As a result, tight tolerances of ± 0.1 mm or less are standard, says Tracy Wolf, director of sales and business development. Accounting for half of Tek Pak’s business, the 35 carrier-tape forming
“I want to push the limits of what our tooling people think they can do. We live by accomplishing new things, so we have to take risks.
lines at the Batavia plant constitute the largest production facility for this product in North America, according to Beyer. (He says the largest plant in Asia has over 600 lines.) The tapes are extruded on-site from fve small extrusion lines with fat
dies up to 8 in. wide. Typical materials are conductive HIPS 0.3-0.4 mm thick or 40-mil conductive ABS. These specialized antistatic compounds are not available from standard sheet producers, so Tek Pak has to work directly with compounders. It also sells some sheet to electronic OEMs that do their
Design engineer Kevin Swanson showing a CAD model for the cellphone package on the desk in front of him. Tek Pak uses two 3D CAD programs as well as 2D AutoCAD.
carrier-tape forming. Some of the sheet is slit into narrower tapes and wound on
around a rotary forming mold and then is slit in two. Deionized air
reels for subsequent thermoforming. Some is extruded, formed,
is blown over the tape to remove particulates, which are trapped in
and punched inline. In the latter cases, the hot sheet passes
a receptacle underneath.
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@plastechmag
Plastics Technology
51
On-Site
Tek Pak, Inc.
One specialty of Tek Pak’s is carrier tapes for electronic assembly, an example of which is shown here, made of 0.3-0.4 mil antitstatic HIPS. With fve small tape extrusion lines and 35 forming machines, Tek Pak reportedly has the largest carrier-tape plant in North America.
Because of frequent product changes, quick mold changes are vital in the carrier-tape business, typically taking 30 min, though sometimes as little as 5 min if there is no material change. According to Beyer, quick changes are also “becoming more critical in general thermoforming as we grow the business.” A second specialty, of much newer vintage, is being developed at Tek Pak. Production forming (not just prototyping) of very thin, fexible materials, such as LDPE or EVA at 2-3 mils up to 20 mils, has promising potential for diaphragms, containment bladders,
A new specialty is forming very thin, fexible materials. “We’re doing it because most people don’t want to do it. Standard equipment can’t handle it.” and gaskets for medical and electronic applications. An example is a domed diaphragm 4-6 mils thick ± 2 mils. “We’re doing it because most people don’t want to do it,” says Beyer. “Standard equipment can’t handle it. That’s why we built our own with fnger grippers instead of
gala-industries.com
540.884.2589
pin chains, which won’t hold these materials.” He adds, “Most of these projects start out very small—no truckload orders in six months.”
52
Plastics Technology
OCTOBER 2015
PTonline.com
Tek Pak, Inc.
On-Site
Beyer sees opportunities for thin fexibles in markets that don’t exist yet. This LDPE tray is an example of a new specialty niche in thermoforming very thin, fexible materials. The 0.015-in.-thick tray was designed to test the limits of the material and process.
For instance, he envisions that such materials in medical applications could reduce hospitals’ disposal costs for hazardous or infectious “red-bag waste” by making the waste less bulky and more compressible.
‘GAME CHANGER’ AHEAD Tek Pak has carved out another niche for itself, by riding the leading edge of what Beyer sees as a new wave about to wash over the medical thermoforming busi-
‘Game-change’: Medicaldevice OEMs want to do their own thermoforming in-house to save freight.
ness. “It’s a game-changer that’s just happening now and is gaining momentum. Medical-device OEMs want to do their own thermoforming in-house to save freight.” Examples are packaged surgical kits, for which the OEM ultimately may want to make the devices and package them in the same facility. Since few medical OEMs have much experience in thermoforming, Tek Pak has developed a role as a consultant and a supplier of turnkey forming systems. The Kiefel machine, because of its mid-range
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production capacity, is a good tool for developing a turnkey package. “It has already happened in carrier tape for the past decade around the world,” says Beyer. “We have supplied 15 or 16 carrier-tape systems with our own specialized machines. There’s no standard catalog for that.” When a “game-change” like this threatens to strike your market, Beyer says, a manufacturer has to ask some vital questions: “How do you position yourself for that change? When do you invest to
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survive and proft from that change? And how long is the ‘on ramp’ before you can get cash out of it?” @plastechmag
Plastics Technology
53
Tips and Techniques
Here’s What You Need to Know to Make World-Class Stretch Film Advances in materials, feedblock/ die technologies, and winding can help processors develop more sophisticated cast-stretch products. Nanolayer feedblock and die package from Cloeren. Nanolayer feedblocks are considerably larger than conventional coex blocks. For dies, fow-channel shapes had to be reexamined, and precision of tolerances had to be tightened up, in order to meet the process demands associated with such thin layers.
The dynamics of the stretch flm market are continuously
mechanical properties such as puncture and tear resistance and
evolving. Worldwide, the big trends and drivers in cast stretch are:
allows thinner pure-metallocene PE layers.
By Trudy Iaccino, ExxonMobil Chemical Co. Peter F. Cloeren, Cloeren Incorporated Dr. Frank Hoffmann, Windmoeller & Hoelscher
• Downgauging:
processors include the likes of Apeldoorn Flexible Packaging B.V.
of hand wrap has
(AFP), a Dutch producer of a wide range of blown and cast flms for
gone from 25 microns to 10 microns (µ) and the average gauge for
packaging, which has been utilizing nanolayer technology since
machine wrap and power pre-stretch has gone from 35µ to 15µ.
January 2009. AFP’s original nanolayer launch was for 27-layer
Cast-flm lines are being engineered to allow production of thinner
flms, but Eddy Hilbrink, who heads up strategic R&D projects,
flms at higher-than-ever winding speeds (up to 2300 ft/min or 700
told Plastics Technology of plans to push the envelope further with
m/min). More fexible inline winding has been developed to reduce
the installation of a third nanolayer line, this one for more than 50
labor costs and scrap rates.
The industry did not jump from fve-layer flms to 55 layers in one fell swoop. It took two decades to arrive there.
• Higher stretch percent:
layers (see May Close-Up). Among North American processors, no one seems willing to
The upper end of the
even discuss numbers of layers. A 2012 patent lawsuit probably
stretch range has risen
explains why. In February of that year, a technology licensing frm
from 200% to 300%.
called Multilayer Stretch Film Holdings fled separate lawsuits
• Increased use of
against nine leading North American stretch-flm processors,
machine wrap by end
claiming they had violated a patent covering stretch cling flms
users: The trend is moving
with seven or more layers. Industry sources report that most of the
from hand wrap to machine wrap—a result of increasing labor costs.
processors named have since settled out of court. Last November,
• Higher machine wrapping speed among end users: Average
however, the Federal District Court in Memphis ruled in favor of
wrapping speed has moved from 25 rpm to 60 rpm (the latter
stretch-flm processor Berry Plastics, Evansville, Ind. Multilayer
applies only to orbital/rotary arm-wrapping machines).
Stretch Film Holdings has appealed that ruling. Berry (berryplastics.
• More layers: The movement towards multilayer flms continues to grow and diversify. Film confgurations range from
54
In Europe, nanolayer technology is growing quickly. Progressive
The average gauge
com) would not comment on the matter. Nonetheless, signs suggest that more processors in North
three layers all the way up to dozens of nanolayers. Nanolayer
America are moving beyond the fve-layer structures that have been
structures give the flm a “plywood” efect that enhances
generally considered “state of the art” in the NAFTA region since
Plastics Technology
OCTOBER 2015
PTonline.com
S T R E TC H F IL M
Peter Cloeren launched Chaparral Films in Orange, Tex., in 1994. In
FIG 1
August, Sigma Stretch Film, Lyndhurst, N.J., the largest producer
Seven-Layer/Five-Component Confguration for Power Pre-Stretch Films (>250%)
of stretch flm in North America, announced that it would be installing a nine-layer cast-stretch line from SML of Austria (U.S. ofce in Gloucester, Mass.; sml.at) with a Cloeren die/feedblock package. The line, which is expected to be delivered by the frst half of next year, will be used to run 20-in.-wide rolls nine up.
Reference
Exceed mPE Resin and Vistamaxx Alternative
17 μm LLDPE Market ref
15μm EBDCDBA Coex 10%/17%/16.5%/16%/16.5%/17%/10% Non-cling Layer A: 100% ZN-LLDPE (2.0-2.8 MI/0.920 d)
Another major processor, Inteplast Group’s AmTopp Stretch Film Div. (inteplast.com), also announced a major expansion recently
Sub-skin Layers B: 100% Exceed 4518
(see sidebar). Market consultant Mastio & Co., St. Joseph, Mo.
Sub-skin Layers D: 100% Exceed 4518
(mastio.com), projects stretch flm will grow at 4.5%/yr through
Core Layer C 100% Vistamaxx 3980FL
2017, when it will consume more than 2.2 billion lb of PE.
Cling Layer E: ZN-LLDPE (2.0-2.8 MI/0.920 d) + Vistamaxx 6202
How does a processor serving this market kick it up a notch from a technology standpoint? While stretch lines are large and
Highlight Ultimate Stretch, % 400
complex, three keys to developing world-class stretch flm are materials, feedblocks/dies; and winding. In this article, industry leaders in each of these areas—ExxonMobil, Cloeren, and Windmoeller & Hoelscher, respectively—share their expertise.
Tensile Force @ NDR, N/15mm 5 4
In trials with customers and leading machinery suppliers, ExxonMobil has found that certain of its resins ofer desirable properties for stretch flm: • Enable metallocene-based PE (mPE) resin provides high holding
200 2
20 100 15 5 10
25 30
Stretch Force @200, kg
500 Elmendorf Tear TD, gr
force at low flm thickness. • Exceed mPE resin provides high holding force and puncture
Pallet Wrapping Test - Puncture Measurement
resistance at high stretch ratios. • Vistamaxx performance polymers are propylene-based elasto-
(300% Pre-stretch with Variable Lay-On Tension)
mers that provide high tear-propagation resistance at high EMC
stretch ratios. These resins are also commonly used to efective cling in these multilayer flms. Enable mPEs are
cene resins. This metallocene resin family has higher shear thinning, which allows for low-melt-index grades to be used in cast-flm extrusion to obtain improved physical properties. The strain-hardening curve illustrates that these resins have a distinct second yield point, which provides a step change in tensile strength. Using these resins in cast stretch flms yields high tenacity and high holding force across a wide stretch range, which delivers additional value in cast hand-wrap and machine-wrap applications. Exceed mPE resins have become an industry standard for high-stretch, high-puncture-resistance stretch flms. A broad portfolio of resins—including Enable mPE and Exceed mPE resins, and Vistamaxx polymer—is utilized to tailor solutions for specifc equipment and application requirements.
Low
Ref
provide reliable, cost-
branched metallo-
@plastechmag
3
1 100 200 100 0.5 300 1 200 Puncture Force 1.5 400 2 2.5 @250%, kg 300 NDR, % 400
IT STARTS WITH MATERIALS
When you combine the available selection of polymers and the ‘plywood effect,’ more layers are inevitable.
300
80 79 60 50 40 30 20 10 0
Holding Force, N
100 95 90 85 80 75 70 65 60
Film Weight, g
Ref EMC Ref EMC Standard Tension
High Pass
80 79 60 50 40 30 20 10 0
Very High Break
Holding Force, N
100 95 90 85 80 75 70 65 60
Film Weight, g
Ref EMC Ref EMC High Tension
Holding force is measured using a Lantech, Q300XT at 300% pre-stretch
Here, a 17-micron LLDPE reference flm is compared with a 15-micron, seven-layer flm comprising Exceed mPE resins and Vistamaxx polymers. The thinner, 15-micron flm delivers physical properties similar to those of the 17-micron flm, as highlighted by the blue line in the center spider chart. The chart at the bottom demonstrates that the holding force of the thinner, 15-micron flm is almost equivalent to that of the 17-micron reference flm, despite the weight of the flm being considerably less. Also, the 15-micron flm breaks at a higher tension than the 17-micron reference flm during a pallet-wrapping test. Plastics Technology
55
Tips & Techniques
Nanolayer Confguration for Power Pre-Stretch Films (>250%)
FIG 2
Vistamaxx performance polymers ofer improved puncture and tear-propagation resistance at high stretch and tension. In addition, they provide a more efcient cling solution.
Exceed mPE Resin and Vistamaxx Alternative
Reference 17 μm LLDPE Market ref
Achieving cling in stretch flm has been an evolutionary process that began with the use of polyisobutylene (PIB). PIB is a sticky
15μm A/B/C/D/E/F/G 30%/10%/10%/12%/18%/10%/10%
liquid that’s very difcult to meter into the product. Next came
100% ZN-LLDPE (2.0-2.8 MI./0.920 d) 95% Exceed mPE 3518 5% Vistamaxx 6102 100% Vistamaxx 6102 ZN-LLDPE (2.0-2.8 MI./0.920 d) + Vistamaxx 6102 B
A
F
10%
15%
10%
D E D E D E D E D E D
G
A
C
10%
15%
10%
300 4
3
300
NDR, %
200
400
200 2
1
100
100 10
5
15
Highlight Stretch 30 Force 25 @200, kg 20
(300% Pre-stretch with Variable Lay on Tension)
Ref 80 79 60 50 40 30 20 10 0
Holding Force, N
Ref EMC
100 95 90 85 80 75 70 65 60
of the previous options. A variety of multilayer confgurations are used in the stretchflm industry. Solutions using Exceed mPE resin and Vistamaxx polymers have been developed that provide signifcant unit-cost
• Outstanding pre-stretch and high-speed wrapping performance. • Less flm, by weight, to wrap a pallet at equal load stability. Figures 1 and 2 review two multi-layer confgurations that provide examples of value-added flms. The seven-layer example is
High
layer confgurations, whether higher or lower in layer count. In both instances, thinner flm yields equivalent physical properties. There are many options for customizing stretch-flm performance. Options that ExxonMobil Chemical has proven to be successful, for a variety of
Pallet Wrapping Test - Puncture Measurement
Pass
provides comparable cling performance at a better value than either
representative of a multi-layer approach and can be adapted to other
100 0.5 1 1.5 Highlight 200 2 Puncture 2.5 300 Force 400 @250%, kg 500
Low
cling layers. Today, adding about 10% or less Vistamaxx often
• Improved toughness at thinner gauge.
