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Exclusive Benchmarking Survey Shines a Light
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VOLUME 63 NUMBER 3
Cover Story
Meet Plastics
Preeminent Processors
Plastics Technologys second annual
benchmarking surveyWorld Class
2 01 7 WO R L D C LASS Processorsis back with a new
honor roll of companies from across
the industry. One of the ties that
binds these progressive processors
is their reliance on data.
By Tony Deligio, Senior Editor
32
cvi.canon.com | 1.866.99.CANON
Canon is a registered trademark of Canon Inc. in the United States. 2016 Canon Virginia, Inc. All Rights Reserved.
From The Editor
Our cover story in this issue reports on the results of our latest metrics. Every employee that works that day earns the incentive,
World Class Processors benchmarking study, our second in what Koster says, with the RBIs paid out on a quarterly basis. Besides the
will be an annual research project. The carrot, there is also one stick: If we have a significant safety incident
intention of the survey is to shine a light or customer complaint, part or all of the incentive is lost, Koster says.
on best practices in the industry at a time
when more and more processors are com- Focus on technology and training: Custom molder CNR Group LLC
peting globally for business. (cnr-plastics.com), Jackson, Wis., has 10 machines, all are all-electric
In reading Senior Editor Tony Deligios and most are less than five years old. For those 10 machines, CNR has
report, which starts on p. 32, a few things 11 full-time employees, says Bob Albrecht, company president, with
jumped out: two of those being certified molding technicians, applying scientific
molding principles and robust process development.
Jim Callari Metrics matter: Paul Koster is CEO of
Editorial Director full-service injection molder Selmax Corp., Tonys article lays out the methodology we used to determine the
Selinsgrove, Pa. Selmax (selmax.com) was cream of the crop11 metrics covering operations, business perfor-
among the 25 members of our 2016 group of World Class mance, and human resources. Those measures included everything
Processors. On the subject of collecting, disseminating, and using from scrap and on-time delivery rates to employee turnover and sales
data in a tactical way, Koster puts it succinctly: We share perfor- growth. We generated a tremendous amount of data in the process.
mance metrics, because what gets measured gets achieved. Tonys report includes selected data, but only survey participants get
the complete data set.
Be transparent with employees: When you finish reading the
Mossberg Industries Inc. article, I hope one of your take-
(mossbergind.com), Garrett, Ind., aways is, Were doing all this stuff.
makes spools and reels using 201 7 WO RL D CL ASS Why arent we mentioned? Well,
injection molding and extru- first, you have to respond to the
sion. Performance metrics like survey. Second, you have to make
on-time delivery, as well as the cut for World Class status. And
customer concerns, are posted third, you have to agree to divulge
monthly in the shop breakroom and are also reviewed in the com- your companys identitywhich is not required to participate in the
panys monthly plant meetings, notes James S. Khorshid, president survey, but only if you want to be recognized by name in print.
of the company. We share these items with everyone so they can For this years report, 22 out of the 25 processors identified as
give direct input if anyone has an idea to improve a process, World Class elected to make themselves known (21 did last year). To
Khorshid says. Adds Missy Rogers, president of custom injection my way to thinking, it should be 25 out of 25. Wouldnt that World-
molder Noble Plastics Inc. (nobleplastics.com), Grand Coteau, La., Class Processor designation be a useful credential when your
We display metrics and hold regular meetings to review goals and customers put projects out to bid? Wouldnt it be a good thing even
measures, because communication is key to success. to put such a designation on your own website?
Get involved in the next survey by emailing Tony at
Reward stellar performance with cash: 83% of the World Class tdeligio@ptonline.com.
Processors offered a bonus, while only 69% of total survey respon-
dents did. Selmax links operational performance and pay via its
Results Based Incentive (RBI). This molder posts machine run time,
reject rates, and production cycle times daily. RBIs can be earned for FOLLOW US
@plastechmag
every day that the team achieves the targets established for those @jimcallari
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R O B OT S A N D AU TO M AT I O N
Close-Up On Technolog y
As with almost everything else in plastics these days, robots are include Xdesign linear robots with payload capacities of 3 to
less and less likely to be considered in isolation, rather than as 20 kg (6.6 to 44 lb) for presses of 20 to 800 metric tons; high-
part of a system, an automated cell, or a net- speed sDesign linear robots for packaging with up to 3 kg (6.6
By Matt Naitove
Executive Editor worked plant. Hence, much of the emphasis at K lb) capacity for presses of 75 to 300 m.t. The new xLine for large
was on how robots play well with othersi.e., parts has been expanded to include presses from 75 to 2500 m.t.
connect with other equipment, how they can be programmed The smaller models are mainly for multi-component machines
simply and easily, and how they can operate safely and collabora- with vertical injection units. The newest models are the 600
tively in close proximity with humans. xLine with 60-kg (132-lb) capacity for presses of 1300 to 2500
m.t. and 120 xLine with 12-kg (26.4-lb) capacity for presses of
NEW CARTESIAN ROBOTS & PICKERS 250 to 500 m.t. Wemo also showed eDesign and iDesign linear
Our previous reporting has covered new linear robots and servo robots/pickers with capacities of 2 to 10 kg (4.4 to 22 lb) for
pickers from Boy Machines, Engel, KraussMaffei, Sepro, and presses of 25 to 300 m.t. Wemo is represented here by Robotic
Yushin (August, September, and November Automation Systems, Waunakee, Wisc.
Keeping Ups). In addition, Arburg (U.S. (roboticautomationsystems.com).
office in Rocky Hill, Conn.; arburg.com) OPC-UA interfaces Wittmann Battenfeld (Torrington,
brought out a large Multilift V model with are bringing robots Conn; wittmann-group.com) showcased
40-kg (88-lb) payload capacity. And Yushin into Industry 4.0. the new R9 controller for all its robots.
of Japan (Cranston, R.I.; yushinamerica. Retaining the look and feel of the R8
com) had two new servo models. One is the control, with which it is backwards-
RCII-150 kick-driven robot for handling large and long parts such compatible, the R9 TeachBox pendant has a larger (10.1-in.)
as auto bumpers. The unit has a two-axis servo wrist and 40-kg screen with higher resolution and a glass covering that accepts
payload. Its telescoping vertical stroke is 1550 mm, kick stroke is multi-touch/gesture commands like a smartphone or tablet, as
1200 mm, and traverse stroke is 2500 mm. There was also a new well as membrane keys for essential inputs. It also weighs 10%
version of Yushins ultra-high-speed HAS robot with takeout less and is more comfortable to use.
time of only 0.27 sec. Further optimization of the unit intro- The R9 control is standard on Wittmanns new Primus 16
duced at K 2013 gave this double-wing model (two robots on one robot for machines from 50 to 200 metric tons. This economical
rail) a slimmer profile, less vibration, and 13% lower weight. model (an adapted version of the W818) is aimed primarily at
After two years of integration and redesign, Wemo Asian molders, but is also available here to molders in areas like
Automation of Sweden (wemogroup.com) has combined its Southern California, where a small, low-cost, pick-and-place unit
lines and those of Hahn in Germany to provide a full range of is desirable. The Primus 16 has three servo axes and a pneumatic
top-entry and side-entry sizes in a consistent design. These wrist. Payload capacity is 5 kg (11 lb).
!
New
Temptender T-Series
!
New
G-Series
VE-Series
Nee collaborative robots were shown by ABB (left) and Fanuc, among others.
Fanuc demonstrated the ability to stop robot motion with the touch of a hand.
CONNECTIVITY FOR INDUSTRY 4.0 Kuka Robotics (Shelby Township, Mich.; kukarobotics.com) has
Wittmanns new R9 robot control has the OPC-UA (Open added an OPC-UA interface to its LBR iiwa (Lightweight Robot intel-
Platform Communication-Unified Architecture) interface that ligent industrial work assistant) collaborative model.
has been adopted in Europe for machine-to-machine commu-
nications under the umbrella concept of Industry 4.0. It is also MORE COLLABORATIVE ROBOTS
part of Wemos WIAP 4.0 (Wemo integrated automation pro- Testimony to the growing interest in so-called collaborative robots,
cess). This includes Wemo connecta function utilizing a which can work safely alongside humans without mechanical
wireless transmitter inside the robot that can communicate guarding, is ABBs introduction of its first cobot entry, called YuMi
with the cloud and with mobile devices. It transmits numbers (see December Starting Up and short.ptonline.com/Kcollabora). This
of cycles, operating hours, cycle times, tabletop, two-armed (each with six axes) unit
color-coded operating status, and energy- has a soft, padded covering and no pinch
saving information. Another element is Standard robots are points. Motor torque is low, but it is relatively
WRS (Wemo Remote Service) for the robot. being made safer and fast for pick-and-place operations. Besides
At K 2016, Wemo demonstrated WIAP 4.0 more collaborative. safety, the focus is on ease of use; simple
through individualized production of laser- lead-through programming eliminates the
printed visitor name labels with a QR code. need for an operator screen.
A company official said five individualized-production systems In addition, Fanuc Automation (Rochester Hills, Mich.;
have been sold in Europe for electronic, medical, and automo- fanucamerica.com) showed off a smaller model of its CR six-axis
tive customers. The first commercial user is producing electrical collaborative robot (see Feb. 16 feature). And Boy Machines
plugs in several varieties using insert molds. WIAP 4.0 reportedly (Exton, Pa.; boymachines.com) demonstrated direct robot-to-
reduces setup time for multiple short runs of different plugs. human handoff of glasses of beer, using cobots from Universal
Wemo has also received inquiries for such systems from the U.S. Robots of Denmark (E. Setauket, N.Y.; universal-robots.com).
and a Western company operating in India. Meanwhile, several suppliers focused on making conventional
OPC-UA and Industry 4.0 were also highlighted at the show robots more collaborative. Sytrama of Italy (New Castle, Del.;
by makers of six-axis robots. For example, ABB Robotics (Auburn sytrama-usa.com) and Staubli Robotics (Duncan, S.C.; staubli.us)
Hills, Mich.; abb.com/robotics) introduced its Connected Services demonstrated linear and jointed-arm robots that use compact
program, which allows for monitoring essential data for predic-
tive maintenance. These include both mechanical and electrical LOOKING FOR MORE ROBOTICS NEWS AT K 2016?
parameters, such as motor temperature, torque, and current draw.
Another feature is fleet assessment, whereby users can compare Visit ptonline.com/zones/k-2016 and
utilization of various ABB robots in their plants. short.ptonline.com/Krobots
performed with the robot OEM control. Then the SCP2 is connected
and runs the robot in a Sytrama environment. The SCP2 can control
two robots (linear or six-axis) from one pendant. It can also control
upstream and downstream automation.
