Canadian Plastics February 2016 by Annex Business Media

Canadian Plastics www.canplastics.com

FEBRUARY 2016

SPECIAL REPORTncy

ie Energy effic ical m in the che industry

Putting materials

TOGETHER » »

C o-injection technology isn’t just for niche markets anymore A re you ready for multi-material 3D printing?

Tips for better GRANULATION How to get the BEST PURGE for your money

UNIVERSAL GRAVO-PLAST is getting a reboot

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contents

Canadian Plastics FEBRUARY 2016 VOLUME 74 • NUMBER 1

LOOKING BACK...

The November 1995 issue of Canadian Plastics reported on two manufacturers that each won a 1995 Canada Export Award from the Department of Foreign Affairs and International Trade. Mississauga, Ont.-based plastic film equipment maker Macro Engineering received the award for having increased its export sales by 33 per cent over the past three years, with half of its business now coming from China. Montreal’s Wrebbit Inc. was the second award winner, having gotten the nod for the success of its PUZZ-3D full colour, three-dimensional plastic jigsaw puzzles, which were being exported into more than 65 countries.

Number of the month:

7,000*

* The ultra-low price tag, in U.S. dollars, of the new MultiFab 3D printer developed by the Massachusetts Institute of Technology. (See pg. 17)

in every issue 4 Editor’s View:

The gains and pains of falling oil prices 5 Ideas & Innovations:

Ceramic resin can be used to 3D print hypersonic jets. Really.

6 News: •S epro opens Canadian

subsidiary

•K raussMaffei sold to

•A lpha Poly Packaging buys

•S upplier News & People

ChemChina for $1 billion Mikia Printing 10 Executive’s Corner:

The right way to do a trade show 38 Technology Showcase 44 Classified Ads 44 Plastics Data File 44 Advertising Index 46 Technical Tips:

Maximizing the value of regrind

12 cover stories 12 INJECTION MOLDING: Co-injection goes mainstream After decades as a niche application, co-injection technology is finally moving to the forefront thanks to new processing equipment and better resins. But some challenges remain.

15 ADDITIVE MANUFACTURING: The multi-material future is here Multi-material 3D printers have arrived. But so have challenges to wide-scale adaptation, beginning with the machines’ hefty price tags.

features 19 SPECIAL REPORT: Energy efficiency in the chemical industry Energy costs are on the rise in Ontario, and chemical manufacturers are huge consumers. So now is definitely the time to get serious about finding new and efficient ways of using your electricity. Good thing there’s a wealth of experts and incentive programs available to help you out.

27 GRANULATORS: Improving the daily grind Understanding some of the basic errors in granulation can help you get the most out of your unit.

30 PURGING COMPOUNDS: Choose, use, measure Commercial purging compounds might be the most misused technology in all of plastics processing. But it doesn’t have to be this way. Adopting this three-step program will give you better results from your CPCs.

34 DOING IT BETTER: Universal Gravo-Plast is getting a reboot New ownership is reinventing a familiar fixture on Ontario’s plastics processing scene.

Visit us at www.canplastics.com www.canplastics.com February 2016 Canadian Plastics

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editor’s view

The gains and pains of falling oil prices

t’s a testament, I suppose, to the impressive scale and diversity of North America’s plastics industry that the same economic force that helps one part of it can hurt another. I’m talking about the price of crude oil, which has been on a downward dive for several years now due to the classic tale of supply/demand imbalance. New oil sources have contributed significantly to the global supply. In Canada and the U.S., companies are using techniques like fracking and horizontal drilling to extract oil from shale formations — a development that has helped turn the U.S. into the world’s biggest oil producer, overtaking Saudi Arabia and Russia. And the resumption of significant Libyan production is putting further downward pressure on the prices. At the same time, weak economic activities, along with a shift to cheaper and cleaner alternatives, have led to lower demand, particularly in Asia and Europe. The imbalance became structural in November 2015, when OPEC (Organization of Petroleum Exporting Countries) decided to maintain the current production output target of 30 million barrels a day. As a result, oil prices went into an even steeper free-fall and eventually hit a five-year low of US$53.60 a barrel in December. While falling oil prices have created mayhem for industries like energy, companies engaged in plastics production are huge beneficiaries. Resin is, of course, a derivative of oil, and makes up a major portion of the cost to produce plastic goods. Falling oil prices provide a cost tailwind, lower the transportation costs for the industry, and boost demand due to the increasing disposable income at the customer level. It’s a winning alignment of the planets that doesn’t happen very often in the manufacturing universe. 4

But not everyone in our industry has cause to celebrate. The same fall in oil prices that is so beneficial to the plastic product makers spells trouble for the recyclers, whose advantage is being erased as the price of virgin resin drops — in large part because the drop prompts many manufacturers to favour virgin plastic over the recycled alternative, since it’s easier to determine the exact chemical composition of virgin plastic. Indeed, the collapse in oil prices is pushing plastic recyclers towards the brink of disaster, the head of one of the world’s largest waste companies has warned. David Steiner, chief executive of Waste Management in Houston, one of North America’s largest waste collectors and processors by volume, recently told the Financial Times that the oil rout had followed a fall in Chinese demand for recycled products that was already troubling the industry. “We’ve had a double whammy in the last six months: Chinese demand hasn’t picked up and oil prices have come way down,” Steiner said. Waste Management is now shuttering recycling plants, and it’s not alone: two large German recyclers have gone bankrupt since December 2014; and ECO Plastics Ltd., a British firm that touted in 2012 the opening of what it called “the world’s largest plastics processing facility,” recently went into administration, a form of bankruptcy. Especially hard hit are the middlemen of the plastics recycling supply chain, who buy used bottles and postconsumer items and then sort, bale, and sell the recyclables. Prices middlemen get when reselling some types of plastic have plummeted by as much as 50 per cent in just a few months. As I opined at the outset, only a massively important industry sector could be large enough to have factions that are helped and hurt by the same economic force. But that’s cold comfort to the recyclers, no doubt. Mark Stephen, editor mstephen@canplastics.com

Canadian Plastics magazine reports on and interprets developments in plastics markets and technologies worldwide for plastics processors, moldmakers and end-users based in Canada.

www.canplastics.com EDITOR Mark Stephen 416-510-5110 Fax: 416-510-5134 mstephen@canplastics.com ART DIRECTOR Andrea M. Smith ACCOUNT COORDINATOR Cheryl Fisher 416-510-5194 cfisher@annexnewcom.ca PUBLISHER Greg Paliouras 416-510-5124 Fax: 416-510-5134 gpaliouras@canplastics.com CIRCULATION MANAGER Anita Madden 416-442-5600, ext. 3596 Fax: 416-510-6875 amadden@annexnewcom.ca VICE PRESIDENT ANNEX BUSINESS MEDIA EAST Tim Dimopolous 416-510-5100 tdimopoulos@canadianmanufacturing.com PRESIDENT & CEO Mike Fredericks mfredericks@annexweb.com 80 Valleybrook Drive, Toronto ON, M3B 2S9 416-442-5600, Fax: 416-510-5134 CANADIAN PLASTICS is published 7 times a year by Annex Business Media. 2016 SUBSCRIPTION RATES 6 issues Canadian Plastics, plus Dec. 2017 Buyer’s Guide: CANADA: 1 Year $71.95 plus applicable taxes; 2 Years $117.95+ taxes; single copy $10.00+ taxes. USA: US$81.95/year FOREIGN: US$126.95/year Buyers’ Guide 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, 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 Greg Paliouras, 416-510-5124. For reprints call RSiCopyright, Michelle Hegland, msh@rsicopyright.com PAP Registration No. 11035 CANADA POST – Publications Mail Agreement No. 40065710. 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 of the Department of Canadian Heritage.

Canadian Plastics February 2016 www.canplastics.com

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ideas & innovations

Photo Credit: HRL Laboratories LLC.

Ceramic resin can be used to 3D print hypersonic jets. Really.

An image shows HRL Laboratories’s 3D printed ceramic able to withstand extreme heat.

D printing is almost as popular these days as Black Friday shopping. Except in the world of ceramics. To date, ceramic is generally 3D printed by sintering powder materials that result in porous, relatively weak end products with low heat resistance, which greatly limits the size and shape of objects that can be printed. Which is why 3D printed ceramic objects have so far been limited to relatively small decorative items or tableware. But that might just change, thanks to a new material developed by Malibu, Calif.-based research and development company HRL Laboratories LLC. HRL, which is owned by Boeing and General Motors, has developed a ceramic resin that can be printed through stereolithography — one of the oldest methods of 3D printing, in which a uniquely designed 3D printing machine, called a stereolithograph apparatus, converts liquid plastic into solid objects. The company actually calls the material a “pre-ceramic” resin that prints like a typical plastic resin, and is then fired in a high temperature kiln, which turns it into a dense ceramic. The resulting objects are said to be ten times stronger than other 3D printed ceramics, have virtually no porosity, and can withstand temperatures beyond a whopping 1,700°C. The first tests of the new material mark the first time that silicon carbide ceramics have ever been 3D printed, HRL said. The material — which was created by senior chemical engineer Zak Eckel and senior chemist Dr. Chaoyin Zhou — can also be altered to produce a multitude of ceramics by tweaking the chemical makeup of the resin, the company added. The potential implications of the new ceramic resin are huge, HRL said, beginning with the fact that it could be used

for currently off-limits applications like aerospace parts. Traditional ceramics have been used in aerospace manufacturing for a long time; they’re ideal because of their light weight, high strength, and resistance to heat. Traditional 3D printed ceramics are lacking in exactly those qualities, but now that HRL has found a way around those limitations, the door to use 3D printed ceramic in jet engines — and even the entire bodies of jets — has just been kicked wide open. And as good a fit as traditionally manufactured ceramics are for aerospace parts, the new material might just go one better. Traditional ceramics are — and always have been — difficult to machine or cast, which limits their possible sizes and shapes. 3D printed ceramics, however, can be manufactured in any shape or size. In addition to printing large components such as jet engines, HRL expects that the ceramic resin can also be used for tiny, complex applications like microelectromechanical systems and electronic device packaging. CPL

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www.canplastics.com February 2016 Canadian Plastics

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news

SEPRO OPENS CANADIAN SUBSIDIARY

all it a blend of red wine and cold beer: France-based robot and automation maker Sepro Group has come to Canada. On January 1, Sepro’s Canadian daughter company, Sepro Canada Inc., officially opened its doors in Montreal. With 20-year manufacturing industry veteran Firaz Sharaf as its national sales manager, Sepro Canada is the latest in a long line of Sepro daughter companies. Founded in 1973, Sepro created the first three of its subsidiaries in 1990: Sepro Germany, Sepro United Kingdom, and Sepro Spain. Sepro America was established in 2007 and is located in Warrendale, Pa., just north of Pittsburgh. Other daughter companies are located in Benelux, Mexico, Brazil, and China. “Establishing a Canadian company is the final stage of our three-step process of creating a complete North American footprint,” said Jim Healy, vice president of sales and marketing at Sepro America. “Sepro has now had three consecutive years of record sales, and Canada has been a part of that success. We believe it’s time for this investment. Our intention has always been to be number one in North America, and this is the next step.” The Canadian daughter company will run in parallel with Sepro America, which has managed activities in Canada until this year. Prior to the founding of Sepro Canada, sales of Sepro robots and automation in Canada were handled by representatives Dier International, headed by Greg Reid and located in Unionville, Ont.; and Industries Lafer-

riere, managed by Francois Laferriere and headquartered in Mascouche, Que. Sharaf will now manage their activities. “We’ll continue to work with our Canadian sales reps moving forward, but it’s important to us to have a physical presence in the country, and to have Sepro Canada as a separate entity that can provide oneone-one sales and service,” Healy said. With no immediate plans for assembly of automation systems in the Montreal office, Sepro Canada’s prime Firaz Sharaf directives are sales, parts supply, and Photo Credit: Sepro America LLC service. “Sepro Canada already has one technical service agent based in Toronto, and we’re planning to add a second in the near future,” Sharaf said. “Between the technician and myself, we can be in instant contact with our customers in Canada; and Sepro America is also maintaining its existing 24/7 hotline to the U.S., so our Canadian customers have an additional layer of support.” The entire Sepro lineup of 3-, 5-, and 6-axis robots, as well as side-entry robots and sprue pickers, is available through Sepro Canada, Sharaf added. Sepro Canada is located at 1010 Rue De La Gauchetiere Ouest, unit 1230, Montreal, Que., H3B 2N2. The company can be reached at 514-515-9349 (phone), and 412-459-0470 (fax). CPL

KRAUSSMAFFEI SOLD TO CHEMCHINA FOR $1 BILLION

oronto-based private equity firm Onex Group has sold KraussMaffei Group, a major global plastics machinery maker headquartered in Munich, Germany, to state-owned China National Chemical Corporation for 925 million euros (US$1 billion). Onex bought KraussMaffei from U.S. investor firm Madison Capital in 2012 in a 568 million euro deal. China National Chemical Corporation — called ChemChina for short — supplies agrochemicals, rubber products, chemical materials and specialty chemicals, industrial equipment, and petrochemical processing. Founded in 2004, the Beijing-based company is said to be China’s largest chemicals group, having generated revenues of around 37 billion euros in 2015 with approximately 140,000 employees, of whom 45,000 are located outside China. The company claims to be China’s largest exporter of rubber machin6

ery, and is also one of China’s most active investors abroad. Its most recent acquisition was the high-end tire manufacturer Pirelli for $7.7 billion in 2015. In a statement, KraussMaffei said it will continue to operate in its current corporate structure, that its headquarters will remain in Munich, and that the operating and corporate responsibility for the company will stay in Europe. “We expect that KraussMaffei Group will maintain its identity and independence,” said Jianxin Ren, chairman of ChemChina. “The growth potential of the KraussMaffei Group is tremendous, especially through improved access to the Chinese market, which we can make possible. We expect trends in the automotive industry towards advanced manufacturing and lightweight components will provide a huge development opportunity for the high-end plastic injection molding industry.”

