Automotive

PLASTICS
Lightweighting, resistance to heat, chemicals and
weathering drive materials innovations for interiors,
exteriors, underhood, powertrain, and chassis

48 Medical Tubing Innovator

Bets on Silicone Solutions

52 Tips on How to Mount an

Injection Mold

56 Troubleshooting Ultrasonic
Welding

A property of Gardner Business Media JUNE 2017 No- 06 VOL 63

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 VOLUME 63 NUMBER 06

Cover Story
Material Developments
Abound in Automotive
Lightweighting and resistance to
heat, chemicals, and weathering
drive developments in thermo-
plastics for interiors, exteriors,
underhood, powertrain and
chassis.
By Lilli Manolis Sherman,
Senior Editor

44

On-Site 48 Medical-Tubing Innovator 6 FROM THE EDITOR

Bets on Silicone Solutions
Trelleborg gains footprint in 8 STARTING UP
silicone-based implantable
medical extrusions. CLOSE-UP
By Jim Callari, 14 Polyolefins
Editorial Director
20 Automotive
26 Foam Molding

KNOW HOW
30 Materials
Tips and Techniques 52 How to Mount an
Injection Mold 34 Injection Molding

Five industry pros with more than 40 Extrusion

200 years of combined molding
experience provide step-by-step best KEEPING UP WITH TECHNOLOGY
practices on mounting a mold in an 62 Injection Molding
injection press.
62 Compounding
By Piotr Witaszek, John Klees, Jim Fattori,
Ernie Di Siro, and John Bozzelli 64 Extrusion
67 Tooling
67 Heating/Cooling
68 Drying
Troubleshooting 56 How to Solve Common
69 Materials
Ultrasonic Welding Problems
Understand and address the likely YOUR BUSINESS
origins of welding problems to keep
71 Resin Pricing Analysis
production on track.
By David Dahlstrand, 73 Plastics Business Index
Branson Ultrasonics 74 Market Watch
75 Marketplace
80 Processors Edge

PTonline.com Plastics Technology 1

 Web Exclusives

Theres more on the web at PTonline.com Molding Goes Metal

Beach Plastic
Plastics Technologys Heather
Caliendo hit the beach in San Diego
to follow the story of P&Gs newest
sustainable bottle to its source:
plastic waste collected from the
beach. Read about the collabora-
tion among community groups,
TerraCycle, and P&G, and see video of a clean-up in action.
short.ptonline.com/beach
Plastics Technologys Molding 2017
conference focused, naturally, on
plastics, but over lunch on the first
day, Liquidmetal Technologies Paul
Hauck walked attendees through
metal injection molding and his

BLOG: Have Camera Will Travel

Plastics Technology Executive Editor Matt Naitove
brought his camera to Farrel Pominis new head-
quarters in Ansonia, Conn. Read his report and companys proprietary process.
see the 19 pictures he took of the new facility Watch the video of Hauck describ-
and mixing components (see p. 10). ing where metal molding is headed
short.ptonline.com/FP and why plastics molders could be
part of its future.
Stay up with our video reports by subscribing to our
short.ptonline.com/MIM
YouTube Channel: short.ptonline.com/yfZBD0uY

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 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
ALL THE RIGHT RESINS. senior editors Lilli Manolis Sherman
FOR ALL THE RIGHT REASONS. lsherman@ptonline.com
Tony Deligio
A capacity for leadership in what matters most to you.
tdeligio@ptonline.com
When it comes to PET Resin, DAK Americas has just what Heather Caliendo
you are looking for...Innovative PET Resins from pioneering hcaliendo@gardnerweb.com
research and development, state-of-the-art technologies and
advertising sales Lou Guarracino
market know-how. All from one of the largest producers
loug@ptonline.com
of PET Resins world-wide. DAK Americas broad line of
Laser + PET Resins give you exceptional flexibility in meeting Jackie Dalzell
your design and production goals. From trade leading products jdalzell@ptonline.com
and technical service to recycling, to sustainable raw materials, Ryan Mahoney
we continue to demonstrate not just our record of innovation, rmahoney@gardnerweb.com
but our steadfast commitment to you and to the industry today, art director Sheri Kuchta Briggs
tomorrow, and well into the future... DAK Americas. sbriggs@gardnerweb.com
dakamericas.com | 1.888.738.2002 marketing manager Kim Hoodin
khoodin@gardnerweb.com
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 From The Editor
Connecting with the
Profoundly Disconnected
Foundation formed to help close the skills gap.
Ive been reporting about plastics for nearly 30 years, but my first
job in business journalism was for a magazine that was directed
at the freight-transportation industry. It
was in the early 1980s, I was fresh out of
college, and it was actually an exciting
time to be reporting about shipping
especially on the trucking and rail-
freight industries, which had just been
deregulated by Congress.
During my seven-year period at this
job, I remember being told over and
Jim Callari over by my more-seasoned colleagues
Editorial Director at this publicationand by freight
industry experts I would speak with on
a regular occasionthat the U.S. economy was in the process
of a paradigm shift, moving away from being based largely on
manufacturing and toward more service-
based industries. Honestly I didnt know
what this meant at first, but the people The skills gap is here,
telling me this were sure it would be a and if we dont close
good thing for the freight-distribution it, itll swallow us all.
industry. This was a real head-scratcher
for me: I mean, our readers were respon-
sible for the shipment of their goods to customers, and if there
were no goods being manufactured for them to ship ?
Anyway, that paradigm shift I was hearing about sure did
unfold. Manufacturing became a smaller piece of the economy,
outsourcing and offshoring became part of the business want. The young people you would like to recruit, meantime,
parlance, and the service industry sector (financial, legal, insur-
ance, etc., etc.) started to grow. Colleges began to adjust their
curricula accordinglyin fact, a college education became
mandatory to even be considered for a joband this had a trick-
ledown effect on high-school programs (remember shop class?)
and trade schools, which started vanishing.
So here we are in the middle of 2017. We are in full what-
goes-around-comes-around mode. Another paradigm shift.
Jobs in service-based business are drying up. The manufac-
turing segment is growing and there are jobs to be had. Just
not nearly enough people qualified (or willing?) to fill them.
6 Plastics Technology JUNE 2017
Instead, we are graduating students with mountains of debt
and degrees in fields for which job potential is currently poor.
I cant tell precisely how many 65+ year-olds Ive spoken to
in this industry who are prepared to retire but have opted not
to because the pipeline behind them is empty. But there have
been lots. In a recent survey, more than 90% of members of
the Manufacturers Association for Plastics Processors identi-
fied workforce development as the number-one challenge they
currently confront.
To its credit, the plastics industryprocessors, moldmakers,
key trade associations, and suppliers alikehas done a good
job of stepping in by developing apprenticeship and training
programs of its own. And now TV personality Mike Rowe has
thrown his hat into the ring. Rowe, known mainly for hosting
(and participating in) The Discovery Channels Dirty Jobs
series, has started profoundlydisconnected.com to help address
the situation. Quoting Rowe on the site,
The mikeroweWORKS Foundation started
the Profoundly Disconnected campaign
to challenge the absurd belief that a four-
year degree is the only path to success. The
skills gap is here, and if we dont close it,
itll swallow us all.
So who is profoundly disconnected? Most likely not you, if
youre reading this, as youre already part of the industry. But you,
according to Rowes website, are part of a growing manufacturing
economy with three million good jobs that no one seems to
are facing a trillion dollars in student loans ... and record high
unemployment.
Rowes foundation is a 501(c)(3) public charity that rewards
people with a passion to get trained for skilled jobs that
actually exist. And its looking for help from companies like
yours to help fund them.
I thought youd like to know.
FOLLOW US
@plastechmag
@jimcallari
PTonline.com
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 T ECHNOLOG Y A ND INDUS T RY NE W S
Star ting Up

More Examples of Advanced Chilling Technology

Last month, we reported in a Close Up article on a new line of small portable chill-
ers due to hit the market in July from Delta T Systems, Richfield, Wis., that is said to
embody a unique collection of technologies and features that provide significant
energy savings and process stability. Supporting the claim that these technologies
establish a new benchmark for chiller efficiency is that fact that one other supplier is
using two of these advances to achieve similar benefitsand, at press time, another
chimed in with similar energy-saving technology.
NPE2015 in Orlanda, Fla., saw the introduction of
the NQV portable chillers10 and 20 tons, air or water
cooledfrom Thermal Care, Niles, Ill. (see June 15
Keeping Up). It incorporates what both Thermal Care
(thermalcare.com) and Delta T Systems (deltatsys.com)
agree is the most significant recent advance in process
chilling, the variable-speed condenser, which allows the
chiller to operate over a wide range of loads without use
of an energy-wasting hot-gas bypass valve. Variable-
speed condensers have a 20-yr history in HVAC applica-
tions, but had not been used in process chillers.
Thermal Cares NQV chillers also utilize the elec-
tronic expansion valverarely used before now on
small portable chillerswhich Delta T Systems credits
with adding to the energy savings obtained with the
variable-speed condenser.
Audrey Guidarelli, marketing services manager for
Thermal Care, says the NQV chillers have been highly
successful products since their release in 2015 and that
its sales continue to grow as more of our customers
understand the cost-saving benefits of using variable-speed compressor technology.
Just before we went to press last month, Conair, Cranberry Township, Pa.
(conairgroup.com), a sister company of Thermal Care within the IPEG group,
announced availability of 10- and 20-ton EP2 Series portable chillers (air or water
cooled) with variable-speed condensers and premium touchscreen controls. They are
said to deliver energy savings of 20-50% compared with conventional fixed-speed
compressors and the latest digital scroll compressors. Both Conair variable-speed
models are said to handle loads as low as 3 tons efficiently. The 20-ton unit incor-
porates a 10-ton fixed-speed and a 10-ton variable-speed compressor. With that
unit, Conair notes, energy savings are not as significant in the middle range, where
either compressorfixed or variablewould be running at full capacity of 10 tons. But
energy savings in the 3-8 and 13-16 ton ranges are still impressive, Conair claims.
New Group & Big Firms Seek to Energize Reshoring
In April, Walmart issued an open call supplying the U.S. market via manufac-
for U.S. products, inviting companies turing offshore or domestically.
to come to Bentonville, Ark., on June 28. ROMJ is cooperating with the Reshor-
Walmart said the event supports its bid ing Initiative (reshorenow.org). That group
to purchase an additional $250 billion in offers a Total Cost of Ownership (TCO)
U.S. products through 2023. Estimator to help companies quantify
A week later, Return One Million Jobs the hidden costs of offshoring. Says
(ROMJ) LLC (returnonemillionjobs.com) Carstensen, If they do the math, using
was created to raise $20 million to bring the TCO tools and advanced data analyt-
one million manufacturing jobs back ics, many manufacturers should want to
to the U.S. from offshore. Headed by return jobs to the USA to increase profits.
Carl Carstensen, who recently retired Last month, Apple CEO Tim Cook told
after 37 years with IBM global consult- CNBC that Apple will start a $1 billion
ing services, the project will reportedly fund to promote advanced manufactur-
apply global data analytics to help ing jobs in the U.S. The ultimate goal:
companies compare the total cost of making Apple products domestically.
NDC Moving to Ohio
NDC Technologies, which makes preci-
sion measurement and process-control
solutions for film, sheet, pipe, profile, and
tubing extrusion, has announced that it
will be consolidating its Irwindale, Calif.,
production and administration functions
into its facility in Dayton, Ohio, which will
become the company headquarters. The
Irwindale facility will be upgraded and
become its Web Process Solutions Techni-
cal Center of Excellence.
Dayton has been the long-time
home of Beta LaserMike, which supplies
measurement technology for pipe and
profile extrusion. In 2014, Beta LaserMike
merged with NDC Infrared Engineering to
form NDC Technologies.
937-233-9935 betalasermike.com
Rapid Granulator Moves to new HQ
Rapid Granulators U.S. operations have
moved from Cranberry Township, Pa.,
to Leetsdale, Pa., remaining within the
Pittsburgh area. The new 65,000 ft2 facil-
ity includes offices, warehousing, and a
3500 ft showroom sufficient to display
the companys full range of granulators,
shredders, and post-consumer recycling
equipment. It also brings in-house all
U.S. production that had previously been
outsourced. Rapid was acquired in 2015
by Lifco AB of Sweden from IPEG Inc. of
Cranberry Township.
724-584-5220 rapidgranulator.com
Baerlocher Boosting Metal Soap
Capacity by 50%
Baerlocher USA, Cincinnati, will add a
third reactor for production of calcium,
zinc, sodium, and other metal soaps at
its Cincinnati facility, which will boost
capacity by 50% when fully operational
this month. The company is responding to
steadily accelerating demand from North
American polyolefin and PVC industries.
The investment will also support
development of Baeropol RST polyolefin
stabilization technology (see January
K 2016 Materials/Additives report) and
solid calcium-based PVC stabilizers. Use
of metal soaps is spurred by interest
in reducing VOCs and heavy-metal and
organotin stabilizers targeted by Euro-
pean REACH regulations.
(800) 342-6158 baerlocher.com

8 Plastics Technology JUNE 2017 PTonline.com

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 T ECHNOLOG Y A ND INDUS T RY NE W S
Star ting Up

Farrel Pomini Shows Off New HQ

For Continuous Compounding Business
Continous compounding equipment supplier Farrel Pomini now
occupies a handsome new headquarters and assembly plant
in Ansonia, Conn. Although the official ribbon cutting was last
month, the firms 86 employees actually moved into the 60,000-
ft facility last September.
More than 50 visitors were given a tour of the new headquar-
ters for Continuous Mixers and Compact Processors. It incorpo-
rates offices, machine assembly, spare-parts stocking, rotor repair
and refurbishment, and a processing laboratory and customer
demonstration area with a CP550 Compact Processor equipped
with automated upstream materials handling and downstream
pelletizing, plus the new CPeX lab-sized Compact Processor that
was introduced at K 2016. Theres also an R&D department with a
3D printer for prototyping scaled-down rotors and other machine
components, and an automation laboratory for designing and
testing control systems for compounding process lines.
The company supplies continuous compounding systems
primarily for flexible PVC, polyolefins, and TPEs. According to Paul
Lloyd, business unit director, a promising new area of opportunity
is biopolymers such as PLA, which require gentle handling due
to their heat and shear sensitivity. The Compact Processor is well
suited to PLA, says Lloyd, because its short 6:1 L/D minimizes heat
history and its design separates mixing and pressurizing functions,
so mixing can be optimized while still providing a shorter residence
time than a twin-screw extruder. (More at short.ptonline.com/FP.)
203-736-5500 farrel-pomini.com

Plastic-Eating Caterpillar Could Halt PE Bag Waste

Scientists claim that a caterpillar
commercially bred for fishing bait has
the ability to biodegrade polyethyl-
ene. Called wax worms, the larvae of
the common insect Galleria mellonella,
or greater wax moth, live as parasites
in honeybee colonies. Wax moths lay
their eggs inside beehives, where the
worms hatch and grow on beeswax
whence they get their name.
A chance discovery occurred when
one of the scientific team, Federica
Bertocchini, an amateur beekeeper,
was removing the parasitic pests from
the honeycombs in her hives. The
worms were temporarily kept in a typi-
cal plastic shopping bag that became
riddled with holes. Bertocchini, from
the Spanish National Research Council
(CSIC), collaborated with colleagues
Paolo Bombelli and Christopher Howe
at the University of Cambridges Dept.
of Biochemistry in the U.K. to conduct
a timed experiment.
Around 100 wax worms were
exposed to a plastic bag from a
supermarket. Holes started to appear
Toshiba Machine Splits
after just 40 min, and after 12 hr there
from Parent Company
was a reduction in plastic mass of 92
If any owners or potential buyers of
mg from the bag. Scientists say that
Toshiba injection molding machines
the degradation rate is extremely fast
have been concerned by recent grim
compared with other recent discover-
headlines from Japan, they apparently
ies, such as bacteria reported last year
need not worry. On March 3, Toshiba
to biodegrade some plastics at a rate
Machine Co., Ltd. of Japan (U.S. office in
of just 0.13 mg a day.
Elk Grove Village, Ill.) bought back 18.1%
If a single enzyme is responsible for
of the 20.1% of total shares of its stock
this chemical process, its reproduction
owned by Toshiba Corp., the previous
on a large scale should be achievable,
parent company and top shareholder.
stated Bombelli, co-author of the study
As a result, they are no longer our top
published last month in the journal
shareholder and we no longer belong
Current Biology. This discovery could be
to the Toshiba Group, said Toshiba
an important tool for helping to get rid
Machine chairman and CEO Yukio Imura.
of the polyethylene plastic waste accu-
This announcement was made in
mulated in landfill sites and oceans.
response to speculation about Toshiba
The beeswax on which wax worms
Machines financial soundness following
feed is composed of a diverse mixture
reports that Toshiba Corp. had taken
of fats, oils and some hormones. The
a loss of $6 billion in consequence of
researchers say it is likely that digest-
the bankruptcy of its Westinghouse
ing beeswax and polyethylene involve
Electric subsidiary in the U.S. West-
breaking similar types of chemical
inghouse foundered because of the
bonds. Wax is a polymer, a sort of
drastic slowdown in U.S. construction
natural plastic, and has a chemical
of nuclear power plants. This has left
structure not dissimilar to polyethyl-
the Toshiba parent company on shaky
ene, said Bertocchini.
financial ground, according to reports in
Spectroscopic analysis showed that
the business press.
the worms transform the polyethyl-
According to Imura, the separa-
ene into ethylene glycol. We showed
tion from the parent company has
that the polymer chains in polyeth-
been seamless, with no impact on its
ylene are actually broken by the wax
operations, customers, shareholders,
worms, said Bombelli. The caterpillar
employees, or business partners. Also
produces something that breaks the
substantiated is the value of Toshiba
chemical bond, perhaps in its salivary
Machines stock, which is currently
glands or a symbiotic bacteria in its
about even with 2014, one of the
gut. The next steps for us will be to try
companys best years.
and identify the molecular processes in
888-593-1616 toshiba-machine.com
this reaction and see if we can isolate
the enzyme responsible.