For high-speed pick-and-place and assembly operations,
compact SCARA (selective-compliance articulated robot arm)
robots are a well-known option. ABB brought its first SCARA
model to K. The new IRB 910SC family is modular with max.
payload capacity of 6 kg (13.2 lb) and reach from 450 to 650 mm.
Engel has also added a four-axis SCARA model to its line (see
August Keeping Up).
www.engelglobal.com
Know How
INJECTION MOLDING
A Simpler Way to Calculate Shot Size vs. Barrel Capacity
Lets take another look at this seemingly dull but oh-so-crucial topic.
Like many crusty veteran processors, I do not like admitting my Properly specified and with a skilled operator, barrels can be
mistakes. Yet, in a column in wrote in October 2011, I tackled the topic swapped in less than 30 min, even if the barrel is hot.
of calculating shot size vs. barrel capacity How do you figure out what barrel/screw size youll need? If it is
andupon further reviewconcluded a new part and the mold hasnt been built yet, running a mold-filling
the article had some flaws. So, heres a analysis will give you the volume of the part and runner. If your
second try with simpler advice. mold is in the building stage, your moldmaker may have calculated
Calculating shot volume to make the volume of your shotand make sure to also include the runner
sure your barrel has enough capacity volume if its a cold-runner mold. If you already have the mold and
seems like a dull topic. But trust me, you are purchasing a new machine, you have two sets of data: the part
youll have a significant emotional and runner weights, plus the shot size of the existing machine. With
By John Bozzelli experience if you were to put a mold in either part plus runner weight or the volume of the total shot, you
a machine only to find out there is not have your starting point. So how do you do the calculation?
enough barrel capacity to make the part. Especially if it is a new Lets start with the scenario in which you know the part weight. I
machine you bought for that mold. like to work in grams but most machine specifica-
Perhaps that has never happened to you, tions are in ounces. If the part, runner (cold), and
Trust me, youll
but I do get emails about this, and my answer sprue together weigh 164 g of PP, that comes to 5.8
have a significant
is never well received. Most molders dont like oz (164g/28.3 g/oz). Assuming you have a barrel
emotional experience
to hear they need to buy a new barrel, because capacity of 8 oz, you might be tempted to conclude
if you were to put a
of the time and cost involved. So, if you are that you have plenty of shot volume available.
mold in a machine
buying a new machine or scheduling a mold Unfortunately, this is where things start to unravel.
only to find out there
to a machine, do your homework before the First, look at the machine specification, it
is not enough barrel
machine is ordered or the schedule is set. usually is in grams or ounces (weight) of PS. So
capacity to make the
Most likely youll have a variety of part the machine specification is 8 oz, or 266 g of
part, especially if you
sizes, so it is unlikely you will find a one- PS (8 28.3 g/oz = 226 g). But you want to mold
bought the machine
screw-size-fits-all remedy. Some molders go PP. There is an important density difference
for that mold.
with the biggest screw possible, but do not do between these resins. At room temperature, the
this, as it will cost you more money long term. density of PS is 1.04 g/cm3 and PP has a room-
Super-small shot sizes, using less than 20% of the barrel capacity, temperature density 0.90 g/cm3. You cannot compare your PP number
often lead to long residence times, which in turn lead to polymer to the machine specification because of the difference in densities
degradation and poor process control. Plus, big screws usually mean between materials. So, for your 164 g shot size you need to correlate
lower plastic pressure capability. Large shot sizes, using greater the PP grams to PS grams. For your 164 g part, the conversion factor
than 65% of the barrel capacity, tend to have melt-quality issues like is not 28.3 g/oz but 28.3 times the ratio of densities: 164 g 28.3g/oz
unmelt, poor melt uniformity, and long screw-recovery times. 1.04/0.90 or 6.72 oz equivalent to PS. So comparing this new PS equiv-
Its great if you find one screw that can accommodate all your alent oz to the machine specification of 8.0 oz, youre still okay, right?
parts; but if not, consider ordering two barrels. Two barrels will Unfortunately, this is when Mr. Murphy usually enters the equation
allow even a greater range of molds. You may be surprised at the to remind you that what can go wrong usually does. Hell remind you
low price of a second barrel when ordered with the new machine. that these are room-temperature densities, and in molding (that is in
the hot barrel) we deal in melt-temperature conditions. Sorry, heres
KNOW HOW INJECTION MOLDING another step of complexity. You must work with melt densities.
Learn more at PTonline.com When melted, the polymer molecules are farther apart and
Get more insights on Injection Molding from our expert density decreases. Melt densities are not often found on the
authors: short.ptonline.com/moldingKH material specification data sheet. Usually they can be found using
THE HOME OF
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INNOvATION
For as long as ARBURG has been involved with injection molding, its aim has always been
to be the home of the process. You wont find another company in the world that is
dedicated to the development and perfection of injection molding with the same level
of consistency and commitment. We always have one objective in mind: your success.
www.arburg.us
Know How
your search engine. (Plastics Technologys Universal Selector is one place to check; visit stand how this happens. There is a difference
ptonline.com/materials.) For PS, the melt density is 0.945 g/cm3 and for PP it is about in how certain polymers melt. In particular,
0.74 g/cm3. This changes our calculation; it is now 0.945/0.74 or 1.28. Now we need a understand that PP is a semi-crystalline resin,
minimum shot size of 7.4 oz (164 1.28 = 210 g or 7.4 oz). We are still (just barely) within which melts differently than amorphous
our 8-oz barrel capacity, but Murphy isnt done with us yet. resins. Semi-crystalline resins stay hard up
Is it practical to attempt to use 93% of the barrel capacity (7.4/8.0 oz)? No, that is not going to their melting point, and normally require
to work. My recommended working range for a barrel is between 25% and 65% of the barrel twice as many BTU/g to melt than amorphous
capacity. Then I add in another 10% safety factor, for check-valve leakage and melt unifor- resins. This double whammy makes semi-
mity. So the real target is 7.4 + 10%, or 8.14 oz shot size in PS equivalents for PP. Seeking to use crystalline resins significantly harder to melt
only 65% of the barrel, final calculation is (0.65 x = 8.14) or 12.5 oz barrel capacity in PS units. uniformly than amorphous resins.
But why the extra barrel capacity? Because youre melting plastics and you need to under- Think about it: In a 20:1 L/D screw,
you have 10 flights for feeding (little to
no melting in this section); five flights of
transition or compression, where melting
occurs; and five flights in the metering
zone, which are designed not to melt but
to pump or push the plastic through the
non-return valve to build backpressure and
Advanced Plastic s Education & Training your shot. These are significant factors that
are not obvious, but they are the reason you
need a larger barrel.
Simplified message: Stick with volume
and melt densities. Do not work in weights.
www.AIM.Institute or 1-866-344-9694
ABOUT THE AUTHOR: John Bozzelli is the
founder of Injection Molding Solutions
(Scientific Molding) in Midland, Mich., a
provider of training and consulting services to
injection molders, including LIMS, and other
specialties. Contact john@scientificmolding.com;
scientificmolding.com.
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EXTRUSION
SIDE-ACTION SYSTEMS
Extruding with Fillers Make Perfect Parts and
Save Money!
You can use the reference point from processing
unfilled polymer to determine whether you can
run filled resin on your current system.
Fillers are added to polymers to accomplish many different property changes and Preload cores for perfect parts.
improvements. They can alter physical properties, reduce costs, trim weight, change the Save $$$$ with a smaller cylinder.
electrical conductivity, and enhance thermal properties, just to Simplify mold operation and design.
name a few. In almost every case they also have an effect on Smaller mold base = low cost parts.
processing behavior during extrusion. Fully Preloads at only 1,500 psi.
Questions are often asked whether filled polymers can be Stays locked without hydraulics.
processed on a specific extrusion system. This question can be 400 F systems available.
answered for inert fillers, which do not chemically change or Rush 0-2 day shipping available.
go into solution after mixing. But finding the answer requires a
reference point with the unfilled polymer. KOR-LOK TRADITIONAL
YE
Core IN
accompanying table gives some of the required data for such a calculation. Notice
that the fillers all have a higher specific gravity and lower specific heat (the amount of S!
Core PRE-LOADED
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A M E R I M O L D E X P O . C O M
PRESENTED BY:
Know How
than the polymers. For example, the Specific Specific Specific temperature by multiplying the S.G.
Polymer
compounded specific gravity of 40% Gravity Gravity Heat by the specific heat for each, since
& Filler
calcium carbonate (CaCO3) filled PP (Solid) (Melt) (BTU/lb-F) the volume of output is approxi-
can be computed by the formula for Polypropylene 0.92 0.72 0.5 mately the same:
mixtures as follows: Nylon 6 1.14 0.932 0.406
CaCO3 2.71 0.1994 Neat PP: 0.72 0.5 = 0.36
1/[(% Polymer/S.G. Polymer) + Mica 2.88 0.12
Mixture: 1.019 0.312 = 0.318
(% filler/S.G. Filler)] = S.G. Mixture Ratio: 0.318/0.36 = 0.883
Clay 2.50 0.22
(Ratio of drive load)
Talc 2.75 0.208
EXAMPLE ONE
Average S.G. of mixture: Barium Sulfate 4.49 0.113 This indicates a decrease in
1/[(0.60/0.72) + (0.40/2.71)] = 1.019 power requirement for the filled
S.G. PP of 11% versus the neat PP. This
(Note: the polymer melt density is used in this calculation.) means the filled PP would have a lower motor load with 40% CaCO3
and require no changes in either the specific output of the screw or in
In this case, the extruder specific output in pounds will increase the torque capacity. But if you processed nylon 6 with 40% CaCO3 , the
by more than 40% (1.019/0.72 = 1.415) with the 40% filled polymer drive load would be almost exactly the same as with neat nylon 6, so
because CaCO3 has three times the S.G. of PP and the screw has a its a combination of all the variables that determines the load.
relatively fixed volumetric Because this is a simplified calculation, several variables can
output per rpm. affect its accuracy, the primary one being the change in viscosity
Inert fillers almost
We can also use the same with the addition of 40% CaCO3. Inert fillers almost always increase
always increase the
formula for mixtures to obtain the viscosity, which increases the pressure drop through the tooling
viscosity, which affects
a very good estimate of the and can decrease output. However, the increased head pressure also
the pressure drop
average specific heat of a increases the melt temperature, so the overall effect on power require-
through the tooling.
mixture that is not alloyed. ment often follows the calculation closely. Keep in mind that PP with
40% CaCO3 by weight is only about 15% filler by volume, so the mixture
EXAMPLE TWO is still 85% PP by volume. Also, inert fillers do not normally change
Average specific heat of mixture: 1/[(0.60/0.5) + the shear sensitivity in the processing shear-rate range, so the die flow
(0.40/0.1994)] = 0.312 (BTU/lb-F). with the filled polymer would not be expected to change significantly.
