Canadian Plastics CanadianPlastics www.canplastics.com
FEBRUARY 2012
Plus!
What’s around the bend in 2012?
ATHENA AUTOMATION:
Robert Schad talks about his new company
Maximizing shredders & granulators p16 p14
Getting lean on the shop floor p20 Purging with the latest compounds p24 CANADA POST PUBLICATIONS MAIL AGREEMENT NO. 40069240
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contents
Canadian Plastics FEBRUARY 2012 VOLUME 70 NUMBER 1
LOOKING BACK... Nineteen sixty-one was a good year for war movies (The Guns of Navarone), Elvis (It’s Now or Never), and — as it turns out — Canada’s plastics industry. According to the February 1962 issue of Canadian Plastics, Canada used 363 million lbs. of plastics in 1961 — a new high of approximately 20 lbs. per person, and up almost nine per cent over the previous year. Exports rose 14 per cent to 76 million lbs., production of thermoplastics increased by 17 per cent, and at least 17 new plants and 900 employees were added to the industry. The most popular material? Polyethylene, the market for which grew by 20 per cent.
page 14
Number of the month:
$14.75*
*Average hourly I/M machine operator wage, excluding benefits. (See pg. 13)
in every issue 4 Editor’s View: • Help Wanted: Teens for manufacturing 5 Ideas & Innovations: • Record-breaking organic solar cells incorporate new polymer
page 10
page 22 cover story
10 INJECTION MOLDERS’ SURVEY: What’s around the bend? A fter the TKO of the Great Recession, Canada’s plastics processors have bounced back and are ready to do battle. Our latest Benchmark Survey gives you a unique look at some of the I/M segment as they lace up the gloves. Markets served, buying intentions, utilization rates, business expectations for 2012 — it’s all here.
features
6 News: • CPIA names trade association veteran Carol Hochu as new president and CEO • Canada’s Onex Corp. buys Davis-Standard • Supplier News & People
14 ATHENA AUTOMATION: The return of Robert Schad
9 Executive’s Corner: • Understanding recent changes to the SR&ED program
16 SHREDDERS & GRANULATORS: Get efficient!
26 Technology Showcase 26 Plastics Data File 26 Advertising Index 29 Classified Ads 30 View from the Floor: • Goodbye...and thank you (Or, my last rant)
I n 2007, Husky Injection Molding Systems founder and president Robert Schad sold his shares and seemed to vanish into the quiet life. Only he didn’t. After a false start and several years of product development, he’s back in the game with Athena Automation Ltd., a supplier of hybrid injection molding machines and lights-out automation systems. M aterial might just be the biggest cost for plastics processors these days, so it’s important to reclaim as much of it as possible. Maximizing your shredders and granulators is a good way to start. Our experts tell you how.
20 LEAN MANUFACTURING: Taking it to the shop floor T oyota developed them; introduce some lean manufacturing principles into your production process and you can benefit from 'em.
24 PURGING COMPOUNDS: Slip-sliding away T he right commercial purging compounds can help transform your processing equipment from plugged up to mean and pristine. Inside, we spotlight some of the latest offerings.
Visit us at www.canplastics.com www.canplastics.com February 2012 Canadian Plastics
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editor’s view
Help Wanted: Teens for manufacturing
U
nless you were hanging out with one of the Occupy movements this past fall, you’ll probably agree that manufacturing is a beneficial activity. Acting as an engine for economic growth and a catalyst for prosperity, the sector spurs demand for everything from raw materials and intermediate components to software and services of all kinds. And as we come out of the worst economic downturn since the Great Depression, it’s manufacturing that leads the way. So here’s my question: Why don’t more young people want to get involved? A recent U.S. national poll of teenagers highlighted — in flashing neon — teens’ disinterest in manufacturing and working with their hands. The poll showed that 52 per cent of teens have little or no interest in a manufacturing career, while another 21 per cent are ambivalent. When asked why, 61 per cent said they wanted a more “professional” career. And in both the U.S. and Canada, this disinterest is already having an effect. Almost half of those Canadian manufacturers who responded to a recent PwC manufacturing survey said the lack of qualified workers was a significant barrier to their growth. In other words, companies can’t find people to fill jobs in an economy still reeling from months of almost doubledigit unemployment rates. And as more baby boomers retire, the problem is only going to get worse. So how did it come to this? Several reasons. First, among young people, manufacturing has an image problem that disgraced Illinois governor Rob Blagojevich would pity. Too many teens evidently picture today’s factories as something right out of a Karl Marx pamphlet, complete with grime, monotony, and backbreaking labor. For good measure, throw in the gazillion or so movies aimed at young audiences that portray entrepreneurs and manufacturers as the bad guys, poisoning the oceans and atmosphere with toxins. As 4
Canadian Plastics magazine reports on and interprets develop ments in plastics markets and technologies worldwide for plastics processors, moldmakers and end-users based in Canada.
www.canplastics.com
images, they’re definitely not cool. Reinforcing the problem is the disinterest that many North American adults take in the manual arts. More and more, Canada and the U.S. have become nations of “non-tinkerers.” Unless it involves changing a light bulb, many of us opt out of household repairs — far easier, it seems, to contact the property manager or hire a handyman. With manually dexterous role models thin on the ground these days, young people essentially have no one to emulate when it comes to making repairs or building something useful. Nor do today’s educational systems help much. Forget the short shrift given to shop class in most high schools; many college-level technical courses and apprenticeship programs are dying on the vine, the victims of budget cuts and declining enrolment. One of the most well-known recent casualties was the Canadian Plastics Training Centre at Toronto’s Humber College, which closed in 2009. Finally, the manufacturing sector itself isn’t entirely blameless. Often wrapped up in their own financial challenges, many companies have done little to help develop skilled workers or to participate in the apprenticeship programs that do remain. Another symptom of this lack of engagement is the failure of some to even try and connect with young people faceto-face. I’ve been to many a trade show, for example, and watched as the students attending from nearby schools (invariably shuttled through on the last day) are ignored by exhibitors as though they were squeegee kids at a red light. We’re definitely not going to win any hearts and minds that way. To sum up, a confluence of factors is at work, and the solution will have to address each and every one of them. One thing seems clear, though: Unless we can find the skilled labor needed to handle the kinds of sophisticated production processes required on the shop floor, Canada’s plastics and moldmaking industries are in for real trouble in the years ahead.
EDITOR Mark Stephen 416-510-5110 Fax: 416-510-5134 E-mail: mstephen@canplastics.com TECHNICAL EDITOR Jim Anderton 416-510-5148 E-mail: janderton@canadianmetalworking.com ART DIRECTOR Andrea M. Smith PRODUCTION MANAGER Steve Hofmann 416-510-6757 E-mail: shofmann@bizinfogroup.ca PRINT PRODUCTION MANAGER Phyllis Wright SENIOR PUBLISHER Judith Nancekivell 416-510-5116 Fax: 416-510-5134 E-mail: jnancekivell@canplastics.com SALES MANAGER Brayden Ford 416-510-5124 Fax: 416-510-5134 E-mail: bford@canplastics.com CIRCULATION MANAGER Anita Madden 416-442-5600, ext. 3596 Fax: 416-510-6875 E-mail: amadden@bizinfogroup.ca HEAD OFFICE: 80 Valleybrook Drive, Toronto ON, M3B 2S9. 416-442-5600, Fax: 416-510-5134 CANADIAN PLASTICS is published 7 times a year by BIG Magazines LP, a div. of Glacier BIG Holdings Company Ltd., a leading Canadian information company with interests in daily and community newspapers and business-to-business information services. 2012 SUBSCRIPTION RATES
6 issues Canadian Plastics, plus Dec. 2012 Buyer’s Guide: CANADA: 1 Year $70.95 plus applicable taxes; 2 Years $115.95+ taxes; Single copy $10.00+ taxes. USA: US$79.95; FOREIGN: US$124.95 B uyers’ G uide only : CANADA: $103.00 plus applicable taxes and $5.00 shipping USA & FOREIGN: US$103.00 plus $5.00 shipping. From time to time we make our subscription list available to select companies and organizations whose product or service may interest you. If you do not wish your contact information to be made available, please contact us via one of the following methods: phone 800-668-2374; fax 416-442-2191; e-mail: privacyofficer@businessinformationgroup.ca; mail: Privacy Officer, Business Information Group, 80 Valleybrook Drive, Toronto ON M3B 2S9. The contents of this magazine are protected by copyright and may be used only for your personal non-commercial purposes. All other rights are reserved and commercial use is prohibited. To make use of any of this material you must first obtain the permission of the owner of the copyright. For further information please contact Judith Nancekivell, 416-510-5116. For reprints call RSiCopyright, Michelle Hegland, msh@rsicopyright.com USPS 745-670. U.S. Office of Publication, 2424 Niagara Falls Blvd., Niagara Falls, NY. 14304-0357. Periodical Postage paid at Niagara Falls NY USA. Postmaster: Send address changes to Canadian Plastics, PO Box 1118, Niagara Falls NY 14304-0357. PAP Registration No. 11035 CANADA POST – Publications Mail Agreement No. 40069240. Return undeliverable Canadian addresses to: Circulation Dept. – Canadian Plastics, 80 Valleybrook Drive, Toronto ON M3B 2S9. RETURN POSTAGE GUARANTEED INDEXED BY CBPI ISSN 0008-4778 (Print) ISSSN 1923-3671 (Online) MEMBER: Canadian Business Press, Canadian Plastics Industry Association. We acknowledge the financial support of the Government of Canada through the Canada Periodical Fund (CPF) for our publishing activities.
