Electric Machines Starting to buzz

Posted on April 6, 2011 by admin

    

Growing use of electric drives in blow molding machinery gathered steam at the K 2010 show, as suppliers rolled out new all-electric and hybrid models for extrusion blow, injection-blow, and stretch-blow production. There was also a strong emphasis on higher output as demonstrated by a new dual-parison hydraulic wheel machine that claims production rates approaching that of PET.
 
Other new developments included novel lightweighting options for PET containers, an automatic handle-insertion system, a novel mold-change system with removable inserts, and a vision-based quality-management system for rigid containers. (Additional news was reported in our September K show preview.)
 
 
ALL-ELECTRIC EXTRUSION BLOW
Uniloy Milacron (uniloy.it) introduced the first all-electric sequential coextrusion machine for producing 3D automotive air ducts. The twin-parison UMA 12 SeCo2 EnergiaZero has a clamp force of 12 metric tons in a tiebarless configuration. W. Muller GmbH (wmuller.com) developed a patented sequential coextrusion head for the machine.
 
Bekum (bekum.de) launched the production model of its EBlow x07 D series all-electric shuttle machine. The series is available with platen widths of 350 to 700 mm and clamp force of 8 to 24 metric tons (m.t.) in single and twin-station versions.
 
In development is an all-electric continuous-extrusion shuttle from Automa (automaspa.com) for bottles up to 6L. The Apex AT480D, slated for commercialization early next year, has 10 m.t. of clamp force and can run up to six cavities. The double-carriage machine has a dry cycle of 2.2 sec.
 
Plastimac (plastimac.com) showed off its latest all-electric Plastiblow PB5E/DL. The double-station extrusion blow unit comes with 80-mm horizontal extruder and a smaller vertical extruder for producing 5L jerry cans with a view stripe. The head design is said to facilitate precise parison control and rapid color change.
 
For injection-blow, MBM Maschinenbau Muhldorf GmbH (maschinenbau-muehldorf.de) unveiled its second-generation fully-electric machine. The Unimax 50FE-EcoSpeed has a 50-m.t. clamp and is about 20% more energy efficient than its predecessor. It is designed to process a wide range of materials while offering improved process control and quiet operation. Cleanroom compatibility suits it to pharmaceutical and cosmetic/personal-care bottles.
 
The new 85S hybrid injection-blow unit from Jomar Corp. (jomarcorp.com) produced 4-oz clarified PP medical bottles in 10 cavities at 3500/hr at the show. Another new injection-blow machine from Jomar is the Model 20 for small bottles.
 
PUSHING THE ENVELOPE ON SPEED
Wilmington Machinery (wilmingtonmachinery.com) highlighted dual-parison capability for its SB (Small Bottle) Series of extrusion blow wheel machines (introduced at NPE 2009), boosting production output to near PET levels. It molds 80- to 250-ml containers for single-serve dairy, juice, yogurt, and food. With 40 stations, a two-parison model has demonstrated 6-sec cycles for an 80-ml HDPE bottle, a rate of 800 bottles/min. With 60 stations, output could be 1200/min.
 
Kautex Machines Inc. (kautex-group.com) showcased its KLS machine range with integrated downstream automation for quality management and product traceability. Off-spec parts were identified via leak detection, part weighing, and vision inspection.
 
There was also strong emphasis on improved speed and output in stretch-blow molding, as demonstrated by KHS GmbH’s (khs.com) InnoPET Blomax Series IV reheat model, which now produces 0.2- to 2L bottles at 72,000/hr, vs. the previous rate of 43,200/hr.
 
SIPA SpA (sipa.it) launched a new rotary stretch-blow molder that’s said to offer increased production flexibility for different size containers. The SFR 6 EVO has six cavities and is the smallest version in the series, producing up to 13,800 bottles/hr. It is ultra-compact and can be equipped with preferential heating. It has produced 1L water bottles weighing just 16 g (with a stretch ratio of 18) at 2200/hr.
 
Nissei ASB Co. (nisseiasb.co.jp) has boosted PET bottle output with a new two-row, one-step stretch-blow machine and also introduced a reheat model for wide-mouth hot-fill applications.
 
SAVING ENERGY & MATERIAL
Sidel (sidel.com) showed SmartWeight, a lightweight 500-ml PET water bottle weighing less than 10 g with a much stiffer base for better mechanical performance and appearance. The company’s overstroke base technology consists of synchronizing the blow molding process with the rise of the base, thus increasing the lengthwise stretching rate of the preform. This helps to decrease the quantity of material in the base and ensures more uniform distribution.
 
Krones AG (krones.com) introduced its NitroPouch concept to produce a “featherweight” 330-ml PET water bottle weighing just 4.4 g with wall thickness from 0.06 to 0.1 mm. Nitrogen gas at 1.5 bar introduced during filling and capping gives the bottle sufficient rigidity. Bottles meet topload requirements for warehouse storage and transit even after internal pressure falls to 1 bar. A minimum nitrogen pressure of 0.3 bar is required to maintain adequate stiffness for a good consumer “feel.”
 