When considering processing of filled polymers, a quick estimate
Since about 90% of the drive power requirement on a single can save a lot of difficulty and predict possible equipment changes.
screw goes to raising the temperature of the polymer from solid
ABOUT THE AUTHOR: Jim Frankland is a mechanical engineer who
to melt, we can ratio the drive load requirements for similar filled
has been involved in all types of extrusion processing for more than
and unfilled polymers. The ratio of the power requirement for the 40 years. He is now president of Frankland Plastics Consulting, LLC.
neat PP and the mixture can be approximated at the same melt Contact jim.frankland@comcast.net or (724)651-9196.
TOOLING
PART 1
What You Need to Know About Locating Rings
Selecting the right locating ring and putting it
to good use takes a lot of thought.
It takes a significant amount of time to design an injection mold. The outside diameter of an American standard locating ring is
The types of steel, heat treatment, surface finish, gate size, and a typically 3.990 in. Smaller ones or rings mounted in a counter-bore
hundred other details are carefully consid- that is larger than 3.991 in. can also cause misalignment.
ered. But how much thought is given to the There are several different types of locating rings. Almost all of
selection of the locating ring? In many them are mounted in a 7/32-in.-deep counter-bore in the top or injec-
cases, not enough. This month I will discuss tion clamp plate. The basic or standard type of locating ring can
the various types of locating rings available properly align a mold to a platen, but it is not user-friendly, especially
and the intended function of each design. on large molds. It only extends beyond the face of the clamp plate by
A locating rings basic job function 5/ in. The LN version, which is specifically for the old Lester and
16
is to locate or align the orifice of the hot Newbury machines, extends only 7/32 in. If you factor in the 0.100-in.
By Jim Fattori or cold sprue with the through hole in chamfer on the front face of the rings, theres not a lot of land or
the machines stationary platen. The bearing surface holding the ring in the platen-alignment hole.
sprue orifice is usually in the center of a sprue bushing, and the Another type of locating ring has a tapered or extended lead-in.
locating ring aligns the bushing to the center of the platen. One This is always a welcome sight for the setup men on the production
exception is if a MUD or other quick-change type of frame is floor. This type makes it faster and easier to position the mold in the
used. In this case, the locating ring aligns the frame to the platen. machine, thereby reducing potential damage to the ring and the platen.
The locating ring is usually in the center of the mold. Sometimes, Most extended lead-in locating rings extend beyond the face of the
though, the locating ring is offset by several inches to reduce the molds clamp plate by 25/32 in. The initial tapered portion is about 7/16 in.
size of the mold base, such as with a single-cavity, edge-gated part. long. The remaining 5/16-in. straight portion is the required land length.
Cross-Section of
FIG 1 Cross-Section of
FIG 2 FIG 3 Cross-Section of Tall or
Standard Locating Ring Extended Locating Ring Insulator Locating Ring
It is also offset in a MUD or other quick-change U style frame. The Most commercially available locating rings with a tapered or
locating ring must always be concentric with the orifice of the sprue, extended lead-in will not work with molds having a high-temper-
no matter where its position. If not, there will be a misalignment ature insulation sheet. Insulation sheets are typically - or -in.
between the molded sprue and the machines nozzle tip. thick. Even the thinner -in. sheet will almost wipe out the land
However, you will need to add a dowel pin, key, or other alignment
method when the bushing needs to be oriented due to the runner or
part geometry. If the sprue bushings orientation is critical, it is best to
key the bushing to the mold basenot the locating ring. Most locating
rings are retained with socket-head cap screws. The screws have clear-
ance around their head and body, which allows the locating ring (and
sprue bushing) to rotate as much as one or more degrees.
The locating ring must always be concentric with The best type of locating ring to use is the flanged or platen-backed
the orifice of the sprue, no matter where its position. type. It can provide three additional advantages that the other types of
If not, there will be a misalignment between the
molded sprue and the machines nozzle tip.
rings cannot. First, since the screws are mounted outboard of the 3.990
in. diam., its almost impossible to fill up the heads of the mounting bolts
or the threads of the jackscrew holes with plastic. Second, they provide
length required to hold the ring in the platen. In this case, youll a little more support to the center of the mold because the flange butts
need a taller locating ring designed specifically for an insulator up against the platen. Third, you can add shim to the underside of the
sheet. Unfortunately, very few suppliers offer this type of ring with flange to compensate for a worn or dished platen. Depending on
a tapered lead-in to help guide the mold into the platen orifice. how much shim is used, a flanged locating ring can actually preload
Another type of locating ring is the clamp type. The inside the center of the mold to help prevent parting-line flash. How impor-
diameter of this type of ring is stepped down to 13/4 in. to retain the tant is that! If your platen is dished and you try to process around
sprue bushing and prevent it from blowing back. Bushings are this flash, your process window becomes less robust. If you do not
usually bolted to the mold base with one or two 1/4-20 socket-head process around this flash, your parting-line will eventually hob.
cap screws through the bushings shoulder. The clamp-type locating Most locating rings have an inside diam. of 2 to 23/8 in. If the
ring eliminates the need for this extra machining step, and there are sprue bushing is recessed in the mold, you will not be able to seat
no exposed screws on the face of the bushing to fill up with plastic. the machine nozzle tip against the bushing without ripping the
In the DARK
You never know when your
conveying pumps are about to fail...
no pellet flow
no material
at the press
low oil
bearing failure
turn
page
heater band off the nozzle body or nozzle tip. In this case, you choose the best one commercially available to suit each particular
need an Extension or Extension Nozzle type of locating ring. application. The cost difference between the least and most expen-
They have a 31/4-in. inside diam., which provides the necessary sive type is not a lot and the benefits are significant.
clearance. Depending on the supplier, they are available in the
standard, extended, or insulator styles.
Many mold-component suppliers offer various combina- ABOUT THE AUTHOR: Jim Fattori is a third-generation injection molder
with more than 40 years of molding experience. He is the founder of
tions of the different types of locating rings mentioned above.
Injection Mold Consulting LLC, and is also a project engineer for a large,
Personally, I would like to see even more combinations offered. multi-plant molder in New Jersey. Contact jim@injectionmoldconsulting.com;
Unless you are going to machine your own custom locating ring, injectionmoldconsulting.com.
Noble Plastics is a The 2016 selection of World Class Processors once again reflects the eclectic nature of the plastics-pro-
custom injection cessing industry, with winners hailing from different regions, running various technologies, and occu-
molder with a
dozen presses and
pying disparate points on the supply chain. What is once again a common unifying
By Tony Deligio,
a heavy emphasis Senior Editor factor is the collection, dissemination,
on automation and tactical use of operations data.
including 15 Fanuc
We share performance metrics, because what gets
6-axis robots
and process measured gets achieved, explains Paul Koster, CEO of full-
and production service injection molder Selmax Corp., Selinsgrove, Pa. Selmax
monitoring via (selmax.com) was among the 25 members of 2016s newest
IQMS and RJG
eDart modules at group of World Class Processors. Surveys were sent to Plastics
every molding cell. Technologys subscription list, including all major processing
technologies. The World Class Processors were selected from
the overall pool of respondents to the survey, based on their
performance in 11 different metrics. These metrics covered
everything from operations and business performance to
Rodney Davenport, v.p. manufacturing
human resources and operational strategy. & quality at CH3 Solutions, says his
Beyond simply compiling statistics about the output of the company launched molding operations
shop floor, the winners shared a common culture of using that in 2015 when it couldnt find a supplier
able to consistently mold its
information to make the companys success more tangible to
proprietary flooring product.
the employees who ultimately dictate the companys success.
The single biggest initiative we have done to promote involve- all others, fully 83% of the World Class Processors offered a bonus,
ment in continuous improvement is education of the whole while only 69% of total survey respondents did. The World Class
staff on the cost of process inconsistencies, says Missy Rogers, Processors also did a better job of holding onto their employees. The
president of custom injection molder, average employee turnover rate for our 2016 World Class Processors
Noble Plastics Inc. (nobleplastics.com), was 6.3%, while it reached 9.8% for the survey group as a whole.
We share
Grand Coteau, La. Obviously,
performance
customers need to receive quality A FOCUS ON EQUIPMENT
metrics,
products free from defects, but when The World Class Processors Plastics Technology spoke with had
because what
you understand how the cost of something else in common: a keen understanding of the role
gets measured
scrap, waste, and rework dont just technology can play in their success. At Mossberg Industries,
gets achieved.
affect the company, but provide a Khorshid notes that over the last five years, the company has
clear measure to tie cost of scrap to added seven all-electric injection machines, replacing older
cost of sales, everyone sees how his or her contribution to our hydraulic presses, while also installing robots and updating its
processes delivers the best value to customers and staff. production tracking system. When you mix these improvements
James S. Khorshid, president of Mossberg Industries Inc., with a business that dates back more than 100 years, then you can
Garrett, Ind., a manufacturer of spools and reels with injection
molding and extrusion capacity, says his World Class facility also
makes a point of sharing operations data. At Mossberg (moss- And the Winners Are
bergind.com), performance metrics like on-time delivery, as well
Of the 25 winners of Plastics Technologys second annual
as customer concerns, are posted monthly in the shop breakroom
World Class Processors benchmarking study, 22 agreed to
and are also reviewed in the companys monthly plant meetings.
be identified. They are listed below alphabetically:
We share these items with everyone so they can give direct input
if anyone has an idea to improve a process, Khorshid says. 3M, St. Paul, Minn., 3m.com
BPC Plastics, Meredosia, Ill.