10 Plastics Technology JUNE 2017 PTonline.com

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 T ECHNOLOG Y A ND INDUS T RY NE W S
Star ting Up

Teknor Apex Debuts New Engineering Resins Div. with Novel Nylon Family
Following its acquisition of German custom compounder Plastic- The first three new Creamid A3H7 grades contain 40%, 50%,
Technologie-Service (PTS) in March, Teknor Apex Co., Pawtucket, and 60% glass fiber. These compounds are used in Europe for
R.I., has recast its former Nylon Div. as the new Engineering automotive air vents, spoilers, fan blades, spring adapters, and
Thermoplastics (ETP) Div. That unit will globalize a wide range of key fobs. Future introductions will include PTS-developed Dura-
engineering thermoplastics technologies developed in Europe but mid aromatic nylons, said to offer similary distinct improvements
not widely available before now in the Americas or Asia.
Founded in 1986, PTS has a portfolio of more than 700 Notched Izod Impact: Glass-Filled Creamid vs. PA66 & PA6
commercial ETP products based on nine major techno- 15
logical platforms and resins such as nylons of various
13
types, PBT, PC, PC/ABS, other blends, TPEs, and TPVs.
The first new ETP products will be Creamid ultra-high- 11
performance, glass-reinforced, aromatic nylons, which will PA66
9 33% PA66 PA6 Creamid Creamid Creamid
be produced in the U.S. as well as in Europe. These are said 43% 30% 40% 50% 60%
to be unique materials based on different polymer chemis- 7
Notched Izod Impact, KJ/m2
try than widely used nylons like Teknors Chemlon products.
Creamid reportedly delivers processing and physical Tensile Strength: Glass-Filled Creamid vs. PA66 & PA6
properties dramatically better than typical nylon 66 270
compounds. Creamid boasts excellent dimensional stabil-
230
ity, low water absorption, improved chemical resistance,
PA66
and better surface aesthetics. For example, a 40%-glass 190 33% PA6
PA66 Creamid Creamid Creamid
Creamid compound shows 68% longer spiral flow than a 43% 30% 40% 50% 60%
standard 43%-glass nylon and requires 41% lower peak 150
Tensile Strength, MPa
injection pressure and 43% less clamp force. The accom-
panying graphs show much higher notched Izod impact
strength and tensile strength than typical glass-filled nylon 6 and 66. over Creamid, as well as various blends, specialized formulations
These show tensile strengths up to 260 MPa (37,700 psi), comparable with crosslinking properties, and materials for electroplating, TPE
to die-cast metals. Grades can be formulated with flexural modulus overmolding, and PEEK replacement.
up to 21 GPa (3.05 million psi) for metal replacement. 800-237-3167 teknorapex.com

12 Plastics Technology JUNE 2017 PTonline.com

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 P O LYO L EF IN S
Close-Up On Technolog y
Conference Uncovers Innovations
Across a Range of Processes, Markets
New materials and additives for injection and blow
molding, extrusion, compounding, and thermoforming
highlighted the SPE Polyolefins Conference.
Several promising material and process developments were pre-
sented at SPEs International Polyolefins 2017 conference, held in
Houston this past March. Among the
By Lilli Manolis Sherman, highlights were new materials and
Senior Editor
additives for applications ranging from
food and non-food flexible and rigid
packaging, to pipe, consumer goods, and automotive.
GAME-CHANGING POLYOLEFINS
Houston-based LyondellBasell Industries (LBI; lyondellbasell.com)
touted its Spherizone processa two-in-one circulating reactor
that can produce novel PP grades said to be suited for inter-mate-
rial applications. Included are PP pipe grades that offer up to 30%
weight reduction, homopolymer grades with improved pro-
cessing, transparent random copolymers, and random/impact
copolymer combinations with good transparency.
In heavy-duty sacks, Dows
Innate precision packaging resins
show outstanding toughness.
Among the latest additions is Purell RP320M, a PP random
copolymer that can be used in caps and closures, labware, and
flexible and rigid packaging of medical devices and pharmaceuti-
cals. RP320M reportedly offers good clarity and excellent homoge-
neity to meet high quality requirements in cast film and injection
14 Plastics Technology JUNE 2017
molding. The material exhibits low gel content, which contributes
to end-use applications that require superior gloss, transparency,
surface smoothness, and planarity, as well as good tear resistance.
Also claimed are excellent sealing properties in cast film and good
processability for
injection molding.
Advanced specialty poly-
SABIC SK
olefins are emergingboth
Nexlene Company
POEs with bimodality that
(U.S. office in
offers better impact, and
Houston; sabic.
POPs with molecular design
com), the new
that renders it more elastic.
50/50 joint venture
between SABIC and
South Koreas SK Global (skglobalchemical.com), is moving ahead with
development of high-performance PE products made with post-metal-
locene single-site catalysts and octene-1 comonomer in the Nexlene
bimodal solution process. Included are mLLDPE
and mMDPE grades with 0.5-3.0 MI and densities of
0.857-0.945 g/cc for applications ranging from food
and non-food film packaging to pipe, rotomolding
of chemical tanks, and heavy-duty film.
New Nexlene film grades reportedly deliver
enhanced toughness, low heat-seal temperature,
downgauging potential, low extractables, and
excellent bubble stability. Meanwhile, Nexlene
MDPE grades boast a good impact/stiffness balance,
as well as excellent ESCR and processability.
Also newly emerging are advanced specialty
polyolefinsboth polyolefin elastomers (POEs)
with bimodality that offers better impact, and
polyolefin plastomers (POPs) with molecular
design that renders it more elastic. Theres also a
new bimodal POE with improved heat resistance
that is reportedly based on a new olefin beyond
octene in performance and also costs less.
Characteristics of Nexlene POEs reportedly include excel-
lent impact strength, flexural modulus, and low-temperature
ductility, and better physical properties than butene-based POEs.
Applications include blending at 10-25% levels with mineral-filled
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 P O LYO L EF IN S
Close-Up On Technolog y

PP in automotive bumper/grilles, side-sill panels, instru-

ment panels, and door trim. Other target applications
include wire & cable, due to easy processing, high elec-
trical resistivity and heat resistance; and encapsulants for
solar cells due to moisture and weather resistance and no
lamination defects.
Nexlene POPs, meanwhile, are characterized by
enhanced toughness, excellent hot-tack and seal-initiation
temperature, and superior transparency. Target applica-
tions included packaging film (stretch hood, shrink, and
silage); specialty film (thermal laminates and foam);
industrial film (waterproof sheet, protective film); and
specialty food-packaging films (barrier film, stand-up
pouches, snacks, and processed-meat packaging). LyondellBasells new PP random copolymer for caps,
closures, and medical/pharmaceutical packaging boasts
excellent homogeneity to meet high quality requirements
ADVANCES IN FILM, LARGE-PART FORMING
in cast film extrusion and injection molding.
Dow Chemical, Midland, Mich. (dow.com), discussed the
latest on its Innate precision packaging resins launched in
2015. Made with a novel post-metallocene catalyst and a new pro- melt-strength (HMS) TPO for this purpose. Senior research scientist
cess, these resins can incorporate various copolymers, according to Kurt Koppi noted that TPOs have had limited acceptance in thermo-
Christina Serrat, application technology leader for packaging and forming primarily due to processing issues: excessive sag, webbing,
specialty plastics. She said 1-mil film of Innate ST60 (0.85 MI, 0.918 and inconsistent forming from lot-to-lot or within a lot.
density) exhibits significantly higher dart impact at similar mod- Key thermoformability findings, according to the Dow
ulus and better optics than a competitive mLLDPE. researchers, included the following:
In heavy-duty sacks, Innate shows outstanding toughness. In
bag-in-box liquid packaging, Innate resins boast excellent stiffness/ For large-part thermoforming, slow sheet sag rate is desirable.
toughness balance compared with mLLDPE. Moreover, Dow reports While with pre-compounded TPO, sag rate increases with sheet
that downgauging with Innate shows a significant reduction in flex extrusion rate; the opposite occurs with on-line compounded
cracking. Overall, these resins are said to deliver film toughness TPO.
without compromising stiffness or other properties. TPO made with POE/talc concentrate sags faster, while TPO made
Houston-based Kraton with PP/talc concentrate sags slower.
Polymers (kraton.com) TPO sheet prepared via on-line compounding with a PP/talc con-
Unlike conventional
unveiled a developmental centrate exhibits a sag rate very similar to that of pre-com-
styrene block copo-
class of styrenic block pounded TPO when sheet was extruded at a fast rate.
lymers, Kratons new
copolymers. This new semi- Such on-line compounded TPO sheets exhibit less thinning in
class of polymers is
crystalline block copolymer the corners than those made of POE/talc concentrate.
resistant to oil and
(SCBC) offers PE-like crystal- Dow says on-line compounded TPO sheet matches the perfor-
organic solvents.
linity but is also said to be mance of pre-compounded TPO sheet when a talc concentrate
elastic, stiff, and strong. It is used in the formulation vs. a POE. A simple single-flighted
is compatible with PE and can be used in conjunction with PE screw works as well as a high-performance screw for on-line
and oil to make elastic and soft compounds. Moreover, unlike compounding. And on-line compounding of TPO sheet offers the
conventional SBCs, the new polymers are resistant to oil and potential to reduce manufacturing cost by eliminating a separate
organic solvents. Other potential applications are elastic film for compounding step.
packaging, automotive soft-touch skins, and non-woven fabrics.
Dow also discussed on-line compounding of TPO blends for NOVEL ADDITIVES
large-part thermoforming and development in recent years of high- Solvay (through its Cytec acquisitionnow Cyasorb Cynergy
Solutions; cytec.com) unveiled two new proprietary stabilizers at
QUESTIONS ABOUT POLYOLEFINS? the conference. Cyasorb Cynergy M535 UV stabilizer is designed for
general PE injection molding applications, where it offers twice the
Visit the Polyolefins Zone and the Additives Zone. performance of existing stabilizers at reduced concentrations.

16 Plastics Technology JUNE 2017 PTonline.com

 LETS RE|DEFINE PLASTICS MANUFACTURING.
2017 Plastics Industry Association (PLASTICS)

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 P O LYO L EF IN S
Close-Up On Technolog y

Cyasorb Cynergy B878T is a requirements as compared with

combination UV/heat stabilizer for conventional HMS-PP.
PP/TPO building and construction Taiwans Chitec Technology
applications such as roofing and (U.S. office in Houston;
solar shingles. chitec.com) launched a novel
Total Cray Valley (TCV, U.S. plant-based dialkyl hydrox-
office in Exton, Pa.; ylamine antioxidant (DAHA).
crayvalley.com) discussed its While DAHA antioxidants have
new technology for improving shown a negative impact on
PP melt strength. According long-term stabilization, this
to TCVs global business- Cyasorb Cynergy M535 UV stabilizer is designed for palm-based DAHA antioxidant
development manager Anthony general PE injection molding applications, where it combined with a HALS stabilizer
offers twice the performance of existing stabilizers.
Marozsan, new Dymalink 9200 has been shown to outperform a
zinc diacrylate salt coagents traditional phenolic antioxidant.
(also available as 9201 masterbatch) are comprised primarily of Baerlocher (U.S. office in Cincinnati; baerlocher.com) discussed
ionomeric zinc salts, which reportedly represent a new class of its new Baeropol RST stabilizer for use with recycled materials (also
polyolefin additives with a novel set of performance attributes. reported in our February K 2016 review of materials and additives).
They are now globally available. Its claim to fame is that it can reduce the use of phosphite antioxi-
Addition of these zinc salts to conventional PP at low dants in polyolefins and assist in switching away from TNPP.
loadings (1%) has been shown to result in improved tensile The plastic additives business of BASF, Florham Park, N.J., (basf.com),
strength, HDT, and flexural modulus. Melt strength of PP is said presented its latest work aimed at optimizing stabilization systems for
to be enhanced with very few observed drawbacks. This is said to improved discoloration resistance while reducing costs in critical appli-
allow greater flexibility to tailor compounds to specific end-use cations like cast and blown PE films and injection molded PP.

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18 Plastics Technology JUNE 2017 PTonline.com

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 AU TO M OT I V E
Close-Up On Technolog y
Giant Electric Presses Are Key
To Productivity Gains at Subaru
Car builder reaps cycle-time improvements and
other benefits with large electric presses.
By years end, Subaru of Indiana Automotive Inc. (SIA) expects
somewhere around 400,000 cars to roll off its manufacturing and
assembly line in Lafayette, Ind. They will require 800,000 bum-
pers, front and rear. And the number comes to
By Jim Callari,
Editorial Director nearly 1 million when you count the bumpers
the automaker molds for aftermarket service.
While the automotive industry relies heavily on tiered
suppliers to furnish parts, components, and sub-assemblies,
Japanese-based OEMs tend to prefer making their own bumpers
the face of the car, notes Troy W. Castor, an SIA specialist in
manufacturing engineering and stamping. The Lafayette facility
spreads out to 3.4 million ft2the equivalent of 58 football fields
with some 33,000 ft2 dedicated to molding TPO bumpers.
In Indiana, Subaru has two 3850-ton all-electric presses from Ube. Inset (top
to bottom): Ichiro Motoki, president, Ube Machinery Inc.; David Bernardi, sr.
sales and marketing manager; Ube sales manager Daniel Cerimele; and Troy
Castor, SIA specialist in manufacturing engineering and stamping.
20 Plastics Technology JUNE 2017
The molding plant is equipped with four injection presses, all from
Ube Machinery Inc., Ann Arbor, Mich. (ubemachinery.com). Two of these
machines are older hydraulic models. Two recent additions, however,
are 3850-ton all-electrics, said to be the largest machines of their kind
running in the U.S. In fact, Ube has sold 14 all-electric machines of
this size to various automotive molding plants in the U.S., notes David
Bernardi, the machine builders sr. sales and marketing manager.
SIAs two all-electrics are part of Ubes UF series. With a
maximum shot capacity of 400 oz, the UF3850 units at SIA are built
with Ubes Box Sleeve platen design that is said to result in 60%
less deflection. Improved ballscrew seals reportedly reduce grease
volume by 90% compared with conventional designs. Grease distri-
bution control reduces both grease consumption and ballscrew
wear for longer life, according to Ube.
The machines newly developed Flex
Servo control is said to provide a more
accurate and consistent process. The
presses are also equipped with an easy-to-
use e-Humma control system and a fully
automated quick-mold-change package.
Conventional wisdom holds that
higher-tonnage all-electric presses have
issues maintaining long hold-pressure
cycles efficiently. But SIA, which started
running its first all-electric in 2015 and had
its second installed this past Christmas, has
experienced across-the-board increases in
efficiency since it installed the all-electrics.
Since it also still runs the two hydraulic
machines of similar size, it can make apples-
to-apples comparisons between the machine
configurations. Notably, the electric presses
run cycles of about 43 sec, compared with
roughly 61 sec for the hydraulics.
Castor adds, In terms of efficiencies,
were seeing less scrap generation with the
newer machines. They are cleaner, have
required less in the way of maintenance,
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 AU TO M OT I V E
Close-Up On Technolog y

While TPOs technically do not require drying,

Subaru recently added a Conair central drying
Subaru has documented an 18-sec improvement in system to ensure material is fed to presses at a
cycle times since switching to all-electric presses. consistent temperature with no surface moisture.

and offer more efficient mold changes. SIA has yet to figure out Still, SIA is not ready to mothball its hydraulic 3150 and 3300
how much it has cut its energy bill by switching to all-electrics, but tonners. We decide whether to run a bumper on a hydraulic or an
Castor is confident that the savings will be there. all-electric based on a combination of production requirements,
SIA molds bumpers 24:7. It currently has seven active molds, all machine performance capabilities, and mold-change times,
built in Japan, and makes on average four to five mold changes per Castor explains. Some molds run nearly an entire shift in the
machine per shift. The move to all-electrics required the automaker same machine without being changed because of current produc-
to work with its moldmakers to ensure that the molds are up to the tion demand. Also, due to auto-connector/auto-coupler styles,
task. Explains Bernardi, The moldmaker some older molds connect easier to
needs to be aware of the capabilities of the the older machines and likewise the
machine and make design enhancements Were seeing less scrap newer molds connect easier with
accordingly. Speed is a major issue: We generation with the newer the electric machines. We are in the
could be talking about moving the core in a machines. They are cleaner, process of standardizing these differ-
half-second. The tooling has to be up to the require less maintenance, ences so it wont matter as much.
capabilities of the machine. and offer more efficient Castor continues, We also tend
At press time, SIA was preparing to fire mold changes. to run the molds that have lower
up its second UF3850, which it will use production requirements (require
primarily to make bumpers for its 2018 more mold changes) in the electric
Legacy sedan. The Ube controllers are set up so that data from one machines because of the speed they offer during mold-change
press can be transferred seamlessly to another. and startup processes.
SIAs relatively recent adoption of all-electric technology in Though it runs non-hygroscopic TPO, the SIA molding operation
the U.S. came after it conducted internal comparisons of metrics also includes a new central drying system from Conair, Cranberry
such as cycle time, mold development times, maintenance costs, Township, Pa. (conairgroup.com). We dry the material to remove
operational cleanliness, and mold-change times. Ube did a lot of
QUESTIONS ABOUT AUTOMOTIVE?
presentations and we became convinced about the efficiencies of
servos and that servo-driven machines represented the future in
injection molding, notes Castor. Visit the Automotive Zone.

22 Plastics Technology JUNE 2017 PTonline.com

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 AU TO M OT I V E
Close-Up On Technolog y

The electric presses run

bumpers at cycles of
about 43 sec, compared
with roughly 61 sec on
the hydraulics.

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Subaru has seven active bumper that we are delivering material at a
molds, and makes on average four or consistent temperature to the presses
five mold changes per shift per day.
all year round, says Castor.

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 17th-Annual

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 F OA M M O L D IN G
Close-Up On Technolog y
New Process & Material
Permits Big Weight Savings
In Foamed Parts
New firm develops technology
that offers weight reductions
up to 65% for large injection
molded polyolefin parts.
A maker of duck decoys has applied for a patent on a plastic cel-
lular structure technology that allows dramatic density reductions
in large injection molded polyolefin parts, using
By Tony Deligio,
Senior Editor a standard press and without affecting the parts
surface or structural integrity. In addition to
cutting weight by 65%, the inventors say the foam structure, for
which they can control bubble size and arrangement, imparts
greater strength to the finished components.
For hunters of water fowl, apart from a gun, a dog, and warm
clothes, one must-have element to a successful trip are decoys.
Startup company Moxietecs NautXcell technology, available for license,
creates a plastic cellular structure on standard injection machines.
Typical decoys are hollow blow molded parts, designed to float, but
if struck by shotgun pelletsa distinct possibility given their role
in luring ducks within firing rangethey tend to sink.
26 Plastics Technology JUNE 2017
Moxietecs NautXcell technology can tailor
the cell structure of molded parts and is
suitable for large, thick components.
To overcome this, some decoy makers have turned to foamed
PS cores, which must be wrapped in burlap and other materials
in a labor- and time-intensive process that precludes them from
mass production and still presents durability issues. Thats why
Jason Minnich and Travis Biggs, owners of Lake Effect Decoy Co.
LLC (leddecoys.com) in Cochranton, Pa., saw a market opportu-
nity if they could mass produce a rugged decoy that wouldnt be
hamstrung by the volume and variability issues associated with
hand-made solid decoys.
The technology they came up with, for which they filed for
patents in February, has led to the creation
of a new company, Moxietec (moxietec.com),
which will license the process and materials
for the technology, tradenamed NautXcell,
to other companies and markets.
NautXcell requires a very unique
blend of materials and process to achieve
the solid core. Were looking to partner
with some bigger companies that can
utilize this technology, Biggs says. Thats
our main goal: grow the Moxietec business
with the technology of NautXcell and find
other companies that can utilize it.
FIVE-PLUS YEARS OF R&D
Biggs says Lake Effect began development of
a solid alternative five or six years ago,
initially focusing on the ducks head. Once
that was perfected, the company moved
onto the larger decoy body, spending nearly
two years tweaking the compound, process,
and mold for that larger component.
There were major hurdles to overcome, Biggs says. We wanted
to create a solid, lightweight part, utilizing a standard injection
molding machine. The biggest challenge was being able to create
PTonline.com
 F OA M M O L D IN G
Close-Up On Technolog y

the honeycomb-like solid core. Early testing produced parts that were severely deformed In terms of materials, the company
and exhibited a loss of surface detail, according to Biggs. has had success with high- and low-
The heads and bodies are molded on two separate machines. The heads have a density polyethylene, as well as poly-
volume of 49.6 in.3 and a weight of 9 oz, while the bodies have a volume of 291.15 propylene. The technology utilizes a
in.3 and a weight of 59.2 oz. If the head and body were molded as solid parts without pre-compounded pellet loaded with a
NautXcell, Biggs says the respective part weights would be 27.12 and 154 oz. The inven- blowing agent and what was described
tors see great potential utility in other thick parts, given that the decoys body measures as several other chemicals. The company
9.25 in. wide at its thickest point, with a length of 16 in. declined to say whether the blowing agent
was of the physical or chemical variety.
Biggs noted that there are some
pretty unique elements to the process
itself, in terms of temperatures, injection
phase, and cooling, but added that all
the work was done on a standard press,
Move up to a with no changes to its primary compo-

higher level of control nents. Elements of the tools venting and

heating/cooling had to be specially devel-
oped as well.

Were looking to partner with

some bigger companies that
can utilize this technology.

Today using NautXcell, Biggs says a

A higher level of control
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variety of wear, impact, and anti-ballistic
characteristics. In durability testing, the
company has shot at and run over its Gale
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offer the most durable production decoy
on the market.

