CanadianPlastics www.canplastics.com
OCTOBER 2012
GOT redundant
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CONVEYING PIPES ...and other problems to solve for building a better raw materials handling system
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The latest in HOT RUNNER VALVE GATES
Taking a fresh look at LIQUID COLORANTS
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The results are in for our annual MOLDMAKING BENCHMARK SURVEY p14
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contents
Canadian Plastics OCTOBER 2012 VOLUME 70 NUMBER 5
LOOKING BACK...
The February 1962 issue of Canadian Plastics reported on the manufacture of Canada's first self-supporting reinforced epoxy gasoline road tanker. Developed by vehicle supplier F.R.P. Products Ltd., of Brantford, Ont., the tanker was 35 feet long, 10.5 feet high, and under-tipped the scales at 10,000 pounds — some 2,000 pounds lighter than equivalent aluminum semitrailers. Which was partly the point. Made of a combination of fibreglass and fibreglass fabric, polyurethane foam, and PVC tubing, the tanker also provided an estimated 15 times the flexibility of steel and complete corrosion resistance. As our issue went to press, the tanker was undergoing road tests by customer-in-waiting the British American Oil Company.
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Number of the month:
$25.41*
* Average hourly wage paid to a mold shop worker in Canada. (See pg. 14)
in every issue 4 Editor’s View: Frack yeah!
10 cover story 10 RAW MATERIALS HANDLING EQUIPMENT: Tips for a better installation or upgrade
5 Ideas & Innovations: Steel-strength plastics might just replace metals 6 News: • Eyeing expansion, Quebec’s Polykar bulks up with new bag converting system • Magna reports record sales, buys rest of E-Car partnership • Supplier News & People 8 Executive’s Corner: Stay focused! (Five strategies for how) 25 Technology Showcase 28 Plastics Data File 28 Advertising Index 29 Classified Ads 30 Technical Tips: It ain’t necessarily so — Misbeliefs and elastic truths in extrusion
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If you’re not conveying your resin as efficiently as possible, you’re just not ready for prime time. But a successful materials handling system doesn’t have to be out of reach. Whether you’re starting from scratch or revamping your existing equipment, a few hints from the experts can help you do it right.
features 14 MOLDMAKING BENCHMARK SURVEY: Four-warned is forearmed
The results of our fourth annual survey are in. Last year, our respondents reported a return to semi-prosperity after the Great Recession. How does the situation stack up 12 months later? Find out inside.
18 HOT RUNNERS: Gate crashers hat’s not to love about hot runner valve gates? They give the molder W the ability to shut off the gate more precisely than with an open or thermal gate, produce quality gate marks, and deliver precision performance and accurate melt flow control in the fill, pack, and cooling phases of your plastic part. So we know you’ll want to read about some of the latest offerings.
22 COLORANTS: Making a mark with liquid color kay, so they’re not exactly new, but liquid colorants are growing O more popular with processors looking for a competitive advantage. Here’s why: they can offer more economical letdown ratios and work especially well with heat-sensitive materials. But are they right for you?
Visit us at www.canplastics.com www.canplastics.com October 2012 Canadian Plastics
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editor’s view
Frack yeah! G
ot fracking fever yet? If not, you should. Hydraulic fracturing — known by the unfortunate-sounding sobriquet “fracking” — is the practice of sending pressurized water down wellbores to fracture deep bedrock formations and release natural gas. The “fracking revolution” has liberated enormous quantities of crude oil, and especially natural gas, from previously uneconomic deposits trapped deep underground in isolated pockets within sedimentary rock known as shale. The fracking boom has increased natural gas supplies; lowered gas prices; and transformed North American producers of resins such as polyethylene, which are favored by lighter natural gas-based feedstocks, into some of the most cost-competitive producers in the world. It’s the most significant development in the North American energy sector in generations — but, as with anything that concerns plastics lately, there’s trouble brewing on the PR front. There has been a public backlash to shale gas development both in Canada and the U.S., sparking moratoriums, debates, and regulatory investigations from New Brunswick to Wyoming due to concerns about groundwater contamination, air pollution, and methane leaks. The industry has argued that fracking is safe and sustainable and provides major economic benefits, an argument environmental groups reject. And the latter are taking action. In Alberta, protesters are suing EnCana, one of the continent’s largest unconventional gas producers, for negligence causing water contamination and the Alberta Energy Resources Conservation Board, the province’s energy regulator, for breaching the Charter of Rights. In addition, the $33 million lawsuit alleges that Alberta Environment, one of two agencies responsible for groundwater protection, failed to uphold its regulatory responsibilities. This and other lawsuits have effectively put fracking on trial — which is
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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 a shame because the potential upsides of the process are pretty clear. First, it’s good for consumers’ pocketbooks by helping to reduce energy costs: In Canada and the U.S., fracking has helped stimulate major infrastructure investments in natural gas pipelines. Second, fracking spurs economic growth by bringing industrial jobs back to North America — jobs that left several years ago when domestic natural gas supplies were considered scarce and expensive. And third, fracking reduces our dependence on coal, which is one of the best things we can do to improve air quality; modern gas-fired power plants produce effectively no sulfur dioxide or fine particulates, no mercury or toxic ash pollution, use less water, and generate about half the carbon dioxide pollution of coal. (There’s also a geopolitical takeaway, if you’re interested: As North America becomes self-sufficient in oil, we’ll no longer need to kowtow to despotic rulers and feudal monarchs whose oil supply lines are crucial to other aspects of foreign policy.) At present, the loud voices at the anti-fracking extreme are dominating the debate — those who want no fracking, no way, no how. But the benefits are already becoming apparent. Thanks to fracking, for example, the national production of natural gas in the U.S. is up 25 per cent from 2004-06 levels, according to the U.S. Energy Information Administration. That’s a major reason domestic energy prices have stabilized — and why the country’s annual carbon dioxide emissions are at their lowest level in two decades. With so much at stake, several U.S. states are already recognizing the need to disarm the environmental lobbies by establishing appropriate frameworks for regulatory safeguards. In particular, Texas — a fracking pioneer — is poised to step forward in developing promising state guidelines. More power to them; safe and sensible fracking in North America is a win-win situation.
EDITOR Mark Stephen 416-510-5110 Fax: 416-510-5134 E-mail: mstephen@canplastics.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 October 2012 www.canplastics.com
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ideas & innovations
Steel-strength plastics might just replace metals D
on’t tell Superman, but a Tel Aviv University (TAU) researcher is developing an eco-friendly, superstrength polypropylene that might give the Man of Steel a run for his money in the toughness department. Dr. Moshe Kol, who holds the Bruno Landesberg Chair in Green Chemistry at TAU’s School of Chemistry, is leading a team of Israeli scientists to develop the polypropylene — one of the world’s most common plastics — to replace steel and other materials used in pipelines and machinery. The development could have an impact on many industries, such as car manufacturing, in which plastic parts would replace metallic ones. The potential upsides are compelling. It takes less energy to produce durable plastics than steel; in cars, plastic parts would make the vehicles lighter than those with steel parts, thereby consuming less fuel; and because the material is cheap, plastic parts would be more affordable for the manufacturer. Beyond auto parts, Kol envisions a number of uses for this and related plastics, including water pipes, which he says could ultimately conserve water use. Drinking water for the home has been traditionally carried by steel and cement pipes, which are susceptible to leakage, leading to waste and therefore higher water bills. But they’re also very heavy, so replacing them can be a major, expensive operation. “Plastic pipes require far fewer raw materials, weighing ten times less than steel and a hundred times less than cement. Reduced leaking means more efficient water use and better water quality,” Kol said. “The replacement of steel water pipes by those made of plastic is becoming more common, and the production of plastics with even greater strength and durability will make this transition even more environmentally friendly.” Although a promising field of research, biodegradable plastics have not yet been able to mimic the durability and resilience of common, non-biodegradable plastics like polypropylene. The key to the TAU team’s development is a chemical catalyst. A quick science lesson: Plastics consist of very long polymer chains, made of simple building blocks assembled in a repeating pattern. Polymerization catalysts are responsible
for connecting these building blocks to create a polymer chain; the better the catalyst, the more orderly and well-defined the chain, leading to a plastic with a higher melting point and greater strength and durability. “Everyone is using the same building blocks, so the key is to use different machinery,” Kol said. With their catalyst, Kol and his team claim to have produced the most “regular” polypropylene ever made, reaching the highest melting point to date. Another benefit? Unlike our friend with the red cape, the material won’t turn into a soggy Kleenex at the first whiff of kryptonite. CPL
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news
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aint-Laurent, Que.-based Polykar Industries Inc. is a bit of a rare bird: the garbage bag, food packaging, and polyethylene film maker sells excluPolykar also has a CMD 5213ED sively in Canada through a network of extended-dwell rotary bag machine distributors. and a CMD 1113 coreless bag winder, But Canada is a big place, with Polykar’s David Andrews (left) purchased in April 2011. The system plenty of room for growth — and to and Amir Karim examine gusseted bags. runs up to 600 feet per minute and that end the family-owned company is used to produce Polykar’s highrecently installed a new 1400DBS clamp-stacking, bottom seal bag converting system from density star seal trash bags. Polykar — which was founded in 1987 — has annual Appleton, Wis.-based equipment manufacturer CMD Corporation. The system, which accepts web widths up to 54 capacity of 25 million pounds along with recycling services, inches, features integrated slit-sealing and gusseting and can with average monthly production of 25 million bags and run up to eight lanes at 140 cycles, producing 1,000 bags per 120,000 cases. The company’s 240,000-square-foot facility minute to manufacture bulk packaging products like bread includes a new production centre, which is set to receive bags, freezer bags, and trash bags. It’s designed to make mul- LEED certification (Leadership in Energy and Environtiple product designs and sizes and can handle frequent job mental Design). The company claims to be the first plastic bag manufacturer in Canada to have both ISO 9001 and ISO changes efficiently. “We had several choices for a bottom seal bag making 14001 certifications, and manufactures products from polysystem,” said Amir Karim, Polykar’s vice president of busi- ethylene and biodegradable, oxodegradable, and recycled ness development. “We chose the CMD unit because it allows resins. According to Karim, the 1400DBS system is part of a greater versatility in the type of bags we make — especially Polykar’s current push to penetrate the Canadian market varying thicknesses and sizes — at a faster speed, which helps west of Quebec. “The machine gives us the added production lower the unit cost.” Installation of the system and training of capacity and versatility needed to offer products further into the company’s 60 employees took one week, he added. Ontario and western Canada,” he said. CPL
Humber College grad wins scholarship from Horizon Plastics 6
Cobourg, Ont.-based tural foam and structural custom molder Horizon web molding processes. Plastics International Held in Toronto on May Inc. handed out its inau12-13, the Rocket Design gural scholarship to a stuShow was sponsored by dent entered in the recent the Association of CharRocket Design Show and tered Industrial DesignCompetition. ers of Ontario and feaThe company awarded tured the thesis projects of Mark Walsh, Horizon’s key account the scholarship to Amanda graduates from Ontario’s manager, presents the scholarship to Ruscica, a Humber College three schools of industrial Amanda Ruscica. graduate, for her design of design: Carleton Univera bicycle trailer called the “Karyolla”, which sity, Humber College, and the Ontario Colcan use the advantages of Horizon’s struclege of Art & Design. CPL
Photo Credits: CMD Corporation
Polykar’s new CMD 1400DBS bottom seal system converts up to eight lanes of film, producing 1,000 bags per minute.