Mark Stephen, editor
mstephen@canplastics.com
Canadian Plastics February 2012 www.canplastics.com
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ideas & innovations
Record-breaking organic solar cells incorporate new polymer
S
ome record-breaking events command attention: a new NHL winning streak, for example, or even — God help us — the results from a speed-eating competition. While not exactly big news among the general public, a group of Canadian scientists recently shattered a milestone of a different kind: They produced the world’s most efficient “inverted” organic photovoltaic (OPV) solar cells, outperforming a previous record established by a Belgian team just a few months earlier. So why do we care? The achievement might just accelerate the adoption of OPV devices in novel solar power applications — and it couldn’t have been done without the use of a newly-developed polymer. Created by a team of researchers from the Ottawa-based National Research Council of Canada (NRC) and the Department of Chemistry at Quebec’s University of Laval, the new material is an alternating copolymer of dithienosilole and thienopyrrole-4,6-dione, PDTSTPD. If it sounds complex...well, so was the problem the team was trying to solve. Due to their mechanical flexibility, OPV solar cells can make electricity when spread over irregular shapes such as briefcases, backpacks, military equipment, tents, store awnings — even entire buildings. They can also form a dual-purpose semitransparent window coating that can be tinted any color, producing power while creating an interior mood and/or exterior pattern. “OPVs have the potential to provide power at less cost than silicon cells because you don’t need as much material, and devices can be produced using low-cost fabrication techniques, such as high-speed, roll-to-roll printing technology,” said the NRC’s Dr. Jianping Lu. “To cover one square metre with a thickness of 100 nanometres, you only need about 0.1 grams of active materials.” Trouble is, there are several stability issues associated with this device structure, such as the rapid oxidation of the
low work-function metal cathodes when exposed to air and water vapor, and the instability of the interface between the active layer and the cathode. Encapsulation with high oxygen and water vapor barriers is required for typical organic solar cells, but these add significantly to the production cost. The polymer developed by Dr. Lu and the other researchers — specifically the PDTSTPD element — has features that make it a very promising candidate for solar cell applications, including good electrical conductivity, excellent solubility in organic solvents even at room temperature, and a relatively simple synthetic procedure. “The device is highly stable, retaining 85 per cent of its original efficiency after being stored in air for 32 days
without encapsulation,” said Dr. Taya Chu, another NRC team member. The development is the latest in a series of increasingly efficient organic solar cells created by the NRC team, which is being led by Dr. Ye Tao. In November 2011, the team’s inverted OPV cells were officially certified by an independent U.S. certification lab at a power conversion efficiency of 7.1 per cent, which means they convert 7.1 per cent of incoming solar light into electricity. OPVs that incorporate the new polymer have a power conversion efficiency of 7.3 per cent. “We fully expect that the device performance can be further improved by continued optimization of the material,” Dr. Lu said. In other words, the sky might just be the limit for these solar cells. CPL
www.canplastics.com February 2012 Canadian Plastics
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news
CPIA names trade association veteran CAROL HOCHU as new president and CEO
T
he Canadian Plastics Industry Association (CPIA) has a new leader. As of January 3, Carol Hochu is the Mississauga, Ont.-based trade organization’s new president and CEO. Greg Wilkinson, the interim leader of the CPIA for the past 10 months, is returning to his energy, chemicals and plastics consultancy, Third Oak Associates Inc. “The CPIA is fortunate to have found a leader of Carol Hochu’s caliber, and I’m confident that between Carol, the CPIA staff and our Board, the important work of the association is in very good hands,” Wilkinson said. “As for me, I’m happy to still be connected to and supporting the industry.” Hochu’s background is in trade association and industry group management. Before signing on with the CPIA, she served a three-year stint as the executive director of the Ontario Electronic Stewardship (OES), a not-for-profit industry funding organization charged with implementing a province-wide electronic waste diversion program. Prior to that, her positions included president of the Ontario Stone, Sand & Gravel Association, and president of the Confectionery Manufacturers Association of Canada. “There’s definitely a learning curve for me to go through as I familiarize myself with the plastics industry,” Hochu told Canadian Plastics. “I’m
very busy these days meeting with CPIA staff and Board members, and will be broadening that out soon to include meeting with other CPIA members in their places of business, and also meeting with affiliated associations, and government and other stakeholders. I want to introduce myself to as many people as possible, and see as many facilities as possible.” According to Hochu, the CPIA Board is set to undertake a periodic review to reflect upon what the association does and why it matters, so as to confirm and update its value proposition. Member input via a short survey will play a role in determining these strategic priorities. “Hopefully, the survey feedback will give us good ideas of what we’re doing well and what we can improve upon,” she said. It seems safe to say, though, that some things won’t be tampered with. If, for example, the waste-diversion aspect of Hochu’s tenure at the OES reminds you of recent CPIA recycling initiatives, it’s no coincidence — and, Hochu said, it’s something she hopes to continue to build on going forward. “The post-use recovery initiatives that Greg Wilkinson and his predecessor Mark Badger championed remain very important,” she said. Though hardly a novice to the manufacturing sector before the CPIA came knocking, Hochu’s sudden immersion in the polymer world is already making its mark. “Before joining the CPIA, my impression was that plastic production was a hugely important sector of the Canadian economy, making products that are integral to the quality of life we enjoy,” she said. “Given what I’m learning, I’m more convinced of it now than ever. It’s a privilege to be in a position to help the industry move forward.” CPL
Canada’s Onex Corp. buys Davis-Standard Extrusion equipment supplier Davis-Standard LLC now has Canadian-based ownership. Private equity firm Hamilton Robinson Capital Partners has sold Pawcatuck, Conn.-based Davis-Standard to ONCAP, the middle market investing platform of Toronto’s Onex Corporation. The terms of the deal haven’t been disclosed. Hamilton Robinson, headquartered in Stamford, Conn., acquired Davis-Standard in 2003 and — according to a press release — has grown the company’s revenue from US$30 6
million to over US$300 million. “This revenue growth was accomplished through management’s execution on strategic acquisitions, lean manufacturing, global sourcing, enhanced technical capabilities, and penetration of new markets,” the release said. For Onex, the purchase is the latest in a line of plastics holdings, chief among them Husky Injection Molding Systems. Onex bought Husky in December 2007, and sold it last year to Berkshire Partners LLC and Omers Private Equity Inc.
Canadian Plastics February 2012 www.canplastics.com
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news
Ontario siding maker Mitten bought by U.S. equity firm Mitten Inc., an Ontario extruder and vinyl siding distributor, has been acquired by U.S. private equity firm Graham Partners. The terms of the deal haven’t been disclosed. Brantford, Ont.-based Mitten, the sixth platform investment for Graham Partners in the past 10 months, makes the majority of its sales in Canada, a more stable market than the U.S., according to Graham Partners. “Mitten is a world-class manufacturer and a leading player in the Canadian siding market,” said Joe May, managing principal of Newtown Square, Penn.-based Graham Partners. “The company’s excellent reputation and established distribution network provide a strong platform upon which to expand.” Mitten was founded in 1959 as a manufacturer and distributor of vinyl siding, siding accessories, and other exterior building products. It serves the repair/ remodel and new housing segments in Canada, the U.S., and abroad.
SUPPLIER NEWS — Processing and auxiliary equipment supplier Wittmann Canada Inc., of Richmond Hill, Ont., has signed Torontobased Ontor Ltd. (Romark Division) as their new exclusive representative for the company’s robots, in-mold labeling, automation, and injection molding machines. The agreement is Canada-wide, with the exception of the province of Quebec. Ontor will also be the exclusive agent for the entire Wittmann line of products for Western Canada. — W. Amsler Equipment Inc., a Toronto-based manufacturer of all-electric, reheat stretch-blow molding machines, has appointed Chicago-based GMK Advisors Inc. to manage its sales and marketing in the U.S. and the Caribbean. — Hamilton Plastic Systems Ltd., of Mississauga, Ont., has been appointed by Milan, Italy-based Plastiblow as North American agents and distributors. Plastiblow manufactures extrusion blow molding machines for parts and containers from 250 cc to 30 litres.
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news
PEOPLE
Gerardo Chiaia
Mike Urquhart
Bill Davison
— Husky Injection Molding Systems, of Bolton, Ont., has named Gerardo Chiaia, currently leading the company’s Asia Pacific and EMEA sales organization, as vice president, global sales for Beverage Packaging. In addition, Mike Urquhart, currently Husky’s sales leader in the Americas, has been named vice president, global sales for Packaging Systems. — David Palmer has been named as the new chairman of the Canadian Association of Mold Makers. Palmer is also the sales manager at Windsor, Ont.based mold maker Build a Mold. — Bill Davison has been named the service director of Vecoplan LLC, an Archville, N.C.-based supplier of shredding, recycling, and waste processing technologies.
8
Raimar Jahn
Willem De Vos
Reinhold Ganzer
— Mississauga, Ont.-based plastic film and sheet machinery manufacturer Macro Engineering & Technology Inc. has appointed John Sproule as its sales manager for Quebec. —R aimar Jahn, currently head of BASF’s Coatings division, will become president of BASF’s Polyurethanes division, headquartered in Brussels, Belgium, effective March 1, 2012. — The Newtown, Conn.-based Society of Plastics Engineers has named Willem De Vos as its new CEO. He succeeds Susan Oderwald, who left the organization in December 2011. — Germany-based Injection molding machine supplier Sumitomo (SHI) Demag has named Reinhold Ganzer as worldwide customer service leader.