Order BEDROS direct from Athena. Act now to SAVE 10%. QUESTIONS ABOUT FOAM MOLDING?
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28 Plastics Technology JUNE 2017 PTonline.com

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 Know How
MATERIALS
PART 1
Cycle Time: Science vs. Rules of Thumb
What temperature must the polymer reach so the part
can be ejected from the mold? Here, more than for any
other variable, rules of thumb unfortunately prevail.
Anyone who has spent any time quoting jobs in the plastics
industry knows that little, if any, science is brought into the pro-
cess. For most plastic parts, approximately
half of the cost is in the raw material and
the other half is related to the machine
time required to make the part. The mass
of the proposed part is relatively easy to
determine with current technology, based
on the volume and the solid-state density
of the specified material. The number of
By Mike Sepe cavities that will be tooled can be speci-
fied so that everyone involved in the
quoting process is working from the same general parameters.
The big variable then becomes the estimated cycle time. If the
process involves a new product, the quoting is done from a two-dimen-
sional drawing or a 3D model. But even in a situation where an actual
part is available, you can provide this part to five different people
in the industry and get five different estimates of the cycle time.
30 Plastics Technology JUNE 2017
If you inquire of the participants in this exercise as to how they
arrived at the cycle time, you will get a lot of answers that fall into
the category of rules of thumb. Factors such as wall thickness, flow
length, and specified tolerances will likely be mentioned. But the
quantitative relationship between these factors and the estimated
cycle time will be elusive. Utilities that are used to determine cycle
time can be found everywhere, and it can be a fascinating exercise
to examine the underlying assumptions that go into them.
A lot of thought has gone into understanding how to calculate
cycle time, and some models have been developed that use impres-
sive-looking equations. These expressions include some quantities
such as wall thickness, the thermal diffusivity of the material, and
the temperature of the melt and the mold. But there is always one
factor that is challenging to define and is a favorite candidate for
employing rules of thumb. This is the temperature the polymer
must reach so that the part can be ejected from the mold.
What exactly is this temperature? Some programs use the
deflection temperature under load (DTUL), also often referred to as
the heat-deflection temperature (HDT) of the material.
This is a curious choice because it assumes that
there is a scientific relationship between the ejection
temperature and the DTUL. But if we inquire about the
origin of such a relationship, the picture gets a little
murky. Ask most people in the industry about the
significance of the DTUL and you will get an answer
that bears very little resemblance to the true picture.
A reading of the ASTM or ISO method used to
measure the DTUL will show that it is the temperature
at which a certain deflection is obtained while placing
a sample of a very specific and regular geometry
under a constant stress. A flex bar is mounted on a
three-point bending fixture and the specified stress
is applied to the center of the bar. The sample is
Part ejection temperature is often assumed to be
related to HDT or DTULthe temperature at which a
material achieves a certain modulusbut is it? Shown
here: a flex modulus tester. (Photo: Teknor Apex).
PTonline.com
 Know How
then heated at a rate of 2o C/min until the required deflection
is attained. Since stress divided by strain is the modulus of the
material, another way of stating this result is to say that the DTUL
is the temperature at which a material achieves a certain modulus.
The quantitative relationship between the estimated cycle time
and factors like wall thickness, thermal diffusivity of the material,
and temperature of the melt and the mold will be elusive.
In 1978, Michael Takemori presented a paper at the SPE ANTEC
where he calculated the modulus associated with the DTUL. As
most people who have looked at a data sheet know, DTUL can be
measured at a stress of 66 psi (0.455 MPa) or 264 psi (1.82 MPa).
The ISO method rounds off this higher stress to 1.80 MPa and then
adds a third stress level of 1160 psi (8.00 MPa). The modulus asso-
ciated with 66 psi stress was calculated by Takemori to be 29 ksi
(200 MPa) while the modulus associated with the 264 psi stress
was calculated to be 116 ksi (800 MPa).
Takemori did not comment on the higher stress of 1160 psi
introduced by ISO because it did not exist at the time he wrote his
paper. But if it had, he could have easily shown that the associated
modulus would have been approximately 510 ksi (3520 MPa).
Which modulus and DTUL stress level should be used for esti-
mating ejection temperature, and why? And what are the chances
that a property (DTUL) that has
nothing to do with the engineering
properties of a polymer is somehow
related in a scientific way to the
temperature at which a part molded
from that material can be ejected
without undergoing an unacceptable
degree of post-mold distortion?
Takemori went on to show that the DTUL test incorporates a
measurement of short-term creep. The sample is placed under
constant stress for the duration of the test. This test may last
anywhere from 30 min for a material such as a PP copolymer to
over 2 hr for a reinforced PEEK or PEK. For the entire duration of
that test, the sample is under constant stress and the measured
deflection is therefore continually increasing independent of
the effects of the increasing temperature. This means that if the
sample is left under stress for a sufficient period of time, it will
deflect the required amount to signal failure without any need
to increase the temperature of the sample.
Screenshot of Loader Control
Screenshot of Dryer Control

Takemori also pointed out that as the material temperature
increases, the dimensions of the sample increase due to thermal
expansion. This introduces a countering influence into the mix
that actually pushes on the device used to measure the deflec-
tion, prolonging the test.
It has also been noted that the level of molded-in stress in
the specimen influences the temperature at which the DTUL is
measured. Compression molded samples contain less internal
stress than injection molded ones and therefore register a higher
DTUL. Samples that have been annealed will also produce a
higher measured DTUL for the same reason.
And not all samples are prepared to the same thickness.
Thinner samples will deflect at a lower temperature than thicker
ones. Given all these variables that are inherent in determining
this temperature, how useful can it be as a factor in an equation?
Even if we were to assume that there is some solid science
behind this, there are some glaring problems. These are most
readily observed in soft, flexible materials. Polyethylene, some
KNOW HOW MATERIALS
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Get more insights on Materials from our expert author:
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polypropylenes, most elastomers, and even PTFE do not have a
measurable DTUL because they do not exhibit a modulus high
enough to bear the specified stresses prescribed by the test
method without immediately deflecting to the degree that signals
the conclusion of the test. In order to measure the DTUL of these
materials it would be necessary to cool the material below room
temperature, allowing the material to stiffen to a point where
the test could be started. The result would be a heat deflection
temperature at some point below room temperature. Therefore,
if we use the DTUL as the ejection temperature, these materials
would have to be cooled to some very low temperature before the
mold could be opened and the part ejected.
This is just the beginning of the problem associated with the
way we propose to calculate the cycle time of a part. In the next
article we will look at how we treat temperature in our equations.
We will also explore further some adjustments made to the use of
DTUL and review some alternative approaches.
ABOUT THE AUTHOR Mike Sepe is an independent, global materials and
processing consultant whose company, Michael P. Sepe, LLC, is based
in Sedona, Ariz. He has more than 40 years of experience in the plastics
industry and assists clients with material selection, designing for manu-
facturability, process optimization, troubleshooting, and failure analysis.
Contact: (928) 203-0408 mike@thematerialanalyst.com.
www.wittmann-group.com
*resin and bulk density specific
 Know How

INJECTION MOLDING
Clamp Tonnage:
More Is BetterRight?
Determining the correct tonnage
provides a foundation that must
be rock-solid to avoid flash and
damage. But applying excessive FIG 1

force can create problems with Material selected for this lid was a low-viscosity
LDPE, indicating that the pressure required from the
the part, mold, and machine. injection unit to pack the part would be fairly low.

Many factors must be considered to determine if an injection
molding machine has the capability to mold parts on a consistent
basis. The injection unit must have the
correct shot volume to avoid degradation
and unmelt. It must also have pressure in
abundance and a flow rate high enough to
allow for proper part filling.
Plastic variables also must be consid-
ered, focusing on how important it is to
process from the plastics point of view. provide enough force to overcome the pressure applied in the cavity.
By Jeremy Williams Its important to dry the material to appro-
priate moisture content, process within
the recommended melt temperature,
select the correct flow rate for injection, apply adequate hold time
and pressure, and cool long enough to maintain dimensional
stability. However, these variables only focus on the injection
aspect of the process.
The clamp end of the
The starting point machine is responsible for
for determining providing force to counter the
appropriate clamp pressure that is applied from
tonnage is to calcu- the injection unit. How much
late the projected tonnage is applied, location
area of a single part. of that force, type of clamping
mechanism, and size of
the mold base all affect the
success of the molding process. Determining the correct tonnage
is not a simple task. It provides a foundation that must be rock-
solid to avoid flash and mold damage. Is it possible to apply too
much clamp force, narrowing the process window before molten
material is ever injected?
In the following examples, we will focus on using a Decoupled
Molding II processing strategy. During the process, the filling of
the cavity is separate from the pack/hold phase. The filling stage
should yield a part that is 95% to 98% visually full, resulting in
zero pressure at the end of the mold cavity.
As the machine transfers from velocity to pressure control for the
pack/hold phase, the cavity becomes visually full. Additional material
is packed into the cavity to minimize sinks and decrease dimensional
variation. Inside the cavity, the pressure increases, so the clamp must
DETERMINING CLAMP TONNAGE
The starting point for determining appropriate clamp tonnage is to
calculate the projected area of a single part. Then any cored-out surface
area shall be removed from the overall surface area of the single part.
Once the total surface area of the part is determined, we must multiply
it by the number of cavities in the mold. If the mold has a cold runner,
its entire surface area must be taken into consideration as well.
After obtaining the total projected area of all parts plus the
cold runner, we must then multiply that area by a tonnage factor.
Tonnage factors used to be found on the material specification
sheets, but nowadays that information rarely finds its way onto
those data sheets. Typical tonnage factors can range from 2 to 10
tons/in.2, but for a starting point we recommend 3 tons/in.2.
As an example, lets propose molding a lid for a square leftover
dish (Fig. 1) with a hot-runner mold and eight cavities:
KNOW HOW INJECTION MOLDING
Learn more at PTonline.com
Get more insights on Injection Molding from our
expert authors: short.ptonline.com/moldingKH

34 Plastics Technology JUNE 2017 PTonline.com

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 Know How

FIG 2 Comparing MFI Range and Melt Viscosity in Molding

2 g/10 min
High
Viscosity 1 g/ 25 g/10 min 1 g/10 min
SIDE-ACTION SYSTEMS 10 min 1 g/
10 min 24 g/10 min
Make Perfect Parts and Medium 14 g/ 2 g/
10 min 10 min
Save Money! Viscosity
68 g/ 1 g/
10 min 2 g/ 10 min 2 g/
10 min 23 g/ 10 min 40 g/
Low 10 min 10 min
Viscosity 23 g/ 53 g/
10 min 10 min
ABS HDPE LDPE PC PMMA POM PP PS
Low MFI numbers indicate high viscosity.
Preload cores for perfect parts. Melt viscosity is related to clamp-tonnage requirements, but MFI does not reliably
Save $$$$ with a smaller cylinder. correspond to actual melt viscosity in molding and cannot be compared accurately
Simplify mold operation and design. between resin types. For example, PC will always show high viscosity in molding,
regardless of whether the MFI is 2 or 25 g/10 min. Also note than an MFI of 10 g/10
Smaller mold base = low cost parts. min for PP does not mean an equal molding viscosity for the same MFI with PC.
Fully Preloads at only 1,500 psi.
Stays locked without hydraulics.
400 F systems available. Cavity Area = length width = 4.6 in 4.6 in = 21.16 in.2
Rush 0-2 day shipping available. Parts Area = cavity area cavities = 21.16 in.2 8 = 169.28 in.2
Tonnage =parts area tonnage factor = 169.28 in.2 3 tons/in.2 = 507.84 tons
KOR-LOK
TRADITIONAL
SIDE-ACTION VS. SIDE-ACTION
SYSTEMS SYSTEMS Now we have a starting point to determine what clamp tonnage is correct for this mold. But
S! Mold OPEN
S! other factors must also be taken into consideration to determine if the tonnage required
YE Core Out
YE
will be above or below 3 tons/in.2.
S! Mold CLOSED Melt flow index or rate (MFI, MFR);
YE
CANT DO IT!
When evaluating the MFI
Core OUT
Flow length;
ES
! or MFR, it is imperative Wall thickness;
S!
Mold CLOSED
Y YE that a comparison be
Core IN
Gate location;
S! Against FULL
Core PRE-LOADED
done only between the Gate size;
YE CANT DO IT!
Injection Pressure
same types of resin. Number of gates;
Volume of resin.

The first item that needs to be considered after calculating the tonnage based on projected
area is how the material flows. MFI or MFR can be found on the material data sheet from the
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supplier. A material with a high MFI or MFR will require less pressure from the injection
unit to complete the packing phase; therefore, the tonnage required will be lower.
When evaluating the MFI or MFR, it is imperative that a comparison be done only
between grades of the same type of resin. The reason for this is the ASTM test has a different
temperature, orifice size, and weight for each type of resin. These values do not corre-
late directly with molding, because of how the ASTM test is performed and how molding
machines actually operate. The MFR or MFI relate more closely to the packing phase since it
is typically at a much lower flow rate than the filling phase (see Fig. 2).
When reviewing our example of molding a lid, the material selected was LDPE. This

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material will likely have a very low viscosity, indicating that the pressure required from the
injection unit to pack the part will be fairly low. Therefore, based on material selection, the
tonnage required will likely be less than the typical 3 tons/in.2.
Germantown, WI 53022 Next, we need to evaluate both the flow length and the wall thickness. This is referred to as
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the aspect ratio, comparing the flow length (from gate to end of fill) to wall thickness. Generally
KOR-LOK , Hydra-Latch and Hydra-Jaws are trademarks of PFA, Inc.

speaking, an aspect ratio less than 150:1 has a low risk of sinks, short shots, or dimensional issues.
2016 PFA, Inc. All Rights Reserved.
In our example of molding a lid, the flow length is 3.00 in. and wall thickness is 0.100 in.:

36 Plastics Technology JUNE 2017 PTonline.com

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 Know How
FIG 3
This mold was clamped at four
times the required tonnage,
resulting in separation of the
cavity block in two locations.
FIG 4
Several factors contributed
to the frame rails breaking on
this vertical press. The mold
required about 10 tons to be
held shut against the forces
of injection, but the clamp
tonnage was set to 100 tons.
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Aspect Ratio = flow length/wall thickness = 3.00/0.100 in. = 30:1
With a very low aspect ratio, the required pressure to pack this part will lower, thus further
reducing the required clamp tonnage to hold the mold closed. In addition to lower tonnage,
the probability of molding sinks, short shots, or out-of-tolerance parts is reduced.
Next, we need to evaluate the gate size as well as the number of gates. A larger
gate diameter has a much larger area for material to flow through, thus requiring less
pressure from the injection unit to fill and pack the part. The number of gates will affect
the injection pressure during both filling and packing. If there is a greater number of
gates, a larger gate area, or if sequential filling requires less injection pressure, the result
is a lower required tonnage.
Our example of an LDPE lid has a single gate with a diameter of 0.030 in.
Gate Area = diameter x diameter 0.7584 = 0.030 0.030 x 0.7854 = 0.0007 in.2
This is a very small surface area to inject 23 g of material per cavity. Given this amount of mate-
rial and the gate size, expect the injection pressure during the packing phase to be slightly
higher and therefore the tonnage requirements would be a little greater than 3 tons/in.2.
Ultimately, the best method to determine required tonnage is to run a simulation with
correct geometry, characterized material, and full runner system. Without simulation, we can
draw conclusions from evaluating part geometry, material selection, gate size, gate location,
and gate quantity. Based on these factors, an expected range for this mold would most likely
be 339 to 508 tons (at 2 to 3 tons/in.2). A good starting point would be 420 tons of clamp force.
EFFECTS OF TOO MUCH TONNAGE
Now that we have focused on how to determine appropriate clamp tonnage, lets take a
look at the effects of applying excessive tonnage. Here are some typical molding defects
that can be seen on parts almost immediately when tonnage is too high:
Burns;
Short shots;
CW
Gloss level changes.
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Part quality is not the only item affected
when excessive clamp tonnage is applied.
There are long-term effects from over-
clamping that will damage the mold and
machine. First lets review several of the
side effects on the mold:
Crushed vents;
Rolled parting line;
Broken inserts;
Cracked core or cavity block.
Figure 3 is an example of a mold that was
clamped at four times the required tonnage.
Based on surface area, material, and gating,
the mold required roughly 100 tons (at 3
tons/in.2). The molder was inexperienced
and set the clamp tonnage to the machine
maximum of 400 tons (12 tons/in.2). Despite
a robust mold design, quality steel, proper
machining, and correct heat treating, the
result of excessive tonnage was that the
cavity block separated in two locations.
Each split ran the entire depth of the cavity
block (roughly 10 in.) from parting line to
clamp plate. This was a catastrophic failure
that caused delays in production and
upwards of $100,000 to expedite the manu-
facturing of a new cavity block.
Here are some potential failures on the
molding machine when excessive clamp
force is applied:
Cracked hydraulic-cylinder mounting
plates;
Deformed platens;
Fractured machine frame.
In Fig. 4, there were several contributing
factors that caused the frame rails to break
on this vertical C-clamp molding machine.
First, the mold required about 10 tons to be
held shut against the forces of injection,
but the clamp tonnage was set to 100 tons.
Second the mold-base size covered less
than two-thirds of the platen in both direc-
tions. Combining these two poor practices
over years not only fractured the machine
rails, but caused molding defects and mold
failure. No one was sure when the failure
occurred on the machine, but they did
identify when it was first discovered and
documented its progression over time.
Replacing both machine rails cost thou-
@plastechmag
INJEC T ION MOLDING
sands of dollars for materials alone. If we factored in the labor hours to disassemble and
reassemble nearly the entire machine, and the scrap produced over the years before the
rails failed, the number could easily exceed $200,000.
Jeremy Williams has more than 16 years experience in the plastics industry serving the medical,
automotive, furniture, and appliance industries. He previously worked as a principal engineer,
taking projects from design concept to saleable products. Jeremy earned his Master Molder II
certification in 2011, became an RJG Certified Trainer in 2012, and started at RJG Inc., Traverse
City, Mich. in 2016. In addition to his extensive manufacturing background, he holds degrees in
plastics and business. Contact 231-947-3111; jeremy.williams@rjginc.com; rjginc.com.
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Plastics Technology 39
 Know How

EXTRUSION
Sharper Dies Make for
Smoother Extrusions
Dies that have a radius at the exit will result in poorer surface finish.

A number of die-flow issues can affect surface finish, but one Die Exit Radii Influence Extrudate Smoothness
thats often overlooked is the sharpness of the die exit geom-
Sharper Lip Radius4X
etry. Polymers will stick to the die
surfaces unless you use additives such
as fluoropolymers, which can lend a Die Lip
degree of stick/slip flow.
Moreover, all polymers have some
degree of die swell due to molecular Smooth
Surface
orientation that occurs in the die exit.
This is due to uniaxial flow, which Large Lip Radius4X
untangles the long polymer chains in
By Jim Frankland Tears
the direction of flow. Once relieved of
the flow velocity, the polymer returns Die Lip
quickly to its relaxed state and reorients to a random configu-
ration. This results in expansion, primarily in the transverse
Lip
direction, both horizontally and vertically, and is referred to Buildup
as swelling of the extrudate. Die swell increases with velocity,
reduced land length, decreasing temperature, and the molecular On die exits with a large radius (bottom), polymer tends
to follow the radius because of its adhesion to the wall,
properties of the polymer.
and then swells, when it should break away cleanly
Adhesion to the die from the die face and move downstream. This can cause
Even protective surface, combined with die micro-tearing of the surface and leave polymer on the
materials such as brass swell, causes the polymer radius or above it on the die face as die buildup. Sharp
edges (top) result in a much smoother extrudate.
are hard enough to to flow along the face of the
abrade the sharp edge die after the exit if there is
of the die exit, creating a not a sharp break-off point, Although its wise to use soft tools to clean the die, it should be
radius or chamfer. rather than moving directly noted that all metals that have a gold color are not necessarily soft.
downstream away from Typical low-carbon steel has a Rockwell Hardness (Rb) of less than
the die face. This situa- 71. Pure copper has a typical Rb of <10, but some copper alloys are
tion is exacerbated by any radius on the die exit, which causes as hard as 98 Rb while brass alloys can be 63 Rb. Its not uncommon
the polymer to continue following the die surface because of the to observe operators using razor knives, steel spatulas, hardened
combined effects of adhesion and swelling. Such exit radii are not drills, steel-wire brushes, stainless feeler gauges, and even screw
usually there by design but are caused by periodic maintenance drivers to work on the die. These types of tools are often harder than
and/or gauging. Contacting the exit edges of the die with hard the die-exit edges unless the edges are made of heat-treated, high-
objects will eventually wear the sharp edge, creating a radius. carbon steel, and as a result can wear them quickly.
The breakaway effect for a sharp edge is contrasted by one
KNOW HOW EXTRUSION with a radius in the accompanying figure. The polymer tends to
Learn more at PTonline.com follow the radius because of its adhesion to the wall, and then
Get more insights on Extrusion from our expert authors. swell when it needs to break away cleanly from the die face and
short.ptonline.com/extrudeKH move downstream. This can cause micro-tearing of the surface

40 Plastics Technology JUNE 2017 PTonline.com

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 Know How

and leave polymer on the radius or above it on the die face as die are hard enough to abrade a dies sharp edges, creating a radius
buildup. The combination of tearing along with die buildup is or chamfer. To counter this effect, the die-exit face may need
often a largely invisible cause periodic resurfacing to restore the sharp edge. This can be done
of poor surface finish on the by surface grinding, but requires removing and disassembling
The die-exit face extruded part. A radius as the die, resulting in extended downtime.
may need periodic small as 0.010 in. has been Simply using only soft copper scrapers, gauze, feeler gauges and
resurfacing to restore found to result in surface other tools can prevent this abrasion and many surface defects.
the sharp edge. tearing and die-face buildup
with certain polymers.
ABOUT THE AUTHOR: Jim Frankland is a mechanical engineer who
Obviously dies periodi-
has been involved in all types of extrusion processing for more than
cally need cleaning, and if aggressive cleaning is necessary, 40 years. He is now president of Frankland Plastics Consulting, LLC.
even what are believed to be protective materials such as brass Contact jim.frankland@comcast.net or (724) 651-9196.

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 MATERIALS

AUTOMOTIVE PLASTICS
New Thermoplastic Solutions
Redefine Performance from All Angles

Air-intake
Lightweighting and resistance to heat, chemicals and manifolds and
charge-air ducts
weathering drive developments in thermoplastics for are targets for
BASFs Ultramid
interiors, exteriors, underhood, powertrain, and chassis. Endure nylon 66.