Photo Credit: Horizon Plastics International Inc.
GO WEST: Eyeing expansion, Quebec’s Polykar bulks up with new bag converting system
Canadian Plastics October 2012 www.canplastics.com
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news
Magna reports record sales, buys rest of E-Car partnership
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agna International Inc., Canada’s largest auto parts manufacturer, delivered a record-breaking second quarter result driven by a strong performance in the North American market, and has also reached a deal with a company affiliated with the Stronach Group to buy the remaining 27 per cent stake in Magna E-Car Systems for $74.7 million. “We are pleased to regain control of Magna E-Car’s assets and business, which will be absorbed within our existing operating units,” Magna chief executive Don Walker said in a statement. “We expect hybrid and elec-
PEOPLE — DME Company, a Madison Heights, Mich.-based provider of mold technologies, has appointed Michael Lynch as its new Canadian sales manager. — St. Louis, Mo.-based materials supplier Spartech Corporation has named Adam Kempinski as the national sales manager, Canada, for its color and specialty compounds business segment.
Michael Lynch
tric vehicle production to continue to grow globally in the future, and we believe that Magna stands to benefit from this trend by supplying HEV components, systems, and engineering services to our customers.” Magna founder Frank Stronach, whose family long controlled the company, gave up that control in 2010 in exchange for about $1 billion in cash and shares, as well as control over joint venture Magna E-Car Systems. Last August, Aurora, Ont.-based Magna announced it was spending $430 million to research and develop electric vehicle technology in Ontario. The E-Car buyout comes as Magna reported a record second quarter result that exceeded expectations, driven primarily by improved North American vehicle production. The company reported a Q2 2012 net income of $349 million, up from $282 million a year earlier. The performance was driven by a record $7.7 billion in sales during the quarter, up five per cent from a year ago; vehicle production in North America was up 28 per cent, Magna said, more than offsetting a CP Equipment:Layout 1 8/29/2012 10:12 AM Page 1 seven per cent decline in Europe. CPL ®
— Wilmington, Del.-based Ashland Specialty Ingredients, a commercial unit of chemical supplier Ash- Adam Kempinski land Inc., has named May Shana’a as group vice president, technology and growth strategy. — Sheet extrusion equipment supplier Processing Technologies International LLC (PTi), of Aurora, Ill., has named Christopher Curtin as vice president of international sales.
May Shana’a
SUPPLIER NEWS — Blown film machinery and plastic extrusion equipment maker Techflow Design & Manufacturing has moved to a larger facility in Mississauga, Ont. The company’s new address is 3165 Unity Drive, Unit # 1. Business phone numbers and fax numbers remain unchanged. — Simcoe Plastics Ltd., of Shanty Bay, Ont., has acquired the Canadian distribution rights to JTS Tech Products’ Tec-Purge purging compounds.
YOUR #1 SOURCE FOR AUXILIARY EQUIPMENT • Material Handling – Loaders,Tumblers, Material Storage Bins and Dryers • Production – Chillers,Water/Oil Circulators andTemperature Controllers • Post-Production – Lime Buster, Conveyors, Granulators and Static Eliminators To learn more about IMS Industrial Equipment , please call or visit us on the web at:
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Phone: 1-866-467-9001 (US & Canada) Phone: 001-888-304-1307 (Mexico) Fax: 1-888-288-6900 (US & Canada) sales@imscompany.com
A trusted source for Molding & Extrusion Supplies, Mold Components & Supplies, EQUIPMENT & Engineering Services
www.canplastics.com October 2012 Canadian Plastics
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executive’s corner
STAY FOCUSED! (Five strategies for how) By Timothy F. Bednarz, Ph.D., Majorium Business Press
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t’s easy for business managers to start out with the best of intentions, but many can get sidetracked by the uncontrollable events impacting their professional lives and their company. When a crisis occurs, there’s a tendency to immediately confront the challenge. While well-intentioned and often necessary, don’t allow this thinking to cause you to lose focus on your goals and development. To this end, it’s important to understand that maintaining a focus on long-term goals and objectives to attain a desired outcome is the result of doing the right things, at the right time, and in the right sequence.
EXPAND YOUR KNOWLEDGE AND YOUR NETWORK SPE Ontario Board of Directors invites you to our upcoming Events. You don’t want to miss the Fall/Winter line-up! Husky Plant Tour (LIMITED SEATING) Bolton, Ontario (Dinner at The Angry Tomato) Sep 20, 2012 Shawcor Technical Presentation Hilton Garden Inn Oct 18, 2012 Eastman Chemicals Technical Presentation Hilton Garden Inn Nov 15, 2012 For More Information Contact: Sergio Colantonio 416-224-4678 scolantonio@kpmg.ca Please register for events on-line at: www.speontario.com/upcoming-events
To become a proud member of SPE Ontario, register at: www.4spe.org/joinnow
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1 DEVELOP MENTAL DISCIPLINE
Successful managers have developed the mental discipline that keeps them focused on their goals regardless of the problems and uncontrollable events they may encounter. Keep the summit of the mountain in view, don’t allow daily problems to impede your progress, and always make sure you’re moving forward one step at a time.
2 ADOPT STRATEGIC THINKING
To achieve and maintain a resultsoriented focus, learn to take a protracted view of your business, which means acquiring and polishing strategic thinking skills. These skills allow you to create your focus and form part of your personal vision — the top of the mountain — in the first place. This long view is opposed to tactical thinking that focuses only on short-term day-to-day activities — and as your company evolves, you can empower your employees and delegate the tactical activities lower in the organization.
3 PLAN
While strategic thinking was considered passé and outmoded during the heyday of the dot-coms, it’s now clear that a lack of planning contributed directly to their downfall. Successful managers develop a realistic plan, work that plan, and stick to it. It sounds simple, but requires discipline. A great deal of a plan’s success lies in its execution. Many managers develop excellent plans, but because they have not properly executed and held to them, fail to see their fruits. The best plans are simple, not complex.
4 QUESTION ACTIVITIES
Many managers have a natural tendency to want to control everything within their sphere of influence —
but it’s this very desire that causes many to lose focus on their long-range plan as they attempt to personally put out every fire and handle every issue. As a leader, you must empower your employees and delegate tasks, assignments, and responsibilities. But every activity on their to-do list and calendar must be questioned on a consistent basis and either delegated or eliminated if it doesn’t help accomplish the goal.
5 MONITOR RESULTS
Successful managers tie the metrics that measure their unit’s progress directly to their plans; they then determine the frequency and content of the report that allows them to actively monitor progress toward their own and the organization’s goals. Additionally, managers have flags built into their metrics that immediately signal potential problems when the numbers reported to them are outside normal ranges; the report allows them to quickly act and resolve the problem before it gets out of hand. Maintaining a results-oriented focus takes discipline and perseverance in the face of constant interruptions. Think strategically by focusing on the long-term growth of your business rather than on the problem or crisis that seems to demand immediate attention. Remember: The ultimate solution to any problem must fit into your long-term goals. CPL Timothy F. Bednarz, Ph.D., is the author of over 125 books, including “Great! What Make Leaders Great”, which was selected by Forward Review Magazine as one of the top ten career books published in 2011. He is also the founder of Majorium Business Press publishing house. Visit www. majoriumbusinesspress.com for more.