LINKING PERFORMANCE TO PAY CH3 Solutions, Dalton, Ga., ch3solutions.com
At injection molder CH3 Solutions (ch3solutions.com), Dalton, Closure Systems International Inc., Kilgore, Tex.,
Ga., Rodney Davenport, v.p. of manufacturing and quality, says csiclosures.com
this World Class winner not only shares performance data with CNR Group LLC, Jackson, Wis., cnr-plastics.com
its employees but it also discloses its costs and margins so they Desert Molding Concepts Inc., Victorville, Calif.,
appreciate the true impact of a scrap part. desertmoldingconceptsinc.com
We are completely transparent with employees, Davenport ILPEA Industries Inc., Scottsburg, Ind., ilpeaindustries.com
says. They know what parts cost us, what we sell them for, and Mossberg Industries Inc., Garrett, Ind., mossbergind.com
how much it impacts when a part is thrown in scrap or when MRC Polymers, Chicago, Ill., mrcpolymers.com
material spills. It also impacts the employees compensation Noble Plastics Inc., Grand Coteau, La., nobleplastics.com
as well, with bonuses tied to operations performance. If we Parker Hannifin Corp., Tucson, Ariz., parker.com
need to buy equipment, if we had damage to something and Pigstail USA LLC, Brea, Calif., pigstailusa.com
dont pack good product, they know that directly impacts each Pioneer Plastics, Marinette, Wis., pioneerplasticswi.com
persons pocket at the end of the year, Dalton says. Royal Building Products, Shelby Township, Mich.,
Koster says Selmax has a similar linkage between operational royalbuildingproducts.com
performance and pay, deploying the carrot of cash to its workers PolyOne, Lockport, N.Y., polyone.com
through what it calls a Results Based Incentive (RBI). Selmax posts Selmax Corp., Selinsgrove, Pa., selmax.com
machine run time, reject rates, and production cycle times daily. Seneca Railroad & Mining Inc., Bellevue, Ohio, senecarail.com
RBIs can be earned for every day that the team achieves the targets Sharp Packaging Systems Inc., Sussex, Wis.,
established for those metrics. Every employee who works that sharppackaging.com
day earns the incentive, Koster says, with the RBIs paid out on a Toman Thermosonics, Stoddard, Wis.,
quarterly basis. Besides the carrot, there is also one stick: If we tomanthermosonics.com
have a significant safety incident or customer complaint, part or Unitra Inc., Stafford, Tex., unitrainc.com
all of the incentive is lost, Koster says. Urgent Plastic Services, Rochester Hills, Mich.,
Incentivizing workers with cash was a theme amongst our 3dimensional.com
2016 World Class Processors. While the average compensation for Xerox Corp., Webster, N.Y., xerox.com
shop-floor personnel was the same $15/hr for our 25 top shops and
WITH RAPID
Call
rapidgranulator.com +1 724.584.5220
WORLD-CL ASS PROCESSORS
get great results, Khorshid says. Product lines and customers tric and most are less than five years old. For those 10 machines,
have changed over the years, but we continue to focus on sup- CNR (cnr-plastics.com) has 11 full-time employees, with two of those
porting our customers and having the highest product quality. being certified molding technicians, applying scientific molding
Custom molder CNR Group LLC, Jackson, Wis., made the principles and robust process development.
World Class list in part thanks to its investments in equipment, in CH3 Solutions likewise runs a small but highly efficient fleet.
the view of company president, Bob Albrecht. The companys 10 Davenport says that of their five injection machines, four are all-
machines, which range up to 200 tons in clamp force, are all-elec- electric and one utilizes servo drives for its hydraulic pumps. CH3
is working on a project that incorporates valve-gated hot runners,
gas-assisted injection, and in-mold labelingall in one tool.
Were trying to make sure CH3 is not the same-old typical
molder, Davenport says. Were very technology driven and try to
stay up to date with the trends in the market and new technology.
CH3 started molding in 2015 when it couldnt find someone to
make its proprietary flooring product. Davenport notes that even at
the beginning, when it couldnt afford to buy the latest and greatest
machinery, CH3 took pride in its equipment. When we bought
our first piece of used equipment, Davenport says, we painted it,
made it look new. Every employee in the company had hands on.
Its important to have that culture, where people own it.
Looking at the survey data, there was a slight difference in
average machine age between World Class Processors and all partici-
pants12.35 yr vs. 13.08. On the injection side, more World Class
Fully 95.5% of World Class Processors, like
CH3 Solutions pictured here, offer assembly molders deployed all-electric machines (54.5% of their fleet) than
services, up from 82% in the last survey. the full survey group (45.9% all-electric machines). The percentage
PRODUCT DE
FEC
Benchmarking Sur vey Results
CTS
WITH
BALED FILM
By Heather Caliendo,
Senior Editor
Decking
Producer
Becomes
Supplier of
Recycled
Pellets
Chances are youve seen Trex Company Inc.s composite decking at your local Home Depot. You might Trexs Dave Heglas
even own the product and enjoy it every day at your home. The Winchester, Va.-based company showcases a bag
produced with
(trex.com) has extruded composite decks from a blend of 95% recycled wood and plastic film for more
its recycled
than 20 years. The companys products are offered through an extensive LLDPE pellets.
network of building-products distributors and dealers, and are sold at more
Its been
than 6700 retail locations. With about 600 employees, Trex has two manu-
surprising
facturing plants, one in Winchester, Va., and the other in Fernley, Nev.
that more
Trex uses more than 1.5 billion plastic bags each year to make wood-
companies
alternative outdoor products and is one of the largest recyclers of plastic in
are not using
the U.S. But even companies that use recycled materials are left with excess
recycled
material that could have a second life as well.
pellets.
As they say, necessity is the mother invention, observes Jim Cline, presi-
dent and CEO of Trex. He says that as one of the countrys largest recyclers
of post-consumer and commercial PE, the company found itself with a surplus of material beyond
what it could use in its core line of outdoor products. We challenged our engineering team to come
up with ways to use the excess material and, as usual, they didnt disappoint, he says.
And thus began the start of a new recycling chapter for Trex.
This is an example
of a melt-temperature
probe that has a stem
with adjustable depth.
PART 2
How to Collect and Interpret
Process Data in Extrusion
In this second of three installments, the focus
is on the crucial element of melt temperature.
Many modern extrusion lines are equipped with data-acquisi- Part 1 of this three-installment feature (in January) discussed
tion systems (DAS). These systems can present extruder opera- the proper use of a DAS in extrusion. This article will address issues
tors and process engineers related specifically to the polymer melt temperature. This is the
By Chris Rauwendaal
Rauwendaal Extrusion Engineering
with a large amount of data. second of the three vital signs of the extrusion process, as discussed
There are several critical in Part 1, the others being melt pressure and motor load.
issues in the proper use of a DAS: Melt temperature is usually measured with an immersion
melt-temperature probe. The sensing stem of the probe should be
1. Are the correct process variables measured and monitored? immersed at least 5 mm to provide a good measure of melt tempera-
2. Are these process variables measured correctly? ture. Some melt-temper-
3. Is the data collection rate appropriate? ature probes have a stem
4. Can operating personnel properly interpret the data? with adjustable depth. An immersion probe will
These adjustable create some degree of
melt-temperature probes stagnation downstream
WHAT YOU WILL LEARN can be used to measure of the probe. This can
melt temperature at create problems in ther-
1. MEASURING MELT TEMP: Know your probe options.
different locations across mally sensitive materials
2. MELT-TEMP DISTRIBUTION: Use FEA to plot melt- the depth of the channel. like rigid PVC and EVOH.
temperature distribution in the screw channel.
It is good practice to
3. MELT-TEMP VARIATIONS: Non-uniformity will completely retract the
create extrudate dimensional variations. sensing stem before shutdown to minimize the chance of damaging
4. COLLECT DATA RAPIDLY: Variables have to be the melt-temperature probe when restarting.
measured at least 50 times/sec to capture varations. Immersion melt-temperature probes have some drawbacks.
5. TRAINING: Necessary for operators and Since they protrude into the melt stream, they alter the velocities in
process engineers to take full advantage of the melt stream. This, in turn, will change the viscous heating and
the capabilities of the DAS. temperatures of the melt stream. Therefore, the immersion probe
will measure a melt temperature that is different from the melt
temperature that would occur without a results in large temperature differences within
probe immersed in the melt stream. the polymer melt. The largest temperature
Another drawback is the fact that an gradients tend to occur at the barrel surface.
immersion probe will create some degree of The melt-temperature distribution
stagnation downstream of the probe. This can be determined by performing a non-
can create problems in thermally sensi- isothermal analysis of the flow in the
tive materials like rigid PVC and EVOH. screw channel. In case of a non-Newtonian
A further drawback is the slow thermal polymer melt, this is typically done using
response of an immersion probe. For this finite-element analysis (FEA). Figure 1 shows
reason, an immersion probe cannot detect a color contour plot of melt temperatures in
rapid changes in melt temperature occur- the screw channel of a 63-mm single-screw
ring over a few seconds or less. This is a extruder running a 0.2 melt-index HDPE at
serious limitation of immersion probes 100 rpm. The vertical axis has been stretched
because rapid melt-temperature changes You can also measure melt about eight times to make it easier to
temperature by infrared
occur in every extrusion process. radiation. These thermometers examine the temperature distribution.
Another method of measuring melt are readily available and relatively The top surface is the barrel, the bottom
temperature is by measuring infrared inexpensive. Photo: Raytek surface is the root of the screw, the left vertical
radiation (IR). Infrared thermometers are boundary is the pushing flank of the flight,
readily available and relatively inexpen- and the right vertical boundary is the trailing
sive. Inside the extruder or the die, the melt temperature can be flank of the flight. It is clear that the melt temperatures are highly
measured through a transparent window. non-uniform. The temperatures close to the barrel are relatively low
Another way to measure the melt temperature with IR is to because of the heat transfer to the barrelthe barrel cools down the
use a probe with a sapphire window at its end in contact with the melt that is in close proximity to the barrel. The temperatures at the
molten polymer. The transparent window is mounted in a threaded pushing flight flank are low because the cool melt close to the barrel
stem. The window is made out of sapphire so that it can handle moves down along the flight when it reaches the pushing flight flank.
high temperatures (up 600 C/1112 F) and pressures (up
to 1500 bar or about 22,000 psi). The probe fits in a FIG 1 Melt-Temperature Distribution Using FEA
standard pressure-transducer hole, making installation (63-mm Extruder Running at 100 rpm)
293.8
quite easy. These probes are commercially available.
286.4
The threaded probe with the sapphire window can be 279.0
used in combination with a simple IR thermometer. 271.6
264.1
This allows IR melt-temperature 256.7
Another way to measurement in the extruder 249.3
measure the melt 241.8
barrel or in the die. 234.4
temperature with
IR is to use a probe IR temperature measure- 227.0
219.6
with a sapphire ment provides two important
212.1
window at its end benefits: One, the response 204.7
in contact with the 197.3
molten polymer. time is fast, about 10 millisec.
