Article Archive

April 2009


Past Issues

Troubleshooter

The Eight Stages of Mold Repair
While the mold was still being disassembled, two “cleaners” began pulling tooling out of plates and putting them into buckets in preparation for a good scrubbing—and I mean a scrubbing.

How to Solve Uneven Clamping
Of the hundreds of variables involved in injection molding, clamping mechanisms and platens often get less attention than they deserve.

Better Purging Saves Money, Material and Time
How much money can a better purging compound save even a small molder?

Internal Benchmarking: Setting Targets
Last month, we discussed how to graph your plant’s “process energy fingerprint.” Now we’ll show you how to make use of that information.

Keeping Up With Technology

First High-Pressure Tank That’s Not Filament Wound
A cylindrical high-pressure hydrogen tank in development for future automotive applications was made last year by Profile Composites Inc., Sidney, B.C., to prove out a new process (patent pending), funded by the National Center for Manufacturing Sciences in Ann Arbor, Mich.

Gravimetric Dispensing Of a Single Ingredient
AccuDispense is a new single-ingredient gravimetric dispensing unit from Process Control Corp., Atlanta.

New Service Verifies Flow-Simulation Predictions
An economical approach to verifying that computer-aided flow simulation will give an accurate molding prediction with your particular resin is offered as a new service from Beaumont Technologies, Inc., Erie, Pa.

Polyols from PET and Starch
Two firms recently announced ecofriendly production of urethane polyols from recycled PET waste and from chemicals derived from cornstarch by bio-fermentation.

Silicone Stabilizer Cuts Flame Retardant Use
New Niax L-655 silicone stabilizer (surfactant) is said to allow use of 10% to 30% less flame retardant in flexible polyether slabstock foams for bedding, furniture, and carpeting, and automotive use.

Integrated Multi-Loop Controller Saves Time, Space and Cost
Watlow, St.

Hand-Held Sonic Welder With Digital Control
Microprocessor controls on two new hand-held ultrasonic welders from Sonics & Materials Inc., Newtown, Conn., allow the devices to be set to weld with digital time and/or energy control.

Complete PUR Panel Lines From a New Source
Polyurethane Process Industries, LLC (PPI), Latrobe, Pa., now can offer complete turnkey design, equipment systems, and technical support for continuous and discontinuous rigid foam panel lines.

Flat Die Cuts Color-Change Time by 75%
A new constant-shear manifold for film and sheet balances the flow of virtually any polymer or blend, regardless of viscosity, for dies up to 36 in. wide, according to Premier Dies Corp., Chippewa Falls, Wis.

New Inorganic Orange
WEB EXCLUSIVE BASF Coating & Plastic Chemicals in Germany (U.S. office in Florham Park, N.J.) has developed a new brilliant orange pigment that has been granted Color Index designation Pigment Orange 82.

High-Pressure Valve Gates
A new line of hot-runner valve-gate systems designed for high-pressure processes comes from Gunther Hot Runner Systems Inc., W.

Non-Alergenic Natural Rubber for Medical Products
WEB EXCLUSIVES The bark of a high-yield variety of guayule plant is being used to produce a medical grade of natural rubber that is free of Hevea rubber proteins associated with allergies to latex from rubber trees.

Trade in and Upgrade Magnet Separators
WEB EXCLUSIVE Industrial Magnetics, Inc. (IMI), Boyne City, Mich., has a new “Trade-In/Upgrade” program on drawer-in-housing, bullet, and EP tube magnetic separators.

Stronger Mold Steel Gives Faster Cycles
A family of prehardened mold steels from France that boast faster and easier machining and higher strength than standard P20-grade steels also are notable for their higher thermal conductivity, which can lead to faster mold cycles.

Tighter Tolerances for Ultra-Thin Films
Magnat-Fairview Inc. in Chicopee, Mass., the result of the 2005 merger of Magnat Rolls in E.

Urethane Hybrid Resin For Pultrusion
WEB EXCLUSIVE Dion 31040-00 is a low-viscosity, medium- to high-reactivity urethane hybrid resin for pultruding tough composites.

