Mar 2017

On Top of
The World
Exclusive Benchmarking Survey Shines a Light
On Plastics Preeminent Processors
2017 WORLD CLASS
38 Decking Manufacturer Moves

Into Recycled Pellets
40 How to Measure Melt

Temperature in Extrusion
46 15 Things to Know About Servo-

Driven Injection Machines
A property of Gardner Business Media MARCH 2017 No- 3 VOL 63

>extruders >feeders >components >pneumatic conveying >complete systems
>>Integrated compounding and bulk materials handling systems.

From raw ingredient handling and weighing to feeding and
extrusion, all the way to packaging, Coperion and Coperion K-Tron
offer years of processing experience from a single source provider.
>>www.coperion.com | www.coperionktron.com
YOUR BENEFITS
> Integrated process know-how and a perfectly balanced portfolio
for a wide range of applications and systems
> Ultimate engineering workflow
> Core components of the process coming from a single source
> Global service network to optimally serve your needs and provide
local support
Silo I
Truck/Railcar Unload
Pneumatic Conveying
Ingredient
Bulk Materials Handling
Feeding
Packaging Logistic
Extrusion Pelletizing Solutions Solutions
VOLUME 63 NUMBER 3
Cover Story
Meet Plastics
Preeminent Processors
Plastics Technologys second annual
benchmarking surveyWorld Class
2 01 7 WO R L D C LASS Processorsis back with a new
honor roll of companies from across
the industry. One of the ties that
binds these progressive processors
is their reliance on data.
By Tony Deligio, Senior Editor
32
On-Site 38 Decking Producer Becomes 4 FROM THE EDITOR

Supplier of Recycled Pellets
Composite decking manufacturer 6 STARTING UP
Trex expands from using recycled
LLDPE internally to also supplying CLOSE-UP
recycled pellets to others. It found the 12 Robots and Automation
commercial recycled plastics market a
journey full of rewards and challenges.
KNOW HOW
By Heather Caliendo, Senior Editor
20 Injection Molding
25 Extrusion
Tips and Techniques 40 How to Collect and Interpret
28 Tooling
Process Data in Extrusion
In this second of three installments, KEEPING UP WITH TECHNOLOGY
the focus is on the crucial element
of melt temperature. 54 Injection Molding
By Chris Rauwendaal, 57 Mixing/Blending
Rauwendaal Extrusion Engineering
57 Auxiliaries
58 Decorating
59 Recycling
59 Additives
Tips and Techniques 46 15 Things to Know About 60 Testing/Measuring
Servo-Driven Injection Machines 62 Materials
Drive technology for injection
molding machines has been continu- YOUR BUSINESS
ously evolving, and servo motors
63 Resin-Pricing Analysis
have become widely used in a variety
of roles. Heres what molders need to 65 Plastics Business Index
know about todays servo drives in 66 Market Watch
terms of cost, performance, mainte-
67 Marketplace
nance, and training.
By Markus Klaus, Wittmann Battenfeld 72 Processors Edge
PTonline.com Plastics Technology 1

ptonline.com @plastechmag
publisher Rick Kline, Jr.

rkline2@gardnerweb.com
associate publisher Jim Callari
editorial director jcallari@ptonline.com
executive editor Matthew Naitove
mnaitove@ptonline.com
senior editors Lilli Manolis Sherman
lsherman@ptonline.com
Tony Deligio
tdeligio@ptonline.com
Heather Caliendo
hcaliendo@gardnerweb.com
advertising sales Lou Guarracino
loug@ptonline.com
Jackie Dalzell
jdalzell@ptonline.com
Ryan Mahoney
rmahoney@gardnerweb.com
ALL THE art director Sheri Kuchta Briggs
sbriggs@gardnerweb.com
RIGHT RESINS. marketing manager Kim Hoodin
khoodin@gardnerweb.com
FOR ALL THE RIGHT REASONS. ad production manager Becky Helton
bhelton@gardnerweb.com
A capacity for leadership. Subscription Inquiries: For questions or issues related
In what matters most to you. to your subscription, please call 513-527-8800 or email
subscribe@ptonline.com.
When it comes to PET Resin, DAK Americas

has just what you are looking for...Innovative
PLASTICS TECHNOLOGY IS A PROPERTY OF
PET Resins from pioneering research and
development, state-of-the-art technologies
and market know-how. All from one of the
largest producers of PET Resins world-wide. HEADQUARTERS NEW YORK OFFICES
DAK Americas broad line of Laser + PET 6915 Valley Avenue 1441 Broadway, Room 3037
Cincinnati OH 45244-3029 New York, NY 10018
Resins give you exceptional flexibility in Phone 513-527-8800 Phone 646-827-4848
Fax 513-527-8801 Fax 513-527-8801
meeting your design and production goals. gardnerweb.com ptonline.com
From trade leading products and technical
CEO Rick Kline, CBC
service to recycling, to sustainable raw COO Melissa Kline Skavlem
President Rick Kline, Jr.
materials, we continue to demonstrate Senior V.P., Content Tom Beard
not just our record of innovation, but our Director of Market Intelligence Steve Kline, Jr.
Treasurer Ernie Brubaker
steadfast commitment to you and to the Advertising Manager Bill Caldwell
industry. Today, tomorrow, and well into the Director of Editorial Operations Kate Hand
Creative Director Jeff Norgord
future... DAK Americas. Creative Department Manager Rhonda Weaver
Director of Marketing and Events Dave Necessary
dakamericas.com | 1.888.738.2002
GARDNER BUSINESS MEDIA ALSO PUBLISHES
Plastics Technology Handbook NPE Official Show Directory

Plastics Technology Mexico Moldmaking Technology
Modern Machine Shop IMTS Directory
Additive Manufacturing Products Finishing
CompositesWorld Automotive Design & Production
Production Machining
2 Plastics Technology MARCH 2017 PTonline.com

Where others see complexity,
we see a powerful opportunity.
High-performance, high-volume injection molds. At Canon Virginia,
thats been our focus for more than 20 years. Now the same
expertise that creates world-class Canon products is available to
your business. With personalized engineering, we can help solve
your manufacturing challenges and develop the mold you need
for your complex plastic part. Proof that when you trust in Canon,
youre partnering with a mold maker like no other.
cvi.canon.com | 1.866.99.CANON
Canon is a registered trademark of Canon Inc. in the United States. 2016 Canon Virginia, Inc. All Rights Reserved.
From The Editor
Four Takeaways from Our

Exclusive Benchmarking Survey
On top of the list: Be a data wonk.
Our cover story in this issue reports on the results of our latest metrics. Every employee that works that day earns the incentive,
World Class Processors benchmarking study, our second in what Koster says, with the RBIs paid out on a quarterly basis. Besides the
will be an annual research project. The carrot, there is also one stick: If we have a significant safety incident
intention of the survey is to shine a light or customer complaint, part or all of the incentive is lost, Koster says.
on best practices in the industry at a time
when more and more processors are com- Focus on technology and training: Custom molder CNR Group LLC
peting globally for business. (cnr-plastics.com), Jackson, Wis., has 10 machines, all are all-electric
In reading Senior Editor Tony Deligios and most are less than five years old. For those 10 machines, CNR has
report, which starts on p. 32, a few things 11 full-time employees, says Bob Albrecht, company president, with
jumped out: two of those being certified molding technicians, applying scientific
molding principles and robust process development.
Jim Callari Metrics matter: Paul Koster is CEO of
Editorial Director full-service injection molder Selmax Corp., Tonys article lays out the methodology we used to determine the
Selinsgrove, Pa. Selmax (selmax.com) was cream of the crop11 metrics covering operations, business perfor-
among the 25 members of our 2016 group of World Class mance, and human resources. Those measures included everything
Processors. On the subject of collecting, disseminating, and using from scrap and on-time delivery rates to employee turnover and sales
data in a tactical way, Koster puts it succinctly: We share perfor- growth. We generated a tremendous amount of data in the process.
mance metrics, because what gets measured gets achieved. Tonys report includes selected data, but only survey participants get
the complete data set.
Be transparent with employees: When you finish reading the
Mossberg Industries Inc. article, I hope one of your take-
(mossbergind.com), Garrett, Ind., aways is, Were doing all this stuff.
makes spools and reels using 201 7 WO RL D CL ASS Why arent we mentioned? Well,
injection molding and extru- first, you have to respond to the
sion. Performance metrics like survey. Second, you have to make
on-time delivery, as well as the cut for World Class status. And
customer concerns, are posted third, you have to agree to divulge
monthly in the shop breakroom and are also reviewed in the com- your companys identitywhich is not required to participate in the
panys monthly plant meetings, notes James S. Khorshid, president survey, but only if you want to be recognized by name in print.
of the company. We share these items with everyone so they can For this years report, 22 out of the 25 processors identified as
give direct input if anyone has an idea to improve a process, World Class elected to make themselves known (21 did last year). To
Khorshid says. Adds Missy Rogers, president of custom injection my way to thinking, it should be 25 out of 25. Wouldnt that World-
molder Noble Plastics Inc. (nobleplastics.com), Grand Coteau, La., Class Processor designation be a useful credential when your
We display metrics and hold regular meetings to review goals and customers put projects out to bid? Wouldnt it be a good thing even
measures, because communication is key to success. to put such a designation on your own website?
Get involved in the next survey by emailing Tony at
Reward stellar performance with cash: 83% of the World Class tdeligio@ptonline.com.
Processors offered a bonus, while only 69% of total survey respon-
dents did. Selmax links operational performance and pay via its
Results Based Incentive (RBI). This molder posts machine run time,
reject rates, and production cycle times daily. RBIs can be earned for FOLLOW US
@plastechmag
every day that the team achieves the targets established for those @jimcallari

LOAD.
SET.
BLEND.
INTELLIGENCE AND SIMPLICITY IN
3 SIMPLE STEPS.
DOWNLOAD MAGUIRE 5D
AUGMENTED REALITY APP TODAY
ON APPLE AND ANDROID TO SEE
THIS PRODUCT COME ALIVE.
MAGUIRE.COM/5D
50,000+ Blenders Installed To

Date Since We Revolutionized
Blending In 1989.
USA: 610 459 4300 | CANADA: 905 879 1100 | EUROPE: +44 1827 338 280 | ASIA: +65 68487117 | IMEA: +971 4 881 6700
T ECHNOLOG Y A ND INDUS T RY NE W S
Star ting Up
All-Electric, Tabletop Injection Machine

Fully Automatic Mold Change
Designed for Simplicity, Low Price
In Under 2 Min
Two engineers and entrepreneurs who were buying plastic parts to manu- At K 2016 in Dusseldorf, Staubli (U.S. office
facture a line of automotive aftermarket air/fuel ratio gauges decided they in Duncan, S.C.) demonstrated complete
hands-off mold changing in
wanted to mold them in-house, but balked at the cost of conventional
less than 2 min, and company
injection machines. So they decided to design and build their own. About spokesmen said the system can
a year ago, Burak Cevik and Kubi Kara, partners in APSX LLC, Blue Ash get that down to 1 min. A mold table on
rails carried a preheated mold into posi-
(Cincinnati), Ohio, came up with a tabletop machine with 7.5-ton clamp
tion beside the press. A sensor in the cart
and plunger injection unit capable of 1.83 in.3 (3 to 40 g) shot size and 5000 read the mold setup parameters from a
psi injection pressure. All axes on the machine are driven by servo step- chip in the mold. For the mold already in
the press, all power and data connections
per motorsanother product line of APSX. The two partners have been
were disconnected automatically within
using the press to mold cases and bezels of TPO and PP, but they have also 3 sec. A single manual lock disconnected
used it with HDPE, PS, ABS, and powdered-metal injection molding (PIM/
MIM) compounds. Starting in December, the partners began promoting the
machine to inventors, custom molders, and small manufacturers of toys
and other products for prototype and short-run production.
The APSX-PIM machine measures 43 in. long x 12 in. wide x 15 in. high and
weighs 250 lb. It was designed for simplicity and low cost. It has no air or
water connections. Mold cooling is external, applied by a variable-speed,
electronically controlled fan mounted over the clamp. The machine has a
feed auger to move pellets from the hopper to the injection barrel, which
has a 1-in.-diam.
all water lines. Ejectors retracted auto-
plunger instead of a matically, and the Staubli magnetic plates
screw. Heater bands declamped the mold in another 3 sec. The
mold then slid out of the machine onto
on the barrel provide the cart, which indexed forward so the
the energy to melt the new mold could slide into place, clamp
on magnetically, and make all the utilities
small shots of resin.
connections. The final step was automatic
APSXs in-house mold- exchange of robot grippers for the new job.
ing produces a part in Staubli sources said this system is
being used at a new Plastic Omnium plant
about 60 sec.
in Mexico, where several rail-mounted
The four-tiebar clamp mold tables exchange 60-ton molds in
is driven by a stepper 3700-ton presses in under 2 min.
800-257-8235 staubli.us
motor and ballscrew.
The injector is driven by
Lanxess to Acquire Chemtura
a stepper motor push-
Pittsburgh-based Lanxess is acquiring
ing against a spring, Chemtura, Philadelphia. The transaction,
which pushes against is expected to be complete by midyear.
The move will make Lanxess one of the
the plunger. A shutoff nozzle opens for injection and closes after mold fill- major global players in a broad range of
ing. Max. mold size is 4.8 x 6 in. and clamp stroke is 6 in. The machine costs additives. Chemtura is one of the worlds
$12,500, but is available for as little as $6250 to participants in a Kickstarter three largest manufacturers of bromine
and bromine-based products such as
crowd-funding capital-raising campaign started last month. Machines flame retardants for plastics. The FR addi-
usually ship in two to six weeks; several units were in stock at press time. A tives will be integrated into the companys
Rhein Chemie Additives business unit.
video of the machine in action is available at https://youtu.be/E_l6PvF2Ju8.
800-526-9377 lanxess.com
513-602-9730 apsx.com

IF OUR NEW MOLD
TEMPERATURE CONTROLLERS
WERE ANY MORE
ENERGY- EFFICIENT,
THEYD CARPOOL
AND MILK THEIR OWN GOATS.
Introducing the Thermal Care Aquatherm RQE Series of pressured water temperature-control units, with pumps that are
up to 70% more efcient than ever before. Weve also minimized cycle time, doubled the capacity and increased the
power, with options from 9kW-48kW and hp-10hp. All with exceptional accuracy, temperature control and reliability.
To pocket eco-friendly energy savings, call 888.383.8108 or visit thermalcare.com/RQE.
2016 Thermal Care, Inc.

Star ting Up
Artificial Joints Make Strides with 3D Printing

Additive manufacturing is a polymers. It runs every day
big strategy for us, says Ryan and overnight, according to
Loftus, engineering manager for Loftus. He says this workhorse
Exactech, Inc., Gainesville, Fla., machine can make parts accu-
a producer of artificial hip, knee, rate to 0.003-0.005 in. for only a
and shoulder joints. His firm, few dollars.
with sales of $250 million annu- More recently, Exactech
ally, is reportedly the fifth larg- installed a MakerBot printer,
est joint orthopedics supplier, which uses the FDM process of
but Loftus claims it is the first to extruding thermoplastic fila-
use additive manufacturing (AM, ments. MakerBot Industries,
aka 3D printing) in production Brooklyn, N.Y., is a subsidiary
of metal large-joint components, such as titanium hip cups. AM of Stratasys (makerbot.com). Though a less exact system, it
is perfect for us because of our low-volume/high-mix product produces parts for less than $1, Loftus says. His firm uses it to
line. For example, each Exactech knee set contains nine sizes, make PLA prototypes of surgical devices, which are machined from
and many parts are designed to accomodate a specific patients Radel polyphenylsulfone (PPSU) from Solvay Specialty Polymers,
anatomy. He also notes that AM can make smooth, organic Alpharetta, Ga. (solvay.com). Loftus sees a large opportunity
surfaces that can improve a products aesthetics and functionality to reduce costs by 3D printing the actual surgical instruments,
over products typically produced by traditional machining. (Photo but it is not clear that a printable material is available that can
shows plastic trial tibial inserts made by conventional machining withstand multiple autoclave sterilization cycles. And not just the
that could benefit from 3D printing.) material, but actual printed parts, would have to be subjected
Exactech (exac.com) has three AM machines (from EOS and to extensive sterilization and other testing before they could be
Arcam) for laser sintering of metal powders. It also has two approved for production.
machines (Objet and MakerBot) for printing plastic prototypes of Loftus is chairman of the Advanced Manufacturing Council
instruments and implants, as well as soft jaws to hold printed of the Gainesville Chamber of Commerce (madeingnv.com). Also
parts for machining (formerly machined out of aluminum). Its involved in the Council are the Wertheim College of Engineering
Objet 3D printer, supplied by Stratasys, Eden Prairie, Minn. (stra- at the Univ. of Florida-Herbert, Santa Fe Community College
tasys.com), uses inkjet-style deposition of UV-curable acrylate (Santa Fe, N.M.), and Alachua County (Fla.) Public Schools.
Chinese Buick Sports Largest-Ever Victrex Expands in

PC Rear-Quarter Window Downstream Parts Molding
A 20-yr-old Chinese joint venture Tier I supplier Ningbo Shentong Victrex, W. Conshohocken, Pa., has formed
of General Motors and SAIC Motors, Auto Decoration provided design a joint venture with Tri-Mack Plastics Manu-
SAIC-GM (SGM), has introduced its assistance and technical support facturing Corp. of Bristol, R.I., to accelerate
latest Buick GL8 and GL8 Avenir from the windows concept to valida- commercial adoption of PAEK composites
luxury multi-purpose vehicles (MPVs), tion. Shentong also invested in a new in aerospace applications. Called TxV Aero
which sport what is reportedly the production facility in Yuyao City with Composites, the venture includes the estab-
largest PC lishment of a new U.S. manufacturing facility.
rear-quarter This new venture represents the second
window in the move into downstream processing by Victrex,
world. Molded which in 2015 acquired polymer gears
in Lexan PC specialist Kleiss Gears, Grantsburg, Wisc.,
from SABIC which has particular expertise in molding
(U.S. office in PEEK. TxV Aero Composites intends to offer
Houston), it is a range of PAEK composites, from custom
said to be 40% laminates to pre-formed composite inserts
lighter and for hybrid molding processes, as well as
significantly finished parts and overmolded hybrid
more impact composite components and assemblies. One
resistant than example is new Victrex AE 250 composites,
a comparable glass window, and the first mass-production PC glazing embodying a unique hybrid molding process
also features design elements not line in China. Its capabilities include in which continuously reinforced PAEK
achievable with glass. The Buick GL8 advanced two-component injection- composite preforms are injection over-
has been a mainstay of the Chinese compression molding and flow coat- molded with PEEK compounds.
market since 2000, with more than ing processes.
800-victrex victrex.com
700,000 sold. 713-532-4999 sabic.com

Thru Thick
& Thin
Ross Planetary Mixers are versatile.
While suited to handle a wide range
of processes, they are uniquely built to
take on viscous applications. Mix gels,
pastes, putties and shear-sensitive
materials up to 6 million cP.
With laboratory sizes starting at 1/2-pint,

up to 1000-gallon units for large-scale
production, Ross has the Planetary
Mixer to fit your process line.
Learn more at mixers.com.

Call 1-800-243-ROSS or try our
free online Knowledge Base &
Product Selector web app
at Mixers.com/web-app.
1000-Gallon
1-Quart
Scan to learn more.