Canadian Plastics February 2012 www.canplastics.com
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executive’s corner
Understanding recent changes to the SR&ED program By Michael Crozier, Northbridge Consultants
S
till one of the largest subsidy programs offered by the federal government, the Scientific Research & Experimental Development (SR&ED) program provides over $3 billion annually to Canadian companies that are conducting innovative work. But the past few years have seen some changes to the program, including new releases of the T661 claim form, a new auditor review manual, and an evolution in the approach of the Canada Revenue Agency (CRA) as to how claims are reviewed. It may seem as though the guidelines for the SR&ED program have suddenly become stricter, and that there is much uncertainty as to the adequate levels of documentation required in the event of an audit. To make it less mysterious, here’s a quick breakdown of some of the changes the program has undergone. During 2011, the CRA definitely moved towards conducting more reviews of SR&ED claims, at increased levels of detail and documentation. But despite these modifications, the overall goal of ensuring compliancy hasn’t changed.
DETAILING DETAILS While the CRA strives to appoint a reviewer for your claim who has background knowledge of your industry, it doesn’t always work out that way. In order to facilitate the review process, talk to the reviewer about the unique technical challenges you faced while working on the SR&ED activities, and identify the SR&ED work for them. Also, clearly explain the merits of the projects as you see them, making your case as to why they fit SR&ED eligibility criteria. A tour of your facility can be beneficial in showing the reviewer where your SR&ED work takes place; plan ahead on highlighting sample prototypes (both small and large) where SR&ED activities were conducted, and also take the time to comment on any issues and/or limitations that you encountered. Documentation is one of the most important parts of any SR&ED review, of course, and, as noted, there is now a stronger emphasis for contemporaneous documentation than in the past. The reviewer now expects to see at least one example of every type of documentation that you checked off on your T661 form when you submitted your SR&ED claim. At the very minimum, the CRA reviewer will expect to see a labor breakdown detailing the hours each employee worked, the cost and amount of materials used, a differentiation between SR&ED activities and non-SR&ED activities, key experimental activities, subcontractor information (with statements of work), and supporting documentation for your SR&ED activities.
WHAT’S THE FREQUENCY? With this in mind, tips for creating useful contemporaneous documentation include tracking your activities on a weekly basis, at the very minimum; tracking all activities that are done, not just the ones that you know from the beginning are going to
be SR&ED-eligible activities; keeping notes that detail the purpose and results during all trials; keeping multiple versions of designs, which help show the design’s progression and provide an opportunity to explain why certain changes needed to be made; and, most important, dating all documents. The changes that have been made to the SR&ED program are geared at improving the program as a whole, with an increased focus on improving integrity. They may seem overwhelming, but don’t let them prevent you from taking advantage of a potentially golden opportunity to recoup some of your product development costs. CPL Michael Crozier is the group manager, technical services, with Cambridge, Ont.-based Northbridge Consultants. Northbridge specializes in assisting companies to maximize their SR&ED claims. For more information about Northbridge’s services, please go to www.northbridgeconsultants.com. CP Molding Ad:Layout 1 1/13/2012 2:26 PM Page 1
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For 63 years... a trusted source for MOLDING & EXTRUSION SUPPLIES, Mold Components & Supplies, Equipment & Engineering Support www.canplastics.com February 2012 Canadian Plastics
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injection molders’ survey
Light Around the Bend?
The manufacturing sector is back on its feet after the TKO of the Great Recession, and our latest Injection Molders’ Benchmark Survey gives us a look at an industry ready to do battle again. Markets served, buying intentions, utilization rates — it’s all here. Let’s see how some of Canada’s injection molders fared over the past 12 months, and what they think is coming their way in 2012.
By Mark Stephen, editor
F
or the past few years, the Canadian Plastics injection molders’ surveys charted an industry in free fall, reflecting everything from declining utilization rates to freezes on equipment purchases. Now, as Canada recovers from the worst economic cratering since the 1930s, it’s the manufacturing sector that leads the way. Are injection molders sharing in the recovery? Let’s let this year’s respondents speak for themselves.
SETTING THE STAGE
BY THE NUMBERS
Right off the bat, there seems to be some good news: Almost 60% of respondents this year said they worked in an I/M shop with 50 or more employees, compared to 25% reporting the same last year, and 20% in 2009. This seems to show a continuing recovery from the employee downsizing that many companies underwent during the recession. Sixty-two per cent of respondents to this year’s survey worked in shops that had either an ISO or QS9000 standard. Even with another 10% of respondents saying their shops are in the process of becoming certified, this still shows a
10
1.6%
Average percentage of 2011 budgeted expenses allocated to employee training Average amount of resin consumed at plant (lbs.)
19,135,250
Average hourly rate paid to machine operator, excluding benefits
$14.75 82 Average number of employees
slight falling off from the 81% that had one or the other standard last year. As always, the majority of respondents — 83.8% — work in Ontario, but we also heard from British Columbia (8.1%), Alberta (5.4%), and Quebec (2.7%).
MARKETS SERVED To the surprise of no one, our surveys over the past few years have recorded a steady decline in the number of shops that specialize in molding automotive parts. In 2009 and 2010, in fact, more respondents reported consumer goods as their main market served than automotive. Whether it signals the return of the auto industry or not, auto parts molding finally came out on top again this year — barely. Just over 25% of respondents this year primarily serve the auto market, with 22.7% doing mostly consumer goods molding. Additionally, 19.5% of respondents this year specialize in parts for the construction industry, 14.2% specialize in parts for electronic goods, 13.8% specialize in medical parts molding, and only 4.5% specialize in packaging. By the way, despite the ongoing hype that surrounds medical parts molding, the percentage of molders making primarily medical parts this time around remains virtually unchanged from last year. The Injection Molders’ Benchmark Survey was sent to 770 people at injection molding shops throughout Canada, with one survey going to one respondent per facility. We received 53 completed surveys. Because not everyone answered each question, the percentage values in the charts and tables might be given as a percentage of the respondents to that question, with the number of respondents given in parenthesis, for example (n=41). We thank the participants.
Canadian Plastics February 2012 www.canplastics.com
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injection molders’ survey
MAIN MARKET SERVED Automotive 25.3%
Consumer Goods 22.7%
Electronic 14.2%
The number of exclusive captive molders, meanwhile, continues to bounce around; Almost 10% of respondents this year said their shops were exclusive captive molders, up from just 2.9% of respondents last year, but down from 15% in 2009. The largest number (31.8%) this year identified themselves as custom molders doing some proprietary work on the side, followed by exclusively custom molding (29.5%), captive molding with some custom molding (20.5%), and exclusively proprietary molding (9.1%).
(n=53)
Construction 19.5%
Medical 13.8%
TO BUY OR NOT TO BUY Whatever they’re making, business for most our respondents is picking up. Thirty-two per cent said business volume improved in 2011 by more than 10% compared to 2010, 19.4% said it was up by between 1% and 5%, and 16.1% reported a bump of between 6% to 10%. That’s good news any way you slice it, since it reinforces similar improvements reported by respondents last year after a whopping 77% of respondents reported a “significant” business downturn in the dark days of 2009. Furthermore, 35.5% of respondents this year anticipate a business volume increase of more than 10% during 2012, and 64.5% expect business to either remain the same or improve by up to 10%. Doing the math thusly, we see that no one — not a single respondent — expects their business to fall off in the next 12 months. Utilization rates are trending upwards too. In 2009, an anemic 4% of respondents reported utilizing more than 80% of their machines; last year, a relatively healthy 15% hit the same mark, and this year it remains about the same, at 14.7%. Another 52.9% from this year’s group had a utilization rate of between 60% and 79%, which is also on par with the rates reported 12 months ago. So far, so good, but here’s the big question for the machinery suppliers: Will this improvement whet the processors’ appetites for new equipment? It depends. Almost 42% told us their shops
Packaging 4.5%
NUMBER OF I / M MACHINES (%) Number of machines at plant
2011 (n=38)
2010 (n=27)
2009 (n=26)
16+
38.7
48.1
30.8
11-15
29.0
29.6
19.2
6-10
19.4
14.8
23.1
1-5
12.9
7.5
26.9
AVERAGE MACHINE UTILIZATION RATE (%)
PURCHASING PLANS FOR 2012 (%) 80
(n=41)
50
yes
70
no
60
40
don't know
50
30
40 30
20
20
10
10
0 0
12
< 39%
21.1
9.1
40-49% 50-59%
9.1
45.5
9.1
60-69% 70-79% 80-89%
6.1 90-100%
0
41.9
19.4
70 38.7
Injection Molding Machines (n=38)
10
32.2 20
Auxiliary Equipment (n=37)
22.6 Linear Robots (n=38)
10.3 45.2
55.2
34.5
Articulated Robots (n=36)
Canadian Plastics February 2012 www.canplastics.com
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injection molders’ survey
WHAT THEY’RE DOING IT WITH According to our survey, commodity and engineering resins still make up the lion’s share of what’s being processed at Canadian plants, with 78% of respondents primarily using commodity and 80% using engineering resins. But specialty materials and biopolymers have their customers too: 36% of respondents mold at least some parts with the former, and 14% report using the latter. planned on buying injection molding machines in 2012, but 70.8% of these said they’d be either entirely or partly on the lookout for pre-owned units. Only 29.2% are focused on buying new I/M machines. Additionally, 38.7% of this year’s respondents said they were unsure about adding any kind of molding machines during the next 12 months, but didn’t rule it out. On the auxiliary equipment front, it gets better. Approximately 70% of respondents this year plan on buying auxiliary equipment during 2012; of these, 77.5% are at least considering
buying linear robots, with the rest more or less on the hunt for six-axis robots.