An optimized oven configuration helps reduce power consumption by up to 45% and heating time by up to 15% with Sidel’s SBO Universal2 Eco stretch-blow molder. It uses fewer heating modules and fewer lamps per module.
 
New FlexWave microwave heating technology from Krones uses significantly less energy than infrared ovens. This oven concept for Contiform stretch-blow machines requires no start-up time and offers processing flexibility because it is not affected by preform color, initial temperature, grade of PET, or proportion of recyclate. It can even process two-color preforms. Fewer heating stations means less waste in case of an emergency stop.
 
Krones also launched the ProShape alignment and temperature-control module for molding oval or asymmetrical containers. Inserted between the standard ovens and blowing wheel, the module uses aluminum molds to achieve a precise temperature profile for producing unusual bottle designs or for lightweighting oval containers. Production rates can be up to 2000/hr.
 
Meanwhile, Siapi S.r.l (siapi.it) launched its HandleMatic 360° concept, which permits integration of a handle for any type of container during or after blowing. The system has been successfully implemented in North America with Siapi’s EA2S blow molding machines for 5-gal refillable PET water jugs.
 
Sidel has developed the 3L DeepGrip PET bottle with a deep blow molded grip that requires no external handle. Developed with PTI-Europe, the container uses Sidel’s punching-conforming technology to produce a single-material bottle and handle suitable for water and vegetable oil. The bottle is formed in a standard mold where the reversed cavity of the future grip is preformed, creating two “ears.” The bottle is then conveyed by its neck with grips for transfer to the conforming mold. The two ears are pressed against each other via punching to obtain the deep grip. The pistons turn the material over and form the grip, while simultaneous blowing at a pressure of less than 20 bar prevents bottle deformation.
 
For greater production flexibility, Sidel developed the Modulomold system, which enables several different bottles of the same size (up to 0.7L) to be produced in a single mold using removeable inserts. The bottles have two shared parts (the labeling area and the base) while the shoulder and/or body can be customized using the inserts. It takes less than 30 sec to change a set of inserts.
 
Sidel also showed the SafeSense stretch-blown HDPE bottle as an option to extrusion blown HDPE containers for dairy products. It is 20% lighter thanks to the preform conditioning that precisely controls thickness distribution. Airtight capping is also possible without an aluminum sealing lid. Stretch-blown HDPE bottles also offer higher output and less waste than extrusion blowing.
 
A vision-based quality-management and process-monitoring system was shown by Agr International Inc. (agrintl.com). The OptiCheck finish/seal surface module monitors and manages finish defects and helps ensure proper closure fit and function. A multi-camera imaging system provides 360° gauging of container finishes from 20 to 80 mm. The OptiCheck sidewall uses four cameras for 360° inspection for common defects in translucent materials.
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Lots of Action in Plastics Recycling

Posted on March 10, 2011 by admin
Clear Path Recycling, LLC (CPR) last month completed the first phase of its new PET recycling facility in Fayetteville, N.C. Phase 1 can recycle up to 160 million lb/yr of PET bottles into flake. CPR is a joint venture of carpet maker Shaw Industries Group, Inc. and PET resin supplier DAK Americas LLC (dakamericas.com), both of which will use the flake from CPR in their products.
 
•Meanwhile, this past summer, MVR, a supplier of recycled PP, PS, LDPE, LLDPE, and HDPE pellets based in Boca Raton, Fla. (mvrecycling.com), opened a new recycling plant in Frankfort, Ky. It can sort, wash, and pelletize 90 million lb/yr.
 
•Leigh Fibers, Inc., Wellford, S.C. (leighfibers.com), reportedly the largest fiber recycler in North America, established this past fall a dedicated business unit to divert used carpet from landfills and turn it into fibers and densified “agglomerate” ready for use by plastic molders. Leigh Carpet & Plastics Recycling, LLC in Spartanburg, S.C., can reclaim more than 100 million lb/yr of used carpet. The new venture is already reprocessing the most common carpet fibers—nylon 6 and 66, PP, and PET.
 
•HPC Industries LLC, Los Angeles, a holding company active in plastics packaging, recently established a recycling venture, CarbonLITE Industries LLC. It will open a 220,000-ft2 plant in Riverside, Calif., by around mid-year to turn PET bottles into bottle-grade pellet and flake. The first-phase capacity will be 100 million lb, which is planned to double by 2012.
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How to Set Up & Maintain an Efficient Resin Handling System

Posted on February 21, 2011 by admin
Materials represent the single largest expense in most plastics processing facilities. In today’s world, having a reliable resin-handling and conveying system is as important as having reliable electrical power. Design, maintenance, and operation of the system can have everything to do with how well it meets production goals and objectives. Some systems can be quite big and complex, and it is always a good idea to get the advice of experienced system specialists. From design to installation to start-up and ongoing operation, their knowledge can help you avoid problems and get the most from your system.
 