From left: Ting Cai, chairman and CEO of China National Chemical Equipment Co. Ltd.; Frank Stieler, CEO of KraussMaffei Group; and Chen Junwei, CEO of the ChemChina Finance Co. Ltd. Photo Credit: KraussMaffei and ChemChina

In 2014, KraussMaffei — which employs approximately 4,500 employees globally — generated revenues of approximately 1.1 billion euros, and is expected to achieve year-on-year revenue growth of approximately 10 per cent for 2015. The sale of KraussMaffei is expected to close in the first half of 2016. CPL

Canadian Plastics February 2016 www.canplastics.com

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news

ALPHA POLY PACKAGING BUYS MIKIA PRINTING

SUPPLIER NEWS Uxbridge, Ont.-based equipment sales firm Shadow Automation is the new representative for Vulcan Hot Runner Controls in Ontario. Headquartered in El Paso, Tex., Vulcan manufactures hot runner controls from 1- and 2-zone units up to 48-zone units. Headed by Larry Bonehill, Shadow Automation also represents Haitian injection molding machines, Absolute Robots, and Zerma Granulators.

lastic bag maker Alpha Poly Packaging Solutions, of Brampton, Ont., has boosted its flexible packaging printing business with the acquisition of lithographic printer Mikia Printing of Acton, Ont. While the specific terms of the arrangement have not been disclosed, Mikia leadership, staff, and supply chain joined the Alpha Poly team effective February 2016, Alpha Poly said in a statement. “This is a perfect fit for Mikia, and a giant leap forward for Mikia’s customers, who will immediately benefit from our combined skill set and cost efficiencies,” said Mikia president Vaughan Campbell. Campbell will remain with the new organization as sales lead/technical support. Mikia was founded in 2001. “Adding Vaughan Campbell and his Mikia staff bring a whole new dimension to our growing team that will benefit all of our customers” said Alpha Poly president Patrick Kerrigan. “Both companies have strong reputations built on quality and service, and our combined expertise and scale efficiencies will position us for continued exponential growth.” The companies have a combined client base that consists of Canada, the U.S., and the Caribbean, Kerrigan added. CPL

HUSKY MAKES BIG APPOINTMENTS

Jack Truong

Randal Levine

Stefano Mirti

Husky Injection Molding Systems Ltd. has already made a slew of appointments in the new year of 2016, the biggest of which is naming the former head of Electrolux North America as its new president and chief operating officer. Jack Truong took the executive position at Bolton, Ont.based Husky in February. Truong was previously president and CEO of Electrolux North America, as well as executive vice president of the parent company, Swedish appliance manufacturer AB Electrolux. Before working at Electrolux, Truong had a 22-year career at 3M, where he held senior leadership positions throughout the U.S., Europe, and Asia-Pacific. Truong will have complete oversight for the day-to-day operations of Husky’s global business, Husky said, and will have leadership responsibility for executing the company’s strategy and priorities. In the past two months, Husky has also named Randal Levine as its vice president, finance and chief finance officer; and Stefano Mirti as president of its hot runners and controllers business. CPL

PEOPLE Shashi Caan

Leon Desrocher

Bob Milojevic

John Haller

Nathaniel Leonard

– Techmer PM, a Clinton, Tenn.-based manufacturer of colours and additives, has named Shashi Caan as its design and innovation lead. – Mississauga, Ont.-based material distribution company Pounds of Plastic Inc. has added Leon Desrocher and Bob Milojevic to its sales team. – Carolina Color Corporation, a Delaware, Ohio-based maker of colour concentrates, has named John Haller as director of sales. –S mithers Rapra, an Akron, Ohio-based testing equipment maker, has named Nathaniel Leonard as its president, and

James Popio

Steve London

Gary Carr

Robert Malburg

Steve Maxson

James Popio as its vice president, North America. – Williamston, Mich.-based blow molding machine maker Bekum America Corporation has named Steve London as its president and chief operating officer, and Gary Carr as its vice president of sales. – Liquid colour and additive maker Riverdale Global, headquartered in Aston, Pa., has named Robert Malburg as its new vice president of sales. – York, Pa.-based Graham Engineering Corporation has named Steve Maxson as the global director of business development for its medical division.

Canadian Plastics February 2016 www.canplastics.com

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executive’s corner

The right way to do a trade show By Russell Trahan, PR/PR Public Relations

he year 2016 will be a big one for plastics industry trade shows: PlastImagen Mexico in March, Chinaplas in April, and the K show in October, to name just a few. Industry-specific trade shows are crucial for business networking. But they can also be chaotic enough to overload your senses once you actually hit the show floor. Which is why you should have a plan in place before you arrive, and stick to it during the show and in the weeks of follow-up afterwards.

THE TRADE SHOW STARTS BEFORE TAKEOFF There’s no doubt that a loose-fitting outfit and an early-morning mimosa or two can take away travel-related irritations, but if you arrive at the airport in track pants and a T-shirt with a head full of bubbly, you’ve already started your trade show off on the wrong foot. From the moment you leave your front door, you’re in the world of the show. Every interaction at the terminal should be

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treated as potential business, and this means dressing and acting as professionally as you would on a sales call. Because you never know who you’ll run into at the airport or on the flight.

GET SERIOUS ABOUT YOUR BOOTH For many companies, a large portion of time and money is dedicated to the trade show booth. While investing in a sponsorship that involves a booth setup in the exhibit area can prove costly, it can also prove lucrative by giving your company a physical presence throughout the show, exponentially increasing your visibility. Curiosity will often bring attendees to your booth, so make sure it’s managed by your ablest staff members. Arrive early each day to make sure everything is in working order by the time the convention opens; and also create a schedule with time off for one-on-one meetings with any potential clients.

DELIVER A WORKSHOP An excellent way to create some buzz around the trade show is to deliver a presentation or workshop, and if this opportunity is available, you should take it. Attendees can read about your expertise or services until their eyes bleed, but there’s no better way to get your ideas across than delivering a presentation. But remember, these workshops should be contentdriven and informational, not advertorials.

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You return home exhausted from multiple days of booth duty and/or walking the floor and networking, but the real work is just beginning. It seems like a simple concept — follow-up — but it’s surprising how many people don’t do it. Potential customers may have met you at the show but they also met your competition, so phone and /or email your new contacts ASAP and let them know how much you appreciated their time during such a busy event, and offer dates and times to continue your conversation. Waiting for them to contact you won’t cut it. Regardless of your status in Canada’s plastics industry, your 2016 calendar should already be highlighted with the dates of the trade shows you’re planning to attend. Even in the Internet Age, attending/exhibiting/networking at a trade show remains an excellent way to boost your company’s profile. CPL Russell Trahan is president of PR/PR Public Relations, an Orlando, Fla.-based agency specializing in positioning clients in front of their target audience in print and online. For more information, visit www.prpr.net.

Canadian Plastics February 2016 www.canplastics.com

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cover story

CO-INJECT goes View of Wittmann Battenfeld’s MacroPower sandwich machine’s injection units from above. Photo Credit: Wittmann Battenfeld

By Mark Stephen, editor

After decades as a niche application, co-injection technology is finally moving into the spotlight thanks to new processing equipment and better resins. But some challenges remain.

f you’re big into something, it’s always nice to see it go from marginal to mainstream. Supporters of Canada’s Liberal Party now know what that feels like. And so do suppliers of co-injection molding technology. Also called sandwich molding, coinjection uses a specially designed nozzle to simultaneously inject two materials into a mold through a single gate so that one completely encapsulates the other in a multi-layer structure. The process isn’t exactly new: it’s been around for decades, and was usually focused on highly specialized niche applications like medical vials, ketchup containers, and stadium beer bottles; or parts with large wall thicknesses like covers or housings. Which was a shame, because co-injection technology for manufacturing sandwich-built components meets a variety of requirements very well. For example, inexpensive filler material or regenerated material can be used for the component’s core to keep the unit costs down, while maintaining consistently high surface quality. Despite these benefits, co-injection remained a niche technology for a couple of reasons. The first was economic: The highly specialized, dedicated capital equipment often cost 50 to 100 per cent more than a traditional injection molding machine. And second, material selection for co-injection is critical, since the core and skin material must shrink and expand at the same rate and be compatible, and resins that were up to the technical challenge could be hard 12

MAINSTR

to come by. But that was then. Today, there are new solutions coming on the market that allow molders to create co-injection systems at a far more reasonable cost because they are now able to use their existing machines and standard molds for the solution; and a new generation of resins are more co-injection-friendly. And these advancements are opening up a number of new target markets that can benefit from co-injection technology.

PACKAGING POTENTIALS The biggest of these markets is food and beverage packaging, in particular multilayer containers — markets that have traditionally been served by glass, can, and multi-layer thermoforming products. “Basically, any food or beverage product that requires a package with enhanced barrier properties can benefit from co-injection,” said Clive Toomey, barrier systems product manager with Husky Injection Molding Systems Ltd. “Many of our customers are exploring co-injection for oxygen-sensitive products such as ketchup and carbonated drinks, particularly small formats under 400 ml and light-sensitive products such as UHT milk.” PET perform beverage applications in particular can benefit from the process. ”A co-injection molded multi-layer PET container can offer as much as 60 times the oxygen barrier performance of a monolayer PET container, which greatly improves shelf life,” a 2014 paper by co-injection machine maker

Kortec — now Milacron Co-injection — said. In one of the bigger developments to come out of the NPE2015 trade show in Orlando, Fla. last year, Husky unveiled a new barrier co-injection technology for PET performs built on its HyPET HPP5 platform, meaning there are minimal requirements for special tooling or equipment. According to Husky, the system includes a multichannel co-injection nozzle, small sidemounted secondary injection unit, and the mold with hot runner system; and can produce multi-layer preforms with a wide range of barrier content, even below 3 per cent, while delivering up to 50 per cent savings on barrier material costs for some applications and increasing system availability. And since packages can be blown and filled on existing lines, Husky’s barrier technology is a drop-in solution that still benefits from all future advancements to the HyPET HPP technology. After PET performs, PP performs for food and barrier thin-wall containers for food are also obvious targets for coinjection molding. “The three-layer thinwall injection molded containers are constructed of an EVOH barrier layer between two layers of PP, without the typical adhesive layers used in extrusionbased blow molded or thermoformed containers, which typically end up as a five- to seven-layer structure,” the Kortec paper said. “An adhesion promoter is added to the skin layers to prevent delamination, and the PP can be a clarified grade for clear containers if desired.”

Canadian Plastics February 2016 www.canplastics.com

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cover story

CTION

TREAM

Co-injection molded multi-layer containers, meanwhile, can be produced with the same cycle times as traditional monolayer containers. “Besides the obvious advantages these containers offer over glass and metal packages, the injection molded containers provide higher quality, faster line fill speeds, better partto-part consistency, and longer product shelf life,” the Kortec paper continued. Along with Husky, processing machinery maker Milacron also unveiled a new co-injection method for product packaging at NPE2015. Milacron has bet heavy on co-injection technology over the last few years, buying E-Multi sup-

MACHINERY STEPS UP At the NPE show, Milacron manufactured Klear Cans in a four-cavity work cell that featured the company’s new Ferromatik 580 co-injection machine. The Ferromatik 580 isn’t just for coinjection molding; it can also be built in single- or multi-component, mono-sandwich, and cube machine form with electric, hydraulic, and hybrid drive options. And that’s the point: Expensive dedicated machines are no longer necessary to get in the co-injection game, since processors now have the option of using existing machines for the solution. “The transition to the co-injection process from existing injection molding equipment is not difficult,” said Shih-Po Sun, a division manager at injection molding simulation software provider Moldex3D. “The challenge lies in optimizing part design and processing conditions to achieve desired material distribution.” As noted above, Husky’s new barrier co-injection technology for PET performs is built on its existing HyPET HPP5 platform. In another example, Engel’s tiebar-less victory injection

Milacron’s Klear Can co-injection molded application is designed to replicate the benefits of airtight metal or glass cans in a plastic container by placing a thin barrier inside the container’s core. Photo Credit: Milacron

plier Mold-Masters, of Georgetown, Ont.; and the aforementioned Kortec/ Milacron Co-injection. Milacron’s new Klear Can co-injection molded application, shown at the show, is designed to replicate the benefits of airtight metal or glass cans in a plastic container by placing a thin barrier inside the container’s core. “While this barrier is less than 0.001-inches thick, it covers more than 99 per cent of the part and can be controlled precisely in up to 96-cavity molds,” Milacron said.

molding machines are suitable for coinjection as well as a variety of other applications, including the company’s “combimelt” and “foammelt” processes. And Wittmann Battenfeld’s MacroPower injection molding machine offers similar flexibility. “Because of the arrangement of its injection units in Y-configuration, our MacroPower unit can be used for sandwich molding with a few simple adaptations,” said Edmund Kirsch, regional sales manager with Wittmann Battenfeld. “Other adapta-

tions allow for one-component and twocomponent molding.” The main adaptation for any coinjection process involves hot runners, which are crucial to the technology. “The hot runner design and process control are the single most important elements to consistently producing high quality co-injection parts, since they have to manage the timing of the process to simultaneously inject two materials within the same cycle time,” said Clive Toomey. And without a very balanced fill profile in all cavities, the experts say, co-injection technology will be limited to small cavitation applications. Which is why a specialized nozzle design is required. Another reason for co-injection coming into the spotlight lately is that the machines are also processing resins that are better suited to the technology than previous generations of materials. For example, barrier resins (typically EVOH and nylon) have evolved over time to be more stable and more compatible with skin resins such as PP, HDPE, PET, and PC. “Also, new adhesives have been developed to help bond the dissimilar skin and barrier resins,” said Edmund Kirsch. “These have addressed one of the main issues in the past: problems relating to adhesion between the layers.” But that’s not to say there aren’t still limitations. “Two materials can only be processed successfully by co-injection molding if their processing properties match,” said Shih-Po Sun. “Studies have suggested that the core/skin viscosity ratio should be between 0.5 and 5. Lower viscosity ratios would lead to breakthrough of the core material, while higher viscosity ratios would lead to poor mold filling, finger-like defects, and a variable core thickness through the part.”