Summarizing recent innovations in thermoplastics for automotive is no small task. Virtually everything
that meets ones eye in a vehicles interior is thermoplastic these days, and the same goes for a look under
the hood and a good deal of what is visible on the exteriornot to mention innumer-
By Lilli Manolis Sherman
Senior Editor able plastic components that dont meet the eye in powertrain, chassis, and else-
where. And while much of the conversation about automotive plastics dwells on
lightweighting for fuel efficiency, there are many other performance requirements that drive materials
developments, such as resistance to fuels and chemicals, heat, wear, sunlight, and weather. In other cases,
the goal is improved processability to enhance quality and reduce manufacturing cost.
Jeffrey Helms, global automotive OEM corporate accounts director at Celanese (celanese.com), Irving,
Texas, is among those who note that vehicle fuel economy and CO2 emission targets are the two biggest
drivers and challenges in the global automotive market. Driving materials developments are hotter under-
hood temperatures associated with downsized and turbocharged internal combustion engines, and an
increase in electrification with a corresponding need to reduce vehicle mass to increase vehicle range.

44 Plastics Technology JUNE 2017 PTonline.com


Helms also sees increasing demand for power electronics in both
vehicle interior and exterior. You can imagine these systems will
continue to grow as more active safety systems are incorporated,
culminating in a growing fleet of autonomous and semiautonomous
vehicles He notes that Celanese is working with both OEMs and
component suppliers to help them manage heat dissipation in
these devices while minimizing the added part weight and cost.
Mike Chiandussi, powertrain market segment specialist
at BASF (basf.com), Florham Park, N.J., notes that powertrain
and chassis account for more than 50% of the total weight of
the vehicle. He notes that thermoplastics allow one to achieve
complex geometries and design while driving weight out of the
vehicle. But He also identifies technical challenges such as high-
operating temperatures and chemical wear.
Lanxess (lanxess.com), Pittsburgh, sees OEMs targeting
improvements in the powertrain, aerodynamics, and overall weight
to meet global fuel-efficiency regulations. With the introduction of
more small, turbo-charged engines and exhaust-recovery systems,
the demand is for materials that can withstand higher engine oper-
ating temperatures in a smaller space. Cooling systems also are
operating at high temperatures, explains, Jose Chirino, Americas
technical director at Lanxess
high-performance materials
business unit.
Solvay Specialty Polymers
(solvay.com), Alpharetta, Ga.,
has focused on three areas
for its polymers, according to
global automotive business-
development manager Brian
Baleno: transmissions, where
the need is for thermally
stable, wear-resistant mate-
rials; lightweighting; and elec-
trification of the drivetrain.
Jerry Mazur, new business development manager for automo-
tive at Trinseo (trinseo.com), Berwyn, Pa., views semi-structural
applications as the most dramatic development. Lighter, safer
and environmentally sustainable vehicles are a priority, and cost
savings is a primary target for manufacturers.
HEAT, CHEMICAL & WEAR RESISTANCE
As underhood temperatures rise, suppliers are offering more heat-
resistant products, often with an added lightweight advantage. The
new Fortron flexible PPS by Celanese has enabled significant
weight reductions in underhood applications while resisting
extreme temperatures (>75% tensile strength retention after 1000
hr at 175 C/347 F). Helms notes that because nylon absorbs moisture
and undergoes variable performance with rising temperatures,
parts manufacturers and OEMs will look to PPS for its chemical
@plastechmag
Materials Innovations in Automotive
resistance and long-term high-temperature performance stability
under the hood and in applications such as EDS (electrical distribu-
tion system) fasteners. Chinas Chinaust utilizes Flexible Fortron PPS
to blow mold and thermoform a positive crankcase ventilation (PCV)
tube that is now in production on three GM car platforms. The mate-
rial reduces part count by 50%, saves over $3/car per car, and consoli-
dates a metal-and-plastic assembly into one plastic unit.
Lanxess has responded to these needs with Durethan XTS series,
its latest generation of high-heat-resistant nylon 6 grades, as well
as the Durethan HR line of high-temperature, hydrolysis-resistant
nylon 66 for cooling systems. Chirino sees further opportunities for
high-tech plastics in battery systems, engines, and power electric.
He adds that newer designs for oil-pan modules are rejecting nylon
66 in favor of equally robust but economical nylon 6. The latest
example is the module for the new six-cylinder Boxster engines of
the Porsche 911 Carrera, which is made with Durethan BKV 30 H2.0.
BASFs Chiandussi says the companys Ultramid Endure high-
New Fortron flexible PPS from Celanese has enabled
major lightweighting in underhood components.
heat-resistant nylon 66 portfolio can be used in turbocharged air-
induction systems, including the air-intake manifold, charge-air
ducts, resonators, intercooler end caps, and throttle bodies. It can
also achieve long-term-service temperatures of 220 C/428 F and
withstand peak temperatures of 240 C/464 F.
Two new powertrain applications, which debuted on the 2017
Alfa Romeo Giulias 2.0L GME engine, utilize BASFs high-heat
nylon. The air-intake manifold with integrated charge-air cooler is
made with Ultramid Endure D3G7, a 35% glass-filled nylon 66 that is
replacing less thermally stable versions of nylons 6 and 66. And the
hot-side turbo duct is made with Ultramid Endure D5G3 BM, a 15%
glass-filled nylon 66 that is replacing metals in turbo ducts.
Higher temperatures and more demanding wear requirements
for transmissions are fueling the need for heat-stable and more
wear-resistant materials like Torlon PAI and KetaSpire PEEK, says
Solvays Baleno. Applications in transmissions that demand high-
temperature and wear resistance are seal rings, thrust washers, and
QUESTIONS ABOUT MATERIALS?
Find articles at ptonline.com/zones/materials
Plastics Technology 45
 MATERIALS
thrust bearings. Thrust bearings AESTHETICS,
of PAI and PEEK now replacing AERODYNAMICS &
axial needle bearings can save 2.5 STRUCTURAL PROPERTIES
mm/0.098 in. per bearing. This Automotive interiors str one key
space savings enables designers to focus for A. Schulman, Fairlawn,
downsize aluminum housings and Ohio (aschulman.com), says Frank
achieve significant weight savings. Roederer, senior v.p. & general
Torlon PAI is known for manager for North America. He
maintaining strength, stiffness, and his European counterpart
and toughness at high tempera- Heinrick Lingnau, point to the
ture. Its claim to fame is wear growth of touchscreen tech-
resistance in both lubricated 2017 Renault Espace lift gate is made nologies that demand special-
of Trinseos 60% long-glass PP.
and dry environments. Some ized plastics and the demand for
grades specially formulated for plastic parts with the look and
wear resistance include ones feel of natural materials.
with PTFE and graphite, carbon fiber, and carbon fiber plus PTFE. The firms high-flow, low-emissions Schulablend M/MK ABS/
KetaSpire PEEK reportedly offers better fatigue and wear resis- nylon and M/MW ASA/nylon and other alloys offer the potential to
tance, higher impact strength, and higher ductility than other eliminate painting and achieve a consistent low-gloss/matte finish.
PEEK products. Wear-resistant grades used in powertrain compo- Available in UV-stabilized custom colors and low gloss, they are
nents include carbon fiber or graphite with PTFE. found in trim such as loudspeaker grilles, pillar covers, instrument
Celaneses CoolPoly thermally conductive plastics, which come panels (masks, end caps, HVAC bezels), trunk and window frames,
in electrically conductive and insulative grades, have taken hold in seat side shields, and AV system bezels.
automotive heat sinks by matching thermal properties of aluminum Roederer also highlights softer flexible materials like Polyvin PVC
while offering weight and cost savings. These plastics enable 40-55% and Invision TPEs for decorative trim like door and console armrests,
mass savings due to reduced density and design optimization. A shifter knobs, bin liners, and cup holders, which need a dry-to-the-
commercial use is in the Ford Mondeo lighting module, where touch and non-tacky feel. Polyfort filled, unfilled, and impact-modi-
replacing die cast aluminum fied PP in UV-stabilized custom colors also get play in pillar covers,
saved 54% in weight. CoolPoly door and instrument-panel components, and rear-quarter trim panels.
Trends toward is also being evaluated for Lingnau also notes the higher-quality appearance trend in exte-
smaller, more fuel- metal replacement in power riors, where Schulmans fully compounded materials are replacing
efficient vehicles and electronics and lighting. painted parts in metallic colors. The company provides silver
electrification have For underhood parts such metallic compounds by using special pigments and mineral fillers
placed a premium on as radiator air fans, the leading to achieve metallic optics without weld lines and injection marks.
more heat-resistant producer of styrene-maleic This earned the 2016 Grand Innovation Award of SPE Europe for the
materials. anhydride (SMA) copolymers, Mercedes Benz GLA skid plate for front and rear bumpers, produced
The Netherlands Polyscope with Polyfort FIPP 10 T K2369, a silver-metallic, impact-modified PP
(U.S. office in Novi, Mich.; compound using an innovative filler system.
polyscope.eu), is developing highly glass-filled SMA/nylon blends Meanwhile, car makers are striving to make premium inte-
to address water-absorption issues of nylons and replace over- riors affordable, says Trinseos Mazur. They want surfaces to have
engineered nylons, according to CEO Patrick Muezers. a high-quality look and feel, to be durable and less expensive to
Houston-based SABIC (sabic.com) sees PP making its way manufacture in order to pass savings on to customers. This is why
into underhood applications. Scott Fallon, global leader of the OEMs have stringent requirements for plastics with aesthetics
SABICs automotive business, points to the 2016 SPE Automotive and haptics and best-in-class scratch resistance, along with good
Innovation Award powertrain winner: the air-intake manifold processability and cost-effectiveness.
in VWs 2015 EA21 1.6L engines, said to be the first such part Trinseo focuses on interior applications for its Velvex family
launched in China using 35% glass-reinforced PP to replace of factory-colored TPOs with glass reinforcement. With these
nylon 66. The part provides a 25-30% cost reduction and 15-20% products, we bridge the gap between technical and aesthetic
weight reduction while retaining properties and improving weld performance, and were doing so at an affordable cost, says
strength. SABICs G3135X PP in this part utilizes finer glass fibers Mazur. These materials boast improved soft touch, outstanding
and special sizing. scratch resistance, and low gloss while meeting key requirements

46 Plastics Technology JUNE 2017 PTonline.com


for cost-efficiency. They reportedly offer a superior finish for
unpainted parts such as door panels.
Trinseo has also developed lower-density Pulse PC/ABS
products that not only enable lower weight and cost in parts, but
also offer low gloss, easy flow, faster cycles, high impact strength
at low temperatures, heat resistance optimized for the majority of
interior auto components, and low odor and VOCs. For example,
Pulse GX50 is approved by BMW for UV and hydrolytic stability
and is used on the BMW 1 series, i3 and i8.
Mark Minnichelli, director of technical
development at BASFs performance mate- Car makers are focusing on making premium interiors more
rials division, points to Fords new Lincoln affordable, putting emphasis on materials with improved
Continental, which features an innovative aesthetics and haptics, as well as low volatile emissions.
seating architecture. With its 35% glass-filled,
impact-resistant Ultramid nylon 6, BASF
contributed a 20% weight reduction for the front-row seat pan
vs. the metal predecessor, and 15% cost savings.
Minnichelli also heralds the use of a 20% carbon-fiber rein-
forced Ultramid nylon 66 to produce the grille-opening reinforce-
ment (GOR) on the 2016 Ford Shelby GT359 Mustang. Not only 2.5
lb lighter than the traditional GOR of metal stampings overmolded
with plastic, but the new parts aesthetic quality prompted Ford to
forgo the beauty cover to hide the GOR, saving another 1.9 lb for
a 45% weight reduction overall.
Meanwhile, Polyscopes main focus is on interior structural
parts. Says Muezers,We are aiming to achieve performance proper-
ties that bridge the gap between nylon 6 and nylon 66 in applica-
tions such as instrument-panel supports, structural consoles,
audio components, and interior trim. Since 2013, its Xiran IZ
terpolymersbased on SMA and N-phenylmaleimide, have made
significant commercial strides with several OEMs in sunroof
frames. Applications such as this require a high degree of functional
integration,
high-precision
Torlon PAI thrust molding, and
washer developed
by Solvay and
greater stiff-
Freudenberg- ness. Xiran
NOK was an products replace
SPE Innovation
glass-filled PBT/
Awards finalist.
ASA blends,
which can have
warpage issues,
cost more, and
are more diffi-
cult to process.
Polyscope
is also targeting instrument-panel carriers where SMA can meet a
broader temperature range (-35 C to 120 C or 31-248 F) than the widely
used PP. In particular, PP does not have comparable low-temperature
performance, which is important for airbag deployment.
@plastechmag
Materials Innovations in Automotive
At the K 2016 show in Dusseldorf, Ineos Styrolution, Aurora, Ill.
(styrolution.com), launched what are believed to be the first styrenic
thermoplastic composites, called Stylight, with mechanical proper-
ties that reportedly exceed composites of nylon 6 or PC (see Februry
2017 feature). In cooperation with German engineering company
KTM Technologies, the company has developed a selection of
concept studies of StyLight in exterior and interior applications like
body panels, tailgates, door modules, and consoles.
Celanese has continued to reduce volatile emissions in inte-
riors with a novel family of acetals that boast formaldehyde
emission levels as low as 2 ppm. These Hostaform XAP2 grades
reportedly are now the benchmark for acetals in vehicle interiors.
They are used in locks, head-rest guide sleeves, HVAC components,
buttons, speaker grilles, etc. Speaker grilles represent a fairly large
interior acetal part where its contribution to interior emissions is
more heavily weighted. Celanese is continuing to push emission
levels down with a next-generation XAP3 acetal line that promises
formaldehyde emissions of 1 ppm.
In the area of aerodynamics, active grille shutters play a role
in increasing fuel efficiency by as much as 1.1 mpg, but weight and
warpage can be an issue. To address this, Lanxess new Durethan XF
(Xtreme Flow) easy-flowing nylon 6 is being evaluated for reduced
warpage and improved cycle times.
LIGHTWEIGHTING ALL AROUND
Each of these, and other, material suppliers, are targeting light-
weighting with certain materials:
Lanxess Durethan XF is gaining in structural parts such as front
ends, cross-car beams, rear bumpers, and door modules.
Solvays lightweighting materials include Amodel PPA and Omnix
HPP nylon with 30-60% long fiber, aimed at gears , structural
parts on interior panels and chassis components.
A. Schulman has compounds based on innovative reinforce-
ments and polymer alloys that have lower density than conven-
tional compounds, including Polyfort impact-modified PP and
Shulamid nylon 6 and RD nylon 66
SABIC sees Stamax long-glass PP (LGF-PP) replacing metal in
structural applications like front-end modules, door modules,
inner tailgate components, and instrument panels.
Trinseo has worked with long-standing partner Renault to con-
vert semi-structural parts to LGF-PP. Targets have included lift-
gates, front-end and door modules, air-flow systems, IPs, under-
vehicle belly pans, and seat structures.
Plastics Technology 47
 On-Site Trelleborg Sealing Solutions Fort Wayne, Ind.

By Jim Callari
Editorial Director

Medical-Tubing Innovator
Bets on Silicone Solutions

Trelleborg gains footprint in silicone-based

implantable medical extrusions.

For more than 100 years, and around the world, Trelleborg has provided an extremely Trelleborg runs
diverse range of products that seal, damp, and protect highly demanding applications in a wide range of
silicone-based
aerospace, automotive, oil and gas, mass transit, marine equipment, construction, and medical tubing, all
more. They even make tires and wheels for industrial, construction, and agricultural to customer specs.
vehicles. The Trelleborg Group (trelleborg.com) has operations in 50 countries with
annual sales in excess of $3.6 billion.
Talk about a powerhouse.

48 Plastics Technology JUNE 2017 PTonline.com

 Trelleborg Sealing Solutions
On-Site
Headquartered in Sweden, Trelleborg has been doing business Trelleborgs third medical manufacturing plant is in Elk Grove,
in the U.S. for decades, with Trelleborg Sealing Solutions for the Mich. At this site, dip coating operations are used to produce
Americas based in Fort Wayne, Ind. But until last June, the company minimally invasive surgical instruments.
had a limited presence in key areas of the high-growth
health care and medical market in the Americas. So
Trelleborg went out and bought privately held, family-
owned Specialty Silicone Fabricators (SSF).
Trelleborg Sealing Solutions has been in the
medical market for many years but our offering,
though at the forefront of technology, was primarily
for healthcare equipment, explains Drew Rogers,
global director, Healthcare and Medical for
Trelleborg Sealing Solutions.
The acquisition of SSF allowed us to bring into
our portfolio solutions that could be implanted into
a patient, enhancing our already established global
offering, adds Rogers. Trelleborg has now broad-
ened its capabilities to tap into a growing industry.
Trelleborgs medical and healthcare operations in the
Americas are focused on siliconewith both LSR and
The Trelleborg plant in Paso Robles, Calif., is where the
HCR capacityand form part of a global network for
company does the majority of its medical parts manufacturing.
extruded and molded products in its other markets.
The acquisition of SSF enhanced Trelleborgs
capabilities with what Rogers describes as a clearly differenti- CUTTING ITS TEETH IN EXTRUSION
ated product line. He elaborates, The implantable footprint The majority of what the company makes in Paso Robles are
is really the major step that Trelleborg has taken. SSF had a custom components. On the tubing side, they can range from a
long history and a lot of expertise in implantable devices; 60% few hundred feet to several thousand. About half of what the
of what we manufacture are company extrudes is coiled, the other half cut to length. Tubing
implantables. extrusion equipment is moved around to accommodate other
The implantable
Trelleborgs healthcare and production processes as needed.
footprint is really
medical segment is supported But extrusion is our differentiator, states Rogers. Extrusion
the major step
by various plants located across is where we cut our teeth. Trelleborg offers high-precision, tight
that Trelleborg has
the world. Through the SSF tolerance silicone extrusion tubes in wall thickness of 0.004 in. at
taken. SSF had a
acquisition, Trelleborg gained excruciatingly tight tolerances of 0.001 in.
long history and a
three additional manufacturing About 10 years ago, the company developed its own extrusion
lot of expertise in
facilities. One is in Paso Robles, tooling process, called GeoTrans (short for geometric transition). In
these devices.
Calif., a 102,000 ft plant that is this technology, components within the die can be moved on the
ISO 9001 and 13485 certified and fly to change tubing geometry, to transition from single to multiple
houses ISO 8 and ISO 7 cleanrooms. Trelleborg does a majority of lumens, or even to split a single tube into two in a Y shapes. The
its medical parts processing in Paso Robles, with an undisclosed technology eliminates secondary assembly steps.
number of extrusion lines for tubing and sheet. GeoTrans technology is used on Trelleborgs balloon cath-
Trelleborgs second facility dedicated to medical is in eters, bump and tapered tubes. It is also deployed on what the
Tustin, Calif., and is registered with the Food and Drug processor calls its Material Transition tubes, in which one
Administration (FDA) as a finished medical-device manufac- silicone material transitions to another over the length of the
turer. Also ISO 13485 certified, this 55,000 ft plant has ISO tube, where different mechanical properties, additives, color,
Class 8 and Class 7 cleanrooms. In Tustin, the company does opacity, radiopacity, and durometer are required. A typical application
product assembly, packaging, sterilization and drug-device
work; the Tustin facility is licensed to work with active phar- QUESTIONS ABOUT MEDICAL TUBING?
maceutical ingredients (API), meaning that it can produce Learn more at PTonline.com
tubing that elutes anti-microbial agents, for example. Visit the Tubing and Medical Zones.