Star ting Up
Concurrent Events at Chinaplas 2017

Nova Chemicals Starts Up Focus on Industry 4.0, Design & Medical Plastics
LLDPE Reactor Chinaplas 2017 (May 16-19 in Guangzhou) will once again host three concurrent confer-
In December, Nova Chemicals Corp., Moon ences along with its massive exhibition with an expected 3300 exhibitors. According to
Township, Pa., started up its new world- show organizer Adsale Exhibition Services, Hong Kong, these are the second Industry
scale, gas-phase LLDPE reactor at Joffre, 4.0 Conference, Design x Innovation, and the third Medical Plastics Conference. Adsale
Alta., and is now shipping butene LLDPE Chairman Stanley Chu noted that China is no longer a low-wage country, and adop-
produced by this unit to its customers. tion of Industry 4.0 technologies can help it remain competitive. A few companies are
making use of networking production technologies, Chu said. Industry 4.0 is still a
vision for many Chinese companies, but an attainable one.
Chinaplas 2016 in Shanghai drew 148,575 visitors, including 39,454 from overseas,
representing more than 160 countries and regions. For 2017, the show will host more
than 30 overseas groups, including delegations from Finland, Jordan, Thailand, Malaysia,
and the Philippines. In addition, there will be more than 110 Chinese groups visiting.
Braskem Americas UHMWPE

Representing the first new LLDPE reactor Plant is Up and Running
to be brought on stream in the Americas in Braskem America, Philadelphia, brought
over 10 years, this units capacity will help on stream its new UTEC UHMWPE plant
the company to meet the growing demand at LaPorte, Texas, in mid-January. The
for flexible films used in food packaging, new plants output was not disclosed. As
heavy-duty sacks, and can liners. The reac- reported last year, Braskem enhanced
tor boosts Novas LLDPE production capac- its Pittsburgh Innovation and Technology
ity by nearly 1 billion lb out of its total PE Center with the addition of advanced
capacity of about 5 billion lb. UHMWPE R&D capabilities to support
412-490-4000 novachem.com the launch of UTEC production in the U.S.
215-841-3100 braskem/com/utec
+1.616.738.9000 | ENSIGNEQ.COM
Smart Solutions to
Keep You Moving.
nsign
EQUIPMENT
BULK MATERIAL HANDLING EQUIPMENT, SYSTEMS

AND AUTOMATION. MADE IN THE USA.
BULK CONTAINER FILLING BAG BREAK STATIONS

SYSTEMS MECHANICAL CONVEYORS:
BULK BAG / SUPER SACK SCREW & BELT
UNLOADING SYSTEMS LIVE-BOTTOM STORAGE BINS
HIGH-CAPACITY VERTICAL GAYLORD & DRUM TILTERS
AUGER MIXERS
SURGE BINS &
DUMPERS AND PORTABLE STORAGE BINS
DUMPING SYSTEMS

WITH DRI-AIR YOU GET MORE THAN JUST THE
BEST DRYER.
We studied 4 or 5 brands in deciding where to source our dryers and Dri-Air
came out on top. We found them to be so much more energy efficient than any wheel
dryer by at least 40%! As soon as we placed an order, they came right into our plant
to train our facilities people on Dri-Air equipment they partnered with us immediately.
Nobody else before had ever offered to do that. They have really integrated Dri-Air staff
with our Empire staff. Dri-Air is the most reliable supplier that we have found.
LY M Neal Elli, President, Empire Precision

UD A
O
DE
PR
DRI-AIR
Industries, Inc.
IN
T H E S
U T: 860.627.5110 | E: sales@dri-air.com www.dri-air.com The Drying and Blending Experts
R O B OT S A N D AU TO M AT I O N
Close-Up On Technolog y
Connectivity & Collaboration in

Robotics & Automation at K 2016
Besides a handful of new robots
and pickers, the big themes
were modular plug-and-
play automation, Industry 4.0
connectivity, easier programming,
Improved version of
and safer collaboration with Yushins super-fast HAS
Dual-Wing servo robot has
human workers. a takeout time of 0.27 sec.
As with almost everything else in plastics these days, robots are include Xdesign linear robots with payload capacities of 3 to
less and less likely to be considered in isolation, rather than as 20 kg (6.6 to 44 lb) for presses of 20 to 800 metric tons; high-
part of a system, an automated cell, or a net- speed sDesign linear robots for packaging with up to 3 kg (6.6
By Matt Naitove
Executive Editor worked plant. Hence, much of the emphasis at K lb) capacity for presses of 75 to 300 m.t. The new xLine for large
was on how robots play well with othersi.e., parts has been expanded to include presses from 75 to 2500 m.t.
connect with other equipment, how they can be programmed The smaller models are mainly for multi-component machines
simply and easily, and how they can operate safely and collabora- with vertical injection units. The newest models are the 600
tively in close proximity with humans. xLine with 60-kg (132-lb) capacity for presses of 1300 to 2500
m.t. and 120 xLine with 12-kg (26.4-lb) capacity for presses of
NEW CARTESIAN ROBOTS & PICKERS 250 to 500 m.t. Wemo also showed eDesign and iDesign linear
Our previous reporting has covered new linear robots and servo robots/pickers with capacities of 2 to 10 kg (4.4 to 22 lb) for
pickers from Boy Machines, Engel, KraussMaffei, Sepro, and presses of 25 to 300 m.t. Wemo is represented here by Robotic
Yushin (August, September, and November Automation Systems, Waunakee, Wisc.
Keeping Ups). In addition, Arburg (U.S. (roboticautomationsystems.com).
office in Rocky Hill, Conn.; arburg.com) OPC-UA interfaces Wittmann Battenfeld (Torrington,
brought out a large Multilift V model with are bringing robots Conn; wittmann-group.com) showcased
40-kg (88-lb) payload capacity. And Yushin into Industry 4.0. the new R9 controller for all its robots.
of Japan (Cranston, R.I.; yushinamerica. Retaining the look and feel of the R8
com) had two new servo models. One is the control, with which it is backwards-
RCII-150 kick-driven robot for handling large and long parts such compatible, the R9 TeachBox pendant has a larger (10.1-in.)
as auto bumpers. The unit has a two-axis servo wrist and 40-kg screen with higher resolution and a glass covering that accepts
payload. Its telescoping vertical stroke is 1550 mm, kick stroke is multi-touch/gesture commands like a smartphone or tablet, as
1200 mm, and traverse stroke is 2500 mm. There was also a new well as membrane keys for essential inputs. It also weighs 10%
version of Yushins ultra-high-speed HAS robot with takeout less and is more comfortable to use.
time of only 0.27 sec. Further optimization of the unit intro- The R9 control is standard on Wittmanns new Primus 16
duced at K 2013 gave this double-wing model (two robots on one robot for machines from 50 to 200 metric tons. This economical
rail) a slimmer profile, less vibration, and 13% lower weight. model (an adapted version of the W818) is aimed primarily at
After two years of integration and redesign, Wemo Asian molders, but is also available here to molders in areas like
Automation of Sweden (wemogroup.com) has combined its Southern California, where a small, low-cost, pick-and-place unit
lines and those of Hahn in Germany to provide a full range of is desirable. The Primus 16 has three servo axes and a pneumatic
top-entry and side-entry sizes in a consistent design. These wrist. Payload capacity is 5 kg (11 lb).

Sentra temperature control units
Treasured by Processors
Sentra Temperature Control Units Sentra units are also engineered for
provide precise fluid temperature dependability and efficiency with a high
control for a wide range of processing flow centrifugal pump & motor that
applications. With over 40,000 units in generates 20% more flow using the same
service worldwide, it is no secret why power compared to many competitive
Sentra units are so valued. units. The Sentra is as efficient as any
temperature control unit in the industry
The Sentras control instrument and the Temptender & G-series units have
technology is designed and built to the only standard modulating cooling
meet the demanding needs of fluid valve in the industry which explains
temperature control. From our why Sentra units are so treasured by
Temptender T-Series instrument with processors.
advanced color touch screen interface
and clearly worded display, to the You dont need a treasure map, just
G-Series instrument with LCD display or hook it up and reap the riches of
efficient, trouble-free performance
our simple and cost-efficient VE-Series
only a Sentra can provide.
instrument, you can choose the Sentra
control best suited to meet your specific
needs this is the real hidden treasure!
!
New
Temptender T-Series
!
New
G-Series
VE-Series
525 East Stop 18 Road Greenwood, IN 46142 317.887.0729

www.AdvantageEngineering.com
Nee collaborative robots were shown by ABB (left) and Fanuc, among others.
Fanuc demonstrated the ability to stop robot motion with the touch of a hand.
CONNECTIVITY FOR INDUSTRY 4.0 Kuka Robotics (Shelby Township, Mich.; kukarobotics.com) has
Wittmanns new R9 robot control has the OPC-UA (Open added an OPC-UA interface to its LBR iiwa (Lightweight Robot intel-
Platform Communication-Unified Architecture) interface that ligent industrial work assistant) collaborative model.
has been adopted in Europe for machine-to-machine commu-
nications under the umbrella concept of Industry 4.0. It is also MORE COLLABORATIVE ROBOTS
part of Wemos WIAP 4.0 (Wemo integrated automation pro- Testimony to the growing interest in so-called collaborative robots,
cess). This includes Wemo connecta function utilizing a which can work safely alongside humans without mechanical
wireless transmitter inside the robot that can communicate guarding, is ABBs introduction of its first cobot entry, called YuMi
with the cloud and with mobile devices. It transmits numbers (see December Starting Up and short.ptonline.com/Kcollabora). This
of cycles, operating hours, cycle times, tabletop, two-armed (each with six axes) unit
color-coded operating status, and energy- has a soft, padded covering and no pinch
saving information. Another element is Standard robots are points. Motor torque is low, but it is relatively
WRS (Wemo Remote Service) for the robot. being made safer and fast for pick-and-place operations. Besides
At K 2016, Wemo demonstrated WIAP 4.0 more collaborative. safety, the focus is on ease of use; simple
through individualized production of laser- lead-through programming eliminates the
printed visitor name labels with a QR code. need for an operator screen.
A company official said five individualized-production systems In addition, Fanuc Automation (Rochester Hills, Mich.;
have been sold in Europe for electronic, medical, and automo- fanucamerica.com) showed off a smaller model of its CR six-axis
tive customers. The first commercial user is producing electrical collaborative robot (see Feb. 16 feature). And Boy Machines
plugs in several varieties using insert molds. WIAP 4.0 reportedly (Exton, Pa.; boymachines.com) demonstrated direct robot-to-
reduces setup time for multiple short runs of different plugs. human handoff of glasses of beer, using cobots from Universal
Wemo has also received inquiries for such systems from the U.S. Robots of Denmark (E. Setauket, N.Y.; universal-robots.com).
and a Western company operating in India. Meanwhile, several suppliers focused on making conventional
OPC-UA and Industry 4.0 were also highlighted at the show robots more collaborative. Sytrama of Italy (New Castle, Del.;
by makers of six-axis robots. For example, ABB Robotics (Auburn sytrama-usa.com) and Staubli Robotics (Duncan, S.C.; staubli.us)
Hills, Mich.; abb.com/robotics) introduced its Connected Services demonstrated linear and jointed-arm robots that use compact
program, which allows for monitoring essential data for predic-
tive maintenance. These include both mechanical and electrical LOOKING FOR MORE ROBOTICS NEWS AT K 2016?
parameters, such as motor temperature, torque, and current draw.
Another feature is fleet assessment, whereby users can compare Visit ptonline.com/zones/k-2016 and
utilization of various ABB robots in their plants. short.ptonline.com/Krobots

performed with the robot OEM control. Then the SCP2 is connected
and runs the robot in a Sytrama environment. The SCP2 can control
two robots (linear or six-axis) from one pendant. It can also control
upstream and downstream automation.
For high-speed pick-and-place and assembly operations,
compact SCARA (selective-compliance articulated robot arm)
robots are a well-known option. ABB brought its first SCARA
model to K. The new IRB 910SC family is modular with max.
payload capacity of 6 kg (13.2 lb) and reach from 450 to 650 mm.
Engel has also added a four-axis SCARA model to its line (see
August Keeping Up).
MODULAR AUTOMATION PACKAGES

Plug-and-play modular automation cells were Several suppliers featured plug-and-play mobile automation
shown by CBW Automation, Engel, Fanuc (seen modules that can easily be rolled up beside a press and put quickly
here), Hekuma, and KraussMaffei.
to use. Examples previously reported (September Keeping Up) are
the Hekuflex system from Hekuma of Germany (hekuma.com), the
laser scanners (such as from Sick AG in Germany) to sense the easicell from Engel (York, Pa.; engelglobal.com), and a similar con-
presence of humans. When a person approaches within a certain cept from KraussMaffei (Florence, Ky.; kraussmaffeigroup.us).
distance, the robot continues its cycle, but at a slower speed, Also making
which Staubli calls Safe Limited Speed (SLS). Coming even closer its debut at
can cause the robot to stop completely (Safe Operating Stop, or the show was
SOS). It starts up again instantly when the person moves away a a modular LR
certain distance. Staublis new TX2 six-axis robots also define a Mate robot cell
Safe Zone around the EOAT to prevent collisions with inanimate from Fanuc,
obstacles. These models also have a sensor skin; when touched, it supplied with
brings the robot to a halt. (For more, see December Starting Up and a Quick Startup
short.ptonline.com/Kcollabora.) software package
Kuka also showed off a new that includes
Modular auto-
way to make standard six-axis integration with
mation cells go
robots more like cobots by Fanuc vision
plug-and-play.
adding simple lead-through teach systems. And
programming. This is accom- CBW Automation,
plished via a software upgrade and temporarily connecting a Fort Collins,
3D mouse (photo) that communicates via Bluetooth to a tablet. Colo. (cbwau-
After programming, the mouse can be removed and used tomation.com),
somewhere else, while the robot operates normally. demonstrated its
new Advantage
SIX-AXIS & SCARA NEWS Series automa-
Kuka introduced a new focus on solutions rather than compo- tion module
nents with a series of custom package concepts at various levels at the booth
of integration. These Ready2 solutions can include preconfigured of Milacron,
software and hardware for specific functions or complete turnkey Cincinnati Standard six-axis robots can
cells. Kuka works with partners such as robot integrator FPT Robotik (milacron.com). be made simple to program via
GmbH in Germany (fpt.de). Among other things, FPT can program All wired and lead-through teach programming,
similar to collaborative robots.
a Kuka robot with a Fanuc-style operator screen for users that are ready to go, the The key is a 3D mouse that can be
already familiar with Fanuc equipment and software. Advantage series temporarily attached to a robot
In a similar vein, Sytrama now offers its SCP2 control and uses a standard- and manipulated with fingertips.
It communicates wirelessly with
pendant, standard on its Cartesian robots, for use with six-axis ized base and
a tablet.
robots from ABB, Kuka, and others. Basic programming is frame to reduce

Arburg demonstrated an automated cell that molded and

assembled PS petri dishes and lids. An electric Allrounder
470 A (110 tons) used a 2 + 2 stack mold and automation
from Mould & Matic Solutions, part of Kiefel (U.S. office in
Portsmouth, N.H.; mouldandmatic.com). Parts were ejected
into free-fall with guides that led to a conveyor that
assembled dishes and lids and stacked the assemblies.
temperature-resistant HNBR rubber. They are said to avoid

scratching or marring even painted or plated parts. They contain
no silicone. Worn pads can be replaced in minutes.
FIPA also introduced a quick-change system for robot EOAT.
It incorporates a snap-on function with a visual locking indica-
costs. Modularity allows the system to be quickly and easily tion (Safe-Lock).
adapted to new parts, minimizing downtime for changeovers. ASS Maschinenbau GmbH (Plymouth, Mich.; eoat.net)
CBW also reduced cost and increased flexibility by replacing high- presented three new options for handling warm parts such as
flow vacuum blowers with a suction-cup retrieval system. Suction preheated organosheet composites. A special heat-resistant
cups can easily be relocated to accommodate different parts. gripper of the 10-12 series, GRZ10-12 HT, has serrated aluminum
Expensive plumbing of vacuum to the EOAT was eliminated. jaws and withstands long exposure to 150 C (302 F). For dent-free
suction holding of warm parts such as organosheets, ASS offers
NEW GRIPPERS PEEK inserts for its VSE vacuum cups. VS HT+ vacuum cups can
FIPA GmbH of Germany (Cary, N.C.; fipa.com) brought out new take long-term use at up to 300 C (572 F). The company also has
100 series grippers with aluminum jaws fully coated with high- new needle grippers for flexible composite materials.
ALL-ELECTRIC PRECISION AT A CONSIDERABLY LOWER PRICE
Zhafir Zeres 44 to 730 U.S. tons
The all-electric Zeres injection molding machine delivers precision perfor-

mance and impressive repeatability at a surprisingly affordable price. High
acceleration, speed and energy efficiency are maximized with the latest The control on our ZE3000 is
control technology. Plus you save floor space and the cost of an external easy to use and the press is
hydraulic power pack with the Zeres integrated hydraulic system for core simple to operate. It has
performed as well as other
pull, valve gates and carriage movement.
well-known machines but at a
Contact us to learn just how much productivity you can gain with the much lower cost to purchase.
all-electric Zeres. John Redden
Facilities Manager
Absolute Haitian 508-459-5372 216-452-1000 www.absolutehaitian.com National Hanger Company

ENGEL automotive
ready for active innovation
The automobile industry is shaping up for the future with

intelligent technology. ENGEL will join your company on
this journey: with competence, experience and visionary
solutions for injection molding. Your plastic components
have wide-ranging requirements; to be safe, functional,
lightweight and attractive. We at ENGEL will work with
you, side by side, allowing you to take your innovations to
production even faster. For example, with our center for
lightweight composite technologies, ENGEL optimizes new
thermoplastic and reactive processes for your pioneering
lightweight construction components.
www.engelglobal.com
Know How
INJECTION MOLDING
A Simpler Way to Calculate Shot Size vs. Barrel Capacity
Lets take another look at this seemingly dull but oh-so-crucial topic.
Like many crusty veteran processors, I do not like admitting my Properly specified and with a skilled operator, barrels can be
mistakes. Yet, in a column in wrote in October 2011, I tackled the topic swapped in less than 30 min, even if the barrel is hot.
of calculating shot size vs. barrel capacity How do you figure out what barrel/screw size youll need? If it is
andupon further reviewconcluded a new part and the mold hasnt been built yet, running a mold-filling
the article had some flaws. So, heres a analysis will give you the volume of the part and runner. If your
second try with simpler advice. mold is in the building stage, your moldmaker may have calculated
Calculating shot volume to make the volume of your shotand make sure to also include the runner
sure your barrel has enough capacity volume if its a cold-runner mold. If you already have the mold and
seems like a dull topic. But trust me, you are purchasing a new machine, you have two sets of data: the part
youll have a significant emotional and runner weights, plus the shot size of the existing machine. With
By John Bozzelli experience if you were to put a mold in either part plus runner weight or the volume of the total shot, you
a machine only to find out there is not have your starting point. So how do you do the calculation?
enough barrel capacity to make the part. Especially if it is a new Lets start with the scenario in which you know the part weight. I
machine you bought for that mold. like to work in grams but most machine specifica-
Perhaps that has never happened to you, tions are in ounces. If the part, runner (cold), and
Trust me, youll
but I do get emails about this, and my answer sprue together weigh 164 g of PP, that comes to 5.8
have a significant
is never well received. Most molders dont like oz (164g/28.3 g/oz). Assuming you have a barrel
emotional experience
to hear they need to buy a new barrel, because capacity of 8 oz, you might be tempted to conclude
if you were to put a
of the time and cost involved. So, if you are that you have plenty of shot volume available.
mold in a machine
buying a new machine or scheduling a mold Unfortunately, this is where things start to unravel.
only to find out there
to a machine, do your homework before the First, look at the machine specification, it
is not enough barrel
machine is ordered or the schedule is set. usually is in grams or ounces (weight) of PS. So
capacity to make the
Most likely youll have a variety of part the machine specification is 8 oz, or 266 g of
part, especially if you
sizes, so it is unlikely you will find a one- PS (8 28.3 g/oz = 226 g). But you want to mold
bought the machine
screw-size-fits-all remedy. Some molders go PP. There is an important density difference
for that mold.
with the biggest screw possible, but do not do between these resins. At room temperature, the
this, as it will cost you more money long term. density of PS is 1.04 g/cm3 and PP has a room-
Super-small shot sizes, using less than 20% of the barrel capacity, temperature density 0.90 g/cm3. You cannot compare your PP number
often lead to long residence times, which in turn lead to polymer to the machine specification because of the difference in densities
degradation and poor process control. Plus, big screws usually mean between materials. So, for your 164 g shot size you need to correlate
lower plastic pressure capability. Large shot sizes, using greater the PP grams to PS grams. For your 164 g part, the conversion factor
than 65% of the barrel capacity, tend to have melt-quality issues like is not 28.3 g/oz but 28.3 times the ratio of densities: 164 g 28.3g/oz
unmelt, poor melt uniformity, and long screw-recovery times. 1.04/0.90 or 6.72 oz equivalent to PS. So comparing this new PS equiv-
Its great if you find one screw that can accommodate all your alent oz to the machine specification of 8.0 oz, youre still okay, right?
parts; but if not, consider ordering two barrels. Two barrels will Unfortunately, this is when Mr. Murphy usually enters the equation
allow even a greater range of molds. You may be surprised at the to remind you that what can go wrong usually does. Hell remind you
low price of a second barrel when ordered with the new machine. that these are room-temperature densities, and in molding (that is in
the hot barrel) we deal in melt-temperature conditions. Sorry, heres
KNOW HOW INJECTION MOLDING another step of complexity. You must work with melt densities.
Learn more at PTonline.com When melted, the polymer molecules are farther apart and
Get more insights on Injection Molding from our expert density decreases. Melt densities are not often found on the
authors: short.ptonline.com/moldingKH material specification data sheet. Usually they can be found using

QuALITy KNOw-HOw
MACHINES TECHNOLOGIES
THE HOME OF
INJECTION MOLDING
MARKET LEADERSHIP
PASSION vISION
INNOvATION
For as long as ARBURG has been involved with injection molding, its aim has always been
to be the home of the process. You wont find another company in the world that is
dedicated to the development and perfection of injection molding with the same level
of consistency and commitment. We always have one objective in mind: your success.
www.arburg.us
Know How
your search engine. (Plastics Technologys Universal Selector is one place to check; visit stand how this happens. There is a difference
ptonline.com/materials.) For PS, the melt density is 0.945 g/cm3 and for PP it is about in how certain polymers melt. In particular,
0.74 g/cm3. This changes our calculation; it is now 0.945/0.74 or 1.28. Now we need a understand that PP is a semi-crystalline resin,
minimum shot size of 7.4 oz (164 1.28 = 210 g or 7.4 oz). We are still (just barely) within which melts differently than amorphous
our 8-oz barrel capacity, but Murphy isnt done with us yet. resins. Semi-crystalline resins stay hard up
Is it practical to attempt to use 93% of the barrel capacity (7.4/8.0 oz)? No, that is not going to their melting point, and normally require
to work. My recommended working range for a barrel is between 25% and 65% of the barrel twice as many BTU/g to melt than amorphous
capacity. Then I add in another 10% safety factor, for check-valve leakage and melt unifor- resins. This double whammy makes semi-
mity. So the real target is 7.4 + 10%, or 8.14 oz shot size in PS equivalents for PP. Seeking to use crystalline resins significantly harder to melt
only 65% of the barrel, final calculation is (0.65 x = 8.14) or 12.5 oz barrel capacity in PS units. uniformly than amorphous resins.
But why the extra barrel capacity? Because youre melting plastics and you need to under- Think about it: In a 20:1 L/D screw,
you have 10 flights for feeding (little to
no melting in this section); five flights of
transition or compression, where melting
occurs; and five flights in the metering
zone, which are designed not to melt but
to pump or push the plastic through the
non-return valve to build backpressure and
Advanced Plastic s Education & Training your shot. These are significant factors that
are not obvious, but they are the reason you
need a larger barrel.
Simplified message: Stick with volume
and melt densities. Do not work in weights.
Learn from the best

The barrel is basically a big syringe. Again,
with a 164 g shot of PP, the calculations
would be: 164 g/0.70 g/cm3 or 234 cm3
volume for PP. Add 10 % for safety = 257
cm3. Barrel size needed: 0.65 x = 257 cm3,
x = 395 cm3. If you work with volumes for
the screws available, you are done. If you
need to work in weights, convert the 395
cm3 to grams of PS using the melt density of
PS which is 0.94 (0.94 395 = 371 g pf PS or
roughly a 13 oz barrel).
Bottom line: Take the time to do the
shot-size calculations. True, its a pain to do
and double-check, but otherwise you are
inviting Murphy to your party and he wont
John John Michael be bearing gifts. If all this is too much, email
Bozzelli Beaumont Sepe me and I will send you a free spreadsheet to
do these calculations, making your day a bit
easier. You plug in the grams and resin melt
densities, and it calculates the suggested
barrel capacity in ounces.
www.AIM.Institute or 1-866-344-9694
ABOUT THE AUTHOR: John Bozzelli is the
founder of Injection Molding Solutions
(Scientific Molding) in Midland, Mich., a
provider of training and consulting services to
injection molders, including LIMS, and other
specialties. Contact john@scientificmolding.com;
scientificmolding.com.