Canadian Plastics October 2012 www.canplastics.com
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Technology working for you. www.wittmann-canada.com
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Wittmann Canada 35 Leek Crescent Richmond Hill, ON L4B 4C2 T (905) 887-5355 Toll Free 1-888-466-8266 F (905) 887-1162
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Photo Credit: Whittmann Canada Inc.
raw materials handling equipment
BUILDING (or rebuilding)
A BETTER
materials handling system By Mark Stephen, editor
If you’re not conveying your resin as efficiently as possible, you’re just not ready for prime time. But a successful materials handling system doesn’t have to be out of reach. Whether you’re starting from scratch or remaking an old workhorse, a few tips from the experts can help you get it right.
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Just like that killer double-breasted suit probably does with your wardrobe, materials represent your single largest expense as a plastics processor. You didn’t sew the suit yourself just to save a few bucks, so why scrimp on having a reliable resin handling system? The design and installation of a materials handling system can have everything to do with how well it goes on to meet you production goals — and a lot of the same rules apply when it comes to remaking a system that no longer runs efficiently. Whether it’s big and complex or small-scale and simple, the following tips can help you work with your equipment supplier to make, or remake, the system of your dreams.
DESIGNING A NEW SYSTEM The first step is a no-brainer: Identify all of the materials that you process in your plant and identify where each material comes from. Refer to those silos, bins, and Gaylord boxes as “sources” — and keep in mind that blenders and dryers may also be considered sources if loaders are pulling material away from them. “Make a complete list for each machine in your plant — injection
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molder, extruder, blow molder, et cetera — and identify them as ‘destinations’,” said Ray Kelly, product manager, material handling for The Conair Group. “In this context, the hopper of a dryer or the material bins on a blender are considered destinations, since the system will be delivering material to them.” Next, determine the maximum throughput rate for each destination. “The sum of these throughput rates, plus a factor for each 90° bend in the system and the horizontal and vertical distances that material must travel, will give you an indication of how large a vacuum pump will be needed and what diameter the conveying lines should be,” Kelly continued. Your equipment supplier can help perform these calculations, but here’s a quick rule of thumb: “On horizontal runs, we usually calculate one foot per linear foot, but we double that on vertical runs, so that a 10-foot lift is equivalent to a 20-foot horizontal run,” said Bob Crawford, vice president of engineering for Universal Dynamics Inc. “We also add between 15 to 20 feet for each elbow in the system.” In most cases, the line size will be dictated by the total throughput rate of all the machines on that system pump. “Remember to keep all the conveying lines served by a given pump of the same size, and make sure the line size matches properly with the horsepower of the pump,” Ray Kelly said. “For instance, never put a large 15-hp pump on a small two-inch OD line; the proper size for a 15-hp pump is three-inch OD.” As with everything else in life, details matter. “Vacuum loader inlet tubes should match the system piping,” said Gary Brock, process and sales engineer for Pelletron Corporation. “Also, make sure existing loader voltages match up properly with the control system.” Speaking of controls, make sure the controller you choose has the features you need, or that can be added in the future. “Having the latest control system is very important,” said Brian Davis, general manager of Maguire Canada. “A lot of the older controls out there are no longer supported — you can’t get the timers for them because of their age, for example.” Next, keep material runs as straight as possible and minimize the number of elbows. “Every change in direction in a material handling system increases back pressure, reduces conveying capacity, and can cause material degradation,” said Jeff Tibbetts, regional sales manager for Vortex Valves. “In pneumatic conveying, you want to run either vertical or horizontal, but no 45° angles — even if it adds to the distance, it’s still better to go over to the wall and up with a single elbow.” A well-planned system also optimizes conveying velocity. “Make sure that the conveying velocity at the material pick-up point is kept as low as possible, preferably between 3,700 and 4,000 feet per minute,” said Ray Kelly. “Material will accelerate over the entire length of the run and if it moves too fast, the material can degrade.” In case you’re
wondering what can happen to resins conveyed at the wrong speeds, it isn’t pretty: softer materials like polyethylene can heat up and smear against the walls of the conveying lines; brittle materials like styrene or polycarbonate can break up and create dust and fines that clog the system; and abrasive materials like glass-filled ABS can actually wear away the inside of the conveying lines, eventually causing leaks and failure. Finally, make sure your vacuum pump is sized for your location. “Power systems that operate at 50 Hz rather than the more conventional 60 Hz can cause the vacuum pump to turn more slowly, actually derating it by about 17 per cent,” Kelly continued. “You’ll need a bigger pump or one that turns at higher rpm in order to compensate.”
REVAMPING AN OLD SYSTEM Even the best maintained car wears out after awhile — and so too with a resin handling system. When you need an upgrade — either through gradual loss of conveying efficiency or because of plant expansion — there are actually a few right ways to do it, depending on the problem and on your needs. Take an older processing facility that has, slowly and steadily, become inefficient at conveying resin. There are usually one or two main reasons. “In many processing facilities, a succession of plant managers will have installed new conveying lines over the course of decades and the original conveying pipe routing has simply become lost,” said Rob Miller, president of Wittmann Canada Inc. “The end result is a patchwork of pipes of different sizes and diameters, often with a multitude of unused pipes running along the ceiling in almost every direction.” You can probably guess the solution: The superfluous pipes have gotta go. “The goal is to identify what works and to remove what doesn’t, in the course of which we’ve done everything from taking everything down and starting from scratch, to taking one or two of the lines that are there and modifying them slightly,” Miller said.
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Photo Credit: Wittmann Canada Inc.
raw materials handling equipment
Expanding even a small-scale raw materials handling system can be very complex.
But don’t assume that dismantled piping represents a previous investment gone for good. “We normally take superfluous pipes down, but we don’t throw them out,” said Brian Davis. “The processor can subsequently use them to expand, or for future replacement of lines and elbows.” Another big culprit of efficiency loss is a vacuum leak, usually in flexible hoses and around couplings, seals, and valves. The first problem is, they can be bloody hard to detect. “Even the best maintained vacuum conveying system www.canplastics.com October 2012 Canadian Plastics
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raw materials handling equipment
can develop leaks, and it’s often very hard to know because there won’t be a visible clue such as a water puddle,” said Bob Crawford. Second, the problem is often made worse by shoddy repair work. “I’ve seen many, many instances of flex hoses simply being taped to seal a leak,” said Brian Davis. “The processor can tape it all they want but, with vacuum constantly being turned on and off, the glue is going to come loose.” Often, a revamp of a well-maintained but aging material handling system can mean nothing more than an upgrade of the control system. “Today’s controllers are capable of storing materials databases, and barcode scanning of a Gaylord of material and configuring the system so that material never goes to the wrong machine,” said Rob Miller. “They’re a good, relatively straightforward fix.” Sometimes there’s a desirable reason to have an underperforming resin conveying system: new business that results in new lines and an increased total throughput rate, resulting in suddenly-insufficient vacuum power. Adding onto the existing material handling system on your own probably isn’t the best idea, though. “Some processors do reasonably good jobs of adding their own conveying lines, but they don’t know all of the nuances,” Brian Davis said. “Expanding even a smallscale raw materials handling system can be very complex, requiring recalculation of throughput, conveying distances, equipment specifications, and more. It’s something the pro-
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cessor should consult their equipment supplier about.” For either a revamp or an installation, that sounds like good advice for getting the most out of your resin handling and conveying. CPL RESOURCE LIST The Conair Group (Cranberry Township, Pa.); www.conairgroup.com; 800-654-6661 Dier International Plastics Inc. (Markham, Ont.); www.dierinternational.com; 416-219-0509 Industries Laferriere (Mascouche, Que.); www.industrieslaferriere.ca; 450-477-8880 Maguire Canada/Novatec Inc. (Vaughan, Ont.); www.maguirecanada.com; 866-441-8409 Barway Plastic Equipment Inc. (Vaudreuil-Dorian, Que.); www.barway.ca; 450-455-1396 Pelletron Corporation (Lancaster, Pa.); www.pelletron.com; 717-293-4008 Universal Dynamics Inc. (Woodbridge, Va.); www.unadyn.com; 703-490-7000 Piovan Canada Ltd. (Mississauga, Ont.); www.piovan.com; 905-629-8822 Vortex Canada (Mississauga, Ont.); www.vortexcanada.com; 905-607-5200 (Dorval, Que.); 514-685-0058 Wittmann Canada Inc. (Richmond Hill, Ont.); www.wittmann-canada.com; 866-466-8266
Canadian Plastics October 2012 www.canplastics.com
CPLOct12 p10-12 Raw mater.indd 12
12-09-06 8:06 AM
Fast Plastic Solutions With
POUNDS of
PLASTIC Inc.
IMPROVING YOUR PROFITABILITY WITH INNOVATIVE POLYMERIC MATERIALS AND ON-TIME DELIVERY CARBONEIGHT® PC228 UV YCE was recently developed based on a Customer’s request. Their request was for ultra violet stabilized lens grade polycarbonate that when molded produced lenses that diffused or scattered light yielding a frosted appearance. As a result of this development, Pounds of Plastic Inc. has included polycarbonates with a spectrum of molecular weights including an extrusion grade named CARBONEIGHT® PC1403 UV YCE. CARBONEIGHT® PC1403 UV YCE is a 3 melt branch polycarbonate for the manufacture of “frost” profile extrusions. The YCE series of polycarbonates are all a minimum V-2 UL flame rated. CARBONEIGHT® YCE series also includes V-0 UL rated flame retarded grades of different molecular weights (different flow). Please note that UL ratings are based on the specimen thickness. Directly proportional to molecular weight (length of the molecule) is impact & flow. The higher the molecular weight of a grade of polycarbonate, the higher resistance to flow it exhibits. The longer the molecules, the more entangled they are. The higher the molecular weight of a grade of polycarbonate, the tougher the molded or extruded part. Polycarbonate is considered one of the toughest thermoplastics. The hearsay is that General Electric, the inventor of polycarbonate began toughness testing of polycarbonate using a metal test for toughness. This test, the notched izod test, became the standard test in industry for impact not only for polycarbonate but most thermoplastics for 25 years or so. See fig. 1. Fig. 1 Flow of polycarbonate versus toughness @ room temperature.
mElT FlOw GRAmS/10 mIN.