The following hints and tips can help you get things right if you choose to design and install a system yourself, or they can help you prepare for a constructive conversation with a system supplier.
 
GETTING STARTED
First: Identify all of the materials that you process in your plant and where each material comes from. Refer to those silos, bins, and gaylord boxes as “sources.” Keep in mind that blenders and dryers may also be considered sources if loaders are pulling material from them.
 
Second: Make a complete list of every molding or extrusion machine in your plant and identify them as “destinations.” In this context, the hopper of a dryer or the material bins on a blender are considered destinations, since the system will be delivering material to them.
 
Third: Determine the maximum throughput rate (weight/hour) for each destination. The sum of these throughput rates, plus a factor for each 90° bend in the system and the horizontal and vertical distances that material must travel, will give you an indication of how large a vacuum pump will be needed and what diameter the conveying lines should be. Your equipment supplier can help perform these calculations and recommend the ideal pump(s) for your application.
 
In most cases, the line size will be dictated by the total throughput rate of all the machines served by that system pump. Remember to keep all the conveying lines served by a given pump the same size and make sure the line size matches properly with the horsepower of the pump. For instance, never put a large 15-hp pump on a small 2-in. OD line. The proper size for a 15-hp pump is 3 in. OD.
 
Rules of thumb for pump horsepower and line sizes:
 
5 hp = 1.75 or 2 in. OD line size.
7.5 hp = 2.25 or 2.5 in. OD.
10 hp = 2.5 in. OD.
15 hp = 3 in. OD.
25 hp = 4 in. OD.
Fourth: Pay attention to details. Vacuum-loader inlet tubes should match the system piping. Make sure existing loader voltages match up properly with the control system. Be sure the controller you choose has the features you need or that can be added in the future. It’s always much less costly to have features added at the factory rather than having technicians visit your plant to download new programs and add input and output cards.
 
Strategically locating the vacuum pump near the farthest machine from the source point will have the effect of balancing the system. A short vacuum line should have a long material line, and vice-versa (see illustration opposite).
 
 
DESIGNING THE SYSTEM
Keep material runs as straight as possible and minimize the number of elbows. Every change in direction in a material-handling system increases backpressure and reduces conveying capacity. A vacuum pump of a given size can do only so much work, and it is important to make sure as much of that work as possible goes into moving material instead of overcoming system design flaws. The expensive alternative is to install a larger pump, but remember larger pumps require larger line sizes, in most cases.
 
Optimize conveying velocity. When laying out your system and sizing your pumps, the designer will want to make sure the conveying velocity at the material pick-up point (gaylord, storage bin, or drying hopper) is as low as possible—preferably between 3700 and 4000 ft/min. Material will accelerate over the entire length of the run, and if it moves too fast, the material can degrade. Softer materials (like polyethylene) can heat up and smear against the walls of the conveying lines, deforming and leaving “angel hair” behind to clog the system. Brittle materials (like polystyrene or polycarbonate) can break up and create dust and fines that also clog the system. Abrasive materials (like glass-filled ABS) can wear away the inside of the conveying lines, eventually causing leaks and failures.
 
Make sure your vacuum pump is sized for your location. Power systems that operate at 50 Hz rather than the more conventional 60 Hz can cause the vacuum pump to turn more slowly, actually de-rating it by about 17%. You’ll need a bigger pump or one that turns at higher rpm in order to compensate. And don’t assume that a system specified for San Diego will operate the same way in Denver or Mexico City. Thinner air at high altitudes has the same effect as lower electrical frequency. Because the air is less dense, you need to move more of it in order to achieve the same conveying capacity as you would have closer to sea level. Again, you’ll need a bigger or faster pump.
 
If you are purchasing new loaders, an optional fill sensor in each loader can help avoid problems of overfilling or underfilling, which can occur when using only timer control. These devices can be invaluable in preventing equipment damage and keeping your conveying system running automatically.
 
 
MAINTENANCE
Keep your filters clean. Your material-handling system is equipped with filters at two locations: one in the dust collector near the vacuum pump and the others in each vacuum receiver. A blinded filter has the same effect as too many elbows in a system design: Backpressure builds and your system loses conveying capacity. As the filters clog, you’ll notice that it takes longer and longer to fill a vacuum receiver or, if the fill time is not changed, the receiver will not fill completely.
 
Locate and eliminate vacuum and material line leaks. Either one will diminish performance because the system will be sucking air rather than material. Again, you’ll notice sluggish conveying, longer fill times, and, in the case of a material line leak, you may see pellets on the floor. Leaks most often occur in flexible hoses and around couplings, seals, and valves. They can usually be located by visual inspection. Sometimes you can actually hear a hiss as air is pulled through a hole in the line. Smoke can also be used to locate a leak.
 