189.9
Photo: FOS Messtechnik Two, the measurement does 182.4
not disturb the flow, unlike the 175.0
case with an immersion probe. Shown here, the top surface is the barrel, the bottom surface is
Because of the fast response, the IR measurement can the root of the screw, the left vertical boundary is the pushing
detect rapid changes in melt temperature that cannot flank of the flight, and the right vertical boundary is the trailing
flank of the flight. It is clear that the melt temperatures are
be detected by an immersion melt-temperature probe.
highly non-uniform. The temperatures in the hot spot are more
than 100 C above the barrel temperature.
MELT-TEMPERATURE VARIATION
Melt temperatures in extrusion result from viscous
dissipation and heat transfer. In drag flow, the shear
QUESTIONS ABOUT EXTRUSION?
rates and viscous dissipation are relatively uniform.
However, the heat transfer to the screw and barrel Visit the Extrusion Zone.
FIG 2 Experimental Setup for Melt-Temperature Study When the screw discharges the melt,
this melt will be non-uniform in tempera-
57mm 174mm
ture. A number of studies have examined
Sensor
38mm Ports Extruder Screw the variation of melt temperatures in
extruders. One such study was made by E.
Brown and A. Kelly at Bradford University
in England. In this work, a fast-response
thermocouple (TC) mesh was used to
Die measure melt-temperature variation using
Exit
three different extruder screws. The TC
Sensor Port
mesh was located in the breaker-plate
Thermocouple Grid 30mm 30mm
recess of the extruder barrel (Fig. 2).
Support Matrix Screw TC Grid or
Melt temperature was measured at
Breaker Plate Location
multiple locations, as shown in Fig. 3.
It is clear from this figure that the melt
FIG 3 Melt Temperatures vs. Radial FIG 4 Melt Temperature vs. Time temperatures across the channel are quite
Distance from the Center non-uniform, with a low temperature of
220
225 215 190 C/374 F and a high temperature over
220 210 215 C/419 F. The melt temperatures vary
Melt Temperature, C
Temperature, C
215 205 not only across the melt stream but also
210 200 over time, as shown in Fig. 4.
205 195 The melt at TC4 (radial location -10 in
200 190 Fig. 3) drops from 215 C/419 F to 180 C/356
195 185
190 LD150R 70rpm Tapered F within 4 sec and then increases again
180
185 Compression Screw to almost 215 C/419 F within 2 sec. This is
175
180 0 2 4 6 8 10 rapid and substantial melt-temperature
-20 -10 0 10 20 Time, sec
variation. Interestingly, this melt-temper-
Radial Distance, mm TC Location 3 TC Location 4
ature variation cannot be detected with
In this research project, a fast-response thermocouple (TC) mesh was used to measure an immersion melt-temperature probe
melt-temperature variation using three different extruder screws. The TC mesh was because of the slow response time.
located in the breaker-plate recess of the extruder barrel (Fig 2). Melt temperature
was measured at multiple locations (Fig. 3), and was quite non-uniform. The melt In this study the melt temperatures
temperatures vary not only across the melt stream but also over time (Fig. 4). were also measured with an infrared
thermometer. The results are shown in
Fig 5. This figure shows temperatures at
At the root of the screw, the cool melt from the pushing flight three screw speeds: 50, 70, and 90 rpm. The temperature variation
flank moves towards the trailing side of the flight. If there is no increases with screw speed. The variation in TC mesh tempera-
heat transfer with the screw, the melt temperatures will gradually tures is substantially smaller than in IR temperatures. Also, the IR
increase as the melt moves from the pushing flank to the trailing temperatures show much faster variation as a result of the short
flank. The melt reaching the trailing flight flank moves up along the response time of the IR measurement.
flight until it gets close to the barrel. At that point the cycle starts Figure 6 shows infrared melt-temperature measurements
again. The outer region of the screw channel stays relatively cool plotted vs. time for three extruder screws running at 90 rpm. The
because of the heat transfer from the melt to the barrel. The situa- melt-temperature variation for the tapered and stepped screw is
tion is quite different for the inner region of the screw channel. quite large, 15-20 C (27-36 F). The melt-temperature variation for
The melt in the inner region remains in this region as it travels the barrier screw is smaller, about 5-7 C (9-13 F) and displays a
down the length of the screw channelit will not come into close more regular pattern. The time between peaks corresponds closely
proximity with the barrel. The inner region is thermally insulated with the screw speed90 rpm corresponds to 0.67 sec/revolution.
from the barrel by a relatively thick layer of polymer melt. As a result, This means that the screw speed can be determined from the IR
the temperatures in this region rise higher than any other part of the melt-temperature measurement.
channelit is a natural hot spot. In Fig. 1, the temperatures in the The reduced melt-temperature variation in the barrier screw
hot spot are more than 100 C/180 F above the barrel temperature. may be due to the barrier geometry. However, this screw was
Melt Temperature, C
that the reduced melt-
205
temperature variation is
200
due to the presence of the
fluted mixer. The tapered 195
50
screw and the stepped 190
screw had no mixing 185
elements; therefore, these 180
screws can be expected IR Temperature 90 rpm 175 Tapered Stepped Barrier
to result in larger melt- 0 8 0 8 0 8
This shows temperatures at Time, sec
temperature variation.
three screw speeds: 50, 70, and HDPE LDPE
These results clearly 90 rpm. Temperature variation
demonstrate that short- increases with screw speed. Melt-temperature variations in tapered,
The variation in TC mesh stepped, and barrier screw designs. While
term melt-temperature some designs result in more dramatic
temperatures is substantially
variations occur in polymer smaller than in IR temperatures. variationsthe tapered and stepped in
extrusion. In fact, these Also, the IR temperatures particularthe results demonstrate that
show much faster variation as short-term melt-temperature variations are
variations are inherent in
a result of the short response inherent in the extrusion process.
the extrusion process. They time of the IR measurement.
occur because polymers
have very low thermal
conductivity. As a result, conductive heat transfer is very slow. The ID waviness is a common problem in pipe extrusion, but the
time that is required for the melt temperatures to become uniform cause of this problem is not widely recognized. One approach to
by conduction is very longit can be measured in hours for reduce the problem is the use of a large-inventory die. Such a die
production-size extruders. will have long melt-residence times and this will reduce the melt-
Typical residence times for the molten polymer in extruders are temperature variation at the die exit. However, large-inventory dies
around 20-40 sec. The residence times are usually much shorter, by have several drawbacks:
orders of magnitude, than the times required to achieve uniform
melt temperatures by conduction. Therefore, melt temperatures They are expensive.
in extrusion will be non-uniform in most typical extrusion opera- They take up a large amount of space.
tionsespecially when the extruder operates at high screw speed They take a long time to heat up.
and when the melt temperatures are higher than the barrel temper- Long residence times increase polymer degradation.
ature. These melt-temper- They increase changeover times.
ature non-uniformities They result in more scrap.
It is equally important to
are more pronounced on
provide training so that
larger extruders where A much more effective solution is to enhance the mixing capa-
operators and process
heat-transfer distances bility of the extruder. With proper thermal mixing, large-inventory
engineers can take
are greater. dies are not necessary and the ID waviness can be largely eliminated.
full advantage of the
When the tempera-
capabilities of the data-
tures of the melt exiting DATA COLLECTION RATE AND FFT
acquisition system.
the extruder are non- From the information presented earlier, it is clear that rapid data collec-
uniform, the dimensions tion is necessary for certain process variables such as melt pressure, melt
of the extrudate will become non-uniform as the extrudate cools temperature, and motor load. In order to capture short-term process
down and solidifies. These dimensional variations result from variation, these variables have to be measured at least 50 times/sec.
non-uniform shrinkage. The manifestation of this problem in Unfortunately, this capability does not exist on many extrusion lines.
pipe extrusion is waviness of the internal diameter. The calibra- A useful feature of a DAS is Fast Fourier Transform (FFT). This
tion process fixes the outside diameter of the pipe, but the inside is a technique that determines the base frequencies making up a
diameter will vary if the shrinkage is non-uniform. complex signal. FFT is very useful in troubleshooting because
TRAINING
It is not enough to have good instrumenta-
tion and data-acquisition capability. It is
equally important to provide training so
that operators and process engineers can
GW80 Series Super Heavy Duty Wet Granulator take full advantage of the capabilities of
Advanced Technologies, Improved Capacity, Born for Recyclers! the DAS. This is an essential element in a
successful extrusion operation. Some
AVIAN (USA) MACHINERY, LLC. companies skip this critical step and, as a
1901 Powis Court, West Chicago, IL. 60185
TEL: 630.687.9876 FAX: 866.755.9258 result experience only limited benefits
WEB: www.aviangranulator.us E-MAIL: sales@avianusa.com from a good DAS.
Good instrumentation is critically
important in extrusion. Without good
instrumentation and data-acquisition
capability, it is hard to:
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Tips and Techniques
15 Things to Know
About Servo-Driven
Injection Machines
Drive technology for injection
molding machines has been
continuously evolving, and
servo motors have become
widely used in a variety of roles.
Heres what molders need to
know about todays servo drives
in terms of cost, performance,
maintenance, and training.
Shown here: an
injection servo
motor. Speed and
acceleration of servo
vs. hydraulic drives
are hotly debated.
Use of a servo drive with a hydraulic pump Acceleration of a
is becoming more and more common. It servo drive is almost
offers considerable energy savings. certainly greater.