TOUGHNESS FT.lBS./IN.
22 16.5
12 13
9.5 8.0 6.5
15 16 17
5.3
18
Pounds of Plastic Inc. in the development of CARBONEIGHT® YCE series of compounds addressed the flow versus impact in the sense that by not changing the molecular weight certain CARBONEIGHT® YCE grades exhibit high flows with superior impact properties relative to the competition. In other words CARBONEIGHT® PC220 YCE that has 20 melt flow will exhibit the impact of unadjusted 15 melt.
TECHNICAL SOLUTIONS SERIES #4
Introducing CARBONEIGHT® PC228 UV YCE PRElImINARY
CARBONEIGHT Grade: PC228 UV YCE Color: FROST CARBONEIGHT® 228 UV YCE is an injection molding grade of polycarbonate for thin walled lens applications. CARBONEIGHT® 228 UV YCE is UV stabilized. CARBONEIGHT® 228 UV YCE exhibits excellent flow and high impact @ -40 – 80oC. moldings from CARBONEIGHT® 228 UV YCE will be translucent with a frosted appearance. CARBONEIGHT® 228 UV YCE has high temperature resistance and good chemical resistance against acids. CARBONEIGHT® 228 UV YCE is available as NSF/FDA versions for packaging applications. PHYSICAl PROPERTY
NoTChED IzoD IMPACT (1/8” bAR) TENSILE STRENGTh @ YIELD TENSILE ELoNGATIoN @ YIELD FLExURAL MoDULUS MELT FLow RATE (190 °C /16.0 kG.) DENSITY
ASTm TEST mETHOD
UNITS
VAlUE
D1822 D 638 D 638 D 790 D 1238 D792
ft-lb/in. Psi/MPa % Psi/MPa g/10 min g/cm.3
12 9,500/65.5 120 333,500/2,300 28 1.2
In regard to the cutting of a mold for gate and runner configurations please consult your Pounds of Plastic Inc. technical representative.
Processing Conditions: CARBONEIGHT® 228 UV YCE is hygroscopic (absorbs moisture) and requires drying prior to processing. It is highly recommended that CARBONEIGHT® 228 UV YCE be dried in a desiccant bed dryer @ 250oF where the temperature is measured inlet to the hopper. The drying duration is 2-4 hours to a moisture content of 0.03% by weight. More drying time may be required to obtain this “bone dry” condition. A dryer that is producing dry air @ a dew point of -40oF is recommended. Drying also acts as a pre-heat. Pre-heating/ drying assists in plasticating CARBONEIGHT® 228 UV YCE. Failure to dry adequately will result in chain scission in the barrel. Chain scission results in brittle parts. Moisture content of 0.03% or lower entering the throat of the molding machine is essential for “good” moldings. Ideal compression ratio screw configuration for the molding machine is 2.5:1. Melt temperatures between 500-530oF are recommended for running CARBONEIGHT® 228 UV YCE. Depending on part thickness a mold temperature of 150oF is a good starting point. Regrind levels of 10% can generally be used with confidence. Pigments may alter the physical properties of CARBONEIGHT® 228 UV YCE. The data contained in this document are based on our current knowledge and experience. As a result of the many factors that may affect processing and application of this product, these data do not absolve processors from carrying out their own investigations and test nor do they imply any guarantee of certain properties or the suitability of the product for a specific purpose. Any descriptions, data, proportions, weights, etc. given herein may change without prior notice and do not constitute the agreed contractual quality of the product.
Additional information regarding CARBONEIGHT® YCE series, please contact Richard Pounds @ 905-286-9894.
INJECTION MOULDING • EXTRUSION • BLOW MOULDING • ROTO MOULDING • FILM
Distributors quality products: Omni Plastics LLC, Vi-Chem, Reinier • Antimicrobial thermoplastics (Kills bugs) Biodegradable thermoplastics (Degrades in Landfill) • Black colour concentrates • Reprocessed post consumer thermoplastics OmnilonTM OmniproTM OmnitechTM OmnicarbTM Many unique and specialized nylon 6 and nylon 6,6, polypropylene, ABS, PBT, PET/polycarbonate and polycarbonate/ABS compounds.
Rigid and flexible PVC compounds.
POUNDS of
PLASTIC Inc.
POUNDS OF PLASTIC INC. www.poundsofplastic.com
3130 Pepper Mill Ct., Mississauga, Ontario L5L 4X4 Canada • PH: 905-286-9894 • FA: 905-286-9893 • rpounds@poundsofplastic.com
CPLOct12 p13 Pounds of Plastic AD.indd 13
12-09-06 9:46 AM
moldmaking benchmark survey
FOURWARNED The results of the fourth annual Canadian Plastics’ Moldmaking Benchmark Survey are in. Last year, our respondents reported a return to semi-prosperity after the Great Recession. How does the situation stack up 12 months later? Read on. By Mark Stephen, editor
T
he survey, consisting of 33 questions, was emailed in August 2012 to approximately 160 moldmakers across Canada in the Canadian Plastics database, as well as to members of the Canadian Association of Mold Makers (CAMM). We received 23 completed surveys. As usual, most of the respondents this year — 81% — are located in Ontario, with 38% in the Toronto area, 19% in
Windsor, and the rest spread throughout other parts of the province. The remaining 19% are in Quebec. When asked how many employees work at their plant, answers varied from 120 to two. Almost 50% of this year’s respondents are with firms that employ 50 workers or more. The average shop employed 59 workers, compared to an average of 46 workers in 2011 and 36 in 2010 — perhaps indicating that more of the shops that are still around today are larger. The average hourly wage is $25.41, a very slight
PROJECTION FOR BUSINESS CONDITIONS FOR THE NEXT 12 MONTHS
CURRENT QUOTING ACTIVITY VS. THE SAME TIME LAST YEAR
WHO, WHAT, WHERE
(n=21)
(n=22)
Down moderately 23.8%
Good 35% Fair 35%
Poor 15% 5%
Up moderately 28.6%
Same 23.8%
Down substantially 9.5% 14.3%
Bad 10% Up substantially
Excellent
To view the full survey results, go to http://www.canplastics.com/survey/moldarchives2012.asp
14
Canadian Plastics October 2012 www.canplastics.com
CPLOct12 p14-16 Mold Survey.indd 14
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moldmaking benchmark survey
uptick from the 2011 average of $24.33 per hour and the 2010 average of $22.65 per hour. This year’s average might be skewed slightly by one respondent who reported a whopping hourly wage of $39.00. (None of us wish we worked there, right?) The majority of respondents — 71.4% — said they manufactured molds and dies for injection molding applications, down from 90% last year. Thirty-eight per cent this year make injection molds/stack molds, 23.8% make blow molds, 23.8% make die cast molds, 19% make injection molds/unscrewing molds, 19% make reaction injection molds, 14.3% make structural foam molds, and 14.3% make vacuum forming molds. Compared with 2011, the 2012 responses reveal a slight but noticeable shift in the manufacturing habits of the moldmakers. Last year, 95% of respondents listed the auto industry as their top market; this year, only 71.4% said the same. Eighty-one per cent of respondents this year said molds for consumer goods and houseware products are their top markets, up from 70% in 2011. In other words, it seems like the see-sawing fortunes of the automotive industry are continuing. Also, 76.2% of respondents this year supply molds for packaging applications, and 38.1% supply molds for electrical applications. Not surprisingly, the number of moldmakers working with medical parts molders continues to creep higher as the boomers get older: Fifty-four per cent of respondents this year make molds for medical applications, compared to 45% in 2011 and 30% in 2010. Eighty-five per cent of this year’s respondents offer custom machining, compared with 81% last year; also, 85% offer mold cleaning and repairing, also compared with 81% last year. A similar 85% reported having an EDM facility this year, an increase from 72% with EDM last year. Here’s a bigger change: this year, only 66.7% provide mold polishing, compared to 91% last year. Also this year, 52.4% reported offering CNC duplicating, and 42.9% perform engraving works. Almost 30% of this year’s respondents have in-house mold testing or tryouts, compared to just 10% last year.
BUSINESS: PAST, PRESENT, FUTURE Asked for a prediction of business conditions in the next 12 months, only 5% expected an “excellent” year ahead, 35% expected “good” conditions, 35% expected “fair” results, and 25% feared either a “poor” or “bad” outcome. Last year, 27.3% expected excellent conditions, 45.4% expected good conditions, 27.3% expected fair conditions, and nobody thought they were in for either a poor or a bad year. Asked for their average machine utilization rate for the past 12 months, 20% reported using 80% or more of their equipment — a big drop, as we’ll soon see. Sixty-
Response count
WHAT SERVICES DOES YOUR PLANT OFFER?