AT YOUR SERVICE As a result of the growing acceptance of the process, there’s now a wide range of accessories aimed squarely at co-injection molders. Milacron, for example, recently began offering Co-Injection Connect, a suite of services, including consulting, for clients interested in co-

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injection technology. And Moldex3D profile is the enemy, which is why the provides a modeling tool specifically for experts recommend having no drastic co-injection, designed to solve what the changes in wall sections along the flow company calls the main challenge fac- path. “Also, thin-wall sections can be ing co-injection molders: determining more challenging for co-injection,” the optimal ratio of skin material to core said Clive Toomey. But don’t bet on material. “The software tracks interface those being challenges for long. “For shape and distribution of individual all the applications we have tested to components at any time and location in date, we’ve been able to achieve suca cavity, evaluates the flow front pattern cess by adjusting various processing to aid in part design and gate placement, parameters, such as injection prespredicts the penetration of the core sures, temperatures, and fill rates,” material and the skin breakthrough Toomey added. Also, there are product types that point, determines injection pressure and clamping force for proper molding simply don’t need to be co-injection machine selection, and detects potential molded. “Not all food and beverage defective locations with high tempera- applications require or benefit from a multi-layer package,” Toomey continture and stress,” said Shih-Po Sun. The Moldex3D software points to ued. “For many, a mono-layer package perhaps the last limitation to the tech- is sufficient.” With costs coming down and ever nology: the simple fact that some part designs are more successful for co- more solutions available to help molders injection than others. Not surprisingly, incorporate the process within their curoperations, anything that affects the barrier 1filling 01-7523-CanadianAd-FINAL_Layout 1/15/16 rent 9:56 AM Page 1 the mainstreaming of

co-injection technology seems certain to continue. “Co-injection integrates rigid and flexible components into a single molded structure with a single step, and also provides the ideal material combination of soft skin and hard core to meet design criteria,” Shih-Po Sun said. “For these reasons, it will keep gaining acceptance.” And gaining acceptance is rewarding. Just ask the Liberals. CPL RESOURCE LIST Engel Canada (Waterloo, Ont.); www.engelglobal.com/na; 519-725-8488 Husky Injection Molding Systems Ltd. (Bolton, Ont.); www.husky.com; 905-951-5000 Milacron Canada Corporation (Burlington, Ont.); www.milacron.com; 888-254-1919 Moldex3D Northern America Inc. (Farmington Hills, Mich.); www.moldex3d.com; 248-946-4570 Compuplast (Mississauga, Ont.); www.compuplast.ca; 905-814-8923 Wittmann Canada Inc. (Richmond Hill, Ont.); www.wittmann-canada.com; 905-887-5355

Introducing Sepro Canada The only supplier of robots for plastics injection molders with Canada in its name! Since 2007, we’ve served Canadian molders through our subsidiary, Sepro America, which is based near Pittsburgh, PA. Today however – as of January 1 – we’ve made an even stronger commitment to Canada with the formation of a new, wholly-owned daughter company – Sepro Canada. Firaz Sharaf, Canada Sales Manager, supports the ongoing activities of two independent sales representative organizations: Dier International Industries Laferriere Unionville, Ontario Mascouche, Québec 416.219.0509 450.477.8880 Local technical service is available and our parts and service hotline can be reached 24/7/365. 1 514 515-9349 www.sepro-group.com www.sepro-group.com/FR

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For your free, Canadian choice in robots for injection molding -including 3-, 5- and 6-axis robots, driven by one universal control platform – contact Sepro Canada.

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The

Multi-Material

FUTURE is here

Multi-material 3D printers have arrived. But so have challenges to wide-scale adaptation, beginning with the machines’ hefty price tags.

ow revolutionary is 3D printing for the manufacturing world? Potentially as game-changing as Neil Armstrong stepping onto the Moon was for NASA. By enabling a machine to produce objects of any shape, on the spot and as needed, 3D printing is ushering in a genuinely new era. And it’s happening fast. The process was actually invented back in the early 1980s, and languished for the better part of two decades before going mainstream 10 years ago. Since then, there seems to be no stopping it. The technology has captured the popular imagination, and 3D printers have evolved to the point where they can now use all kinds of materials, including plastics, chemicals, rubber, metals, ceramics, sugar, wax, and even living cells. It means designers can progress rapidly from concept to final product. But if the process has an Achilles Heel, it’s this: Most machines are still limited to a single-material build, which has set a limitation on the technology when many finished products today require multiple materials. But that’s about to change. Innovators in the field are beginning to release multimaterial 3D printers, capable of producing parts with complex and variable properties.

By Mark Stephen, editor

SAVING STEPS

At its most basic, multi-material 3D printing lets the user combine two or three base resins in a single print job to simulate overmolding, generate three-material prototypes, or produce trays of assorted parts in a single print job. With more advanced systems, software combines even more materials in specified concentrations and microstructures to produce digital materials with varying translucency, rigidity, thermal resistance or colour. Multi-material 3D printing will impact the general population by allowing mass customization of personalized products. On the industry level, meanwhile, there are good reasons for manufacturers — in particular plastics processors — to get excited. “For rapid prototyping and concept modeling, multi-material 3D printing helps you communicate ideas more clearly and identify design problems earlier,” 3D printing machine maker Stratasys noted in a recent technical paper. “Because additional steps like painting, post-curing, and assembly can often be eliminated, you reduce the time and cost of prototyping — and ultimately shorten your product development cycle.” Production manufacturers, meanwhile, can further compress the product development cycle by producing multi-material tooling, patterns, molds, jigs, and fixtures, the company continued. “And printing multiple parts and properties on a single build tray also means the user will spend less time changing materials and loading parts, making the entire operation more productive,” Stratasys said. Stratasys released its first multi-material 3D printer way back in 2007. Its latest offering, the Objet500 Connex3 system, is capable of working with 14 different base materials, the company said, allowing for hundreds of two- and three-component mixes that offer a range of property variations with colour, bioAll of these coloured, multi-material parts were built in one job on compatibility, rigidity, thermal resistance, and optical Stratasys’s Objet 500 Connex3 printer. Photo Credit: Stratasys www.canplastics.com February 2016 Canadian Plastics

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level. “In a single build, the machines are able to mix three different base resins in pre-set configurations that can produce up to 82 different material properties,” Stratasys said. Other printer makers are following suit. Hewlett-Packard plans to release the new Multi Jet Fusion technology later this year, capable of employing various materials across a given object, point-by-point, at the level of the volumetric pixel. According to Hewlett-Packard, its technology will be able to produce variable mechanical and physical properties, including opacity and translucence, texture, strength and elasticity, colour, and electrical and thermal conductivity. Hewlett-Packard will start with thermoplastics, but the company said it intends to expand into ceramics and metals.

THE PRICE ISN’T RIGHT This isn’t to say there aren’t still drawbacks. Current multimaterial 3D printing systems have a couple of shortcomings, beginning with price. A Stratasys Objet500 Connex3 printer costs up to $250,000, for example, with materials priced at $500 per kilogram. Massachusetts Institute of Technology researcher Javier

COLOUR YOUR WORLD

Ramos put his finger on a second limitation in a 2015 technical paper. “The hardware and software architectures for current multi-material 3D printers are proprietary and inextensible,” he wrote. “The exposed input file format, made of separate STL files for each material, is limiting; and any changes to the underlying hardware and software are virtually impossible.” Third — and as with traditional 3D printing — multimaterial printing is slow. The slow speed is inherent to the 3D printing process, alas, because it makes a product one layer at a time — which means it’s not a problem that’s going to be solved anytime soon. These are still very early days for multi-material 3D printing, of course, and — with the possible exception of the slowness of the process — it’s unlikely that today’s technical hurdles will remain hurdles for long. So don’t be too surprised if the far-ranging potentialities of the technology — allowing users to fabricate materials with combinations of density, strength, and thermal expansion that don’t exist yet — might just further revolutionize the manufacturing sector. Neil Armstrong would understand. CPL

A new, extended materials portfolio makes multi-colour, multi-material 3D printing more realistic.

designers to validate designs and reduce the cost of tooling, It took decades for Hollywood to transition from black and slashing the development cycle and the time it takes to bring white films to colour; the 3D printing industry is moving a a product to market,” Fischer said. lot faster. The range of colour options now spans from transparent Case in point: Stratasys has extended its range of to opaque in a wide range of Shore A values. The new materials for the Objet500 Connex3 multi-material, colour options are comprised of six rubber material palmulti-colour 3D printer. The machine can now print ettes, including three flexible 72-colour palettes, comwith hundreds of new rubber-like colour materials posed of rubber-like (TangoPlus) and combinations of and numerous rigid material combinations in just rigid opaque (VeroCyan, VeroMagenta and one print run. VeroYellow) materials; three flexible 68-colour “The ability to mix rigid, flexible, transpalettes, built with rubber-like (TangoBlackPparent, and opaque colours offers users lus) and combinations of the same rigid unprecedented versatility to design and opaque (Vero) colours; three 45-colour perfect products faster,” said Stratasys rigid grey palettes, each of which comdirector of materials and applications bines rigid VeroWhite and VeroBlack Fred Fischer. “By extending the range with colours; and one 45-hue grey of material options available, users palette, with varying levels of transcan improve workflow speeds and lucency, and which includes a enhance efficiency.” reflective luster for the producThe new colour options can tion of sleek, high-quality help users create medical, autoparts for products such as motive, and consumer products consumer electronics. in grey along with vibrant The new flexible colour colour components, while options are available immedithe production of products ately to Objet500 Connex3 colour multican be completed without material 3D printer owners through a free the need for manual assemThe Cyan/Magenta/Yellow palette. software update. bly. “This allows product CPL Photo Credit: Stratasys 16

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WAIT – A MULTI-MATERIAL 3D PRINTER THAT ISN’T RIDICULOUSLY EXPENSIVE?!

Despite all the hype, 3D printers haven’t yet become a staple of the manufacturing world — in large part because the cost of these systems has hindered their wide-scale use. But that might change. Researchers from the Computer Science and Artificial Intelligence Laboratory at the Massachusetts Institute of Technology (MIT) have developed the new MultiFab 3D printer, a relatively inexpensive machine that can print up to 10 different materials simultaneously onto a single object. How inexpensive? It costs US$7,000, compared to a cool quarter-million for commercially available multi-material 3D printers. In addition to the low price, the MIT scientists and engineers were able to design a system with significant improvements over existing technologies. A single CPU is in charge of all the printer subsystems, which include a positioning subsystem (with X, Y, and Z axes), a material feeding subsystem, printhead modules, and UV-curing modules. The system relies on inkjet printer technology, with the printhead module containing five channels, each of which can

nte

e res

house different materials. The system also has a real-time 3D scanning module, a significant new feature that allows every layer to be scanned as it’s printed, enabling the ability to generate correction data if necessary. After correction, the average error is only 5μm. The platform is run using an application called Fabricator, which receives input in a multi-material voxel format and then processes the information from the bottom up in a layer-by-layer fashion. The Fabricator is able to control the material loading, droplet sequence, and size at each printhead nozzle, positioning module, and UV-curing module. The platform also uses a software technology known as machine vision, which controls the 3D scanner, a 2D camera, and the other hardware. The platform can currently print up to 10 different materials that can interact optically and mechanically. The system’s material library currently includes rigid, elastic, high refractive index, and low refractive index materials, and the MIT team expects to expand that library in the near future. CPL

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n Ca

The MultiFab multi-material 3D printer.

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THE

ENERGY-EFFICIENT

CHEMICAL SUPPLIER

ÂŠAnson_iStock/Getty Images/Thinkstock

(And How To Become One)

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Energy Efficiency in the Chemical Industry Brought to you by the Independent Electricity System Operator and your local electric utility.