Performing complex
measuring jobs at a glance.
ZEISS Computer Tomography
// INNOVATION
MADE BY ZEISS
ZEISS METROTOM
Industrial computer tomography (CT) gives you entirely new insights by
making it possible to capture the whole volume with all internal structures.
With the ZEISS METROTOM family, you can successfully perform complex
measuring and inspection jobs with only one X-ray scan.
Find out more at www.zeiss.com/metrotom

EXTRUSION | PRINTING | CONVERTING
3X FASTER
Changeovers!
VAREX
The intelligent blown film line with TURBOCLEAN.
Experience "Passion for Innovation"
WINDMOELLER & HOELSCHER CORPORATION

Lincoln, Rhode Island 02865-4252
Phone 800-854-8702
info@whcorp.com www.whcorp.com
Know How
EXTRUSION
SIDE-ACTION SYSTEMS
Extruding with Fillers Make Perfect Parts and
Save Money!
You can use the reference point from processing
unfilled polymer to determine whether you can
run filled resin on your current system.
Fillers are added to polymers to accomplish many different property changes and Preload cores for perfect parts.
improvements. They can alter physical properties, reduce costs, trim weight, change the Save $$$$ with a smaller cylinder.
electrical conductivity, and enhance thermal properties, just to Simplify mold operation and design.
name a few. In almost every case they also have an effect on Smaller mold base = low cost parts.
processing behavior during extrusion. Fully Preloads at only 1,500 psi.
Questions are often asked whether filled polymers can be Stays locked without hydraulics.
processed on a specific extrusion system. This question can be 400 F systems available.
answered for inert fillers, which do not chemically change or Rush 0-2 day shipping available.
go into solution after mixing. But finding the answer requires a
reference point with the unfilled polymer. KOR-LOK TRADITIONAL

SIDE-ACTION VS. SIDE-ACTION

By Jim Frankland Most inert fillers have a higher specific gravity than SYSTEMS SYSTEMS
polymers, which increases the compounded specific gravity S! Mold OPEN

S!
YE Core Out
YE
(S.G.). Since the extruder screw is a volumetric device, a compound with higher S.G. will
typically increase the specific output (lb/hr-rpm) proportional to the density. This might S! Mold CLOSED
YE Core OUT CANT DO IT!
be expected to result in drive overload at higher filler loadings.
To evaluate this possibility, some simple calculations will provide guidance. The S! S!
YE
Mold CLOSED
YE
Core IN
accompanying table gives some of the required data for such a calculation. Notice
that the fillers all have a higher specific gravity and lower specific heat (the amount of S!
Core PRE-LOADED
YE CANT DO IT!
Against FULL
Injection Pressure
energy required to raise the temperature of a particular substance by a specified amount)
HYDRA-JAWS
Every Mold,
Every Machine, Every Time!
Adjusts to Fit Every Mold
Quick and Secure
Consistent Clamping Force
Fillers change the specific output of a compound, and calculations must

be done to be sure not to overload the extruder drive. (Photo: Chemours) pfa-inc.com
N118 W18251 Bunsen Drive
KNOW HOW EXTRUSION Germantown, WI 53022
(262) 250-4410
Learn more at PTonline.com Fax (262) 250-4409 Designed &
Made in USA
Get more insights on Extrusion from our expert authors. KOR-LOK , Hydra-Latch and Hydra-Jaws are trademarks of PFA, Inc.

short.ptonline.com/extrudeKH 2016 PFA, Inc. All Rights Reserved.
@plastechmag Plastics Technology 25

REGISTER NOW & SAVE!
June 14-15, 2017
DONALD E. STEPHENS CONVENTION CENTER | ROSEMONT, IL, USA
A M E R I M O L D E X P O . C O M
Exhibit Hall Amerimold Tech Talks

featuring machine tools, on designing, machining,
mold components, tooling, maintaining molds
materials, software, more
BOOTH SALES ARE OPEN
Business Development Reserve Early and Save!
Opportunities Sales@amerimold.com
for mold builders
and mold buyers
CO-LOCATED WITH:
PRESENTED BY:
Know How
than the polymers. For example, the Specific Specific Specific temperature by multiplying the S.G.
Polymer
compounded specific gravity of 40% Gravity Gravity Heat by the specific heat for each, since
& Filler
calcium carbonate (CaCO3) filled PP (Solid) (Melt) (BTU/lb-F) the volume of output is approxi-
can be computed by the formula for Polypropylene 0.92 0.72 0.5 mately the same:
mixtures as follows: Nylon 6 1.14 0.932 0.406
CaCO3 2.71 0.1994 Neat PP: 0.72 0.5 = 0.36
1/[(% Polymer/S.G. Polymer) + Mica 2.88 0.12
Mixture: 1.019 0.312 = 0.318
(% filler/S.G. Filler)] = S.G. Mixture Ratio: 0.318/0.36 = 0.883
Clay 2.50 0.22
(Ratio of drive load)
Talc 2.75 0.208
EXAMPLE ONE
Average S.G. of mixture: Barium Sulfate 4.49 0.113 This indicates a decrease in
1/[(0.60/0.72) + (0.40/2.71)] = 1.019 power requirement for the filled
S.G. PP of 11% versus the neat PP. This
(Note: the polymer melt density is used in this calculation.) means the filled PP would have a lower motor load with 40% CaCO3
and require no changes in either the specific output of the screw or in
In this case, the extruder specific output in pounds will increase the torque capacity. But if you processed nylon 6 with 40% CaCO3 , the
by more than 40% (1.019/0.72 = 1.415) with the 40% filled polymer drive load would be almost exactly the same as with neat nylon 6, so
because CaCO3 has three times the S.G. of PP and the screw has a its a combination of all the variables that determines the load.
relatively fixed volumetric Because this is a simplified calculation, several variables can
output per rpm. affect its accuracy, the primary one being the change in viscosity
Inert fillers almost
We can also use the same with the addition of 40% CaCO3. Inert fillers almost always increase
always increase the
formula for mixtures to obtain the viscosity, which increases the pressure drop through the tooling
viscosity, which affects
a very good estimate of the and can decrease output. However, the increased head pressure also
the pressure drop
average specific heat of a increases the melt temperature, so the overall effect on power require-
through the tooling.
mixture that is not alloyed. ment often follows the calculation closely. Keep in mind that PP with
40% CaCO3 by weight is only about 15% filler by volume, so the mixture
EXAMPLE TWO is still 85% PP by volume. Also, inert fillers do not normally change
Average specific heat of mixture: 1/[(0.60/0.5) + the shear sensitivity in the processing shear-rate range, so the die flow
(0.40/0.1994)] = 0.312 (BTU/lb-F). with the filled polymer would not be expected to change significantly.
When considering processing of filled polymers, a quick estimate
Since about 90% of the drive power requirement on a single can save a lot of difficulty and predict possible equipment changes.
screw goes to raising the temperature of the polymer from solid
ABOUT THE AUTHOR: Jim Frankland is a mechanical engineer who
to melt, we can ratio the drive load requirements for similar filled
has been involved in all types of extrusion processing for more than
and unfilled polymers. The ratio of the power requirement for the 40 years. He is now president of Frankland Plastics Consulting, LLC.
neat PP and the mixture can be approximated at the same melt Contact jim.frankland@comcast.net or (724)651-9196.
What you CANT SEE

will hurt you.
turn
page

Know How
TOOLING
PART 1
What You Need to Know About Locating Rings
Selecting the right locating ring and putting it
to good use takes a lot of thought.
It takes a significant amount of time to design an injection mold. The outside diameter of an American standard locating ring is
The types of steel, heat treatment, surface finish, gate size, and a typically 3.990 in. Smaller ones or rings mounted in a counter-bore
hundred other details are carefully consid- that is larger than 3.991 in. can also cause misalignment.
ered. But how much thought is given to the There are several different types of locating rings. Almost all of
selection of the locating ring? In many them are mounted in a 7/32-in.-deep counter-bore in the top or injec-
cases, not enough. This month I will discuss tion clamp plate. The basic or standard type of locating ring can
the various types of locating rings available properly align a mold to a platen, but it is not user-friendly, especially
and the intended function of each design. on large molds. It only extends beyond the face of the clamp plate by
A locating rings basic job function 5/ in. The LN version, which is specifically for the old Lester and
16
is to locate or align the orifice of the hot Newbury machines, extends only 7/32 in. If you factor in the 0.100-in.
By Jim Fattori or cold sprue with the through hole in chamfer on the front face of the rings, theres not a lot of land or
the machines stationary platen. The bearing surface holding the ring in the platen-alignment hole.
sprue orifice is usually in the center of a sprue bushing, and the Another type of locating ring has a tapered or extended lead-in.
locating ring aligns the bushing to the center of the platen. One This is always a welcome sight for the setup men on the production
exception is if a MUD or other quick-change type of frame is floor. This type makes it faster and easier to position the mold in the
used. In this case, the locating ring aligns the frame to the platen. machine, thereby reducing potential damage to the ring and the platen.
The locating ring is usually in the center of the mold. Sometimes, Most extended lead-in locating rings extend beyond the face of the
though, the locating ring is offset by several inches to reduce the molds clamp plate by 25/32 in. The initial tapered portion is about 7/16 in.
size of the mold base, such as with a single-cavity, edge-gated part. long. The remaining 5/16-in. straight portion is the required land length.
Cross-Section of
FIG 1 Cross-Section of
FIG 2 FIG 3 Cross-Section of Tall or
Standard Locating Ring Extended Locating Ring Insulator Locating Ring
The basic type of locating ring

can properly align a mold to a Locating rings with a tapered or
platen, but it is not user-friendly, extended lead-in are always a Locating rings with a tapered or extended
especially on large molds. welcome sight for the setup men on lead-in generally will not work with molds
the production floor, as they make having a high-temperature insulation sheet.
it faster and easier to position the You will need a taller locating ring designed
mold in the machine. specifically for an insulator sheet.
It is also offset in a MUD or other quick-change U style frame. The Most commercially available locating rings with a tapered or
locating ring must always be concentric with the orifice of the sprue, extended lead-in will not work with molds having a high-temper-
no matter where its position. If not, there will be a misalignment ature insulation sheet. Insulation sheets are typically - or -in.
between the molded sprue and the machines nozzle tip. thick. Even the thinner -in. sheet will almost wipe out the land

TOOLING
However, you will need to add a dowel pin, key, or other alignment
method when the bushing needs to be oriented due to the runner or
part geometry. If the sprue bushings orientation is critical, it is best to
key the bushing to the mold basenot the locating ring. Most locating
rings are retained with socket-head cap screws. The screws have clear-
ance around their head and body, which allows the locating ring (and
sprue bushing) to rotate as much as one or more degrees.
The locating ring must always be concentric with The best type of locating ring to use is the flanged or platen-backed
the orifice of the sprue, no matter where its position. type. It can provide three additional advantages that the other types of
If not, there will be a misalignment between the
molded sprue and the machines nozzle tip.
rings cannot. First, since the screws are mounted outboard of the 3.990
in. diam., its almost impossible to fill up the heads of the mounting bolts
or the threads of the jackscrew holes with plastic. Second, they provide
length required to hold the ring in the platen. In this case, youll a little more support to the center of the mold because the flange butts
need a taller locating ring designed specifically for an insulator up against the platen. Third, you can add shim to the underside of the
sheet. Unfortunately, very few suppliers offer this type of ring with flange to compensate for a worn or dished platen. Depending on
a tapered lead-in to help guide the mold into the platen orifice. how much shim is used, a flanged locating ring can actually preload
Another type of locating ring is the clamp type. The inside the center of the mold to help prevent parting-line flash. How impor-
diameter of this type of ring is stepped down to 13/4 in. to retain the tant is that! If your platen is dished and you try to process around
sprue bushing and prevent it from blowing back. Bushings are this flash, your process window becomes less robust. If you do not
usually bolted to the mold base with one or two 1/4-20 socket-head process around this flash, your parting-line will eventually hob.
cap screws through the bushings shoulder. The clamp-type locating Most locating rings have an inside diam. of 2 to 23/8 in. If the
ring eliminates the need for this extra machining step, and there are sprue bushing is recessed in the mold, you will not be able to seat
no exposed screws on the face of the bushing to fill up with plastic. the machine nozzle tip against the bushing without ripping the
In the DARK
You never know when your
conveying pumps are about to fail...
no pellet flow
no material
at the press
low oil
bearing failure
turn
page

TOOLING
FIG 4Cross-Section of Cross-Section of

FIG 5 FIG 6Cross-Section of
Clamp Locating Ring Flanged Locating Ring Extension Locating Ring
If the sprue bushing is recessed in

the mold, you will not be able to seat
The inside diameter of the clamp The flanged or platen-backed the machine nozzle tip against the
locating ring is stepped down to type locating ring can provide bushing without ripping the heater
13/4 in. to retain the sprue bushing several advantages that the band off the nozzle body or nozzle tip.
and prevent it from blowing back. other types of rings cannot. In this case, you need an extension or
extension-nozzle type of locating ring.
heater band off the nozzle body or nozzle tip. In this case, you choose the best one commercially available to suit each particular
need an Extension or Extension Nozzle type of locating ring. application. The cost difference between the least and most expen-
They have a 31/4-in. inside diam., which provides the necessary sive type is not a lot and the benefits are significant.
clearance. Depending on the supplier, they are available in the
standard, extended, or insulator styles.
Many mold-component suppliers offer various combina- ABOUT THE AUTHOR: Jim Fattori is a third-generation injection molder
with more than 40 years of molding experience. He is the founder of
tions of the different types of locating rings mentioned above.
Injection Mold Consulting LLC, and is also a project engineer for a large,
Personally, I would like to see even more combinations offered. multi-plant molder in New Jersey. Contact jim@injectionmoldconsulting.com;
Unless you are going to machine your own custom locating ring, injectionmoldconsulting.com.
In the KN W Avoid unplanned downtime with Prophecy PumpSense

now standard on NOVATEC VPDB pumps.
Measures & Predicts:

Filter Condition
Vacuum Analytics
Oil Condition
Bearing Condition
Pump Health
Get Out of the Dark, and Into the Know

1-800-237-8379 | sales@novatec.com
NOVATEC products are made in the USA. Supported worldwide. www.novatec.com

WORLD-CL ASS PROCESSORS
Meet Plastics Preeminent Processors

Plastics Technologys second annual benchmarking survey is back with
a new honor roll of companies from across the industry. One of the ties
that binds these progressive processors is their reliance on data.
Noble Plastics is a The 2016 selection of World Class Processors once again reflects the eclectic nature of the plastics-pro-
custom injection cessing industry, with winners hailing from different regions, running various technologies, and occu-
molder with a
dozen presses and
pying disparate points on the supply chain. What is once again a common unifying
By Tony Deligio,
a heavy emphasis Senior Editor factor is the collection, dissemination,
on automation and tactical use of operations data.
including 15 Fanuc
We share performance metrics, because what gets
6-axis robots
and process measured gets achieved, explains Paul Koster, CEO of full-
and production service injection molder Selmax Corp., Selinsgrove, Pa. Selmax
monitoring via (selmax.com) was among the 25 members of 2016s newest
IQMS and RJG
eDart modules at group of World Class Processors. Surveys were sent to Plastics
every molding cell. Technologys subscription list, including all major processing
technologies. The World Class Processors were selected from
the overall pool of respondents to the survey, based on their
performance in 11 different metrics. These metrics covered
everything from operations and business performance to
Rodney Davenport, v.p. manufacturing
human resources and operational strategy. & quality at CH3 Solutions, says his
Beyond simply compiling statistics about the output of the company launched molding operations
shop floor, the winners shared a common culture of using that in 2015 when it couldnt find a supplier
able to consistently mold its
information to make the companys success more tangible to
proprietary flooring product.
the employees who ultimately dictate the companys success.

Benchmarking Sur vey Results
The single biggest initiative we have done to promote involve- all others, fully 83% of the World Class Processors offered a bonus,
ment in continuous improvement is education of the whole while only 69% of total survey respondents did. The World Class
staff on the cost of process inconsistencies, says Missy Rogers, Processors also did a better job of holding onto their employees. The
president of custom injection molder, average employee turnover rate for our 2016 World Class Processors
Noble Plastics Inc. (nobleplastics.com), was 6.3%, while it reached 9.8% for the survey group as a whole.
We share
Grand Coteau, La. Obviously,
performance
customers need to receive quality A FOCUS ON EQUIPMENT
metrics,
products free from defects, but when The World Class Processors Plastics Technology spoke with had
because what
you understand how the cost of something else in common: a keen understanding of the role
gets measured
scrap, waste, and rework dont just technology can play in their success. At Mossberg Industries,
gets achieved.
affect the company, but provide a Khorshid notes that over the last five years, the company has
clear measure to tie cost of scrap to added seven all-electric injection machines, replacing older
cost of sales, everyone sees how his or her contribution to our hydraulic presses, while also installing robots and updating its
processes delivers the best value to customers and staff. production tracking system. When you mix these improvements
James S. Khorshid, president of Mossberg Industries Inc., with a business that dates back more than 100 years, then you can
Garrett, Ind., a manufacturer of spools and reels with injection
molding and extrusion capacity, says his World Class facility also
makes a point of sharing operations data. At Mossberg (moss- And the Winners Are
bergind.com), performance metrics like on-time delivery, as well
Of the 25 winners of Plastics Technologys second annual
as customer concerns, are posted monthly in the shop breakroom
World Class Processors benchmarking study, 22 agreed to
and are also reviewed in the companys monthly plant meetings.
be identified. They are listed below alphabetically:
We share these items with everyone so they can give direct input
if anyone has an idea to improve a process, Khorshid says. 3M, St. Paul, Minn., 3m.com
BPC Plastics, Meredosia, Ill.
LINKING PERFORMANCE TO PAY CH3 Solutions, Dalton, Ga., ch3solutions.com
At injection molder CH3 Solutions (ch3solutions.com), Dalton, Closure Systems International Inc., Kilgore, Tex.,
Ga., Rodney Davenport, v.p. of manufacturing and quality, says csiclosures.com
this World Class winner not only shares performance data with CNR Group LLC, Jackson, Wis., cnr-plastics.com
its employees but it also discloses its costs and margins so they Desert Molding Concepts Inc., Victorville, Calif.,
appreciate the true impact of a scrap part. desertmoldingconceptsinc.com
We are completely transparent with employees, Davenport ILPEA Industries Inc., Scottsburg, Ind., ilpeaindustries.com
says. They know what parts cost us, what we sell them for, and Mossberg Industries Inc., Garrett, Ind., mossbergind.com
how much it impacts when a part is thrown in scrap or when MRC Polymers, Chicago, Ill., mrcpolymers.com
material spills. It also impacts the employees compensation Noble Plastics Inc., Grand Coteau, La., nobleplastics.com
as well, with bonuses tied to operations performance. If we Parker Hannifin Corp., Tucson, Ariz., parker.com
need to buy equipment, if we had damage to something and Pigstail USA LLC, Brea, Calif., pigstailusa.com
dont pack good product, they know that directly impacts each Pioneer Plastics, Marinette, Wis., pioneerplasticswi.com
persons pocket at the end of the year, Dalton says. Royal Building Products, Shelby Township, Mich.,
Koster says Selmax has a similar linkage between operational royalbuildingproducts.com
performance and pay, deploying the carrot of cash to its workers PolyOne, Lockport, N.Y., polyone.com
through what it calls a Results Based Incentive (RBI). Selmax posts Selmax Corp., Selinsgrove, Pa., selmax.com
machine run time, reject rates, and production cycle times daily. Seneca Railroad & Mining Inc., Bellevue, Ohio, senecarail.com
RBIs can be earned for every day that the team achieves the targets Sharp Packaging Systems Inc., Sussex, Wis.,
established for those metrics. Every employee who works that sharppackaging.com
day earns the incentive, Koster says, with the RBIs paid out on a Toman Thermosonics, Stoddard, Wis.,
quarterly basis. Besides the carrot, there is also one stick: If we tomanthermosonics.com
have a significant safety incident or customer complaint, part or Unitra Inc., Stafford, Tex., unitrainc.com
all of the incentive is lost, Koster says. Urgent Plastic Services, Rochester Hills, Mich.,
Incentivizing workers with cash was a theme amongst our 3dimensional.com
2016 World Class Processors. While the average compensation for Xerox Corp., Webster, N.Y., xerox.com
shop-floor personnel was the same $15/hr for our 25 top shops and