(n=21)
CNC duplicating
11
52.4%
18
85.7%
Custom machining
18
85.7%
EDM facilities
9
42.9%
6
28.6%
5
23.8%
10
47.6%
14
66.7%
18
85.7%
11
52.4%
5
23.8%
Response count 2 5 15 17 8 11 2 16 6 3 6
Engraving In-house mold testing & try-outs Injection molding of parts Jigs & fixtures manufacturing Mold polishing Mold repair & cleaning Prototyping SLA modeling
WHAT MARKETS DO YOU SERVE? (n=21) 9.5% Aerospace 23.8%
Appliance
71.4%
Automotive Consumer goods & housewares
81% 38.1%
Electrical & electronic
52.4%
Medical
9.5% Oil & gas 76.2%
Packaging
28.6% 14.3% 28.6%
Sporting goods Toys Other
five per cent reported using between 79% to 60% of their machinery, and 15% used 59% or less. Last year, 72% used 80% or more, and no one reported using 59% or less. www.canplastics.com October 2012 Canadian Plastics
CPLOct12 p14-16 Mold Survey.indd 15
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12-09-06 8:09 AM
moldmaking benchmark survey
Turning to quotations for new business, the numbers align better with last year’s results — sort of. Thirty-eight per cent of respondents this year reported quoting for moderately or substantially more business than in 2011, almost even with the 40% last year who quoted more than in 2010. But that’s where the similarities end. Another 23.8% of respondents this year said they placed the same number of quotes as last year — a falloff from the 40% reporting the same number of quotations as the year before in 2011. And 38.1% reported a moderate to substantial quoting decrease compared to 2011 — up from the 20% of respondents last year reporting a moderate to substantial quoting decrease compared to 2010. RFQs are one thing — quotes that result in actual new business are something else. This year, 35% of respondents said that 50% or more of their quotes wind up winning the contracts — up from 18% saying the same thing last year. Another 10% said they were successful between 21% and 50% of the time, and the remaining 55% reported getting the contract 20% of the time or less.
PURCHASING, TRAINING, R&D When it comes to buying new moldmaking machinery, the respondents were clear — and for the third year in a
row, most are in a buying mood. To be precise, 52% are looking for new equipment, although this is down from 72% last year. The better news? Seventy-two per cent will be on the hunt for new equipment exclusively, compared to 60% in 2011. The rest are willing to consider either new or pre-owned. Digging a bit deeper, 45% of this year’s respondents will be buying to add new capacity, and the rest to replace existing equipment. On the training front, 28.6% of this year’s respondents report allocating 1% of annual budgeted expenses for employee training, 28.6% will spend 2% on training, and an obviously ultra-safe and efficient 23.8% will invest 3% or more. Nineteen per cent reported having no expenses at all set aside for training in 2012, compared to zero with nothing set aside last year. When it comes to research and development, the spending continues to hold steady. Sixty-five per cent of this year’s respondents will invest 3% or more of their annual budgeted expenses on R&D — exactly the same as last year. On the other hand, 20% will make no R&D investments in the next 12 months, compared to only 5% saying the same last year. CPL
AUTOMATED CONTRACT INJECTION MOLDING
Lights out up to 200 tons
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www.niigon.com 16
Canadian Plastics October 2012 www.canplastics.com
CPLOct12 p14-16 Mold Survey.indd 16
12-09-06 8:10 AM
THE BASICS OF INJECTION MOLDING Learn the ABCs of... successful injection molding at this full-day workshop. An ideal introduction if you are new to the injection molding industry or would like a refresher. Instructor Kip Doyle has more than thirty years experience in the injection molding industry. He spent seven years working for injection molding machinery companies supporting injection molders in various technical positions. He has proven expertise in Scientific Molding techniques and is an RJG certified Master Molder & Trainer (level III).
Workshop topics include: Scientific injection molding expert Kip Doyle, Master Molder level III & Certified Trainer
part design • Material selection • injection mold components • injection molding machine components • injection process variables • specialized injection processes (e.g. gas assist, insert molding, etc.) • injection molding economics Wednesday, november 28 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
Following on the success of our Basics of Plastics Seminars
Check www.canplastics.com for detailed information and registration, or call 416-510-6867
Sponsored by:
CPLOct12 p17 Basics of InjMold AD.indd 17
12-09-05 11:28 AM
hot runners
Photo Credit: Husky Injection Molding Systems Ltd.
GATE CRA Seriously, what’s not to love about hot runner valve gates? They give the molder the ability to shut off the gate more precisely than with an open or thermal gate, produce quality gate marks, and deliver precision performance and accurate melt flow control in the fill, pack, and cooling phases of your plastic part. So we know you’ll want to get familiar with some of the latest offerings.
Husky’s UltraSync hot runner valve gate.
F
act: Valve gating has become the preferred method of gating for precision molders, offering a more stable injection process without stringing and drooling of the melt. And these are particularly interesting times for valves gates: two themes — electric drive and precise control — are dominating a lot of the new entries, hydraulic and pneumatic products are getting ever more sophisticated, and a familiar distributor is launching its own product offering.
THE ELECTRIC COMPANIES From Husky Injection Molding Systems Ltd., the UltraSync-E electric technology is designed to offer shot-to-shot and part-topart consistency through precise stem closing to help eliminate variability from the injection molding process — and by allowing for a minimum nozzle spacing of 18 mm, it’s said to be particularly well-suited for precision molding of small parts. “The unique plate actuation mechanism requires the lowest amount of maintenance of any product in its category, and wear is eliminated by the use of bearings for moving components,” said Martin Baumann, Husky’s business manager, hot runners. “Accessibility to perform routine maintenance tasks is simple and easy — stems on the UltraSync-E can be exchanged in the machine in less than five 18
By Mark Stephen, editor minutes.” In addition to the UltraSync-E, Baumann added, Husky offers its UltraSync hot runners in hydraulic (the UltraSync-H) and pneumatic (the UltraSync-P) versions. “Electric, hydraulic, and pneumatic options are available with Ultra 300, Ultra 500, and Ultra 750 valve gate hot runner nozzles,” he said. Synventive Molding Solutions recently introduced its new eGate high performance electric valve gate hot runner system, designed for injection molded parts that require multi-shot/ multi-material applications, sequential/cascading molding, cleanroom environments, and premium cosmetic surfaces. According to Synventive, the eGate provides numerous advantages over traditional valve gates, including greater control, as processors can adjust the flow rate out of each nozzle gate at any time during the fill process; valve pin position that improves cosmetic gate quality; improved shot-to-shot and part-to-part consistency; and process monitoring that gathers and monitors data for real-time pin position. The eGate is said to be particularly effective when combined with the company’s eGate Shop software, which monitors the open and closed positions of the valve pins within 0.01 mm, as well as velocities and accelerations, resulting in improved gate quality and quicker closing of the valve pin. The E-Drive electric valve gating system from Mold-Masters Ltd. is now available in larger sizes for automotive and large appliance parts. An example is the new EVH 110 (110 mm). The E-Drive is designed for multi-cavitation and precision molding applications in cleanroom and oil-free environments; its valve pin plate concept utilizes the full capabilities of servo technology, with the servo motor’s power transmitted to the valve pin plate by a timing belt and two ball screws, resulting in accurate linear motion to open and close the gates. And the E-Drive continues to help simplify the barrier process for food and medical packaging applications, the
Canadian Plastics October 2012 www.canplastics.com
CPLOct12 p18-20 Hot Runners.indd 18
12-09-06 3:21 PM
hot runners
RASHERS company said. At the recent NPE2012 show in Florida, for example, MoldMasters included its E-Drive in a work cell for co-injection of three-layer HDPE caps with a three per cent to six per cent barrier layer of EVOH in the centre. This IRIS co-injection technology also utilized Mold-Masters’ E-Multi secondary injection unit and an instrument from Swiss-based IMD Ltd. to test for the presence of the barrier layer. Medical and electronics industry injection molders might just be able to attain a higher degree of process reliability for precision valve gate applications with an electric drive system that’s now available with an optional position encoder
from Ewikon Molding Technologies Inc. “The encoders provide real-time monitoring of valve pin position with an accuracy of 0.01 mm,” said company president David Boxall. Also new for the system is a second-generation touchscreen electric drive controller that monitors the valve pin position and corrects for any deviation. According to Boxall, the controller will trigger an error message and alarm if the drive fails to reach its position, allowing it to detect gate blockages caused by resin contaminants. “The controller shows the current valve pin positions graphically and digitally, and allows operators to select for synchronous or sequential control on all drives,” Boxall said. “The system can handle up to 32 drives, and slave units can be grouped together to control larger layouts. In addition to the normal functions, multiple valve pin positions within one injection cycle are also possible in the standard unit. Various trigger signals can be used to open and close valves, and the signals may be digital from pressure or temperature systems or analog signals such as linear position devices for screw position. Data and settings can be saved on a compact flash card.”