Clear, High-Strength TPEs
A new series of clear, oil-free, SEBS-based TPEs eliminates oil bloom onto wood and other surfaces.

Better Bubble Stability For Blown Film
Macro Engineering & Technology Inc., which has stacked dual-lip air rings on top of each other since the early 1980s, recently developed a new version for improved output and film gauge with low-melt-strength materials like LLDPE and metallocene PE.

Ejector Pins Are Now Corrosion Resistant
A new line of stainless-steel ejectors is designed for use where traces of oxidation can cause impermissible contamination of parts for medical, food-contact, or other sensitive uses.

Small Presses Get Energy-Efficient Servo Pump
A servo-motor pump drive is at the heart of a new series of electric/hydraulic presses said to be quieter, faster, and more precise than standard hydraulic models and more economical than all-electrics.

Marble and Swirl Effects Masterbatches
Color masterbatches for marble and swirl effects are new from Techmer PM of Clinton, Tenn., and Rancho Dominguez, Calif.

Nucleating Agent Aids PP Recycling
Recycling of polypropylene is made more difficult by the presence of various colorants and nucleators in mixed batches of reclaim, which can affect shrinkage and warpage.

World’s First Recyclable Single-Use Baby Bottle
A novel disposable, single-use baby bottle is said to be 100% recyclable and BPA-free.

‘Quick Ship’ Blenders and Lower Prices For Gravimetric Extrusion Control
WEB EXCLUSIVE Process Control Corp., Atlanta, has a new Quick Ship program for three of its most popular sizes of Guardian batch weight blenders.

Tougher Wood/PP Compounds
JER Envirotech International Corp., Vancouver, B.C., has a new series of compounds of recycled PP and wood fiber with higher toughness than before.

Largest Series Part By Vacuum Infusion
Premium Aerotec in Augsburg, Germany (formerly EADS, the European Aeronautic Defense and Space Co.), molded six enormous reinforced skins for the cargo doors of the first preproduction models of the Airbus A400M military transport plane using EADS’ patented VAP vacuum infusion process.

Tester Checks Cavity Sensors
Cavity pressure and temperature sensors can be checked to confirm proper operation with a new signal tester from Priamus System Technologies LLC., Brunswick, Ohio.

Low-Warpage LCP For High-Speed Connectors
A new low-warp grade of liquid-crystal polymer is designed to provide the precise dimensional tolerances and easy flow needed to injection mold connectors with higher pin densities that enable increased bandwidth and higher data-transfer speeds.

New Looks in Acrylic Sheet
WEB EXCLUSIVE Two new aesthetic effects in formable acrylic sheet were introduced by Acrilex, Inc., Jersey City, N.J.

‘World’s Fastest’ Extrusion Coating Line
A combination of new engineering features and chemistry allows Davis-Standard’s fastest extrusion coater, the Synergy 750, to coat at 750 meters/min vs. a top speed of 600 m/min when the machine was first built in 2004.

High-Flow FR Nylons For Appliance Connectors
Rhodia Engineering Plastics, Cranbury, N.J., has launched its first high-flow, flame-retardant nylon 66 grades specifically for appliance connectors.

New Screw Lowers Temp. In CPVC Pipe Extrusion
A new screw runs 15 to 20° F cooler than typical CPVC screws, significantly increasing uptime in CPVC extrusion, according to American Maplan Corp., McPherson, Ks.

CPE Impact Modifiers From a New Source
Alternative Rubber & Plastics, Inc., Amherst, N.Y., is now offering chlorinated polyethylene (CPE) produces from Hangzhou Keli Chemical in China, said to be the second largest CPE producer in the world.

Say ‘Oui’ to French Wine In PET Barrier Bottle
Three varietals of French wine from Boisset Family Estates are the first in the U.S. that are packaged in PET bottles using MonOxbar Plus oxygen scavenger from Constar International Inc., Philadelphia.

TPE Toughens PP, SEBS While Retaining Clarity
Commercialized four years ago by ExxonMobil Chemical, Houston, Vistamaxx olefinic TPE was used originally for spunbond nonwovens because of its elasticity.