Pay attention to preventive maintenance on your vacuum pump. Follow the manufacturer’s recommendation for changing gear oil, and make sure all drive belts are tight and undamaged. Especially important, make sure the vacuum breaker valve is working properly. This valve is designed to break the system vacuum if it exceeds safe levels (about 15 in. of mercury) due to a clog in the line. If a dirty valve fails to open, a functioning breaker valve will keep the pump from overheating and damage.
 
 
OPERATION
Make sure your system is set up properly at the beginning. Have the manufacturer’s service technician check overall system integrity and see that all components are routed properly. All feed tubes should be properly set and receiver controls should be programmed with appropriate load and dump times.
 
Take care that the system always has material to convey. It sounds like a simple thing, but an empty gaylord or surge bin, or a feed tube that has become dislodged or clogged with a plastic box liner, will cause loader controls to alarm for lack of material. This can result in processing machine downtime and unscheduled maintenance. By making sure employees check material levels periodically, you can avoid costly production disruptions.
 
Train your operators. Especially when employee turnover levels are high, don’t forget to make sure everyone has the information they need to keep the system running. As noted above, a simple thing like allowing material to run out can be very disruptive. All employees should have a basic understanding of how the material-handling system operates and what their specific responsibilities are.
 
If you don’t have the resources in-house, a competent system manufacturer will usually be able to perform this training. Classroom training will cover how the system is set up and how material is transported. On the plant floor, employees can learn how to operate the various components, how to log into controls and make day-to-day adjustments, and how to change connections on a fantail manifold to source material from a different location or direct it to a different machine. Employees also need to understand various alarms and when a problem is simple (e.g., the feed wand fell out of a gaylord) or more complex, like an electrical issue that needs attention from an electrician or the supplier’s service technician.
 
Even small-scale material-handling systems can be complex, requiring careful calculation of throughput, conveying distances, equipment specifications, etc. Perhaps the most valuable tip of all is this: Take advantage of the knowledge, experience, and advice of your equipment supplier. With such help, you can avoid many of the common problems that can arise in the design, installation, operation, and maintenance of your material-handling system. 
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The working principle of Dryer

Posted on December 29, 2010 by admin

Drying machine is a water use of heat to reduce material mechanical equipment for operation on the object to dry. Dryer by heating the materials in the moisture (usually water or other volatile liquid component) vapor to escape, to obtain the specified moisture content of solid materials.

The purpose of drying is to use or further processing of materials needs. Mold in the production of wood such as timber, wood products prior to drying can prevent deformation of Ceramic Materials in the calcined product before drying to prevent cracking. Other dried materials are also easy to transport and storage, such as the harvest moisture content of grain drying to a certain following, to prevent mildew. Due to natural drying can not meet the production needs of the development of various mechanical dryer more widely applied.

The working principle of dryer

Drying process consumes a lot of heat, in order to save energy, some of the high moisture content of materials containing solid material suspension or solution of the general first by mechanical dehydration or heat evaporation, then dried in the dryer to get dry solids.

During the drying process needs to complete both heat and mass (moisture) transfer, to ensure that the material surface moisture vapor partial pressure (concentration) is higher than the external space moisture vapor partial pressure, to ensure that the heat source temperature is higher than the material temperature.

Heat from the heat source to pass to the wet material in various ways, so that the material surface moisture evaporation and emission to the external space, which appears in the material surface and internal moisture content differences. Internal moisture to the surface diffusion and evaporation, continue to lower the moisture content of materials, the gradual completion of the dry material as a whole.

The drying rate depends on the surface evaporation rate and diffusion rate of internal moisture. Drying rate is usually dry and pre-vaporization rate control by surface; then, as long as external conditions remain unchanged drying, the material of the drying rate and surface temperature that is stable, this stage is called constant rate drying stage; when reduced to a moisture content of materials Level, the internal moisture diffusion rate to the surface of the lower and smaller than the surface evaporation rate, the drying rate is mainly determined by the internal diffusion rate, and with the decrease of moisture content continuously decreased, the phase known as the falling rate drying period.

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Ultra-cold treatment to improve the tool, die life

Posted on December 6, 2010 by admin

 I.           The competitiveness of traditional industries in the face of industrial   restructuring and upgrading, we must make the right changes. Guarantee of product quality will be competitive into living conditions.

 II.         However, the basic engineering metallic materials is even more important, heat treatment for industrial products based on the quality of the work might not be perfect, although the heat treatment of metal materials to give life, but did not give life and performance. In addition to complete the foundation of the previous heat treatment, but also include follow-up of the metal super-cold treatment, the foundation is working to ensure product quality.

Metal ultra-cold treatment (DeepCryogenicTreatment) will be the only choice for quality metal products.

III.    Ultra-cold materials after heat treatment technology is only available in the already forming tools, cutting tools, part of the treatment process, the precise size of materials can be stabilized to improve the wear resistance of materials to restore the mechanical properties.