@plastechmag Plastics Technology 49

 On-Site Trelleborg Sealing Solutions

for this technology would be a catheter that has a soft tip for of the API. Explains Rogers, Cancer drugs are often taken by pill
patient comfort but is otherwise stiff, making it easier to be or injection. Of course these are very strong medicines that, when
placed where it belongs in the patients body. delivered this systemically, travel through the entire system. The
Trelleborg is also on the cutting edge of technology that result is many well-known and undesirable side effects, including
uses its silicone-based devices or parts as a vehicle to deliver tissue degeneration. With an implant delivery device, you can
drugs. We have a lot of deliver a drug right at the point of the tumor, using a drug reservoir
experience in this area, and release control or a patch. Generally speaking, a drug/ device
With an implant and its a segment of the combination product may be a part already going into a patient: a
delivery device you medical market that is wound-drain catheter, for example. Impregnating the antimicrobial
can deliver a drug growing very quickly, into the wound-drain tube itself turns that tube into a solution as
right at the point of says Rogers. Weve been opposed to a culprit (for infection).
the tumor, using a drug working with API for Silcone products and drugs can be combined in one of
reservoir and release 7-8 years, not only with three ways, Rogers explains. In one scenario, raw silicone and
control or a patch. antimicrobials but with a powdered form of a drug are mixed prior to fabrication. The
hormones for contraception drawback of this technique, Rogers notes, is that silicone is typi-
and devices that include cally cured at high temperatures, and the extreme heat can affect
medicines for sexually transmitted diseases. Weve worked on the efficacy of the medicine.
a molded silicone implant that elutes a drug specifically for In the second approach, a silicone part like a tube is immersed
malaria-infested populations. In this case the drug that elutes into a liquid form of the drug or a drug in solution for a very
kills not only the diseases but the mosquitos too. specific period of time. States Rogers, In addition to being
Combining silicone products with an API provides a variety biologically inert, the great thing about silicone is that it has very
of benefits. For one, it can permit a more controlled release rate consistent absorption and elution characteristics. So if you take a
of the medicine. Secondly, it allows for a more targeted delivery particular durometer of silicone and immerse it into a particular

NYLON AIRBAG
SCRUB PADS S
 Trelleborg Sealing Solutions
On-Site
concentration of a drug for a partic- We can help with material
ular amount of time, it will always selection and process develop-
absorb the same amount of drug and ment to accommodate those
once implanted will always elute performance characteristics.
at the same rate. You can get a very Rogers continues: There
consistent effect. Most of the time, are other benefits silicone
Trelleborg develops an application- brings to the table in medical.
specific drug-device combination to Once its cured, the shape will
meet the customers elution specifica- not change. It can be sterilized
tions. These formulas, as Rogers puts in any method. Thin silicone
it, are both precise and precious. sheets can be gas permeable. Of
The third way silicone and APIs are course, not every application
mixed is by producing small, propri- requires this. If you just want
etary drug-delivery reservoirs, used in a good hard tube to run from
conjunction with a vaginal ring. This an oxygen tank to a mask, you
approach is being widely embraced in probably dont need silicone.
womens health on a global scale. Medical tubing runs at Trelleborg range We dont push anyone to
from a few hundred feet to the thousands. silicone unless its the right
WHY JUST SILICONE? solution.
States Rogers, We are experts in material selection and recipe We also think of ourselves as a safe haven for start-up
formulation for the particular solution. If, for example, the tube companies who come to us with an idea and a picture and who
has to be firm when inserted into the body but be able to be want to ensure they will pass regulatory or not experience a
twisted when its inserted, we can develop a recipe to that spec. shutdown due to FDA findings down the road.

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 Tips and Techniques

How to Mount an
Injection Mold
Five industry pros with more
than 200 years of combined
molding experience provide
step-by-step best practices
on mounting a mold in
a horizontal injection
molding machine.

What started out as a routine request from one Plastics Technology WITH THE PUMP MOTOR OFF:
columnist to another to review a draft for an upcoming article led to 1. Check that the mold will cover at least 70% of the distance
five highly experienced between the tiebars.
By Piotr Witaszek, John Klees, Jim Fattori,
industry professionals a. This is a good rule of thumb. Most machine manuals will
Ernie Di Siro, and John Bozzelli
collaborating to create specify the minimum mold size for a given machine. Some
this article about something virtually every molder does every machines even have placards mounted on the frame.
daysometimes many times a daymounting a mold in a press. b. The smaller the mold, the more the platens will wrap around
A well-trained and knowledgeable setup person understands or bow when clamped under high pressure. This can cause flash
the importanceand dangersassociated with the job. They have in the center of the mold.
a heightened respect for their safety, as well as the safety of others, c. If the mold is excessively small, catastrophic damage to the
and for the molds, machines, platen can occur.
and equipment they work
A well-trained and
with. They are an extremely 2. Ensure the safety strap is in the correct position and in good
knowledgeable setup
valuable asset to every condition.
person understands
molding company.
the importanceand
Before digging in, take 3. Check that the molds eye bolt is secure.
dangersassociated with
note: No single procedure is a. Only use shouldered eyebolts, or preferably, swivel-type
the job.
correct for all applications. hoist rings.
This procedure most likely
will need to be modified to suit your special/unique situation or
conditions. Also note that for safety reasons, the general procedure
QUESTIONS ABOUT INJECTION MOLDING?
outlined here requires the pump to be turned on and off repeatedly.
This and all other applicable safety requirements must be observed. Visit the Injection Molding Zone.

52 Plastics Technology JUNE 2017 PTonline.com

 M OL D M O U N T ING

TABLE 1
Fastening the Mold to the Platen:
Minimum Depth in Cast Iron B
B
B A<B
Bad
Bolt Size & Depth, Full
Pitch, in. in. Turns A>B
A A>B
A A=B Good
-13 1 13 Good
A OK
5/8 - 11 1.25 14

- 10 1.5 15 FIG 1 FIG 1

18 2 16 The clamp bolt should always be closer to the toe than the heel.

b. Eyebolts must be threaded all the way in and tightened.
c. Two eyebolts are safer than one and can help prevent the
mold from tilting.
d. Ideally, the location of the eyebolt is at the molds center of
gravity, so it does not tilt.
4. Check the size and condition of the nozzle seat. It will be dif-
ficult to check after the mold is installed.
a. Write down or find an appropriate nozzle tip type and size
before you forget.
5. Ensure the carriage is back and/or the screw is forward.
a. Be alert for resin drool or spitting.
b. The barrel heats may be on or off, depending on the situation.
12. Lubricate the clamp bolts.
a. If the bolts are not lubricated, 85% of the torque is used to
overcome friction and only 15% is available to produce bolt
load. If the bolts are lubricated (with cadmium plate,
molybdenum disulfide, anti-seize compounds, etc.), the
friction is reduced and greater preload is produced with
the same torque.
13. Check that the crane can adequately lift the mold over the
machines tiebars.
a. Check for obstructions above the machine, such as sprin-
kler heads, ceiling fans, etc.
b. Check that the robot, picker, or other automation is safely
out of the way.

6. Check that the 14. Lift the mold up over the tiebars and lower it into the molding area.
No single procedure is resin is not a. Keep your fingers away from the chain links.
correct for all applications. degrading in the b. Make sure no one is in the immediate area during this
barrel from sitting process. Use safety cones, barrier tape, or other preven-
there too long. tive measures.
a. Many materials, such as PVC or POM (acetal), produce gases
that can develop high pressures within the barrel. 15. With your hand on the side or top edge of the mold, guide it
into the machine and engage the locating ring into the align-
7. Clean the machine platens and the molds clamp-plate faces. ment hole in the fixed platen.
a. Check for dings or raised areas on the mold and platenespe- a. Do not let the edges or corners of the mold hit the platens
cially the locating-ring alignment hole. Stone flush if necessary. or tiebars.

8. Check for damage to the clamp bolt threads in the platens.
9. Spray a light mist of overnight preservative or WD-40 on the
platens and the clamp-plate faces of the mold.
10. Check that the clamp bolts have the correct thread type:
English (SAE) versus Metric.
11. Check that the clamp bolts are the correct length.
a. If the bolts are too short, with insufficient engagement, or too
long and bottom out, you can strip the threads in the platen. 18. Open the gate and level the mold.
IN SETUP MODE:
16. This is a good time to check the machines safety switches.
17. Advance the moving platen until it just touches the back of
the mold.
a. You can make sure the locating ring remains engaged in
the platen alignment hole by occasionally looking at it
from the barrel side.
WITH THE PUMP MOTOR OFF:

@plastechmag Plastics Technology 53

 Tips & Techniques

b. If the mold is equipped with

X
knockout extensions, the ejector
bars should be flush or slightly
recessed from the face of the moving
Y platen when the machine ejector
Bad OK Good (aka butterfly) plate is fully retracted.
FIG 2

Ideally, the tip of the mold clamp should touch IN SET-UP MODE:
the face of the clamp slot at about a 1 angle. 23. Advance the moving platen until it is 4
to 6 in. away from the back of the mold.

19. Attach the clamps on the fixed-platen side to prevent the WITH THE PUMP MOTOR OFF:
mold from rotating or the locating ring from disengaging 24. Slide the knockout bars forward and thread them into the back
from the alignment hole, but do not yet fully tighten the bolts of the mold.
to the specified torque value.
a. Grade 8 bolts should engage the relatively soft die-cast platens 25. Tighten the knockout bars with a pipe wrench or other suitable tool.
by a minimum of 1.5 times their diameter to prevent stripping
the threads. Two times their diam- IN SET-UP MODE:
TABLE 2
eter is preferred (see Table 1). 26. Advance the moving platen up against the back of the mold.
Mold Fastening
b. Ideally, the mold clamp should a. Look and listen for the knockout rods binding or bending.
Torque For Lubricated
be square with the mold and the
Grade 8 Bolts
toe of the clamp be fully engaged 27. Lower the chain hoist slightly to remove any tension.
Bolt Size & Torque, in the slot.
Pitch, in. ft-lb c. The clamp bolt should be as close 28. Set the die height to the pre-established clamp pressure.
-13 75 to the mold as possible. You want a. If the clamp pressure has not been established yet, use a
the pressure of the bolt acting on high pressure value for large molds or large parts, and a
5/8 - 11 150
the toenot the heel (see Fig. 1). medium pressure value for small molds or small parts.
- 10 270
d. If the bolt is closer to the heel
18 560 end than the toe end, switch to a WITH THE PUMP MOTOR OFF:
longer clamp. 29. Attach the clamps on the moving-platen side (see steps 19 a-e)
e. It is acceptable for the clamp to be parallel with the platen,
but it is preferred that the heel end of the clamp be slightly 30. Torque the clamp bolts on both the fixed and moving platens
farther from the platen than the toe end. This puts the front to the appropriate value (see Table 2).
edge of the toe in contact with the face of the clamp slot a. Click-type torque wrenches help ensure all of the
(Fig. 2). Failure to do either of these two steps may result in clamps have the same amount of torque. If all the
the mold dropping out of the machine. clamps are not torqued evenly, the one(s) with the lower
f. Forged, closed-toe clamps with no-turn washers are preferred. torque value may come lose.

20. Use only hardened-steel washers designed to distribute 31. Remove the safety strap(s) and eyebolt(s).
the load on the clamp. Soft hardware-store washers will
deform and come loose. 32. Move the hoist out of the molding area.

IN SET-UP MODE: IN SET-UP MODE:

21. Retract the moving platen enough to install the ejector 33. Open the mold and advance the ejector plate, if needed, to
barstypically 8 to 12 in. gain access to the back of the knockout rods.

WITH THE PUMP MOTOR OFF: WITH THE PUMP MOTOR OFF:
22. Put ejector bars in the holes matching the pattern on the mold. 34. Install the hex nuts or socket-head cap screws on the end of the
a. Make sure ejector bars are the correct length, the same length, knockout rods with a ratcheting socket wrench or other suitable
that they are straight, and the threads are in good condition. tool until they are tight.

54 Plastics Technology JUNE 2017 PTonline.com

 M OL D M O U N T ING

IN SET-UP MODE:
35. Stroke the ejectors forward and
backward a few times to make sure
they function properly and
nothing is binding or squealing.
36. Wipe off any dirt or grease you may
have deposited on the machine and
clear the area of your tools and equip-
ment. If you want to maintain a clean
work environment, lead by example.
The general procedure outlined here requires the pump to be
turned on and off repeatedly. This and all other applicable
safety requirements must be observed.
the problem, the mold half attached to the moving platen should be re-hung with a
slight amount of lift or pre-load from the hoist. This usually helps, but does not solve the
root cause, which is platen tilt. Platen tilt will be the subject of a future article.
(If readers think anything should be added here, the authors would like to hear from them.)

The above procedure ensures that the

mold is securely fastened to the platens
and will not shift or loosen during produc-
tion. But there is one final step to consider,
which will help prevent premature tool
wear and rejected parts.
On occasion you might hear the leader
pins hit the bushings when you slowly
close the mold. This is not uncommon
when hanging a mold that doesnt have a
lifting strap or interlocks that help verti-
cally align the two mold halves. To correct

ABOUT THE AUTHORS:

John Bozzelli is the founder of Injection Molding
Solutions (Scientific Molding) in Midland, Mich.,
Blendtec case study
a provider of training and consulting services
to injection molders, including LIMS, and other
Unmatched experience available upon request.

specialties. Contact john@scientificmolding.com;

scientificmolding.com.
Ernie Di Siro is the Molding Manager for
Nordson EFD LLC, a proprietary injection
molder. He has 40 years of injection molding
experience starting out as a machine
operator. Contact ernie.disiro@nordsonefd.com
Jim Fattori is a third-generation injection
molder with more than 40 years of molding
experience. He is the founder of Injection Mold
Consulting LLC, and is also a project engineer
for a large, multi-plant molder in New Jersey.
Contact jim@injectionmoldconsulting.com;
injectionmoldconsulting.com.
John Klees is a retired plastics specialist with
more than 40 years of processing, part and
mold design and construction expertise.
in material-joining technologies
Emerson offers a wide array of Branson-brand advanced solutions for
superior plastics-joining, metal-welding, and precision-cleaning equipment.
Through Bransons line of advanced ultrasonic welding, as well as
leading-edge laser, vibration welding, and more, Emerson technologies
assure you of:
The right solution for your specic application through our
process-neutral approach
Application experience and technical expertise
The worlds premier resource for plastics-joining technologies
True global support and rapid-response service
BransonUltrasonics.com
Americas 203-796-0400 l Europe 49-6074-497-0
Asia 86-21-3781-0588

Piotr Witaszek is the plant manager for

LMT-Mercer Group, Inc., a custom injec-
tion molder with multiple facilities. He has Branson Ultrasonics Corporation 2017.
25 years of injection molding experience, The Emerson logo is a trademark and service mark of Emerson Electric Co.

starting out as a machine operator. Contact

pwitasek@lmtproducts.com.

@plastechmag Plastics Technology 55

 Troubleshooting

How to Solve
Common Ultrasonic
Welding Problems
Understand and address the
likely origins of welding problems
to keep production on track. High-frequency vibrations are applied
to two parts surfaces by a vibrating tool,
commonly called a horn or sonotrode.

Ultrasonic welding is a widely recognized and accepted process for two parts by a vibrating tool, commonly called a horn or
joining thermoplastic materials. It offers many advantages, sonotrode. Welding occurs as the result of frictional heat generated
including process reliability and repeat- at the interface between the parts. The ultrasonic vibrations are cre-
By David Dahlstrand
Branson Ultrasonics ability, lower energy usage than other ated by a series of componentsthe power supply, converter,
joining techniques, material savings booster, and hornthat deliver mechanical vibration to the parts.
(because there is no need for consumables, such as glue or As shown in Fig. 1, the power supply takes a standard elec-
mechanical fasteners), and labor savings. trical line voltage and converts it to an operating frequency. In the
But as with any process, there are situations where apparent following example, we will utilize a common ultrasonic welding
problems with this technique may interrupt the production process. frequency of 20 kHz, though welding can take place over a range
The key to resolving and avoiding these problems is to understand of 15 to 60 kHz to meet specialized needs. In operation, the power
their likely origins. supply sends electrical energy at the specified frequency through
Processors that are an RF cable to the converter. The converter utilizes piezoelectric
Higher-frequency
successful in using ultra- ceramics to convert the electrical energy to mechanical vibrations
welders are considered
sonic welding typically at the operating frequency of the power supply. This mechanical
more gentle in the
share two principal traits: vibration is either increased or decreased based on the configura-
application of ultra-
they have a well-docu- tion of the booster and horn. The proper mechanical vibration
sonic energy to parts.
mented, validated welding amplitude is determined by an applications engineer and is based
process; and that process is on the thermoplastic materials used in the parts.
supported and maintained by a resident well-trained champion. If The parts to be welded are put under a mechanical load, generally
one or both of these important factors are not present, youll likely with a pneumatic actuator that holds the booster and horn. Under
very soon call for help. Even with both present, it is possible that this load, the mechanical vibrations are transmitted to the interface
youll need some help or technical assistance at least once in a while. between the material surfaces, which focuses the vibrations to create
intermolecular and surface friction. This friction creates heat and a
HOW THE PROCESS WORKS subsequent melt, which solidifies into a welded bond.
Before examining common causes of ultrasonic welding problems, The basic components of an ultrasonic system are a power
lets take a moment to understand the welding cycle itself. In ultra- supply, an actuator, and a stack (see Fig. 2). The power supply takes
sonic welding, high-frequency vibrations are applied the surfaces of line voltage at a nominal 120-240V and transforms it into a high-

56 Plastics Technology JUNE 2017 PTonline.com

 U LT R A S O N I C W EL D IN G

voltage, high-frequency signal. It also contains the programming FIG 1

necessary to operate the actuator and stack in a controlled manner
to achieve a desired weld result. The actuator, either pneumatically
or electric servo-operated, and available as a stand-alone benchtop
unit or integrated into an automated system, moves the ultrasonic 20 kHz Power Supply 50/60 kHz
tooling toward the parts to be joined. It applies the needed force to
the materials to help create the welding conditions. Converter Booster Horn
The ultrasonic stack completes the system. It transfers vibratory
energy, through direct contact with the parts, to the sealing/joining
surface. The stack typically consists of three items: the transducer
or converter (described above), which contains the piezoelectric
The power supply takes a standard electrical line
ceramic crystals that oscillate voltage and converts it to an operating frequency.
at the frequency of the applied
Heeding a squeaky
power-supply signal. As these
wheel sooner rather
crystals oscillate, they physi- FIG 2 Ultrasonic Welder Components
than later may well
cally expand and contract,
permit identification
creating measurable mechan-
and resolution of Actuator/
ical motion (referred to as Stand
a problem before
peak-to-peak amplitude) in the
production is
output side of the transducer. Converter
adversely affected.
The second section, the
Ultrasonic
booster, with an attached ring Power Stack Booster
in its mid-section, serves two functions: It acts as a mounting Supply
point for the stack into the actuator, and also serves to amplify or
reduce the output motion created in the transducer. Horn
The third and final component of the stack is the horn
(sonotrode) that will contact the parts to be joined. The horn will be
designed to match the profile of rigid parts to be joined or can have a
Basic components of an ultrasonic welder.
sealing profile added to its contact face in a film/textile application.
For each application, the horn is designed to combine with the other
stack components to reach the optimum level of amplitude output Lets start with equipment. It is easy and usually logical to
to allow ultrasonic welding to occur as efficiently as possible. think the equipment and approaches that produce successful
welds in one application will do so in another. But that is not
TYPICAL SETBACKS universally true. Worldwide, 20-kHz ultrasonic welders are by far
Issues usually occur in one of four areas: the most widely used; due to their versatility, these welders can
deliver high-power (up to 6000 W) and high-amplitude outputs,
1. Equipment: The ultrasonic welding equipment or various and they can accommodate a wide range of available tooling sizes.
welding components are not suited to the application. For a contract manufacturer that produces ultrasonically welded
parts, 20-kHz equipment can be a great investment since it offers
2. Process parameters: The parameters used are not suited to the promise of future use in many applications.
the parts being joined. However, there are some instancesespecially with small and
delicate partswhere the high-power, high-amplitude capabilities of
3. Materials: Changes are made in the type, composition, or phys- 20-kHz equipment may prove too aggressive for certain assemblies,
ical/mechanical characteristics of the materials used in the parts. potentially resulting in damage. One possible solution is to reduce
the input amplitude, but this wont work if the amplitude applied is
4. Part design: Certain details of the parts geometry are not below the recommended level for the polymer being welded.
suited to repeatable or successful welding.
QUESTIONS ABOUT ULTRASONIC WELDING?
It should also be noted that sometimes a problem identified in
one area may expose a weakness or deficiency in another area. Visit the Welding, Bonding and Assembly Zone.