A Sampling of Survey Data
Here is just a small sample of the data gleaned from the 2016
survey. Survey participants will be given the complete data OPERATIONAL METRICS
set, including breakdowns by process technology, plant size, Scrap Rate (%) for 2015
and amount of resin processed annually. In addition, key
World-Class All
financial metrics including capital spending on equipment, Processors Processors
spending on resin, sales/number of machines, sales/number Median 2.00 3.00
of employees, and annual sales growth will be provided. If Average 3.60 5.41
youre interested in participating next year, please email
80th Percentile 4.00 10.00
senior editor Tony Deligio (tdeligio@ptonline.com).
20th Percentile 1.00 2.00
PROFILE DATA HUMAN RESOURCES

Total Number of Primary Processing Number of Employees Directly
Machines in the Plant Involved in Manufacturing Operations
World-Class All World-Class All
Processors Processors Processors Processors
Median 16.0 16.0 Median 38 32
Average 22.6 24.9 Average 87 102
80th Percentile 35.0 33.0 80th Percentile 100 135
20th Percentile 4.0 5.0 20th Percentile 9 8
Main Industries Served Average Training Hr per

World-Class All
Production Employee
Processors Processors
World-Class All
Automotive 42.3% 46.0% Processors Processors
Building/Construction 50.0% 28.7% Median 37 33
Consumer Goods, Housewares 30.8% 33.3% Average 58 67.8
Defense 11.5% 13.8% 80th Percentile 80 80
Electrical/Electronics 30.8% 33.3% 20th Percentile 12 10
Industrial 53.8% 52.9%
Medical/Healthcare 53.8% 46.0%
PROCESSING/BUSINESS
Packaging 26.9% 28.7%
STRATEGIES & PERFORMANCE
White Goods/Appliance 30.8% 17.2%
Value-Added Services Offered
Primary Processes Performed World-Class All
Processors Processors
World-Class All
Processors Processors Product Design 71.0% 70.0%
Injection Molding 65.4% 68.6% Product Testing 62.0% 58.0%
Blow Molding 7.7% 4.7% Inventory Stocking/
76.0% 74.0%
Logistics
Thermoforming 0.0% 7.0%
Shipping/
Film/Sheet 7.7% 5.8% 81.0% 84.0%
Packaging/Labeling
Pipe/Profile 3.8% 3.5% Contract
71.0% 66.0%
Manufacturing
Tubing 3.8% 3.5%
Additive
Compounding 11.5% 7.0% 38.0% 26.0%
Manufacturing

GET
WITH RAPID
Better regrind = Better parts =

MORE profitability!
Rapids superior regrind Regrind from other granulator
You can sell it for pennies a pound, or, you can

recover the full value of your regrind and get MORE
out of your production.
Even the best molding processes cannot produce
high quality parts if the regrind is poor.
Rapid Granulators superior cutting technology and
engineering has helped improve customers bottom
lines for almost 70 years.
Get MORE call Rapid to arrange for a free test of
your most demanding material.
It isnt scrap unless you throw it away!
Call
rapidgranulator.com +1 724.584.5220
get great results, Khorshid says. Product lines and customers tric and most are less than five years old. For those 10 machines,
have changed over the years, but we continue to focus on sup- CNR (cnr-plastics.com) has 11 full-time employees, with two of those
porting our customers and having the highest product quality. being certified molding technicians, applying scientific molding
Custom molder CNR Group LLC, Jackson, Wis., made the principles and robust process development.
World Class list in part thanks to its investments in equipment, in CH3 Solutions likewise runs a small but highly efficient fleet.
the view of company president, Bob Albrecht. The companys 10 Davenport says that of their five injection machines, four are all-
machines, which range up to 200 tons in clamp force, are all-elec- electric and one utilizes servo drives for its hydraulic pumps. CH3
is working on a project that incorporates valve-gated hot runners,
gas-assisted injection, and in-mold labelingall in one tool.
Were trying to make sure CH3 is not the same-old typical
molder, Davenport says. Were very technology driven and try to
stay up to date with the trends in the market and new technology.
CH3 started molding in 2015 when it couldnt find someone to
make its proprietary flooring product. Davenport notes that even at
the beginning, when it couldnt afford to buy the latest and greatest
machinery, CH3 took pride in its equipment. When we bought
our first piece of used equipment, Davenport says, we painted it,
made it look new. Every employee in the company had hands on.
Its important to have that culture, where people own it.
Looking at the survey data, there was a slight difference in
average machine age between World Class Processors and all partici-
pants12.35 yr vs. 13.08. On the injection side, more World Class
Fully 95.5% of World Class Processors, like
CH3 Solutions pictured here, offer assembly molders deployed all-electric machines (54.5% of their fleet) than
services, up from 82% in the last survey. the full survey group (45.9% all-electric machines). The percentage
PRODUCT DE
FEC
Benchmarking Sur vey Results
of revenue that SIZING UP THE CLASS

World Class The 2016 World Class contingent was quite diverse, consisting of
Processors every kind of business from family-owned to Fortune 500, from OEM
reinvested in to job shop. Of the 25 World Class respondents, 22 chose to be identi-
capital equip- fied and they hailed from 13 states in virtually every region of the
ment (12%) was country: Arizona, California (two), Georgia, Illinois (two), Indiana
lower than the (two), Louisiana, Michigan
larger survey (two), Minnesota, New York
We display metrics
group (15.3%), (two), Ohio, Pennsylvania,
and hold regular
but in total Texas, and Wisconsin (four).
meetings to review
they spent 34% Among them were OEMs,
goals and measures,
more on capital custom and captive injection
because communica-
equipment for molders, a resin recycler, and
tion is key to success.
A 6-axis robot handles a part at Mossberg.
the year. a rapid manufacturing service.
Three-quarters of World Class Processors Fully 81% of The World Class group also
utilize articulating-arm robots, compared the World Class deployed all the major processes, save thermoforming, with winners
with 65% of all respondents.
Processors offering injection, blow molding, and several varieties of extrusion,
had achieved a including film/sheet, pipe/profile, tubing and compounding.
quality certification, like ISO, compared with 67% for the full survey Their common characteristic: a unifying company culture
group. Of the five World Class winners, all acknowledge the impor- undergirded by data. We display metrics and hold regular meetings
tance of certification. Koster noted that Selmax is currently working to review goals and measures, because communication is key to
toward ISO 9001:2015 certification in May. Noble Plastics, CH3, success, Nobles Rogers says. We believe that our team thrives on
Mossberg Industries are already certified, while CNR Group notes a culture aligned with our core values: To do what you say, to care
that its quality system conforms to ISO 9001:2000. about getting it right, and to help people succeed.
CTS
Built To Run: 24 Hrs. a Day, 7 Days a Week, 365 Days a Year

UNDER THE MOST EXTREME CONDITIONS! NYLON TRIMMER LINE
HDPE
CONTA X-RAY FILM
PLASTIC PURGINGS INERS HDPE AUTO PARTS
WITH
BALED FILM
(336) 790-5752 www.Vecoplanllc.com

Plastics Technology
5708 Uwharrie road archdale, nc 27263
On-Site Trex Company Inc. Winchester, Va.
By Heather Caliendo,
Senior Editor
Decking
Producer
Becomes
Supplier of
Recycled
Pellets
Composite decking manufacturer Trex expands from using

recycled LLDPE internally to also supplying recycled pellets
to others. It found the commercial recycled plastics market
to be a journey full of both rewards and challenges.
Chances are youve seen Trex Company Inc.s composite decking at your local Home Depot. You might Trexs Dave Heglas
even own the product and enjoy it every day at your home. The Winchester, Va.-based company showcases a bag
produced with
(trex.com) has extruded composite decks from a blend of 95% recycled wood and plastic film for more
its recycled
than 20 years. The companys products are offered through an extensive LLDPE pellets.
network of building-products distributors and dealers, and are sold at more
Its been
than 6700 retail locations. With about 600 employees, Trex has two manu-
surprising
facturing plants, one in Winchester, Va., and the other in Fernley, Nev.
that more
Trex uses more than 1.5 billion plastic bags each year to make wood-
companies
alternative outdoor products and is one of the largest recyclers of plastic in
are not using
the U.S. But even companies that use recycled materials are left with excess
recycled
material that could have a second life as well.
pellets.
As they say, necessity is the mother invention, observes Jim Cline, presi-
dent and CEO of Trex. He says that as one of the countrys largest recyclers
of post-consumer and commercial PE, the company found itself with a surplus of material beyond
what it could use in its core line of outdoor products. We challenged our engineering team to come
up with ways to use the excess material and, as usual, they didnt disappoint, he says.
And thus began the start of a new recycling chapter for Trex.

Trex Company Inc. Winchester, Va.
On-Site
DISCOVERING ANOTHER (GREEN) NICHE have requirements that need to be met for recycled content. With
Dave Heglas, sr. director of material resources at Trex, is a chemical this certification, companies know that using Trex pellets can help
engineer with a background in rocket science and missile design, meet their recycled-content requirements and sustainability goals.
who joined Trex in 1996 as an engineer responsible for the raw- The recycled pellets are useful for molding, profile extrusion, and
materials and processing side of the business. He helped formal- blown film. Heglas says that Trex recycled pellets have proven to
ized the companys recycling operations, an initiative that has since work well in production of commercial trash bags and molded plastic
evolved into what Trex calls a company within the company. garbage/recycling bins, as well as specialty applications like irrigation
Heglas says that turning Trex from a company using recycled tubing. Trex is working with manufacturers in various industries to
plastics into a plastics recycler was something that made perfect explore additional uses for its LLDPE pellets. The company has the
strategic sense, as the firm was collecting much more than flexibility to color, modify, and reformulate pellets as needed to fit
it needed or could ever use in its deck boards. The company specific needs and processes, and it offers technical assistance in
began selling off some of its inventory to manufacturers in incorporating pellets into other manufacturers products.
other industries, which included small companies that Trex had Says Heglas, We have the knowledge of how to recycle PE film
contracted to produce plastic pellets. from doing it for 25 years and making it into decking products. We
After nearly a decade of experience producing pellets for Trexs understand what the end user needs and how to process a chal-
own products, the next step was to leverage its in-house expertise lenging material stream to make something very consistent. Thats
and expand capabilities to produce pellets for additional indus- what sets ourselves apart from others in the market: consistency
tries and markets. So the company launched a new business in in color, melt flow, and physical properties. We assure every load is
2015 that uses its excess raw material to produce LLDPE pellets homogeneous and consistent.
from recycled materials. Starting up any new venture has its challenges, some big, some
Previously, manufacturers had to rely on multiple sources for small. And those in the recycling industry understand that recy-
recycled plastic pellets, which meant unpredictable quantities cling comes with its own set of unique obstacles.
and widely varying product characteristics, Heglas says. We One of the biggest challenges that we uncovered, or were
decided to set up this business and produce a very consistent surprised by, was the state of end-use demand for recycled content.
product in high volumes; so when the user buys the pellets, they Not as many companies as you would think want to get started on that
are consistent from load to load.
The company explored this
possibility by leveraging its own
recycling and extrusion capabilities.
Trex personnel worked on this using
equipment downtime to experiment
and test different solutions. The engi-
neering team eventually delivered an
LLDPE plastic pellet suited for use in a
variety of products and industries. While Trex salvages PE material to create its decking, it Trex is now one of the largest
was still left with excess material, which planted the seeds producers of recycled LLDPE
BUSINESS WITHIN A BUSINESS for a new business venture in merchant pellet sales. pellets in the country.
Trex now has four lines dedicated to
recycled pellet production at its Winchester facility and ranks path, he says. They see recycle as not as easy to use as virgin because
as one of the largest producers of recycled LLDPE pellets in the there is some product and product development to address. Its been
country. When it launched this venture, the company increased surprising that more companies are not using recycled pellets.
its workforce and invested in its facility and equipment. Heglas has noticed in the past six months an increase in
In an effort to provide rotational molders and other plastics companies wanting to use recycled pelletsmuch of that due to
processors with further incentive to use its recycled pellets, Trex California. Theres a big push for recycling in California. A lot
sought and achieved certification with the International Code of businesses there are looking to use recycled content, and we
Council (ICC) for its recycled LLDPE. This certification confirms have companies working with us to develop new applications for
that both the Trex Spartan and Trex Cardinal lines of LLDPE pellets recycled pellets.
contain 100% post-consumer content.
Heglas considers the ICC certification to be a key step. One of QUESTIONS ABOUT RECYCLING?
the reasons we went after recycle certification is because it does Learn more at PTonline.com
separate you from everyone elseespecially as other countries do Visit the Recycling & Scrap Reclaim Zone

Tips and Techniques
This is an example
of a melt-temperature
probe that has a stem
with adjustable depth.
PART 2
How to Collect and Interpret
Process Data in Extrusion
In this second of three installments, the focus
is on the crucial element of melt temperature.
Many modern extrusion lines are equipped with data-acquisi- Part 1 of this three-installment feature (in January) discussed
tion systems (DAS). These systems can present extruder opera- the proper use of a DAS in extrusion. This article will address issues
tors and process engineers related specifically to the polymer melt temperature. This is the
By Chris Rauwendaal
Rauwendaal Extrusion Engineering
with a large amount of data. second of the three vital signs of the extrusion process, as discussed
There are several critical in Part 1, the others being melt pressure and motor load.
issues in the proper use of a DAS: Melt temperature is usually measured with an immersion
melt-temperature probe. The sensing stem of the probe should be
1. Are the correct process variables measured and monitored? immersed at least 5 mm to provide a good measure of melt tempera-
2. Are these process variables measured correctly? ture. Some melt-temper-
3. Is the data collection rate appropriate? ature probes have a stem
4. Can operating personnel properly interpret the data? with adjustable depth. An immersion probe will
These adjustable create some degree of
melt-temperature probes stagnation downstream
WHAT YOU WILL LEARN can be used to measure of the probe. This can
melt temperature at create problems in ther-
1. MEASURING MELT TEMP: Know your probe options.
different locations across mally sensitive materials
2. MELT-TEMP DISTRIBUTION: Use FEA to plot melt- the depth of the channel. like rigid PVC and EVOH.
temperature distribution in the screw channel.
It is good practice to
3. MELT-TEMP VARIATIONS: Non-uniformity will completely retract the
create extrudate dimensional variations. sensing stem before shutdown to minimize the chance of damaging
4. COLLECT DATA RAPIDLY: Variables have to be the melt-temperature probe when restarting.
measured at least 50 times/sec to capture varations. Immersion melt-temperature probes have some drawbacks.
5. TRAINING: Necessary for operators and Since they protrude into the melt stream, they alter the velocities in
process engineers to take full advantage of the melt stream. This, in turn, will change the viscous heating and
the capabilities of the DAS. temperatures of the melt stream. Therefore, the immersion probe
will measure a melt temperature that is different from the melt

E X TRUSION DATA
temperature that would occur without a results in large temperature differences within
probe immersed in the melt stream. the polymer melt. The largest temperature
Another drawback is the fact that an gradients tend to occur at the barrel surface.
immersion probe will create some degree of The melt-temperature distribution
stagnation downstream of the probe. This can be determined by performing a non-
can create problems in thermally sensi- isothermal analysis of the flow in the
tive materials like rigid PVC and EVOH. screw channel. In case of a non-Newtonian
A further drawback is the slow thermal polymer melt, this is typically done using
response of an immersion probe. For this finite-element analysis (FEA). Figure 1 shows
reason, an immersion probe cannot detect a color contour plot of melt temperatures in
rapid changes in melt temperature occur- the screw channel of a 63-mm single-screw
ring over a few seconds or less. This is a extruder running a 0.2 melt-index HDPE at
serious limitation of immersion probes 100 rpm. The vertical axis has been stretched
because rapid melt-temperature changes You can also measure melt about eight times to make it easier to
temperature by infrared
occur in every extrusion process. radiation. These thermometers examine the temperature distribution.
Another method of measuring melt are readily available and relatively The top surface is the barrel, the bottom
temperature is by measuring infrared inexpensive. Photo: Raytek surface is the root of the screw, the left vertical
radiation (IR). Infrared thermometers are boundary is the pushing flank of the flight,
readily available and relatively inexpen- and the right vertical boundary is the trailing
sive. Inside the extruder or the die, the melt temperature can be flank of the flight. It is clear that the melt temperatures are highly
measured through a transparent window. non-uniform. The temperatures close to the barrel are relatively low
Another way to measure the melt temperature with IR is to because of the heat transfer to the barrelthe barrel cools down the
use a probe with a sapphire window at its end in contact with the melt that is in close proximity to the barrel. The temperatures at the
molten polymer. The transparent window is mounted in a threaded pushing flight flank are low because the cool melt close to the barrel
stem. The window is made out of sapphire so that it can handle moves down along the flight when it reaches the pushing flight flank.
high temperatures (up 600 C/1112 F) and pressures (up
to 1500 bar or about 22,000 psi). The probe fits in a FIG 1 Melt-Temperature Distribution Using FEA
standard pressure-transducer hole, making installation (63-mm Extruder Running at 100 rpm)
293.8
quite easy. These probes are commercially available.
286.4
The threaded probe with the sapphire window can be 279.0
used in combination with a simple IR thermometer. 271.6
264.1
This allows IR melt-temperature 256.7
Another way to measurement in the extruder 249.3
measure the melt 241.8
barrel or in the die. 234.4
temperature with
IR is to use a probe IR temperature measure- 227.0
219.6
with a sapphire ment provides two important
212.1
window at its end benefits: One, the response 204.7
in contact with the 197.3
molten polymer. time is fast, about 10 millisec.
189.9
Photo: FOS Messtechnik Two, the measurement does 182.4
not disturb the flow, unlike the 175.0
case with an immersion probe. Shown here, the top surface is the barrel, the bottom surface is
Because of the fast response, the IR measurement can the root of the screw, the left vertical boundary is the pushing
detect rapid changes in melt temperature that cannot flank of the flight, and the right vertical boundary is the trailing
flank of the flight. It is clear that the melt temperatures are
be detected by an immersion melt-temperature probe.
highly non-uniform. The temperatures in the hot spot are more
than 100 C above the barrel temperature.
MELT-TEMPERATURE VARIATION
Melt temperatures in extrusion result from viscous
dissipation and heat transfer. In drag flow, the shear
QUESTIONS ABOUT EXTRUSION?
rates and viscous dissipation are relatively uniform.
However, the heat transfer to the screw and barrel Visit the Extrusion Zone.