Elmendorf Tear TD, gr
EMC
alternative to achieve cling by blending as much as 30% into the
savings versus the alternative by providing these benefts:
Highlight Ultimate Stretch, % 400 Tensile Force @ 5 NDR, N/15mm
metallocene elastomers, which provided a cleaner, more precise
Very High Break
scenarios, include the following: • Enable mPE resin can be used to adjust load force/working range.
Where nanolayer flms appear to excel is in the wrapping process itself.
• Vistamaxx 3980FL has provided improved stretch/puncture resistance in a nanolayer structure. • Exceed mPE resins have been used to improve many stretch-
Film Weight, g
Ref EMC
80 79 60 50 40 30 20 10 0
Standard Tension
Holding Force, N
Ref EMC
100 95 90 85 80 75 70 65 60
Film Weight, g
flm properties. Exceed 3812CB has provided cling /toughness improvement. Exceed 7518CB has provided process continuity, cling, cling retention, and stretch performance. Using it as a cling layer with Vistamaxx performance polymers provides improved cling and blocking resistance. It also provides softer, higherstretch flm used in skin and/or core layers. Moreover, it improves extrusion processing, edge-fow stability, and web stability, which
Ref EMC
High Tension
allows stable operation at higher rates, as well as improving flm continuity and consistency.
Holding force is measured using a Lantech, Q300XT at 300% pre-stretch
Here, a 17-micron LLDPE market reference flm is compared with a 15-micron nanolayer flm comprising Exceed mPE resins and Vistamaxx polymers. The thinner 15-micron flm delivers physical properties similar to the 17-micron flm, as highlighted by the blue line in the center spider chart. The chart at the bottom demonstrates that the holding force of the thinner 15-micron flm is almost equivalent to that of the 17-micron reference flm, despite the weight of the flm being considerably less. Also, the 15-micron flm breaks at a higher tension than the 17-micron reference flm during a pallet-wrapping test. 56
Plastics Technology
OCTOBER 2015
FEEDBLOCKS, DIES & NANOLAYERS With the commercial introduction of metallocene resins in the mid-1990s, the 15-year standard of three-layer stretch films was challenged, and the world’s first commercial five-layer film was introduced to the marketplace in 1994 by Chaparral Films. Was this development “smoke and mirrors” or “hocus-pocus”? Something new had upset the industry status quo, and the industry icons of the time, who had yet to understand the techPTonline.com
S T R E TC H F IL M
nology and its promise, did not
FIG 3
respond kindly. Fast-forward to 2015, and flms are being processed comprising 50+
legend Yogi Berra reportedly once said, “It’s like deja vu all over again.” The industry did not jump from five-layer films to 55 layers
of seven-layer films at the turn of the 21st century and the earnest use of polypropylene as a tear-propagation-resistance layer. Between 2000 and 2005, some firms even ventured into nine-layer films. The first nanolayer film, comprising
scale, layer thicknesses. However, as industry is coming to the resolution
4 0
comprise sub-micron, or nanometera practical matter, it appears that the
6
two decades to arrive there. The industry saw commercialization
Under-utilized Capacity
8
2
nanometers (0.0009 mil).
example, even fve-layer flms could
10
in one fell swoop. Instead, it took
at layer thicknesses of less than 25
today at or less than 10 microns, for
12 Number of Units
corners of the industry. As baseball
stretched above 300%, you arrive
With many flms produced
14
layers, and the 1995 song of “smoke and mirrors” again rings in some
Purchased Layer Capacity by Region for Lines ≥ 3000 mm (2010 – Sept. 1, 2015)
that a “nanolayer flm” is comprised of a majority of layers of less than 5-6 layers NAFTA
7-11 layers Europe
Nanolayers
Asia
Other
The current distribution of purchased layer capacity during 2010-2015 shows the surging activity in Europe for nanolayer technology. For the U.S., the box labeled Under-Utilized Capacity refers to installed capacity not being utilized owing to patent litigation. Source: Cloeren Incorporated
one micron each. Perhaps some nineand 11-layer flms, and certainly all 20-50 layer flms, technically ft the developing consensus defnition of nanolayer flm. The principles of laminar fow apply to all thermoplastic extrusions and coextrusions. The number of layers is indiferent to these principles. However, the required attention
21 layers, was introduced to the market by Pinnacle Films (now part of AmTopp). Next,
to design detail does increase signifcantly, if not exponentially. We
industry expert and visionary Hilbrink of AFP introduced a
at Cloeren assumed we knew a lot of things well, but it turned out
27-layer film and now is adding a third nanolayer line with
that we didn’t know as much as we thought. Increasing the number
more than 50 layers.
of layers while simultaneously reducing the layer thicknesses has a
Today, it is rare to see new fve-layer and even seven-layer capacity being acquired on large-scale commercial lines. It’s fair
way of humbling someone really fast. To meet customer expectations,
to say that nine- and 11-layer capacity is the current norm, and
new software had to be developed,
nanolayer capacity not so unusual. Figure 3 shows the current
new tooling had to be implemented,
distribution of purchased layer capacity during 2010-2015, by
and new manufacturing techniques
geographical region.
had to be applied.
So why more and more layers? One reason is that the stable of
Feedblocks that house nanolayer
polymers available today—including mPEs, propylene-based elas-
technology are substantially larger
tomers, olefn block copolymers, LLDPEs, ULDPEs, and VLDPEs—to
than conventional (three- to 11-layer)
construct higher-performance flms is signifcantly larger than a
feedblocks. Usually, as things become
decade ago. When you combine the available selection of polymers
larger, allowable manufacturing toler-
and the so-called “plywood efect,” more layers are inevitable.
ances also become larger and more
High-speed production of stretch flms requires a dedicated winder that incorporates all three ‘TNT’ principles.
The plywood efect is the mutual reinforcement of plies
forgiving. That is not the case with nanolayer feedblocks: The toler-
(layers) to obtain unique properties. Plywood relies on orienta-
ances actually had to be tightened up to provide the required preci-
tion of grain structure in varying or opposing directions to obtain
sion of mass distribution, which is proportional to the number of
its unique strength and pliability. While the coextrusion flm-
layers involved.
forming process does not allow for diferent directional orienta-
At the same time, it was clear that fexibility could not be sacri-
tion of each ply, discrete layers of difering polymers do, in fact,
fced. This required a modular design concept to be able to change
result in diferent crystalline structures per layer. These difering
layer position, polymer selection, and the like. The modularity and
crystalline layer structures, when produced at the appropriate
precision levers typically don’t move in the same direction, but in
thicknesses of apposite polymers, provide mutual reinforcement.
this case they had to if customer expectations were to be met.
Hence, more, and thinner, layers. What constitutes a nanolayer? A nanometer is 1/1000 of a
QUESTIONS ABOUT FILM EXTRUSION?
micron. There are 25,400 nanometers in one mil. In a cast flm, layers can be a thin as 100 nanometers. Then, when this flm is @plastechmag
Visit the Film Extrusion Zone. Plastics Technology
57
Tips & Techniques
AmTopp’s Layered Approach Supports Growth Strategy Layers explain why Inteplast Group’s
in Phoenix, Ariz., and Houston. One
says helps distinguish AmTopp from its
AmTopp Stretch Film Div. is among the
of the two new lines will be located
competitors. “We manufacture a wide
largest stretch-flm
in Charlotte; the other in Phoenix.
range of cast-flm products that are
processors in North
Currently, only Sigma Stretch Film Group
designed for specifc applications,” he
America, nearly 25
By Jim Callari Editorial Director
and AEP Industries, Montvale, N.J., are
elaborates. “We manufacture machine
years after fring up its frst lines in Lolita,
believed to have more capacity. The line
flm, hand flm, and specialty flms for our
Tex. “Layers” does not exclusively mean
in Charlotte is expected to be operational
customers. If a customer needs a highly
flm layers. When you lay a philosophy of
by the end of 2015; the Phoenix line
engineered flm, we have it. If they need
continuous improvement atop a diverse
should be commissioned at some point
something more basic, we have that too.”
and fexible product line, R&D, invest-
in the frst quarter of next year.
ment in new technology, commitment to shorter lead times, and customer service,
AmTopp ofcials say the two new lines do not mark the end of its expan-
applications, and this is our singular
the company’s formula for stretch flm
sion plans. In fact, the company sees
strength in the market. We launched
success becomes clear.
opportunities to sell stretch flm beyond
our pre-stretch flm in 2014, which has
In just the past fve years, the company has more than doubled its
the borders of NAFTA. “We are strongly
proven to be one of the most successful
committed to this industry and will
launches in our product catalog. The
capacity by adding lines and by acquiring
continue to expand,” states Homer Hsieh,
entire group—manufacturing, sales, and
the Pinnacle Films operation in Charlotte,
president. “We believe the economy is
marketing—is singularly committed to
N.C. Its recent investment of $15 million
improving and that the cost of polyeth-
the process, the products, and contin-
ylene in North America will be competi-
uous improvements, with the focus
tive globally long-term, which will
being on supplying our customers with
support our objective to be an exporter of
consistent, quality product.”
stretch flm manufactured in the U.S.” While all of AmTopp’s capacity is multi-layer, the company didn’t want to
Inteplast Group’s AmTopp Stretch Film Div. has 13 stretch lines at four locations in the U.S. and recently installed capacity for about 320 million lb/yr. Pictured here is Scott Stevens, sr. dir. of product and business development at Inteplast.
In North America, stretch flm is sold through distributors, whereas flm processors in Europe have more
get specifc about how many layers. “We
direct connections to end users. That’s
invest in R&D,” notes Scott Stevens, sr.
a simple function of the size of the U.S.
dir. of product and business develop-
compared with most European coun-
ment at Inteplast. “But it’s not all about
tries. While European flm producers
layers. We are open to new technology
view this as a competitive advantage,
and stay abreast of it, in keeping with
Stevens notes that AmTopp spends
our standing in the industry. Ultimately,
considerable time and efort training its
the demands of the marketplace, the
distributors on how their flm performs
needs of our customers, and anticipated
and how it should be utilized. Stevens
ROI for investments in new technology
says the distribution network does not
and new equipment drives decisions.
detach AmTopp from its customers.
“For stretch flm, our goal is products that perform according to the needs of the customer at a price that is competi-
“We’re directly in the loop with all of them, the high-profle ones in particular.” Continuous improvement is deeply
tive and in line with the requirements of
ingrained at Inteplast Group, driven by
their specifc application,” Stevens adds.
Dr. John Young, group president. “It’s
“It is possible to over-engineer a flm,
an ongoing practice at Inteplast and
giving it more performance attributes
an important part of our company
in two new multilayer lines will give the
than it needs to serve a specifc purpose.
culture,” says Stevens. “It is ingrained in
frm about 320 million lb of capacity from
That doesn’t do the end user any favors,
everything we do. We never stop asking
13 lines in four plants.
as they wind up paying for more func-
ourselves how can we do something
In addition to Lolita and Charlotte, AmTopp also produces stretch flm
58
Adds Hsieh, “We ofer a stretch-flm solution for every one of our customers’
Plastics Technology
OCTOBER 2015
tions than they need.” Product diversity is what Stevens
better and more efciently, and we work hard to put our best ideas into practice.”
PTonline.com
S T R E TC H F IL M
further postulate that if the allowable
Then came the die. To distribute nano-thickness layers
acceleration forces are measurably
uniformly across a 3.5-5.5 m
higher, then so too are the allowable
(150-220 in.) die required a second
deceleration forces. Allowable decel-
look at die design. Flow-channel
eration forces are particularly impor-
shapes had to be reexamined, and
tant in Europe where pallets are side
precision of tolerances had to be
loaded, and nesting of pallets is not
tightened up, in order to meet the
inherently attainable, as is the case
process demands associated with
with end-loaded trucks in the U.S.
such thin layers.
WINDING IT UP
So what are the benefts of nanolayer stretch flms? When
High winding quality is essential for
looking at standard laboratory
reliable and safe usage of stretch flm
testing, or controlled testing stan-
in tertiary packaging. The majority of
dards, the results for nanolayer
challenges during winding are
flms are not overwhelmingly
tightly connected to the extrusion
apparent when compared with conventional seven- to 11-layer flms. However, when looking deeper, or further downstream in the process, other benefts present themselves.
For high-speed, high-performance stretch-flm winding, flmwidth format fexibility must be maintained. On this W&H Filmatic PS winder, the trim pick-up system provides seamless adjustability for trim removal at multiple roll widths.