@plastechmag Plastics Technology 57

 Troubleshooting

FIG 3 DCX Test & Graph Screen of a Typical Good Weld such as noise, can alert the user to worrisome
trends before they become major issues. Power
20450 120 90
20350 108 72
supplies, through advanced communication
Power, % / Current, % /

20250 96 54 protocols, can obtain data such as weld graph

Frequency, Hz

20150 84 36
Amplitude, %

Phase,
results and horn scans that can be compared
20050 72 18
with baseline data obtained when the equip-
19950 60 0
19850 48 -18 ment was new, recently serviced, or known to
19750 36 -36 be performing up to standard.
19660 24 -54 With this information, experienced users
19550 12 -72
19450 0 -90 can then focus their troubleshooting and
0 75 150 225 300 375 450 525 600 675 750 determine whether additional action or further
Time, millisec
Frequency Power Current Amplitude Phase monitoring is required. Once an area of concern
has been identified, substituting known good
Amplitude Phase Current Update Graph
Power PMW Amplitude Frequency components for suspect components is one
Export Graph Data way to positively identify weld equipment that
Draw from 0 ms to 750 ms
require repair or corrective action. Examples of
Redraw Graph Set Default useful diagnostic data include:
Graph Selection Phase X Value 0 Y Value 0 Update Value

Diagnostic of a good ultrasonic weld: Within 150 millisec after Weld graph data. This can help pinpoint
weld initiation, all parameters of the weld are up to specification differences between good parts and suspect
and continue to operate smoothly to weld conclusion. parts. Data displayed on a weld graph, as
seen in Fig. 3, include amplitude, current
Another remedy is to look at equipment that operates on a draw, power, frequency, and phase. Amplitude, phase, frequency,
higher frequency, perhaps 30 or 40 kHz, provided the tooling and current variations can indicate a problem with a power
required by the application is available for use at this frequency. supply or stack. A discrepancy in power draw could indicate a
Higher-frequency equipment produces lower amplitude output, process change (such as in weld pressure), part-geometry change
but compensates by resonating at a higher frequency. Thus, higher- (tolerances, especially in the joining area may have changed) or a
frequency welders are considered more stack-component problem (a horn or con-
gentle in the application of ultrasonic verter is beginning to fail).
energy to parts. Electronic assemblies,
Substituting known
especially those with delicate timers/oscil-
good components for Diagnostic scan of horn. This identifies
lators and other components located on
suspect components is whether the horn is drawing more power
printed circuit boards, have benefitted from
one way to positively (displayed as an increase in the wattage
this approach. In a similar way, parts that
identify weld equipment needed to run in air). Increased power draw
suffer from diaphragming or oil canning
that requires repair or could indicate that a crack is forming in the
due to excessive movement of one of the
corrective action. horn. Such cracks are sometimes internal and
mating parts, will often benefit from the therefore not always visible to the naked eye.
change to higher-frequency equipment.
Another potential factor is equipment malfunctions. These Random data. Data that appears chaotic when compared with
rarely occur without warning. One obvious example is a change known, good data may indicate a fault in the converter, the horn, or
or increase in the noise generated when a welder is operating. in the radio-frequency cable, as seen in Fig. 4.
Experienced operators and maintenance personnel are often
attuned to such subtle harmonic fluctuations and should always PROCESS PARAMETERS & MATERIALS
communicate about these changes to supervisors. Heeding a Careful control and documentation of process parameters is
squeaky wheel sooner rather than later may well permit iden- another area that cannot be overlooked. Medical and automotive
tification and resolution of a problem before production is component producers know this and follow strict procedures, often
adversely affected. mandated by regulating agencies such as the FDA, that result in a
Similarly, newer ultrasonic equipment allows users to perform high degree of success when using ultrasonic welding.
interactive diagnostic function checks, which if interpreted Unfortunately, processors of other products, such as toys or
properly and used in combination with other warning signs disposable products, often operate under much less stringent

58 Plastics Technology JUNE 2017 PTonline.com

 U LT R A S O N I C W EL D IN G

requirements and exercise much weaker process controls. In situ-
ations like these, it may be common for operators to continually
adjust settings in response to changing part or production condi-
tions. While this approach may result in satisfactory production,
any problems that occur can be harder to diagnose, especially
remotely, when process parameters vary frequently. For example,
was the latest parameter change prompted by an equipment
problem or a change in part composition or quality?
Typically, when an application such as this requires assis-
tance, an ultrasonic-welding applications engineer, after asking
a few basic questions surrounding the parts (material, joint
design, test requirements, and current machine setup) can direct
the customer to the proper solution. This approach is especially
useful if the troubleshooting can be accomplished directly at the
machine, using production parts. An overview of the trouble-
shooting/parameter adjustment process is shown in Fig 5.
Material-related issues are a frequent source of inconsis-
tencies or problems in production. As noted in the following
examples, even slight variations in materials can have dramatic
effects on weld or production quality:
FIG 4 DCX Test & Graph Screen of a Defective 20 kHz Horn
PS Test
Start Test Reset Overload
Status Result
Run OK-Stored
Seek Overload-Cleared
20450 120 90
20350 108 72
Power, % / Current, % /
Polymer changes. As prices fluctuate, it is common for proces-
sors to want to switch between similar polymers for economic
reasons. However, it is wise to consult with an ultrasonic-welding
applications expert before making any change.
One example of a common but potentially troublesome
change involves moving from an easy-to-weld amorphous
material such as ABS, to a much more difficult-to-weld semi-crys-
talline polymer, such as PP. ABS requires lower ultrasonic stack
output (30-70 microns at 20 kHz) for successful welding than does
PP (90-120 microns). If this change results in parts that dont have
the strength they had before, or take longer to weld, or if the welds
cause damage to sensitive assembly surfaces/components, the
issue could be a lack of ultrasonic stack output. An examination of
stack components, particularly the horn and booster, is warranted
to determine if improvements to either component will allow
the application to weld the new polymer efficiently and bring the
application back to a normal range of success.
High regrind content. Reground thermoplastics, though capable
of being melted and reformed numerous times, undergo some
degradation of their physical properties with
each subsequent melt. The cumulative effect of
too much reground material can lead to a failure
of parts to meet specifications. For this reason,
Frequency XXXX Branson recommends that no more than 10%
Memory XXXX regrind be used in parts that are to be ultrasoni-
Amplitude XXXX cally welded. In specific applications that
Power XXXX demand compliance with rigorous testing and
acceptance criteria, producers should strongly
consider periodic analysis of production mate-

rials to continually validate the quality of mate-

20250 96 54
rials going into finished parts.
Frequency, Hz

20150 84 36
Amplitude, %

Phase,

20050 72 18
19950 60 0 Filler content. Often, fillers are essential to
19850 48 -18
ensure part strength and durability. However,
19750 36 -36
19660 24 -54 different types and percentages of fillers in parts
19550 12 -72 can affect the success of plastics joining processes.
19450 0 -90 Branson recommends that filler content be kept at
0 75 150 225 300 375 450 525 600 675 750
Time, millisec less than 30%. Joining parts that contain a higher
Frequency Power Current Amplitude Phase percentage of filler, particularly long fibers, will
Amplitude Phase Current sometimes result in fillers accumulating at the
Update Graph
Power PMW Amplitude Frequency weld joint, which can reduce weld strength.
Export Graph Data
Another issue is abrasive fillers. Some
Draw from 0 ms to 280 ms
fillers that impart added strength or toughness,
Redraw Graph Set Default including calcium carbonate, silica, and talc,
Graph Selection Phase X Value 0 Y Value 0 Update Value can also be abrasive to the contact surfaces of
Note that while the frequency line at center remains relatively stable, tooling. Prolonged exposure of abrasive parts
reflecting the output of the power supply, the other parameters vary to tooling surfaces can cause wear that could
wildly, as the power supply attempts to compensate for a problem farther lead to cosmetic damage to parts and inad-
downstream in the weld stack. In this case, it is a defective horn.
equate energy transfer to part-joining surfaces.

@plastechmag Plastics Technology 59

 Troubleshooting

FIG 5
Overview of Troubleshooting/Parameter Adjustment Process Changing to titanium horns with wear-
After setup, conduct an initial weld. If resistant surfaces (carbide or titanium
Increase Pressure/
Downspeed, Energy, the weld fails inspection due to under nitride, for example) is recommended. For
Amplitude welding (e.g., incomplete weld or
inadequate weld depth), an increase
fixturing, steel or hardened stainless steel
Underwelded?
in pressure/down speed, energy, or is recommended.
Process
Initial Setup Inspect Part amplitude is probably needed. If the
Validation
part is over welded (e.g. excessive
Overwelded? PART CONFIGURATION &
weld depth) a decrease in the same
Decrease Pressure/ parameters, or a diagnostic display of TROUBLESHOOTING
Downspeed, Energy,
Amplitude the weld amplitude, may be needed Having everything else rightequipment,
Amplitude Profile? to identify the problem and bring the materials, and processwont mean much
weld into specification.
if the parts youre attempting to weld are
not properly designed. But rather than try
to review all of the details of a good part
design here, lets focus instead on some of
the basic causes of improper part design:

Lack of clearly defined project or applica-

tion goals. Many application projects expe-
The Pellbow rience difficulties when there is a moving
target for testing and acceptance. For
to optimize example, will the application require a drop
your conveying test? A pressure test? And if so, at what
system values? These values are essential to pro-
ceed effectively with the design of a sealing
joint. Generally, acceptance criteria need
early consideration and decision making if
a design is to proceed smoothly.

Lack of understanding about the best joint

types for particular applications. Sub-
optimal joint designs often occur when a
principal designer, who may only have a
marginal understanding of plastics joining
processes, moves a project forward only to
find that an incorrect decision has been
st
Reduced du Better systems for made and that part joint and weld charac-
s t re a m e r s teristics havent been properly considered.
+ No brilliant products
and higher margins.
Le s s m a in tenance Often, such findings are made only after
= n costs
significant investment (mold completion,

d p ro d u c t io part production, and initial weld trials) has

an already been made. Once again, key part- and
weld-related considerations (weld flash
control and sealing typehermetic, struc-
tural, or both) ought to be determined early in
the project. Collaboration with an ultrasonic-
Learn more: welding engineer in the initial stages of a
project can help to identify key part criteria,
www.pelletroncorp.com better educate designers, and help to mini-
mize or at least illuminate possible risks.

60 Plastics Technology JUNE 2017 PTonline.com

 U LT R A S O N I C W EL D IN G

Mold wear, usually caused by the use of pion well informed about the latest technology and ready to train and maintain tech-
abrasive polymers or fillers, can result over nology as needed in your facility. Design engineers, quality engineers, equipment main-
time in parts that are substantially and tenance personnel, and operations/production personnel can all reap benefits from
dimensionally different from earlier vali- time invested in training sessions.
dated parts. As a result, principal joining
features, such as energy directors or shear
interference joints, are no longer within ABOUT THE AUTHOR: David Dahlstrand is Emerson's sr. regional technical coordinator/textile devel-
opment engineer for Branson Ultrasonics, Danbury, Conn. He has applications knowledge
specifications. Part profiles may no longer
and tooling design for ultrasonic, vibration, orbital, thermal, and laser joining technologies used
fit properly into the tooling set. Weld in the assembly of rigid thermoplastics, synthetic textiles, and films. Contact: (770) 962-2111, ext 17;
results may become more and more incon- david.dahlstrand@emerson.com; emerson.com.
sistent. The remedies for this problem
include reworking the existing mold or
producing a new mold.
Ultimately, issues with ultrasoni-
Complete Blown Film

X-DIE
cally welded parts can crop up from many

THE
sources. Calling your local ultrasonic-
welding equipment representative as
soon as an issue is suspected could allow
diagnosis and remedial tips, often accom- & High Performance

V-RING
plished via phone calls or e-mails that can
help you identify, minimize, or resolve
potential production problems. To reduce
the need for troubleshooting, follow these
best practices:

Collaborate early in your projects

design (or redesign if significant material,
form, or functional changes are contem-
plated) with your ultrasonic-welding
equipment suppliers application-engi-
neering experts.

Always keep a reserve of spare, produc-

tion-quality components available, par-
ticularly for critical applications where
production interruptions would cause
significant operational or financial con-
cerns. Spare production parts are a vital aid
to troubleshooting joining problems and,
in a supply pinch, can keep production
rolling with a minimum of downtime.

Take advantage of training opportuni-

ties that enable you to master the plastics
joining technology you are using.
Branson, for one, offers seminars at a THE BLOWN FILM EXPERT S
variety of corporate locations and cus-
tomer sites, providing the practical ALPINE AMERICAN
training and technical assistance needed
www.halpine.com T: (508) 655-1123 F: (508) 655-9337
to keep your ultrasonic process cham-

@plastechmag Plastics Technology 61

 Keeping Up
With Technology

New Range of
INJECTION MOLDING

All-Electric Machines
A new generation of small to mid-size IntElect all-electric injection machines
was presented to the public at an in-house fair last month at the German
headquarters of Sumitomo (SHI) Demag Plastics Machinery. The firm
previewed the first model, of 50 metric tons, in the series at the K 2016 show
in Dusseldorf last October. Sumitomo Demag (U.S. office in Strongsville, Ohio)
now has added units of 75, 100, 130, and 180 m.t. The largest unit closes the
gap between large and mid-size IntElect machines. The new units are said to
significantly reduce the price difference between hydraulic and all-electric
machines, with an objective to enable a ROI in less than one year while
providing the complete range of options.
A key feature of these presses is a brand-new generation of highly
dynamic servo drive motors, developed in-house, which boast extended
memory for brake energy and 20% overall energy savings versus comparable
all-electric machines. In addition, the control cabinet is integrated into the
machine base, freeing up space for downstream equipment and allowing
easy access to the nozzle area and clamp unit. The new design has signifi-
cantly smaller footprint than its predecessorseven the smallest (50-m.t.)
model is 1.6 ft shorter than earlier models. On average, the setup area is 10%
less than that of comparable all-electrics, the company says.
Other features include sensitive mold protection and a linear guide system
said to provide maximum platen parallelism right down to symmetric application
of nozzle force. Redesigned platens are up to 30% stiffer than before. The NC5
controller comes with a new capacitive glass color touchscreen with the improved
brilliance and sharpness of a smartphone. In addition to the standard version,
the electric ejector package is available with additional force and/or speed.
440-876-8960 sumitomo-shi-demag.us

COMPOUNDING
High-Throughput
Polyolefin Pellet Dryer
Gala Industries, Eagle Rock, Va., has engi-
neered a centrifugal dryer with the highest
known capacity for drying polyolefins. The
latest version of the Model 100 dryer has
resulted in an increased drying capacity
of 150 tons/hr, processing 0.35 MI HDPE
with lentoid pellet geometry and moisture
below 500 ppm.
540-884-2589 gala-industries.com

62 Plastics Technology JUNE 2017 PTonline.com

 WEBINAR a feature of PTonline.com

Tuesday, June 27th WATCH ON-DEMAND NOW AT:

2:00 PM EST short.ptonline.com/Autodsk627

Reducing Mold Cycle Time With Moldflow PRESENTER

Joe Huegel
Reducing cycle time can have a significant impact on the profitability of a Technical Specialist
project and lower the piece part cost, however, there is a trade off between MoldFlow SME
cycle time reduction and increased mold costs. Autodesk Moldflow allows
you to study different methods of mold cooling, mold design, and part
quality to achieve an optimal mold design and injection molding process.

PRIMARY TOPICS: Joe Huegel has a Plastics Engineering

Using simulation to efficiently optimize part Degree from Penn State University
design and mold cooling and has spent most of his profes-
sional career focusing on injection
Analyze multiple effective heat extraction strate-
molding simulation using Moldflow.
gies before cutting steel
He is now a subject matter expert on
Evaluate alternative technologies, such as the Simulation team at Autodesk. He
conformal cooling, before investment lives in Erie, Pennsylvania.
 Keeping Up With Technolog y

COMPOUNDING EXTRUSION

New Screw Elements Fluid-Coating Die Boosts Accuracy, Adjustability

Permit Major Output Gains
Involute screw and kneading elements
with a new and patented cross-section
design have been introduced by
Coperion (U.S. office in Sewell, N.J.) to
significantly increase throughput rates
of its twin-screw ZSK compounding
extruders. These screw elements are
suited to highly filled recipes, such as
70-85% CaCO3 or TiO2, and 20-50% talc,
in PP or PE. Besides higher throughput
rates, these involute screw elements
ensure higher loading of filler, better
dispersion and homogenization, and
lower energy consumption.
Coperions tests reportedly showed
remarkable throughput increases.
For example, when processing PP
with 70% CaCO3 on a ZSK 58 Mc18, the
new screw elements achieved a 64%
increase from 1212 to 1984 lb/hr. When
processing PE with 80% CaCO3 on a
ZSK 92 Mc18, throughput increased 36%
from 4850 to 6614 lb/hr.
856-589-0500 coperion.com
A new, patent-pending design for dual- or
multi-layer versions of Premier and Ultra-
coat fluid coating dies from Nordson Corp.,
Chippewa Falls, Wis., reportedly makes it
easier to achieve parallel alignment of the
lip faces, which is critical for maintaining
uniform, defect-free coating and preventing
impingement of the lips against the roll.
In the standard
design for Premier
fixed-lip and Ultracoat
adjustable-lip slot dies,
operators make changes
to the die gapand
thus the wet film thick-
ness of the coatingby
inserting thin metal
strips or shims between the die bodies, then
using more shims at the rear of the die to
eliminate the resulting offset of the lip faces
and to ensure that they are once again in
the same plane. Until now, use of these
offset shims has been more complicated
in multi-layer dies, requiring calculations to
determine which shim thickness most closely
achieves lip-face parallelism. The new
design makes such calculation unnecessary,
ensures a more precise lip-face alignment,
and prevents human error.
Nordson reconfigured the die bodies of
multi-layer Premier and Ultracoat systems
so that the offset blocks, where the offset
shims are inserted, are now in the same
plane as the lip face. As in
the past, body shims and
offset shims are available
in thicknesses ranging
up to 0.060 in. With the
new design, the accuracy
of the offset adjustment
is independent of body
shim thickness.
Replacing multiple coating passes with
a single product run means an increase in
output and a reduction in machine use,
energy consumption, and scrap. Additional
cost savings result from control over the
thickness of each layer, preventing over-use
of expensive high-functionality fluids.
715-726-1201 nordson.com

TEAM UP.
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64 Plastics Technology JUNE 2017 PTonline.com

 SAVE THE DATE!
October 18-20, 2017
Sheraton-Le Meridien Charlotte / Charlotte, NC

The Extrusion 2017 conference is the only

conference of its kind devoted to all aspects
of extrusion processing.
General sessions at Extrusion 2017 will focus on important issues to all
extrusion processors, including the latest innovations and best practices
in everything from resin conveying, drying, blending, purging, direct
extrusion, melt filtration, foaming, screw design, and more.

Breakout sessions are devoted to specific types of extrusion:

Compounding, Sheet, Film, and Pipe/Profile/Tubing.

If its part of the extrusion process, youll hear

about it at Extrusion 2017! Make plans now
to be there!

For more information, please visit:

ExtrusionConference.com

PRESENTED BY:

Inset photo courtesy of Windmoeller & Hoelscher Corp.

THANKS TO OUR SPONSORS:

Platinum Sponsors:

Gold Sponsors: Silver Sponsors:

AEC Innovative Recycling Solutions The Advanced Team, Inc. PSI - Polymer Systems, Inc.
C.W. Brabender Instruments, Inc. Nordson Corporation D.R. Joseph Inc. Tria America
CDS Custom Downstream Systems Novatec, Inc. Extrusion Control & Supply Trendelkamp LP
Conair Process Control Corporation
Davis-Standard Una-Dyn, a Piovan Company
Gala Industries, Inc. Windmoeller & Hoelscher Corp.
 The Automotive Division of the Society of Plastics Engineers
(SPE) is announcing a Call for Nominations for its 47th-annual

Call for Nominations Automotive Innovation Awards Gala, the oldest and largest
recognition event in the automotive and plastics industries. This
years Awards Gala will be held Wednesday, November 8, 2017 at
Most Innovative Use the Burton Manor in Livonia, Mich. Winning part nominations (due by
September, 13, 2017) in 9 different categories, and the teams that
of Plastics Awards developed them, will be honored with a Most Innovative Use of Plastics
award. A Grand Award will be presented to the winning team from all
category award winners. An application that has been in continuous use
Go to www.speautomotive.com to submit for 15 years or more, and has made a significant and lasting contribution
to the application of plastics in automotive vehicles will be honored with a
nominations and get more information.
Hall of Fame award.
For more information on the Society of Plastics Innovative Part Competition Categories:
Engineers, visit www.4spe.org. Aftermarket Hall of Fame
Body Exterior Materials

Sponsorship Body Interior

Chassis/Hardware
Process, Assembly &
Enabling Technologies
Opportunities Electrical Systems
Environmental
Powertrain
Safety
This annual event typically draws over 700 OEM
engineers, automotive and plastics industry
executives, and media. A variety of sponsorship
packages - including tables at the banquet, networking
receptions, advertising in the program book,
signage at the event and more are available.
Contact Teri Chouinard of Intuit Group at
teri@intuitgroup.com.