IV.   Super cooling technology is not limited to the treatment of materials   surface treatment material, and penetration of the internal organization of the material, reflecting the overall effect, especially for heavy cutting tool grinding, does not affect the organizational structure, can be used repeatedly, its performance can be reused superior coating technology.

Meanwhile, super-cold treatment technologies can effectively reduce the workpieces quenching stress and enhanced dimensional stability performance.

V.      Ultra-cold applications industry, including: precision stamping dies, nano-materials, precision plastic mold, cutting tools, hobbing cutter, aluminum alloy, carbide cutting tools / fixtures, powder metallurgy molds.


  a.  Ultra-high-speed steel for cold treatment ：
     In the super-cold treatment process, the metal in a large number of residual austenite into martensite, the martensite supersaturated metastable reduce its saturation, reducing micro-stress, dispersed precipitates, and precipitation of fine dispersed small carbides in the material effectively barriers to plastic deformation dislocation motion, thus effectively strengthen the matrix. Since ultra-fine carbide particles uniformly distributed in the martensite, the effective grain boundary strengthening to improve the performance of high-speed steel, so that impact toughness, red hardness, wear resistance has increased dramatically.
   b.  Ultra-cold treatment for Carbide：
       In the super-cold treatment process, the effective internal stress in the carbide and effective adjustment to reduce the tensile stress produced by Cobalt, and enhance the resistance of micro-cracks have effective to reduce the micro-cracks, thereby increasing fatigue strength, toughness, while enhancing the binding properties of cobalt and tungsten carbide, carbide to reduce stripping, to effectively improve the wear resistance.

Carbide abnormal tissue does not occur by the ultra-cold treatment (DeepCryogenicTreatment) increased significantly after the life of the workpiece material, the exact organization of a carbide will be more compact, while promoting aging (aging), an increase of plastic deformation impedance, single-use addition to an increase of 30% to 5 times the life, the carbon layer from the original 0.02-0.05mm increased to 0.08-0.13mm, can significantly reduce the amount of re-grinding.
   C. Ultra-cold treatment for aluminum：
    The hard alloy (duralumin) solution treatment, then the super-cold treatment (DeepCryogenicTreatment), because you can make a significant limitation and elimination of residual stress, which can improve the overall mechanical properties. Machinery industry in foreign countries now use super-cold treatment to enhance the performance of many aluminum cases, most of the material through the super-cold treatment have 7075,6061 and so on. In particular, aluminum alloy used in high-speed operation of the machine parts treated by the ultra-cool life more significant.
   D. Ultra-cold technology：
   High-speed steel and carbide cutting tools, cutting tools, measuring the improvement of life Nozzles, springs, gears, bearings, wear resistance and service life,
Hot die, cold die service life and dimensional stability,
Diamond, cubic boron nitride to improve the performance of manufactured goods,
Dimensional stability of precision machine parts, wear resistance and service life, Cold assembly of mechanical.  

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On the structural design of plastic injection molding

Posted on November 26, 2010 by admin

I. Introduction:
Plastic and steel, cement, wood, and the four major engineering materials. With the progress of science and technology, plastic has become even more widely applied. There are some knowledge of plastic component design to practice this field.

II. Design points:
2.1 Reasonable wall thickness
Forming quality from the point of view, the wall thickness of plastic is too large, in the process of forming prone to depression, shrinkage and other defects; wall thickness is too small, will result into the plastic hard and difficult to fully

Full cavity caused by lack of material. Plastic parts of the wall thickness should be as uniform as possible, may take the form of easing the transition, but also can be partial hollowing out of the structure, the wall thickness becomes uniform, to avoid the forming process and other defects.

2.2 Structure of rebar design principles
Set the ribs on the plastic parts, plastic parts can improve the strength and rigidity to prevent deformation of plastic parts. Select the appropriate location can improve the plastic ribs melt mobility.

Stiffener sizes generally follow the following principles: ① tendon thickness t wall thickness is generally 0.4 times the main maximum of not more than 0.6 times; ② bar is greater than the spacing between the 4t, bar height less than 3t; ③

2.3 Screw column:

The below the column stiffener surface at least 1.0mm; ④ ribs should be below the part surface or sub-surface at least 1.0mm. There are intersections of a number of ribs, to bring attention to the intersection of local materials

Accumulation of problems. The improved method is: ① to strengthen the tendons dislocation; ② stiffener cross-site designed hollow structure [1].
Slender ribs, such as force, should try to bear tension, to avoid to put too much pressure.

 During the design of metal castings are followed by the opposite principle of the priority under pressure, need special attention.
2.4  Avoid stress concentration:
* The structural design of plastic parts with particular care to avoid sharp edges and corners of the produce. Angular geometry at the transition is not continuous, here will produce stress concentration, so that it will crack.