Where nanolayer flms appear
process, so it’s essential that extrusion and winding be closely integrated. Film profle tolerances in the sub-micron scale are inevitable and add up layer by layer in the roll of flm, so that the flm could be deformed and damaged inside the
to excel in practice is in the
wound roll. In some applications,
wrapping process itself. Typical orbital wrapping speeds are in
stretch winders have to be designed for frequent roll changes so
the range of 20-25 rpm. When nanolayer flms are applied to the
that the extrusion line speed can be kept high.
same wrapping process, all else being equal, we see attainable
The “TNT” principles of winding are the basic parameters
and reliable wrapping speeds at least double those of conven-
that control the build-up of pressure inside the roll: tension of
tional flms. To big bottlers and packagers, this equates to big
the film, nip force between contact roll and film roll, and torque
money—twice as many pallets per wrapping machine per hour.
on the winding shaft at the center of the roll. The TNT settings
What these feld results tell us is that nanolayer flms yield
determine the general tightness of the film layers within the
signifcantly higher allowable acceleration forces. One can then
roll. At the same time, the outer layers of flm in the roll act as
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Incompatible PP/PET/PE– No Additive
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Plastics Technology
59
Tips & Techniques
compression tapes on the inside layers and particularly on
widths, the extruded web is split into a maximum of 12 webs in the
the paper core, where the pressure is the highest. Depending
slitting station of the winder.
upon film resin formulation, the film may “age” by thermal
Usually, a “bleed” trim is cut between the webs, so that the
shrinkage and post-crystallization after production. Stretch
paper cores in the center of the rolls extend over the edges of the
films with a functional layer of PP, for example, exhibit a signif-
rolls. These trims are typically tacky and highly extensible; they
icant change in their mechanical properties and subsequently
must be cut reliably at high speed and re-fed into the extrusion
tend to develop higher core pressures during storage.
process for better material and energy efciency. All in all, one stretch-flm product can difer a lot from
Three diferent types of stretch flms are commonly produced: hand wrap, machine wrap and super-power stretch wrap. These flms have application-optimized properties concerning ultimate stretch, holding force, puncture, tear-propagation resistance, and cling. All of these parameters afect slitting and winding processability.
another on the winder. As a conclusion, the
It’s fair to say that nine- and 11-layer capacity is the current norm, and nanolayer capacity not so unusual.
winder needs to provide high fexibility, easy handling of complexity, high reliability, and—last but not least—good roll quality. High-speed production of stretch flms requires a dedicated winder that incorporates all three TNT principles. In the case of W&H´s Filmatic PS winder, two winding units are
For example, the winding tension for
positioned on top of each other in a laterally
thin super-power stretch wrap should be as low as possible to prevent core crushing. Furthermore, the appli-
ofset arrangement, each winding one half of the web. Identical web
cation afects the roll dimensions. For compatibility with the
paths through both winding units guarantee consistent roll quality
wrapping machine, rolls for machine wrap have a standardized
across the complete web. All rolls in the winder are optimized for
roll diameter of about 10 in. and fxed flm widths of 20, 30, or
enhanced traction at low web tensions for thinner flms. In addition, the tension zones for slitting and winding are
even 40 in. Hand-wrap rolls, in contrast, might have any width in the range between 10 and 20 in. The roll diameter for the fnal
mechanically isolated from one another to widen the process window.
hand application is less than 10 in. Sometimes there are only a
A unique, stif bearing assembly for the winding shafts ensures
few thousand feet of flm on the core.
minimal defection during winding, ensuring perfect roll edges and consistent roll hardness at high speeds. Furthermore, the winder
Hand–wrap rolls can be produced inline with extrusion or ofine by slitting larger “jumbo” rolls with typical diameters
ofers an innovative feature to optimize and maintain the winding
of up to 16 in. High production speeds of up to 2300 ft/min,
hardness by a fne adjustment of the air entrained in the winding gap. Traditionally, elimination of air in the rolls was paramount. Now,
combined with small roll diameters, result in roll-change cycle times from 30 sec to several minutes. Depending on roll and die
with the advent of higher-performing, thinner stretch flms, running
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info@nordsonpolymerprocessing.com
60
Plastics Technology
OCTOBER 2015
www.nordsonpolymerprocessing.com
PTonline.com
S T R E TC H F IL M
at higher line speeds, there is the need to control air distribution throughout the roll. Rolls with controlled softness ofer these benefts: • Low unwinding forces cause fewer flm breakages in the stretch wrapper head. • Low unwinding noise is a prerequisite for fully automated packaging lines in warehouses. • Higher possible cling levels are
ABOUT THE AUTHORS: Trudy Iaccino is customer development sr. engineer at ExxonMobil Chemical Co., Baytown, Tex. She provides technical support to customers and assists with their development projects. Contact: trudy.iaccino@exxonmobil.com; exxonmobilchemical.com. Peter F. Cloeren is president and CEO of Cloeren Incorporated, Orange, Tex., a global leader in feedblock and die technology. He holds more than 30 patents in the feld of extrusion and coextrusion. An SPE Fellow, Cloeren also has received the SPE Jack Barney Award, the TAPPI Samuel Zweig Award, and the DuPont Sustainable Packaging Award for nanolayer coextruded flms. Contact: (409) 951-7600; pcloeren@cloeren.com; cloeren.com. Dr. Frank Hofmann is team manager of winding technology at Windmoeller & Hoelscher in Lengerich, Germany, where he is responsible for the technology design of blown and cast flm winders. Contact: (+49 5481) 14-2115; frank_hofmann@wuh-group.com; wuh-group.com.
critical for load stability and higher load-holding forces. • Elimination of flm wrinkles gives few flm breakages during stretching on the wrapper. • The ability to run thinner machine flm cores provides huge potential
5 IS THE NEW 3!
savings to the flm converter. An automation system is mandatory at high web speeds to achieve operator safety and process stability. Each winding turret features three winding shafts so that paper cores can be loaded onto a shaft and rolls can be pulled from another shaft in parallel to the winding process. At the same time, flm-width format fexibility has to be maintained (see photo p. 59). Therefore each winding turret has core bins for two diferent core lengths. Cores from either bin can be combined with a manually fed core size in a programmable core pattern. All core bins
NGS I V A $ RESIN
ICAL S Y H P D E ENHANCOPERTIES PR D S TAILORESTRUCTURE
for both turrets are easily accessible to the operator in a single location. A new trim-suction system in the slitting station ofers width-format fexibility and easy operation. Position of the fow-optimized suction pipes can be adjusted seamlessly according to the roll widths for best slitting performance and stability. Finally, specialized high-speed shafts are available that can cope with any core pattern that might be necessary. Winding a good roll of stretch flm can be the most demanding part of the production process. The features enumerated above simplify the art of winding with additional adjustability and
THE BLOWN FILM EXPERTS
ALPINE AMERICAN • www.halpine.com • Tel: (508) 655-1123 • Natick, MA •
enhanced fexibility. @plastechmag
Plastics Technology
61
Tips and Techniques
Spec’ing a Robot? Match It To Your Press Size & Project Where is your business today? What might tomorrow’s molding projects look like? These are among the questions you need to answer when deciding what style of robot is best for you.
Selecting the proper design for a robot is one of the most critical steps in maximizing its value. If the robot is unprepared for heavier By Jason Long Wittmann Battenfeld USA
duty, high-payload jobs that arise, it
Three main aspects of robot design include:
becomes efectively useless. However, to
• Mounting options;
purchase the longest stroke and highest
• Payload;
payload available, when the robot will never be handling more than short-reach, light-load tasks, is a waste of your money.
• Kick-forward design (for large-tonnage presses) vs. kick-back design (for small-tonnage presses).
To specify your robot properly, you need to have a thorough and complete knowledge of where your own business stands
MOUNTING OPTIONS
today, as well as any directions in which it might be going. Be
Every molding cell is unique, and one of the most important require-
prepared for any potential future, but don’t be unrealistic.
ments of a new robot is that it ft into the design of its cell as seamlessly
The intention of this article is to help you to use your knowl-
as possible. Where the robot is mounted on the injection molding
edge of your own molding business to help select the right design
machine and where it
for your next perfect robot.
drops the fnished parts are extremely important to creating
WHAT YOU WILL LEARN 1. MAKE INTEGRATION SEAMLESS. Know your mounting options so that your robot will ft into your molding cell as seamlessly as possible. 2. HOW TO MEASURE PAYLOAD: Payload handling is not just a measure of the plastic parts or shot size. Calculate it for current and future needs. 3. HOW PRESS SIZE FACTORS IN: This determines whether you should go with a kick-forward or kick-back design. 4. 3D PROGRAMMING: Robots should allow for easy programming in three dimensions simultaneously to permit curve motions, not strictly linear singlemotion-at-a-time programming.
the most efcient molding process possible. Ideally, the
One of the most important requirements of a new robot is that it ft into the design of its molding cell as seamlessly as possible.
robot will ofer traverse-beam modularity, which gives the molder the ability to move it to various orientations to accommodate changes in the workcell. There are many diferent positions in which to mount a robot, but the four standard ones are operator side, rear side, T-mount, and longitudinal. Rear and operator-side part drops are good for applications that require room for an operator or mold setter to access both doors on the press. The rear side of the injection machine can often use shorter horizontal strokes because it requires less access. These are the two most common robot orientations. The T-mount design is a solution for separating diferent parts, whether it’s “lefts” on one side and “rights” on the other, or dropping bad parts into a granulator on one side while good parts
62
Plastics Technology
OCTOBER 2015
PTonline.com
SELEC TING ROBOT S
The four standard positions to mount a robot are (far l. to r.) operator side, rear side, T-mount, and longitudinal.
are moved to the next stage of the molding cell on the other side.
KICK-FORWARD VS. KICK-BACK
This design is also customizable, as the robot can be ofset to one
Small to medium-sized machines often require a kick-forward, or
side more than the other, allowing it to reach slightly farther in
carriage-forward, design. This design allows the back side of the
one direction if it has to. Access to the press doors is the same on a
platen to be clear to avoid obstructions such as a hopper on a short-
T-mount as it is on a normal rear-side or operator-side design.
barreled injection unit, throat-mounted dryers, building columns,
The longitudinal design, or L-mount, is most useful for molders
catwalks, etc.
that need to conserve foor space. By depositing parts at the clamp end of the machine, this design allows molders to ft up to 50% more machines (based on foor layout) than conventional operatorside placement. It also allows use of a central conveyor that will bring all the parts to one central location and require fewer operators. To use this design, ensure there are no obstacles over or past the clamp unit of the press such as clamping cylinders, oil flters,
Standard Payload Recommendations for Robots Press Tonnage
Light Duty
Standard Duty
Heavy Duty
50-100
6 lb
11 lb
NA
100-200
6 lb
13 lb
28 lb
200-300
22 lb
22-33 lb
44 lb
300-500
22 lb
33 lb
44-55 lb
600-800
33 lb
44 lb
55-75 lb
900-1100
44 lb
55-75 lb
110 lb
1200-1500
NA
75 lb
110 lb
1600-2500
NA
110 lb
220 lb
2600-5000
NA
220 lb
300 lb
water lines, or light fxtures. The molder should also be sure there is room for beam support legs and that the horizontal stroke can make it past the clamp by at least the width of the tiebars.
PAYLOAD HANDLING Robots should have sufcient payload for current and future application needs. Remember that payload handling is not just a measure of the plastic parts, or shot size: PAYLOAD = SHOT SIZE + EOAT WEIGHT + CENTER-OF-GRAVITY OFFSET ALLOWANCE. For example, due to its inclusion of heavier materials and sturdier EOAT, an insert application on a 500-ton press might require a 55- to 75-lb robot payload capacity when all payload sizing criteria are calculated—even though the plastic parts themselves weigh only 2 lb. Remember, long-term reliability and robustness are both important considerations when calculating
QUESTIONS ABOUT ROBOTS?
proper payload-handling specifcations. See the accompanying table for standard payload recommendations for your robot. @plastechmag
For more information visit the Robot Zone. Plastics Technology
63
Tips & Techniques
For medium to larger molding machines, the kick-back design is more balanced and allows for a heavier payload.
Kick-forward designs are more suitable for small- to mediumtonnage presses. They allow the back side of the platen to be clear to avoid obstructions.
Medium to larger machines can beneft from robots with a
To achieve this, robot drives must be properly specifed. Today,
kick-back, or carriage-back, design, which is more balanced and
servo drives are generally standard, but there are options within
allows for a heavier payload. This payload, as mentioned earlier,
the servo family for high-speed and heavy-duty applications. High
takes into account end-of-arm tools, so this design is also
speed is required for sub-10-sec cycles and heavy duty is required
useful when a molder needs an oversized EOAT for the likes of
for applications such as pallets or large automotive parts.
instrument panels, bumper fascias, or house-siding panels. The
Note that some robot manufacturers still use pneumatic
kick-back also allows clearance for obstructions over the mold,
cylinders instead of servo drives. These are inferior in every way,
such as core cylinders and unscrewing racks.
limiting your programming, stunting your payload, and requiring
Secondary fip or rotation
more maintenance than a full-
axes can also help to remove parts from larger molding machines. These axes can be pneumatic or servo driven
servo option.
Long-term reliability and robustness are both important considerations when calculating proper payload specifcations.
to allow the part to rotate
Robots also should have options readily available for special requirements such as additional inputs and
or fip at the same time that
outputs, an additional access
the robot is exiting the mold area. This allows the part to be
door, box-filling controls, extended line cords, tooling identifi-
manipulated more easily and more completely to help it ft
cation, and crane interlocks.
through difcult spaces while exiting. Sometimes, with presses of 1500 tons and above, the
As always, these are general guidelines. Every molder is unique and has difering applications and requirements for its
press height allows no room for a gantry-style robot to
robots. If none of these categories quite ft what your company
be mounted and clear obstructions like overhead cranes.
is after, contact your robot supplier and it can work with you to
Most robot manufacturers have options for crane inter-
fgure out exactly the right ft for your specifc usage.
locks. These interlocks help to ensure that the robot is parked in a safe location before allowing the crane to move over the press. Another tip: Robots should allow for easy programming in three dimensions simultaneously to permit curve motions, not strictly linear, single–motion-at-a-time programming. 3D motions make the sequence more efficient and reduce wear and tear on the robot’s mechanics. 64
Plastics Technology
OCTOBER 2015
ABOUT THE AUTHOR Jason Long is regional manager, robots and automation, for Wittmann Battenfeld USA, Torrington, Conn. Long started his career at Wittmann Battenfeld in 2007 as a robot feld-service technician. Before joining WB he worked for eight years as a lead automation technician for SAS Automation. Contact: (860) 496-9603; jason.long@wittmann-group.com; wittmann-group.com. PTonline.com
WEBINAR
a feature of PTonline.com
Thursday, November 5th
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Liquid Color and Additives: The Future for Plastic Processing Advancements in carrier
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PRESENTER Brian K. Cochran Technical Manager, Liquid Color and Additives
Brian K. Cochran is Technical Manager at iD Additives, Inc. a manufacturer of Liquid Color and Additives. He has over 30 years of extensive experience in the Plastics Industry that include positions as President, Senior Plastics Engineer and Consultant at Britec Solutions Inc.; President and Founder of Polytech Color and Compounding Inc.; Sales/Technical Manager for Marco Color Laboratory. His areas of expertise include Product Development, Plastics Engineering, Color Appearance and Technology, Dispersion Practices and Performance Improvement, Thermoplastic Compound Formulation.
Tips and Techniques
To Improve Feeder Performance, Start by Understanding Three Key Components These are the screw trough, agitator, and the screw itself. It’s crucial to understand the different types and the advantages/disadvantages of each.
Many loss-in-weight feeders incorporate a screw as the feed
reducing cross-section dimensions in the screw trough eventually
device due to its wide feed-range capability. Each selected feed
reach the bridging dimension. An agitation device is incorporated
By Walt Folkl & Andy Kovats Brabender Technologie Inc.
device has a range of available screws with diferent diameters and
in the screw trough in order to prevent the bridge from forming. There are two common types of agitation devices:
pitches. Each feeder supplier provides a range of models
capable of providing feed rates over the spectrum of normal applications. The feed device is comprised of several components. Those discussed here are shown in the accompanying image.