PEOPLE POWER? As interesting as they are, stats about machine utilization only tell part of the I/M industry’s story. Take wages, for instance. According to last year’s survey results, the average hourly wage paid to an I/M machine operator in 2010 was $15.62, excluding benefits — a big drop off from previous years that almost certainly reflected the impact of the Great Recession. So how did wages in 2011 compare? Not so good, at least from the workers’ perspective. Averaged out, the decline continues, with the hourly machine operator wage registered at — ouch! — $14.75. Does this reflect recessionary cut backs that keep cutting back, or simply the quirks of this year’s responses? You be the judge. CPL
VIEW SURVEY RESULTS ONLINE If you’re curious, the complete 2011 Injection Molders’ Benchmark Survey results are available at: www.canplastics.com/survey/archives/ IMSurvey2011.pdf
AUTOMATED CONTRACT INJECTION MOLDING
Lights out up to 200 tons
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www.niigon.com www.canplastics.com February 2012 Canadian Plastics
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All photos courtesy of Athena Automation Ltd.
company profile
Athena Automation:
The return of ROBERT SCHAD By Mark Stephen, editor
O
ne of the most recognized and storied names in plastics is back. In 1953, Robert Schad, a recent émigré from Germany, started a small machine shop in a Toronto garage. He already had designed a snowmobile which he intended to build under the “Huskymobile” name. You probably know the rest. The snowmobile wasn’t a success, and Schad built the company into Husky Injection Molding Systems, a leading global manufacturer of hot runners, PET perform molds, and injection molding machinery. Sitting atop a billion dollar a year enterprise, Schad — who had taken Husky public in 1998 — sold his shares in 2007 and seemed to vanish into the quiet life. Only he didn’t. He took over the reins at Earth Rangers, a non-profit organization he co-founded with partner Peter Kendall that works with children to protect endangered species, and also built a plant in Vaughan, Ont., to manufacture air boats — a hobby that can be traced back to his snowmobile
Athena 150 tonne hybrid.
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beginnings. Not finding much satisfaction in this latter activity, he put together some ideas about hybrid injection molding systems, and worked with MacTier, Ont.-based contract molder Niigon Technologies Ltd. on lights-out plant automation. Enthused, he sold the air boat business and converted the Vaughan plant for development of hybrid injection molding machines and lights-out technology, under the new name Athena Automation Ltd. It’s a project the 83-year-old Schad is finally ready to talk about.
GIVING THE PEOPLE WHAT THEY NEED Athena’s 40,000-square-foot headquarters has everything you’d expect from Schad, a pioneering environmentalist: solar panels on the roof that tie into the province’s feed-in tariff program, skylights, motion-activated LED lighting, geothermal heating and cooling, energy-efficient washrooms, and low-maintenance landscaping for the company’s 50 employees. But if the facility is well-planned, the development of Athena was anything but. “The idea for the company came about very organically,” Schad explained. “I was tired of the idea of a public company and the attached bureaucracy, but I wasn’t tired of the industry. I simply prefer a more entrepreneurial approach, and especially enjoy working with customers to develop the things they need.” So what exactly does the industry need? “I think processors have been oversold on all-electric machines,” Schad said. “It’s become a fad, and the machines aren’t always the best fits for
Canadian Plastics February 2012 www.canplastics.com
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All photos courtesy of Athena Automation Ltd.
company profile
the jobs they’re purchased for. I’ve always thought the hybrid was the better approach, and I wanted to build a very simple modular machine that can be customized for any given market.” Sounds simple enough, but turning the idea into reality took an enormous amount of work. “We expect it will take us four to five years to develop a product from scratch,” Schad said. Fortunately, he didn’t have to do it alone. “I surrounded myself with very experienced people, and hired a lot of very smart graduates from universities and colleges,” he added. The result is a range (100 to 400 tonnes) of hybrid injection molding machinery that, Schad said, satisfies his wish list. “The units offer excellent shot-to-shot accuracy, noise levels consistently around 70dB, dry cycle times of about two seconds, the smallest footprint in the industry, cleanroom readiness, and easy configuration for specific markets.” Not surprisingly given Schad’s green credentials, efficiency was a paramount requirement. “The energy consumption of our units is on par with all-electric machines,” he said. “And the oil tank is less than half the volume of conventional hybrid tanks, with an expected oil change interval of five years.” The first prototype of its 150 tonne machine has been validated over millions of cycles, Schad continued, and beat a comparable all-electric machine from another manufacturer in benchmark testing; the first units will be commercially available by June 2012. And Athena is also developing a small PET preform molding machine, expected to enter testing shortly. “Two of the primary markets we’re aiming at are medical parts manufacturing and packaging applications, but we’re interested in any market that benefits from our modular approach,” Schad said. “We might possibly compete with Husky to some extent, but we’re so small that the impact should be minimal.”
anticipate and didn’t want,” he said. Having the Great Recession as a development backdrop probably didn’t help, either. “It’s a crazy time to be putting together a new machinery company. Launching Athena in today’s climate can only work if we can supply leapfrog technology, coupled with faster and better machine customization than the competition offers,” Schad said. “It’s a balancing act; at the moment we’re printing red numbers, not selling anything, and have a very expensive development to maintain, but we expect to be in the black in about three years.” On the plus side, Schad plans to apply some lessons learned from his more than 50 years of experience. “I don’t intend to turn Athena into a publicly traded company, because in my experience it blunts the drive to innovate,” he said. “Our team is very committed to innovation. Other companies think they can teach this to their staff quickly, but it can’t be done — innovation has to be in a company’s culture.” So will the man who built one global manufacturing juggernaut be able to repeat the trick? “When I sold Husky I had two choices: go forward or get out. Well, I wasn’t ready to get out,” Schad said. “I’ve assembled the best team I’ve ever had, and I’m having the most fun I’ve ever had. I can’t wait to get to work in the morning.” In other words, don’t bet against it. CPL
SPOTLIGHTING LIGHTS-OUT The other side of the Athena coin is supplying lights-out automation technology for injection molders. The company has an ongoing pilot project with Niigon Technologies. Niigon’s seven molding machines, central materials handling system, backup power generators, UPS, 42kW photovoltaic panels, cooling towers and pumps are all tied into a single building automation system, with the result, Schad said, that Niigon now can run its complete operation with just two operators, who handle finished products and inspect part quality, but do not attend the machines. And all at minimal power consumption. “We can now start a project to transport finished goods within the plant using automated guided vehicles,” Schad added. “The lights-out business complements our injection molding machine business. No other company offers quite what we do.”
Machines being tested in Athena’s lab.
FROM RED TO BLACK In case you’re wondering, there are both pros and cons to starting a new company if you’re Robert Schad. “My name definitely opened some doors and helped me get the team I wanted, but the downside was a lot of attention that I didn’t
A 42 mm injection unit on a 150 tonne machine.
www.canplastics.com February 2012 Canadian Plastics
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shredders & granulators
TWEAK OUT: Improve your shredder & granulator performance By Mark Stephen, editor
Material might just be the biggest cost for plastics processors these days, so it’s important to reclaim as much of it as possible. Maximizing the performance of your shredders and granulators is a good place to start. Some simple fixes make it easy.
A
recurring character with the English novelist Charles Dickens is the rich businessman who comes to everyone’s rescue by giving away his money. Sounds nice, but businesses in the real world survive in large part by keeping their money. For injection molders, extruders and blow molders, material is one of the biggest costs of doing business — so why waste it? Shredders and granulators are crucial in making effective use of reclaimed resin, but are you making effective use of your shredders and granulators? Keeping the knives clean, oiled and sharp is a textbook no-brainer. Beyond that, a preventative maintenance program is great, but it still only gets you so far. Getting the best regrind for your buck means maximizing every aspect of your equipment. Here’s some efficiency-boosting tricks you might not know. 16
lator Inc. id Granu redit: Rap Photo C
SHREDDERS IN SYNCH Shredders are capable of processing a large variety of materials to a multitude of fraction sizes and throughput rates. Placed ahead of a granulator, the theory is simple. “Preshredding material before granulation will typically improve the throughput of the granulator, and can reduce wear of the granulator blades and screen by reducing the amount of recirculation,” said Mike Davison, applications manager with Shred-Tech Corp. But the reality is often plagued with problems, the most common of which is running the shredder too fast, thereby turning the slower-operating granulator into a bottleneck. “I’ve seen many systems where the shredder is completely independent of the granulator and runs ahead; the processer ends up throttling back on the shredder, which prevents them from maximizing production,” said Madison Burt, national sales manager with Weima America Inc. System integration is key here. “Tying the amperage of the granulator to the ram of the shredder keeps the two machines in synch; when the granulator amperage peaks, the shredder stops the ram until the granulator catches up,” Burt explained.