3. Servo (driven) hydraulic IMM pump. Of course, the amount of energy savings depends highly on
A servo-driven hydraulic (or servo-hydraulic) machine is a full- the process point of each specific application. A fast-cycling pack-
hydraulic IMM with a servo motor to drive the hydraulic pump. aging application will have a lower percentage energy savings than
These machines often have a fixed-displacement-pump, but could an application with a long cooling time when the constant-speed
also have variable-displacement-pumps (often DFEE or DFEC) motor would be idling for seconds or minutes.
with a swash-plate. Full-electric machines, where the electric energy is directly
converted into kinetic energy, have the best energy efficiency,
4. Standard hydraulic IMM with variable-displacement pump since there is no transformation from electric energy to hydraulic
These machines usually have a constant-speed motor and a vari- pressure and then to kinetic energy.
able-displacement pump with a swash plate that can be adjusted by A very rough classification would be:
the control to regulate the oil-volume flow of the pump adjusting to
the current demand of the hydraulic system. If the machine does Hydraulic machine with constant speed motor: 100% energy
not move at all, the pumps will still idle and waste energy. consumption;
Hybrid machine with only metering fully electric: 75% to 80%
5. Energy efficiency energy consumption;
The European plastics industry has developed a system to classify Servo-driven pump machines: 65% to 70% energy consumption;
energy efficiency of IMMs. The Euromap 60.1 standard categorizes Full-electric machines: 45% to 60% energy consumption.
machines in certain categories and has developed certain stan-
dards to compare the energy efficiency of similar machines from 6. Repeatability of electric vs. hydraulic drives
different suppliers or executions (full-electric, hybrid, and so on). On full-electric machines, the repeatability of a servo-driven axis
Servo-driven pump (or servo-pump) machines unsurprisingly is at least 10 times higher than hydraulic-driven axis. An active
show much better energy efficiency than machines with a constant- servo-driven axis has almost no delays, while delays with hydrau-
speed motor and a variable-displacement pump. The servo motor
QUESTIONS ABOUT INJECTION MOLDING?
on the servo-driven pump machine only operates if the hydraulics
demand oil flow. During the time when no axis is operating, there is
no pump movement, and therefore no energy consumption by the Visit the Injection Molding Zone.
lics are inevitable. Acceleration, and specifically deceleration, are related to the design and work principle of a variable-displacement
also more accurate with a servo drive than on hydraulic-driven pump and the constant-speed motor. The servo-driven pump
machines. Full-electric machines also allow for instant produc- machine does create a smaller amount of heat in the hydraulic
tion stability, as there is no necessary oil warm-up, and start-up is system. In fact, some manufacturers run a special oil-heating
faster after production has timed out. This is an advantage for sequence to keep the oil at operating temperature during production,
full-electric machines, not for servo- depending on the process point, the machines operating environ-
driven pump machines. ment, and the process sequence of
the specific product/process.
7. Noise level An active servo-
Full-electric and servo-driven pump 11. Machine cost driven axis has
machines usually have a noise level that A full-electric machine is always almost no delays,
is far lower than a standard hydraulic more expensive than a hydraulic while delays with
machine. Modern full-electric and machine due to the necessary hydraulics are
servo-driven pump machines should number of electric drives and inevitable.
have a noise level around 68 dbA. motors and gears (ballscrew or
gearbox or rack and pinion) for the
8. Speed and/or acceleration former. However, in many cases it is easy to calculate an ROI using
Official energy-
Comparison of servo versus hydraulic energy savings and improved utilization (faster cycle due to parallel
rating symbol of
EuroMap 60.1. speed and/or acceleration is matter of movements and greater uptime due to less maintenance), as well as
lively debate in the industry. Full-electric energy rebates that some states and energy companies offer. Servo-
drives have great accelerationmuch better than a pump ramp-up driven pump machines can (with some suppliers) still be slightly
in a hydraulic system, which suffers due to compressibility of the more expensive than standard hydraulic machines, but since servo-
oil and the hydraulic hoses and lines
that expand. The counterpoint cited
by some suppliers is that a perfectly
designed hydraulic system with accu-
mulators and strategically placed valves
can be even more spontaneous and
agile than the servo-driven machines.
9. Parallel movements
Full-electric IMMs generally use a
separate servo drive for each axis. This
makes those machines very flexible
since it allows all axes to be used with
parallel movements, which makes
sense when it is necessary to meter
during mold opening and ejection,
inject during mold closing, eject
during mold opening, and so on.
Servo-driven pump machines and
standard hydraulic machines do not
necessarily have that advantage. Most
suppliers offer a second or even a
Use of separate servo drives for each machine axis allows for parallel clamp and
third pump and hydraulic accumula-
injection movements. Hydraulic machines can accomplish this with multiple pumps.
tors as an option.
10. Hydraulic Design driven pump technology is being pushed hard by the industry as a
A standard hydraulic machine creates a lot of wasted heat through whole, there is more and more competition even among compo-
shearing and friction of the oil during idling, which is mainly nent suppliers, which allows the difference in price (where it still
exists) to be narrowed down to a minimum.
48 Plastics Technology MARCH 2017 PTonline.com
Tips & Techniques
No Water Consumption
consumption changed, fixed-displacement pumps that
including oil-
need no calibration are faster and easier to
cooling waterfor
Drive a conventional change than variable-displacement pumps.
kWh
BUNTING
maintain the pump.
Of course, full-electric machines either
never, or only rarely, need to deal with
pump maintenance at all. The well-known
No Metal. No Doubt.
Rotex coupling (spider-gear) does not
exist on servo-driven pump machines and
full-electric machines, and therefore does
not need to be exchanged. This is some-
thing that the maintenance crew in every
molding shop knows all too well.
On servo-driven pump
machines, the oil does not get
stressed very much and the
FF Series Drawer Filter
oil quality therefore degrades
slower than on a standard
hydraulic machine.
kWh/g
the hydraulic machine puts more strain 0.44
0.30 a standard hydraulic
on the oil. Full-electric machines might
machine, a servo-
not have to deal with oil at all. 0.20 0.27 driven pump
0.10 machine, and a full-
0.00 electric machine.
14. Complexity of machines Hydraulic Servo-Hydraulic Full-Electric
Hydraulic machines in general, whether 240 Ton 240 Ton 240 Ton
they are servo-driven or not, have elec-
tronics, mechanical parts, and hydraulics.
Full-electric machines might only have www.negribossi.com
electronics and mechanical parts, which
reduces the complexity. A good electri-
cian can work on the machine without ACCURATE. EFFICIENT. DEPENDABLE.
needing to understand hydraulics.
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Keeping Up
With Technology
INJECTION MOLDING
New Monitors, Controls, Sensors
Two well-known suppliers of injection monitoring and control Also new in ComoNeo 2.0 is a Restart Assistant, a wizard
systems and sensors introduced several new and upgraded that helps re-establish the process after a mold is moved to a
products at the K 2016 show in Dusseldorf in October. different press. It analyzes the difference between current and
The Swiss parent of Kistler Instrument Corp., reference pressure curves to offer the user suggestions on how
Amherst, N.Y. (kistler.com), brought out ComoNeo to optimize the processfor example, Please change holding
2.0, a brand-new version of the ComoNeo process moni- pressure to 500 bars (7255 psi). The process is iterative, requiring
toring system introduced at Fakuma 2015 a couple of test cycles.
(see Feb. 16 Keeping Up), which itself ComoNeo 2.0 also now incorporates
was an enhanced successor to Kistlers the OPC-UA (Open Platform Communica-
Como Injection system. ComoNeo 2.0 tion Universal Architecture) interface that
(pictured on opposite page) adds auto- is becoming the standard for Industry 4.0
matic process control to the monitoring machine-to-machine data connectivity. This
functions. It controls the switchover enables the ComoNeo system to fully imple-
point from speed to pressure control in ment Multiflow controlautomatic hot-runner
mold filling within each cycle, based on balancing by adjusting tip temperatures
cavity-pressure signals, and analyzing the without the need for a separate PC. It also
difference between current and reference can talk to higher-level MES and ERP
pressure curves. The switchover point can computer systems.
be set manually or determined automati- A second major introduction for Kistler was
cally by the system through analyzing a the ComoDataCenter 3.1, a new version of the
sequence of five test cycles. central monitoring system for all Como
TO THIS!
716.822.2804 www.PTM.Rapistak.com
Injectionand now ComoNeosystems plantwide. It now stores Priamus also has enhanced the Q-Button on its FillControl
all mold settings centrally. It also now offers the same user systems. When a user has established a process that produces
interface as ComoNeo and will translate input from older Como good parts, pushing the Q-Button automatically sets the six-
Injection systems to the new interface. Both types of systems sigma SPC limits for key process variables. In its latest iteration,
are now linked by a common database. Extended functionality the button establishes three levels of limitspre-warning,
includes more detailed good/bad part analysis, with ability to warning, and alarmto alert the user to process drift well
zero in on any cycle and the pressure curve for each cavity. It before bad parts are produced.
also provides cpK values A new portable
for the process. FillControl system
Kistler also has a new (photo on opposite
piezoelectric pressure page) allows moni-
sensor, Type 6185, toring the process by
which measures only 2 means of a large tablet
mm frontal diam. and computer that plugs
is insensitive to the into the sensors on the
position in which it is machine and mold. All
installed. This elimi- the required cables,
nates the susceptibility amplifiers, and power
to inaccurate measure- supply are housed in
ments due to mounting the transport case.
tolerances, making Also new is FillCon-
installation by mold- trol V for automatic
makers much easier balancing of valve
and more reliable. gates. It detects the
Kistler also brought out arrival of the melt
the Type 1722 multi- front via in-cavity
channel connector, temperature sensors,
which simplifies connection of single-wire coaxial cables. thereby detecting the different filling times from cavity to
Meanwhile, Priamus of Switzerland (U.S. office in Bruns- cavity. The Priamus system calculates the optimized settings
wick, Ohio; priamus.com), showed several updated injection of the pin stroke for every cycle and transmits them to the
monitoring/control products. Under the banner of Quality valve controller via an interface. FillControl V can work with
4.0, Priamus has added an OPC-UA interface to its FillCon- the valve-gate controls of sister company Synventive Molding
trol systems, which allows it to transmit quality data from Solutions, another member of the Barnes Group (synventive.
an entire molding cell to a network via an MES system. At com) to profile the opening speed as well as timing of the
the show, Priamus demonstrated this connectivity with the valve pins. For cold-runner LSR molding with valve gates, the
authentig MES system from T.I.G. of Austria (tig-mes.com), Priamus system has worked successfully with the Servo Shot
recently acquired by Engel. system of ACH Hefner of Austria (ach-solution.com).
M-ATEX Die Splitting TITAN Plus Control 100% Flake Capability A/B/A Co-ex
Support Automation Structure
High vacuum
twin screw extruder
by Bandera
HVTSE Model 5 Zone Temp Station Dual Payoff Lamination Cell Film Access Hatchways
170mm/42D w/3500
Co-extruder
Processing Technologies International, LLC | 2655 White Oak Circle Aurora, IL 60502 | Tel: 630.585.5800 | Fax: 630.585.5855
INJECTION MOLDING
Industrys most
reliable Melt Pump
From through-hardened gears to high-wear
bearings to leak-free, anti-galling seals, PSI
www.psi-polymersystems.com melt pumps provide you consistent, trouble-
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What more can you get Join the ranks of processors turning to PSI
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More than 45,000
successful machines
BOY has become the leading
www.boymachines.com supplier for injection molding
machines up to 110 U.S. tons
design
clamping forces.
ll proven
We logies
With efficient Servo-Drive, the
new techno
EconPlast technology and the
control Procan ALPHA BOY
BOY Machines, Inc. | Exton, PA 19341 | Ph 610.363.9121 | Fx 610.36
610.363.0163 | E-Mail: sales@boymachines.com sets standards world-wide.