Tips & Techniques
FIG 2 Experimental Setup for Melt-Temperature Study When the screw discharges the melt,
this melt will be non-uniform in tempera-
57mm 174mm
ture. A number of studies have examined
Sensor
38mm Ports Extruder Screw the variation of melt temperatures in
extruders. One such study was made by E.
Brown and A. Kelly at Bradford University
in England. In this work, a fast-response
thermocouple (TC) mesh was used to
Die measure melt-temperature variation using
Exit
three different extruder screws. The TC
Sensor Port
mesh was located in the breaker-plate
Thermocouple Grid 30mm 30mm
recess of the extruder barrel (Fig. 2).
Support Matrix Screw TC Grid or
Melt temperature was measured at
Breaker Plate Location
multiple locations, as shown in Fig. 3.
It is clear from this figure that the melt
FIG 3 Melt Temperatures vs. Radial FIG 4 Melt Temperature vs. Time temperatures across the channel are quite
Distance from the Center non-uniform, with a low temperature of
220
225 215 190 C/374 F and a high temperature over
220 210 215 C/419 F. The melt temperatures vary
Melt Temperature, C
Temperature, C
215 205 not only across the melt stream but also
210 200 over time, as shown in Fig. 4.
205 195 The melt at TC4 (radial location -10 in
200 190 Fig. 3) drops from 215 C/419 F to 180 C/356
195 185
190 LD150R 70rpm Tapered F within 4 sec and then increases again
180
185 Compression Screw to almost 215 C/419 F within 2 sec. This is
175
180 0 2 4 6 8 10 rapid and substantial melt-temperature
-20 -10 0 10 20 Time, sec
variation. Interestingly, this melt-temper-
Radial Distance, mm TC Location 3 TC Location 4
ature variation cannot be detected with
In this research project, a fast-response thermocouple (TC) mesh was used to measure an immersion melt-temperature probe
melt-temperature variation using three different extruder screws. The TC mesh was because of the slow response time.
located in the breaker-plate recess of the extruder barrel (Fig 2). Melt temperature
was measured at multiple locations (Fig. 3), and was quite non-uniform. The melt In this study the melt temperatures
temperatures vary not only across the melt stream but also over time (Fig. 4). were also measured with an infrared
thermometer. The results are shown in
Fig 5. This figure shows temperatures at
At the root of the screw, the cool melt from the pushing flight three screw speeds: 50, 70, and 90 rpm. The temperature variation
flank moves towards the trailing side of the flight. If there is no increases with screw speed. The variation in TC mesh tempera-
heat transfer with the screw, the melt temperatures will gradually tures is substantially smaller than in IR temperatures. Also, the IR
increase as the melt moves from the pushing flank to the trailing temperatures show much faster variation as a result of the short
flank. The melt reaching the trailing flight flank moves up along the response time of the IR measurement.
flight until it gets close to the barrel. At that point the cycle starts Figure 6 shows infrared melt-temperature measurements
again. The outer region of the screw channel stays relatively cool plotted vs. time for three extruder screws running at 90 rpm. The
because of the heat transfer from the melt to the barrel. The situa- melt-temperature variation for the tapered and stepped screw is
tion is quite different for the inner region of the screw channel. quite large, 15-20 C (27-36 F). The melt-temperature variation for
The melt in the inner region remains in this region as it travels the barrier screw is smaller, about 5-7 C (9-13 F) and displays a
down the length of the screw channelit will not come into close more regular pattern. The time between peaks corresponds closely
proximity with the barrel. The inner region is thermally insulated with the screw speed90 rpm corresponds to 0.67 sec/revolution.
from the barrel by a relatively thick layer of polymer melt. As a result, This means that the screw speed can be determined from the IR
the temperatures in this region rise higher than any other part of the melt-temperature measurement.
channelit is a natural hot spot. In Fig. 1, the temperatures in the The reduced melt-temperature variation in the barrier screw
hot spot are more than 100 C/180 F above the barrel temperature. may be due to the barrier geometry. However, this screw was

E X TRUSION DATA
also equipped with a

FIG 5 Comparison of TC Mesh FIG 6 IR Melt-Temperature Measurements
fluted mixing element and IR Temperatures for Three Screws Running at 90 rpm
in the metering section. Thermocouple Mesh 215
Therefore, it is also possible
Wall Thermocouple
70
Pressure 210
Melt Temperature, C
that the reduced melt-
205
temperature variation is
200
due to the presence of the
fluted mixer. The tapered 195
50
screw and the stepped 190
screw had no mixing 185
elements; therefore, these 180
screws can be expected IR Temperature 90 rpm 175 Tapered Stepped Barrier
to result in larger melt- 0 8 0 8 0 8
This shows temperatures at Time, sec
temperature variation.
three screw speeds: 50, 70, and HDPE LDPE
These results clearly 90 rpm. Temperature variation
demonstrate that short- increases with screw speed. Melt-temperature variations in tapered,
The variation in TC mesh stepped, and barrier screw designs. While
term melt-temperature some designs result in more dramatic
temperatures is substantially
variations occur in polymer smaller than in IR temperatures. variationsthe tapered and stepped in
extrusion. In fact, these Also, the IR temperatures particularthe results demonstrate that
show much faster variation as short-term melt-temperature variations are
variations are inherent in
a result of the short response inherent in the extrusion process.
the extrusion process. They time of the IR measurement.
occur because polymers
have very low thermal
conductivity. As a result, conductive heat transfer is very slow. The ID waviness is a common problem in pipe extrusion, but the
time that is required for the melt temperatures to become uniform cause of this problem is not widely recognized. One approach to
by conduction is very longit can be measured in hours for reduce the problem is the use of a large-inventory die. Such a die
production-size extruders. will have long melt-residence times and this will reduce the melt-
Typical residence times for the molten polymer in extruders are temperature variation at the die exit. However, large-inventory dies
around 20-40 sec. The residence times are usually much shorter, by have several drawbacks:
orders of magnitude, than the times required to achieve uniform
melt temperatures by conduction. Therefore, melt temperatures They are expensive.
in extrusion will be non-uniform in most typical extrusion opera- They take up a large amount of space.
tionsespecially when the extruder operates at high screw speed They take a long time to heat up.
and when the melt temperatures are higher than the barrel temper- Long residence times increase polymer degradation.
ature. These melt-temper- They increase changeover times.
ature non-uniformities They result in more scrap.
It is equally important to
are more pronounced on
provide training so that
larger extruders where A much more effective solution is to enhance the mixing capa-
operators and process
heat-transfer distances bility of the extruder. With proper thermal mixing, large-inventory
engineers can take
are greater. dies are not necessary and the ID waviness can be largely eliminated.
full advantage of the
When the tempera-
capabilities of the data-
tures of the melt exiting DATA COLLECTION RATE AND FFT
acquisition system.
the extruder are non- From the information presented earlier, it is clear that rapid data collec-
uniform, the dimensions tion is necessary for certain process variables such as melt pressure, melt
of the extrudate will become non-uniform as the extrudate cools temperature, and motor load. In order to capture short-term process
down and solidifies. These dimensional variations result from variation, these variables have to be measured at least 50 times/sec.
non-uniform shrinkage. The manifestation of this problem in Unfortunately, this capability does not exist on many extrusion lines.
pipe extrusion is waviness of the internal diameter. The calibra- A useful feature of a DAS is Fast Fourier Transform (FFT). This
tion process fixes the outside diameter of the pipe, but the inside is a technique that determines the base frequencies making up a
diameter will vary if the shrinkage is non-uniform. complex signal. FFT is very useful in troubleshooting because

Tips & Techniques
signals are often complex and difficult

to interpret. This is because the extru-
Granulator sion process is influenced by 50 to 100
Granulator,Shredder,Pulverizer and different factors. At any one time, 10
Recycling Wash Equipment
to 20 factors may have a measurable
effect on the extrusion process. For that
reason, process variables such as melt
pressure, melt temperature, motor load,
extrudate dimensions, etc. often show a
complex pattern.
TRAINING
It is not enough to have good instrumenta-
tion and data-acquisition capability. It is
equally important to provide training so
that operators and process engineers can
GW80 Series Super Heavy Duty Wet Granulator take full advantage of the capabilities of
Advanced Technologies, Improved Capacity, Born for Recyclers! the DAS. This is an essential element in a
successful extrusion operation. Some
AVIAN (USA) MACHINERY, LLC. companies skip this critical step and, as a
1901 Powis Court, West Chicago, IL. 60185
TEL: 630.687.9876 FAX: 866.755.9258 result experience only limited benefits
WEB: www.aviangranulator.us E-MAIL: sales@avianusa.com from a good DAS.
Good instrumentation is critically
important in extrusion. Without good
instrumentation and data-acquisition
capability, it is hard to:
Know what is happening in the extruder.

Control the extrusion process.
Optimize the extrusion process.
Know when something is wrong.
Troubleshoot the extrusion process.
Have a profitable extrusion operation.
Size Reduction Solutions ABOUT THE AUTHOR: Dr. Chris Rauwendaal

Granulators Shredders Pulverizers Pipe Grinders is a well-known author, lecturer, researcher,
entrepreneur, and consultant in the field of
extrusion. He holds numerous patents and has
written more than 200 articles and seven books
related to extrusion, mixing, injection molding,
and statistical process control. A Fellow of the
Society of Plastics Engineers (SPE), he is the
developer of the CRD, VIP, and ASM mixing
technologies that utilize strong elongational
Choose from a wide range of standard equipment to solve a specific problem or let
flow to improve mixing in extrusion and
us custom design a size reduction system to satisfy all your application requirements.
From advice to design to installation and start-up, we guide you every step of the molding. Rauwendaal also developed the HHT
way. Talk to an application specialist today to discuss your recycling system needs. (high heat transfer) extruder screw designed
to improve cooling in foam tandem and other
extrusion operations. In 1990 he founded and
888.612.7774 www.herboldusa.com is still president of Rauwendaal Extrusion
info@herboldusa.com Engineering. Contact: (530) 269-1082;
chris@rauwendaal.com; rauwendaal.com.

KNOWLEDGE CENTER
Predictive Maintenance
Best Practices,
Cost Saving Tips,
Product Technology
Comprehensive collection
of technical content
On-Demand
Videos & Webinars
The latest technology in
action and explained by
industry experts
Ask Experts
Connect with industry
leaders for immediate
answers
Find Predictive Maintenance Solutions at:
short.ptonline.com/prophecykc
Get more KNOWLEDGE

Plastics Feeding Plastics Training
Learn about Learn how to
Various Types train your own
of Continuous experts:
Feeders Injection Mold
Key Aspects of Training
Operation Extrusion Training
How to Select Paulson Academy
a Feeder certification
short.ptonline.com/feed short.ptonline.com/KC-train
Tips and Techniques
15 Things to Know
About Servo-Driven
Injection Machines
Drive technology for injection
molding machines has been
continuously evolving, and
servo motors have become
widely used in a variety of roles.
Heres what molders need to
know about todays servo drives
in terms of cost, performance,
maintenance, and training.
In order to get a better understanding of todays available machine 1. Full-electric IMM

technologies, it is important to use a common language for the Following the standards of the Plastics Industry Association (for-
different drive technologies for modern merly SPI), a full-electric injection molding machine is one that has
By Markus Klaus
Wittmann Battenfeld
injection molding machines. Varied uses of at least its three main axes (clamp movement, injection, and
servo motors is one of the complicating metering/plasticating) driven by servo motors. The remaining three
factors. This article will discuss and explain 15 of the most common axes (nozzle touch, ejection, and
terms and concepts involving machine drive technology, regarding mold-height adjustment) can still
cost, performance, maintenance, and employee training. be driven by hydraulics. The most
Metering/plastication
efficient machines are capable of
is the biggest energy
using a kinetic-energy recovery
drawbesides barrel
system (KERS). This patented
heatingon any
WHAT YOU WILL LEARN injection machine.
process makes use of the servo
1. TERMINOLOGY: Distinguish one type of drive motors as generators and can
from another.
collect all deceleration energy from each axis and convert it back
2. ENERGY EFFICIENCY: The difference a servo into electric energy. The converted energy is then fed back into the
makes, even with a hydraulic pump. machine, usually for heating or control functions.
3. REPEATABILITY: Consider delays, differences in

2. Hybrid IMM
acceleration and deceleration, and changing
oil tempertures . Machines that have one or more of the three main axes driven by
hydraulics but do have at least one electric-driven axis are called
4. SPEED/ACCELERATION: Hotly debated contest hybrid machines. One common example of this is a hydraulic
between drive types.
machine with servo-driven metering. The metering is the biggest
5. TRAINING & MAINTENANCE: Additional factors energy draw (besides barrel heating) on any IMM. Therefore, it is a
to consider. smart decision to at least use a servo-electric drive for the metering.
Hybrid machines are not machines with a servo-driven pump,
because all movements on the latter are still driven by hydraulics.

INJEC TION MOLDING
Constant-speed hydraulic motor with three variable-displacement

pumps is one example of a fully hydraulic configuration.
Shown here: an
injection servo
motor. Speed and
acceleration of servo
vs. hydraulic drives
are hotly debated.
Use of a servo drive with a hydraulic pump Acceleration of a
is becoming more and more common. It servo drive is almost
offers considerable energy savings. certainly greater.
3. Servo (driven) hydraulic IMM pump. Of course, the amount of energy savings depends highly on
A servo-driven hydraulic (or servo-hydraulic) machine is a full- the process point of each specific application. A fast-cycling pack-
hydraulic IMM with a servo motor to drive the hydraulic pump. aging application will have a lower percentage energy savings than
These machines often have a fixed-displacement-pump, but could an application with a long cooling time when the constant-speed
also have variable-displacement-pumps (often DFEE or DFEC) motor would be idling for seconds or minutes.
with a swash-plate. Full-electric machines, where the electric energy is directly
converted into kinetic energy, have the best energy efficiency,
4. Standard hydraulic IMM with variable-displacement pump since there is no transformation from electric energy to hydraulic
These machines usually have a constant-speed motor and a vari- pressure and then to kinetic energy.
able-displacement pump with a swash plate that can be adjusted by A very rough classification would be:
the control to regulate the oil-volume flow of the pump adjusting to
the current demand of the hydraulic system. If the machine does Hydraulic machine with constant speed motor: 100% energy
not move at all, the pumps will still idle and waste energy. consumption;
Hybrid machine with only metering fully electric: 75% to 80%
5. Energy efficiency energy consumption;
The European plastics industry has developed a system to classify Servo-driven pump machines: 65% to 70% energy consumption;
energy efficiency of IMMs. The Euromap 60.1 standard categorizes Full-electric machines: 45% to 60% energy consumption.
machines in certain categories and has developed certain stan-
dards to compare the energy efficiency of similar machines from 6. Repeatability of electric vs. hydraulic drives
different suppliers or executions (full-electric, hybrid, and so on). On full-electric machines, the repeatability of a servo-driven axis
Servo-driven pump (or servo-pump) machines unsurprisingly is at least 10 times higher than hydraulic-driven axis. An active
show much better energy efficiency than machines with a constant- servo-driven axis has almost no delays, while delays with hydrau-
speed motor and a variable-displacement pump. The servo motor
QUESTIONS ABOUT INJECTION MOLDING?
on the servo-driven pump machine only operates if the hydraulics
demand oil flow. During the time when no axis is operating, there is
no pump movement, and therefore no energy consumption by the Visit the Injection Molding Zone.

Tips & Techniques
lics are inevitable. Acceleration, and specifically deceleration, are related to the design and work principle of a variable-displacement
also more accurate with a servo drive than on hydraulic-driven pump and the constant-speed motor. The servo-driven pump
machines. Full-electric machines also allow for instant produc- machine does create a smaller amount of heat in the hydraulic
tion stability, as there is no necessary oil warm-up, and start-up is system. In fact, some manufacturers run a special oil-heating
faster after production has timed out. This is an advantage for sequence to keep the oil at operating temperature during production,
full-electric machines, not for servo- depending on the process point, the machines operating environ-
driven pump machines. ment, and the process sequence of
the specific product/process.
7. Noise level An active servo-
Full-electric and servo-driven pump 11. Machine cost driven axis has
machines usually have a noise level that A full-electric machine is always almost no delays,
is far lower than a standard hydraulic more expensive than a hydraulic while delays with
machine. Modern full-electric and machine due to the necessary hydraulics are
servo-driven pump machines should number of electric drives and inevitable.
have a noise level around 68 dbA. motors and gears (ballscrew or
gearbox or rack and pinion) for the
8. Speed and/or acceleration former. However, in many cases it is easy to calculate an ROI using
Official energy-
Comparison of servo versus hydraulic energy savings and improved utilization (faster cycle due to parallel
rating symbol of
EuroMap 60.1. speed and/or acceleration is matter of movements and greater uptime due to less maintenance), as well as
lively debate in the industry. Full-electric energy rebates that some states and energy companies offer. Servo-
drives have great accelerationmuch better than a pump ramp-up driven pump machines can (with some suppliers) still be slightly
in a hydraulic system, which suffers due to compressibility of the more expensive than standard hydraulic machines, but since servo-
oil and the hydraulic hoses and lines
that expand. The counterpoint cited
by some suppliers is that a perfectly
designed hydraulic system with accu-
mulators and strategically placed valves
can be even more spontaneous and
agile than the servo-driven machines.
9. Parallel movements
Full-electric IMMs generally use a
separate servo drive for each axis. This
makes those machines very flexible
since it allows all axes to be used with
parallel movements, which makes
sense when it is necessary to meter
during mold opening and ejection,
inject during mold closing, eject
during mold opening, and so on.
Servo-driven pump machines and
standard hydraulic machines do not
necessarily have that advantage. Most
suppliers offer a second or even a
Use of separate servo drives for each machine axis allows for parallel clamp and
third pump and hydraulic accumula-
injection movements. Hydraulic machines can accomplish this with multiple pumps.
tors as an option.
10. Hydraulic Design driven pump technology is being pushed hard by the industry as a
A standard hydraulic machine creates a lot of wasted heat through whole, there is more and more competition even among compo-
shearing and friction of the oil during idling, which is mainly nent suppliers, which allows the difference in price (where it still
exists) to be narrowed down to a minimum.
Tips & Techniques
Energy Consumption Comparison 12. Service of pumps, servo motors

Electric energy In cases where a hydraulic pump must be
No Water Consumption
consumption changed, fixed-displacement pumps that
including oil-
need no calibration are faster and easier to
cooling waterfor
Drive a conventional change than variable-displacement pumps.
kWh
Power hydraulic machine Fixed-displacement pumps also are usually

Input
Oil Cooling Drive with fixed-speed much less expensive than variable-dis-
Water Power pump is greater
Consumption Input than for a servo- placement pumps. Even though a servo
hydraulic machine. motor may be more expensive than a con-
Constant-Speed Pump Servo-Hydraulics stant-speed motor, it is more likely over
time that a molder will need to exchange or
BUNTING
maintain the pump.
Of course, full-electric machines either
never, or only rarely, need to deal with
pump maintenance at all. The well-known
No Metal. No Doubt.
Rotex coupling (spider-gear) does not
exist on servo-driven pump machines and
full-electric machines, and therefore does
not need to be exchanged. This is some-
thing that the maintenance crew in every
molding shop knows all too well.
On servo-driven pump
machines, the oil does not get
stressed very much and the
FF Series Drawer Filter
oil quality therefore degrades
slower than on a standard
hydraulic machine.
In general, modern machines offer much

better analysis features than their predeces-
sors. Servo drives can usually be analyzed
When it comes to magnetic systems, theres more than meets the eye.
with ease through embedded oscilloscope
From detecting and separating the smallest flakes of metal, Bunting Magnetics makes magnetic functions, which some suppliers offer as a
products and systems the plastics industry has come to trust. Take for example our FF Series
Drawer Filter. What makes this Bunting different? standard addition to their modern machine
Temperature-compensated, Rare Earth Magnets for superior high temperature operation
controls. This, together with the possi-
Drawer gasket resists heat aging and compression set offering greater durability bility to access the machine through web
A broad Line of Manual or Pneumatic Cleaning Options to fit any application
In-stock and ready to ship service, creates a powerful tool to service
In all of our products, we begin with the end in mind. We start with better components, innovative
and troubleshoot machines remotely.
design and finish production with superior attention to detail. Whether you need individual Constant-speed pump motors usually do not
components or complete, custom systems, we will purify your product, protect your brand and
make your plant more efficient. offer that possibility. Even alarm messages
Dont just remove metal, remove all doubt.
on the control of a servo-driven machine
Call us at 800.835.2526 or visit buntingmagnetics.com are more precise since the monitoring of
servo drives is so much more detailed.
Designed Manufactured In The USA

13. Oil quality & maintenance
500 S. SPENCER ROAD / P. O . B O X 4 6 8 / NEWTON, KANSAS 67114-0468
On servo-driven pump machines, the oil
does not get stressed very much and the
8008352526 buntingmagnetics.com
oil quality therefore degrades slower than

INJEC TION MOLDING
on a standard hydraulic machine. Of Specific Energy Consumption

course, this always depends on the pro- 0.70 Comparison of
specific energy
cess and how much the oil is moved and 0.60 0.65 consumption (per
sheared; but as a general rule of thumb, 0.50 weight of plastic
0.40 processed) between
kWh/g
the hydraulic machine puts more strain 0.44
0.30 a standard hydraulic
on the oil. Full-electric machines might
machine, a servo-
not have to deal with oil at all. 0.20 0.27 driven pump
0.10 machine, and a full-
0.00 electric machine.
14. Complexity of machines Hydraulic Servo-Hydraulic Full-Electric
Hydraulic machines in general, whether 240 Ton 240 Ton 240 Ton
they are servo-driven or not, have elec-
tronics, mechanical parts, and hydraulics.
Full-electric machines might only have www.negribossi.com
electronics and mechanical parts, which
reduces the complexity. A good electri-
cian can work on the machine without ACCURATE. EFFICIENT. DEPENDABLE.
needing to understand hydraulics.
15. Training of maintenance staff

One point that is easily forgotten is the
CAN BI O ST
training of the molders own mainte- Servo-Pump Injection Molding Machines
nance staff. For standard hydraulic with New TACTUS Touchscreen PC Controller
machines, it is recommended that the
hydraulics be calibrated once a year.
Better training of staff can lead to better
calibration and spotting of problems. No
pump-related calibration is needed on
electric machines, so the necessary
training of the staff is less complex.
These 15 critical points of interest

and comparison about partially and fully
servo-driven and hydraulic machines
are important for every molder to know. MODELS 180 250 330 400 500
With these points in mind, suppliers can
help work with molders to find the best BRAND NEW FROM NEGRI BOSSI... The CANBIO ST!
machine for their desired process. The best performing 5-point double toggle machine
just got better! Cutting-edge servo-pump injection
molding technology results in maximum efficiency,
repeatability, reliability, and SAVINGS!
ABOUT THE AUTHOR: Markus Klaus is Five flexible models in the 180500 tonne range
Divisional Manager of Injection Molding with injection capacities of 9.5155.7 oz. PS. Heavy
Machines for Wittmann Battenfeld, Inc., duty construction and generous specifications
Torrington, Conn. He earned a mechanical
engineering degree from the College of
ensure an excellent return for your investment.
Darmstadt, Germany. He has worked in
the plastics industry for almost 20 years in NEGRI BOSSI NORTH AMERICA
Germany at Wittmann, Ferromatik Milacron,
Tel: (302) 328-8020 | info@negribossi.us
and Toyo, and joined Wittmann Battenfeld in
the U.S.A. in 2013. Contact: 860-496-9603, x198;
markus.klaus@wittmann-group.com;
wittmann-group.com.