FEEDING TIME Another common problem with shredders is underfeeding them. “Many operators, fearful of jamming the shredder,
Canadian Plastics February 2012 www.canplastics.com
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r Inc. Granulato
shredders & granulators
don’t put in enough material; or they choose a screen size that’s too small and starve the shredder that way,” said Greg Parent, Canadian sales representative at Vecoplan LLC. “Actually, it’s better to put as much in as you can, because the ram pushing the material into the rotor, and the weight of all the material pushing down, helps maximize throughput.” An even better way to maximize throughput is to maximize the bulk density on the floor of the machine, which is where the cutting takes place. How? “Maximizing the bulk density on the floor depends in part on the material being processed,” Parent continued. “If you’re putting in long parts like pipes or bumpers, you’ll get better maximization if they’re cut small enough to lie flat, as opposed to having only the ends of the parts hitting the rotor.” Also, remember to feed material across the full width of the shredder. “With shredders, operators often feed from the side, which means they’re only hitting, and wearing down, one-half of the rotors,” said Madison Burt. “A conveyor can help here, or a feed chute that has a chevron on it to spread out the load. But however it’s done, we always recommend that processors feed from the back of the machine, which gives a much more controlled feed.”
GRANULATORS CUTS LIKE A KNIFE The granulator is the most common type of size reduction equipment used by plastics processors, capable of turning almost any plastic product — including the largest jugs and auto parts — into regrind flakes. It’s a sexy technology, but also — according to the experts — perhaps the single most misapplied piece of equipment in our industry. On the assumption that you’ve already matched your granulator throughput to the shredder (see above), let’s proceed to the second line of attack: the knives. You might not know it, but the material matters. “It’s possible to keep a poor quality knife sharp, but only through constant resharpening,” said Mike Cyr, vice president of Rotogran International Inc. “A better approach is to use knives that have been cryogenically treated. It’s an extension to the heat-treating process, and makes the knife tougher — although not harder — so that it keeps its edge longer. Also, the cryogenic treatment has to be done as part of the heat-treating process, not separately; the process isn’t nearly as effective once it’s been interrupted.”
SCREEN IT, CONVEY IT And don’t forget to readjust the bedknives after the first day of running new or resharpened knives. “The very first day will take the keen edge — as small as one-4,000th of an inch — off the knives, so go back and micro-readjust them,” Cyr said. “If you do, the knife edge will become much stronger, and the regrind quality will be better for
THEY SAID IT: Hardcore efficiency tips from the experts Looking for something beyond the obvious? Consider these suggestions. SHREDDERS
1. “With any belt-driven shredder, the belt will flex on a new machine after the first few hours of operation. We advise our customers to tighten the belts after the eight-hour point. Those that don’t usually call us after 20 or so hours of operation because the belts have gotten loose and torn up.” Madison Burt, Weima America Inc. 2. “Select a shredder to run at about 80 per cent of its fullload amperage; this will leave room for cutting chamber component wear and unanticipated load due to contaminated material.” Mike Davison, Shred-Tech Corp.
GRANULATORS
1. “When purchasing the granulator, consider adding a second flywheel on the other side to act as a ‘dummy’ fly-
wheel. It’s not driven, but supplies more energy to the rotor by inertia. Also, when you shock-load a granulator — just before lunch break, for example — this second flywheel supplies the necessary power. If you have a 40 hp granulator, a second flywheel can give you the equivalent of a 50 hp unit without adding to your power consumption.” Mike Cyr, Rotogran International Inc. 2. “If you’re using vacuum evacuation or even a manual evacuation, a high level detector in a bin — which tells you not to feed the granulator any more — is crucial. The problem is, these detectors aren’t standard on most units and are very rarely purchased; too many processors expect the operator to simply monitor the level visually.” Brian Davis, Maguire Canada.
www.canplastics.com February 2012 Canadian Plastics
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shredders & granulators
longer, especially with film.” Processors might also want to consider a granulator screen that has a tungsten carbide coating, Cyr continued. “Commonly, screen holes become slurred or elongated over time from abrasive resins like glass-filled polymers, causing material to slide along the slurs and remain in the chamber for a few extra revolutions, which reduces efficiency and creates more fines,” he said. “Protecting the screen with a tungsten carbide coating allows the screen to last longer.” And whether you’ve already matched shredder and granulator throughput or are using only a granulator, an easy way to help feed the machine is with our old friend the conveyor. Also, Cyr said, make sure the conveyor has a true-guide belt tracking system to eliminate belt wandering and costly maintenance. “Conveyor rollers should also have a minimum one-inch diameter shaft; anything less for beside-thepress conveyors might not hold up for the job,” he explained.
IN SYNCH (PART 2) As with tying shredders and granulators together, make sure the different parts of the granulator are working in synch: for example, the feed system and the evacuation system. “Vacuum loaders or compressed air loaders are commonly used, but the problem is that they both work on cycles,” said Brian Davis, general manager of Maguire Canada. “If a loader is designed
New KLENZ, the perfect purge for hot runners! Uses GRAS-rated food-safe ingredients. Get a free trial sample at www.slideproducts.com Get trial samples at www.SlideProducts.com 1-800-323-6433
©2012 Slide Products Inc.
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Conveyors with true-guide belt tracking systems eliminate belt wandering and costly maintenance.
Photo Credit: Rotogran International Inc.
to handle 100 lbs. of material an hour and the scrap is put in too quickly, the loader won’t be able keep up; and if it doesn’t, the material builds up through the screen, remains in the cutting chamber longer, and creates more dust and fines.” Also, consider a negative pressure hot air flow or a blower/cyclone system on your granulator to streamline material evacuation. “Since you’re pulling a negative across the granulator screen, as soon as the particle is physically small enough to pass through the screen hole, the negative pressure pulls it through,” said Bengt Rimark, global sales and marketing director with Rapid Granulator Inc. “Other benefits include cooling the cutting chamber, and not adding heat history to the material.” Finally, it doesn’t hurt to know your material, and how quickly — or slowly — it reduces to granulate. “PET material is tougher than anything else, and reduces throughput production by up to 40 per cent, regardless of the granulator,” said Mike Cyr. “So don’t waste time trying to boost PET throughput to match other types of plastic — it’s not going to happen.” So if you don’t want to give away your expensive resin — if, to return to Dickens, you’d rather be a little more like Ebenezer Scrooge — maximizing shredder and granulator efficiencies is a good place to start. A few small fixes and investments can transform your system from so-so into superstar. CPL RESOURCE LIST Maguire Canada/Novatec Inc. (Vaughan, Ont.); www.maguirecanada.com; 866-441-8409 Rapid Granulator Inc. (Cranberry Township, Pa.); www.rapidgranulator.com; 724-584-5220 Dier International Plastics Inc. (Markham, Ont.); 416-219-0509 D Cube (Montreal); 514-272-0500 Rotogran International Inc. (Toronto); www.rotogran.com; 905-738-0101 Shred-Tech Corp. (Cambridge, Ont.); www.shred-tech.com; 800-465-3214 Vecoplan LLC (High Point, N.C.); www.vecoplan.com; 336-861-6070 Greg Parent; 416-678-0154 Weima America Inc. (Fort Mill, S.C.); www.weimaamerica.com; 888-440-7170
Canadian Plastics February 2012 www.canplastics.com
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8.125x10.875
READY TO RESHAPE YOUR FUTURE REGISTER NOW AT NPE.ORG
From more large-scale, running machines than ever before to solutions that cover the entire plastics industry lifecycle, the advancements that deliver a competitive advantage can only be found this April at NPE2012, the world’s largest plastics conference, exposition and technology exchange. Join your peers in Orlando to Break the Mold — and reshape the paradigms that will lead to a more successful future. Showcasing innovations from more than 2,000 globally focused exhibitors, NPE features: 2+ million square feet of tomorrow’s solutions, today More large-scale, running machines in action Interaction with 75,000 industry peers from more than 120 countries Access to hundreds of timely educational programs and daily emerging technology demos
The International Plastics Showcase April 1– 5, 2012 | www.npe.org Orange County Convention Center Orlando, Florida USA
And much, much more! Don’t wait — connect with the entire lifecycle of plastics this year and uncover the solutions needed to move your company, products and career forward.
ATTEND NPE2012!
Co-located at NPE2012:
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lean manufacturing
Getting LEAN on the shop floor Toyota developed it; implement lean manufacturing principles in your production process and you can benefit from it. Here’s how.
M
anufacturing facilities aren’t exactly like socks — you don’t change them every day. They take years to commission, and their lifetime is measured in decades. By their nature, they’re one of the most important strategic elements of a business enterprise. If laid out properly, they can operate at low cost, provide fast delivery, and accommodate frequent new products. But the operative word is “if.” A plant that isn’t laid out properly — one with so many meandering paths from station to station that, if seen from above, it might remind you of a plate of spaghetti — deprives a manufacturer of an important competitive advantage. But you don’t have to reinvent the wheel to get your house in order. Whether you consult the professionals or do it yourself, tapping into some of the established principles of lean manufacturing — which is all about adding value and avoiding waste — is an effective way to unravel the mess; to make your plant work for you, not against you.