A NEW WAY OF THINKING ABOUT ENERGY EFFICIENCY Conventional wisdom used to be that increased demand for electricity was a great indicator of economic growth. The logic was simple — the more we produce, the more energy we must need. Not anymore. Today, businesses throughout Ontario have embraced energy efficiency as a key to greater competitiveness. For them, using less energy actually powers new business opportunities. Between 2011 and 2014, Save On Energy business programs saved 4,077 GWh of energy and 389 MW of demand in the province. With energy efficiency, businesses can realize substantial energy savings, but also improve their cost structures, processes and overall competitiveness. Some businesses see improved employee engagement, for others it means reinforcing ties with their community, and for others still, it translates into a better customer experience. And perhaps most of all, many value the opportunity to contribute to the health and well-being of their communities by using energy wisely. To help businesses continue to move forward toward greater efficiency and competitiveness, the province has introduced a new approach that puts energy efficiency ahead of all other supply options. This approach, “Conservation First”, is designed to take us to the next level of energy savings. With ambitious new energy reduction targets in place, the bar is set higher now than it’s ever been. Save On Energy programs delivered by local electric utilities have been re-designed to ensure that, together, businesses can meet provincial goals while at the same time reaping the rewards of sound internal energy management practices. Looking ahead, there will be even greater opportunities for businesses to reduce their overhead through retrofits, energy audits, lighting and equipment upgrades. This publication will help you find ways to take advantage of the many benefits of using energy wisely. In reading about different approaches to energy management, and business leaders’ determination to turn great ideas into great results, perhaps you’ll find the inspiration to do the same. To find out more about what energy efficiency can do for your business, visit saveonenergy.ca or contact your local electric utility (ieso.ca/findutility). Terry Young Vice-President, Conservation and Corporate Relations Independent Electricity System Operator

Energy costs are on the rise in Ontario, and chemical manufacturers are huge consumers. So now is definitely the time to get serious about finding new and efficient ways of using your electricity. The good news? There’s a wealth of experts and incentive programs at hand to help you along. By Mark Stephen

esin is the lifeblood of the plastics industry, and electricity is the lifeblood of the chemical facilities that manufacture it. Now picture having to pay an everhigher bill for your blood: That’s how it feels to be a chemical supplier in 2016. Why? Unless you hit the snooze button about five years ago and never woke back up, you’re probably aware of a constant and growing din of noise from all business segments in Ontario about the high price of electricity and its effects. Energy costs have always been an issue for Canadian manufacturers. But rising energy costs — particularly in Ontario — are now becoming a real threat to their competitiveness, and might just become the tipping point that weighs against international investment. It’s a particular problem for Ontario’s chemical sector. Three years ago, a report prepared by the Canadian Industrial Energy End‐use Data and Analysis Centre for the Chemistry Industry Association of Canada found that feedstock and energy costs make up about 70 per cent of a chemical company’s process costs. So you can take it as a given that the number has risen in the ensuing years — unless you’ve discovered opportunities to cut costs, which means understanding how and when your facility uses electricity, and acting on that information to implement a serious and coherent energy saving program. Did you know, for example, that businesses that use over 250,000 kilowatt-hours (kWh) of electricity per year (or at least $2,000 per month in electricity costs) pay the market price for electricity rather than the time-of-use prices that households, small businesses, and designated consumers such as farms pay? Or that, as a business that pays market prices for electricity, your costs are based on how much you use, your peak demand, and the time of day and week you use it if you have an interval meter? Too many chemical makers don’t know these and other facts, making it hard for them to implement a conservation strategy that will give them a break on costs. Which

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is a shame, because there are a host of experts, tools, and programs available to make it happen. But it’s not too late to turn things around. Helping Ontario’s chemical industry get smarter about electricity consumption is the goal of this report, made possible by the Independent Electricity System Operator (IESO). Canadian Plastics interviewed chemical manufacturers, utility providers, and energy industry consultants, and engaged them in a debate about such questions as how to keep consumption figures from rising further, and what it would take to get them to level off or — better yet — drop. The answers can mean the difference between making a profit and losing money…and maybe even losing your business.

EXECUTIVE DECISION When it comes to taking the first step towards developing an effective energy saving strategy, the interviewees for this report are unanimous: engagement from senior management is crucial. They’re equally unanimous, however, that it’s not always easy to achieve. “Getting buy-in on the executive level — particularly the CEO and CFO — is critical to a chemical maker putting an energy saving policy in place, but they’re often the ones who are the most difficult to convince,” said Brian Baxter, the supervisor of conservation and demand management and program delivery at Hydro One Brampton. “As opposed to mid-level managers, it can be hard to get table time with upper management because they tend to be very busy. But they’re the decisionmakers that we have to convince to do these projects.” Adding to the challenge, Baxter continued, some senior management still believe that power is a fixed cost — which, given the wide range of programs available today, it definitely doesn’t have to be. “Trying to get management buyin to invest half a million dollars in a lighting project can be difficult when some of the CFOs and others still don’t believe it will reduce their power bill,” he said. “So we talk their talk, and try to put the investment in a language they understand — for example, that the cost of a program will equal the cost savings of ‘X’ amount of chemicals. Since companies are looking at all costs, and since Ontario is a high-cost jurisdiction, we always relate our conversations with management back to the priority of costs. Once you can relate the payback to company priorities, it connects with the C-suite and vice presidents and really drives the project home.” On the subject of saving energy, DuPont Canada is what you’d call an early adopter. The company has been engaged in energy conservation for almost 50 years, and has continued to maintain energy use data since 1972. Examples of energy saving projects are legion. In 2002, for example, it

REDUCING YOUR PEAK DEMAND You can use the same amount of energy overall and still reduce your electricity bill. Sounds far-fetched? The trick is to manage your company’s electricity demand and draw the same amount of electricity from the system at a slower rate. Demand charges cover the cost of the size and type of wires and equipment needed to get the electricity to your business. Drawing a lot of electricity at one time creates a higher demand, and higher demand requires additional wires and transformers that can supply electricity at the rate you draw it without overloading. So, the higher your monthly peak demand, the higher your bill. Your electricity delivery charges for the month are based on one 15-minute or 60-minute peak. If you can reduce your peak, you’ll also reduce your delivery charges. Your local utility has conservation and demand management programs to assist in reducing or shifting the peak demand of your facility — so contact them for more information.

invested $1.2 million for a complete energy-efficient lighting retrofit at its site in Kingston, Ont. — a project that reduced electricity demand by 575 kW and helped them save significantly on annual energy use. So it knows how to do it right, beginning with executive buy-in. “DuPont has a global executive network, and the energy saving mandate comes directly from them,” said Scott Sharpe, the company’s FS&RE facilities supervisor, Western Region. “They decided a long time ago that treating energy savings as a series of one-off projects at various sites was not the way to do it. So right from the start, they implemented a coherent corporate strategy.” Buy-in from senior management wasn’t an issue at Hamilton, Ont.-based Benson Chemicals, either. “Electricity was a significant cost for us and we wanted to reduce it,” said Randy Wagenaar, the company’s marketing manager. “Senior management talked about energy saving strategies with the lower echelon employees — who had their own ideas, which they in turn shared with senior management. So while everybody at the company agreed on doing it, the key to going forward with the reforms we’ve made — which include installing automatic light switches and LED lighting, and improving the insulation of our chemical tanks — was the firm commitment at the executive level. Without that, we wouldn’t have had a consolidated strategy.” For mid-level managers at chemical manufacturing companies who are looking to engage an unconvinced senior management in an energy saving strategy, try this: Special Report | ENERGY EFFICIENCY 3

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undertake a relatively small project that demonstrates a quick return on investment. It helps to know that not all energy saving ideas require a big capital investment. For chemical manufacturers in Ontario, the Save on Energy program provides incentives for upgrades to old equipment and energy-efficient lighting. “Depending on the number of lights installed, the payback period for a relatively simple project like switching to LED lighting can be shorter than you’d think — within a matter of months, in some cases,” said David Whitehouse, corporate services and conservation officer with Peterborough Utilities Group. “This tends to gain management’s attention because it can be amplified over the entire plant or the enterprise infrastructure.”

AUDIT THIS! Once senior management is on board, launching a new energy efficiency strategy begins with understanding how electricity is used in a typical chemical plant. In other words, you have to measure it before you can control it. Two words describe this next step: energy audit. An energy audit provides a useful, detailed breakdown of how much electricity is consumed in your facility and where, which is crucial to identify opportunities for improvements. Moreover, audits can identify energy savings by potential projects; identify potential non-energy related improvements by project, including productivity, safety, yield, sales, and so on; identify the capital cost of the projects; summarize the return on investment for each project; and prioritize the projects based on capital cost, life cycle cost savings and non-energy related financial benefits, return on investment, savings to investment ratio, payback periods, and more. The good news is, Ontario’s Save on Energy incentive programs can cover up to 50 per cent of audits — and once opportunities are identified in the audits, more detailed engineering studies can define what exactly is required and provide more accuracy on the potential savings and costs. Even better, Save on Energy users can receive 100 per cent of study costs up to $10,000 in incentive funding for completing a Preliminary Engineering Study, and 100 per cent of study costs up to $50,000 in incentive funding for completing a Detailed Engineering Study. Hydro One Brampton and Peterborough Utilities both identify three basic kinds of audits: a building electrical survey — typically done by an outside company or consulting firm — which provides an overview of a company’s energy consumption; a system-specific audit of important, potentially energy-wasting equipment like compressors; and higher level audits of processing systems, characterized by detailed engineering studies. A thorough audit also reviews more than just machinery.

“A good auditor interviews staff to find out what they do during the day, what their energy habits are, what maintenance programs the company has, and who the providers are,” David Whitehouse said. The cost of the audit depends on how many layers of the onion it peels back. According to Brian Baxter, the price can range from $1,000 on the low end all the way up to a whopping $100,000 for a truly deep dive audit. Kitchener, Ont.-based chemical supplier Ampacet Canada Co. had an intensive energy audit performed a few years ago as part of a program offered by the Canadian Plastics Industry Association. “The audit was all-inclusive, and found a number of areas that needed improvement, from compressed air leaks to inefficient lighting,” said Ampacet Canada president and CEO Terry Elliott. “As a result, we upgraded our compressor technology and improved our heat recovery, and also switched over to efficient LED lighting.” DuPont Canada is a long-time believer in energy audits. “We’ve had a series of energy audits performed over the years — not at all sites, but those where we think the biggest energy hits are taking place,” said Scott Sharpe. “On the basis of these, we compile lists of which projects should be tackled first in accordance with budget constraints.” Aside from lighting upgrades, Sharpe continued, the latest audits highlighted improving HVAC unit efficiency as a top priority. “We have made progress installing variable frequency drives on some of the HVAC units, and also found big savings by installing cutting-edge control systems,” he said.

LET THERE BE (ENERGY-EFFICIENT) LIGHT Once the energy audit has been completed, the focus usually shifts to implementing your program. Not surprisingly, grabbing the low-hanging fruit is the first and easiest step. A favorite target is switching to energy-efficient lighting — which is ironic, given that lighting is typically the last line item on the budget that operators worry about or assess. Building lighting systems have been the subject of energy saving retrofit projects for decades now, so this isn’t exactly a new fix, and a lot of companies take this project on even without the benefit of an energy audit. It had a respectable run, but after more than 100 years of market dominance, the age of the incandescent light bulb is definitely over, killed by the LED. And it’s about time, too; most older-type lights produce 30 per cent less light after just one year and continue to dim until they die, which means that manufacturers are paying the full light bill for less than half the light output. Old lighting includes highpressure sodium and metal halide lamps that can take up to five minutes to achieve full brightness, and T12 fluorescent lights. By comparison, LEDs use up to 90 per cent less energy in a manufacturing setting. In addition to LEDs,

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new lighting technology includes energy-efficient metal halide, T5, and T8 fluorescents. LED lighting in particular makes especially good sense in a chemical facility. Why? Since many chemicals are highly flammable or even explosive, fire represents a higher than average risk for these plants. LED industrial lighting, unlike legacy light sources, is spark-free, since it doesn’t require ballasts or other potential sources of ignition. There is also very little heat generation from LED industrial lighting fixtures. Finally, because maintenance and replacement frequency is reduced, there’s less need for employees to access lighting in areas where chemical exposure poses a risk. So while it’s true that LED lights are triple the cost of regular lighting, they should more than make up for that in a chemical plant over their eight-year lifespan. Material supplier Kal-Trading Inc., of Mississauga, Ont., began its aggressive energy reduction strategy with its lighting. ”With incentive funding from Save on Energy, we started by reducing the number of light fixtures in our warehouse by one-third, and then switched the remaining light fixtures from HPS 400 Watts to more energyefficient induction lights, and also equipping them with motion sensors,” said company president Gobi Saha. ”We then upgraded over 400 office lights to LEDs, and reduced the number of light fixtures by 50 per cent, as well. All our offices are equipped with occupancy sensors to further save energy.” How much energy? “Occupancy sensors can reduce your lighting energy use by 25 per cent,” said Bob Arbuckle, director of energy services at Nedco. The amount of the incentive is based on the difference between the amount of electricity the lighting currently uses and the amount that the new lighting will use. After the relatively easy fix of lighting, there are other areas that can deliver big energy savings. As identified by an Ontario Power Authority (now IESO) Achievable Potential study conducted last year, leading candidates for improvement include installing variable frequency drives (VFDs) for fans, pumps, and HVAC; compressed air systems upgrades or replacements; and chiller plant upgrades or replacements. Kal-Trading is set to start work on several of these. “As the next step in our program, we will be replacing all our high-power motors with new energy-efficient motors and VFDs,” Gobi Saha said. “We will also be looking to install energy-

EIGHT STEPS TO A BETTER ENERGY MANAGEMENT PLAN

Having an energy management plan helps you to identify goals and systematically work to achieve them. Understanding your business’s technical systems and how your employees operate them are two of the keys to identifying opportunities to use electricity wisely and reduce your electricity costs. Outlining this information in an official plan helps your employees understand what changes need to be made and why. It also helps you track your progress, cost savings and payback on investments in energy efficiency over time. The following eight steps provide a simple, systematic approach to understanding how your business uses electricity, what influences costs, how you can use less and how to chart your success. STEP 1:

Knowing the factors on your bill that influence your demand (kW or kVA) and energy (kWh) costs provide insight to the steps you can take to reduce those costs.