SCREW-TROUGH AGITATION The screw trough is a critical component of a screw
Large exposed section of screw in screw trough
feeder. It converges dimensionally from the inlet,
Screw trough with small inlet
attached to the extension hopper, and into the screw. It transitions the mass of dry ingredient contained in the feeder from the larger-dimension extension hopper into the smaller-dimension screw. Most dry ingredients (powders, granules, pellets, fbers, and
Short exposed section of screw in screw trough
Screw trough with large inlet Conical screw trough
fakes) do not fow reliably through converging transitions. There is friction between the particles and an interlocking tendency that restricts or stops the fow. When the fow stops it is called a “bridge.” All dry ingredients have a minimum bridging dimension. Flow stops and a bridge forms at this cross-section dimension. The 66
Plastics Technology
OCTOBER 2015
Schematic summary of critical design considerations for a screw trough. The best screw trough shape is a wedge rather than a spherical or conical shape at the bottom of the screw trough in order to expose the required length of screw to fll properly. Shown here are a properly exposed screw and a starved screw.
PTonline.com
LOS S -IN-WEIGHT FEEDER S
Flexible Walled/Internal Paddle
Internal Stirring Feeder Extension Hopper
Polyurethane Screw Trough Stainless Steel Screw Trough External Paddle Agitation Internal Stirring Agitation Screw
Comparison of feeder components for external paddle agitation and internal stirring agitation.
Flexible walled/External paddle: The screw trough is constructed
properly designed agitation device (fexible-walled with external-
of a fexible material, normally polyurethane, in a wedge shape on
paddle massage or with internal stirring). Also, there must be suf-
two sides and near vertical on the other two sides. Movable metal
cient screw fights exposed openly in the bottom of the screw trough
paddles contact the two wedged-shaped sides and “massage” them,
so that complete and repeatable flling occurs before the ingredient is
pushing the sides in and out continuously. This movement causes
enclosed in the screw tube. The best screw-trough shape is a wedge, rather than a spherical or conical shape at
an unstable support for the dry ingredient particles. A restriction movement followed by a void movement causes any bridges that are starting to form to collapse. Gravity acts on the particles to move them down and eventually into the screw.
Screw troughs generally need agitation to prevent bridging—either a fexible wall with external paddles or internal stirrers.
Internal stirring: The screw trough is
the bottom of the screw trough, in order to expose the required length of screw to fll properly (see image opposite). Lately, the fexible-walled/externalpaddle-massaged screw trough, available from several suppliers, has drawn more interest. One important reason for this is
constructed of metal, normally stainless steel, and is curved in a
that the movement of the fexing screw trough directly contacts and
constant radius to accommodate the close movement of rotating,
massages the ingredient in the screw trough on both sides of the
agitating blades. The agitator blades move through the dry par-
wedge surfaces, from the top inlet to the top of the screw.
ticles on each side of the screw, which is positioned directly below
Since the stirring agitator has a circular motion, there are two
the agitator blades. Movement is down into the screw on one side
dead zones (no agitation) at the top of the screw trough. The screw
of the screw trough and up on the other side. This blade move-
trough is sized to reduce the volume of the dead zone. As a result,
ment prevents bridging in the screw trough.
the fexible-walled/external-paddle-massaged screw trough typically has a larger volume and inlet dimension than the internal-stirring
The shape of the screw trough is critical. A loss-in-weight feeder’s main purpose is to feed the ingredient accurately at
QUESTIONS ABOUT FEEDING AND COMPOUNDING?
the desired setpoint. The weight-feedback control requires that each screw fight be flled with the same weight of ingredient. Repeatable-weight flling of each screw fight is achieved by a @plastechmag
Visit the Feeding & Blending Zone and the Compounding Zone. Plastics Technology
67
Tips & Techniques
feed rates. The screw diameter and pitch are sized to achieve the feed rate at an optimal screw rotational speed. At too low a screw speed the “pulsing fow” may cause an undesired variation in the fnal product. Too high a screw speed may cause incomplete flling
Spiral Screw
of the screw. There are three common screw types, shown in the accompanying image: • Spiral screw: The single-spiral screw is the most common selection. It is “open” for the ingredient to fow freely into the fights of
Blade Screw
the screw. It has a smaller surface area that helps reduce adhesion of the ingredient, which changes the screw volumetric geometry. Ingredients are transferred with low shear. On the negative side, aerated ingredients can easily food past the screw fights. • Blade screw: The single-blade screw ofers more resistance to aerated ingredients, but because there is more surface area, sticky
Twin Concave Screws
ingredients can adhere, reducing the volumetric geometry. Blade screws are often preferred for heavy powders with bulk densities of
Three types of common feeding screws. Each has its advantages/disadvantages.
more than 80 lb/ft3. • Twin concave screw: Twin concave screws can provide superior performance for poorly fowing powders. Twin concave screws are
screw trough. Since the extension hopper is mounted directly above
co-rotating, intermeshing, and self-wiping. The powder fows
the screw trough, the bottom dimension of the extension hopper is
around the fights of both screws. The negative efects of some
typically the same as the inlet to the screw trough. Loss-in-weight
adhesive powders are reduced by the self-wiping of the two screws.
feeder extension hoppers are commonly sized (rule of thumb) to
Twin concave screws are solid and the screw fights have a low
contain 4 minutes of storage at the maximum feed rate/minimum
volume compared with spiral and blade screws. The shear on the
bulk density of the ingredient. The extension hopper often can be
powder is high, particularly in the screw tube. The screw tube is
supplied with vertical sides, which provides foorspace advantages
typically short to reduce negative efects of high shear.
over conical extension hoppers. Also, there is no requirement for additional stirring agitation in the extension hopper, since the sides
Twin concave screws are ideally suited to powders with feed rates below 5 ft³/hr. The cross-section of the two screws is wider than an equivalent single screw, reducing the tendency
are vertical (no converging). Generally, a screw feed device with fexible-walled/external-paddle-massaged screw trough is a frst choice for loss-in-weight feeders. However, there are situations where
Screws are selected to achieve maximum and minimum feed rates.
the stirring agitator is required: • Cohesive ingredients: These form a solid mass when exposed to
to bridge in the transition from the screw trough into the screw. Also, screw speeds for twin concave screws can be higher than single screws for the same feed rate because of the larger inlet and low volume of the screw
fight. Higher screw speeds reduce the negative efects of pulsation.
compression. Some are so sensitive that the force of gravity acting
Reliable performance of loss-in-weight feeders begins with the
on their own head mass can cause them to solidify. These ingredi-
selection of three critical components: The screw trough, the agita-
ents are difcult, sometimes impossible, to feed reliably without
tion, and the screw itself. It is necessary to understand the diferent
excessive maintenance. Testing is highly recommended at feeder
types and the advantages/disadvantages of each. You’d be wise to
manufacturers, who ofer several types of feed devices. Stirring
witness testing the alternatives frst-hand at the feeder manufac-
agitators may have the best chance of success in such cases.
turer’s facility, using a sample of the ingredient to be fed.
• Ingredient temperature: Polyurethane becomes too soft at ingredient temperatures above 50 C (122 F), requiring a metal screw trough.
SCREW SELECTION The screw is the component of the feeder that provides the feeding. The agitation only ensures that the screw fights fll uniformly. Screws are selected to achieve maximum and minimum 68
Plastics Technology
OCTOBER 2015
ABOUT THE AUTHORS Walter Folkl has more than 30 years of experience in plastics material handling, compounding, and feeding equipment. He is a sales manager for Brabender Technologie Inc., Mississauga, Ont., an international company specializing in feeding equipment. Contact (845) 651-0381; wfolkl@brabenderti.com; brabenderti.com. Andy Kovats is also a sales manager at Brabender Technologie, where he has worked on a wide variety of feeding projects for more than three decades. Contact: (905) 670-2933 x 1302; akovats@brabenderti.com. PTonline.com
Keeping Up With Technology INJECTION MOLDING
Sneak Peek at Fakuma News
What’s billed as the frst demonstration of injection-compression molding on stack molds is one of several new developments slated to be on display this month at the Fakuma 2015 plastics show in Friedrichshafen, Germany. Others involve new machine models, “fexible” IML automation, micro-injection, dual-durometer LSR injection, integrated metal/plastic processing, new cleanroom technology, and new or modifed machine models. • Stack-mold injection-compression: Netstal of Switzerland (U.S. offce in Florence, Ky.; netstal.com) will show off a “world frst” by injection-compression molding margarine tubs (15 oz/425 g) in a 4 + 4 stack mold on a 280-metric-ton Netstal Elion hybrid machine. The cavities will be partly flled in only 100 millisec, and total cycle time—including IML—will be 5 sec. Netstal says the low-pressure flling reduces stresses in the material and warpage, especially in lids. Weight reduction of up to 20% through thin-walling is also said to be possible with injection-compression. • Improved energy effciency: Netstal’s sister company, KraussMaffei (U.S. offce in Florence, Ky., kraussmaffeigroup.us), will show off the upgraded version of its CX hydraulic two-platen machines, whose drive has been energy-optimized and now requires 10% less power. • Micro-injection: Arburg (U.S. offce in Rocky Hill, Conn.; arburg.com) will operate an all-electric, 35-m.t. Allrounder 270 A with a new micro-injection unit with two-stage injection. It has either a 15-mm or 18-mm screw for plastication (both of which can take standard pellets) and an 8-mm screw for injection. It will mold four 0.004 g PBT micro counter wheels in 12 sec. • Dual-durometer LSR molding: Arburg will also run an electric, 100 m.t. Allrounder 470 A with two injectors in an L-arrangement, molding two-material liquid silicone buttons for car interiors in a 32 + 32 cavity rotary mold. The diaphragm of the part is a colored LSR with 50 A Shore Hardness, and the inner disc is a clear LSR with 80 A hardness. 70
Plastics Technology
OCTOBER 2015
• New machine and medical technology: Engel (U.S. offce in York, Pa.; engelglobal.com/us) will debut the largest member yet in its all-electric, tiebarless e-motion TL series. The frst 30-m.t. model appeared at K 2013, and a 50-m.t. unit followed at last year’s Fakuma show. This year brings an 80-m.t. addition, which will mold medical parts in 16 cavities using GMP-compliant cleanroom production. Two new elements of the cell (photos at right) are a stainless-steel pipe distributor for cavity separation and a special robot gripper housing with smooth, easily cleanable surfaces, which allows use of standard grippers in a GMP environment. • Integrated metal/plastic processing: Engel will also present for the frst time a highly integrated, fully automated process (photos below) for manufacturing thermal switch housings from metal/plastic composite. The sheetmetal and plastic operations are usually performed in separate locations. But here, a metal strip is unrolled from a coil and fed into a punch press and a thread is servo-electrically tapped in the same station. Next, the metal carrier plate is overmolded with glass-flled nylon in a vertical Engel machine. That is followed by camera-based inspection, high-voltage testing, laser marking, and subgate removal. Eight fnished parts leave the cell every 20 sec. • Highly fexible IML: Engel’s booth will also host the global debut of the newest Beck-Flex IML system from Beck Automation of Switzerland (beck-automation.com). Within the footprint of a standard system, this “all-around IML system” offers the fexibility to handle from one to four cavities, parts with inside or outside gating, both lids and containers, part diam. from 40 to around 200 mm, and a wide variety of labels— fat, 3- or 5-sided, with or without closed edges, and 360° labels. All of this is engineered for fast changeovers—e.g., from one lid to another in less than 30 min and from a lid to an inside-gated container in less than 60 min—and for fast cycles of around 4 sec. PTonline.com
NE W PRODUC T S FOR PL A S T IC S PROCE S SING
INJECTION MOLDING
INJECTION MOLDING