High-Level Training
for Molders
ProMolder 3 is a new, highest-level certi-
fication seminar from Paulson Training
Programs, Chester, Conn. This rigorous,
hands-on, certification course features
20+ hr of machine time plus time with
Paulsons SimTech injection molding simu-
lator. The aim of the course is to prepare
graduates to confidently make production
floor decisions and become key produc-
tion personnel. Paulsons ProMolder
Ribbon Blenders with
3 seminar is a completely immersive Higher Precision
learning experience over five days. Gradu-
ates of Paulsons ProMolder 1 & 2 or those New features are being offered on Ross
who successfully complete the equivalent Ribbon Blenders from Charles Ross &
Paulson CD/DVD or web-based training Son, Hauppauge, N.Y., for processors
meet the requirements to enroll in Paul- requiring extra precision and efficiency.
sons newest seminar. The course begins Materials are blended by a horizontal
with a review of ProMolder 2 and covers agitator consisting of inner and outer
key concepts including: helical ribbons in a U-shaped trough. The
ribbons are precisely pitched to move
Advanced analysis of part properties materials in a well-balanced axial and
and machine solutions based on four radial flow pattern.
plastic variables; The Model 42N-120SS (shown) is a
Practical hands-on application experi- 120-ft unit, now equipped with:
ence in machine settings;
Establishing upper and lower SPC A solid agitator shaft with precision-
control limits (UCL and LCL), trend formed ribbons having angled leading
analysis, and more. edges to prevent material buildup;
860-526-3099 paulsontraining.com Scrapers welded to the spokes and
ribbons, having a close tolerance (1/8
AUXILIARIES in.) to the end walls. As a standard,
trough corners are radiused to further
Small Dry-Ice Blaster eliminate dead space;
For Mold & Parts Cleaning Clear polycarbonate on the cover
and shaft guards. The cover can also
At Octobers K 2016 show in Dusseldorf,
include multiple ports for ingre-
Asco Carbon Dioxide Ltd. of Switzerland
dient additions, lights, spray system,
(U.S. office in Jacksonville,
venting, and vacuum transfer. Opera-
Fla.) presented its newest
tors can safely view the batch and
and smallest dry-ice blasting
charge raw materials while the agita-
unit for cleaning molds and plastic
tors are running;
parts. The Ascojet 608 boasts low
Air-purged mechanical shaft seals with
compressed-air
replaceable fluoropolymer seal faces;
consumption
Pneumatic spherical disc valve, which
and low noise
provides a large opening and minimizes
level. Its inte-
dead space. Discharge connections can
grated pellet
be customized to mate with the users
grinder allows
material-handling system.
blasting with
631-234-0500 mixers.com
the finest ice
particles for
even gentler
cleaning of molds and part surfaces. It
also has a vertically adjustable handle
and integral safety grounding roll.
904-278-6503 ascoco2.com
DECORATING
TEAM UP.
Score a touchdown with
Lusin and Ultra Purge!
ChemTrend.com
Austria-based Lindner Group (U.S. office in Raleigh, N.C.) introduced High-Performance Stabilizers
the Micromat WS wet shredder at K 2016; it is specially designed For Polyolefins Outdoors
for pre-shredding contaminated post-consumer plastic
A new line of stabilizers said to deliver exceptional
scrap, such as lightweight packaging, bottles, or films.
UV and long-term thermal stability to PP and other
By directing a jet of water onto the rotor, friction during
polyolefins used in outdoor building and construction
shredding can be used to detach dirt particles. This means that the
has been added to the proprietary Cyasorb Cynergy
material undergoes pre-cleaning from the outset, which has a positive
Solutions portfolio of Solvay Technology Solutions,
impact on downstream processing. The water simultaneously ensures
Woodland Park, N.J. (formerly Cytec Industries).
uniform and controlled material discharge.
New B Series stabilizers are suitable for use with neat
Once the material has passed through the pre-shredder, screw
and reinforced resins, and reportedly will not contribute to
conveyors deliver it, together with the water, directly to the new
blooming or delamination in painted parts. Target appli-
Rafter pre-washer. The Rafter gently and thoroughly detaches and
cations include TPO roofing, polyolefin roofing tiles and
separates contamination and adhering paper from the plastic.
shakes, solar shingles, siding, shutters, and geomembranes.
919-610-2835 l-rt.us
973-357-3100 solvay.com
Meet us at
Chinaplas!
Booth F41,
Hall 2.1
EXTRAORDINARY TECHNOLOGIES
WWW.NORDSONPOLYMERPROCESSING.COM FOR TODAYS PLASTICS
TESTING/MEASURING
60
ROI IN JUST
DAYS
Reduced 3 operators to 1 per shift Easy programming and safe, flexible deployment
RECYCLING ADDITIVES
& Sorting edly has performance equivalent to industry workhorse 810TM linear trimellitate
plasticizer and is formulated for wire/cable and automotive slush molding. New
Sesotec GmbH (U.S. office in Bartlett, SynPlast L9TM, which relies on a linear 9-carbon alcohol, offers abundant supply
Ill.) showcased its Rapid Pro-Sense availability to help counteract historic supply-chain disruptions of 810TM.
metal separator at K Flexible PVC compounders have traditionally relied on 810TM to achieve critical
2016. The unit detects and performance properties at both elevated and low temperatures. When linear 810
separates magnetic and non- alcohol became scarce in 2013, leading to a supply shortage in the workhorse plas-
magnetic metal particles, even if they ticizer, PolyOne began developing its alternative in cooperation with a leading wire
are encased in plastic. This ensures the and cable PVC compounder.
quality of plastic granulate and protects 866-765-9663 polyone.com
processing machines against damage
and clogging.
In addition, Sesotec presented for
the first time the new Flake Purifier+
sorting system, which is based on a
modular approach that allows combina-
tions of various sensors for contaminant
detection, including sensors for metal
separation, color separation/sorting,
and separation/sorting by polymer types.
The + in the system stands for
optimized material infeeding for a more
evenly distributed material flow and
increased material throughput. The
system also allows easier maintenance
and integration. The + also stands
for the dust-proof system design and
for the integrated connections for dust
and label extraction, which increase
efficiency in recycling.
224-208-1900 sesotec.us
COMPONENTS
FOR PLASTICS
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THE CONVEYING PRODUCTS PEOPLE
MATERIALS
THE X-DIE
& High Performance
Polypropylene Greenberg reported at the end of January PVC Price expected to settle 2/lb higher after a
Price Trends that the PP market went from bear to bull Trends similar move in December, PVC suppliers
even before monomer costs began to soar, were aiming to implement their February
Homopolymer Pipe
attributing the sharp market turnaround 4/lb hike and also issued 3 increases for
JAN FEB and tighter supplies to months of lowered JAN FEB March 1.
production output and heavy exports. RTis Kallman ventured that 3-4 of
10/lb Spot prime PP prices shot up by 11/lb and 3-4/lb the February increase would go through,
offgrade even more, Greenber reported. noting that he expected a third successive
Copolymer Explaining the monomer price Gen. Purpose 2/lb ethylene price increase for February
JAN FEB surge, PCW cited tightness due to throt- JAN FEB contracts. Ethylene tightness due to both
tling back of production at the end of scheduled and unplanned outages has
10/lb 2016, along with a spate of planned and been driving the higher prices. Kallman
3-4/lb
unplanned outages. PCW also reported also predicted that if suppliers imple-
that Formosa was about to restart a PP unit after a maintenance mented the full February 4/lb increase, the March increase could
outage, while two other suppliers were said to experience be pushed off.
lingering effects from outages in late 2016, such as delayed ship- He also noted that although PVC suppliers had strong inven-
ments and limited spot resin availability. tories going into this year, there may be some resin constrictions
Newell said the market is likely to become more balanced in due to planned maintenance outages, particularly as processors
April, and prices would settle down a bit. Still, he and Greenberg would be looking to stock up before the start of the construction
expected PP prices to reach as high as the low 60s (/lb) before the season in the second quarter. Kallman said all indications were
end of March. Both concede that the low prices of 2016 are unlikely that little resin is available for exports, but there is adequate
to recur this year. Newell foresees prices in the high 40s to low 50s. supply for domestic consumption. He ventured that once
Higher monomer prices were expected to cause PP demand ethylene and PVC maintenance turnarounds are completed, there
destruction through the first quarter, noted Newell, who saw PP may be some easing of prices; though if PVC demand is as strong
processors working off inventories and buying only as needed. as some predict, the price increases now going through might
well be maintained for a time.
JAN FEB
affects HIPS) tabs are also higher. Kallman editor for this PCW report, said the average
attributed the situation to a global tight- 1.1/lb 1.7/lb cost of feedstocks in January was 55.8/lb, up
ness in benzene, monomer, and butadiene 3/lb from December, according to one
5/lb
supplies, primarily due to planned and calculation used for monthly PET pricing tied to contracts. Meanwhile,
HIPS unplanned production outages and higher DAK Americas successfully hiked its PET resins by 5/lb on Jan. 1.
oil prices. He also noted that there have been Imported prime PET averaged 52.45/lb in January, up 1.95
JAN FEB
no lower-priced PS imports coming in. He from December (delivered duty-paid U.S. port basis). The volume of
expected some softening in PS prices during imports was up 13% through November 2016 from 2015, according
5/lb the second quarter, possibly as early as April. to USA Trade Online data, Cronin noted.
January 201754.7
Custom processors grow at fastest clip since March.
With a reading of 54.7, the Gardner Plastics Business Index grown every month but two since March 2016. Companies with
showed that industry grew for the first time since October 2016 50-99 employees had an index above 60 for the first time since
and at its fastest rate since January May 2016. Processors with 20-49 employees grew for the fourth
2015. In general, the industry has time in five months. Processors with fewer than 20 employees
trended up since July. expanded for the second
Both new orders and produc- straight month.