STEP 2:

Comparing monthly data can help you determine how energy consumption at your facility varies over time. For example, comparing energy consumption against production can help you determine energy costs per unit of production as a means of assessing potential savings opportunities.

STEP 3:

The cost of electricity is influenced by when it’s consumed. Your company’s demand profile shows your energy use patterns — information which is essential if you’re considering changes to lower demand, or, if you have an interval meter, to take advantage of times of day or month when electricity prices are lower.

STEP 4:

Identify equipment that draws the most power. If you improve its efficiency, you will see a bigger reduction in your electricity costs. An energy audit provides a useful, detailed breakdown of how much electricity is consumed in your facility and where.

STEP 5:

Energy waste can appear in many forms including excess time, volume, pressure and temperature. In order to realize energy savings opportunities, it’s important to match the energy your business actually uses to what is really needed. Once these requirements are established, eliminating waste becomes an effective cost-savings tool.

STEP 6:

The condition of your company’s equipment and operating conditions can have a significant impact on potential energy savings. Consider changing the way you operate, maintain existing equipment, or investing in more energy-efficient technology. While some operational changes can have relatively low or no implementation costs, investments in equipment upgrades or retrofits may have a shorter payback period than you would think and can lead to permanent long-term savings.

STEP 7:

Once you have reduced your requirement for energy, you may consider supply-side alternatives to meet your energy needs such as heat recovery, cogeneration and renewable generation options like wind, solar or biofuels.

STEP 8:

Charting your progress over time helps you share these successes with staff and encourage them to keep looking for ways to lower electricity costs.

Understand your energy costs Monitor and target

Understand when energy is used

Understand where energy is used

Eliminate waste

Maximize efficiency

Optimize the energy supply

Monitor your progress, share the results

Source: IESO Special Report | ENERGY EFFICIENCY 5

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efficient compressors and chillers.” You might be surprised at the difference new or retrofitted equipment can make to your power bill. “A 20 per cent reduction in motor speeds could result in 50 per cent less demand for energy,” Bob Arbuckle said. Building envelope improvements shouldn’t be ignored, either. “A year ago, Ampacet Canada put an economizer on its rooftop unit to reduce our cooling water costs,” said Terry Elliott. “We were recognized by Kitchener Wilmot Hydro for that project, and received capital support from them for it.” The company has also replaced its wooden bay doors with insulated bay doors, Elliott continued, and is considering increasing its natural lighting by putting in skylights and window panels along the top of the bay area walls. Once a business is ready to upgrade to high-efficiency systems, funding is available through Save on Energy. Companies can receive up to 50 per cent of their project costs through the program. “The most popular Save on Energy offering for chemical makers is the Equipment Replacement Incentive Initiative, which focuses on improvements in lighting, motors, heating ventilation, HVAC, and overall electricity systems,” Brian Baxter said. Even with all this funding, there’s definitely an up-front financial investment for new lighting and retrofitting. But Brian Baxter, for one, has noticed a phenomenon which makes the return on investment seem even sweeter. “One thing that I’ve found, historically, with companies that go through an energy saving process and want to develop a long-term strategy, is that they develop what’s called a

revolving energy fund,” he said. “The savings from the initial project — the low-hanging fruit — can pay for the next project, which then pays for the next project, and so on. Instead of realizing the savings on their bottom line, a company uses the savings to continue with the development of its energy saving plan.”

TEAMING UP Another step towards having an effective energy saving program is to appoint an energy manager — or even an energy management team — charged with overseeing the company’s energy needs and developing its future energy strategy. It’s the best way to avoid what you don’t want: people on the plant floor, in IT, and in the front office all pursuing their own independent energy saving schemes. When it comes to fielding energy management teams, DuPont Canada might be the ultimate best-practices example. “Almost every DuPont site that I’m involved with has an energy representative; some sites will have two or more, depending on the size,” said Scott Sharpe. “I meet with these representatives approximately every two months, and we discuss the global management team’s directives and, based on those, look for opportunities for energy savings where we can. But I’m not forcing a corporate viewpoint on them; we have genuine conversations, since each representative knows more about his or her particular site than I do. At the end of the day, we set project goals from a site level, a regional level, and a corporate level.” It’s one thing for a global player like DuPont to assemble a group of energy management teams; it’s a lot more

UNDERSTANDING POWER FACTOR

n theory, it’s simple: Power factor is a measure of how effectively you’re using electricity. More specifically, it’s the ratio of the real power that is used to do work and the apparent power that is supplied to the circuit. But you’d be amazed how many manufacturers — chemical and otherwise — don’t really understand the concept…and how much money they’re wasting as a result. Hydro companies supply two kinds of power: active power (measured in kW), which is used by all types of electrical equipment to deliver required work; and reactive power (measured in kVAr), which is only required by certain types of equipment, such as those that produce motion (motors, for example), and those containing electronics (everything from computers to fluorescent lights with electronic ballasts). Power factor is expressed as a percentage, with 100 per cent being ideal. The trouble starts when equipment is drawing

too much reactive power, causing inefficiencies in the electricity transmission system. The lower the percentage falls below 100, the less efficiently your operation is handling its reactive power needs. And the higher the inefficiency, the more your utility company charges you, since generating facilities and carrying facilities must be sized for peak demands. Distribution and transmission charges are often billed on either the metered kW or 90 per cent of the metered kVA, whichever is greater. Luckily, it’s easy to reduce power factor surcharges. In most situations, the key is to install one or more capacitors, either at the specific point where equipment is using reactive power, or where electricity is delivered to your overall operation. And you better believe it’s worth the time and trouble. According to the IESO, correcting power factor can provide one of the fastest paybacks when making investments to reduce industrial electricity costs. Contact your local utility to find out more about your power factor.

6 Special Report | ENERGY EFFICIENCY

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challenging — and might seem impossible — for smaller firms to do the same. Some chemical suppliers have a large enough pool of skilled employees to form an ad-hoc energy management team that can do the job satisfactorily. “We don’t have an energy team per se, but our global engineering department plays a strong role in looking at Ampacet plants and performing internal audits,” said Terry Elliott. “They will come in and examine the plant and offer recommendations. If we have a very old compressor, for example, they’ll recommend that we upgrade it.” For other, smaller companies, sometimes finding even one person to act as an energy manager can be tough, since the ideal candidate needs the ability to understand the dynamics of the various energy markets and identify the trends that will define the framework of their energy strategy. “Energy managers require a sophisticated skill set to maximise the potential of this situation, and the more sources of energy used, the more difficult the role becomes,” said Brian Baxter. “It can be tough to ask for a volunteer to do this, especially since, post-recession, most manufacturers already have fewer employees doing more work.” And even if someone does step up, the odds are that he or she won’t have either the expertise or the technical background needed to do the job properly. One way around this hurdle for small and medium-sized enterprises is to rely on outside energy consultants to help them address their energy challenges. These advisers design energy purchasing strategies that minimize risk for clients, and may also negotiate with potential energy providers to get the best deals or organize buying pools. A second strategy comes courtesy of the Energy Manager initiatives through Save on Energy and Industrial Accelerator programs. For eligible firms, the IESO and local distribution companies can offer significant funding for the hiring of an energy manager. With the added bonus of the incentive, hiring an energy manager becomes feasible for many companies.

GETTING INCENTIVIZED We’re listing this one last, but it should actually be among the first things you investigate before implementing a consolidated energy saving program: learning how to work with your local utility, the IESO, and your natural gas supplier to make the most of the available financial incentives for businesses that take steps to conserve electricity or change the way they use electricity. And at the risk of repeating ourselves, there are a lot of incentives available. “As long as a project saves energy, the IESO and your local distribution company will give you funding for it — this money is available on the table right now,” said David Whitehouse. Even a short list of the Save on Energy incentives would

have to include audit funding, with building owner incentives available up to $25,000 for audits; tenant incentives available up to $7,500; and up to 50 per cent of the total cost of the energy audit paid for. There’s also retrofit incentives, with up to 50 per cent of the project cost paid for; non-lighting incentives of $800 per kW or $0.10 per kWh of first-year energy savings; and lighting incentives of $400 per kW or $0.05 per kWh of first-year energy savings. And finally, VFD funding, including $2,565 in incentives for 50 HP motors and $4,835 in incentives for 100 HP motors. And some of Ontario’s various industry associations are there to help, too. In partnership with energy services provider 360° Energy, CME Ontario is offering its members the CME 360° Energy Coach Program. The program brings trained consultants into a client company to analyze its workflow and areas of potential energy savings; and also includes training client staff members to serve as energy coaches who develop, recommend, and implement energy saving policies and changes on an ongoing basis. The result is an in-house energy management team drawn from all major departments that comes up with energy saving ideas, many of them not requiring any capital investment to put into action. CME is also teaming up with the IESO for Ontario’s Energy Pathfinder Research Initiative, designed to help companies achieve easy wins in process energy savings by identifying new best practices for process energy management, and also enabling them to quickly identify areas where they can go further. So if you’ve always thought of your electricity bill as a fixed cost of doing business in Ontario, think again. With all of the best practices, programs, and incentives available, there’s almost no industrial hydro bill that can’t be reduced — and sometimes dramatically so. And it’s not like you have much of a choice. With Ontario’s electricity policy moving towards decentralized technologies, including energy efficiency and low-impact renewables, energy conservation is becoming the new normal. Manufacturers that don’t get with the program — literally — will find themselves paying an increasingly heavy price for their carbon footprint. “I can make a business case for any chemical maker out there, no matter how large or small, to do something to reduce its electricity usage,” said David Whitehouse. “You might not be able to do everything at once, and you might have to stage the changes, but there is no business model in which you’re good where you are without having done anything. Companies that don’t have an energy program need to run — not walk — to their utility provider and say, what can you do for me?” So get running, and start saving. Special Report | ENERGY EFFICIENCY 7

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Energy Managers Mean Business

Energy Managers are trained to ﬁnd energy savings, make smart energy investments, boost their organization’s bottom-line and unleash competitive advantage. Can your business aﬀord not to hire one? Incentives through Save on Energy and Industrial Accelerator are available to help bring an energy manager into your workforce. Contact your local hydro company or the Independent Electricity System Operator (IESO) to see what programs are available in your area.

“The best part about being an energy manager is that I’m helping my company to stay competitive. The less energy we use, the more efficient we are.” Behdad Bahrami, Energy Manager, Vision Extrusions Ltd

saveonenergy.ca

industrialaccelerator.ca

Subject to additional terms and conditions found at saveonenergy.ca. Subject to change without notice. OM Official Mark of the Independent Electricity System Operator.

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granulators

Improving the

Photo Credit: Conair Group

DAILY GRIND

Granulation is an important step in the total production process. But it doesn’t always feel that way, as some processors treat their granulators like second-class citizens — and then wonder why they get bad regrind. Understanding some of the basic errors in granulation can help you get the most out of your unit.

t’s always easy to spot someone else’s mistakes. It’s not hard to figure out what the Toronto Maple Leafs ownership has been doing wrong decade in and decade out, for example. But owning up to our own mistakes can be harder. Take granulating. If you’re a plastics processor, granulation is an important step in the total production process — and never more so than today, when the high cost of materials is combined with growing pressure from the end-user market to include as much regrind and/or recycled material as possible in consumer products. So it should be a given that they’re maximizing the process, especially given the advances in cutting technology and machine design. Think again. Too many processors continue to make unforced granulation errors, and then wonder why they end up with consistently poor regrind. Here are just a few of the mistakes to avoid when thinking about granulators.

SIZING MATTERS All too often, processors trip themselves up right out of the gate by using the

By Mark Stephen, editor

wrong size granulator for their application. As a technical paper by Rapid Granulator noted, it’s a mistake borne of the belief that “a granulator is just a granulator, and that horsepower and throat size are all one needs to know to size and have an effective granulation process, when in fact nothing could be further from the truth.” It’s a hard mistake to recover from, and is especially common with granulators that were bought on auction without input from the professionals. But it doesn’t have to be this way, since most granulator machinery producers offer modular products that allow a processor to configure core machine components to match the specific application requirements. And those requirements can be determined by answering a few key questions. “The processor needs to communicate to the granulator supplier what the application is — blow molding, injection molding, extrusion or recycling; what kind of material will be processed; what the method of feeding is going to be; what the part dimensions will be; and how many pounds per hour

the customer wants to process,” said Brian Davis, president of Maguire Canada Inc. “Once we have this information, we can recommend the best solution, including the screen size, the rotor and cutting chamber design, the number of knives required, the hopper design, and whether or not a metal detector is necessary.” How much the material type matters to the granulator selection is open to debate among the experts. The Rapid Granulator paper noted that “each material can react very differently in a granulator.” Some other granulator suppliers agree, and some don’t. “Generally speaking, there isn’t much behavioural difference from one resin to the next in a granulator,” said Mike Cyr, president of Rotogran International Inc. “The big exception is PET bottles, which are harder to cut because they tend to stretch. A customer will get between 20 to 30 per cent less throughput when grinding PET, so they should plan accordingly. PET aside, the geometry of the part and the desired throughput mean more to the selection of a granulator than the material.”