Infrared Sensors Measure ‘Real’ Melt Temperature A new solution to injection molders’ longstanding need for more effective melt-temperature monitoring is one of a range of process-monitoring products being introduced to the U.S. from Futaba of Japan (see also p. 14). Futaba Corp. of America, Schaumburg, Ill., is offering the following: • Melt-temperature sensors: The reportedly unique products in the lineup are fber-optic infrared (IR) sensors that directly sense the temperature of the melt. They come in long knockout-pin type versions (photo) or short fush-mount versions for installation in a mold fow path. Unlike thermocouple-type sensors (which Futaba also supplies), the IR type is not affected by the surrounding steel temperature, and it can sense the IR emissions of the melt even as the part cools and shrinks away from direct contact with the sensor. Futaba says effective melt-temperature sensing gives molders insight into the combined effects of barrel heating and shear heating, and the measured cooling rate correlates with the degree of packing of the part. Thus, knowing the actual plastic temperature as the runner and part cool allows better decisions on injection speeds, pack pressures, mold temperatures, cooling time, and cycle time. Futaba sources also say melt-temperature sensing is useful for detecting end-of-fll in mold cavities, due to its fast (8 millisec) response rate. The IR melt sensor reportedly is being used in Japan by major customers such as Toyota, Nissan, Panasonic, and Denso. • Cavity-pressure sensors: Futaba also markets standard strain-gauge sensors of knockout-pin or button type. • Process monitors: Futaba’s Mold Monitoring System (MMS) is described as a “simple and smart” solution for cavity-pressure or melt-temperature monitoring. The eight-channel pressure amplifer is said to be simple to set up and run with very little training, and it reportedly sells for much less than competing systems. It can operate with a PC link or stand alone. Users can choose from eight parameters to make accept/reject decisions (peak pressure, area under the curve, etc.). (847) 884-1444 • futaba.com
INJECTION MOLDING
The new SR Series of round quick-change systems for robot end-of-arm tooling (EOAT) is said to be quick and easy to install and helps molders accommodate frequent mold changes. Supplied by FIPA Inc., Cary, N.C., their visual locking indication (red for locked, green for open) reportedly ensures safe operation, along with the snap-on Safe-Lock mechanism, robust construction, and pneumatic connections that are always correctly aligned. Made of aluminum alloy, the SR Series comes in three sizes with maximum lifting capacities from 45 to 225 lb. (919) 651- 9888 • fpa.com INJECTION MOLDING
New Controls for Hot Runners, Auxiliary Injectors Milacron Plastics Machinery, Batavia, Ohio, has introduced its Adaptive Process System (APS) for its Mold-Masters melt-delivery control technologies. The APS will now be used in Milacron’s entire core controls product line, including hot-runner and valve-gate controllers, E-Multi auxiliary injection units, and the new SmartMold monitor announced at NPE2015 (see July show report on hot runners and tooling). The APS includes a number of proprietary technologies for adaptive auto-tuning heat control, as well as adaptive motor control with auto tuning for maintaining precise linear movement. Other features include short-circuit protection, automatic even heating to ensure proper thermal expansion, auto purge cycle, intelligent leak detection, and auto alarm for water fow based on fow, temperature, and pressure monitoring. According to Milacron, the APS will help molders deal with challenges related to diffcult engineering materials, high pressures, small shot sizes, high viscosity, and electrical environment variations. (513) 536-2000 • milacron.com
High-Temperature Heat-Transfer Fluid and ‘Rejuvenating’ Additive
Two new products from Paratherm, W. Conshohocken, Pa., offer benefts for users of hot-oil heat-transfer systems. First, new Paratherm HT heat-transfer fuid is a partially hydrogenated terphenyl suitable for very high-temperature uses— up to 675 F. The material is not new—it has @plastechmag
Robot EOAT Quick-Change System
proven performance—but was not previously offered by Paratherm. Second, Paratherm has introduced a brand-new type of product for the company—an additive to extend the useful life of fuids in hot-oil systems. Paratherm AP (Antioxidant Protection) prevents
acids formed at high temperatures from converting to sludge. The additive depletes over time, so it does not eliminate the need for preventive maintenance, but it does reduce or delay the need for an oil change. (610) 314-7080 • paratherm.com Plastics Technology
71
Keeping Up With Technolog y
COMPOUNDING
Twin-Screw Extruder Now Has Servo-Motor/Drive
For use in pharmaceutical and medical cleanrooms, Leistritz has introduced an improved ZSE 18-mm, co-rotating twin-screw extruder that uses a brushless AC servo-motor sealed against water spray and dust. The new motor is also said to be signifcantly quieter than standard motors; and servo-motor technology facilitates a 1000:1 turndown with 0.01% speed accuracy, which is particularly benefcial in a laboratory environment developing multiple products over wide screw rpm ranges. Some of the unique new features that reportedly make the ZSE-18 well suited for use in GMP (Good Manufacturing Practice) environments include: • Segmented stainless-steel screws on high-torque, splined shafts; • 72 Nm torque rating and screw speeds to more than 1200 rpm; • Modular stainless-steel barrels with a tie-rod assembly system for quickchange capability;
EXTRUSION
• Gearbox positioning plate that allows gearbox repositioning for shorter or longer L/Ds (a cantilevered front end allows use of gear pumps and other front-end devices); • Quick-clamp assembly mates the process section to the gearbox for accelerated changeovers; • Quick-connections for electrical and plumbing utilities; • Side stuffer for downstream introduction of shear-sensitive materials; • Stainless-steel base frame (unpainted), deemed optimum in a cleanroom environment; • Allen-Bradley PLC and operator interface with fash-drive download ability. A ZSE-18 extruder is available for testing at the Leistritz process laboratory in Somerville, N.J. The ZSE-18 can be mated with pelletizing, tube, flament, flm, and/or sheet downstream systems. (908) 685-2333 • leistritz-extrusion.com
Patented Seal for Screen Changers
Kolcor Technologies LLC, Agawam, Mass., has been awarded a U.S. Patent for the unique sealing device on its line of hydraulic and manual screen changers. The seal design reportedly ensures no material leakage at pressures up to 10,000 psi and temperatures to 650 F. This seal is supplied standard on all Kolcor hydraulic and manual screen changers. Unlike other designs, which need to get up to operating temperature for the seal to work, this seal features springs that provide lock-up force for immediate seal protection, the company says. Once the Kolcor screen changer is running at operating temperature, the polymer pressure only increases the seal force, creating true leak-free processing. (413) 821-8948 kolcor.com
FEEDING
Closed-Loop Controls Boost Feeder Accuracy Loss-in-weight feeders from Lingood USA, Houston, utilize an enclosed scale and provide users with closed-loop control, which increases performance and reliability. The improved loss-in-weight feeder control accelerates the servo motor’s reaction time and improves feeder accuracy. It also supports the process interface for multi-range PLC/DCS. The feeders are said to achieve ±0.5% accuracy and have feed rates between 2 and 4000 lb/hr. Feeders come with standard twin- or single-screw confgurations, and interchangeable screw types are offered. Lingood feeders are available in the U.S. through Field Industries LLC. (832) 736-1839 • feldindustries.com 72
Plastics Technology
OCTOBER 2015
THERMOFORMING
Training Program Aims At Thin-Sheet Forming Paulson Training Programs, Chester, Conn., recently released what it says is the industry’s only comprehensive interactive training program in thermoforming. Titled Thin Sheet Thermoforming, this six-lesson program, available in CD and online formats, is designed specifcally for the training needs of the thin-sheet thermoformers. Paulson previewed an early demo of the course during March’s NPE2015 show in Orlando, Fla. This training course covers all aspects of the thin-sheet thermoforming process. Users will learn the function of each component of the thermoforming line, plastic behavior during the process, sheet extrusion fundamentals, optimizing operating controls, safety around thermoforming machinery, and thermoforming for maximum effciency and proft. (800) 826-1901 • paulsontraining.com PTonline.com
Keeping Up With Technolog y
MATERIAL HANDLING
TESTING/MEASURING
Versatile Spectrophotometer Measures Variety of Samples The newest benchtop spectrophotometer from Konica Minolta Sensing Americas, Ramsey, N.J., is an all-in-one system capable of evaluating the color and appearance of opaque, transparent, and translucent samples. Suited to R&D and laboratory environments, the CM-5 boasts high precision and ability to measure color and appearance of solids, liquids, pastes, powders, pills, and granules in a streamlined process. Used as a standalone instrument, the CM-5 is compatible with SpectraMagic NX software to record measurements and provide a more comprehensive color analysis, as well as Colibri software to formulate the color recipes for various applications. Among its notable features are aperture sizes of 3, 8, and 30 mm to evaluate very small to large samples; large color LCD screen to display data and graphs; top-port area for measuring opaque samples; and a transmittance chamber for transparent and translucent samples. (201) 236-4300 • sensing.konicaminolta.us
SIZE REDUCTION
Pulverizers Offer Faster Cleanout, Higher Effciency New pulverizers from Reduction Engineering Scheer, Kent, Ohio, offer a highly compact design, faster cleanout, and more effcient production. The new RE Series, which debuted in March at NPE2015, uses the frm’s proven disposable-disk system and is coupled with a new airfow-management system. A touchscreen graphic user interface comes with PLC tracking modes and Internet access for remote diagnostic and troubleshooting. Non-PLC versions are also available. An Orbital Classifcation System occupies less space than standard systems and features a larger screen. It boasts 35% faster cleandown and has fewer parts to service. A mill-and-drive system features a new head design that eliminates cross-currents and has a lower-profle shaft and drive design to allow for higher motor torque. (330) 677-2225 • reductionengineering.com
74
Plastics Technology
OCTOBER 2015
Powder Loaders & Receivers Two new powder-conveying units from the Conair Group, Cranberry Township, Pa., are suited to loading PVC and other powders down to 1 micron, and dusty regrind as well. They are available in a PR (powder receiver) model for use in central vacuum systems and a self-contained PM model (photo) with integral vacuum motor. The integral-motor version is useful for conveying material from gaylords or bins directly to a molding machine or extruder. PM motor loaders come in three sizes, with conventional DC brush or brushless motors. They can transport up to 1000 lb/hr (454 kg/hr) over distances up to 50 ft (15.25 m). The PR powder receivers come in fve sizes ranging in volume from 0.14 to 3 ft³ (4 to 85 L) and accommodate line sizes up 4 in. OD. In both units, the powder remains in bottom of the receiver while conveying air and any suspended particles are drawn upward past as many as three pleated polyester cartridge flters that separate air from particulates. At the end of every load cycle (when an integrated fll sensor registers that the receiver is full), a blowback system directs high-power blasts of compressed air down through the flters, blowing off accumulated material, dust, and fnes. Thus, each new loading cycle starts with a clean flter. A 3:1 air-to-cloth ratio ensures maximum fltration effciency. The largest PR receiver has 168 ft² (15.5 m²) of flter area, and the PM units have up to 56 ft² (5.2 m²), yet they are compact enough to be used even in low-headroom areas. The PM motor loader is programmed, controlled, and monitored by a Conair ELC-M (Easy Loader Control) with LED icons. An optional ControlMate pendant expands the capabilities of the basic ELC controls by allowing users to enable higher-level functions and change settings that need less frequent adjustment. It comes complete with a 10-ft power/communications cable so operators can safely adjust settings from ground level with no need to climb on the machine to reach the receiver-mounted ELC. The ControlMate pendant can be stored in a surface-mount cradle for convenient access. PR model receivers can also be controlled by the ELC or by a Universal Terminal Box (UTB) that connects to any Conair central material-handling control systems, including the FLX-128, ELS, or B-32 loading controls. (724) 584-5500 • conairgroup.com
PTonline.com
NE W PRODUC T S FOR PL A S T IC S PROCE S SING
MATERIALS
Permanent ESD Sheet for Electronics PermaStat compounds from RTP Co., Winona, Minn., are now available in sheet form. These compounds are based on a proprietary polymeric additive that provides permanent static-dissipative performance independent of ambient humidity. Now, RTP’s Engineered Sheet Products (ESP) division is offering thermoplastic sheet with permanent antistatic properties for applications such as electronics packaging. PermaStat sheet features consistent surface resistivity of 109 to 1010 ohm/sq, said to be suitable for superior ESD (electrostatic dissipative) protection and dust control. For even higher conductivity and lower surface resistance—107 to 108 ohm/ sq—ESP offers PermaStat Plus sheet. Because they are made from allthermoplastic compounds, the antistatic properties are inherent throughout the sheet, which maintains ESD protection with scratches, wear, machining, or forming. Fully colorable, they are available in a variety of resins, including PP, PC, acrylic, PETG, and ABS.