27th International Conference & Exhibits
Sheraton Charlotte Hotel | Charlotte, NC
April 4-6, 2017
REGISTER TODAY!
NEW IN 2017!
PRE-CONFERENCE
WORKSHOP & SEMINAR
Molding At the Press*
by John Bozzelli
*Separate fee required
POST-CONFERENCE
TOUR & ON-SITE
DEMONSTRATION
at RocTool
Molding 2017 brings global leaders and innovators

in injection molding together under one roof
in the worlds premier technical conference on this
processing sector. Come away with valuable tips
and insights that you cant find anywhere else.
PRESENTED BY:
To learn more or register visit:

MoldingConference.com
Molding 2017 offers KNOWLEDGE,
NETWORKING & BUSINESS DEVELOPMENT
for Injection Molding Professionals!
Learn from experts on process Network with peers and Meet with buyers and
management, materials, automation, industry professionals that can suppliers that will help
tooling, and materials drying, help improve your operations. grow your business.
handling, and conveying.
FEATURED SESSIONS: PLATINUM SPONSOR
KEYNOTE PRESENTATION SPECIAL LUNCHEON PRESENTATION

Pellet to Gate Control: Advances in Injection Molding of Metals
The Value of a Holistic - Paul Hauck, Liquidmetal Technologies
View of Melt Management
- Bruce Catoen, Milacron
GOLD SPONSORS
Attend sessions on the hottest topics in injection

molding and beyond, including additive manufacturing
and Industry 4.0, presented by industry leaders!
EMERGING MATERIALS & ADDITIVES ROBOTS
TECHNOLOGIES Asaclean & AUTOMATION
Arburg Eastman Chemical Arburg
Engel Extreme Molding Noble Plastics
IML Solutions ID Additives Sepro America
KraussMaffei Momentive Yushin America
Prophecy Sensorlytics PolyOne
Riverdale Global Sigma Plastic Services TECHNOLOGY
MEETING TODAYS
MOLDS & TOOLING KEEPING YOUR PLANT NEEDS
ACS Group RUNNING SMOOTHLY: Absolute Haitian
HASCO AUXILIARIES Athena Automation
HRSflow Burger & Brown Beaumont
Nypromold Engineering, Inc. Cold Jet
Design Safety SILVER SPONSORS
PFA Inc. Dri-Air Industries
PTI Engineered Plastics Moretto Engineering, Inc.
StackTeck Novatec Engel
Stratasys The Conair Group Ettlinger
Synventive Molding Solutions Extreme Coatings
Wittmann Battenfeld ESTABLISHING & Makuta Technics
Zahoransky USA Inc. MAINTAINING A Milacron
ROBUST PROCESS Proto Labs
PROCESS MONITORING Elmet RocTool
& CONTROL FIMMTECH Trexel
HTS International Corp. Piovan Zeiger Industries
KraussMaffei RJG Inc.
Md Plastics Plastic411
Oden Technologies Vikram Bhargava, Consultant Presentations
Wittmann Battenfeld subject to change.
REGISTER TODAY at
MoldingConference.com
Keeping Up
With Technology
INJECTION MOLDING
New Monitors, Controls, Sensors
Two well-known suppliers of injection monitoring and control Also new in ComoNeo 2.0 is a Restart Assistant, a wizard
systems and sensors introduced several new and upgraded that helps re-establish the process after a mold is moved to a
products at the K 2016 show in Dusseldorf in October. different press. It analyzes the difference between current and
The Swiss parent of Kistler Instrument Corp., reference pressure curves to offer the user suggestions on how
Amherst, N.Y. (kistler.com), brought out ComoNeo to optimize the processfor example, Please change holding
2.0, a brand-new version of the ComoNeo process moni- pressure to 500 bars (7255 psi). The process is iterative, requiring
toring system introduced at Fakuma 2015 a couple of test cycles.
(see Feb. 16 Keeping Up), which itself ComoNeo 2.0 also now incorporates
was an enhanced successor to Kistlers the OPC-UA (Open Platform Communica-
Como Injection system. ComoNeo 2.0 tion Universal Architecture) interface that
(pictured on opposite page) adds auto- is becoming the standard for Industry 4.0
matic process control to the monitoring machine-to-machine data connectivity. This
functions. It controls the switchover enables the ComoNeo system to fully imple-
point from speed to pressure control in ment Multiflow controlautomatic hot-runner
mold filling within each cycle, based on balancing by adjusting tip temperatures
cavity-pressure signals, and analyzing the without the need for a separate PC. It also
difference between current and reference can talk to higher-level MES and ERP
pressure curves. The switchover point can computer systems.
be set manually or determined automati- A second major introduction for Kistler was
cally by the system through analyzing a the ComoDataCenter 3.1, a new version of the
sequence of five test cycles. central monitoring system for all Como
MORE THAN JUST STORAGE!

Manage your inventory
Become better organized
Protect your investment
Create a safer working environment
GO FROM THIS
TO THIS!
Our mold management systems are

designed to save you space, time & money.
Visit our website or give us a call to learn more

about how we can help you with your
die or mold management needs.
716.822.2804 www.PTM.Rapistak.com

NE W PRODUC T S FOR PL A S T IC S PROCE S SING
Injectionand now ComoNeosystems plantwide. It now stores Priamus also has enhanced the Q-Button on its FillControl
all mold settings centrally. It also now offers the same user systems. When a user has established a process that produces
interface as ComoNeo and will translate input from older Como good parts, pushing the Q-Button automatically sets the six-
Injection systems to the new interface. Both types of systems sigma SPC limits for key process variables. In its latest iteration,
are now linked by a common database. Extended functionality the button establishes three levels of limitspre-warning,
includes more detailed good/bad part analysis, with ability to warning, and alarmto alert the user to process drift well
zero in on any cycle and the pressure curve for each cavity. It before bad parts are produced.
also provides cpK values A new portable
for the process. FillControl system
Kistler also has a new (photo on opposite
piezoelectric pressure page) allows moni-
sensor, Type 6185, toring the process by
which measures only 2 means of a large tablet
mm frontal diam. and computer that plugs
is insensitive to the into the sensors on the
position in which it is machine and mold. All
installed. This elimi- the required cables,
nates the susceptibility amplifiers, and power
to inaccurate measure- supply are housed in
ments due to mounting the transport case.
tolerances, making Also new is FillCon-
installation by mold- trol V for automatic
makers much easier balancing of valve
and more reliable. gates. It detects the
Kistler also brought out arrival of the melt
the Type 1722 multi- front via in-cavity
channel connector, temperature sensors,
which simplifies connection of single-wire coaxial cables. thereby detecting the different filling times from cavity to
Meanwhile, Priamus of Switzerland (U.S. office in Bruns- cavity. The Priamus system calculates the optimized settings
wick, Ohio; priamus.com), showed several updated injection of the pin stroke for every cycle and transmits them to the
monitoring/control products. Under the banner of Quality valve controller via an interface. FillControl V can work with
4.0, Priamus has added an OPC-UA interface to its FillCon- the valve-gate controls of sister company Synventive Molding
trol systems, which allows it to transmit quality data from Solutions, another member of the Barnes Group (synventive.
an entire molding cell to a network via an MES system. At com) to profile the opening speed as well as timing of the
the show, Priamus demonstrated this connectivity with the valve pins. For cold-runner LSR molding with valve gates, the
authentig MES system from T.I.G. of Austria (tig-mes.com), Priamus system has worked successfully with the Servo Shot
recently acquired by Engel. system of ACH Hefner of Austria (ach-solution.com).
NORTH AMERICAS LEADING TECHNOLOGY

HVTSE DRYER-LESS EXTRUSION SYSTEMS
M-ATEX Die Splitting TITAN Plus Control 100% Flake Capability A/B/A Co-ex
Support Automation Structure
High vacuum
twin screw extruder
by Bandera
HVTSE Model 5 Zone Temp Station Dual Payoff Lamination Cell Film Access Hatchways
170mm/42D w/3500
Co-extruder
World Class Sheet Extrusion Systems

Model GCH841830
Horizontal Five Chrome
Roll Stand
Processing Technologies International, LLC | 2655 White Oak Circle Aurora, IL 60502 | Tel: 630.585.5800 | Fax: 630.585.5855

Keeping Up With Technolog y
INJECTION MOLDING
Larger Pressurized Hopper For

New Physical Foaming Process
Arburg, Rocky Hill, Conn., demonstrated a new, larger size of its Profoam physical
foaming system at the recent K 2016 show. A sealed, pressurized hopper (now available
in 5-liter capacity) impregnates pellets with nitrogen gas before they enter
the injection barrel. The larger hopper allows foaming of larger parts.
The German Institute for Plastics Processing (IKV) in Aachen, which
helped develop Profoam, demonstrated production of a bicycle seat using the
process to foam long-glass PP in a sandwich with outer layers of unidirectional,
continuous glass/PP laminates. Foaming is said to permit gentle, stress-free molding
of the LGF-PP so as to attain greater fiber lengths in the core of the finished part.
860-667-6500 arburg.us
SCREEN CHANGERS MELT PUMPS MIXERS PACKAGED SYSTEMS
Industrys most
reliable Melt Pump
From through-hardened gears to high-wear
bearings to leak-free, anti-galling seals, PSI
www.psi-polymersystems.com melt pumps provide you consistent, trouble-
free performance, year after year.
What more can you get Join the ranks of processors turning to PSI
from your process? and put us to the test. Discover how much
more you can get from your process!
Precise dimensional control
Better melt integrity Call today to ask for a no-risk trial!
Stabilized output 1-828-468-2600
Increased yield Dont forget to ask about our Pump
Higher use of regrind Exchange program!
FROM THE EXTRUDER TO THE DIE - PERFORMANCE GUARANTEED! www.psi-polymersystems.com sales@psi-polymersystems.com
BOY
(
VV
EconPlast
Servo Drive EconPlast Procan ALPHA Insert moulding Industry 4.0
Spritzgiessautomaten
More than 45,000
successful machines
BOY has become the leading
www.boymachines.com supplier for injection molding
machines up to 110 U.S. tons
design
clamping forces.
ll proven
We logies
With efficient Servo-Drive, the
new techno
EconPlast technology and the
control Procan ALPHA BOY
BOY Machines, Inc. | Exton, PA 19341 | Ph 610.363.9121 | Fx 610.36
610.363.0163 | E-Mail: sales@boymachines.com sets standards world-wide.

INJECTION MOLDING MIXING/BLENDING
High-Level Training
for Molders
ProMolder 3 is a new, highest-level certi-
fication seminar from Paulson Training
Programs, Chester, Conn. This rigorous,
hands-on, certification course features
20+ hr of machine time plus time with
Paulsons SimTech injection molding simu-
lator. The aim of the course is to prepare
graduates to confidently make production
floor decisions and become key produc-
tion personnel. Paulsons ProMolder
Ribbon Blenders with
3 seminar is a completely immersive Higher Precision
learning experience over five days. Gradu-
ates of Paulsons ProMolder 1 & 2 or those New features are being offered on Ross
who successfully complete the equivalent Ribbon Blenders from Charles Ross &
Paulson CD/DVD or web-based training Son, Hauppauge, N.Y., for processors
meet the requirements to enroll in Paul- requiring extra precision and efficiency.
sons newest seminar. The course begins Materials are blended by a horizontal
with a review of ProMolder 2 and covers agitator consisting of inner and outer
key concepts including: helical ribbons in a U-shaped trough. The
ribbons are precisely pitched to move
Advanced analysis of part properties materials in a well-balanced axial and
and machine solutions based on four radial flow pattern.
plastic variables; The Model 42N-120SS (shown) is a
Practical hands-on application experi- 120-ft unit, now equipped with:
ence in machine settings;
Establishing upper and lower SPC A solid agitator shaft with precision-
control limits (UCL and LCL), trend formed ribbons having angled leading
analysis, and more. edges to prevent material buildup;
860-526-3099 paulsontraining.com Scrapers welded to the spokes and
ribbons, having a close tolerance (1/8
AUXILIARIES in.) to the end walls. As a standard,
trough corners are radiused to further
Small Dry-Ice Blaster eliminate dead space;
For Mold & Parts Cleaning Clear polycarbonate on the cover
and shaft guards. The cover can also
At Octobers K 2016 show in Dusseldorf,
include multiple ports for ingre-
Asco Carbon Dioxide Ltd. of Switzerland
dient additions, lights, spray system,
(U.S. office in Jacksonville,
venting, and vacuum transfer. Opera-
Fla.) presented its newest
tors can safely view the batch and
and smallest dry-ice blasting
charge raw materials while the agita-
unit for cleaning molds and plastic
tors are running;
parts. The Ascojet 608 boasts low
Air-purged mechanical shaft seals with
compressed-air
replaceable fluoropolymer seal faces;
consumption
Pneumatic spherical disc valve, which
and low noise
provides a large opening and minimizes
level. Its inte-
dead space. Discharge connections can
grated pellet
be customized to mate with the users
grinder allows
material-handling system.
blasting with
631-234-0500 mixers.com
the finest ice
particles for
even gentler
cleaning of molds and part surfaces. It
also has a vertically adjustable handle
and integral safety grounding roll.
904-278-6503 ascoco2.com

DECORATING
High-Speed Inkjet Printer for Cables

The Jet3up Rapid is latest high-speed continuous inkjet printer
from Paul Leibinger (U.S. office in East Troy, Wis.). The unit, which
The first name in materials testing debuted at K 2016, reportedly allows cables to be
marked immediately after extrusion at up to 1000 m/min
(60 km/hr). The inkjet coder is said to achieve unprece-
dented speeds in marking and coding other plastic products as well.
According to the company, the Jet3up Rapid can achieve up
to 40% higher printing and production speeds due to its much
higher drop frequency,
among other features.
It also sports print-
heads that are specially
designed for high speeds.
The automatic nozzle
Tension Puncture Melt index seal, called Sealtronic,
prevents ink from drying
Compression Peel Impact
even during long shut-
Flexure Tear Vicat /HDT downs. During pauses in
Shear COF Hardness production, the gutter
All tests can be performed in accordance with and the nozzle are said
ASTM, ISO and industry specific standards to form an airtight
circuit: No ink can leak out of the circuit and no air can get in.
www.tiniusolsen.com Even after long shut-downs, the high-speed coder is ready to
sales@tiniusolsen.com 215 675 7100 print within 1 min without cleaning cycles.
262-642-4030 leibinger-group.com
TEAM UP.
Score a touchdown with
Lusin and Ultra Purge!
Lusin and Ultra Purge are now on

the same Chem-Trend roster, providing
thermoplastics processors with a
stronger range of purging compounds,
release agents and mold maintenance
products. Were focused on helping
our customers score big with increased
efficiency, less scrap and reduced
operational costs. Get in the game
and call Chem-Trend today!
ChemTrend.com

RECYCLING Wet Shredder for Films, Bottles ADDITIVES
Austria-based Lindner Group (U.S. office in Raleigh, N.C.) introduced High-Performance Stabilizers
the Micromat WS wet shredder at K 2016; it is specially designed For Polyolefins Outdoors
for pre-shredding contaminated post-consumer plastic
A new line of stabilizers said to deliver exceptional
scrap, such as lightweight packaging, bottles, or films.
UV and long-term thermal stability to PP and other
By directing a jet of water onto the rotor, friction during
polyolefins used in outdoor building and construction
shredding can be used to detach dirt particles. This means that the
has been added to the proprietary Cyasorb Cynergy
material undergoes pre-cleaning from the outset, which has a positive
Solutions portfolio of Solvay Technology Solutions,
impact on downstream processing. The water simultaneously ensures
Woodland Park, N.J. (formerly Cytec Industries).
uniform and controlled material discharge.
New B Series stabilizers are suitable for use with neat
Once the material has passed through the pre-shredder, screw
and reinforced resins, and reportedly will not contribute to
conveyors deliver it, together with the water, directly to the new
blooming or delamination in painted parts. Target appli-
Rafter pre-washer. The Rafter gently and thoroughly detaches and
cations include TPO roofing, polyolefin roofing tiles and
separates contamination and adhering paper from the plastic.
shakes, solar shingles, siding, shutters, and geomembranes.
919-610-2835 l-rt.us
973-357-3100 solvay.com
Meet us at
Chinaplas!
Booth F41,
Hall 2.1
Our Recycling Revolution For

Highly Contaminated Materials:
Prolonged production time with
a unique filter media design
BKG HiCon R-Type 250 Minimal melting loss in pressure
Filtration System constant operation
EXTRAORDINARY TECHNOLOGIES
WWW.NORDSONPOLYMERPROCESSING.COM FOR TODAYS PLASTICS

TESTING/MEASURING
New Automated Laboratory & Thickness

Sensor for PET Bottles
At the recent K 2016 show in Germany, Agr International Inc., Butler, Pa., intro-
duced an automated laboratory test cell, a customized system designed for high
productivity by combining multiple test devices into one compact
station. It can integrate Agrs Gawis thickness and dimensional
measuring units, TL 2000 Topload tester, Combi unit for testing both
fill height and topload, and PPT3000 for measuring pressure, volume expansion,
and shelf-life. The cell combines up to three of these devices together with a
small articulated-arm, pick-and-place robot and laboratory information-manage-
ment system (LIMS) software for job management, documentation, and reporting.
Agr also brought out the MBTxt series of portable thickness gauges, which
can measure plastics, glass, and aluminum containers up to 24 mm thick. They
use the Hall effect, which measures precisely the distance between a magnetic
probe and a target ball. It is especially well suited for measuring sharp corners,
tight radii, and complex shapes. In addition to a redesigned sensor and a wider
range of target balls, the new xt version offers two sensor options with ranges
of 0-9 mm and 0-24 mm. Light enough for handheld use, these units are battery
powered with an onboard datalogger and ability to transfer data via USB or
RS232 connection.
Two versions are MBT7200xt with automatic storage of 100,000 values; and
MBT7400xt with database storage of 240,000 values, plus real-time trending and
statistical graphing of histograms and trends.
724-482-2163 agrintl.com
We essentially quadrupled our production capacity,

and our scrap went from significantly high to near zero.
Joe McGillivray, CEO Dynamic Group
60
ROI IN JUST
DAYS
Reduced 3 operators to 1 per shift Easy programming and safe, flexible deployment
Universal Robots boosts injection molding capacity 4X

A UR robot tends a complete injection molding cycle for a medical device with parts that are extremely heat sensitive, requiring a perfectly
consistent cycle from part to part. The robot helped Dynamic Group move from 3 operators on a single shift, to running 3 shifts per day with
just 1 operator per shift, freeing up staff for higher-value tasks. Production capacity quadrupled, and scrap was nearly eliminated.
Optimize your plastics processes with affordable, accurate UR robots.
Scan code to read case study and watch the video:

www.universal-robots.com/case-stories/dynamic-group
Find your distributor: www.universal-robots.com/distributors

RECYCLING ADDITIVES
Metal Detection High-Performance PVC Plasticizer

An alternative PVC plasticizer launched by PolyOne Corp., Avon Lake, Ohio, report-
& Sorting edly has performance equivalent to industry workhorse 810TM linear trimellitate
plasticizer and is formulated for wire/cable and automotive slush molding. New
Sesotec GmbH (U.S. office in Bartlett, SynPlast L9TM, which relies on a linear 9-carbon alcohol, offers abundant supply
Ill.) showcased its Rapid Pro-Sense availability to help counteract historic supply-chain disruptions of 810TM.
metal separator at K Flexible PVC compounders have traditionally relied on 810TM to achieve critical
2016. The unit detects and performance properties at both elevated and low temperatures. When linear 810
separates magnetic and non- alcohol became scarce in 2013, leading to a supply shortage in the workhorse plas-
magnetic metal particles, even if they ticizer, PolyOne began developing its alternative in cooperation with a leading wire
are encased in plastic. This ensures the and cable PVC compounder.
quality of plastic granulate and protects 866-765-9663 polyone.com
processing machines against damage
and clogging.
In addition, Sesotec presented for
the first time the new Flake Purifier+
sorting system, which is based on a
modular approach that allows combina-
tions of various sensors for contaminant
detection, including sensors for metal
separation, color separation/sorting,
and separation/sorting by polymer types.
The + in the system stands for
optimized material infeeding for a more
evenly distributed material flow and
increased material throughput. The
system also allows easier maintenance
and integration. The + also stands
for the dust-proof system design and
for the integrated connections for dust
and label extraction, which increase
efficiency in recycling.
224-208-1900 sesotec.us
COMPONENTS
FOR PLASTICS
Plastics Conveying
Professionals
Lorenz Conveying solutions are built to
last. For more than 40 years we have been
building the industrys best conveying
systems which handle the hardest materials
and are delivered on time, every time.
#lorenzquality #lorenzconveying
Canadas Fastest
Growing Companies
2014 2015 2016
THE CONVEYING PRODUCTS PEOPLE
Check Out Our Online Product Catalogue