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granulators

But if the resin type can get overemphasized, another factor probably isn’t given enough attention. “Proper evacuation of a granulator is just as important as steady feeding into the machine, but a lot of people don’t realize this,” Cyr continued. “A properly sized evacuation system does more than just remove regrind from the granulator; it also pulls air through the machine, which benefits the regrind process by keeping the unit cooler and adding to overall throughput.”

OPEN ACCESS If picking the wrong size unit for the application constitutes the biggest error in granulation, maintenance — or the

in general, easy to inspect. “The granulator should have features such as power assisted tilt-back hoppers, rotor locking devices, and easily accessible and removable screen cradles and screens,” Rapid Granulator noted. “The operator should have visible paths to all areas of the machine, with no hidden nooks and crannies, to inspect and confirm the machine is free from all previous colours or materials.” Some granulator suppliers, however, advise their customers not to get too hung up on accessibility. “There are granulators on the market that are very easy to open, but typically that’s because they’re light-weight and not as durable,” said John Farney, global sales manager

There are three mainstream types of knife configuration, and each has situations where it’s the best choice. lack thereof — qualifies as a close second. As Rapid Granulator put it, “the maintenance service of granulators, and their critical cutting components, is normally the most neglected area of service in many production plants.” But maybe the customer isn’t completely to blame, since some granulators — especially older models — came with inadequate instruction manuals and improperly gapped knives. In other words, they’re not exactly maintenancefriendly. So if your granulator is more than a few years old, it’s probably time to take a closer look at it. By contrast, most modern granulators offer quick and safe access to the heart of the unit for easy cleaning and knife maintenance. The latest addition to the range of Wittmann Battenfeld’s screenless granulators, the new Junior 3 Compact model, is said by the company to be very easy to clean, in addition to offering a 30 per cent reduction in size and weight. But you still need to have a defined preventive maintenance program — so it’s a good thing today’s granulators are, 28

for size reduction with ACS Group. “So there’s a trade-off with greater accessibility, and customers should be aware of that. Also, every granulator has to meet a local safety code, and these vary; so if a particular granulator seems cumbersome to open, it might have to be to comply with regulations.” But if you do only one thing, do this: keep the knives sharp. “Dull knives can create angel hairs, fines, and dust in the granulate,” Brian Davis said. “The sharper the knives, the more efficiently the granulator will chop the scrap, especially the softer materials.”

DOESN’T CUT LIKE A KNIFE Speaking of knives, a third big mistake is using a granulator with a poor knife design. Poor scissor-cutting action, bad rotor design, and slow rotor knife speed all qualify for this. “Any of these can lead to non-uniform regrind, and also to a high level of wear and tear on the granulator,” Rapid Granulator noted. There are three mainstream types of knife configuration. The first, and probably most common, is the double

angle cut, also known as the double scissor cut. In this configuration, straight rotor and bedknives are used and mounted at slightly opposing angles, which creates a constant gap along the full length of the blades. Second, the chevron, or “V-type” rotor cut; the rotor knives and bedknives are V-shaped where the cutting edge is located on the interior of the “V”, with the cutting edge starting at the outer edge and conforming into a single point. And third, the helical cut, with the rotor knives arranged in a spiral design while straight bedknives are mounted horizontally. Each configuration has different advantages, and each has situations where it’s the best option. Consult your granulator machinery producer before making a choice, and remember this one golden rule: “If the representative can’t recommend the right rotor blade design for your needs, don’t do business with them,” said Brian Davis.

TOO MUCH TOO SOON Just because a granulator is sized to a particular application and armed with the right knife configuration doesn’t mean things can’t still go south. The problem usually starts when the granulator is moved to another line to grind a different part made of different materials at a different throughput. The result can be catastrophic: the granulator is overfed, exceeds the maximum amp load capacity of the drive motor, and stops working. “We encounter this problem every day,” said John Farney. “Even when we attach an hourly performance figure to a granulator, the shop floor operators often ignore it and overfeed the machine.” One solution is to automatically meter-feed the granulator. “Meter-feeding, either by robot or conveyor, is a common feeding method,” said Vincent Carpentieri, size reduction sales manager for Conair Group. “Keep in mind that this determines the feed hopper design and other options needed.” Or consider using a high-amp alarm. “High-amp alarms can tell the operator

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granulators

when they’re working the drive motor too hard,” Rapid Granulator noted. “They can also help the operator understand and avoid evacuation problems; for example, if the feed rate is exceeding the evacuation rate, it may be as simple as waiting for the evacuation system to catch up.” A third strategy involves putting a shredder in front of the granulator. “The shredder cuts large volumes of heavy plastic scrap into smaller, more manageable pieces, which are then channeled into the granulator and turned into uniform regrind,” said Greg Parent, Canadian sales representative for Vecoplan LLC. “It takes a lot of the work load off the granulator, and is a good way to maximize throughput.” In certain circumstances, that is. “Using a shredder in front of a granulator wouldn’t make sense for a medical parts molder, because their reject rate is

very low,” said John Farney. “For an automotive parts molder making bumpers, on the other hand, the return on investment will be very fast.” It took hockey sweaters being flung on the ice by disgusted fans before Toronto Maple Leafs management woke up to the error of its ways. You don’t want to be the equivalent in the regrind world, so give granulation the planning it deserves. “Processors should look beyond what they’re grinding at the moment,” said Brian Davis. “You’re reducing preforms today, but will you be doing bottles tomorrow? Ask yourself this, and a few other questions before you buy a granulator, and you’ll get a lot more productivity from your unit.” CPL RESOURCE LIST ACS Group/EquiPlas (Markham, Ont.); www.aecinternet.com; 416-407-5456

The Conair Group (Cranberry Township, Pa.); www.conairgroup.com; 724-584-5500 Dier International Plastics Inc. (Unionville, Ont.); www.dierinternational.com; 416-219-0509 Industries Laferriere (Mascouche, Que.); www.industrieslaferriere.ca; 450-477-8880 Turner Group Inc. (Seattle, Wash.); www.turnergroup.net; 206-769-3707 Maguire Canada/Novatec Inc. (Vaughan, Ont.); www.maguirecanada.com; 905-879-1100 Barway Plastic Equipment Inc. (VaudreuilDorian, Que.); www.barway.ca; 450-455-1396 Rapid Granulator Inc. (Cranberry Township, Pa.); www.rapidgranulator.com; 724-584-5220 Dier International Plastics Inc. DCube (Montreal); www.dcube.ca; 514-272-0500 Rotogran International Inc. (Toronto); www.rotogran.com; 905-738-0101 Vecoplan LLC (Archdale, N.C.); www.vecoplanllc.com; 336-447-3573 Greg Parent; 416-678-0154 Wittmann Canada Inc. (Richmond Hill, Ont.); www.wittmann-canada.com; 905-887-5355

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purging compounds

Don’t ask us why, but commercial purging compounds are among the most misused technologies in all of plastics processing. But it doesn’t have to be this way. Implementing the three-step program of picking the right compounds, using them wisely, and keeping track of the results will give you better results from your CPCs.

e owe a lot to three-step processes. Where would we be without the wash-rinse-spin cycle in our washing machines, for instance? And on the topic of getting things clean, some plastics processors would be surprised at how a standardized three-step program can ensure they’re purging their machines in the best and most cost-effective manner possible. Surprised, that is, because commercial purging compounds (CPCs) might just be the most misused technology in the plastics processing universe. Chalk it up to a mixture of carelessness and laziness. “The misuse of CPCs is fairly widespread, and is usually caused by processors simply not following the directions properly,” said Tim Cutler, vice president of the Dyna-Purge division of Shuman Plastics. “Making the problem worse, they’re not always using the right compound for their application in the first place.” Which is why CPC makers collectively suggest following a three-step process to ensure the best results possible:

Choose the proper CPC, implement the recommended procedure and stick to it, and measure and track the results. It sounds simple enough, but as with any other set of instructions — assembling IKEA furniture comes to mind — things can go off the rails fast. Here’s how to keep it all running smoothly.

©Epitavi/Getty Images/Thinkstock

By Mark Stephen, editor

PICKING A WINNER When deciding which CPC is best for you, there are three big questions that have to be answered — and which any CPC supplier will ask you, right off the bat, if you contact them. “We want to know what resins you’re running, what additives are being used, and what equipment is being used,” Cutler continued. Resin is the lifeblood of whole molding process, so it’s no surprise that understanding the properties of your molding resin is crucial to determining which CPC is the right one for your application. “Knowing the processing temperature range of the molding resin is a critical factor in selecting the

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purging compounds

CPC in the first place. But even light colours can be problematic to purge, especially liquid colourants and organic pigments, and these may require a more aggressive CPC for cleanout, the suppliers say. Additives also play a part in determining the right CPC. “Additives such

manager with Slide Products Inc. “And adding additives to a resin that’s easy to purge by itself, such as PP, changes the makeup of the material and makes it more complicated to remove from the machine.” Last but definitely not least, the equipment configuration and condi-

The misuse of CPCs is widespread, and is usually caused either by processors not following the directions properly or not using the right purging product for the application. as flame retardants break down when subjected to high temperatures, leaving residue behind, and if your purge product doesn’t remove these additives, you may end up with carbon build-up,” said Jeff Lewis, sales and technical

tion will have a major impact on your decision. Take hot runners. “Hot runners have a big influence in the CPC product selection,” said Andrew Reeder, Ultra Purge sales manager in North America for Moulds Plus Inter-

©Epitavi/Getty Images/Thinkstock

proper grade,” said Eric Procunier, product development manager with Sun Plastech Inc. “Every purge product has an optimal processing temperature range, and it could be harmful to your purging process to go above that. If you exceed the auto-ignition temperature, the material could catch fire.” The thermal stability of a resin also plays a role. “Moisture-sensitive resins like nylon, PC or PVC tend to degrade quickly, which leads to carbon build-up and black specking,” said Tony Schoendorf, a specialist with Chem-Trend L.P. “In this situation, a more aggressive CPC is recommended to scrub the build-up from the surfaces of the screw and barrel.” Another crucial resin property is colour. Facilitating the transition from one processing colour to another — typically light to dark — is, of course, one of the biggest reasons for using a

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purging compounds

national USA. “Hot runners can have tight clearances, poorly-designed channels, and uneven temperature profiles, so it’s important to select a CPC that flows evenly through the manifold, tips, and gates.” The good news? Since this is one of the fastest growing areas of use for CPCs, the market is being flooded with products designed specifically to meet the challenges of hot runner applications. So you won’t exactly lack for choices. A final, critical question that often gets overlooked, CPC suppliers say, is the condition of a machine’s screw and barrel. “If you have a worn-out screw — which some processors do — there’s a chance the CPC will not work as well as it could,” Jeff Lewis said.