MATERIALS
Tough, Ultra-Light TPU For Mountain Bike Inner Tube A new inner tube for mountain bikes utilizes a novel Elastollan TPU from BASF (U.S. offce in Wyandotte, Mich.). Schwalbe, the German-based European market leader for bicycle tires and inner tubes, will begin marketing the new tube in December. The two companies worked together to develop a material with mechanical properties that would allow the tube’s wall thickness to be reduced considerably. This reportedly gives the eye-catching blue Evo Tuve an important advantage over butyl-rubber inner tubes: Weight has been reduced by as much as 65% compared with a standard 29-in. tube. Depending on the size of the tire, the Evo Tube weighs 0.15 to 0.17 lb. The unusual TPU is particularly resistant to abrasion and wear. An inner tube made from it can withstand very high continuous loads and—despite its greatly reduced wall thickness—maintain a constant air pressure over long periods of time. The tube, valve base, and valve stem are all made from Elastollan TPU, which simplifes the production process and allows the product to be easily recycled. The new TPU also has potential for a wide range of other applications in automotive, medical, or mechanical products. It can be injection molded, extruded, or blow molded. (877) 297-3322 • polyurethanes.basf.us
(800) 432-2386 • engineeredsheetproducts.com
@plastechmag
Plastics Technology
75
Keeping Up With Technolog y
EXTRUSION
TPE Compounds Offer Vivid Color, Tactile Appeal
MATERIALS
Rotary Dies Run Faster Guill Tool, W. Warwick, R.I., has introduced a new design for its high-production rotary dies in both inline and crosshead styles that reportedly offer a twofold increase in speed. Models are available with running speeds to 1000 rpm, depending on the application. By rotating the tooling in relation to the material fow, a rotary head increases the wall strength of the extrudate, allowing a thinner wall with less material. Typical applications for rotary heads include medical and multi-lumen tubing plus various high-end extrusions with multiple, interlocking layers or multiple striping. Features offered on these new rotating extrusion dies include counter-rotating tip and die; co-rotating tip and die; rotating die with conventional tip; rotating tip with conventional die; and optional quick-change cartridges that minimize cleaning downtime. By using rotary dies, processors can realize cost savings due to the elimination of secondary processes, cosmetic enhancement of the end product with the elimination of weld or parting lines, plus reduction or complete elimination of ovality. Guill offers its new high-speed rotary models as turnkey packages, complete with die cart, tools, and all accessories for installation and maintenance. (401) 828-7600 • guill.com
A new family of TPE compounds from Teknor Apex Co., Pawtucket, R.I., is said to provide consumer goods with vivid color, tactile appeal, and soft-grip ergonomics while spanning a broad range of physical properties and exhibiting excellent moldability. Monprene CP Series compounds are standard products available in identical formulations to customers in North America, Europe, and Asia. The two series now available are: CP-10100 lowdensity compounds with specifc gravity of 0.89; and CP-11100 high-density compounds with specifc gravity of 1.15. Each series is comprised initially of six grades with Shore A hardness ranging from 40 to 90. With a light natural hue, the Monprene CP compounds exhibit excellent colorability. All grades are suitable for skin contact and are resistant to cosmetics and household chemicals. These compounds are said to exhibit excellent adhesion to polyolefns. (866) 438-8737 • teknorapex.com MATERIALS
Antimicrobial Polyolefn Sheet
Granulator 13-17 Oct 2015 Halle: B5 Stand: B5-5318
GF45 Series Sheet & Film Granulator Advanced Technologies for Sheet & Film Inline or Offline Recycling
One of the largest manufacturers of plastic granulators,shredders and pulverizers in the world
AVIAN (USA) MACHINERY, LLC. 1901 Powis Court, West Chicago, IL. 60185 TEL: 630.687.9876 FAX: 866.755.9258 WEB: www.aviangranulator.us E-MAIL: sales@avianusa.com
76
Plastics Technology
OCTOBER 2015
A recently announced license agreement with Gelest, Inc., Morrisville, Pa., gives exclusive use of its Biosafe organosilane-based antimicrobial additive to King Plastic Corp., North Port, Fla., for its polyolefn sheets. King Plastic will make a growing number of its brands available as an upgrade called King Microshield protected with Biosafe technology. According to Michael Fabbri, national sales manager at King Plastic, the antimicrobial is permanently bonded at the molecular level to the matrix resin, keeping it from leaching out of the product. “When customers fabricate and install our products, the fresh surfaces they create are fully antimicrobial. If heavy abrasion occurs during end use, the antimicrobial additive will never lose its effcacy, unlike antimicrobial surface coatings.” (941) 493-5502 • kingplastic.com; (215) 547-1015 • gelest.com
PTonline.com
NE W PRODUC T S FOR PL A S T IC S PROCE S SING
MATERIALS
Hybrid Glass/Carbon Long-Fiber Compounds in PP, TPU
A year after launching its hybrid long-glass + carbon fber nylon 66 compounds, PlastiComp, Winona, Minn., is offering two new hybrid products that combine long glass and carbon fbers in a single affordable, readyto-mold pellet in PP and engineered TPU matrices. The company says it was able to quickly commercialize its nylon 66 hybrid composite in a sportinggoods application where long-glass fber alone could not provide enough stiffness to eliminate a metal insert, and long carbon fber alone was cost-prohibitive. The performance spectrum achievable with long glass + carbon fber hybrids is virtually
MATERIALS HANDLING
High-Precision Weighing Platforms Two new weighing platforms for bench and foor scale applications are now available from Mettler Toledo, Columbus, Ohio. Designed to work in harsh industrial environments, the new PBK9 and PFK9 weighing platforms are available with capacities from 0.6 to 3000 kg at resolutions of up to 750,000 divisions. They are said to virtually eliminate the impact of environmental interferences that cause errors. Advanced Monobloc load-cell and flter technology reportedly guarantees the highest precision and reliability possible. Other reported benefts include: • Reliable performance, as the platforms notify the operator when recalibration or adjustments are needed due to environmental changes. • Easy maintenance, thanks to automated calibration with a built-in calibration weight and plug-in cables. • Versatility, as the platforms are suitable for a variety of challenging environments, including areas with heavy dust, locations that need regular cleaning, and those classifed as hazardous. (800) 638-8537 • mt.com @plastechmag
infnite, says Eric Wolland, technical director. “If durability is a concern, we can formulate a product that has more long glass to improve impact resistance; if higher load-carrying ability is needed we then move to products that include additional long carbon fber to increase stiffness and strength,” Wolland states. He notes that automotive has been adopting long-glass fber PP for a couple of decades because it offers a signifcant weight reduction compared with metal components. “To meet increasing fuel-economy regulations, they still need to go lighter, but LFT-PP can’t get any stronger, and jumping straight to carbon fber is a bold economic step for a price-sensitive industry,” Wolland adds. Meanwhile, in consumer and sporting-goods markets, carbon fber has been synonymous with “high tech” and its use adds perceived value to products, enabling manufacturers to demand a price premium. Including low levels of carbon fber can help upsell products or differentiate them from competitors whose products are made from lower performing materials, says Wolland. (507) 858-0330 • plasticomp.com
MATERIALS
TPE Gives Molded Products Rubber-Like Properties, Good Finish A newly formulated black 48 Shore A TPE from Elastocon TPE Technologies, Inc., Rochester, Ill., is said to give molded products rubber-like properties and a good surface fnish for consumer goods and industrial applications that require UV stability. The latest addition to Elastocon’s 8000 Series of general-purpose TPEs, Grade 8150 can be formulated to run on conventional thermoplastic processing equipment for injection molding, extrusion, or blow molding. As with other Elastocon TPEs, this new material reportedly does not require drying. Also, it can be overmolded onto PP. This new grade recently passed FMVSS302 specifcations for fammability, opening new doors for a range of products. Available as ready-to-use pellets in 1000-lb quantities, the material is California Proposition 65 and RoHS compliant, can be recycled, and contains no phthalates or latex. (888) 644-8732 •elastocontpe.com MATERIALS
Wear-Resistant PESU for Auto Powertrain Components A new high-performance grade of polyethersulfone (PESU) is formulated to replace metal in automotive components prone to friction and wear—especially in contact with metals—such as oil pumps and exhaust-gas recirculation (EGR) systems. Veradel 3300 SL 30 from Solvay Specialty Polymers, Alpharetta, Ga., is a tough, injection-moldable material with low coeffcient of friction in both dry and lubricated environments. It contains carbon fber, graphite, and PTFE. It performs reliably across broad temperature range from -40 F to 392 F. (770) 772-8200 • solvayspecialtypolymers.com Plastics Technology
77
Keeping Up With Technolog y
High-Speed Pump Won’t Increase Melt Temperature
TOOLING
EXTRUSION
IML for Stack Molds Made Simpler, More Versatile
A new melt pump from Maag Automatik (U.S. offce in Charlotte, N.C.) reportedly can run at higher speeds without raising melt temperature. Maag says this is attributable to “tremendous improvements” in the volumetric effciency of the device. Moreover, the pressure-building capability is said to be vastly improved, even at lower speed, increasing the window between minimum and maximum production rates. The pump offers up to 50% higher fow rate on comparable products, Maag says. (704) 716-9000 • maag.com
Waldorf Technik of Germany (U.S. offce in Geneva, Ill.) says its newly simplifed automation for in-mold labeling (IML) with stack molds overcomes previous limitations of this application. According to Waldorf, label placement has been limited to the outer plates of stack molds, which requires that containers be gated on the inside, which brings a risk of stringing due to unavoidable wear on the tools, and often lower productivity from slower cooling of the tool cores. Alternatively, some systems have used complicated sprue-bar systems to distribute melt to the outer mold plates, but this technique is expensive and susceptible to wear, Waldorf says. The company says it can now supply IML systems for up to 8 + 8 stack molds with label insertion on the inner plates and allowing for outside gating. Waldorf also says that existing stack molds can be converted to the new IML system with simple adjustment at modest cost, rather than requiring a whole new stack mold as in the past. (513) 253-0134 • waldorf-technik.com
TOOLING
Tapered Interlocks In 60 Standard Confgurations A series of round, U.S.-made, tapered interlocks is available in 60 standard confgurations from Choice Mold Components, Clinton Township, Mich. They come in 10, 30, 50, and 100 taper angles with both male and female O.D. sizes from 3/8 in. to 2 in. and multiple dimensional options. Also offered is a range of sizes with a convenient counter-bore for optional front-loading installation. They are made from 52100 bearing steel and heat treated to 60-63 Rc hardness for long life. Both 2D and 3D CAD fles are available online to view and download in every native software format. To ensure alignment of the mold halves, these components are designed to locate on the taper and shoulder in order to guarantee a positive stop, unlike competing versions that stop just off the taper. (586) 783-5600 • choicemold.com
G-SERIES® CONFIGURABLE ABLE NEW ROLL STAND DESIGNS SIGNS Available in Vertical (shown), Horizontal & J-Stack arrangements Multi-patented technology Compact for inline or full length for roll stock Configurable downstream (gauge, coater, slitter, conveyor, etc.)
World Class Sheet Extrusion Systems Processing Technologies International, LLC | 2655 White Oak Circle Aurora, IL 60502 | Tel: 630.585.5800 | Fax: 630.585.5855
78
Plastics Technology
OCTOBER 2015
PTonline.com
YOUR BUSINE S S
Resin Pricing Analysis
YOUR BUSINE S S
Major Resin Prices Soften Even prices of high-volume engineering resins are likely to be adjusted downward in this fourth quarter. The continuation of lower feedstock and energy prices has resulted in a downward trajectory for prices of nearly all comBy Lilli Manolis Sherman Senior Editor
modity resins, including common engineering resins like ABS, PC, and nylon 66. Barring any major production
disruptions or reversal in feedstock and energy costs, most fourthquarter prices are likely to be fat to lower. These are among the views of purchasing consultants at Resin Technology Inc. (RTi) of Fort Worth, Texas (rtiglobal.com), and CEO Michael Greenberg of Chicago-based The Plastics Exchange (theplasticsexchange.com).
Polyethylene Price Trends
August, with some ofgrade material down
LDPE AUG
SEPT ?
5¢/lb
3-5¢/lb
LLDPE Butene AUG
SEPT ?
5¢/lb
3-5¢/lb
HDPE Injection AUG 5¢/lb
according to Mike Burns, RTi’s v.p. of client services for PE, and Greenberg of The Plastics Exchange.
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85-87 71-74 46 45 84-86 79-81 44.5 43.75 92-94
POLYPROPYLENE (railcar) G-P HOMOPOLYMER, INJECTION NYMEX ‘FINANCIAL’ FUTURES . MID-OCTOBER . . . . . . . . . . . . . IMPACT COPOLYMER . . . . . . . . . .
. . . .
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. . . .
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64-66 55.25 55.25 66-68
POLYSTYRENE (railcar) G-P CRYSTAL . . . . . . . . . . . . . . . . . . . . . . . . . . . HIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
91-93 98-100
PVC RESIN (railcar) G-P HOMOPOLYMER . . . . . . . . . . . . . . . . . . . . . PIPE GRADE . . . . . . . . . . . . . . . . . . . . . . . . . . . .
74-76 73-75
Greenberg reported that spot PE trading was above average in late August he expected suppliers’ inventories to grow in August and beyond,
SEPT ?
material available at a fair market price,”
further price declines. Asked if prices are likely to stabilize or
3-5¢/lb
SEPT 3-5¢/lb
SEPT ?
5¢/lb
devaluation of the Chinese Yuan,
. . . . . . . . .
as processors have been buying cautiously in anticipation of
HDPE HMW AUG
price drop of 3-5¢/lb was expected for last month, driven by falling oil prices and the
POLYETHYLENE (railcar) LDPE, LINER . . . . . . . . . . . . . . . LLDPE BUTENE, FILM . . . . . . . . NYMEX ‘FINANCIAL’ FUTURES MID-OCTOBER . . . . . . . . . . . . HDPE, G-P INJECTION . . . . . . . . HDPE, BLOW MOLDING . . . . . . . NYMEX ‘FINANCIAL’ FUTURES MID-OCTOBER . . . . . . . . . . . . HDPE, HMW FILM . . . . . . . . . . .
¢/lb
September. “There seems to be plenty of
? 5¢/lb
by as much as 8-10¢/lb since the May price peak. Moreover, another contract-
Resin Grade
and dropped to light trading in early
HDPE Blow Molding AUG
PE PRICES DROP Polyethylene prices dropped a full 5¢/lb in
Market Prices Effective Mid-September 2015
3-5¢/lb
@plastechmag
he commented. Greenberg expected that
start increasing before year’s end, Burns notes a few factors
most suppliers would support a 4¢/lb
that could bring this about: a surge in oil prices; global demand
decrease for September, which would
improvement, or PE supply-chain disruptions.
result in PE contract prices down a net 13¢ for the third quarter—or 20¢ in the last 10 months. Notes RTi’s Burns, “The devaluation
PP PRICES LOWER Polypropylene prices generally dropped in August by about 1.5-2¢/
of the Yuan will limit imported pellets
lb following a 3.5¢ decrease for contract propylene monomer. PP
and accelerate imports of fnished
suppliers aimed for a 5¢/lb proft-margin increase in August,
plastics products such as bags. This
which was realized fully by some, while others saw that increase
global competition will increase price
split between August and September, and some saw none of it. “I
pressure on North America.” Meanwhile,
keep saying there is no one-size-fts-all in the PP market—it Plastics Technology
79
YOUR BUSINE S S
Resin Pricing Analysis
depends on who you’re buying from,
Polypropylene Price Trends
and if you’re behind or ahead of the curve,” says Scott Newell, RTi’s director
Homopolymer AUG
PVC Price Trends Pipe
of client services for PP.
SEPT
This diversity has characterized the
AUG
continued eforts by PP suppliers to
?
gain proft margin while resin supply is
1.5-2¢/lb 1.5-2¢/lb
Copolymer
Another 6¢ PP margin increase was attempted last month but had not gained
SEPT
industry support at press time, since
?
most suppliers were still trying to imple-
1.5-2¢/lb 1.5-2¢/lb
ment the August 5¢ hike, says Newell.
PVC prices dropped 1¢/lb in August and were likely to drop by at least another 1¢/ lb last month, according to RTi’s Kallman.
SEPT ?
While he does not anticipate any upward pressure in the fourth quarter, particularly in view of lower-cost feedstocks
1¢/lb
snug and monomer prices are declining.
AUG
PVC PRICES SOFT
and the slowdown of the construction
Gen. Purpose AUG
SEPT ?
1¢/lb
season, he said it was difcult to predict whether PVC prices would drop farther. He pointed to the start of fourth-quarter PVC plant turnarounds this month, which could tighten the market.
Greenberg’s assessment in the frst week of September was that while suppliers were adamant about enforcing the entire 5¢/lb margin increase for August PP, when the dust settled,
ABS PRICES UP, THEN DOWN
it seemed that only about 2¢ of that increase held. So with
ABS prices moved up on the order of 2-4% in July, following the
propylene monomer down 3.5 ¢/lb in August, average prime
June benzene contract, which settled up 21¢/gal. But ABS reversed
PP prices declined 1.5¢/lb. “There are additional PP margin
course in August, following benzene prices downward. With
increases on the table, so considering that monomer is primed to
benzene’s even heftier price drop in September of 79¢/gal, ABS
decrease about another 3.5¢/lb in September, it’s plausible to see
prices were expected to sink lower last month, noted RTi’s
contract PP go down another 1.5¢/lb.”
Kallman. He foresaw further downward pressure coming from
According to Greenberg, spot PP trades were few and
lower-cost Asian imports, which are on the increase.
prices edged a penny higher in early September. “Surplus material is generally hard to come by and is usually ofgrade. Contract pricing continues to be lower than spot due to
PC PRICES FLAT TO DOWN
continuing inadequate supply, but even contract buyers are
Polycarbonate prices were largely fat through the third quarter
willing to pay up as needed.” Newell says, “Converters have
but fourth-quarter prices were expected to be adjusted lower. PC
continued to buy strongly just to catch up and have a bit more
prices are typically set on a quarterly basis.
inventory on hand just so they don’t have to pay that big premium in the spot market.”