NEW TWISTS AND NEW PLAYERS Hydraulic and pneumatic valve gates are pretty standard by now
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www.canplastics.com October 2012 Canadian Plastics
CPLOct12 p18-20 Hot Runners.indd 19
19
12-09-06 8:11 AM
hot runners — not that there’s anything wrong with that. Hasco’s new Z2371 series valve gates, available in hydraulic or pneumatic versions, are meant to offer a high degree of standardization for high-volume applications ranging from medical to auto parts. “For hydraulic actuation, there are two different types of housings in three sizes and two strokes each available,” said Klaus Kapp, hot runner sales manager with Hasco Hasenclever GmbH. “Pin diameters vary according to the sizes, and maximum pin strokes are eight mm and 12 mm. For maintenance or repair work, the Z2371 can be disconnected without disassembly of the complete unit; the hydraulic circuit won’t be touched and there’s no contamination by hydraulic oil.” In the pneumatic actuation, the Z2371 is designed to be assembled into the back plate of the mold. “This version offers four sizes with different pin diameters and variable pin strokes,” Kapp said. “In addition, you have the ability to lock the piston with the help of a snap ring. In case of trouble, the corresponding pneumatic actuation unit can be locked — it’s an indispensable requirement for the industry to prevent production stoppages due to defects related to a single cavity.” The new Zenith valve gate system from DME Company is the company’s first standard valve gate system of its own design, and is available in hydraulic or pneumatic versions and with nozzles two inches to 20 inches in length. Why bring out their first product now? “Materials in the industry are changing all the time and the valve gates have to change to handle them, and we didn’t want to be dependent on the vendor to
make those alterations for us,” said Craig Kovacic, the company’s hot runner business manager. Zenith valve gates maintain a perfectly flat thermal profile, Kovacic continued, with better heat profiles in the nozzle and tip — areas where uniform heat prevents drooling or stringing. “They’re designed for medical part molders — the pneumatic valve gates in particular — where a cleanroom environment is necessary,” Kovacic said. “They use standard DME Flex manifold heaters and work with DME’s new hydraulic valve gate sequencer, which stores up to 32 recipes and 200 events.” If you’ll pardon the pun, the gates to productivity seem to have opened a little wider. CPL RESOURCE LIST DME of Canada Ltd. (Mississauga, Ont.); www.dme.net; 800-387-6600 Ewikon Molding Technologies Inc. (Rockford, Ill.); www.ewikonusa.com; 815-874-7270 Hasco Canada Inc. (Toronto); www.hasco.com; 888-244-5110 Husky Injection Molding Systems Ltd. (Bolton, Ont.); www.husky.ca; 905-951-5000 Mold-Masters Ltd. (Georgetown, Ont.); www.moldmasters.com; 905-877-0185 Synventive Molding Solutions Canada Inc. (Toronto); www.synventive.com; 416-428-4693
Be part of THE Canadian dELEgaTiOn going to the K 2013 SHOW and SavE! Canadian Plastics and Plastiques et moules is once again partnering with FEPAC (Federation of Plastics and Alliances Composites) and Carlson Wagonlit Travel to offer a group package to the K Show in October 2013.
SHOW: #1 for your business development SHOW: #1 for your competitiveness SHOW: #1 look into the future
Can you afford to miss it? Call Carlson Wagonlit for details
TOLL FREE: 1-888-378-7208
20
Canadian Plastics October 2012 www.canplastics.com
CPLOct12 p18-20 Hot Runners.indd 20
12-09-06 8:12 AM
Turn your Purgings into Profits.
(Savings)
(Purgings)
Stop throwing away money. Reclaim your purgings with Maguire’s unique PURGING RECOVERY SYSTEM™. Get payback right away. Imagine what you could save in recovered purgings across your entire operation. You could easily pay for this unit itself within the first year. The Maguire Purging Recovery System runs about $30,000. Prior to this, size reducers would commonly cost about $150,000 per unit. So don’t throw away those purgings in some landfill, regrind them, recover those resin costs. It’s a new way to find money (savings) within your current system. A small outlay with a quick payback. And it’s the right thing for the environment. The Purging Recovery System (PRS-20) is a unique, yet simple two-
stage process. The first stage takes awkward, large size purgings and planes them into small pieces, somewhat like a carpenter’s plane. Then stage two granulates them into highly uniform regrind ready for processing. With nearly 150 patents in the U.S. and internationally, Maguire is committed to developing unique products and systems for plastic processing. It’s backed by a five-year warranty for your protection. This is another way that Maguire helps you find new profits in your plant. Check out our video on the web. Contact Maguire today.
Purging Recovery System PRS-20 unique two-stage process.
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The perfect blend of simplicity and control. www.MaguireCanada.com
Maguire Products Canada, Inc ®
CPLOct12 p21 Maguire AD.indd 21
12-09-05 11:29 AM
Making a mark with
LIQUID COLORANTS They’re not exactly new, but liquid colorants are growing more popular with processors looking for a competitive advantage. They can offer more economical letdown ratios and work especially well with heat-sensitive materials. But are they right for you? By Mark Stephen, editor
A
ny plastics processor out there who doesn’t want to gain a competitive advantage, raise your hand. Nobody, right? Well, interest in one potential advantage is on the rise: A growing number of molders are considering liquid colorants as a way to improve overall production efficiencies while reducing the total coloring cost. Yes, we know — liquid colors have seen their popularity rise before, which means you’ve probably heard the hype. But what’s the reality? Are liquid color concentrates really a winwin solution — all upside, no downside? Is liquid color the right solution for every application? Before trying to answer that, here’s a quick backgrounder. First brought to market 20-odd years ago, liquid color concentrates are free-flowing pre-dispersions of pigments in carriers that are compatible with the base resin being processed. They are most commonly produced using one of two methods. First, by mixing base pigments in a liquid carrier with a high-speed mixer to achieve the desired color. Additives are often used to minimize the tendency of the pigment to settle out of suspension; the suspension may also require agitation just prior to use to ensure good color consistency in production. The second method involves milling or breaking down the pigments to very fine particles, then dispersing the color into the liquid carrier.
22
This method is recommended when working with organic colorants, and is said to achieve the best color dispersion possible while increasing shelf stability. The use of liquid color concentrates requires technology to meter and pump the material from its storage container into the process to be mixed with the resin material. There are various ways to accomplish this, ranging from simple volumetric systems using peristaltic pumps to more sophisticated and highly accurate gravimetric systems employing computer-controlled metering. A downside? The equipment to do the metering and pumping, which you probably don’t have. “Whatever method is used, it’s important to note that liquid color will require additional equipment to deploy the liquid into your system,” said George Cooke, vice president of sales for Vortex Liquid Color.
GOLDEN OPPORTUNITIES The bite for the new equipment aside, liquid color concentrates offer several advantages over other coloring options. “Because of the physical properties of a liquid, volumetric liquid systems are inherently more accurate than the gravimetric systems typically used for solid colorants,” said Bjoern Klaas, director of new product and technology development for ColorMatrix Group. How accurate? “Our proprietary liquid dosing systems
Canadian Plastics October 2012 www.canplastics.com
CPLOct12 p22-24 Colourants.indd 22
12-09-06 8:37 AM
Photo Credit: ColorMatrix Group
colorants
Photo Credit: ColorMatrix Group
colorants
allow for careful dosing control, to levels as low as 0.001 per cent accuracy,” he said. The liquid also lends itself to dispersion within the base polymer more effectively than other forms of color, enabling processors to achieve good color dispersion throughout their finished products. And from the machine operating perspective, there’s an added benefit. “In some cases, the easy mixing can lead to lower back pressure and lower cycle times to get a homogenous mix for injection molding or extrusion,” said George Cooke. You might also need less liquid than pellets or powdered mixtures to achieve comparable results. “Liquid color can be loaded much higher than masterbatch. We can run liquid colorants at 0.02 per cent to 0.05 per cent, whereas masterbatch typically runs at two per cent,” Cooke continued. “This translates into higher letdown ratios for a given application and can provide a processor with great efficiencies in the coloring operation.” Even with heat-sensitive materials? “The fact that liquid does not require melting prior to mixing with the resin is especially advantageous when working with heat-sensitive resins,” said Bjoern Klaas. And here’s a benefit not to be overlooked in today’s brave new world of bean counters: cost. “Liquid colorant pricing isn’t tied to resin swings,” George Cooke said. “Resin is at over 80 per cent global capacity utilization, which is pushing the prices
up. Liquid color is independent of that, and therefore more stable in pricing over the long term. Also, some liquid producers have flat pricing, which means there’s no penalty for buying in smaller quantities, as there usually is with masterbatch.” And from the finished-appearance standpoint, the results are usually the runway models of plastics parts. “Liquid typically has more gloss, especially for bright colors, and that gloss becomes part of the finished matrix,” Cooke said. “And it has less heat history on it, which also gives you a bigger bang out of your regrind because it hasn’t been diluted as much.”
GREY AREAS But despite big strides forward in the two decades that liquid colorants have been on the scene, some challenges remain. In some applications, for example, the liquid carrier may bloom to the surface if not completely compatible with the base resin; or if they’re past their shelf life, the potential exists for the pigments to fall out of suspension, leading to inconsistent coloring. This last point has become less of an issue recently, however. “In the past, shelf life was a concern because a lot of the liquid manufacturers relied on the customer to finish developing the color,” Cooke said. “Today’s liquid color companies provide a more complete development of the product.” Handling the material can be a concern, too. As with that can of paint you bought at the local hardware store, there’s
Proven Extrusion Systems Our continuous and discontinuous screen changers, melt pumps, pelletizers, and static mixers, are often supplied as systems comprising these and other components. We have over 30 years’ application experience in the extrusion industry and our products are known for their world class technology. You can reduce energy and resin costs, and improve product quality. Call us to learn more. Maag Automatik, Charlotte, NC 704-716-9000 MaagAmericas@maag.com www.maag.com
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colorants
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Liquid colorant pricing isn’t tied to resin swings... and is therefore more stable over the long term.