RACK IT UP A good place to start is with the “5S” workplace organizational methodology. The term refers to five steps — sort, set in order, shine, standardize, and sustain — that can ensure a good visual workplace. In a nutshell, the 5S method dictates
Five lean implementation tips 1. Flow. Physically and visually link all operations, eliminate delays in value-adding processes, and simplify other processes and consolidate operations. 2. Pull. Produce everything at the rate of “production” of the final product, rather than whenever a production step gets completed; known as “pull production control”. 3. Integrate sourcing and suppliers. Build “shared destiny” relationships with suppliers. A lean organization works with and through suppliers to apply lean practices throughout the value chain. 20
By Mark Stephen, editor
that systems should be set up so everything has a place that is available when needed, from the manufacturing floor to the equipment maintenance area. According to Lista International Corporation, a supplier of storage and workspace systems, it’s typically the first lean method that manufacturers implement. “The 5S method encourages workers to improve their working conditions and helps them to learn to reduce waste, unplanned downtime, and in-process inventory,” the company said. “A typical 5S implementation results in significant reductions in the square footage of space needed for existing operations, in the organization of tools and materials into labeled and color-coded storage locations, and in ‘kits’ that contain only what is needed to perform a task.” It’s not rocket science, in other words — more in keeping with the old adage of a place for everything and everything in its place (and clearly labeled). Nor is 5S overly expensive to implement. Since it involves cleaning up and organizing the workplace in its existing configuration, a storage system might be almost the only thing the manufacturer has to shell out for. A new set of modular drawer storage cabinets, for example, will suffice to allow the maximum use of cubic space for the highest density storage of parts, tools, and items of virtually any size and type. 4. Employ lean work methods. A concentration on standardized specifications (for engineering or product development departments, for example) to eliminate re-work and mixups between departments; good housekeeping to make looking for company information easier; better foolproofing of company processes; and more visual control so that when a problem does occur, its roots are quickly uncovered and the problem is permanently resolved. 5. Pursue perfection. Ensure that all employees have a continuous improvement attitude that brings empowerment and a feeling of ownership of the processes. Source: Kelton, Chertow & Boyd Inc.
Canadian Plastics February 2012 www.canplastics.com
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lean manufacturing
WHAT’S YOUR CELL?
one operator can move through several stations or two operators can work back to back in close communication. A straightthrough, or I-shaped, flow is often best for long, narrow buildings. An L-shaped flow configuration may work best for squareshaped buildings when several similar process lines are nested together. Finally, the so-called “comb and spine” arrangement works well for assembly operations when products must exit the process flow at various levels of assembly. A word of caution: The popular U-shaped and L-shaped cells might not make sense for injection molders, who make up the majority of the plastics processing community. “Typically, the flow is simple and less labor-intensive in an injection molding operation, which removes the value of the U-shaped and L-shaped flows,” said Santiago Archila, a member of the Manufacturing Advisory Services team from Husky Injection Molding Systems.
So far, so good. But being tidy only gets you so far; ratcheting up the lean another notch involves choosing a process flow and layout that best suits your company. Not so fast, though. The choice might already be made for you by physical site constraints such as building length and height, the location of receiving and shipping docks, and the location of equipment that can’t be moved. The most common layout for lean is a U-shaped cell, which allows the work cell to occupy a fairly small footprint. Also,
Haremar Plastic Manufacturing: DOING IT THEMSELVES
Photo Credit: Sandra Strangemore
MATERIAL SAVINGS
Toronto’s Haremar Plastic Manufacturing Ltd., a familyowned mono and co-extruded film supplier, is a big believer in the lean shop floor approach. In a do-ityourself project, the management team met with resin suppliers and machine manufacturers during the design stage of the company’s current 139,000-square-foot manufacturing plant. “The goal was to have a facility that helps us minimize the number of double-touches of product,” said vice president Mark Lichtblau. “We eventually settled on an L-shaped design, which funnels the flow of goods from the outside perimeter — which is resin storage and material handling — to the machinery, and then to the warehouse racks, and then out the door.” Speaking of racking, its design was an important enough component of the planning to determine the distance between support columns. “We took a hard look at our production volumes and the realistic density of the type of products we manufacture, and chose single, double-, and triple-deep racks to complement that density,” Lichtblau said. “We then selected distances of either 21 feet or 42 feet between columns, so that the racks could be accommodated without any dead spots.” And the lean quest didn’t end with the completion of the facility. “Since then, we’ve only purchased equipment and adopted product lines that are appropriate for the building shape,” Lichtblau said.
Cell shapes aside, there are plenty of other ways for injection molders to improve their efficiencies. Husky’s Manufacturing Advisory Services team has identified a series of wastes in injection molding, beginning with the resin itself. “Material is the largest contributor to operational cost, and by far the most commonly wasted commodity,” Archila said. “The first way to eliminate that waste is by lightweighting the product; today’s PET performs can produce bottles that contain between 25 to 50 per cent less material than 10 years ago.” Another waste, Archila continued, comes from overpacking the part. “The better a molder’s process control, the more the company can narrow the variation limit and stop putting more weight into a part than is required,” he said. Another tip for injection molders looking to get lean on the factory floor? Be flexible. “Don’t invest in equipment that can’t be adapted to new conditions, like mold changes or color changes, or reduction of lot sizes,” Archila said. “A flexible system lets you change your mold and make something else, no matter what time of day or night. Processors might think they’re saving money by not having a nighttime setup crew, but they’re actually losing by not being able to change molds at night.” On a related note, don’t produce parts that aren’t needed. Sounds like a no-brainer, right? It’s not. “Making product they don’t have orders for is a mistake made by many processors, often simply because there’s a night shift coming on and they don’t want to shut down their machines,” Archila said. “The end result is excess inventory that ties up capital and storage space.” In the end, whether you go for the textbook approach of a classic cell shape or simply follow the 5S methodology of new storage solutions, going lean on the floor can improve manufacturing processes, enable quicker and more efficient production, and help lower overall costs. What part of that don’t you like? CPL RESOURCE LIST Husky Manufacturing Advisory Services (Husky Injection Molding Systems) (Bolton, Ont.); www.husky.ca; 905-951-5000 Lista International Corporation (Holliston, Mass.); www.listaintl.com; 800-722-3020
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Canadian Plastics February 2012 www.canplastics.com
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P P
Class is in session…
THe BasiCs oF PlasTiCs
A full-day workshop on the essentials of plastics processing.
BaCK BY PoPUlaR DeManD! An ideal introduction if you’re new to the industry or would like a refresher. Instructor Paul Waller, President of PlasticsTouchpoint, has over 30 years plastics industry experience and is a member of SPE Ontario board of directors. He has taught plastics processing seminars to companies around the world. The workshop covers:
Plastics industry overview • Injection Molding • Extrusion • Blow Molding • Rotational Molding • Composites • Fabrication & Decorating • Biopolymers • Recycling & Sustainability Plastics industry expert Paul Waller, P.Eng., MBA Wednesday, June 20
8:30 a.m. to 4:00 p.m. Humber Institute of Technology & Advanced Learning 203 Humber College Blvd (Hwy 27 & Finch Ave) Toronto, M9W 5L7
Cost: $199, including lunch and a course manual Organized by:
CanadianPlastics Check www.canplastics.com for detailed information and registration, or call 416-510-6867
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purging compounds
THE
URGE PURGE: TO
Mixing it up with some of the latest commercial compounds
ADIOS TO “MILKY DRAG”
COMPOUND FOR CLEAR PC AND ACRYLIC APPLICATIONS
New from the Dyna-Purge Division of Shuman Plastics Inc., Dyna-Purge C is a clear, non-abrasive, non-chemical purging compound formulated to purge high clarity resins while avoiding the “milky drag” residue that results from transitioning from colored to clear parts. Ease of use, unique cleaning characteristics, and a broad temperature range (380°F to 590°F) make Dyna-Purge C wellsuited for injection molders, extruders, compounders and blow molders. It enables processors to purge through hot runners and other tight clearances, and improves overall changeover times with significant scrap reduction. In addition, all ingredients of the new formula are FDA-compliant. Dyna-Purge Division of Shuman Plastics Inc. (Buffalo, N.Y.); www.dynapurge.com; 866-607-8743
Moulds Plus International’s new Ultra Purge 5060, designed to purge clear PC and acrylic applications, is effective at color changes, material changes, carbon removal, and machine shutdowns and startups. A key feature that separates the Ultra Purge 5060 from other purging compounds is that it’s 100 per cent residue-free; as a result, processors will have less downtime and scrap because of fewer contaminated parts. Additionally, Ultra Purge 5060 is safe and effective at purging hot runners, giving processors the option of purging the screw, barrel, and hot runners at the same time. The 5060 material also contains an antioxidant, and a proprietary material designed to prevent carbon from forming on the screw during a shutdown. Moulds Plus International (Santa Ana, Calif.); www.ultrapurge.com; 714-708-2663
SATISFIES TOUGH PRODUCT HYGIENE REQUIREMENTS Designed to eliminate “black specks” common to color changes in injection molding and extrusion applications, Chem-Trend L.P.’s new Lusin Clean 1020 has also been NSF H2 registered, making it suitable for the manufacture of products that are subject to particularly stringent hygiene requirements. The ready-for-use granulate has been successfully tested by leading industry manufacturers. Compared to conventional cleaning processes and products, the use of Lusin Clean 1020 can lead to cost reductions of between 50 per cent and 70 per cent related to material consumption, downtime, and scrap rates. Additionally, Lusin Clean 1020 can be used in hot runners, and has been used successfully with products such as toothbrushes and thermoplastic hoses. Chem-Trend L.P. (Howell, Mich.); www.chemtrend.com; 517-545-7980 24
WELL-SUITED FOR HOT RUNNERS Available through authorized distributor Acetronic Industrial Controls, the new Klenz purging compound from Slide Products Inc. is a chemicallyreactive purge that’s safe to purge through the mold, and is particularly wellsuited for use through hot runner systems. With operating temperatures of between 330°F and 610°F, Klenz helps eliminate color streaking and black specs caused by stubborn residues baked onto the screw, and can significantly shorten purge times. It uses a polyolefin carrier resin, is odorless, and GRAS-rated safe for food packaging applications. Slide Products Inc. (Wheeling, Ill.); www.slideproducts.com; 800-323-6433 Acetronic Industrial Controls (Mississauga, Ont.); 905-564-7227
Canadian Plastics February 2012 www.canplastics.com
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purging compounds
PROVEN RESULTS ON MIXERS/MEASURING HEADS A recent trial by Sun Plastech Inc. shows that Asaclean purging compound can effectively clean mixers such as C.W. Brabender’s three-piece mixer/measuring head attached to their Intelli-Torque Plasti-Corder torque rheometer. According to Sun Plastech, Asaclean’s EX grade — or its PX grade in a high temperature setting — works best for this application. The trial involved using a small quantity of Asaclean added to the mixer. The blades were turned at high rpm’s for a few minutes in the forward direction, and then in the reverse direction. This process was repeated several times before the mixer was disassembled to finish the cleaning process. The trial showed the blades Rotogran Jan 12-AB-CPL 1/11/12 10:17and AM mixing Page 1bowl thoroughly cleaned, with only slight traces of Asaclean remaining, which were easily wiped off with a brush and cloth (see photo). Sun Plastech Inc. (Parsippany, NJ); www.asaclean.com; 800-787-4348
COMPOUND FOR CLEAR APPLICATIONS Newly commercialized after two years of field trials on all processes, the Magna Clear series of purging compounds from World Class Technologies LLC is designed for clear applications that are experiencing problems with cloudiness, streaking, black specs, and/or hazing. Unlike the many commercial compounds that utilize either an olefin or styrenic carrier and are either opaque or white in color, Magna Clear uses a custom water-clear PC as a carrier with a proprietary chemical agent. The first product in the series, PC 105, is well-suited for use on all PCs, copolyesters such as Tritan, polyetherimides such as Ultem, and on any colored PC/ABS, PC/ PBT, and PC/PET. World Class Technologies LLC (Midway, Ky.); www.magnapurge.com; 859-455-6968
FOR YOUR NEXT GRANULATOR GET THE BEST OF BOTH WORLDS: North American Built and Priced Right for Today’s Economy R
Rotogran granulators are internationally recognized for their superior design, efficiency, durability, and competitive pricing. We are the size reduction specialists for the processing and recycling industry.