Driving the downward price trend are signifcant price drops in both propylene and benzene. And while domestic PC demand has been strong this year, driven by the automotive and construction sectors, exports are down. Domestic suppliers have always
PS PRICES DROPPING
relied on exports, and the decline is afecting overall demand,
Polystyrene prices dropped in August by 2-3¢/lb in step
along with an increase in cheap imports from both Europe and
with a 25¢/gal drop in benzene prices, and PS was expected
Asia, RTi’s Kallman notes.
to fall even more as September benzene contracts settled
Polystyrene Price Trends GPPS AUG
SEPT ?
2-3¢/lb 2-3¢/lb
HIPS AUG
SEPT ?
2-3¢/lb 2-3¢/lb 80
Plastics Technology
79¢/gal lower. Mark Kallman, RTi’s v.p. of client
NYLON 6 PRICES FLAT; NYLON 66 DOWN
services for engineering resins, PS,
Nylon 6 prices moved up by about 5¢/lb in the June/July time-
and PVC, points out that ethylene
frame, following spikes in benzene contract prices, then remained
monomer contracts dropped a total
fat through August. RTi’s Kallman anticipated that with currently
of 4.25¢/lb in July/August to 29.5¢/
lower benzene prices and ample supply, prices of nylon 6, for
lb, the lowest since before 2009. He
which demand has been steady, would remain mostly fat. Nylon
anticipated that PS prices would
66 prices remained primarily fat through the third quarter, but a
defnitely drop farther in September
downward adjustment for fourth-quarter pricing appeared immi-
or October. “Any price recovery for
nent, according to Kallman. Downward pressure is driven by lower
suppliers will be on the smaller
prices for benzene, propylene, and butadiene. This is despite
side for the remainder of the fourth
strong automotive demand for the resin, which is expected to
quarter,” ventured Kallman.
show a bit of an uptick in consumption this year over 2014.
OCTOBER 2015
PTonline.com
YOUR BUSINE S S
PL A S TIC S PROCESSORS’ BUSINESS INDE X
Contraction Continues Index dips for fourth straight month. With a reading of 46.6, Gardner’s Plastics Processors’ Business Index contracted at the same rate in August as it did July. The index has trended lower since March 2014—except for a brief spurt of accelerating growth from October 2014 to January 2015. In August, the index was at its lowest level since December 2012.
Plastics Processors’ Business Index Values above 50 indicate growth 60 55
50
New orders contracted for the
contract at a signifcant rate in August. The backlog index has hovered around 40 for four straight months, but the accelerating contraction in the index has stopped. However, the trend in backlogs indicated that capacity utilization at plastics proces-
SUBINDICES
AUG 15
JULY 15
JUNE 15
APR 15
MAY 15
MAR 15
JAN 15
FEB 15
DEC 14
OCT 14
NOV 14
AUG 14
SEPT 14
DIRECTION
RATE
TREND b
than the new orders index. Therefore, backlogs continued to
Plastics Processors’ Business Index INDIVIDUAL COMPONENTS CHANGE
Generally, the production index has remained much higher
45.9 -0.5
Contracting
Faster
2
JULY
production as virtually unchanged from July to August.
JULY 14
contracted for the second straight month, the index improved over last month and showed
AUGUST.
December 2012. While production
Values below 50 indicate retraction
40
MAY 14
Steve Kline Jr. Dir. Market Intelligence
46.6
JUNE 14
slightly faster rate than in July. The index fell to its lowest level since
45
APR 14
second month in a row, though at a
New Orders
45.4
Production
49.5
46.7
2.8
Contracting
Slower
2
months. Exports continued to contract due to the strong dollar.
Backlog
41.2
39.3
1.9
Contracting
Slower
7
While supplier deliveries continued to lengthen in August, the
Employment
48.6
52.0 -3.4
Contracting
From Growing
1
Exports
44.7
43.2
1.5
Contracting
Slower
8
Supplier Deliveriesa
50.5
52.6 -2.1
Lengthening
Slower
45
Material Prices
45.8
56.1 -10.3
Decreasing
From Increasing
1
Prices Received
45.9
46.6 -0.7
Decreasing
More
9
Future Business Expectations
65.7
64.6
1.1
Improving
More
45
Plastics Processors’ 46.6 Business Index
46.6
0.0
Contracting
Flat
4
sors would continue to fall heading into 2016. Employment contracted for the second time in three
rate of lengthening has decelerated noticeably since May. The material prices index dropped sharply in August to its lowest level since December 2011. Prices received by plastics processors have decreased since December 2014. The rate of decrease has steadily accelerated over that time period. Future business expectations ticked up slightly from last month. Conditions at large processors improved signifcantly in August. Plants with more than 250 employees expanded for the second month in a row and for the third time in four months. Plants with 100-249 employees grew at the fastest rate in August and have grown every month but one since December 2014. The Southeast was the fastest growing region in August and has expanded in fve of the last six months. The Northeast returned to growth after contracting in the previous three months. The West contracted for the sixth time in seven months.
aRefers
to length of delivery times. bHow many months each component has been running in the same direction.
Future capital spending plans improved signifcantly in August and have nearly doubled from two months ago. But compared with one year ago, future capital spending plans were still contracting at a very signifcant rate in August.
@plastechmag
ABOUT THE AUTHOR: Steven Kline Jr. is part of the fourth-generation ownership team of Cincinnati-based Gardner Business Media, which is the publisher of Plastics Technology. He is currently the company’s director of market intelligence. Contact: (513) 527-8800; email: skline2@gardnerweb.com blog: gardnerweb.com/economics/blog Plastics Technology
81
YOUR BUSINE S S
MARKET WATCH
Electronics Production to Slow Further in 2016 Slower growth attributable to consumers spending less. Electronics production has been well below average for at least the Steve Kline Jr. Dir. Market Intelligence
Real Disposable Income. June real disposable income was $12,176 billion (seasonally adjusted annual rate), an all-time high. In June,
last two years, a result of decelerating growth in consumer spending. And electronics production is
disposable income grew 3% compared with a year ago. This was the
likely to see even slower growth in 2016.
slowest rate of month-over-month growth in incomes since
Let me explain why.
September 2014 and the frst month of below-average income growth since that date. The annual
Real 10-Yr Treasury Rate. The real 10-yr U.S. Treasury bond rate (the nominal rate minus infation) was 1.74% in July, the sixth month in a row that the real rate has risen from the previous month. The nominal rate has risen for three months, but is still only about a third of its historical average. However, infation is historically low. The current annual average infation is just 0.17% vs. a historical average of 4.14%. Therefore, the real rate is about two-thirds of its historical average. Low infation is keeping real rates higher than in the past.
Disposable income has been growing at an accelerating rate since June 2014, but that trend looks like it will end soon.
Disposable income has been growing at an accelerating rate since June 2014, but that trend looks like it will end soon, which would become a negative indicator for electronics production. Real Electronics Spending. In June 2015, real electronics con-
The Fed has indicated a desire for interest rates to rise, but due to a host of economic concerns it may not take any action.
sumer spending was $361.8 billion (seasonally adjusted at an
However, with very low (or negative) infation and a generally stable
annual rate). Compared with a year ago, electronics spending in
yield, the change in real 10-yr Treasury rates will likely continue
June 2015 was up 8.8%. This rate of growth was nearly 33% below
to increase. This is a negative sign for electronics manufacturing.
the historical average of 13.9% monthly growth. While the annual
However, interest rates have a long lead time before they begin to
rate of change has been growing faster, the rate of growth is his-
afect industrial production and capital-equipment spending.
torically weak. Electronics Industrial Production. The electronics production index was
40
40
near its all-time high in June 2015.
32
32
However, the rate of growth has been
24
24
16
16
8
8
0
0
Real Electronic Goods Consumer Spending Plastics Technology
OCTOBER 2015
Jan 15
Jan 13
-40
Jan 11
-40
Jan 09
-32 Jan 07
-32 Jan 05
-24
Jan 03
-24
Jan 01
-16
Jan 99
-16
Jan 97
-8
Jan 95
-8
decelerating since last December. Despite the ups and downs from recesElectronics Production, 12-Mo. Rate of Change
Real Electronic Goods Consumer Spending, 12-Mo. Rate of Change
Real Electronics Goods Consumer Spending Leads Electronics Production
82
rate of change ticked up to 3.2%.
Electronics Production
sions, the overall trend since 1998 has been for slower and slower growth in electronics production. And given the trend in many of the leading indicators, it appears that electronics production will continue to see slower growth heading into 2016.
ABOUT THE AUTHOR: Steven Kline Jr. is part of the fourth-generation ownership team of Cincinnati-based Gardner Business Media, which is the publisher of Plastics Technology. He is currently the company’s director of market intelligence. Contact: (513) 527-8800 email: skline2@gardnerweb.com blog: gardnerweb.com/economics/blog PTonline.com
MARKETPL ACE
This is Plastics Technology’s online listing for plastic processing equipment builders, material suppliers, auxillary manufacturers and more.
WWW.TINIUSOLSEN.COM
WWW.CVI.CANON.COM
Test Equipment: Hardware and software for tensile, fexure, compression, puncture/burst, shear, melt indexing, and impact testing of plastics.
Canon offers custom mold making solutions. Contact us at 1.866.CANON or visit www.cvi.canon.com to fnd out more.
WWW.WHCORP.COM
WWW.PPE.COM
Flexographic and gravure printing presses, blown and cast flm extrusion systems, multiwall equipment, plastic sack and bag making machines, form-fll-seal machinery for the converting and packaging industry – all from one leading source.
WWW.MAGUIRE.COM
The perfect blend of simplicity and control. Over 100 pages of easy browsing packed with useful information on Maguire Blenders, Loaders, Granulators, Feeders, and Liquid Color Pumps.
WWW.CWBRABENDER.COM
C.W. Brabender Instruments, Inc. is the leading manufacturer of Polymer Processing Equipment. We offer an extensive product line of extrusion equipment.
With a continually expanding range of products, PPE is the largest supplier of molding accessories to the plastics industry. With offces in Ohio, Nevada and Florida, PPE provides fast delivery and the personal attention that your order deserves. Contact us at 1-800-362-0706, sales@ppe.com or visit www.ppe.com
WWW.MACAUTOMATION.COM MAC serve the Plastics Industry with auxiliary equipment including: Conveyors, Plantwide Equipment, Automated Box-Fill Systems, Portable Resin Bins, Part/Runner Separators and diverters, Inspection Tables, Cleanrooms, Drum and Gaylord Filter Covers, Air Conveying Systems, Robot Guarding, Mold Side Curtains, Tie bar Sleeves and Under-Press Part Chutes.
WWW.NOVATEC.COM
World’s largest selection of dryer technologies and blenders with unmatched system design and control capabilities. 1-800-BESTDRY (1-800-237-8379)
WWW.WITTMANN-GROUP.COM
WWW.ADVANTAGEENGINEERING.COM
Wittmann Battenfeld’s website provides global access to the full range of Battenfeld injection molding machines, process engineering, customer service, training and turnkey solutions, in addition to automation and auxiliary equipment including Wittmann robots and automation, material conveying, drying, blending, granulating and water temperature controllers.
Manufacturer of high quality water and oil temperature controllers, portable chillers, central chilling systems and cooling tower systems.
@plastechmag
Plastics Technology
83
MARKETPL ACE HAMMERTEK CORPORATION Built to endure. Made to save you money. Hammertek’s Smart Elbow.
You can get copies of literature from suppliers listed on these pages by sending an e-mail to the address provided at the end of each writeup. Or, where provided, contact the company by phone or fax. CLEANABLE ROUND AIRLOCK The Mac Process cleanable round airlock (CRA) is perfect for processes requiring quick turnover due to frequent material changes. A demountable rotor with tool-free disassembly simplifes the cleaning step between diferent color runs. The CRA is designed to handle high process rates. Whitewater, WI • mktg@schenckprocess.com
CANON MOLD MAKING SERVICES Scan this code to view our state-of-the-art facility, skilled craftsmen and innovative technologies in action. You can also contact us at 1.866.CANON or visit us at www.cvi.canon.com to fnd out more.
Newport News, VA • cvi.canon.com
FULLY AUTOMATIC SCREEN CHANGERS HITECH™ screen changers operate on a truly continuous principle in harmony with the rest of the extrusion process. The screen, in the form of a long ribbon, moves slowly through the screen changer at an infnitely adjustable rate to blend smoothly with the polymer fow.
Hackensack, NJ • aalroy@screenchangers.com
SOLUTIONS FROM 55-7700 TONS Since 1947 Negri Bossi has been providing innovative, cutting-edge technical solutions for the injection molding market. Today Negri Bossi NA ofers an extensive product portfolio of injection molding machines ranging from 55 to 7700 tons that includes LSR and multi-material models. New Castle, DE • sales@negribossiusa.com
84
Plastics Technology
OCTOBER 2015
Landisville, PA • elbows@hammertek.com
SINGLE AND TWIN SCREW EXTRUDERS 20mm Clamshell Segmented Twin-Screw Extruder: Compounding, Pilot Scale & Nanocomposites applications for product development. Clamshell barrel allows visual processing assessment, easy screw mounting, quick cleaning. Segmented screws ofer numerous processing possibilities.. S. Hackensack, NJ • cwbi@cwbrabender.com
TWIN SCREW EXTRUDERS AND SYSTEMS Twin screw extruders (TSE’s) and systems— Leistritz manufactures twin screw extruders (16 to 180 mm) used for compounding, reactive extrusion, devolatilization and direct extrusion. Services include a fully equipped process laboratory and TSE workshops. Somerville, NJ • sales@alec-usa.com
CLEAR-VU™ LOADING SYSTEM Provides all the benefts of a central loading system with the added convenience of portability & low maintenance. Brochure & video describe this complete vacuum conveying system that will control up to eight stations. Receivers allow full view of the loading action. Aston, PA • info@maguire.com
PPE GATE CUTTERS - LOWER PRICES PPE ofers the best variety of Gate Cutters at the lowest prices in both our Economy and Premium styles. With 74 diferent cutters to choose from including heated & pneumatic, you’re bound to fnd what you needed right here at PPE. www.ppe.com Macedonia, OH • sales@ppe.com
DRY-CONVEY-BLEND-EXTRUSION Novatec is one of the largest U.S. based manufacturers of resin drying and conveying equipment for the plastics industry. Together, with Maguire Products, we ofer the largest line of manufactured resin handling equipment in North America. Product Overview: www.novatec.com/about Baltimore, MD • sales@novatec.com
PLASTIC PIPE GRANULATORS Original Pallmann Pipe Crushers can be used for size reduction of plastic pipes consisting of PE, LD, HD, MD, PP, PVC, ABS, etc. down to extrudable granules. Proven horizontal feeding system handles full length & up to 36” d. pipes, as well as cutofs. Custom models also available. Clifton, NJ • info@pallmannpulverizers.com
MAC AUTOMATION CONCEPTS MAC designs and manufactures conveyors; available in powder coated welded steel, stainless steel and extruded aluminum. Mac precision machined trapezoid crowned steel pulleys provides improved belt tracking and less contamination compared to aluminum pulleys. Woodstock, IL • raulr@macautomation.com
THE SOLUTION TO KNIT/FLOW LINES Per-Fix™ Flaw Repair Coatings—The Solution to Knit/Flow Lines. Chem-pak’s patented line of coatings helps you eliminate most cosmetic flaws common to injection molded plastics. Designed specifically for mattefinished, color-coded, textured, interior parts.