“
almost always some residual colorant left in the container that most metering equipment is unable to extract. Depending on the equipment being used, this material can represent up to 10 per cent of the total volume of color — which makes for a lot of waste. But it doesn’t have to be that way. One method to extract as much as possible involves combining unused colorant with fresh containers of material — it works, but it’s not exactly labor-free, often involving someone physically lifting bulky and awkward containers. A second involves cutting a deal with your supplier. “In some instances, we can give the customer a net credit for residual material,” Cooke said. And with today’s increased regulatory environment, disposal of the spent containers might not be easy. Depending upon the local jurisdiction of your plant, liquid colorant can be considered hazardous material, with all of the associated costs and headaches to dispose of it in a lawful manner. And even if the colorant isn’t considered hazardous, many waste haulers won’t touch it, or will do so only for an additional cost. Lastly, there are some applications that liquid colorants just aren’t right for, period. “One processing area that we’ve been trying to get into for years is film,” Cooke said. “The difficulty is that the film is so thin and the liquid can be too slippery, causing the film to extrude improperly and even breaking the bubble and shutting down the line. It’s an issue that we’re still working to solve.” Film manufacturers aside, companies wanting to make the
move from pellets and powders to liquid colorants might find it well worth the hassles. “If a processor is switching from solids to liquid colorants systems, they’ll need to consider a number of change factors, primarily around handling and operational procedures for dosing liquids, managing inventory status, and matching new colors on their machines,” said Bjoern Klaas. “These would be important, but not onerous, considerations. In the long term, the changes required to switch are generally offset very quickly by the benefits.” CPL RESOURCE LIST ColorMatrix Group (Cleveland, Ohio); www.colormatrix.com; 216-622-0100 Vortex Liquid Color (Sheboygan, Wis.); www.vortexcolor.com; 920-451-9925
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Designed for beside the press loading, the Vectra E Series of loaders from Hamilton are a perfect blend of performance and price. Models are available in either single or dual feed (ratio) to suit your application. Hamilton Plastic Systems Ltd. 1-800-590-5546 www.hamiltonplasticsystems.com
Canadian Plastics October 2012 www.canplastics.com
CPLOct12 p22-24 Colourants.indd 24
12-09-06 8:43 AM
technology showcase
AUXILIARY EQUIPMENT
Filter drawer feature for fast, easy screen maintenance The new filter drawer feature available on The Conair Group’s DuraLoad vacuum receivers eliminates the need to remove the receiver lid to perform routine screen inspection and maintenance. Instead, a slim module, which can be fitted between the lid and the body of the receiver, features a slide-out drawer containing the filter screen disc. To check, clean, or replace the filter, users simply open two tool-free twist clamps and pull out the drawer. The filter drawer adds only 3.5 inches (89 mm) to the installed height of the receiver and is available in all Conair DuraLoad diameters. The option is recommended for processors who do not make frequent material changes but who want an easy way to check their filter screen. It’s also well-suited for installations where ceiling height makes it more difficult to remove receiver lids, or applications that
require frequent screen changes. The filter drawer is available in stainless steel and in a special high-temperature version for when dried material is being conveyed at temperatures up to 350°F (171°C). The Conair Group (Cranberry Township, Pa.); www.conairgroup.com; 800-654-6661 Dier International Plastics Inc. (Markham, Ont.); www.dierinternational.com; 416-219-0509 Industries Laferriere (Mascouche, Que.); www.industrieslaferriere.ca; 450-477-8880
Conveying loader for food, pharma, and chemical apps The new P-Series Venturi loader from K-Tron is designed specifically for conveying powders in sanitary food, pharmaceutical, and chemical applications. It can be used for loading hoppers as well as loss-in-weight feeder refill applications, and meets the rigid 3-A Dairy Sanitary Standards. The efficient and compact Venturi power unit utilizes compressed air to create its vacuum conveying source; this eliminates the need and expense for a separate blower package, making it a more economical solution for applications requiring lower rate conveying over shorter distances. The unit also includes a large area automatic reverse jet filter for
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technology showcase efficient powder conveying. The loader body is made of DIN 1.4404 (AISI 316L) stainless steel, with internal and external electropolished surface passivation. The modular construction and sanitary design, without pockets or dead spaces, allows for easy disassembly and cleaning, as well as simple expansion with extension modules. All conveying line connections have tri-clover quick release fittings to ensure quick disconnection and include special FDA-approved seals and gaskets throughout. The P-Series Venturi loader meets ATEX 2GD/1D and NEC Class 1, Div 2, Group C&D classifications. K-Tron (Pitman, N.J.); www.ktron.com; 856-589-0500 Separator Engineering Ltd. (Toronto); www.separatorengineering.com; 416-292-8822 Mequipco Ltd. (Richmond, B.C.); www.mequipco.com; 604-273-0553
Dryer for medical parts molding Novatec Inc.’s new NDM-5 medical dryer is a compact resin dryer designed specifically for use by medical molders processing small quantities of material up to five pounds per hour,
Power Clean and Still Feel green No chlorinated solvents
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and is based on the same basic principle as the non-desiccant NovaDrier, which has been popular with medical molders since its introduction over 12 years ago. Any type of resin can be dried with this technology, and it’s now available in a compact package that can be machine-mounted. Materials can be changed by removing the integral glass hopper and replacing it with a spare hopper containing another material. As with the NovaDrier, the NDM-5 has no moving parts, so the only scheduled maintenance is to replace the compressed air filter elements every 12 months. Operation is designed to be simple: just turn the dryer on and set the temperature on the microprocessor control, which is equipped with a 12-inch long pendant for remote mounting. The NDM-5 can be equipped with the Novatec MoistureMaster in-line moisture analysis system for molders who are processing materials that cost thousands of dollars per pound, or who are molding parts from materials that are sensitive to moisture content. This sensor monitors moisture in per cent or parts per million (ppm) down to 100 ppm and displays the result on a color touchscreen control, which removes the need to guess about the actual resin moisture content. Maguire Canada/Novatec Inc. (Vaughan, Ont.): www.maguirecanada.com; 866-441-8409 Barway Plastic Equipment Inc. (Vaudreuil-Dorian, Que.); www.barway.ca; 450-455-1396
Small dryer for beside-the-press operations Wittmann Battenfeld’s new Drymax Aton F70 materials dryer is designed to be a small, flexible, and mobile solution for beside-the-press operations. A variety of hopper volumes are offered: The Drymax Aton F70 is able to dry approximately 40 kilograms per hour, based on glass-filled polyamide. To monitor and to run the unit based on the dew point, this Drymax model optionally includes a dew point sensor with a certificate of calibration. The Aton includes 3-Save process and EcoMode situated at the dryer. The insulated stainless steel drying hoppers are also equipped with the “Material-Saver” function, which avoids any thermal damage to the material. The multiple hopper versions come complete with Wittmann’s SmartFlow valve technology. Wittmann Canada Inc. (Richmond Hill, Ont.); www.wittmann-canada.com; 866-466-8266
......stay connected with
Canadian Plastics October 2012 www.canplastics.com
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technology showcase
INJECTION MOLDING
New extended features on set-up assistant Arburg Inc.’s Selogica set-up assistant module is available in a new extended version that enables hydraulic, hybrid, and electric Allrounder injection molding machines to be set up simply, quickly, and reliably, without prior specific knowledge of the control system — from mold installation to the finished sequence. The extended version includes the new mold removal function as standard. Customer-specific material parameters can now also be entered. As a simple human/machine interface, the set-up assistant enables menu-guided “teach-in” functions for the entire injection molding machine sequence, including the robotic system. The installation technician is actively supported during the process. Because the step-by-step guidance for all the necessary actions reduces parameter entry to the absolute essentials, Allrounders can be set up in a very short time. Detailed knowledge of the control system is not necessary. As with mold installation, the set-up assistant now also actively supports mold removal, automatically determining the sequence in which the tasks need to be performed. Arburg Inc. (Newington, Conn.); www.arburg.com; 860-667-6522 DCube (Montreal); www.dcube.ca; 514-272-0500 Dier International (Unionville, Ont.); www.dierinternational.com; 416-219-0509
Servo pump for hydraulic machines
The Motion Control Business of Siemens Industry Inc. recently introduced its new Sinamics servo pump for hydraulic injection molding machines. Built upon standard components such as the Sinamics S120 drive platform and distributed I/O, users can benefit from increased machine output and reduced energy costs of up to 50 per cent. This solution for the plastics industry has been designed to offer simple installation and handling. Advantages of the Sinamics servo pump include significantly reduced energy consumption, reduced noise when compared to a variable capacity pump or control valve, smaller oil tank volume,
reduced dependency on oil temperature, and a simpler pump with a controlled servo motor that can replace the variable capacity pump. Siemens Canada Limited, Drive Technologies Div. (Burlington, Ont.); www.siemens.com/eip; 800-879-8079, ext. Marketing Communications
EXTRUSION
Extruder with reverse air cooling The new Backdraft extruder from American Kuhne Inc. is designed with a reverse air cooling system, making it wellsuited for blown film processing, as well as benefiting other plastic processing applications. The Backdraft extruder design removes heat and air currents from the extrusion area for optimum bubble stability, while simultaneously improving energy efficiency. Individual dampers for each zone provide good process control and operational simplicity. When the dampers are closed, they prevent the “chimney effect” present in most air-cooled machines that causes energy loss through convection cooling. The dampers are connected to a common air plenum integrated into the machine base, which is in turn connected to a single exhaust fan, either at the base or remote-mounted. The single central exhaust blower removes the need for more
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technology showcase traditional individual blowers on each zone. When a damper opens, air is drawn down through the heater’s cooling fins and through the exhaust system. This reverse cooling arrangement eliminates the need for exhaust hoods, and eliminates any potentially damaging air currents near the bubble area. American Kuhne Inc. (Ashaway, R.I.); www.americankuhne.com; 401-326-6200
BLOW MOLDING
High-speed bottle filling Sidel has redesigned its aseptic Combi Predis FMa technology to answer the growing demand of aseptic filling of teas, juices, nectars, and isotonics. The Combi Predis technology combines bottle blow molding, filling, and capping in a single system. The technology ensures high standards of hygiene as dry decontamination guarantees 100 per cent sterilization without hygienic rinsing, as required by traditional filling methods. This procedure offers increased cost effectiveness along with high product quality and environmental benefits due to water savings and minimized amounts of chemicals used. The new high-speed version is capable of handling up to 48,000 bottles per hour for small containers of up to 700 milliliters, used mainly for on-the-go consumption. Predis is suitable for aseptic bottling of any kind of beverages, whether low- or high-acid. The Combi Predis FMa technology replaces bottle rinsing by
dry preforms decontamination using hydrogen peroxide. Predis dry solution does not require any water and creates no effluent, saving the 250 cubic meters of water and the 200 litres of chemicals used daily on a traditional aseptic bottling line. Dry preforms decontamination also cuts annual operating costs by 30 per cent compared to traditional dry bottle decontamination. It enables sterilization of all types of preforms (Predis) and caps (Capdis) and is available in different configurations. And since bottles are blown from decontaminated preforms, the empty bottle does not endure any thermal stress and can be given any shape and design. Sidel Canada Inc. (Laval, Que.); www.sidel.com; 450-973-3337
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.