2016 Sponsors

VIP Reception & Afterglow Sponsor Main Reception Sponsor Wine & Flowers Sponsor Student Program Sponsor

Gold Sponsors
Silver Sponsor
Advertising Sponsors

Bronze Sponsors

TOOLING
Tunnel-Gate
Inserts for Large
Contour Steps
Tunnel-gate inserts with so-called
banana or cashew geometries
are a practical solution for hidden
gate marks. They allow filling the
part from the bottom, and the
clearly defined tear edge provides
for an exact tear of the sprue.
Meusburger of Austria (U.S. office
in Charlotte, N.C.) has expanded its
range with two new versions espe-
cially for large contour steps.
With new E 1693 tunnel-gate
insert for high-level contours, the
gating point can be behind a step
or fillet or above the split-line face.
New E 1694 tunnel-gate insert for
low-level contours enables gating
below the split-line face.
704-526-0330 meusburger.com
@plastechmag
TOOLING
Easy Lifter Adjustment
In Ejector Plates
A new component makes it easier to fine-
tune the installation of lifters into ejector
plates. The RF lifter adjustment from
CUMSA (U.S. office in Troy, Mich.) allows
for small adjustmentsapproximately 2
mmto the lifter rod height. These can
be used to correct slight inaccuracies in
the tool and its components while also
enabling molders to fine-tune the lifter
head with the ejection plates mounted.
CUMSA notes that the RF lifter is
a good complement for its Double
Rack (DR) and Cooled Rack (KR) lifters
because it allows for
accurate assembly
and disassembly while
leaving the ejector
plates in place.
248-850-8385
cumsa.com
NE W PRODUC T S FOR PL A S T IC S PROCE S SING
HEATING/COOLING
Lower Temperatures
for Portable Chillers
Mokon, Buffalo, N.Y., has expanded its
Iceman SC Series of portable chillers with
the new ASL and WSL lines. They offer a
fluid temperature range of 5 F to 30 F
(-15 C to -1 C) and
capacities of 1.5
to 7.5 tons. The
existing Iceman SC
Series line offers
0.5- to 40-ton
chillers with a
temperature range
of 20-65 F (-7 to 18 C).
The ASL and WSL lines offer air- or
water-cooled condensing, with a scroll
compressor and brazed-plate evaporator.
They feature a stainless-steel centrifugal
pump, insulated nonferrous plumbing and
components, and a heavy-duty insulated
plastic tank with sight glass.
716-876-9951 mokon.com
Plastics Technology 67
 Keeping Up With Technolog y

HEATING/COOLING Mold TCU Gets Smaller, Lighter

Matsuis new MC5 mold temperature-
control units are 27% lighter and have a
23% smaller footprint than previous units.
They are available in 12 different models,
with the MC5-G1 series hot-water control-
lers sold in 25-, 55-, and 88-liter sizes
and in low-temperature (up to 203 F) and
high-temperature (up to 248 F) versions.
Matsui America, Hanover Park, Ill., says
the MC5s achieve target temperature in
less time than previous models, thanks to
a more powerful pump and more respon-
sive thermocouple. Matsui also says
the series achieves target temperatures
within 1 of setpoint and then samples
the temperature four times/sec.
The control panel features a touchpad
and large LCD character display thats
visible even in bright light. The control
can store up to 64 temperature settings,
and it detects heating and cooling errors.
847-290-9680 matsuiamerica.com

DRYING New Mid-Size Vacuum Dryer

The new VBD300 vacuum dryer from Maguire
Products, Aston, Pa., has a rated capacity of up to
300 lb/hr, double the rated capacity of the previous
model VBD150 (though the latter has been shown
in the field to actually be capable of over 200 lb/hr).
The new unit is suited to general-purpose injection
molding and low- to mid-throughput extrusion jobs.
Maguire says its vacuum dryers consume 60%
less energy than desiccant systems, dry in one-
sixth the time, reduce the resins heat history, and
provide greater process control than desiccant
dryers. The VBD reportedly can provide dried
polymer for production in 35 min after a cold start.
The VBDs load cells, which were added in 2015,
monitor material weight at two different points,
giving control over resin level in the dryer and
providing documentation of material consumption.
Maguire says practically all resins can be
processed via vacuum drying. The company is
currently working on the VBD 600, which would
have a throughput capacity of 600 lb/hr. The
largest model in the line, the VBD 1000 for up to
1000 lb/hr, launched in 2013.
888-459-2412 maguire.com

The first name in materials testing

MOLD MANAGEMENT SYSTEMS

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ASTM, ISO and industry specific standards

www.tiniusolsen.com

716.822.2804 www.PTM.Rapistak.com
sales@tiniusolsen.com 215 675 7100

68 Plastics Technology JUNE 2017 PTonline.com

 WEBINAR
Wednesday, June 7th
2:00 PM EST
Micro Molding With
An Easy, Affordable,
And Established Solution
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an established micro molder
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Low energy cost due to heating 75% less steel
Small footprint on the shop floor
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Register for this webinar at:
short.ptonline.com/Alba67
PRESENTER
Bill Hartwick
Injection Machine Installation
& Repair Specialist
With over thirty years of experience in
injection-machinery repair, Bill has
extensive knowledge of troubleshooting & repair techniques.
Bills roots with companies like Engel (17 years), Magna
(5 years), & Negri Bossi (2 years) have afforded him the
opportunity to be tested by fire to find fast, cost effective
solutions for clients.
For years Bill has worked with Babyplast machines repairing &
installing dozens of units throughout the U.S. He has
extensive knowledge of how to efficiently integrate a micro
molder into your existing process & is eager to share this
cost-effective & powerful technology with molders as well as
anyone involved in part design or process optimization.
a feature of PTonline.com
Monday, June 19th
2:00 PM EST
How Collaborative Robots
Can Optimize Your Injection
Molding Production
This webinar details how collaborative
robots (cobots) can automate a wide range of
injection molding tasks. Cobots deliver a fast
ROI & an increase in quality & production
while addressing staff retention & high mix/
low volume challenges.
A presentation by Joe McGillivray will follow
regarding how the UR robots installed at his
facility quadrupled production capacity in
those applications.
PRIMARY TOPICS:
> Tasks to efficiently automate with cobots
> How cobots speed up installation
> How to interface collaborative robots with
other robots/machinery
> How cobots improve the work environment
Register for this webinar at:
short.ptonline.com/UR619
Douglas Peterson
General Manager of
Americas Region
Douglas Peterson has a proven track record of
more than 25 years in industrial automation
& electronics manufacturing. He joined the cobot market
leader in 2016, as a former CEO with Tennessee Industrial
Electronics, a leader in refurbished FANUC CNC & robot parts.
Joe McGillivray
CEO of Dynamic Group, Inc.
Joe McGillivray is one of three second-
generation owner-operators honored to help
celebrate the companys 40th anniversary. The
provider of validated injection molding systems for small,
precise, & complex products leverages cobots to dramatically
reduce customers time-to-market & maintain award-
winning quality for the medical, dental, & other markets.
 Keeping Up With Technolog y

MATERIALS

Granulator
The Professional Manufacturer of
Granulators, Shredders, and Pulverizers. TPE for Drinking Water
Applications
New TPE compounds are available in hard-
nesses from 50 to 90 Shore A, in natural
and black as well as custom colors, from
Hexpol TPE, Sandusky, Ohio. Dryflex DW
compounds are designed for applications
that come into contact directly or indirectly
with drinking water, including domestic and
commercial applications such as plumbing
seals, pipe fittings, and shower heads.
Designed for injection molding or extrusion,
they are said to bond to PP and PE in multi-
component applications.
These compounds have passed German
drinking-water regulations for cold and
AVIAN (USA) MACHINERY, LLC. warm water (73.4-140 F; 23-60 C). They
1901 Powis Court, West Chicago, IL. 60185 reportedly boast no microbial growth
TEL: 630.687.9876 FAX: 866.755.9258 without the use of biocides. The raw mate-
WEB: www.aviangranulator.us E-MAIL: sales@avianusa.com
rials used to produce these compounds are
compliant with EU food-contact regulation
No. 10/2011.
800-837-4921 hexpoltpe.com

COMPONENTS
FOR PLASTICS
Laser-Markable Compounds
Allow High Contrast
A new series of thermoplastic compounds

Plastics Conveying from RTP Company, Winona, Minn., is

formulated to allow for high-contrast

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Lorenz Conveying solutions are built to be compounded to optimize laser marks,
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building the industrys best conveying and dyes, thus saving on processing costs.
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70 Plastics Technology JUNE 2017 PTonline.com

 YOUR BUSINE S S
Resin Pricing Analysis

Commodity Resin Prices Falling

Lower feedstock costs, improved supplies,
lower export prices are among key factors .

Overall, the trajectory of prices for commodity resins appeared to be second increment to May. So far this year, PE Polyethylene
downward last month. Prices of three of the five resinsPP, PS and prices are up 8/lb due to tight supplies. Price Trends
PET, dropped. While prices of PVC and PE Mike Burns, RTis v.p. of client services
By Lilli Manolis Sherman LDPE
Senior Editor held even in April, the former was likely for PE, said implementation of the May
APR MAY
to decline before the end of May and the increase was unlikely, as inventories have
latter had potential for a decrease this month after remaining flat in been improving. He expected PE prices in
May. Key drivers included lower feedstock costs, lower export prices May to remain flat with possible downward
and, very crucially, improved feedstock and resin supplies. pressure this month. But he cautioned, If oil LLDPE Butene
That was the outlook last month from purchasing consultants remains at $50/bbl, we may expect a return APR MAY
at Resin Technology, Inc. (RTi), Fort Worth, Texas (rtiglobal.com), of the March 3/lb increase. His message
CEO Michael Greenberg of the Plastics Exchange in Chicago was that the slow but steady recovery of
(theplasticsexchange.com), and Houston-based PetroChemWire inventories will keep prices less volatile
HDPE
(PCW; petrochemwire.com). and perhaps lower. He also cited new PE
Injection
capacity scheduled to be brought on stream
APR MAY
at summers end by both Dow and CPChem.
Market Prices Effective Mid-May 2017 The Plastics Exchanges Greenberg
Resin Grade /lb supported this view: Many market partici-
POLYETHYLENE (railcar) pants believe that peak pricing is already HDPE
LDPE, LINER . . . . . . . . . . . . . . . . . . . . . . . . . . . 93-95 in place. Market momentum has turned Blow Molding
LLDPE BUTENE, FILM . . . . . . . . . . . . . . . . . . . . 79-81 towards bearish as several of the new or APR MAY
NYMEX FINANCIAL FUTURES . . . . . . . . . . . . 50 expanded petrochemical complexes get
JUNE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
HDPE, G-P INJECTION . . . . . . . . . . . . . . . . . . . . 95-97
closer to completion.
HDPE, BLOW MOLDING . . . . . . . . . . . . . . . . . . . 85-87 PCW reported that PE spot prices moved
HDPE HMW
NYMEX FINANCIAL FUTURES . . . . . . . . . . . . 46 .25 lower in export and wide-spec channels,
JUNE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 .50 APR MAY
while domestic prime price levels appeared
HDPE, HMW FILM . . . . . . . . . . . . . . . . . . . . . . . 98-101
to hold firm. Availability continued to
POLYPROPYLENE (railcar) improve, led by HDPE blow molding and
G-P HOMOPOLYMER, INJECTION . . . . . . . . . . . 74 .5-76 .5
film grades. May was expected to be a turning point for HDPE
NYMEX FINANCIAL FUTURES . . . . . . . . . . . . 48 .00
JUNE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 .25 injection molding, LLDPE, and LDPE supply balance.
IMPACT COPOLYMER . . . . . . . . . . . . . . . . . . . . . 76 .5-78 .5
POLYSTYRENE (railcar)
G-P CRYSTAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 102-104 PP PRICES DROP
HIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108-110 Polypropylene prices dropped 6/lb in April, in step with March
PVC RESIN (railcar) propylene monomer contracts, which settled at 46/lb. Based on
G-P HOMOPOLYMER . . . . . . . . . . . . . . . . . . . . . 83-85 declining spot monomer prices in early May, April monomer
PIPE GRADE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82-84
contracts had the potential to drop another 6/lb, with PP fol-
PET (truckload) lowing penny for penny, according to Greenberg and Scott Newell,
U .S . BOTTLE-GRADE . . . . . . . . . . . . . . . . . . . . . 56 .5
RTis v.p. of PP markets. Newell discounted reports that suppliers
might be aiming for PP margin expansion, which he said the
PE PRICES FLAT FOR NOW market would not support. Moreover, he sees potential for further
Polyethylene prices were flat in April, after moving up 3/lb in March price decline this month. PP prices are going to look a lot better
as suppliers split their 6/lb increase into two steps, but delayed the for processors in the second half of 2017, as monomer supplies

@plastechmag Plastics Technology 71

 YOUR BUSINE S S
Resin Pricing Analysis
continue to improve and Enterprise Polypropylene
brings on its propylene plant in October. Price Trends
PCW reported lower PP spot prices
Homopolymer
at the end of April and signs that
offgrade availability had tapered off and APR MAY
that spot prime availability appeared to
be concentrated in mid-range homo- 6/lb
polymer grades. Greenberg observed
Copolymer
that the markets high volatility has
created risk, which generally trans- APR MAY
lates into lower-volume transactions.
Both he and RTis Newell reported that 6/lb
there were several well-discounted
spot opportunities, yet processor demand appeared to remain
cautious. Said Greenberg, The first quarters extreme cost- can expect to see lower vinyl chloride monomer prices from now
push price increases, which totaled just over 20/lb, crimped
resin demand as processors were concerned about their ability
to pass along higher resin costs and their ultimate profitability.
A rebound in PP demand was expected last month, after a
very soft April, as many buyers delayed purchases in anticipa-
tion of lower prices, explained Newell. The question is, how
strong will that rebound be and how much of its will be real
demand vs. restocking? He pegged PP plant operating rates
through the first quarter at around 93%, up 3% from the 2016
average. Inventories grew in March and April to 150 million lb.
Theres been some capacity debottlenecking that has given some
breathing room to the market.
PS PRICES DROP, MORE TO COME
Polystyrene prices dropped 5/lb in April, after spiking a total
of 19/lb in the first quarter. At least one supplier announced a
2/lb decrease for May. Both PCW and Mark Kallman, RTis v.p.
of client services for engineering resins,
PS, and PVC, expected prices to go lower. Polystyrene
Kallman forecasted at least a 2/lb drop Price Trends
in May and again in June. GPPS
PCW reported that PS spot prices
APR MAY
were falling and that availability
appeared to be adequate to meet fore-
5/lb
casted demand, in addition to a reported
surplus of off-grade crystal PS. May
HIPS
benzene contracts dropped 1-3/gal from
APR MAY
April, to $2.69-2.70/gal, and forward bids
were nearly below $2.60/gal.
Suppliers would need to give up some 5/lb
of the hefty profit margin incurred during
the first quarter in order to avoid demand destruction. Global PS
prices have been dropping. Meanwhile, demand for EPS home insu-
lation was said to be at a 10-yr high for the month of March alone.
72 Plastics Technology JUNE 2017
PVC PRICES FLAT-TO-DOWN PVC Price
PVC prices moved up 2/lb in March, rolled Trends
over in April, and May saw potential for a
Pipe
reduction. RTis Kallman ventured that PVC
prices would drop 1-3 in the May-June APR MAY
time frame.
Driving the downward movement are 2/lb
lower feedstock costs and export prices.
Most notably, late-settling March ethylene Gen. Purpose
contracts dropped by 5.75/lb. According APR MAY
to Kallman, April ethylene contracts had
the potential to move up 1-2/lb due to
2/lb
some unplanned production disruptions.
However, he noted that ethylene supplies are improving and we
on. (Ditto for styrene monomer.) Meanwhile, lackluster PVC export
demand led suppliers to drop prices by 4/lb in April. Kallman
expected an uptick in PVC demand as seasonal construction
markets got underway.
PET PRICES DOWN
Domestic bottle-grade prime PET prices in April averaged 56.5/lb,
down 3.5/lb from March, based on PCWs Daily PET Report. That
price represents PET business on a delivered Chicago basis. The
price on May 2 stood at 56.5/lb.
Meanwhile, prices of imported prime PET with an IV of 78 dl/g
or higher also fell in April, averaging 56/lb, down 1.6 from March.
This represented PET resin on a delivered duty-paid U.S. port basis.
The price for imported PET on May 2
stood at 56/lb. Prices fell after an average PET Price Trends
decline in Aprils feedstock costs to
Bottle Grade
52.86/lb, 2.67/lb lower than in March.
APR MAY
PCW noted that the worlds largest
PET plant, under construction by M&G ?
in Corpus Christi, Texas, is reportedly 3.5/lb
facing $100 million in legal claims filed
against it from dozens of companies that have worked on this
Project Jumbo. M&G has acknowledged it was continuing to sort
through the various claims of subcontractors, but that this would
not affect the midyear start-up schedule. Still, market sources close
to the project have been told to expect a startup no sooner than the
fourth quarter. DAK Americas has supply contract rights for about
1.1 billion lb of Jumbos planned capacity, reported to be between
2.4 and 2.8 billion lb.
QUESTIONS ABOUT MATERIALS?
Visit the Materials Zone and the Materials Database.
PTonline.com
 YOUR BUSINE S S
G ARDNER BUSINESS INDE X: PL A S TIC S

Aprils Index: 52
Custom processors and medical market grow for fourth straight month.

With a reading of 52, the Gardner Plastics Business Index grew for first time since November 2016. And automotive contracted for the
the fourth month in a row, although the rate of growth decelerated first time since September 2016.
to its slowest rate in 2017. (Index values The North Central-East region grew at the fastest rate in April.
above 50 indicate growth; values below The region grew for the fifth month in a row and the last four
50 indicate contraction.) The start of months had very strong growth. It was followed closely by the
2017 was still the best period of perfor- South Central region. The North Central-West, Southeast, and
mance for the industry since October Northeast had more moderate growth. The West had rapidly accel-
2014 to January 2015. The index for erating contraction in the last two months. Its index in April was
custom processors, in particular, grew the lowest since the survey began in December 2011.
for the fourth straight month. Plants with more than 250 employees contracted for the first
Steve Kline Jr.
New orders and production both time in 2017. Facilities with 100-249 employees have grown every
Dir. Market Intelligence grew for the fourth month in a row. month but two since March 2016. Companies with 50-99 employees
However, new order growth deceler- grew for the fourth month in a row. Processors with 20-49
ated for the second month, while production decelerated for employees grew for the seventh time in eight months. Processors
the third straight month. The backlog index contracted for the with fewer than 20 employees expanded for the fourth time in five
second time in three months. However, the index still was signifi- months, although the rate of growth has been minimal.
cantly above its level in 2015 and 2016.
Therefore, the trend in the backlog
index indicated that capacity utilization Plastics Industry Business Index
should increase in 2017. Employment
70
increased for the fourth straight
month. Exports have contracted at an
Values above 50 indicate growth
accelerating rate since October 2016.
Supplier deliveries lengthened at their 60
fastest rate since February 2012.
April
Material prices continued to increase,
2017
but the rate of increase decelerated Index
slightly from last month. However, the 50
52
index still was at its third-highest level
since the survey began in December
2011. Prices received increased for the 40
seventh time in eight months. The
index has steadily improved since
June 2015. Future business expecta- Values below 50 indicate contraction
30
tions remained strong, as the index
improved somewhat from last month
JAN 14

JUL 14
JAN 12

JUL 12

JAN 17
JAN 15

JUL 15

JAN 16

JUL 16
JAN 13

JUL 13

Petrochemical processors
(compounders and materials manufac-
turers) represented the fastest-growing
industry, showing strong growth for the fourth straight month.
Electronics, computers, and telecommunications have grown in
seven of the last eight months. Medical grew for the fourth straight
month. Plastic/rubber products manufacturers contracted for the
ABOUT THE AUTHOR: Steven Kline Jr. is part of the fourth-generation
ownership team of Cincinnati-based Gardner Business Media, which is
the publisher of Plastics Technology. He is currently the companys director
of market intelligence. Contact: (513) 527-8800;
email: skline2@gardnerweb.com blog: gardnerweb.com/economics/blog

73 Plastics Technology JUNE 2017 PTonline.com

 YOUR BUSINE S S
MARKET WATCH

Construction Spending Slowing,

But Outlook Remains Strong
The short-term trend is neutral to slightly negative, but leading indicators
are starting to move in a positive direction.
In March, total construction spending was growing at its slowest Housing Permits. March saw 111,900 housing permits filed, the
rate since September 2016 and second slowest rate since December highest level since June 2016 and the second-highest level since
2011. The 10-yr U.S. Treasury bond interest June 2015. Compared with a year ago, housing permits increased
Steve Kline Jr.
Dir. Market Intelligence rate is neutral for future construction 14.5%. This was the third straight month of growth and the seventh
spending, while housing permits are a in the last eight months. Also, permits grew faster than 14% in two
slightly positive leading indicator. of the last three months. The annual rate of growth accelerated to
1%, which was the fastest rate since November 2016.
Real 10-Yr Treasury Rate. The real (inflation-adjusted) 10-yr The change in the real 10-yr Treasury rate is a likely cause for
Treasury rate was 0.85% in March, which was the third straight the September increase in housing permits. Changes in the interest
month of decreases. It was the lowest rate since October. The rate generally lead changes in housing permits by about 12 months.
nominal rate was 2.48%, which was relatively unchanged for the
fourth month in a row. But the rate of inflation was above 2% for Total Construction Spending. The real value of construction put in
the fourth consecutive month. Increasing inflation is depressing place in March was $92.954 million. Compared with one year ago, this
the real 10-yr Treasury rate, even though the nominal rate has was an increase of just 0.9%. The month-over-month rate of change
remained fairly steady (the real rate is the nominal rate minus has grown at a decelerating rate since November 2016. The annual rate
inflation). The year-over-year change in the real rate decreased to of change peaked in March 2016 and has grown at a decelerating rate
-63 basis points (a basis point is 1/100th of a percent). That ended since then. Annual construction spending is growing at a rate of 3.3%,
four straight months of increase. The year-over-year change in the which is the slowest since August 2012.
real rate has not moved much the last four months. On the other hand, residential construction spending has grown
at an accelerating rate in the last two
months. Month-over-month growth
Real 10-Year Treasury Rate Leads Real Construction Spending
accelerated to 5.5% in March. The
-800 20 annual rate of growth, now 4.6%, has
-640 16 decelerated for 15 months in a row and
was the slowest since October 2012.
-480 12
Yr/Yr Change in Basis Points

Real Construction Spending,

Short term, the trend in construc-

Real 10-Yr Treasury Rate,

12-Mo. Rate of Change

-320 8 tion spending is neutral to slightly

negative for products, parts, and
-160 4
production of equipment used in the
0 0 industry. However, the change in the
160 -4 real 10-yr Treasury rate and the change
in housing permits are starting to move
320 -8
in a positive direction.
480 -12

640 -16 ABOUT THE AUTHOR: Steven Kline Jr. is part

of the fourth-generation ownership team of
800 -20 Cincinnati-based Gardner Business Media,
Jan 97

Jan 07

Jan 17
Jan 99

Jan 09
Jan 01

Jan 05

Jan 11

Jan 15
Jan 03

Jan 13

which is the publisher of Plastics Technology.