New Pressure Instruments For Extrusion
WEB EXCLUSIVE Two suppliers have introduced three new pressure instruments, primarily for extrusion, though they could be used in other plastics processing applications: The SPX-T temperature-compensated pressure sensor from Dynisco Instruments, Franklin, Mass., has a built-in RTD temperature sensor.

Medical Tray Has ‘Safe Edges’
Plastic Ingenuity in Cross Plains, Wis., which operates five thermoforming plants and builds its own machines, has patented pressure-forming tools that round the edges of medical trays.

Powered Spur Conveyors Transfer Products Easier
New DynaCon powered spur conveyors have been added to the line of Dynamic Conveyor Corp., Muskegon, Mich.

Electric Press for LSR Micromolding
A new 8-ton all-electric, verticalclamp, vertical-injection press has a two-station rotary table built for insert molding of small LSR parts.

TPU Composite Film Protects Against Bomb Blast
WEB EXCLUSIVE The X-Flex Blast Protection System is a composite of two layers of extruded TPU film on both sides of a nonwoven aramid-fiber scrim with a peel-and-stick acrylic adhesive on one side, protected by a clear, release-coated liner.

Centrifugal Mixer Becomes A Nano-Pulverizer
A prototype nano-pulverizer from Thinky Corp. in Japan is based on the company’s planetary rotation-and-revolution mixer.

All-Electric Line Expands With Three New Models
Smaller and larger tonnages have been added to the Zhafir brand of all-electric “Venus” machines says U.S. sales and service partner Absolute Haitian Corp., Worcester, Mass.

PVC Foam Cell Stabilizer
A new foam cell stabilizer for rigid PVC profile and trim board extrusion is said to provide controlled and finer cell structure without voids.

ABS Light-Diffuser Masterbatch
Ampacet, Tarrytown, N.Y., has expanded its range of clear light-diffuser masterbatches beyond polycarbonate and acrylic to include ABS.

Thermoforming Heat-Resistant PLA Trays
A technique for crystallizing polylactide (PLA) biopolymer trays to make them more heat resistant was disclosed in a recent patent application by NatureWorks LLC, Minnetonka, Minn.

Power Analyzers Aid Energy Management
Get a better handle on your plant’s energy usage with the new EM26-96 Series compact power analyzers from Carlo Gavazzi, Buffalo Grove, Ill.

Dow to Close Acquisition Of Rohm and Haas April 1
WEB EXCLUSIVE Dow Chemical Co., Midland, Mich., said last month that it had reached an agreement with Rohm and Haas Co., Philadelphia, that would allow Dow’s intended purchase of Rohm and Haas to go forward, with an anticipated closing on Apr. 1.

Starting Up

Pricing Update - April 2009
A short, sharp rebound in the first quarter called an abrupt halt to the long slide in commodity resin prices.

Outlook - April 2009
Despite the high hopes that prevailed at the beginning of 2009, it is increasingly apparent that a self-sustaining recovery in the U.S. economy will not get under way until 2010.

Features

We Take You to the Show in Style
This year, you may need to make better use of your time at NPE than ever before.

Injection Molding Biopolymers: How to Process Renewable Resins
U.S. injection molders are still pretty green when it comes to processing the new crop of renewably sourced biopolymers. These biologically derived polymers made from PLA, PHA and starch-based resins are attracting growing market interest as materials with no ties to petrochemical-based thermoplastics.

Strategies

'Piggable' Paint Recirculation Is Key to Efficient Color Changes
When an automotive molder wanted to upgrade from primer painting to multi-color coating, a big concern was costly downtime and material waste during frequent color changes.

Close-Up on Technology

Novel Melt Blending Technology Commercialized in Micro- and Nanolayer Films
The first two commercial devices have been installed to melt blend two or more polymers using a structured fluid-dynamic mixing process known as “chaotic advection.” This process creates unusual micro-scale and nano-scale phase morphologies that potentially can optimize extruded film properties using fewer materials and extruders than with highly layered coextrusion.

CW Brabender
HammerTek
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