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AceTRONIC Basics of Injection Molding Canadian Plastics CanPlastics TV videos DynaPurge Ewikon MoldingTechnologies, Inc. Hamilton Plastic Systems Ltd. IMS JEC Composites K 2013 Show Travel Lorenz Conveying Products Maag Maguire Products Canada Niigon Technologies Ltd. PCS Company Piovan Canada Plastics Process Equipment, Inc. PolyOne Distribution Canada Ltd. Pounds of Plastic Process Heaters SPE Ontario The Shepherd Color Company UltraPurge Wittmann Canada Inc.
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800-803-8871 416-510-5133 866-607-8743 815-874-7270 905-890-0055 800-537-5375 888-510-5133 800-263-1942 704-716-9000 866-441-8409 705-375-0770 800-521-0546 905-629-8822 800-362-0706 888-394-2662 905-286-9894 877-747-8250 513-874-0714 877-884-3129 888-466-8266
sales@acetronic.com mpaquin@bizinfogroup.ca info@dynapurge.com info@ewikonusa.com sales@hamiltonpsl.com sales@imscompany.com www.jeccomposites.com ahoule@voyagelm.ca sales@lorenz.ca maagamericas@maag.com info@maguirecanada.com sales@niigon.com sales@pcs-company.com trodrigues@piovan.ca sales@ppe.com rpounds@poundsofplastic.com proheat@processheaters.ca salesusa@shepherdcolor.com ultrapurge@ultrapurge.com info@wittmann-canada.com
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www.lorenz.ca www.maag.com www.maguirecanada.com www.niigon.com www.pcs-company.com www.piovan.com www.ppe.com www.polyone.com www.poundsofplastic.com www.processheaters.ca http://speontario.com/ www.shepherdcolor.com www.ultrapurge.com www.wittmann-canada.com
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technology showcase
MATERIALS
CLICK ON...
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PLASTICS TV
New high-temperature resins for auto, wire, and cable moldings BASF has introduced two new high-temperature grades of its Elastollan TPUs. Designed for continuous use at 150°C in automotive and in wire and cable applications, Elastollan 785A10HPM is a high performance TPU meant to provide superior performance at high temperatures while exhibiting improved compression set, good surface reproducibility, and superior resistance to chemicals and fuels. This product’s multifaceted haptic possibilities range from velvety to leather-like and are available in several hardnesses. And a new low-smoke, halogen-free flame retardant Elastollan TPU is designed for high performance wire and cable applications. Elastollan 1185A10HFFR is a polyether-based TPU compound intended to complement the existing Elastollan FR TPU portfolio by providing FR solutions. It exhibits good abrasion resistance, toughness, low temperature flexibility, hydrolytic stability, and fungus resistance. BASF Canada (Mississauga, Ont.); www.basf.ca; 866-485-2273
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technical tips
IT AIN’T NECESSARILY SO –
Misbeliefs and elastic truths in extrusion By Allan Griff, consulting engineer I n the famous folk opera “Porgy and Bess”, a character named Sportin’ Life tries to shake up the way his people are living in Catfish Row by telling them, “It ain’t necessarily so.” In extrusion, as on Catfish Row, there are some beliefs that are often taken for granted but that aren’t always true. Here are a few of them, with explanations.
tion of these. Since we measure heat in calories or joules but pay electric bills by kilowatt-hours, it takes a little arithmetic to get a dollar figure in pounds or hours. You need to know that 0.001163 kWh = 1 kilocalorie, and 0.000278 kWh = 1 kilojoule. If you do this, even at 50 per cent efficiency it’s hard to use more than one cent ($0.01) per pound direct extrusion energy. With resin at a buck a pound or more, you see where the money is (and isn’t).
“Don’t mess with the profile.” The profile here refers to the temperature settings on the barrel, and maybe also the die, and the belief is that there is a “right” profile for certain materials and products, and anything else is going to cause trouble. There may be a preferred profile for any one operation, but it depends on the extruder, how fast it’s running, the material being used and its normal viscosity variation, the additives and inclusion of scrap, and the product being made. The problems with sticking to one profile include restricting the freedom to change rear barrel temperature alone (strong influence on intake into feed zone); also, it limits freedom to change barrel temperatures as may be needed if the material varies or screw rpm is changed for whatever reason. What to do? Start with some reasonable values based on experience and allow changes only for reasons entered in writing somewhere. Today’s computerized collecting of process data makes this easier, but it still has to be properly programmed.
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“The screw design is critical.” Not really, unless the original design was way off. Using downstream auxiliaries such as a static mixer, a gear pump, and an automatic screen changer will all make the exact screw design less critical. If there’s any doubt, get a computer simulation, where the problem will be getting good viscosity data for the material to be used, including variation with shear rate and temperature, and some idea of the variation of molecular weight in the resin grade, even at a fixed shear rate and temperature. Without these data, simulation is much less accurate. What to do? Get involved with the screw design — ask for process data (melt temperature, pressure, and amps) with your material type and machine size from whoever is deciding the screw dimensions, and perhaps get a simulation, before metal is cut.
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“Energy is expensive.” This one is easy. It takes a fixed amount of energy to heat a kilogram or a pound of plastic from feed temperature to extrusion temperature, and that’s that. The numbers are available on the Internet or from a slew of books. Extruders are quite efficient in converting electrical energy (motor, heaters) to heat the plastic as needed, and if too much heat is put in it spoils the extrusion, causing degraded plastic, cooling problems, sizing problems, additive interaction, or any combina30
“Worn machinery costs you money.” Sometimes. This is one of the elastic truths, because it is indeed possible, but you don’t have to take the screw out to find out. If you follow output per screw rpm, you’ll see when the pumping capacity has deteriorated enough to require faster screw speeds for the same output. There will be a blip every time screens are changed, but screws don’t wear in a week or two, and if such output/rpm data are collected long enough, the screen changing effect won’t matter. If the input is controlled in the rear by a feeder or feed zone conveying, wear up front won’t matter much. But even if the rpm has to be raised to hold production rate, it may not matter if the increased screw speed is possible and doesn’t cause product damage by overheating. Finally, don’t rebuild the screw without also measuring the barrel. Sometimes, the barrel has expanded or “crept” over time, and clearances are too large even with a new screw.
“Plastics are bad for the environment, and we must justify their use to conceal our guilt.” Absolutely not. This isn’t strictly an extrusion issue, but does affect a lot of extrusion and is such an important “ain’t necessarily so” that I have to include it here. Most plastics do the environment a lot of good — for example, by light-weighting products (saving fuel), and providing sanitary and water-resistant product protection and garbage containment. Nevertheless, the general public believes that there is something inherently bad with “chemical products” such as plastics. No matter that the polymers are nontoxic (even PVC) and harmless in the soil, nor that their recycling and even landfill disposal keeps carbon from returning to the atmosphere where it contributes to global warming. Plastics last forever? So do rocks. There are some exceptions, such as the degradable/compostable plastics and some additives. The plastophobes show pictures of dead birds and are honestly convinced that there must be something wrong with anything synthetic. Do they know how unnatural paper is? The heresy, if anywhere, is with the people who deny scientific and quantitative truth to support their fears. CPL Allan Griff is an independent consulting engineer and plastics extrusion expert based in El Cerrito, Calif. Visit www. griffex.com, or contact him directly at algriff@griffex.com.
Canadian Plastics October 2012 www.canplastics.com
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CPLOct12 p31 PPE AD.indd 31
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12-09-05 11:33 AM
a single polymer supplier could help you design for manufacturability and get to market faster? It can – when you work with PolyOne Distribution. Our healthcare specialists help you leverage the latest advances in polymer technology to find the right solution quickly. We work with you to optimize for manufacturability, speed your design cycle, and improve your bottom line. For answers to the biggest questions facing your business, visit http://healthcare.polyone.com/distribution. Make it possible.
Scan to learn more Š2012 PolyOne Corporation
CPLOct12 p32 Polyone AD.indd 32
12-09-05 11:34 AM