* The strength of plastic materials are usually very low, more damage to the local stress concentration. The main measures to avoid the stress concentration is to improve the component parts of the structure sharp edges and corners. For example, in sharp corners

* Increase site chamfering, rounding or gentle transition section instead. As a result of the needs of member functions not directly increase the chamfering, rounding, the Department can reduce the local structure in the angular intensity

* Degree of inward rounded out ways to reduce stress concentration, as shown in Figure 1, the improved design of linear guides. Plastic screw-shaped teeth with circular and trapezoidal priority should be given to avoid the triangle

* Rectangle, this can reduce the gap effect, raising the carrying capacity of thread.

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Progressive Injection Molder Breakthrough in Thermoforming I

Posted on November 24, 2010 by admin

For most companies in that position, the response might be to buy a few more molding machines, maybe enter a new market, or underprice the competition to secure a greater share of your current piece of the action. All good strategies, to be sure, but perhaps a little too “inside the box” for Tech II Inc., a Springfield, Ohio, custom injection molder whose roots go back to 1969, when it started up to make parts for IBM.

Tech II’s approach to expanding its business this year was a tad more daring and splashy: It decided to get into thermoforming, and not by taking baby steps either. It spent close to $6 million to add 52,000 ft² to its production facility and buy a high-speed, Model FT3500 thermoforming machine from Thermoforming Systems LLC, Union Gap, Wash. With a multi-cavity mold purchased through Hekuma in Germany (hekuma.com). This machine utilizes tilt-mold technology with a synchronized dual-servo toggle that provides a rugged, high-speed forming platform.

And to top it all off, Tech II will become the first processor in North America to use in-mold labeling (IML) with thermoforming (T-IML), courtesy of a high-performance labeling system also furnished by Hekuma. Hekuma, also a prominent supplier of IML systems for injection molding, has been promoting T-IML for years, as have a handful of European thermoforming machine builders.

Hekuma maintains that Tech II is only the second processor in the world to go with T-IML. However, several thermoforming machine builders that have been offering the technology since the mid-1990s say there are a handful of installations in Europe and elsewhere around the world. Illig LP, Cohassett, Mass; Gabler Thermoform GmbH & Co. KG, Luebeck, Germany; Kiefel Technologies, Hampton, N.H. (kiefeltech.com); and OMV, Elkhorn, Wis are among the machine builders that have been showcasing T-IML at trade shows for years. Other sources report that Bartling GmbH & Co. KG of Borgholzhausen, Germany, is thermoforming and in-mold labeling PP food containers on an OMV line.

NOT PLAYING IT SAFE
But there is little dispute that this will be a landmark T-IML installation in North America. For Tech II, which is expecting delivery of the new line by January, “me, too” is not part of the vernacular, so going where no other North American processor has gone before may not be as daunting as it would be for most other firms. “Our philosophy has always been to stay on the cutting edge,” states Dave Shiffer, who shares day-to-day management responsibilities with his sister, Andrea Shiffer Tullis, for the family-owned company. “We’re not going to be the biggest, but we’re going to be technically sound and do what we do better than anyone else,” Shiffer says.

Tullis puts it this way: “We’re going to push the envelope, stay one step ahead.”

Over the years, Tech II has pushed more envelopes than your local post office. It has evolved from primarily a supplier of PP lids for food containers to a full-service molder of complete packaging systems in PP, HDPE, and LLDPE. It deploys 18 printers to support its current container and lid business. If offers prototyping services and can generate 3D scale models from a client’s CAD file. Tech II takes pride in its ability to keep its customers happy—one of its biggest clients has been with the company since 1978.

The processor also has a clearly defined “do-it-yourself” philosophy with respect to equipment. While Tech II’s stable of injection presses includes a handful of machines from Milacron and Netstal, its typical approach is to buy previously owned equipment and rebuild it to its particular specifications, adding proprietary hydraulic valving and manifold systems, among other things. Tech II designs—and sometimes even cuts—it own feedscrews and has also engineered its own production-monitoring and control system from scratch.

 

The machines are supported by resin-conveying systems from Conair, gravimetric blenders from Maguire Products, and robots from Ranger Automation Systems, Wittmann Battenfeld, and others.

ADDING T-IML
Tech II’s foray into T-IML is certainly the most dramatic move the processor has made in its 41-year history. “When our dad, who started this business, passed away in 2005, my brother and I sat down and asked ourselves a question: ‘What do we want Tech II to be,’” recalls Tullis, whose roles with company include resin purchasing. “For a period of time after his death, we pretty much maintained what we had been doing. Finally, after a lot of thought and consideration, we concluded that whatever we were going to do it was going to be big and different.”

Adds Shiffer, “We could have simply added thermoforming, but there are plenty of molders in the food container business—some much bigger than us—who do both injection molding and thermoforming, so we figured that was pointless. We could have gone with IML or in-mold decorating for our molding line of products, but again that was ‘me, too’ and we felt it would have slowed our cycles. So in keeping with our philosophy of being innovative, of differentiating ourselves, and of staying on the cutting edge, IML thermoforming is the path we chose.”