USA 1.800.263.7782 CANADA 1.800.263.1942 LORENZPRODUCTS.COM

MATERIALS High-Heat, Blow Moldable Nylon

A new high-heat-resistant blow metal-replacement opportunities. fied some of the new nylons advantages
moldable nylon was developed by the This Radilon nylon compound is over competing PPS, including 15% weight
Radici Group (U.S. office in Wadsworth, a copolymer with a semi-aromatic reduction; 5-7% lower energy consumption
Ohio) in collaboration with Rochling component for heat resistance, plus due to lower process and mold tempera-
Automotive of Germany and Duncan, S.C., other additives used to retard thermal tures; longer mold life thanks to lower
for initial application in turbo air pipes oxidation. In addition, the material is abrasion of nylon vs. PPS; and enhanced
for a major automotive manufacturer. said to provide high melt strength for impact resistance. Charpy unnotched
Able to withstand continuous exposure good blow moldability. impact strength is 72% higher at 23 C, and
to hot air at up to 446 F, the new Trials and validation tests performed Charpy notched impact is 52% higher.
formulation reportedly opens up new in Rochlings laboratories have quanti- 800-733-7611 radicigroup.com
MATERIALS
Complete Blown Film
THE X-DIE
& High Performance
V-RING Nano-Reinforced Nylon

Alloys For Structural
Medical Components
A line of nylon compounds specifically
designed for medical-device components
that require high strength but cannot use
either metals or traditional reinforced
plastics is newly available from Foster Corp.,
Putnam, Conn. Nanomed Max compounds
are based on an alloy of MXD6 nylon from
Mitsubishi Gas Chemical Co. (U.S. office
in N.Y.C.). They are USP Class VI tested
and suitable for reusable instruments or
components that must withstand gamma,
e-beam, and ethylene oxide sterilization.
These compounds incorporate platelet-
shaped nanoclay particles less than a
nanometer thick and up to 1000 times
greater in surface diameter to provide
reinforcement at the molecular level. This
reportedly enhances strength and rigidity
without hindering flow into thin sections.
Containing less than 10% by weight of
nanoclay, these compounds boast 15%
higher tensile strength than unmodified
PEEK at about half the price. And unlike
PEEK, Nanomed Max compounds do
THE BLOWN FILM EXPERT S not require high-temperature injection
ALPINE AMERICAN molding or extrusion equipment. They can

be processed using standard mold and
barrel heaters that are commonly used for
www.halpine.com T: (508) 655-1123 F: (508) 655-9337 nylons and polyesters, Foster says.
860-630-4537 fosterpolymers.com

YOUR BUSINE S S
Resin Pricing Analysis YOUR BUSINE S S
Higher Prices for Commodity Thermoplastics

PP leads pricing surge.
Prices of the five major commodity thermoplastics were expected
to be higher by the end of last month, with PP leading the way in Market Prices Effective Mid-February 2017
severity of the increase, followed by PE.
By Lilli Manolis Sherman Resin Grade /lb
The market was driven not by demand
Senior Editor POLYETHYLENE (railcar)
typically slow in the first two months of
LDPE, LINER . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-92
the yearbut by a combination of higher global oil prices, LLDPE BUTENE, FILM . . . . . . . . . . . . . . . . . . . . 76-78
planned and unplanned plant shutdowns of several key feed- NYMEX FINANCIAL FUTURES . . . . . . . . . . . . 48
stocks and, in some cases, resins. With the exception of PP and MARCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
HDPE, G-P INJECTION . . . . . . . . . . . . . . . . . . . . 92-94
possibly PVC, prices of the other commodity resins may flatten out
HDPE, BLOW MOLDING . . . . . . . . . . . . . . . . . . . 82-84
in the next couple of months. NYMEX FINANCIAL FUTURES . . . . . . . . . . . . 48.25
These are the views of purchasing consultants from Resin MARCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.50
Technology, Inc. (RTi), Fort Worth, Texas (rtiglobal.com), CEO Michael HDPE, HMW FILM . . . . . . . . . . . . . . . . . . . . . . . 95-97
Greenberg of the Plastics Exchange in Chicago (theplasticsexchange. POLYPROPYLENE (railcar)
com), and Houston-based PetroChemWire (petrochemwire.com). G-P HOMOPOLYMER, INJECTION . . . . . . . . . . . 70.5-72.5
NYMEX FINANCIAL FUTURES . . . . . . . . . . . . 48.25
Polyethylene MARCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.50
PE PRICES UP FOR NOW IMPACT COPOLYMER . . . . . . . . . . . . . . . . . . . . . 72.5-74.5
Price Trends
Polyethylene prices were flat in January, but
POLYSTYRENE (railcar)
LDPE a February 5/lb hike was expected to be G-P CRYSTAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 93-95
JAN FEB implemented by the end of last month. A 6/ HIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99-101
lb increase for March 1, issued by one sup- PVC RESIN (railcar)
5/lb plier, went unsupported. This was not a G-P HOMOPOLYMER . . . . . . . . . . . . . . . . . . . . . 77-79
demand-driven increase, said Mike Burns, PIPE GRADE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76-78
LLDPE Butene RTis v.p. of client services for PE. PET (truckload)
JAN FEB U.S. BOTTLE-GRADE . . . . . . . . . . . . . . . . . . . . . 58
In fact, Burns could not cite any solid
driving factors behind the 5 hike, other
5/lb than lower supplier inventories. In their
aim to reduce inventories by end of 2016, Once the PE market comes more into balance, any further
HDPE suppliers exported 10% more material than upward pressure would come from higher oil prices. That would
Injection
usual. This resulted in a tightening of the PE boost global PE prices and the export market, according to Burns. Oil
JAN FEB market, with off-grade material selling at or prices through January hovered between $50 and $53/bbl despite
above prime resin prices. reported production cutbacks. Burns maintains that direct impact
5/lb Burns expected the market to be more on PE prices will not materialize until oil approaches $60/bbl.
balanced in March and April, noting that many
HDPE processors were working off inventories in
Blow Molding
January and would buy only as needed through PP PRICES SURGE; MORE TO COME
JAN FEB
last month. Supporting that notion was The Polypropylene prices jumped a whopping 10/lb in January, in
Plastics Exchanges Greenberg, who reported step with the late-January settlement of propylene monomer,
5/lb in late January that PE spot trading was very which rose to 41.5/lb. Based on continued upward movement in
strong ahead of the February increase. At the spot monomer prices, February monomer contract prices were
HDPE HMW same time, PetroChemWire (PCW) reported that expected to increase further, with PP following once again,
JAN FEB
higher domestic spot prices and sales volumes according to both Greenberg and Scott Newell, RTis v.p. of PP
in January were aggravated by a flurry of PE markets. Newell ventured that February PP prices could move up
5/lb production issues as well as planned outages. 5-8 in step with monomer but with no margin increases attached.

YOUR BUSINE S S
Resin Pricing Analysis
Polypropylene Greenberg reported at the end of January PVC Price expected to settle 2/lb higher after a
Price Trends that the PP market went from bear to bull Trends similar move in December, PVC suppliers
even before monomer costs began to soar, were aiming to implement their February
Homopolymer Pipe
attributing the sharp market turnaround 4/lb hike and also issued 3 increases for
JAN FEB and tighter supplies to months of lowered JAN FEB March 1.
production output and heavy exports. RTis Kallman ventured that 3-4 of
10/lb Spot prime PP prices shot up by 11/lb and 3-4/lb the February increase would go through,
offgrade even more, Greenber reported. noting that he expected a third successive
Copolymer Explaining the monomer price Gen. Purpose 2/lb ethylene price increase for February
JAN FEB surge, PCW cited tightness due to throt- JAN FEB contracts. Ethylene tightness due to both
tling back of production at the end of scheduled and unplanned outages has
10/lb 2016, along with a spate of planned and been driving the higher prices. Kallman
3-4/lb
unplanned outages. PCW also reported also predicted that if suppliers imple-
that Formosa was about to restart a PP unit after a maintenance mented the full February 4/lb increase, the March increase could
outage, while two other suppliers were said to experience be pushed off.
lingering effects from outages in late 2016, such as delayed ship- He also noted that although PVC suppliers had strong inven-
ments and limited spot resin availability. tories going into this year, there may be some resin constrictions
Newell said the market is likely to become more balanced in due to planned maintenance outages, particularly as processors
April, and prices would settle down a bit. Still, he and Greenberg would be looking to stock up before the start of the construction
expected PP prices to reach as high as the low 60s (/lb) before the season in the second quarter. Kallman said all indications were
end of March. Both concede that the low prices of 2016 are unlikely that little resin is available for exports, but there is adequate
to recur this year. Newell foresees prices in the high 40s to low 50s. supply for domestic consumption. He ventured that once
Higher monomer prices were expected to cause PP demand ethylene and PVC maintenance turnarounds are completed, there
destruction through the first quarter, noted Newell, who saw PP may be some easing of prices; though if PVC demand is as strong
processors working off inventories and buying only as needed. as some predict, the price increases now going through might
well be maintained for a time.
PS PRICES TAKE TWO STEPS UP

Polystyrene prices moved up 5/lb in January, following a near PET PRICES UP
60/gal increase in January benzene contracts to $3.33/gal. PS Domestic bottle-grade prime PET resin in January averaged 56.3/lb,
suppliers also issued increases of 8/lb for February. Mark Kallman, up 1.1 from December, based on PCWs Daily PET Report. On Feb. 3,
RTis v.p. of client services for engineering resins, PS, and PVC, the price moved up to 58/lb (delivered
expected that suppliers would get at least PET Price Trends Chicago basis). Prices rose primarily due to
Polystyrene 6 of that hike. higher costs for feedstocks (including PTA,
Price Trends Bottle Grade
Aside from rising benzene prices, MEG, and paraxylene), driven by rising
JAN FEB
GPPS styrene monomer and butadiene (which hydrocarbon prices. Xavier Cronin, senior
JAN FEB
affects HIPS) tabs are also higher. Kallman editor for this PCW report, said the average
attributed the situation to a global tight- 1.1/lb 1.7/lb cost of feedstocks in January was 55.8/lb, up
ness in benzene, monomer, and butadiene 3/lb from December, according to one
5/lb
supplies, primarily due to planned and calculation used for monthly PET pricing tied to contracts. Meanwhile,
HIPS unplanned production outages and higher DAK Americas successfully hiked its PET resins by 5/lb on Jan. 1.
oil prices. He also noted that there have been Imported prime PET averaged 52.45/lb in January, up 1.95
JAN FEB
no lower-priced PS imports coming in. He from December (delivered duty-paid U.S. port basis). The volume of
expected some softening in PS prices during imports was up 13% through November 2016 from 2015, according
5/lb the second quarter, possibly as early as April. to USA Trade Online data, Cronin noted.
PVC PRICES STARTING TO MOVE

QUESTIONS ABOUT MATERIALS?
PVC prices were flat in January, as they were for eight months of
2016, but change was coming. With January ethylene contracts Visit the Materials Zone and the Materials Database.

YOUR BUSINE S S
G ARDNER BUSINESS INDE X: PL A S TIC S
January 201754.7
Custom processors grow at fastest clip since March.
With a reading of 54.7, the Gardner Plastics Business Index grown every month but two since March 2016. Companies with
showed that industry grew for the first time since October 2016 50-99 employees had an index above 60 for the first time since
and at its fastest rate since January May 2016. Processors with 20-49 employees grew for the fourth
2015. In general, the industry has time in five months. Processors with fewer than 20 employees
trended up since July. expanded for the second
Both new orders and produc- straight month.
Processing plants of all
tion grew at a very strong rate. The The Southeast was the
sizes showed growth.
rate of growth in new orders was the fastest growing region
fastest since March 2016. And the for the third consecu-
rate of growth in production was tive month and has grown for the last nine months. Its index
Steve Kline Jr. the fastest since January 2015. The in January was easily its highest since the survey began in
Dir. Market Intelligence backlog index grew for the first time December 2011. The North Central-East also grew at its fastest
since January 2015. This indicates rate since the survey began. The Northeast grew in four of the
that capacity utilization should increase in 2017. Employment last five months. The North Central-West grew for the first time
increased after one month of contraction. Exports continued since June 2015. Both the West and South Central contracted.
to contract but at a slightly acceler-
ating rate since October 2016. Supplier
deliveries continued to lengthen.
Material prices increased at a Plastics Industry Business Index
significantly accelerating rate in 70
each of the last two months. The
index was at its highest level since Values above 50 indicate growth
February 2014. Prices received
increased for the fourth time in five 60
months. The rate of increase was the Jan.
fastest since October 2014. After a 2017
huge jump in November due to the Index
50
election results, the future business 54.7
expectations index increased again
in January, when the index was at an
all-time high. 40
The automotive industry
continued its strong growth for the
third month in a row. Electronics Values below 50 indicate contraction
30
grew significantly for the fourth
JAN 14
JUL 14
JAN 12
JUL 12
JAN 17
JAN 15
JUL 15
JAN 16
JUL 16
JAN 13
JUL 13
time in five months. And the

medical index grew for the first
time since July 2016.
Plastics/rubber processors had
strong growth in five of the last six months. Custom processors ABOUT THE AUTHOR: Steven Kline Jr. is part of the fourth-generation
grew at their fastest rate since March 2016. ownership team of Cincinnati-based Gardner Business Media, which is
the publisher of Plastics Technology. He is currently the companys director
Plants with more than 250 employees expanded for the first of market intelligence. Contact: (513) 527-8800;
time since August 2016. Facilities with 100-249 employees have email: skline2@gardnerweb.com blog: gardnerweb.com/economics/blog

YOUR BUSINE S S
MARKET WATCH
New Vehicle Sales at All-Time High

Yet production is growing at a slower pace, a trend that is likely to continue.
In December 2016, new vehicle sales in the U.S. were 18,680,000 Real Motor Vehicle & Parts Consumer Spending. Despite the
units (seasonally adjusted at an annual rate). That was the highest increase in the real 10-yr Treasury rate at the end of 2016, real motor
level for vehicle sales since July 2005. But vehicle and parts (MV&P) spending by consumers grew significantly
Steve Kline Jr.
Dir. Market Intelligence
the high level of new vehicle sales is not in the fourth quarter of 2016. In December, MV&P consumer
leading to accelerating growth in produc- spending was 8.7% more than it was a year ago. That was the second
tion. Lets look at some of the leading indicators to see where the fastest rate of growth since January 2015. And it was the fourth time
automotive industry might be headed in the next six to 12 months. in five months that the rate of change from the same month a year
earlier was at least 4.5%. This is significant because the historic
Real 10-Yr Treasury Rate. The real (inflation-adjusted) 10-yr U.S. average for that rate of change is 4.2%. As a result, the annual year-to-
Treasury bond interest rate was 1.23% in December 2016, which date rate of growth accelerated for the third straight month to 2.9%,
was an increase of 24 basis points (hundredths of a percent) from which was the fastest rate of annual growth since February 2016.
the previous month. This was the highest real 10-yr Treasury rate But if the change in the interest rate continues to rise, expect
since last April. The nominal rate was 2.49%, which was the MV&P spending to grow at a slower rate around the second quarter.
highest since September 2014. But the rate of inflation has been
rising too. In December, the inflation rate was above 2% for the Real Motor Vehicle & Parts New Orders. New MV&P orders grew
first time since June 2014. The increase in inflation was limiting 2.7% in December compared with one year ago. This was the third time
the rise in the real 10-yr Treasury rate (the real rate is the nominal in four months that new orders grew. However, the rate of growth from
rate minus inflation). The year-over-year change in the real rate the same month a year earlier slowed noticeably since March 2016.
increased to -89 basis points. That was the second straight month Therefore, the year-to-date annual rate of growth in new orders decel-
of an increase. The increase in the year-over-year change in the erated to 2.1%. This was the ninth consecutive month of decelerating
10-yr Treasury is likely to lead to a decline in new vehicle sales as growth. And the annual rate of growth in December was the slowest
financing becomes more expensive. since May 2010, which was the last time that the annual rate of change
in real motor vehicle and parts new
orders contracted.
Real MV&P Spending Leads MV&P Production
30 40 Motor Vehicle & Parts Industrial
24 32 Production. The growth rate in motor
vehicle and parts production was quite
18 24
strong in December 2016. Compared
12-Mo. Rate of Change
12-Mo. Rate of Change
Real MV&P Spending,
12 16 with one year ago, production grew

MV&P Production,
8.4%, which was the fastest rate of

6 8
growth since February 2016. But the
0 0 general trend has been slower growth
-6 -8 in production since July 2014, which is
likely to continue, given the trends in
-12 -16
the interest rate and new orders.
-18 -24
-24 -32 ABOUT THE AUTHOR: Steven Kline Jr. is part

of the fourth-generation ownership team of
-30 -40 Cincinnati-based Gardner Business Media,
Jan 02
Jan 12
Jan 04
Jan 14
Jan 96
Jan 06
Jan 16
Jan 00
Jan 10
Jan 98
Jan 08
which is the publisher of Plastics Technology.

He is currently the companys director of
market intelligence. Contact: (513) 527-8800
Real MV&P Spending MV&P Production email: skline2@gardnerweb.com
blog: gardnerweb.com/economics/blog

MARKETPL ACE
This is Plastics Technologys online listing for plastic processing equipment

builders, material suppliers, auxillary manufacturers and more.
WWW.TINIUSOLSEN.COM WWW.RAPISTAK.COM
Managing molds
and dies can be
time consuming
and difficult, thats
where our Mold Management Systems help you manage your
inventory, become better organized, protect your investment and
Test Equipment: Hardware and software for tensile, flexure, com- create a safer working environment. For more information email us
pression, puncture/burst, shear, melt indexing, and impact testing at ptsales@rapistak.com.
of plastics.
WWW.ADVANTAGEENGINEERING.COM WWW.SCREENCHANGER.COM
HITECH
Leaders in continuous melt filtration since 1969
Manufacturers of fully automatic, continuous screen changers for

every segment of plastics processing (blown & cast film; sheet,
Manufacturer of high quality water and oil temperature controllers, co-ex, foam, pipe & profile, blow molding, filaments & fibers,
portable chillers, central chilling systems and cooling tower systems. pelletizing, BIAX) for use with all families of thermoplastics.
WWW.ENGELGLOBAL.COM WWW.NOVATEC.COM
Visit our website for informa-
tion on ENGELs machine and
automation concepts, innova-
tive technologies and applica-
tions, and extensive customer support. With global service, pro-
duction and sales resources, ENGEL is a partner you can count on
for long-term quality and technology solutions that support Worlds largest selection of dryer technologies and blenders
innovative products and effective production. with unmatched system design and control capabilities.
1-800-BESTDRY (1-800-237-8379)
WWW.CVI.CANON.COM WWW.PPE.COM
With a continually expanding range of products,
PPE is the largest supplier of molding accessories
to the plastics industry. With offices in Ohio,
Nevada and Florida, PPE provides fast delivery
and the personal attention that your order
deserves. Contact us at 1-800-362-0706,
sales@ppe.com or visit www.ppe.com
Canon offers custom mold making solutions. Contact us at
1.866.CANON or visit www.cvi.canon.com to find out more.
WWW.MAGUIRE.COM WWW.ADVANTAGEENGINEERING.COM
WWW.DAK AMERICAS.COM
As
Manufacturer
one of the worlds
of high
quality
largest water
producers
and oil
of PET
Resins,
temperature
DAK iscontrollers,
committed
The perfect blend of simplicity and control. portable
to the global
chillers,
PET central
market
chilling
with a capacity
systemsof and
over 4.1
cooling
billion lbs/yr.
tower systems.
With
Over 100 pages of easy browsing packed with useful information sustainability initiatives, innovative Laser+ PET resin products,
on Maguire Blenders, Loaders, Granulators, Feeders, and Liquid and trade leading technologies such as IntegRex PTA and PET
Color Pumps. Technologies, DAK is setting new standards for the industry.

