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Taking the Pulse of the Molding Business
Are custom molders in your neck of the woods getting busier, or are they less busy? Are they charging more or less for their services? To help us give you accurate answers, please take part in Plastics Technology Magazine’s twice-yearly survey of custom injection molding capacity and machine-hour rates. You can take the survey on-line by clicking here. Or, if you prefer, look for your copy in the mail soon.  Either way it should only take a few minutes to complete. All responses are kept confidential, and the results will appear first in the April issue of Plastics Technology Magazine.

‘Bio’ was buzz star of K Show

Biopolymers were the attraction at the recent K 2007 show in Dusseldorf, as several companies introduced bioresins made from plant oils, sugars, or starches. The most startling was polyethylene made entirely from cane sugar by Braskem of Brazil. DuPont talked about its pending launches of Sorona PTT polyester and Hytrel RS TPEs, both made from propanediol derived from fermented cornstarch. Arkema announced Pebax Rnew TPEs made up to 90% from castor oil, as well as a copolyamide billed as the first 100% bio-based hot-melt adhesive. Arkema also makes nylon 11 entirely from castor oil. Merquinsa of Spain brought out the first TPUs made from renewable natural sources. Bayer MaterialScience showed off a refrigerator whose urethane foam insulation is made with Baytherm NOP natural-oil polyols (see p. 64). Mitsui of Japan also talked about new bio-based PUR materials. Radici Group of Italy will begin production next year of nylon 610, made in part from castor oil. BASF “reintroduced” its nylon 610 in response to a surge of interest from the auto industry. Toray showed off new Ecodear nano-alloys of polylactic acid (PLA) biopolymer and conventional thermoplastics for making laptop cases and cellphones. And the Fraunhofer Institute in Germany exhibited a biocomposite of PLA with natural fibers like hemp or flax.

Injection, Extrusion Businesses Advance

Plastics Technology Magazine’s Injection Molding Business Index advanced 8% last month compared to the corresponding period of 2006. This followed a 4% increase the month before. Plastics economist Bill Wood, who prepares this index for Plastics Technology, is projecting the index to finish 2007 about 5% above 2006 levels. And his crystal ball says that business for molders will continue on the uptick for 2008. Molders making computer parts will see their business increase 24% in 2007; Wood is projecting a further climb of 15% in 2008. Molding for medical is apparently good business as well. Following a 4% decline this year, Wood sees business for molders serving the motor vehicle market to increase by 4% next year. Packaging will hold steady.

Where the Extrusion Business Index is concerned, Wood reports conditions improved to the tune of 4% last month following a 3% climb the month before. The noted economist predicts extrusion processors will see steady growth throughout 2008. The film index gained for the third straight month, important because it is a critical indictor of the state of the extrusion industry in general. Sheet is also climbing steadily. Markets tied to the construction industry face a tougher road ahead.

Cover Story: PP, PET Battle Over Bottles

Improved clarity and cost competitiveness, added to its inherent heat resistance, are reviving OPP’s prospects in hot-fill barrier containers. But hot-fill PET containers are raising the bar with higher productivity and ‘panel-less’ bottle designs. These developments come at a time when the booming hot-fill packaging sector appears to be cooling somewhat. The hot-fill juice market is said to be flat, while sports drinks and isotonics show moderate growth. The new hot markets are ready-to-drink teas and enhanced waters. Senior Editor Joe Grande has all the details here.

How to Mold Wood Composites

Wood-fiber/thermoplastic blends have already made a name for themselves in extruded decking and fencing boards. Now they are moving into injection molding. Some injection molders are hesitant to experiment with new materials like wood-plastic composites (WPCs). Molders that have experimented with them have encountered a number of challenges, including inconsistent quality, inconsistent supply, and generally greater difficulty in working with WPCs in comparison with more familiar injection molding materials. Here is a guide on what molders need to know about processing this new breed of material.

Processor Strategies: Technology Drives Structural Foam

In structural foam, as in any area of plastics, keeping abreast of the latest technology is a key to competitiveness. For 20/20 Custom Molded Plastics Ltd. in Holiday City, Ohio, that has meant using independent multi-nozzle injection control and robotic parts handling. The company’s 90,000-sq-ft plant houses five structural-foam presses from Uniloy Milacron, Tecumseh, Mich. They range from three 500-tonners to a 1000-ton machine and a 1500-ton behemoth said to be the largest in the country. It can run up to 5000 lb/hr, and the whole plant can consume 300,000 lb/day. Foam makes up more than 80% of the firm’s $25 million sales. The rest is structural-web molding and standard injection molding (on four presses of 375 to 726 tons). Here’s the full story.

New Technology Spotlight:

Foamed PLA used for meat trays
First-ever 11-layer blown film die
Precise, uniform hot-runner nozzle

Mark your calendar...

Novi MI - Rock Financial Showplace
April 23 -24 2008
www.moldmakingexpo.com