Thermoforming will expand Tech II’s product line beyond the round containers to which injection molding is mostly limited. It will also permit the company to get into barrier containers. Tech II officials were hesitant to provide too many details of the first product slated to come from its new technology, except to say that it will be a brand-new product for an existing client. “We had to make the commitment to this technology before we could ask the client to come to us for a project of this scope,” says Shiffer.

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Plastic components introduction

Posted on November 17, 2010 by admin

Plastic components
We usually used the plastic is not a pure substance, which is made by the preparation of many materials. Which polymer (or resin) is the main component of plastic, in addition, in order to improve the performance of plastics, but also add a variety of auxiliary in the polymer materials, such as fillers, plasticizers, lubricants, stabilizers, coloring agent, good performance can be plastic.
1, synthetic resin
Plastic synthetic resin is the most important component in the general content of the plastic from 40% to 100%. The content of large and often determine the nature of resin plastic nature, so people often plastic resin as a synonym. For example, the PVC resin and PVC, phenolic resin and phenolic confused. In fact, resin and plastic are two different concepts. Resin is a raw original polymer, it is not only used to make plastics, but also paints, adhesives and synthetic raw materials. In addition to a tiny percentage of the plastic resin with 100%, the vast majority of plastic, in addition to the main components of resin, but also need to add other substances.
2, filler
Filler called fillers, which can increase the plastic’s strength and heat resistance, and lower costs. For example, after the phenolic resin can be greatly reduced by adding wood flour costs, Bakelite, one of the most cheap plastic, as well as significantly improve the mechanical strength. Organic filler and the filler can be divided into two types of inorganic filler, the former such as wood flour, rags, paper and all kinds of textile fibers, the latter such as glass fibers, diatomaceous earth, asbestos, carbon black.
3, plasticizers
Plasticizers can increase the plasticity and flexibility of plastic, reduce brittleness, so easy to process plastic molding. Plasticizers are generally miscible with the resin, non-toxic, odorless, light, heat stable, high boiling point organic compounds, the most commonly used is phthalates. For example, production of PVC, if adding more soft PVC plasticizer can be, if not add additional plasticizer or less (the amount of <10%), then get hard PVC .
4, stabilizer
In order to prevent the use of synthetic resin in the processing and the role of the process of decomposition by light and heat and destruction and prolong life, to add the stabilizer in plastics. Commonly used stearate, epoxy resin and so on.
5, the coloring agent
Coloring agent can have a variety of colorful plastic, beautiful colors. Organic dyes and inorganic pigments used as coloring agent.


6, lubricants
Lubricant to prevent sticking in the molding of plastic in the metal mold, while allowing a smooth surface appearance of plastics. Commonly used lubricants are stearic acid and magnesium salt.


In addition to these additives, the plastic can also add flame retardants, blowing agents, antistatic agents, to meet different requirements.

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Conical twin screw extruder will be the main plastic processing machinery Thermoforming

Posted on November 8, 2010 by admin

 I.  As we all know, granulating machine on the market today are single screw pelletizing machine, conical twin screw extruder different and parallel twin-screw granulator machines and other equipment. Single screw granulator only advantage is low cost, but out of power, performance and energy consumption in plastics are flawed and can not meet demand;  

II. Highlights observation network to know: conical twin-screw extruder different advantages are: extrusion force, Disadvantages: poor performance plastics, low output and high energy consumption; and parallel twin-screw plastic granulator Although of performance, but out of force is small, low output, energy consumption, and therefore not satisfactory in actual use.

 III. We know that plastics poor performance will directly affect the quality of the product after plastics, and out of power will affect the yield, the growing tension in the period of high energy consumption of equipment to businesses and the community also increased a great deal of pressure. Granulation can design a function for this meet out of force, plastic performance, high-low, appears to have very important economic value and promote the application.
 
 IV.  To overcome these shortcomings, conical twin screw extruder has both good plasticizing properties, but also has a good out of power.
 
 V. Conical twin screw extruder, conical screw in the same direction of its rotation to be processed into plastic barrel after barrel of an 8 around the conical twin-screw shaped extrusion, increased the fusion time reduce the plastic and the friction screw and barrel, thus ensuring the quality of plastics, reducing energy consumption; as used for the tapered screw, to maintain the conical twin-screw extrusion granulator good mechanical properties.
 
VI. Conical twin screw extruder through the above techniques, the full realization of the extrusion force, plastic performance, high output, low energy consumption characteristics, the detection proved the conical twin screw extruder can be saving 30% -50%, and is suitable for all kinds of plastic or rubber molding extrusion granulation new equipment.
 