Martinsburg, WV • info@chem-pak.com
AQUATHERM RQ SERIES CONTROLLERS New compact RQ Series temperature controllers come with the best available components such as cast pump volute/heater tube/mixing assemblies, high fow pumps with leakresistant silicon carbide seals and rugged Incoloy sheathed heaters. Tools-free accessibility for easy maintenance. Niles, IL • info@thermalcare.com
PTonline.com
High Performance Liquid Purging Compound • Use Less, Get Better Results
MATERIALS WANTED/FOR SALE
PURGING COMPOUNDS
CL A SSIFIEDS
• More Cost Effective Than Pellets • Sold Through Knowledgeable Distributors • Samples Available
1-800-797-9244 www.elmgroveindustries.com
TODAY’S ADVERTISER IS TOMORROW’S
SUCCESS
RECRUITMENT
E-mail: sales@elmgroveindustries.com
CAREER OPPORTUNITY
Jomar is looking to fll a position in their R&D Plastics Processing Department. Applicants are required to have a valid driver’s license and have the ability to obtain a passport. Must be able to stand for long periods of time and lift 50 lbs. Occasional travel is mandatory once trained. Job duties are to set up, operate and establish processes for the injection blow molding machine along with performing QC procedures and eventually train customers. Experience helpful but not necessary. If you have the ability to self-motivate, follow simple directions, write reports and communicate ideas with others, please email resume to CAREERS@JOMARCORP.COM Or mail to: JOMAR CORP., P.O. BOX 1020 PLEASANTVILLE, NJ 08232.
Applicants will be seen by appointment only.
To place your classifed ad contact Chris Brock at:
440-639-2311 or fax 513-527-8801
Let Plastics Processors Know
WHO You Are and WHERE You Are Advertise in
@plastechmag
Plastics Technology
85
SPECIAL SERVICES
CL A SSIFIEDS
GRINDING
TIME-CRITICAL CONFIDENTIAL PROBLEM SOLVING Since 1973
Services
• Granulation / Coarse Grinding • Pulverizing / Fine Grinding • Cryogenic Grinding • Sifting / Classifying • Blending / Mixing • Destructive Grinding
P.O. Box 363, Bloomsbury, NJ 08804 908-479-4400
www.allgrind.com • e-mail: info@allgrind.com
• Chemical Analysis and Characterization • Thermal Analysis and Rheology • Mechanical Testing • Organic Synthesis • Lab Compounding, Pelletizing and Injection Molding • Failure Analysis • Quality Assurance • Chemical Resistance • Accelerated Weathering • FDA Extractions • R&D
• PLASTICS • POLYMERS • RUBBER • ASTM 10626 KINGHURST HOUSTON, TX 77099
FAX
281-879-8600 281-879-8666
LABORATORIES, INC. www.polyhedronlab.com
FEATURING
Your #1 Plastics Processing Resource from Plastics Technology!
• Best Practices & Processing Know How • New Technologies & Products • Knowledge Centers • Tips, Techniques & Troubleshooting • Materials Database • PT Blog • And, much more…
IMPROVED NAVIGATION Optimized search and reorganized navigation make it easier to research the products, processes and suppliers you need.
ENHANCED DESIGN Larger article formats, more product images, redesigned emphasis zones.
PTonline.com
86
Plastics Technology
OCTOBER 2015
PTonline.com
ADVERTISERS’ INDE X Advantage Engineering, Inc.
. . . . . . . . . . . . . . 12,
13
Fabricating.com . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Processing Technologies International LLC . . . 78
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Gala Industries, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
�
www.gala-industries.com
www.rapidgranulator.com
Bergen International LLC . . . . . . . . . . . . . . . . . . . . 23
Hosokawa Alpine America . . . . . . . . . . . . . . . . . . . . . 61
�
www.halpine.com
www.schenckprocess.com
CW Brabender Instruments, Inc.
. . . . . . . . . . . 27
IMS Industrial Molding Supplies. . . . . . . . . . 8 a,b
Schneider Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . .53
Canon Virginia Inc. . . . . . . . .Inside Front Cover
Kenrich Petrochemicals, Inc. . . . . . . . . . . . . . . . . . .59
SPE Automotive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Chem-Pak, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Krause Management/PlastImagen . . . . . . . . . . . 73 www.plastimagen.com.mx
Sumitomo (SHI) Demag Plastics Machinery www.sumitomo-shi-demag.us 16 a,b
Maguire Products, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Thermal Care, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Moulds Plus International. . . . . . . . . . . . . . . . 24a, b
Tinius Olsen Testing Machine Co. Inc.. . . . . . . . . 2
....................................3
Nordson Kreyenborg . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Unique Tool & Gauge Inc.
Davis-Standard LLC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Novatec Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6, 7, 44, 45
Universal Robots USA, Inc. . . . . . . . . . . . . . . . . . . . . 18
Dover Chemical Corp.
37
Pelletron Corp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 www.pelletroncorp.com
www.whcorp.com
Dri-Air Industries, Inc. . . . . . . . . . . . . . . . . . . . 30, 31
PFA Inc.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
�
www.advantageengineering.com
Avian USA, LLC
www.aviangranulator.us
�
www.bergeninternational.com �
www.cwbrabender.com �
www.cvi.canon.com �
www.chem-pak.com
Cincinnati Process Technologies www.cinprotech.com
�
. . . . . . . . . . . . . 35
Conair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Back Cover
www.conairgroup.com �
Cumberland
www.cumberland-plastics.com
www.davis-standard.com
www.doverchem.com
�
. . . . . . . . . . . . . . . . . . . . . 36,
www.dri-air.com
www.fabricating.com
www.imscompany.com
www.4kenrich.com
www.maguire.com
www.ultrapurge.com
www.nordsonpolymerprocessing.com
www.novatec.com
www.pfa-inc.com
Eastman Chemical Co. . . . . . . . . . . . . . . . . . . . . . 32a,b
�
www.tritanmoldit.com
www.ppe.com
Erema North America . . . . . . . . . . . . . . . . . . . . . . . . . 40
�
www.erema.net
�
www.ptiextruders.com
Rapid Granulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Schenck AccuRate . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
www.schneiderpackaging.com
www.speautomotive.com/comp
www.thermalcare.com
www.tiniusolsen.com
www.unique-tool.com
. . . . . . . . . . . . . . . . . . . . .69
www.universal-robots.com
Windmoeller & Hoelscher Corp. . . . . . . . . . . . . . .39 Wittmann Battenfeld, Inc. . . . . . . . . . . 40 a,b, 41 outsert
www.wittmann-group.com
Plastic Process Equipment, Inc. . . . . . . . . . . . . 15, Inside Back Cover Plastrac Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
www.plastrac.com
For additional product information, refer to this company’s Advertising/Data Sheets in PLASTICS TECHNOLOGY’s 2015 PROCESSING HANDBOOK & BUYERS’ GUIDE
SALES OFFICES MID-ATLANTIC/NORTHEAST Lou Guarracino District Manager 215/327-9248 Fax: 513/527-8801 loug@ptonline.com
ILLINOIS/INDIANA/WISCONSIN
Ryan Delahanty District Manager 630/584-8480; Fax: 513/527-8801 630/561-6770 (mobile) rdelahanty@gardnerweb.com
OHIO/MICHIGAN/SOUTHEAST/ WESTERN PA/UPSTATE NY, CANADA
Jackie Dalzell District Manager 330/558-0487; Fax: 513/527-8801 216/233-6794 (mobile) jdalzell@gardnerweb.com MOUNTAIN/SOUTHWEST/WEST Rick Brandt District Manager 310/792-0255; Fax: 513/527-8801 805/202-6395 (mobile) rbrandt@gardnerweb.com @plastechmag
CLASSIFIED/RECRUITMENT ADVERTISING Chris Brock 440/639-2311 Fax: 513-527-8801 cbrock@gardnerweb.com JAPAN Toshiro Matsuda Director of Overseas Operations Plastics Age Co. Ltd. (03) 256-1951 KOREA Chang-Hwa Park Far East Marketing Inc. (02) 364-4182 Fax: (02) 364-4184 femchp@unitel.co.kr TAIWAN May Hsiao J&M Media Corp. 886-4-2296-5959 Fax: 886-4-2293-9730 may@jandm.com.tw www.jandm.com.tw
CHINA Lucy Xiao Beijing Vogel Consulting Co. Ltd. (86-10) 63326100 Fax: (86-10) 63326099 lucy@vogel.com.cn ITALY Nicola Orlando Com 3 Orlando sas 39 (02) 4158056 Fax: 39 (02) 48301981 ppoint@com3orlando.it INDIA Paresh Navani Vogel Business Media India Pvt. Ltd. 91 22 4123 4715 paresh.navani@vogel.de
PLASTICS TECHNOLOGY (ISSN 0032-1257) is published monthly and copyright © 2015 by Gardner Business Media Inc. 6915 Valley Ave., Cincinnati, OH 45244-3029. Telephone: (513) 527-8800. Printed in U.S.A. Periodicals postage paid at Cincinnati, OH and additional mailing offces. All rights reserved. POSTMASTER: Send address changes to Plastics Technology Magazine, 6915 Valley Ave., Cincinnati, OH 45244-3029. If undeliverable, send Form 3579. CANADA POST: Canada Returns to be sent to IMEX Global Solutions, P.O. Box 25542, London, ON N6C 6B2. Publications Mail Agreement #40612608. The information presented in this edition of Plastics Technology is believed to be accurate. In applying recommendations, however, you should exercise care and normal precautions to prevent personal injury and damage to facilities or products. In no case can the authors or the publisher accept responsibility for personal injury or damages which may occur in working with methods and/or materials presented herein, nor can the publisher assume responsibility for the validity of claims or performance of items appearing in editorial presentations or advertisements in this publication. Contact information is provided to enable interested parties to conduct further inquiry into specifc products or services.
Printed in the U.S.A. Plastics Technology
87
PROCESSOR’S EDGE
SELFECO — STILLWATER, MINN.
New PLA Molder Anticipates Swift Growth SelfEco developed two diverse PLA product lines in less than a year.
SelfEco’s party and catering line includes higher-end food-service items.
SelfEco is a start-up molder that has hit the ground running. The
and more than 30 part numbers within the two product lines it has
new frm was created by family-owned sister company VistaTek LLC
been developing.
By Lilli Manolis Sherman Senior Editor
(vistatek.com) less than a year ago, when
A “party and catering” line, made with food-grade PLA from
the latter recognized the value of molding
Natureworks LLC, Minnetonka, Minn. (natureworksllc.com),
products from plant-based plastics.
includes food-service items ranging from plates, bowls, cups, and
As both a moldmaker and molder, VistaTek already had a
cutlery to champagne futes and Asian spoons. These are higher-
couple of years’ experience developing molds and proprietary
end products that have been sold initially to caterers and private
processing parameters for PLA biopolymer, explains Danny
venues. But retail opportunities beckon.
Mishek, president of SelfEco and managing director of VistaTek,
Ditto for the “home and garden” line, which includes various
both in Stillwater, Minn. He and his younger siblings, Al Mishek,
sizes of self-feeding plantable pots and self-feeding sleeves that are
account manager for VistaTek; and Jenny Sutherland, VistaTek’s director of fnance, envisioned that the new enterprise would help ofset the highs and lows of the moldmaking and injection molding business. Today, SelfEco (selfeco.com) shares a
made of PLA and a protein nutrient additive.
Compostable products answer retailers’ concerns about disposable plastics going into landflls.
50,000 ft² facility with VistaTek, with 6000 development, and warehousing. It produces most of its products on VistaTek’s 165- to 220-ton injection presses.
are not as stable for growers when using
products supply nutrients to the plants, he notes. Before developing the home-and-garden line, SelfEco intercropping up: fertilizer runof getting into waterways and the waste of petroleum-based plastic containers going into landflls. Because
product develop-
the nutrients are in the plant-based polymer and underground, the
ment, product
self-feeding pots and sleeves reduce fertilizer runof. “Since these pots are plant-based and designed to break down
production, and
while feeding the plants, this will lessen the stress of traditional
patent fling.
petroleum-based plastic pots ending up in the landfll. These
But getting
products have confronted and resolved the two major issues that
compostable
concerned today’s gardeners and growers,” says Mishek.
certifcation from
OCTOBER 2015
containers, which are meant to decompose,
months to do its
branding, pre-
Plastics Technology
out that conventional fabric or peat-moss
viewed gardeners and growers. Two topics of concern kept
Danny Mishek says it took the new company less than three
88
during the growing season. Mishek points
automated planting systems. Nor do these
ft² currently dedicated to SelfEco’s conference room, product
Self-feeding pots and sleeves made of PLA and a protein nutrient additive decompose during the growing season.
The home-and-garden products decompose
The environmental beneft of SelfEco’s products strikes a chord
the Biodegradable
with both growers and caterers, according to Mishek. He also points
Products Institute
out that SelfEco is very cost-competitive with both HDPE- and
(BPI) took nearly
PLA-based Asian imported food-service items.
six months.
Mishek is encouraged by ongoing discussions with such
SelfEco has several
giants as Walmart, Menards, and other retailers: “We’ll be looking
patents pending
at expansion plans in the near future.” PTonline.com
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