Our rugged equipment is precision manufactured to meet individual customer needs. • Complete range from press side to central • The fastest change-over in the industry • Chamber construction second to none • Custom applications our specialty
AS ALWAYS, YOU PRODUCE IT…WE’LL REDUCE IT. INTERNATIONAL INC.
3 Bradwick Drive, Concord (Toronto) Ontario Canada L4K 2T4
For your area rep. or quotation, please call: Tel: (905) 738-0101. Fax: (905) 738-5750 www.rotogran.com
29 years of manufacturing in Canada
www.canplastics.com February 2012 Canadian Plastics
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New 2012
technology showcase
AUXILIARY EQUIPMENT Dryer/conveyors now come with standard controls
Novatec Inc. has now made touchscreen control standard on its mobile NovaWheel Dry/Convey models (75, 100 and 150 lbs. per hour) at no additional cost. The control provides a seven-day timer for auto on/off, process and regeneration filter maintenance alerts, a dew point sensor, loader control, a real-time clock with battery backup, and an Ethernet communications option. The graphical interface lets operators control drying parameters with simple step-by-step commands that virtually eliminate wrong choices. All setups and adjustments are notably faster. Even the most complex setup becomes a brief
plastics data file Wittmann Innovations
Innovations — Wittmann’s quarterly newsletter — offers plastics processors detailed insight into ways to improve their businesses with news and application stories covering Robots and Automation, IML, Injection Molding Machinery, Material Conveying, Drying and Blending, Granulation and Temperature Control. It is available in print and on-line. Wittmann Canada Inc., 35 Leek Crescent Richmond Hill, ON L4B 4C2 Tel: 1-888-466-8266 www.wittmann-canada.com Get free information from the companies that interest you most. Contact the company directly using the telephone number, e-mail address or web site listed above.
sequence of touches. The NovaWheel Mobile Dry/Convey package also includes a NovaWheel Dryer, a strong vacuum blower that pulls material through a vacuum receiver into the fully-insulated drying hopper, a vacuum purge valve with a slide gate discharge, and a machine-mount vacuum receiver. Dew point air of -40°F is guaranteed, and the system employs dry-air conveying to avoid moisture pick-up. Novatec Inc./Maguire Canada (Vaughan, Ont.); www.maguirecanada.com; 866-441-8409 B arway Plastic Equipment Inc. (Vaudreuil-Dorian, Que.); 450-455-1396
INJECTION MOLDING
Software incorporates weld lines into product design
A new functionality of Sigma Plastic Services’ SigmaSoft simulation software predicts and maps weld lines for consideration in the structural design of injection molded parts, thereby reducing structural stresses and optical defects that can compromise surface quality. With the interface SigmaLink, it’s now possible to transfer information about predicted weld lines during the filling stage to the SigmaSoft finite element analysis software, which considers the drop in mechanical properties in these regions when performing structural design. A particular advantage of SigmaSoft is the fully 3D prediction of the weld lines, which reproduces the weld regions not only on the surface, but also through the part’s thickness, as it occurs in reality. The location of the weld lines is described precisely, and an indication is given regarding how critical they are; in this way, the drop in the mechanical properties produced by the apparition
advertising index Advertiser Arburg CPA Canada Canadian Plastics Basics of Plastics Workshop Canadian Plastics Resin Outlook Conference CanPlastics TV videos Conair IMS Niigon Technologies Ltd. PCS Company Plastics Process Equipment, Inc. PolyOne Distribution Canada Ltd. Rotogran International Inc. Schmoltz + Bickenbach SPE Ontario Slide Products Society of the Plastics Industry – NPE Show Staubli Corp UltraPurge Wittmann Canada Inc.
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860-667-6500 888-777-4390 416-510-5116 416-510-5116 416-510-5116 724-584-5500 800-537-5375 705-375-0770 800-521-0546 800-362-0706 888-394-2662 905-738-0101 800-268-4977 800-323-6433 800-257-8235 877-884-3129 888-466-8266
usa@arburg.com Andrew.Spicer@ChannelPA.com jnancekivell@canplastics.com jnancekivell@canplastics.com jnancekivell@canplastics.com sales@imscompany.com sales@niigon.com sales@pcs-company.com sales@ppe.com info@rotogran.com ted.callighen@schmoltz-bickenbach.ca info@slideproducts.com exhibit@npe.org; registration: NPE@experient-inc.com connectors.usa@staubli.com ultrapurge@ultrapurge.com info@wittmann-canada.com
www.arburg.us www.channelpa.com www.canplastics.com www.canplastics.com/conference/ www.canplastics.com www.conairgroup.com www.imscompany.com www.niigon.com www.pcs-company.com www.ppe.com www.polyone.com www.rotogran.com www.schmoltz-bickenbach.ca http://speontario.com/ www.slideproducts.com www.npe.org
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Canadian Plastics February 2012 www.canplastics.com
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New 2012 Feb RESIN CONFAd
1/16/12
4:15 PM
Page 1
Resin supply, demand and pricing forecasts
ON TARGET! Since resin accounts for up to two-thirds of your manufacturing cost,
you can’t afford to miss the mark. Get the information you need by attending the
17th Annual Canadian Plastics Resin Outlook Conference October 2-3, 2012 Doubletree Airport Hotel, Toronto, Ontario Hear forecasts from experts on supply, demand and pricing for the major commodity and engineering resins: polyethylene, polypropylene, PVC, styrenics, PET, nylon, polycarbonate, plus biopolymers, and recycled resin. BONUS: Plastics processors registered for the conference may attend, at no extra charge, a workshop on the afternoon of Oct. 2 on “How to Negotiate the Best Deal for Your Resin Purchases”.
Investment per person: $399 until Aug. 31; $549 after Aug. 31 Group registration: 50% discount for second and subsequent attendees from the same company.
Organized by Canadian Plastics magazine. Endorsed by the Canadian Plastics Industry Association A limited number of sponsorships and tabletop displays are still available.
For more information, contact: Judith Nancekivell, Tel: 416-510-5116, Email: jnancekivell@canplastics.com www.canplastics.com/Conference/ SPONSORS TO DATE:
“Earning your trust one stripe at a Cantec Polymers time.” INC.
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technology showcase
EXPAND YOUR KNOWLEDGE AND YOUR NETWORK Feb. 16 – Arkema Dinner Meeting Functional Polyolefins Courtyard Marriott, 5050 Creekbank Rd, Mississauga, ON Mar 22 – University Night Ryerson University, Toronto
Please register for events on-line at
http://www.speontario.com/ upcoming-events
CLICK ON...
CAN
PLASTICS TV
for interviews with industry experts, coverage of plastics industry events, and more!