USE IT, DON’T ABUSE IT Armed with the best CPC for your needs, you’re ready for Step Two:

implementing the right purging procedure. First, do we really have to tell you to follow your CPC supplier’s directions? Apparently we do. “Processors can be creatures of habit, and some of them have been purging one particular way for so many years — including skipping one or two steps to save time — that it can be difficult to get them to slow down and do it properly with a new product,” said Tim Cutler. “It’s also quite common for different machine operators to use different procedures, which means that results can vary significantly from shift-to-shift; and for an operator to use a procedure designed for one application on every application.” A related problem is sticking closely to the guidelines for Supplier A’s compound when the processor is actually using material from Supplier B. “Using one manufacturer’s guide-

Want help measuring the usage of your purge material? Some CPC makers offer pails with built-in measurement markers. Pictured is Shuman Dyna-Purge’s five-gallon Camo pail. Photo Credit: Shuman Dyna-Purge

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lines for a different supplier’s product is a common mistake, and almost always leads to an unsatisfactory result,” said Kathleen Jarvis, national sales director with Neutrex Inc., the manufacturer of Purgex compounds. Fact is, purging suppliers invest a lot of time developing the procedures for using their own specific products — so why not follow them? The best way to implement a standardized best practice is through a training program, customized for your plant by your purging supplier and delivered in-person on the shop floor by a trainer. It’s a service that virtually every CPC supplier is more than happy to provide, usually for free. “We begin the training program with classroom instruction in the processor’s office, and then take everyone — from the production manager on down — out to the press and run through the procedure with them,” said Andrew Reeder. “We also recommend yearly refresher courses, especially for companies with high staff turnover.” If your shop can’t arrange for

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hands-on training, it’s not exactly the end of the world. This is the Internet Age, after all, and general instructions are usually available on a supplier’s website for almost any of its CPC grades. “Just remember to check with the supplier to make sure you’re accessing the most up-to-date procedure,” said Jeff Lewis. While no one argues that a standard procedure will work well in most cases, there are times when modifying it to suit a process variable will improve the result. The key is to identify and plan for this variable ahead of time through a conversation with your CPC supplier — as opposed to improvising a solution on the shop floor that varies from one operator to the next. “And once you’ve validated a modification with your CPC supplier, make sure it becomes a standard part of your new procedure,” said Kathleen Jarvis. Speaking of the dangers of deviating from procedure, keep well clear of your injection molding machine’s auto purge button. “One of the biggest problems we run into is molders using the auto purge function to try and purge their machines,” said Eric Procunier. “Because it has the word ‘purge’ in it, people assume it provides a proper CPC-style purge. It doesn’t; it simply uses low pressure to repeatedly build a shot and shoot it through the nozzle until the system is empty. It should never be an option for purging.”

know you have a problem.” More and more these days, control charts can be supplemented with — or in some cases replaced by — the processor’s own production monitoring software. “Most modern processing machines have software in them that gives basic tracking data such as cycle time, machine downtime, and scrap rate,” said Jeff Lewis. But whether you use the supplier’s charts or your own in-house quality control technology, one of the big goals of measuring your purging results is to prevent what many CPC suppliers say is the most common error they encounter: overuse of purging material. “We can tell when a customer isn’t tracking their results because they suddenly start buying more purging compound than usual,” said Eric Procunier. “We want them to use as little as possible consistent with a good result, and the

best way to determine that is through data analysis.” If you follow these three steps, don’t be surprised when your suddenly standardized purging program becomes a big success. Sort of like the wash-rinsespin cycle. CPL RESOURCE LIST Chem-Trend L.P. (Howell, Mich.); www.chemtrend.com; 517-546-4520 Moulds Plus International USA (Santa Clara, Calif.); www.ultrapurge.com; 714-708-2663 Neutrex Inc. (Houston, Tex.); www.purgexonline.com; 281-807-9449 Shuman Dyna-Purge (Buffalo, N.Y.); www.dynapurge.com; 866-607-8743 Slide Products Inc. (Wheeling, Ill.); www.slideproducts.com; 800-323-6433 AceTronic Industrial Controls Inc. (Mississauga, Ont.); www.acetronic.com; 905-564-7227 Sun Plastech Inc. (Parsippany, N.J.); www.asaclean.com; 800-787-4348

MEASURE FOR MEASURE With the right purging procedures firmly in place, get ready to measure and track the results. Why? Because the more science applied to managing your purging program, the better. Control charts and/or cost-savings analysis sheets are common methods to monitor the results of the process, and most CPC suppliers offer one or the other. “By visually displaying the fluctuations of a particular process variable — scrap, for example — a control chart lets you determine whether these variations fall within the process limits,” said Tony Schoendorf, “If not, you www.canplastics.com February 2016 Canadian Plastics

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doing it better

UNIVERSAL GRAVO-PLAST is getting a reboot

New ownership is reinventing a familiar fixture on Ontario’s plastics processing scene. By Mark Stephen, editor

ou don’t stay in business for over 60 years without doing something right, but the odds are still strong that you’ll have to reinvent yourself once or twice along the way. Even a venerable institution like McDonald’s — now in its 61st year — has had to shift gears and start supplying salads and other non-fast foods in recent years, to fight the perception that it was out of touch with current tastes. Universal Gravo-Plast Inc. (UGP) can relate to that. Founded in 1954 — just a year before McDonald’s, coincidentally — the Toronto-based injection molder, part prototype maker, and moldmaker has been a familiar feature of the Southern Ontario plastics processing landscape for decades. Maybe too familiar. If you’ve been in the industry for any length of time — especially in Ontario — you probably know the company, if only by name. And you probably think you know what it’s all about: a small-time outfit that does short production runs — as predictable as McDonald’s with its burgers and fries. But just like the Golden Arches, a closer look at what UGP offers these days might surprise you. That’s because the shop is undergoing a major reboot, under the guiding hand of Farhat Buchh, an entrepreneur who purchased UGP in 2013. From its early days as an engraver,

UGP progressed into toolmaking and then low-volume injection molding, so change is nothing new. But what’s going on now is different in both size and scale — a carefully crafted transformation involving new equipment and new staff members, with the goal of substantially increasing the business through higher volume molding with higher tonnage machines. And while these are still early days in the reinvention, the results can already be seen. Call it the beginning of Universal Gravo-Plast 2.0.

NEW BLOOD “The previous owners of UGP did a good job guiding it through the recession, but by 2011 they were tired and wanted out of the business,” said Michael Draga, UGP’s director of sales. “By the time Farhat bought the company, it was basically in a holding pattern, and some of the equipment was a bit antiquated. It didn’t take him long to realize that changes had to be made.” That UGP didn’t exactly have a hammerlock on the industry’s attention quickly became obvious to Draga, too. “I was hired in early 2015, and I realized as soon as I began making sales calls that almost nobody knew we had new ownership, and some people didn’t even realize we were still in

A food container and lid, molded from PP.

An industrial electrical enclosure, part of a three-piece assembly.

A medical bed brake pedal, molded from a PC/ABS/ Santoprene blend.

A four-piece apple conveyor bracket, molded from nylon 6/6.

Photos on pages 34-35 courtesy of Universal Gravo-Plast

A UGP product gallery:

Canadian Plastics February 2016 www.canplastics.com

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doing it better

Photos on pages 34-35 courtesy of Universal Gravo-Plast

Nissei hydraulic machine, as well as a new 200 ton Nissei hydraulic unit, and are planning to buy a third new hydraulic machine within the next few months to help fill in the gaps. We’ve removed some of the older equipment and our stable now consists of eight machines. We’re content to stop at the 500 ton range for the short-term, but we plan to increase our tonnage range again in the future.” The higher tonnage molding machines are necessary to implement the third prong of UGP’s reinvention strategy: diversifying into new markets. “The display and merchandising product markets have always The Universal Gravo-Plast team, with owner Farhat Buchh at far right. been big parts of our core business, and we remain very strong in these, but we’re defibusiness,” he said. “It could have been discouraging, but we nitely planning to expand into new areas,” Draga said. “We’ve actually took it as a challenge, since by that point we had a entered into the mushroom and horticultural markets and will plan already in place to reinvent the company.” be supplying products for these by the first quarter of 2016; The reinvention kicked off with the hiring of some key new we have an exciting new project in the medical/dental field personnel. In addition to Draga, who beefs up the company’s and are building the prototype tools for that; and we’re also sales side, Buchh also brought in industry veteran Ganesh Per- involved in a tooling project for the packaging industry. These saud to serve as director of operations and tooling coordination. last two are both particularly complex parts, and we’ve been These new hires brought the staff size up to approximately 17 able to come up with the solutions.” workers. “The new employees combined with the existing staff The company’s fourth step remains a work in progress: — some of whom have been with us for decades — gives us a relocating to a newer, larger headquarters. “We’ve been in good mix of new blood and old blood, new perspectives and our current 13,000-square-foot facility for about 30 years, so older perspectives,” Draga said. “There are cultural and techni- it’s obviously an older building, and too small to accommocal changes going on at the shop that present learning curves for date the level of growth we’re planning on, which is to double some employees, but they’re all handling it well; in fact, those the business within the next three years,” Draga said. “We who have been with us for the longest are probably the most need a larger, more modern space — preferably between excited about our new direction, because they’re the ones who 26,000 square feet and 30,000 square feet — and are curexperienced the company’s drift.” rently looking for something in the greater Toronto area; With a reinvigorated workforce in place, the next step in something that makes logistical sense for our key customers, UGP’s evolution was to add some much-needed new equip- and that offers better access to the major highways than we ment to its existing lineup of six small-tonnage machines. have now. On the other hand, we don’t want to overextend “We increased our tonnage range from 40 to 500 just within ourselves by choosing a building that’s too big, so we’re the past few months,” Draga said. “We have a new 500 ton going to take the time to get it right.”

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And finally, UGP is well underway with its ISO 9001 certification process and anticipates being registered in the second quarter of 2016. “This will open a lot of doors for us, particularly as we want to grow the automotive content of our business,” Draga said. “To compliment this initiative, we’re expanding our quality control and molding technician departments by adding experienced personnel and new equipment.” Not every aspect of the company needs an overhaul, however. The moldmaking side of the business, for example, has always gone just fine. “We have an in-house tool room, and the goal going forward is to maintain existing tools and perform preventative maintenance on them here,” Draga said. “When we get too busy, we use local sources for our new tools. The previous owners used offshore tooling, but Farhat made the decision to keep the business inside Canada.”

M S Left: Michael Draga and the new 500 ton Nissei unit. Above: Trimming parts on the shop floor.

evolved into a full service processing shop. “We provide fully functional parts, whether for prototyping, short production runs, or bridge tooling; we use high strength aluminum alloys in the manufacturing of our inserts, which allows for quicker machining and also ensures maintaining crucial geometric details for tight tolerance parts; and we also offer complete in-house capabilities, including posting, mold decorating, hot stamping, ultrasonic welding, and assembly,” Draga said. CHANGE AND CONTINUITY Sometimes, though, the more things change, the more So just a few short years into its reboot, UGP has already they stay the same. “Throughout its long history, there’s been one consistency to UGP: flexibility,” Draga said. “We’ve always had the ability to change-out tools very quickly because of our specialization in low volume, low production runs. And we’ve retained that; we’re very comfortable doing changeovers every hour of every day, whereas most companies Get the answers you need try to turn a machine into a dedicated from Chem-Trend. run. We’re going to do that too, to an extent, but the quick changeover is still our biggest strength.” But if the message hasn’t hit home by now, here it is: this isn’t your father’s UGP. “The company drifted for awhile, but now we’re back and reinvigorated,” Draga said. “In the months that I’ve been here, I’ve already seen a wide range of customers and potential customers come in with plans for very complex parts — which other processors didn’t want to get involved with — that Tired of trying to solve purging problems online? we took on and manufactured successOur industry specialists work on plant floors every day, fully. We have the tools, the ability, and developing complete solutions and delivering the service the confidence again, and there’s a lot to overcome purging challenges. we can offer to the industry.” Ask how Chem-Trend’s Lusin® purge compounds You know how McDonald’s boasts of can solve your processing needs. having served billions of satisfied cusFor advertising purposes, some PPE has been omitted. tomers? The revitalized UGP is aiming for lower numbers for sure, but the prinChemTrend.com ciple is the same. CPL

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Canadian Plastics February 2016 www.canplastics.com

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technology showcase

AUXILIARY EQUIPMENT

Beside-the-press granulator for top-notch regrind Cumberland’s new 1000 series beside-thepress granulator is designed to provide superior quality regrind with the added advantage of reduced maintenance costs. The standard design includes integrated rotating end discs for low-heat granulation and reduced frictional wear, and Cumberland offers a wide choice of evacuation systems to meet every production requirement. The 1000 series granulator’s unique, machined, bolted and doweled construction ensures strength and durability; while integrated rotating end discs provide for low-heat granulation for heat-sensitive materials. Doublesealed bearings are lubricated for life. The 1000 series can be used with robot-feed, conveyorfeed or hand-feed applications. Standard features include

pivoting hopper, drop-down removable screen cradle and machined, bolted cutting chamber that simplifies cleaning and maintenance; three-knife, open rotor with scooped wings and slant-cut knives combined with counter-slanted stationary knives that provide true “scissor” cutting action; HCHC knives manufactured in-house that utilize Cumberland’s proprietary process for heat-treating ensures durability and long life; and an oversized solid flywheel. Cumberland (New Berlin, Wis.); www.cumberland-plastics.com; 262-641-3885 Auxiplast Inc. (Ste-Julie, Que.); www.auxiplast.com; 866-922-2894 New Tech Machinery Inc. (Brampton, Ont.); 905-456-2968 Precision Mold Supplies Ltd. (Delta, B.C.); 604-943-7702

INJECTION MOLDING

All-electric series challenges electric, hybrid and hydraulic units New from Sumitomo (SHI) Demag, the SEEV-AHD series of mid-size all-electric machines are designed to bring the precision, productivity, and profitability benefits of all-electric

INTAREMA® The new system generation from EREMA.

Efficiency at the fore. High capacities have never been as easy to achieve as with the new INTAREMA®. Counter Current technology makes it possible. Because the extruder handles more material in a shorter time. And this means for you: constant, top throughput within a considerably larger temperature range. For more productivity, flexibility and process stability.

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Canadian Plastics February 2016 www.canplastics.com

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technology showcase

injection molding machine technology to applications with larger, heavier, and more complex molds. Available in 8 model sizes ranging from 247 to 562 tons, the SEEV-AHD efficiently handles higher injection requirements that would typically have been run on a hybrid or hydraulic machine, and also allows bigger parts to run on smaller machines. Tiebar spacing was increased an average of 8 per cent in the traverse direction and 15 per cent in the longitudinal direction compared with the company’s predecessor SE-HDZ series, and is the highest among machines of the same class. The square configuration of the tiebar spacing also allows molds to be loaded from the side. Bushing-free tiebars keep the mold area clean and free of grease, while the mold opening stroke is 25 mm wider than the SE-HDZ, and the mold thickness range can be optionally extended 100 mm for all model sizes and 200 mm for some model sizes. The ejector stroke is 220 mm for all model sizes, and is the largest among all machines of the same class. Additionally, a

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stronger, more rigid frame construction has increased the allowable maximum mold weight by an average of 22 per cent compared with the SE-HDZ. The new linear guidance system is supplied as a standard feature to ensure that even heavy molds open and close smoothly and parallelism is maintained; and for added application flexibility, an optional high-duty filling specification for thin-wall products raises the maximum injection speed to 220 mm per second. Sumitomo (SHI) Demag Plastics Machinery (Norcross, Ga.); www.sumitomo-shi-demag.us; 866-491-1045 Plastics Machinery Inc. (Newmarket, Ont.); www.pmiplastics.com; 905-895-5054

EXTRUSION

Twin-screw extruder “direct-to-sheet” system The new ZSE-27 MAXX co-rotating, intermeshing, twinscrew extruder from Leistritz Extrusion is a “direct-to sheet” system designed to facilitate rapid in-line compounding and production of prototype sheet samples.