He is currently the companys director of
market intelligence. Contact: (513) 527-8800
Real 10-Year Treasury Rate Real Construction Spending email: skline2@gardnerweb.com
blog: gardnerweb.com/economics/blog

74 Plastics Technology JUNE 2017 PTonline.com

 MARKETPL ACE

This is Plastics Technologys online listing for plastic processing equipment

builders, material suppliers, auxillary manufacturers and more.

WWW.NOVATEC.COM WWW.DAVIS-STANDARD.COM

Davis-Standard is the global leader in the design and manufacturing

Worlds largest selection of dryer technologies and blenders of high-performance plastics and rubber processing equipment,
with unmatched system design and control capabilities. extrusion technology and converting systems. We are committed to
1-800-BESTDRY (1-800-237-8379) cost effective, durable engineering equipment, and we offer a high
return on investment.

WWW.YIZUMI-HPM.COM WWW.ENGELGLOBAL.COM
Visit our website for informa-
tion on ENGELs machine and
automation concepts, innova-
$0HPEHURIWKH<,=80,*URXS tive technologies and applica-
Fast, precise and energy-efficient hybrid injection molding machin- tions, and extensive customer support. With global service, pro-
ery ranging from 65-3500 U.S. tons, powered by the most trusted duction and sales resources, ENGEL is a partner you can count on
name in the industry. Our HST2 Series features proven toggle for long-term quality and technology solutions that support
performance with servo technology and HSII Series represents our innovative products and effective production.
third generation of reliable hydro-mechanical technology.

WWW.CVI.CANON.COM/MFG WWW.HAMMERTEK.COM/PTE
The HammerTek
Smart Elbow - Elimi-
nate wear, stream-
ers, angel-hair,
snakeskins, etc.
From concept to market, Canon Virginia Inc. is uniquely qualified to Trial and warranty
be your outsourced manufacturing partner in a range of industries, programs available.
including medical. Learn more about our full range of services at
cvi.canon.com/mfg.

WWW.MAGUIRE.COM WWW.RAPISTAK.COM
Managing molds
and dies can be
time consuming
The perfect blend of simplicity and control. and difficult, thats
where our Mold Management Systems help you manage your
inventory, become better organized, protect your investment and
Over 100 pages of easy browsing packed with useful information create a safer working environment. For more information email us
on Maguire Blenders, Loaders, Granulators, Feeders, and Liquid at ptsales@rapistak.com.
Color Pumps.

WWW.ADVANTAGEENGINEERING.COM WWW.PARATHERM.COM

Manufacturer of high quality water and oil temperature controllers, Offering thermal fluids for precise, uniform temperature control,
portable chillers, central chilling systems and cooling tower systems. technical tips and online system design assistance.

@plastechmag Plastics Technology 75

 MARKETPL ACE
You can get copies of literature from
suppliers listed on these pages by
sending an e-mail to the address
provided at the end of each writeup.
Or, where provided, contact the
company by phone or fax.
DRY-CONVEY-BLEND-EXTRUSION
Novatec is one of the largest
U.S. based manufacturers of
resin drying and conveying
equipment for the plastics
industry. Together, with
Maguire Products, we
offer the largest line of
manufactured resin
handling equipment in
North America.
Product Overview:
www.novatec.com/about
Baltimore, MD sales@novatec.com
MECHATRON FEEDERS
The versatile
MECHATRON feeder
handles a wide variety of
materials. Quick and easy
disassembly from the
non-process side of the
feeder simplifies cleaning
and maintenance. Feed
rates from .002 to 1,100
cubic feet per hour.
Whitewater, WI mktg@schenckprocess.com
AQUATHERM TEMPERATURE CONTROLLERS
RQE Series Temperature
Controllers are built for
dependable operation using
quality components such as
high flow pumps, twin tank
assemblies, and Incoloy
sheathed heaters. The large,
user-friendly controller
interface makes operation
simple and also provides a
wide array of system and
diagnostic information.
Niles, IL info@thermalcare.com
HAMMERTEK CORPORATION
Built to endure.
Made to save you money.
Hammerteks Smart
Elbow.
Landisville, PA elbows@hammertek.com
76 Plastics Technology JUNE 2017
DRI-AIR INDUSTRIES, OUR NAME SAYS IT ALL PET RESIN MARKET
The industry leader in proven With a PET Resin capacity
DRI-AIR
Visit us online
Industries, Inc. desiccant dryer technology, that has grown thirteen
Dri-Air offers the highest fold (to over 4.3 billion lbs/
Our name says it all quality at competitive pricing. yr), DAK Americas is com-
Our constant attention to mitted to the global PET
detail and incredible Resin Market. With sus-
Since 1974 Dri-Air has been the industry 1 The Dri-Air System
response time helps us sell tainability, innovative new
thousands of drying systems products, and state-of-the-
leader in proven desiccant dryer 3 HPD 4 Bed Portable Dryers
technology, offering the highest quality at 4 Portable Dryers Controls & Closed Loop Loader
5 APD Portable Dryers
competitive pricing. Our constant attention
6 Closed Loop Loading Systems
to detail and incredible response time has
worldwide. We offer solu- art Melt-Tek and Inte-
7 Quick Material Change Systems
helped us sell thousands of drying systems 8 Hopper Bank Series
worldwide. From 1 pound to 3000 pounds 9 Central Loading System
per hour, we offer solutions to a wide 10 Central Drying Systems
tions to a wide range of gRex PET technologies,
range of industries from simple solutions 11 Floor Mount Dryers
12 Drying Hoppers
to complex custom applications.
13 Hopper Mount & Mini Dryers Desiccant
14 Mini PD Dryer Desiccant
industries from simple to DAK is setting new stan-
16 Thompson Road, PO Box 1020
15 Hopper Mount & Mini Dryers Compressed Air
East Windsor, CT 06088-1020
T: 860.627.5110 F: 860.623.4477 16 Mini PD Dryer Compressed Air
17 Blending/Drying Exclusives Virgin & Regrind, Virgin & Colorant
complex custom applications. dards in the industry.
P R O U D LY M A D E I N T H E U S A 18 Blending/Drying Exclusives Virgin, Regrind & Colorant
w w w . d r i - a i r . c o m
East Windsor, CT sales@dri-air.com DAK Americas, Charlotte, NC info@dakamericas.com
SINGLE AND TESTERS
TWIN SCREW EXTRUDERS
DRY-CONVEY-BLEND-EXTRUSION
MELT FLOW FULLY AUTOMATIC SCREEN CHANGERS
20mm
Novatec
Melt Clamshell
is one
indexer of theinlargest
comes HITECH screen changers
Segmented
U.S. based
manual orTwin-Screw
manufacturers
motorized of operate on a truly continu-
Extruder:
versions Compounding,
resin dryingand and conveying
loaded with ous principle in harmony
Pilot Scale &
equipmentand
capability Nanocomposites
forefficiency:
the plastics with the rest of the extru-
applications for product
industry. Together,
three-zone heaters; with
touch sion process. The screen, in
development.
Maguire Clamshell
Products, we the form of a long ribbon,
screen control; tapered
barrel allows visual moves slowly through the
offer the
weight largestsimple
design; line ofdie
processing assessment, screen changer at an infi-
manufactured
release; USB resin
connectivity
easy screw mounting, nitely adjustable rate to
handling
and Horizonequipment
softwarein for blend smoothly with the
quick
North
SPC cleaning.
America.
analyses; Segmented
optional polymer flow.
screws offer
Product or
manual numerous
Overview:
motorized
processing possibilities..
www.novatec.com/about
extrudate cutter.
S. Hackensack,
Baltimore,
Horsham, PANJsales@tiniusolsen.com
MD cwbi@cwbrabender.com
sales@novatec.com Hackensack, NJ aalroy@screenchangers.com
MEDICAL DEVICE CONTRACT MFG. PPE GATE CUTTERS - LOWER PRICES
Canon Virginia, Inc. offers PPE offers the best variety
Medical Device Contract of Gate Cutters at the
Manufacturing. ISO 13485 lowest prices in both our
certified, Canon Virginia Economy and Premium
has 30,000 square feet of styles. With 74 different
manufacturing space, cutters to choose from
including a class 8 clean including heated & pneu-
room, dedicated to new matic, youre bound to find
business. For an overview what you needed right here
of all Canon Virginia, Inc.s at PPE. www.ppe.com
services visit
cvi.canon.com/mfg.
Newport News, VA cvi.canon.com/mfg Macedonia, OH sales@ppe.com
CLEAR-VU LOADING SYSTEM RAPISTAK-MOLD MANAGEMENT SYSTEMS
Provides all the benefits of Mold storage a mess?
a central loading system Rapistak-Mold Management
with the added convenience Systems help you manage
of portability & low your inventory, become
maintenance. Brochure & better organized, protect
video describe this your investment and create
complete vacuum a safer working
conveying system that will environment. For more
control up to eight stations. information email us today.
Receivers allow full view of
the loading action.
Aston, PA info@maguire.com Blasdell, NY ptsales@rapistak.com
PROGRESS THROUGH INNOVATION THE SOLUTION TO KNIT/FLOW LINES
Complete overview of the Per-Fix Flaw Repair
company, its history and CoatingsThe Solution
the relentless product to Knit/Flow Lines.
developments that have Chem-paks patented line
made it the leading of coatings helps you
manufacturer for plastics eliminate most cosmetic
flaws common to injection
processors worldwide. Its
molded plastics. Designed
innovative products
specifically for matte-
include injection molding
finished, color-coded,
machines, robots and textured, interior parts.
automation systems,
auxiliary equipment .
Torrington, CT info@wittmann-ct.com Martinsburg, WV info@chem-pak.com
PTonline.com
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PURGING COMPOUNDS

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@plastechmag Plastics Technology 77

 CL A SSIFIEDS
SPECIAL SERVICES

TIME-CRITICAL
CONFIDENTIAL
GRINDING
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Since 1973
Granulation / Coarse Grinding
Chemical Analysis and
Characterization Pulverizing / Fine Grinding
Thermal Analysis and Rheology PLASTICS Cryogenic Grinding
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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
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R&D

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mixers.com/web-app

1-866-797-2660
www.RossSysCon.com 800-278-4241 info@binmaster.com
2017 BinMaster, Lincoln, NE 68507 USA

Let Plastics Processors Know

WHO You Are and WHERE You Are

78 Plastics Technology JUNE 2017 PTonline.com

 ADVERTISERS INDE X

Absolute Robot Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 ExxonMobil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Plastrac Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

absoluterobot.com mobil.com/hydraulics plastrac.com
Advantage Engineering, Inc.. . . . . . . . . . . . . . . . . . . 11 Foremost Machine Builders Inc. . . . . . . . . . . . . . . 67 Processing Technologies International LLC . . . 24
advantageengineering.com foremostmachine.com ptiextruders.com
Arburg GmbH & Co KG . . . . . . . . . . . . . . . . . . . . . . . . . 35 HammerTek Corp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 PSI-Polymer Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . 42
arburg.us hammertek.com psi-polymersystems.com
Athena Controls Inc.. . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Hosokawa Alpine American . . . . . . . . . . . . . . . . . . . 61 Rapid Granulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
athenacontrols.com halpine.com rapidgranulator.com
Avian USA Machinery, LLC . . . . . . . . . . . . . . . . . . . . . 70 IMS Industrial Molding Supplies . . . . . . . . . .16 a,b Rapistak Corp.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
aviangranulator.us imscompany.com ptm.rapistak.com
Branson Ultrasonics Corp.. . . . . . . . . . . . . . . . . . . . . 55 KraussMaffei Corp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Republic Machine, Inc. . . . . . . . . . . . . . . . . . . . . . . . 42
bransonultrasonics.com kraussmaffeigroup.us republicmachine.com
CAMX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Lorenz Conveying Products. . . . . . . . . . . . . . . . . . . . 70 RF Co., Ltd. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
thecamx.org lorenzproducts.com rfsystemlab.com
Canon Virginia Inc. ............................3 Maguire Products, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Ross, Charles & Son Co.. . . . . . . . . . . . . . . . . . . . . . . . 21
cvi.canon.com maguire.com mixers.com
Chem-Pak . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 MoldTrax . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 SPE Automotive . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25, 66
chem-pak.com moldtrax.com speautomotive.com
Chem-Trend Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Nordson Corp. Polymer Processing Systems Thermal Care, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
chemtrend.com nordsonpolymerprocessing.com 24 thermalcare.com
Conair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Novatec Inc. . . . . . . . . . . . . . . . . . . Inside front cover Tinius Olsen Testing Machine Co., Inc. . . . . . . .68
conairgroup.com novatec.com tiniusolsen.com
Coperion K-Tron . . . . . . . . . . . . . . . . . . . . . . Back Cover Pallmann Industries . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Unique Tool & Gauge Inc.. . . . . . . . . . . . . . . . . . . . . . 27
coperion.com pallmannindustries.com unique-tool.com
Cumberland . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 PCS Co. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Vecoplan LLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50, 51
cumberland-plastics.com pcs-company.com vecoplanllc.com
DAK Americas, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Pelletron Corp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60 Wittmann Battenfeld, Inc. . . . . . . . 24a,b, 32, 33
dakamericas.com pelletroncorp.com wittmann-group.com
Engel Machinery Inc. . . . . . . . . . . . . . . . . . . . . . . . . . 13 PFA Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Zeiss Industrial Metrology, LLC . . . . . . . . . . . . . . . 29
engelglobal.com pfa-inc.com zeiss.com
Ensign Equipment Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Plastic Process Equipment, Inc. . . . . . . Inside For additional product information, refer to
ensigneq.com ppe.com Back Cover this companys Advertising/Data Sheets in
Entek Extruders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Plastics Industry Association ............. 17, 43 PLASTICS TECHNOLOGYs 2017 PROCESSING
entek.com plasticsindustry.org HANDBOOK & BUYERS GUIDE

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@plastechmag Plastics Technology 79

 PROCESSORS EDGE
A SSOCIATED THER MOFOR MING INC. BERTHOUD, COLO.
CAM Adds Agility to
Custom Thermoformer
CNC machining permeates ATIs
business, making its operations
more efficient and responsive.
Not surprising, given its name, the business of Associated
Thermoforming Inc. (ATI) revolves around thermoforming. But
another technologycomputer-aided manu-
By Jim Callari,
Editorial Director facturing (CAM)has played an important role
in improving the processors productivity,
reducing lead times along with operating costs.
Based in Berthoud, Colo., ATI (ati-forms.com) is a custom
former that specializes in producing technically challenging,
heavy-gauge parts via vacuum forming, pressure forming, and
twin-sheet thermoforming. In business for more than 30 years,
ATIs primary markets are medical, aerospace, and general indus-
trial products. These are formed in thicknesses from 0.030 to 0.50
in. from acrylic, ABS, PE, PC, and several other resins.
The requirements of ATIs customer base are diverse, and the firm
likes to fulfill them in-house whenever possible. To that end, ATI has
acquired an extensive array of CNC machining equipment, including
multiple three- and four-axis vertical mills (used for cutting
thermoforming mold components and fixtures, and to complete
secondary operations on formed parts) along with seven sophis-
ticated double-table 5-axis routers used for automated trimming.
All of this equipment is programmed using Mastercam CAD/CAM
software from CNC Software Inc., Tolland, Conn. (mastercam.com).
Twin-sheet forming is an ATI specialty; the company has
developed the tooling and knowledge to hide the parting line
to produce highly cosmetic parts. Tools for this process require
provision for locating inserts within the twin-sheet structure. ATI is
also adept at producing formed components having features with
substantial undercuts. These increase toolmaking complexity by
requiring either additional moving components within the mold,
or if the feature can be pulled, the ability to create precise cavities
using long tools to reach into the undercut for accurate material
removal and finishing.
In the tooling department, Aaron Frison, tooling supervisor,
and two others rely on Mastercam to create efficient CNC manu-
facturing strategies for making mold components with his shops
trio of three-axis vertical mills. They begin their CNC programming
process by importing a Solidworks CAD file developed by ATIs mold
80 Plastics Technology JUNE 2017
Mastercams Work Coordinate System automatically
snaps users into the proper coordinates as they
navigate between different parts and operations.
designer, who starts with a part model provided by the customer.
Frison singles out a number of important CAM capabilities that
make him and his programmers more productive:
Managing operations: The tool design delivered to the CNC
programmers may require dozens of manufacturing operations.
Rather than separate the mold into files for each individual compo-
nent, Mastercams Operations Manager breaks out all of the indi-
vidual parts into their own machine and tool groups so that pro-
grammers can attack their work from within a single CAM file. This
feature saves many hours before and during programming work
10-15% of the total job, by Frisons estimate.
Work coordinates: The software automatically preserves the ori-
entation of each operation within the CAM file in its Work
Coordinate System. This feature is also a big time saver because it
automatically snaps the users into the proper coordinates as they
navigate between different parts and operations.
Toolpath simulation: Programmers routinely use Mastercams
simulation features to verify that a program will remove the exact
amount of material required and that there are no tool interfer-
ences. This gives them the confidence to run at optimal speeds,
without the fear of having a crash that might damage the machine
or result in scrap.
Dynamic motion: ATI uses toolpaths incorporating Mastercams
Dynamic Motion technology whenever possible. This technology
takes into account the material conditions ahead of the tool and
continually adjusts feeds, speeds, and cutting motions to maintain
a constant chip load. Frison comments, With Dynamic Motion, we
can use a long tool to reach into deep undercuts and not worry
about deflection. It is just a much smoother toolpath and it gives
better finishes as well as improved cycle times. For cavity work,
we have probably reduced our machining cycles by at least 25%
on average, and our carbide end mills last a lot longer, so our
cutting-tool costs have gone down.
PTonline.com
 DRYING HOPPERS STAINLESS STEEL
INSULATED
WITH STAND AND CAST DISCHARGE CHUTE
9 SIZES AVAILABLE
100 to 500 lbs. Capacity INCLUDED
6 dia. hole (covered) in top
INCLUDED Lid for Material Loader.
Full size removable
gasketed top Lid. Stainless Steel construction
including interior, air pipes, and
air dispersion cone. Inlet &
2 Lifting Ears on top. Outlet sizes are listed in table.
Thermocouple Port
on incoming air pipe.
M8 x 1.25mm thread
Air Air
Inlet Outlet
Double wall insulated
hopper holds the heat.

OPTIONAL: Large gasketed hinged

Mounting Bracket access door for easy
Assembly for Loader Stainless Steel inspection & cleaning.
Proximity Switch internal air pipes &
Sensor. Attaches to dispersion cone. Large Sightglass window
Sight Glass Door. to view materials.
Switch not included. Large models have two.

Model MVLS1
Venturi Loader INCLUDED
Sturdy all welded
stand with casters

Model DH-120USD INCLUDED

Stainless Steel Cast aluminum Discharge
Drying Hopper Chute with Material Shut-
Off Slide Gate and lower
Model MD-60220 Material Evacuate Slide
Honeycomb Gate with lock.
Desiccant Dryer Sight Glass included.
Bottom flange undrilled
for future suction box or
hopper mounting.

Model
DH-120-USD
(shown)
500lb. Capacity
$1,130.00 Cast Aluminum Discharge Chute
with material shut-off slide gate.
2 sizes available. Can be
purchased separately.
Suction Box
#SUB-100-15
Suction Boxes Our PPE Drying Hoppers are a PPE exclusive
only available from PPE. Do not confuse these
TYPICAL APPLICATION available in 2 sizes. with any other make, model or manufacturer.

PLASTIC PROCESS EQUIPMENT

6385 Montessouri Street, Las Vegas, Nevada 89113
, INC. www.ppe.com e-mail: sales@ppe.com
11218 Challenger Avenue, Odessa, Florida 33556
PPE 702-433-6385 800-258-8877 Fax: 702-433-6388
PPE 727-834-8888 800-282-6783 Fax: 727-834-8873
W E S T SOUTH
8303 CORPORATE PARK DRIVE, MACEDONIA (Cleveland), OHIO 44056, USA 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
 >extruders >feeders >components >pneumatic conveying >complete systems

>>Unmatched level of understanding for material handling and

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