 VII. Conical Twin Screw Extruder history is a technological revolution, the development perspective in the next few years, instead of the traditional plastic extrusion machine plastic processing industry and become a major thermoforming machines have become the inevitable trend.
Conical twin-screw extruder that is the shape of the screw is tapered, and the two are the same direction of rotation of the screw The. Using a conical twin screw extruder technology, to be known conical twin screw extruder.

           

 

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A look at China Plastic Mold Industry

Posted on November 2, 2010 by admin

At present, the application of plastic products has become more widespread, which offered a broad market for plastic moulds, and at the same time, ask higher requirements. Especially, large, high precision and multifunctional moulds are customers’ favorite.

 

Recent years, China has witnessed a rapid development of the plastic mould. Plastic moulds occupy about 30% in the whole mould industry, and this figure will undoubtedly rise in the near future.
With the driving force of high technology and the application needs of pillar industries, plastic moulds in China has formed a huge industrial chain, from the raw material, assist material and processing, detecting equipment in the upstream, to machine, motor, automobile, household appliance, etc. Relevant experts estimated that automobile industry demands over 10billion mould, and color TV also make up for about 280million market.
At present, mould industry in China has an evident regional feature: the development of southeastern coastal areas faster than central and west regions, southern part faster than northern part. The most concentrated area distributed in Pearl River Delta Area and Yangtze River Delta Area, which make up 2/3 mould output value throughout the nation. And plastic mould has a similar region distribution: Zhejiang, Jiangsu, Guang dong have leading superiority compared with their counterparts in China.

 

As to Zhejiang mould industry which centralized in Ningbo Municipality and Taizhou Municipality. Among them, Yuyao, Cixi and Qinzhou mainly produce plastic mould, and Beilun mainly produce die-casting mould; Taizhou mould factories concentrated in Huangyan and Luqiao, with plastic mould in the majority.
Recent years, Zhejiang has gradually formed a clustered group that effectively boosts the economy of local and surrounding area. Especially, Huangyan plastic mould was elected as one of 50 industry cluster brands in China. The election of Huangyan plastic mould will further propel the plastic mould industry cluster construction for local and the whole country, and spur the development of upstream and downstream industries, taking a firm foundation for the construction of plastic mould industrial cluster.

 

 

Structural Inconsistency is the Biggest Challenge of This Year

Experts say, China economy will continuously keep its swift growth on total amount, and they also predict that this year’s GDP growth rate will surpass 9%. However, as the experts said, the biggest challenge of this year will be the structural inconsistency, and this year may become the most complicated for macro-economic regulation.

     

At present, there are several outstanding structural inconsistencies that influencing China economic growth, as follows:

     

First of all, it is the structural inconsistency between overseas market demand and domestic demand that affect China economic growth. Since the 90s in last century, the export growth rate of every year was over 20%, especially before the year of 2007, pushing China’s economic growth rate from 2% to 3%. However, due to the financial crisis, the shortcoming of over relying on overseas market demand has emerged, which leading to a gliding tendency for China economy and forcing China to open its domestic market in order to achieving economic balance.

       

Meanwhile, be alert with the structural inconsistency between investment and consumption while developing domestic market demands. Nowadays, the growth rate of national income is obviously slower than financial and GDP growth rate and the people’s income disparity constantly expand, constraining the consumer demand in national economic structure.

      

Furthermore, the level of urbanization and the process of upgrading of industrial structure fall behind industrialization level. Currently, the level of urbanization of China lag behind the economic development, influencing the expanding of domestic demand and widening the gap of town and county.

 

The Mould localization of China Facing Challenge

Recently, international mould tycoon Finland Belloos company invested a mould factory in China which went into service not long ago. The factory established by Euro American standards, mainly offer high-end mould industry for telecom, health-keeping, electronics and automobile industries. At the same time, the factory has testing and inspecting ability.

 

Some local experts warned foreign mould companies are now accelerating their speed of exploiting mould market in China, threatening the local manufacturers. Hence, the local mould companies should upgrading their techniques and brands.

 

Material from a relevant statistical department shows, many mould enterprises in developed countries transferred to China since last year. Last May, Fuji Co., Ltd and Mitsui & Co., Ltd. cooperated to establish a mould company which is located in Yantai, Shandong. America Cole Asian company and Dong Feng Auto Corporation work together to build Wuhan Dong Feng mould Co., Ltd. Last July, ab company from Japan went to Shanghai to set up a new mould factory, which engaged in the producing of tele mould. Also, companies from Euro Union, South Korea, Singapore organized delegations to make an on-the-spot investigation, looking for area and cooperation partners.

 

Wang Xin, a doctor of institute of industrial economics of Chinese Academy of Social Sciences, analysis that nowadays the world producing basements of manufacturing industry have accelerated their speed transferring to China; at the same time, the manufacturing industry in China is stepping into the high-end developing phase. Therefore, the demands for excellent and precise mould continuously increased. The developed countries want to seize commercial opportunities before us, so our domestic mould industry will face the pressure and competition unprecedented in history.

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