MARKETPL ACE
PROGRESS THROUGH INNOVATION STYRAMA AUTOMATION SOLUTIONS

Complete overview of the Now a part of Negri Bossi
company, its history and (SACMI), Sytrama provides
the relentless product automation solutions for
developments that have the plastics Industry.
made it the leading Sytrama G-Series part
manufacturer for plastics removal robots perform
You can get copies of literature from processors worldwide. Its operations in sequence
suppliers listed on these pages by innovative products including movements in
sending an e-mail to the address include injection molding the mold area, and can be
machines, robots and programmed to operate
provided at the end of each writeup. automation systems, downstream automation
Or, where provided, contact the auxiliary equipment . processes.
company by phone or fax. Torrington, CT info@wittmann-ct.com New Castle, DE info@sytrama-usa.com
DRY-CONVEY-BLEND-EXTRUSION SINGLE AND TESTERS

TWIN SCREW EXTRUDERS
DRY-CONVEY-BLEND-EXTRUSION
MELT FLOW FULLY AUTOMATIC SCREEN CHANGERS
Novatec is one of the largest 20mm
Novatec
Melt Clamshell
is one
indexer of theinlargest
comes HITECH screen changers
U.S. based manufacturers of Segmented
U.S. based
manual orTwin-Screw
manufacturers
motorized of operate on a truly continu-
resin drying and conveying Extruder:
versions Compounding,
resin dryingand and conveying
loaded with ous principle in harmony
equipment for the plastics Pilot Scale &
equipmentand
capability Nanocomposites
forefficiency:
the plastics with the rest of the extru-
industry. Together, with applications for product
industry. Together,
three-zone heaters; with
touch sion process. The screen, in
Maguire Products, we development.
Maguire Clamshell
Products, we the form of a long ribbon,
screen control; tapered
barrel allows visual moves slowly through the
offer the largest line of offer the
weight largestsimple
design; line ofdie
processing assessment, screen changer at an infi-
manufactured resin manufactured
release; USB resin
connectivity
easy screw mounting, nitely adjustable rate to
handling equipment in handling
and Horizonequipment
softwarein for blend smoothly with the
North America. quick
North
SPC cleaning.
America.
analyses; Segmented
optional polymer flow.
Product Overview: screws offer
Product or
manual numerous
Overview:
motorized
www.novatec.com/about processing possibilities..
www.novatec.com/about
extrudate cutter.
Baltimore, MD sales@novatec.com S. Hackensack,
Baltimore,
Horsham, PANJsales@tiniusolsen.com
MD cwbi@cwbrabender.com
sales@novatec.com Hackensack, NJ aalroy@screenchangers.com
MECHATRON FEEDERS DUST FREE CONTAINER LOADING PPE GATE CUTTERS - LOWER PRICES
The versatile The siloadmaxx system PPE offers the best variety
MECHATRON feeder provides fast, dust-free of Gate Cutters at the
handles a wide variety of container loading with lowest prices in both our
materials. Quick and easy nearly 100% filling effi- Economy and Premium
disassembly from the ciency. The unique, self- styles. With 74 different
non-process side of the contained system applies cutters to choose from
feeder simplifies cleaning pneumatic conveying including heated & pneu-
and maintenance. Feed principles to save time matic, youre bound to find
rates from .002 to 1,100 and money. what you needed right here
cubic feet per hour. at PPE. www.ppe.com
Whitewater, WI mktg@schenckprocess.com Lancaster, PA info@pelletroncorp.com Macedonia, OH sales@ppe.com
AQUATHERM TEMPERATURE CONTROLLERS CLEAR-VU LOADING SYSTEM PLASTRAC AUTO-DISC

RQE Series Temperature Provides all the benefits of Plastrac Inc. manufactures
Controllers are built for a central loading system Disc-based Blending and
dependable operation using with the added convenience Dosing equipment for all
quality components such as of portability & low plastics processing. Auto-
high flow pumps, twin tank maintenance. Brochure & Disc features gravimetric
assemblies, and Incoloy video describe this self-calibrating Dosing
sheathed heaters. The large, complete vacuum units and multi-ingredient
user-friendly controller conveying system that will blenders. Plastrac has
interface makes operation control up to eight stations. recently added a Powder
simple and also provides a Receivers allow full view of Additive Feeder option to
wide array of system and the loading action. the Auto-Disc Series.
diagnostic information.
Niles, IL info@thermalcare.com Aston, PA info@maguire.com Edgemont, PA info@plastrac.com
HAMMERTEK CORPORATION THE SOLUTION TO KNIT/FLOW LINES PLASTIC PIPE GRANULATORS

Built to endure. Per-Fix Flaw Repair Original Pallmann Pipe
Made to save you money. CoatingsThe Solution Crushers can be used for
Hammerteks Smart to Knit/Flow Lines. size reduction of plastic
Elbow. Chem-paks patented line pipes consisting of PE, LD,
of coatings helps you HD, MD, PP, PVC, ABS, etc.
eliminate most cosmetic down to extrudable gran-
flaws common to injection
ules. Proven horizontal
molded plastics. Designed
feeding system handles full
specifically for matte-
length & up to 36 d. pipes,
finished, color-coded,
as well as cutoffs. Custom
textured, interior parts.
models also available.
Landisville, PA elbows@hammertek.com Martinsburg, WV info@chem-pak.com Clifton, NJ info@pallmannpulverizers.com

CL A SSIFIEDS
MATERIALS WANTED/FOR SALE

PURGING COMPOUNDS
High Performance
Liquid Purging Compound
Use Less, Get Better
Results
More Cost Effective
Than Pellets
Sold Through
Knowledgeable
Distributors
Samples Available
1-800-797-9244
www.elmgroveindustries.com
E-mail: sales@elmgroveindustries.com
FEATURING
Best Practices &
Processing Know How
PTonline.com New Technologies & Products

Knowledge Centers
Tips, Techniques &
Troubleshooting
Your #1 Plastics Processing Resource Materials Database
PT Blog
from Plastics Technology! And, much more
IMPROVED NAVIGATION
Optimized search and
reorganized navigation
make it easier to research
the products, processes
and suppliers you need.
ENHANCED DESIGN
Larger article formats, more
product images, redesigned
emphasis zones.
PTonline.com

CL A SSIFIEDS
SPECIAL SERVICES
TIME-CRITICAL
CONFIDENTIAL
GRINDING
PROBLEM SOLVING Services
Since 1973
Granulation / Coarse Grinding
Chemical Analysis and
Characterization Pulverizing / Fine Grinding
Thermal Analysis and Rheology PLASTICS Cryogenic Grinding
Mechanical Testing POLYMERS Sifting / Classifying
Organic Synthesis RUBBER Blending / Mixing
Lab Compounding, Pelletizing and ASTM Destructive Grinding
Injection Molding
Failure Analysis 10626 KINGHURST
Quality Assurance HOUSTON, TX 77099
Chemical Resistance P.O. Box 363, Bloomsbury, NJ 08804
Accelerated Weathering 281-879-8600 908-479-4400
FDA Extractions FAX 281-879-8666
www.allgrind.com e-mail: info@allgrind.com
R&D
PLANT INVENTORY MANAGEMENT
LABORATORIES, INC. Need volume accuracy?

www.polyhedronlab.com
START SEEING RED.

The only 3D
RIBBON sensor that

measures &
BLENDERS maps the

material
PRICED 30% LESS surface for

1% to 3%
accuracy of
Scan to see units
in stock for fast delivery. total stored
volume in
Try our mobile app:
resin silos.
mixers.com/web-app
1-800-243-ROSS
www.ribbonblenders.com 800-278-4241 info@binmaster.com
2017 BinMaster, Lincoln, NE 68507 USA
Let Plastics Processors Know

WHO You Are and
WHERE You Are

ADVERTISERS INDE X
Absolute Haitian . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Engel Machinery Inc. . . . . . . . . . . . . . . . . . . . . . . . . . 19 Processing Technologies International LLC . . . 55

www.absolutehaitian.com www.engelglobal.com www.ptiextruders.com
Advantage Engineering Inc. . . . . . . . . . . . . . . . . . . . 13 Ensign Equipment Inc. . . . . . . . . . . . . . . . . . . . . . . . . . 10 PSI-Polymer Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . 56

www.advantageengineering.com www.ensigneq.com www.psi-polymersystems.com
AEC Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Expo Plasticos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Rapid Granulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

www.aecinternet.com www.expoplastiocos.com.mx www.rapidgranulator.com
Arburg GmbH & Co KG . . . . . . . . . . . . . . . . . . . . . . . . . 21 Herbold USA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Rapistak Corp.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

www.arburg.us www.herboldusa.com www.ptm.rapistak.com
Avian USA Machinery LLC . . . . . . . . . . . . . . . . . . . . . . 44 Hosokawa Alpine American . . . . . . . . . . . . . . . . . . . 62 Republic Machine Inc. . . . . . . . . . . . . . . . . . . . . . . . . 59
www.aviangranulator.us www.halpine.com www.republicmachine.com
Beaumont Technologies Inc. . . . . . . . . . . . . . . . . . . 22 IMS Industrial Molding Supplies . . . . . . . . . 24 a,b Ross, Charles & Son Co.. . . . . . . . . . . . . . . . . . . . . . . . . 9
www.beaumontinc.com www.imscompany.com www.mixers.com
Boy Machines Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Lorenz Conveying Products. . . . . . . . . . . . . . . . . . . . 61 Thermal Care, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

www.boymachines.com www.lorenzproducts.com www.thermalcare.com
Bunting Magnetics Co. . . . . . . . . . . . . . . . . . . . . . . . . .50 Maguire Products Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Tinius Olsen Testing Machine Co. Inc.. . . . . . . .58
www.buntingmagnetics.com www.maguire.com www.tiniusolsen.com
Canon Virginia Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Negri Bossi USA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Universal Robots USA Inc. . . . . . . . . . . . . . . . . . . . . .60
www.cvi.canon.com www.negribossi.com www.universal-robots.com
Chem-Pak . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Nordson Corp. Polymer Processing Systems Vecoplan LLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36, 37

www.chem-pak.com www.nordsonpolymerprocessing.com 59 www.vecoplanllc.com
Chem-Trend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58 Novatec Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27, 29, 31 Windmoeller & Hoelscher Corp. . . . . . . . . . . . . . . 24
www.chemtrend.com www.novatec.com www.whcorp.com
Conair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Back Cover PCS Co. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58 Wittmann Battenfeld Inc. . . . . . . . . . . . . . . . .16 a,b
www.conairgroup.com www.pcs-company.com www.wittmann-group.com
Coperion K-Tron . . . . . . . . . . . . . .Inside Front Cover PFA Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Zeiss Industrial Metrology LLC . . . . . . . . . . . . . . . . 23
www.coperion.com www.pfa-inc.com www.zeiss.com/metrotom
DAK Americas Inc. ...............................2 Plastic Process Equipment Inc. . . . . . . . . Inside

www.dakamericas.com www.ppe.com Back Cover For additional product information, refer to
this companys Advertising/Data Sheets in
Dri-Air Industries Inc.. . . . . . . . . . . . . . . . . . . . . . . . . 11 Plastrac Inc.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 PLASTICS TECHNOLOGYs 2017 PROCESSING
www.dri-air.com www.plastrac.com HANDBOOK & BUYERS GUIDE
SALES OFFICES PLASTICS TECHNOLOGY (ISSN 0032-1257) is published

monthly and copyright 2017 by Gardner Business Media
MID-ATLANTIC/NORTHEAST JAPAN EUROPE (except Italy)
Inc. 6915 Valley Ave., Cincinnati, OH 45244-3029.
Lou Guarracino Toshiro Matsuda Edward Kania
District Manager Director of Overseas RGH International (UK) Telephone: (513) 527-8800. Printed in U.S.A. Periodicals
215/327-9248 Operations 44-1663-750242 postage paid at Cincinnati, OH and additional mailing
Fax: 513/527-8801 Plastics Age Co. Ltd. ekania@btopenworld.com offices. All rights reserved.
loug@ptonline.com (03) 256-1951 POSTMASTER: Send address changes to Plastics Technology
ITALY
KOREA Nicola Orlando Magazine, 6915 Valley Ave., Cincinnati, OH 45244-3029. If
MIDWEST/MOUNTAIN/
Chang-Hwa Park Com 3 Orlando sas undeliverable, send Form 3579.
SOUTHWEST/WEST
Far East Marketing Inc. 39 (02) 4158056 CANADA POST: Canada Returns to be sent to IMEX Global
Ryan Mahoney
(02) 364-4182 Fax: 39 (02) 48301981
District Manager Solutions, P.O. Box 25542, London, ON N6C 6B2.
Fax: (02) 364-4184 ppoint@com3orlando.it
513/766-5863 Fax: 513/527-8801 Publications Mail Agreement #40612608.
femchp@unitel.co.kr
303/903-0220 (mobile) INDIA The information presented in this edition of Plastics
rmahoney@gardnerweb.com TAIWAN Paresh Navani
Technology is believed to be accurate. In applying
May Hsiao Vogel Business Media India
OHIO/INDIANA/MICHIGAN/ J&M Media Corp. Pvt. Ltd. recommendations, however, you should exercise care and
SOUTHEAST/WESTERN PA/ 886-4-2296-5959 91 22 4123 4715 normal precautions to prevent personal injury and damage
UPSTATE NY, CANADA Fax: 886-4-2293-9730 paresh.navani@vogel.de to facilities or products. In no case can the authors or the
Jackie Dalzell may@jandm.com.tw publisher accept responsibility for personal injury or
District Manager www.jandm.com.tw damages which may occur in working with methods and/or
(513) 338-2185; Fax: 513/527-8801 materials presented herein, nor can the publisher assume
216/233-6794 (mobile) CHINA
Lucy Xiao responsibility for the validity of claims or performance of
jdalzell@gardnerweb.com
Beijing Vogel Consulting items appearing in editorial presentations or
CLASSIFIED/RECRUITMENT Co. Ltd. advertisements in this publication. Contact information is
ADVERTISING (86-10) 63326100 provided to enable interested parties to conduct further
Chris Brock Fax: (86-10) 63326099 inquiry into specific products or services.
440/639-2311 lucy@vogel.com.cn
Fax: 513-527-8801
cbrock@gardnerweb.com Printed in the U.S.A.

PROCESSORS EDGE
EVCO PL A STIC S DEFOREST, WIS.
Three-Pronged Growth
Strategy In U.S., China
& Mexico
Diversified molder pursues growth
on two continents in medical,
Brand-new 2500-ton Engel press at EVCOs plant in Monterrey,
packaging, and large parts. Mexico, part of its going big strategy in North America. It will
be accompanied by a second 2500-tonner now on order.
The three years since our last editorial visit to EVCO Plastics (reported 2. Packaging: Evans said EVCO plans to double the number of
in Jan. 14) have seen several capacity expansions and exploration of at machines (currently five Huskys with stack molds) at the
least two new, cutting-edge technologies. A recent Advanced Molding Plant (AMP) in DeForest.
By Matt Naitove
Executive Editor
sit-down with Dale Evans, president of the 53-year-
old, family-owned custom molder outlined how the 3. Large parts: While At the
company is pursuing growth on numerous fronts simultaneously. same time that EVCO is
Our new concept is
The company (evcoplastics.com) has 1000 employees and 170 expanding in China for med-
for every operator to
injection molding machines at nine plants in three locations ical parts, Evans noted that
have a cobot buddy.
in The U.S., Mexico, and China. It implemented $10 million in investing in large-part
capital improvements in 2016 alone, including purchase of seven molding is a defensive strategy
all-electric Toyo machines and a new Engel vertical press. Evans against Chinese competition due to prohibitive shipping costs
described three current focuses for the company: from overseas. Applications include parts for tractors, ATVs, jet
skis, golf carts, and outboard motors. EVCO has big presses in
1. Medical devices: EVCO is planning to remodel and expand its Oshkosh, Wis., and in Calhoun, Ga., which has become the com-
MED facility at the company headquarters in DeForest, Wis. Those panys large-part leader, recently expanded from 60,000 to
plans include tripling the size of the 30,000 ft2, Class 100,000 (ISO 110,000 ft2 and housing six large machines. Recent purchases
include two 3300-ton servohydraulic Ube machines and
two all-electric, 1000-ton Toyo presses, the first of that
size in the U.S., according to Evans.
As for implementing new technologies, EVCO has

acquired in the last three years two 3D printers, which
it uses to make CMM fixtures and robot grippers. It
also has two R&D projects underway in 3D printed
plastic molds.
EVCO also has installed two collaborative robots,
or cobots, from Universal Robots, E. Setauket, N.Y.
These are new class of robots equipped with onboard
Clean room at EVCO MED in DeForest, Wis., sensors that allow them to work safely alongside people
which is due for a threefold expansion. without guarding. They are suitable for pick-and-place
jobs like packing lefthand parts in one box and right-
Class 8) clean room. EVCO is also considering adding a clean room hand parts in another box.
at one of its three Mexican plants and recently added one (10,250 ft2, Robots never make a mistake, said Evans. And these robots
ISO Class 8, with nine presses) at its new, 70,000 ft2 Dongguan, cost $40,000 each, while it costs $150,000 a year to put a person
China, plant, which has become more narrowly focused on medical next to a machine 24/7. Our new concept is for every operator to
work since moving from the former location in Shenzhen, China. have a cobot buddy.

YOUR DEPENDABLE SOURCE FOR
MOLDING ACCESSORIES
The Worlds Largest Variety of Accessories for the Plastics Industry!
95% OF ALL STOCK ORDERS SHIPPED THE SAME DAY!
AEROSOLS & CHEMICALS
MOLD WATERLINE COMPONENTS
CONTROLS, HEATERS & T.C.s
SCREWS, TIPS, NOZZLES & MOLD SUPPLIES
MATERIAL HANDLING
MACHINERY
Quality Products, Fair Prices & Best Service since 1974

P LASTIC P ROCESS E QUIPMENT, INC. www.ppe.com sales@ppe.com
PPE 6385 Montessouri Street, Las Vegas, Nevada 89113 PPE 11218 Challenger Avenue, Odessa, Florida 33556
WEST 702-433-6385 800-258-8877 Fax: 702-433-6388 SOUTH 727-834-8888 800-282-6783 Fax: 727-834-8873
8303 CORPORATE PARK DRIVE, MACEDONIA (Cleveland), OHIO 44056, U.S.A. Toll Free: USA, Canada & Mexico
PPE 216-367-7000 Toll Free: 800-321-0562 Fax: 216-367-7022 Order Fax: 800-223-8305 800-362-0706
Doing
our
part...
to help you
make yours
stand out.
Look to Conair for auxiliary equipment that performs, people that solve problems and
support thats there when you need it. Weve served the automotive plastics industry for
more than 60 years, doing our part to help you make products that perform better, last
longer and yes stand out from your competition.
Visit conairgroup.com/transport
1.800.654.6661 724.584.5500 info@conairgroup.com www.conairgroup.com

Mar 2017

Caricato da

Informazioni sul documento

Titolo originale

Copyright

Formati disponibili

Condividi questo documento

Condividi o incorpora il documento

Opzioni di condivisione

Hai trovato utile questo documento?

Questo contenuto è inappropriato?

Copyright:

Formati disponibili

Mar 2017

Caricato da

Copyright:

Formati disponibili

On Top of

2017 WORLD CLASS

38 Decking Manufacturer Moves

40 How to Measure Melt

46 15 Things to Know About Servo-

A property of Gardner Business Media MARCH 2017 No- 3 VOL 63

>>Integrated compounding and bulk materials handling systems.

On-Site 38 Decking Producer Becomes 4 FROM THE EDITOR

PTonline.com Plastics Technology 1

publisher Rick Kline, Jr.

When it comes to PET Resin, DAK Americas

GARDNER BUSINESS MEDIA ALSO PUBLISHES

Plastics Technology Handbook NPE Official Show Directory

2 Plastics Technology MARCH 2017 PTonline.com

Four Takeaways from Our

4 Plastics Technology MARCH 2017 PTonline.com

50,000+ Blenders Installed To

All-Electric, Tabletop Injection Machine

6 Plastics Technology MARCH 2017 PTonline.com

2016 Thermal Care, Inc.

Artificial Joints Make Strides with 3D Printing

Chinese Buick Sports Largest-Ever Victrex Expands in

8 Plastics Technology MARCH 2017 PTonline.com

With laboratory sizes starting at 1/2-pint,

Learn more at mixers.com.

Scan to learn more.

Concurrent Events at Chinaplas 2017

Braskem Americas UHMWPE

BULK MATERIAL HANDLING EQUIPMENT, SYSTEMS

BULK CONTAINER FILLING BAG BREAK STATIONS

10 Plastics Technology MARCH 2017 PTonline.com

LY M Neal Elli, President, Empire Precision

Connectivity & Collaboration in

12 Plastics Technology MARCH 2017 PTonline.com

525 East Stop 18 Road Greenwood, IN 46142 317.887.0729

14 Plastics Technology MARCH 2017 PTonline.com

MODULAR AUTOMATION PACKAGES

16 Plastics Technology MARCH 2017 PTonline.com

Arburg demonstrated an automated cell that molded and

temperature-resistant HNBR rubber. They are said to avoid

ALL-ELECTRIC PRECISION AT A CONSIDERABLY LOWER PRICE

Zhafir Zeres 44 to 730 U.S. tons

The all-electric Zeres injection molding machine delivers precision perfor-

18 Plastics Technology MARCH 2017 PTonline.com

The automobile industry is shaping up for the future with

20 Plastics Technology MARCH 2017 PTonline.com

Learn from the best

22 Plastics Technology MARCH 2017 PTonline.com

Find out more at www.zeiss.com/metrotom

Experience "Passion for Innovation"

WINDMOELLER & HOELSCHER CORPORATION

SIDE-ACTION VS. SIDE-ACTION

polymers, which increases the compounded specific gravity S! Mold OPEN

Fillers change the specific output of a compound, and calculations must

short.ptonline.com/extrudeKH 2016 PFA, Inc. All Rights Reserved.

@plastechmag Plastics Technology 25

Exhibit Hall Amerimold Tech Talks

What you CANT SEE

@plastechmag Plastics Technology 27

The basic type of locating ring

28 Plastics Technology MARCH 2017 PTonline.com

@plastechmag Plastics Technology 29

FIG 4Cross-Section of Cross-Section of