New episodes every two weeks. These 5-minute information packed videos are produced by the editors of Canadian Plastics. To view them, go to our web site,
www.canplastics.com and look in the upper right corner of our home page. SponSored by:
of weld lines can also be considered in the mechanical part design. Sigma Plastic Services Inc. (Schaumburg, Ill.); www.3dsigma.com; 847 558 5600
EXTRUSION
Microextruders with quick-change modules
American Kuhne’s gearless modular microextruders enable barrel and screw modules to be changed quickly and easily. The machines are offered in 13 mm (1/2-inch) and 16 mm (5/8-inch) sizes, and are well-suited for very low output appli cations where conventional size medical extruders such as a 25 mm (one-inch) machine can’t be used because the long residence time in the barrel will degrade the polymer. These machines are available in 20:1 L/D and 24:1 L/D. Additionally, all microextruders are now available with the company’s new AKcess Level II control system that includes a 19-inch widescreen that can be mounted anywhere on the extrusion line. The new AKcess control incorporates 3D graphics, and includes mobile access via iPhone, iPad, Android, and other tablet devices. American Kuhne Inc. (Ashaway, R.I.); www.americankuhne.com; 401-326-6200 Romark Technologies - Div. of Ontor Ltd. (Toronto); 416-781-5286
ROBOTS & AUTOMATION Upgraded robot mounts on I/M machines
Based on the concept of its W811 robots, Wittmann’s new W818 series standard robot has an enhanced payload of six kilograms, making it well-suited for mounting on molding machines up to 300 tons of clamping force. 28
The applications for the W818 models range from simple pick-andplace sequences to the implementation of complicated work cells with extensive downstream equipment. In some cases, the W818 can also be used as a secondary robot for box filling. The high adaptive flexibility for the W818 is achieved through a variety of rotational axes and options: additional in-/output cards, additional vacuum and gripper circuits, as well as servo-driven auxiliary axes. The model W818 robot is equipped as standard with the flexible R8.2 touchscreen control. Other units in the series include the W818S model (with sub-arm for the picking of sprues), the W818T (with vertical telescopic axis), and the W818TS (with vertical telescopic axis and telescopic sub-arm). Wittmann Canada Inc. (Richmond Hill, Ont.); www.wittmann-canada.com; 866-466-8266 Romark Technologies – Div. of Ontor Ltd. (Toronto); 416-781-5286 (all provinces except Quebec)
New line of tool changes
>SAS< Automation LLC recently intro duced a complete line of tool changers that allow end-of-arm tooling (EOAT) and gripper systems to be quickly and accurately mounted to the robot arm. The tool changers have two separate sides. The robot side is permanently attached to the robot arm, and the tool side is permanently attached to each individual EOAT. The EOAT mounts to the robot by fitting the two sides together and then locking them into position. The use of >SAS< tool changers assures superior positioning each time an EOAT is mounted, reducing the risk of damage to both the EOAT and the mold. >SAS< tool changers automatically
Canadian Plastics February 2012 www.canplastics.com
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technology showcase connect multiple ports including air, vacuum, and electric, thereby reducing setup time. Reliable port connections provide additional safety, ensuring that all connections are aligned correctly. >SAS< Automation LLC (Xenia, Ohio); www.sasgripper.com; 888-727-3628 Verick International (Brampton, Ont.); 888-783-7425
MOLD TECHNOLOGY
250 series, with 0.250-inch flow channel diameter; the 375 series, with 0.375-inch flow channel diameter; and the 625 series, with 0.625-inch flow channel diameter. DME of Canada Ltd. (Mississauga, Ont.); www.dme.net; 800-387-6600
MATERIALS
TPU for upscale auto interiors comes to North America
Hot sprue bushings give uniform heat profile
Designed for prototyping and short-run production, the new D-Max line of single hot sprue bushings from DME incorporates the company’s standard slip-on, cast-in heaters on the nozzle body, providing a more uniform heat profile than traditional square coil heaters. The D-Max bushings have two zones of heat: a slipon, cast-in heater on the nozzle body, and a square coil heater on the head area of the nozzle. The square coil heater uses a separate thermocouple, and gives the user an accurate temperature reading to eliminate the heat soak time normally needed. Moldmakers can either control the heaters separately or run them together as one zone. The design of the heating mechanisms enables the bushing to handle a wide range of materials, including a broader range of crystalline polymers. D-Max bushings are available in three sizes, which are convertible for metric applications if necessary: the
Now available in North America, Elastollan AC85A is an aliphatic thermoplastic TPU with soft-touch finishes from BASF Corporation — distributed by Alliance Polymers & Services LLC — designed to open up a range of new possibilities for car and other designers. Used in door handles found on the 3 and 5 Series of BMWs in Europe, Elastollan AC85A is overmolded on an ABS-PC. The Elastollan material is sold with non-fade properties and UV finish, and requires no additional surface lacquer. Other specific applications include cup holders in the Audi A6; gear knob, hand brake, and control switches in the Saab 9-3; and dashboard surfaces, centre consoles, and steering wheels on a variety of other makes and models. BASF Canada (Mississauga, Ont.); www.basf.ca; 866-485-2273 Alliance Polymers & Services LLC (Romulus, Mich.); 734-710-6700
classified ads MACHINERY & EQUIPMENT
MATERIALS
INJECTION MOLDER
To place your classified ad here, contact: Brayden Ford, Sales Manager at 416-510-5124 or bford@canplastics.com
EndusEr Top pricEs paid for
Post Industrial LDPE/LLDPE Scrap Film Mixed colour/Clear. Call 647-444-5083 416-994-6800
www.canplastics.com February 2012 Canadian Plastics
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Goodbye...and thank you (Or, my last rant) By Jim Anderton, technical editor
W
ell, I guess it had to happen sometime. You are reading my last column in Canadian Plastics magazine. It’s been a joy to meet so many of you, visit your operations, and get that whiff of hot resin that was so much a part of working in the industry. Many of you know that the parent of Canadian Plastics has purchased Rogers Communications portfolio of business magazines, and I’m now moving into the editor’s seat of Canadian Metalworking magazine. For the moldmaking community, I’ll still be in your mailbox, but I’ll miss the great people that make up the Canadian plastics industry. It’s been an honor and a pleasure to write to you, and I thank you for reading my columns over the years. But before I go, I can’t resist the opportunity to get one last thing off my chest: As an unashamed supporter of manufacturing in Canada, I believe we’re turning the corner on outsourcing and are poised to grow again, sustainably. We’re doing it with increased automation and quality, leading to much
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higher productivity and — combined with proximity to our major markets — the restoration of the traditional advantage we enjoyed for decades following World War II. We’ve learned how to beat back the low wage competitors, but there’s a bigger threat, and it’s within our borders: The consistent failure of politicians at the provincial and federal levels to understand the importance of our industry, and their even bigger crime of standing in the way of true innovation. They’ll throw money at a major OEM or Tier One to land a plant, but what about small and medium-sized manufacturers? The insane complexity of taxation and accounting practices, combined with escalating environmental and labor regulations, is slowly strangling the innovative core of our nation. And that’s not considering the legendary reluctance of our banking industry to finance enterprise that doesn’t come out of a multinational or foreign corporation. Pioneers like Robert Schad built companies like Husky out of a garage; try doing that today! The number one complaint I’ve been hearing from the owners of small plants is about their inability to actually manage the businesses. They’re trapped in the front office, buried in regulatory paperwork, instead of out back innovating or on the road drumming up new business. The additional paper burden of ISO and quality certifications alone would justify a commitment from government to simplify their processes, but the dogged determination of government to support their welfarefor-lawyers-and-accountants scheme means that we have to effectively subsidize the segment of Canadian society that adds no value to the economy, while weakening our own value-adding businesses. In a country where waitresses have to use tax preparers because the income tax paperwork is too complicated, how can a bright young entrepreneur survive the paper nightmare to get a new business off the ground? They can’t and they won’t, which is one reason why young people are reluctant to go into the manufacturing sector. This can be fixed, but to do it we’ll have to stick together. And now there’s a new difficulty: Automation means that, dollar-fordollar, we employ fewer people than a generation ago....and votes drive policy. This means we have to substitute dollars for employment and use our cash and association power to lobby government like the big boys, the way the energy sector does. Write petitions, send e-mails, and use Twitter, Facebook, and your own websites to push this message home: “Get out of our way and let us build a newer, more robust manufacturing nation.” I cut my teeth (and frequently my knuckles) wrestling four-cavity molds in and out of an oil-soaked, 70-ton Van Dorn press. With every shot, I knew I was doing something that was good for the country. It’s been 50 years since the Avro Arrow debacle and we’ve learned much, but government hasn’t. We can change this...and we have to. CPL Thanks again for reading.
Canadian Plastics February 2012 www.canplastics.com
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CPLFeb12 p31 PPE AD.indd 31
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We drive EDRIVE: the expansion of our electric machine range enables a wide range of applications. Invest in modern electric injection molding machines. In great technology at a low price. In order to reliably make money with top products. The new EDRIVE series: energy efficient, precise, high-performance. A machine for everyone!
ARBURG, Inc. 125 Rockwell Road Newington, CT 06111 Tel.: +1 (860) 667 6500 Fax: +1 (860) 667 6522 e-mail: usa@arburg.com
www.arburg.us
2 -5, 201 April 1 all West H 729 3 Booth # L o, F Orland
Québec: D Cube · Montréal, QC · Phone: 514-831-6623 | Ontario: Dier International Plastics, Inc. · Unionville, ON Phone: 905-474-9874 | Alberta & British Columbia: Turner Group, Inc. · Seattle, WA · Phone: 206-769-3707
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