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technology showcase

The machine comes standard with 52/1 L/D with modular barrels and segmented screws, a 1.66/1 OD/ID ratio for the screw, a 40 kW water-cooled motor, Q2 LSB-26 side stuffers for filler/fibre introduction, and an Allen-Bradley Compact Logix L3 PLC with PanelView Plus 15-inch touchscreen HMI. The 3-roll sheet/film system comes with 8-inch diameter by 16-inch wide rolls with linear motion and individual 1 HP AC motors/drives; driven rotary shear edge-trimming; dual unwinds for extrudate lamination/encapsulation utilizing magnetic particle brakes; integral, centre-driven rewind with automatic gap control and closed-loop tension control; and air-expanding chucks on rewind and unwind shafts. Also, the ZSE-27 MAXX twin-screw extruder system and downstream lamination system each have their own PLC and HMI interface. These two systems can operate independently or together via an Ethernet communications link to allow fully integrated sharing of recipe, data acquisi-

tion, and logic/alarming. Leistritz Extrusion (Somerville, N.J.); www.leistritz-extrusion.com; 201-934-8262

BLOW MOLDING

New business platform helps small-volume bottle production Amcor Rigid Plastics’s new UpStart program is designed to be a cost-effective way for start-up companies who want to explore niche markets, target regional products with lower demand, and test new products. Using the UpStart program, packaging suppliers can launch products at lower volumes with regional production and a nationwide manufacturing network to support simultaneous regional launches. In addition, UpStart offers significant savings in capital investment versus the standard highvolume production scenario, reducing tooling cost by to 75 per cent and affording bottle production with a wide range of technologies, finishes, and shapes. UpStart is also designed for a smooth transition to mediumand large-volume production platforms when demand grows.

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Canadian Plastics February 2016 www.canplastics.com

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technology showcase

Amcor’s network of smallvolume platforms (injection molding and blow molding) are located at four U.S. sites, including Chino, Calif.; Allentown, Pa.; Wytheville, Va.; and Ames, Iowa. These locations provide cavitation up to 24 cavities along with small-scale blow equipment. Additionally, these platforms are located near co-packers who fill products for market trials, to offer potential freight savings with bottle delivery. Amcor Rigid Plastics (Manchester, Mich.); www.amcor.com; 734-428-9741

Next-generation single-cavity machine for stretch PET New from Amsler Equipment Inc., the single-cavity LM15X PET stretch blow molding machine has a very small footprint, and can be used in labs, for small production runs, pilot production, customer trials, mold run-offs, material testing, and

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preform testing. The options of neck orientation, hot fill, and preferential heating can all be included on this machine, which can make up to 11 million 500 ml water bottles per year. Two bottle size ranges are available for the single-cavity machine: the L12X for bottles from 20 ml up to 2 litres, and the L15X for bottles from 20 ml up to 5 litres. Neck sizes for both systems range from 18 mm up to 63 mm. Each size range has two versions: the semi-automatic with hand-loading of preforms, and the fully automatic version with an automatic preform loading system. The neck orientation system feature is unique in that it works with standard preforms. The preferential heating option is designed for oval bottles, and can help to open up the processing window. These options can be used separately or together using a simple bolt-on and bolt-off installation system. W. Amsler Equipment Inc. (Richmond Hill, Ont.); www.amslerequipment.com; 905-707-6704

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technology showcase

RAW MATERIAL HANDLING

Durable bulk bag discharger for sanitary process operations With a chain-style tubular drag conveyor, the new bulk bag discharger from National Bulk Equipment Inc. is built to withstand rigorous duty cycles and stringent process demands. Process requirements include a target material infeed rate of up to 13 tons per hour, and frequent changeovers that demand system-wide cleaning to microbiologically safe levels. The NBE bulk bag discharger uses two integrated hydraulic massage paddles, each with 2,200 lbs of paddle pressure, to condition the material and aid material flow. The material flows through the NBE E3 enclosed bag spout interface where the closed-cycle dust collection system filters migrant material generated during bag unloading and re-introduces the material back into the process flow. The E3 also works during bulk bag unloading to elongate the bulk bag, further ensuring complete material discharge.

Changeover times are reduced as a result of NBE bulk bag discharger sanitary design features, including the elimination of internal angles, corners, and dead spaces to reduce accumulation of contaminants; and angled planes, rounded-radius framework, 32 Ra finish plate, and stand-offs to speed moisture run-off away from product contact areas. The chain-style tubular drag conveyor minimizes product breakage and degradation while providing a dust-free and airtight material transfer method. Integrated clean-in-place capabilities are provided by an automated CIP cart which enables a complete washing and drying procedure, and aids in meeting regulatory requirements for food-grade system design. National Bulk Equipment Inc. (Holland, Mich.); www.nbe-inc.com; 616-399-2220

Automatic drum-refill system for liquid colours With the new RGInfinity auto-refill system, Riverdale

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Canadian Plastics February 2016 www.canplastics.com

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technology showcase

Global has developed a material handling system that automatically refills one or more liquid colour drums during the molding or extrusion process, eliminating downtime for switching Canadian drums Plastics and reducing the occurrence of transitional or offspecification product with little or no colour. 1/2 pg 4c horizontal Riverdale Global supplies liquid colour in pump-equipped V-ECO drums that remain sealed while colour is metered to processing machines. The RGInfinity eliminates need to replace these drums when empty by refilling them from a large central container, or “tote.” One central container can serve one machine or, if desired, be configured to refill multiple machines running the same colour. Sealed connections throughout the system, from tote to delivery tubes to drums to metering tubes, keep liquid colour completely sealed off from the workplace. Each drum is mounted on a Riverdale Gravimetric Stand, which monitors the weight of colour in the drum and signals a pump valve on the tote when the drum is nearly empty and

again when it is full. This prevents uncoloured product. When the central container needs to be replaced with a full one, the sealed connectors make possible a quick changeover. Riverdale Global can provide containers in various shapes and sizes. Riverdale Global (Aston, Pa.); www.riverdaleglobal.com; 610-358-2900

ROBOTS & AUTOMATION

“Solution” initiative offers robot users new choices “Solution by Sepro” is a new program launched by Sepro Group designed to provide injection molders with the equipment, engineering expertise, and additional services needed to bring new levels of efficiency and quality to their processes. “Solution by Sepro” encompasses

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the full range of 3-axis, 5-axis and 6-axis robots, as well as the ergonomic and powerful Sepro Visual control platform that enables advanced automation management as standard. The program makes it possible to employ new or operational Sepro robots, and integrate them into a manufacturing cell built around new or existing molding machines, regardless of brand. Through its automation design and production in Pittsburgh, Pa., a local team can support almost any project. Robots come together with customized, multifunctional endof-arm tooling, insert feeders and positioning systems, and post-mold inspection, assembly, and packaging equipment. Specific solutions are available for control, parts handling, traceability, assembly, and cutting. Once all the components are complete, complex cells can be assembled and tested before shipment to the customer’s plant. Sepro Canada (Montreal); www.sepro-group.com: 514-515-9349

plastics data file

Suction cups offer improved stability at higher speeds

Piab has unveiled a new addition to its range of dual durometer Dura-flex suction cups, designed to speed up robots and improve productivity, especially for the high-speed unloading of parts with textured surfaces, such as molded plastic parts for car interiors. Duraflex suction cups combine firm bellows with soft,

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technology showcase

flexible lips made from a specially developed material that features the elasticity of rubber and wear-resistance of PU, making them particularly suitable for uneven and porous surfaces. The material’s durability and elastic memory increase the longevity of cups. The material is mark-free, and contains no paint-wetting impairment substances. The single bellows version has a lower building height than the multi-bellows cups, making it easier to fit into spacerestricted areas, such as robot arms picking from molds. Additionally, the single bellows provides a better lifting force, so each cup is able to lift heavier loads — which means that fewer cups can be deployed for a specific task, reducing the initial investment. Piab USA Inc. (Hingham, Mass.); www.piab.com; 800-321-7422

MOLDMAKING

High-performance solid carbide end mills Emuge Corporation has introduced an exten-

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sive line of high-performance solid carbide end mills for applications ranging from universal milling to aerospace and high hardness machining. The new Emuge U.S./Canadian solid carbide end mills launch includes the following tool lines: Top-Cut VAR, a versatile, variable helix solid carbide end mill featuring unique geometry and advanced ALCR PVD coating, for universal milling applications in virtually all materials; Top-Cut, metric end mills for universal milling applications with variable helix flutes and TiALN PVD coating, ideal for both roughing and finishing operations; Multi-Cut, carbide roughing end mills designed with a unique serrated cutting-edge chipbreaker technology for optimum chip evacuation that can achieve metal removal rates between 5 and 10 times that of conventional end mills, in a full range of materials; TiNOX-Cut, a coolant-fed roughing end mill for demanding, high-performance applications such as aerospace machining; and Hard-Cut end mills, specially developed for the machining of hardened materials up to 66 HRC. Emuge Corporation (West Boylston, Mass.); www.emuge.com; 800-323-3013

2016-01-22 10:35 AM www.canplastics.com February 2016 Canadian Plastics 45

2016-01-27 7:49 AM

technical tips

Maximizing the value of regrind By John Bozzelli, Injection Molding Solutions

ith today’s consumers demanding ever more sustainable, reused materials in end products, it’s become ever more important to optimize resin usage — which means, in part, optimizing the use of regrind. Regrind is material that has undergone at least one processing method such as molding or extrusion, and the subsequent sprue, runners, flash, rejected parts, et cetera are ground or chopped. To develop a strategy that optimizes the value of regrind, it’s important to know the issues involved. Appropriate shop floor procedures and discipline must also be in place to avoid potentially catastrophic results. Generally the molding community targets 20 to 25 per cent or less for

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blending regrind into virgin. The subtleties here involve proper training of the resin handlers, usually an entry-level position with little attention paid to training; improper calibration of the virgin and regrind feeders; improper blending of the virgin and regrind; and lack of discipline on the shop floor. The general consensus is that using up to 25 per cent regrind does not significantly compromise virgin resin properties. But is it true? For example, unless they’re dried properly, resins such as nylon, PC, PBY, and PET will undergo a chemical reaction called hydrolysis in the barrel of the molding machine, which causes significant lowering of the polymer chain length. The finished parts look fine, but will actually have lower physical or chemical properties. Blending regrind of this quality into virgin at 25 per cent levels may significantly alter subsequent part performance and function.

A FINE PROBLEM When rejected parts go through a grinder, there is the potential to get a wide range of granule sizes — everything from dust-like particles to large chunks. Repelletizing will eliminate this problem, and it also allows for the regrind to be melt-filtered to remove non-plastic contamination. The downside, of course, is that this adds another step to the process, and adds to granulator and blade wear. Excessive fines are often a special problem because they melt differently than larger granules. If you have a clear application, fines are the sources of both black and white speck development. Since there are numerous applications that require fines removal before processing, you might want to consider buying a fine separator. Finally, the heat history is generally considered to be the most detrimental aspect of producing regrind — since stabilizers and antioxidants get con-

sumed in the granulation process — but I’ve read some convincing technical papers that argue that, if treated properly in processing, many resins can hold their physical properties for a short number of regrind passes.

AN ALTERNATIVE APPROACH Blending regrind with virgin polymer can be confusing. For example, does your process require 80 per cent virgin resin and 20 per cent regrind or do you add 20 lbs of regrind to 100 lbs of virgin resin? And how do you track the actual level of regrind in a plastic part if the part subsequently fails? As a way around these problems, you might want to consider using 100 per cent regrind. There are several benefits. First, there is no question about the amount of regrind used or if it has been properly blended. Second, there is obviously no chance of contaminating virgin resin by mixing materials. Third, if there is polymer degradation the machine will tell you, as long as you’re using velocity control and watching actual pressure at transfer. Fourth, tracking the regrind becomes simple, as parts can be labeled with the resin lot number. Fifth, capital costs are lower because you don’t need to buy blending equipment. On the downside, there are issues associated with using 100 per cent regrind. The processor has to watch fibre length in fibre-reinforced resins, for example, and there is also the issue of colour matching. There are compromises to be made in dealing with regrind. Pick the stratCPL egy that works best for you. John Bozzelli is the founder of Injection Molding Solutions in Midland, Mich., a provider of training and consulting services to injection molders, including LIMS and other specialties. He can be reached at john@scientificmolding.com or visit www.scientificmolding.com.

Canadian Plastics February 2016 www.canplastics.com

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