Processing plants of all
tion grew at a very strong rate. The The Southeast was the
sizes showed growth.
rate of growth in new orders was the fastest growing region
fastest since March 2016. And the for the third consecu-
rate of growth in production was tive month and has grown for the last nine months. Its index
Steve Kline Jr. the fastest since January 2015. The in January was easily its highest since the survey began in
Dir. Market Intelligence backlog index grew for the first time December 2011. The North Central-East also grew at its fastest
since January 2015. This indicates rate since the survey began. The Northeast grew in four of the
that capacity utilization should increase in 2017. Employment last five months. The North Central-West grew for the first time
increased after one month of contraction. Exports continued since June 2015. Both the West and South Central contracted.
to contract but at a slightly acceler-
ating rate since October 2016. Supplier
deliveries continued to lengthen.
Material prices increased at a Plastics Industry Business Index
significantly accelerating rate in 70
each of the last two months. The
index was at its highest level since Values above 50 indicate growth
February 2014. Prices received
increased for the fourth time in five 60
months. The rate of increase was the Jan.
fastest since October 2014. After a 2017
huge jump in November due to the Index
50
election results, the future business 54.7
expectations index increased again
in January, when the index was at an
all-time high. 40
The automotive industry
continued its strong growth for the
third month in a row. Electronics Values below 50 indicate contraction
30
grew significantly for the fourth
JAN 14
JUL 14
JAN 12
JUL 12
JAN 17
JAN 15
JUL 15
JAN 16
JUL 16
JAN 13
JUL 13
In December 2016, new vehicle sales in the U.S. were 18,680,000 Real Motor Vehicle & Parts Consumer Spending. Despite the
units (seasonally adjusted at an annual rate). That was the highest increase in the real 10-yr Treasury rate at the end of 2016, real motor
level for vehicle sales since July 2005. But vehicle and parts (MV&P) spending by consumers grew significantly
Steve Kline Jr.
Dir. Market Intelligence
the high level of new vehicle sales is not in the fourth quarter of 2016. In December, MV&P consumer
leading to accelerating growth in produc- spending was 8.7% more than it was a year ago. That was the second
tion. Lets look at some of the leading indicators to see where the fastest rate of growth since January 2015. And it was the fourth time
automotive industry might be headed in the next six to 12 months. in five months that the rate of change from the same month a year
earlier was at least 4.5%. This is significant because the historic
Real 10-Yr Treasury Rate. The real (inflation-adjusted) 10-yr U.S. average for that rate of change is 4.2%. As a result, the annual year-to-
Treasury bond interest rate was 1.23% in December 2016, which date rate of growth accelerated for the third straight month to 2.9%,
was an increase of 24 basis points (hundredths of a percent) from which was the fastest rate of annual growth since February 2016.
the previous month. This was the highest real 10-yr Treasury rate But if the change in the interest rate continues to rise, expect
since last April. The nominal rate was 2.49%, which was the MV&P spending to grow at a slower rate around the second quarter.
highest since September 2014. But the rate of inflation has been
rising too. In December, the inflation rate was above 2% for the Real Motor Vehicle & Parts New Orders. New MV&P orders grew
first time since June 2014. The increase in inflation was limiting 2.7% in December compared with one year ago. This was the third time
the rise in the real 10-yr Treasury rate (the real rate is the nominal in four months that new orders grew. However, the rate of growth from
rate minus inflation). The year-over-year change in the real rate the same month a year earlier slowed noticeably since March 2016.
increased to -89 basis points. That was the second straight month Therefore, the year-to-date annual rate of growth in new orders decel-
of an increase. The increase in the year-over-year change in the erated to 2.1%. This was the ninth consecutive month of decelerating
10-yr Treasury is likely to lead to a decline in new vehicle sales as growth. And the annual rate of growth in December was the slowest
financing becomes more expensive. since May 2010, which was the last time that the annual rate of change
in real motor vehicle and parts new
orders contracted.
Real MV&P Spending Leads MV&P Production
30 40 Motor Vehicle & Parts Industrial
24 32 Production. The growth rate in motor
vehicle and parts production was quite
18 24
strong in December 2016. Compared
12-Mo. Rate of Change
12-Mo. Rate of Change
Real MV&P Spending,
Jan 12
Jan 04
Jan 14
Jan 96
Jan 06
Jan 16
Jan 00
Jan 10
Jan 98
Jan 08
WWW.TINIUSOLSEN.COM WWW.RAPISTAK.COM
Managing molds
and dies can be
time consuming
and difficult, thats
where our Mold Management Systems help you manage your
inventory, become better organized, protect your investment and
Test Equipment: Hardware and software for tensile, flexure, com- create a safer working environment. For more information email us
pression, puncture/burst, shear, melt indexing, and impact testing at ptsales@rapistak.com.
of plastics.
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Leaders in continuous melt filtration since 1969
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Visit our website for informa-
tion on ENGELs machine and
automation concepts, innova-
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tions, and extensive customer support. With global service, pro-
duction and sales resources, ENGEL is a partner you can count on
for long-term quality and technology solutions that support Worlds largest selection of dryer technologies and blenders
innovative products and effective production. with unmatched system design and control capabilities.
1-800-BESTDRY (1-800-237-8379)
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With a continually expanding range of products,
PPE is the largest supplier of molding accessories
to the plastics industry. With offices in Ohio,
Nevada and Florida, PPE provides fast delivery
and the personal attention that your order
deserves. Contact us at 1-800-362-0706,
sales@ppe.com or visit www.ppe.com
Canon offers custom mold making solutions. Contact us at
1.866.CANON or visit www.cvi.canon.com to find out more.
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WWW.DAK AMERICAS.COM
As
Manufacturer
one of the worlds
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Resins,
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Color Pumps. Technologies, DAK is setting new standards for the industry.
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TIME-CRITICAL
CONFIDENTIAL
GRINDING
PROBLEM SOLVING Services
Since 1973
Granulation / Coarse Grinding
Chemical Analysis and
Characterization Pulverizing / Fine Grinding
Thermal Analysis and Rheology PLASTICS Cryogenic Grinding
Mechanical Testing POLYMERS Sifting / Classifying
Organic Synthesis RUBBER Blending / Mixing
Lab Compounding, Pelletizing and ASTM Destructive Grinding
Injection Molding
Failure Analysis 10626 KINGHURST
Quality Assurance HOUSTON, TX 77099
Chemical Resistance P.O. Box 363, Bloomsbury, NJ 08804
Accelerated Weathering 281-879-8600 908-479-4400
FDA Extractions FAX 281-879-8666
www.allgrind.com e-mail: info@allgrind.com
R&D
1-800-243-ROSS
www.ribbonblenders.com 800-278-4241 info@binmaster.com
2017 BinMaster, Lincoln, NE 68507 USA
Avian USA Machinery LLC . . . . . . . . . . . . . . . . . . . . . . 44 Hosokawa Alpine American . . . . . . . . . . . . . . . . . . . 62 Republic Machine Inc. . . . . . . . . . . . . . . . . . . . . . . . . 59
www.aviangranulator.us www.halpine.com www.republicmachine.com
Beaumont Technologies Inc. . . . . . . . . . . . . . . . . . . 22 IMS Industrial Molding Supplies . . . . . . . . . 24 a,b Ross, Charles & Son Co.. . . . . . . . . . . . . . . . . . . . . . . . . 9
www.beaumontinc.com www.imscompany.com www.mixers.com
Bunting Magnetics Co. . . . . . . . . . . . . . . . . . . . . . . . . .50 Maguire Products Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Tinius Olsen Testing Machine Co. Inc.. . . . . . . .58
www.buntingmagnetics.com www.maguire.com www.tiniusolsen.com
Canon Virginia Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Negri Bossi USA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Universal Robots USA Inc. . . . . . . . . . . . . . . . . . . . . .60
www.cvi.canon.com www.negribossi.com www.universal-robots.com
Chem-Trend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58 Novatec Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27, 29, 31 Windmoeller & Hoelscher Corp. . . . . . . . . . . . . . . 24
www.chemtrend.com www.novatec.com www.whcorp.com
Conair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Back Cover PCS Co. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58 Wittmann Battenfeld Inc. . . . . . . . . . . . . . . . .16 a,b
www.conairgroup.com www.pcs-company.com www.wittmann-group.com
Coperion K-Tron . . . . . . . . . . . . . .Inside Front Cover PFA Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Zeiss Industrial Metrology LLC . . . . . . . . . . . . . . . . 23
www.coperion.com www.pfa-inc.com www.zeiss.com/metrotom
Three-Pronged Growth
Strategy In U.S., China
& Mexico
Diversified molder pursues growth
on two continents in medical,
Brand-new 2500-ton Engel press at EVCOs plant in Monterrey,
packaging, and large parts. Mexico, part of its going big strategy in North America. It will
be accompanied by a second 2500-tonner now on order.
The three years since our last editorial visit to EVCO Plastics (reported 2. Packaging: Evans said EVCO plans to double the number of
in Jan. 14) have seen several capacity expansions and exploration of at machines (currently five Huskys with stack molds) at the
least two new, cutting-edge technologies. A recent Advanced Molding Plant (AMP) in DeForest.
By Matt Naitove
Executive Editor
sit-down with Dale Evans, president of the 53-year-
old, family-owned custom molder outlined how the 3. Large parts: While At the
company is pursuing growth on numerous fronts simultaneously. same time that EVCO is
Our new concept is
The company (evcoplastics.com) has 1000 employees and 170 expanding in China for med-
for every operator to
injection molding machines at nine plants in three locations ical parts, Evans noted that
have a cobot buddy.
in The U.S., Mexico, and China. It implemented $10 million in investing in large-part
capital improvements in 2016 alone, including purchase of seven molding is a defensive strategy
all-electric Toyo machines and a new Engel vertical press. Evans against Chinese competition due to prohibitive shipping costs
described three current focuses for the company: from overseas. Applications include parts for tractors, ATVs, jet
skis, golf carts, and outboard motors. EVCO has big presses in
1. Medical devices: EVCO is planning to remodel and expand its Oshkosh, Wis., and in Calhoun, Ga., which has become the com-
MED facility at the company headquarters in DeForest, Wis. Those panys large-part leader, recently expanded from 60,000 to
plans include tripling the size of the 30,000 ft2, Class 100,000 (ISO 110,000 ft2 and housing six large machines. Recent purchases
include two 3300-ton servohydraulic Ube machines and
two all-electric, 1000-ton Toyo presses, the first of that
size in the U.S., according to Evans.
MATERIAL HANDLING
MACHINERY
Look to Conair for auxiliary equipment that performs, people that solve problems and
support thats there when you need it. Weve served the automotive plastics industry for
more than 60 years, doing our part to help you make products that perform better, last
longer and yes stand out from your competition.
Visit conairgroup.com/transport