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INJECTION MOULDING
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Space Puzzle Molding - it's what's left out that counts.
Space Puzzle Molding is an injection mould tooling development process which can make production components during the final tooling of the approved design. It has been in use in Germany for 20 years, with more than 8,000 tools produced, but so far has had little exposure in Britain. SPM tools have all the cores, undercuts, inserts and outserts intended for the production tool but they don't have any ejection systems, hot runners or cooling systems. The moulding is not removed from the tool: the tool is removed from the moulding.
Try a static mixer for a month.
Sulzer Chemtech UK is offering its static mixer nozzles on a 28 day sale or return basis so that moulders can try them out for themselves.
Auxiliary injection unit powers In-Mould Assembly.
Sandretto has supplied TRW Engineered Fasteners & Components with a two component machine fitted with a Windsor PlugXPress injection unit to make automotive air grilles using TRW's patented In-Mould Assembly process. The part is made in a 1+1+1 mould and its several components are attached to each other but are individually movable.
Bigger Boy insert machine reaches Britain.
Boy's new 55 tonne vertical insert moulding machine made its UK debut at the recent in-house exhibition at Boy's new offices in Milton Keynes. The 55 MVV extends the capacity of the existing 22 and 35 tonne machines with tie bar spacing of 360 × 335 mm and shot weights up to 158·9 g.
Milacron to revamp plastics machinery businesses to cut costs.
A shake-up is expected in the Milacron plastics machinery businesses in both Europe and North America to reduce their cost structure with 'a consolidation plan'.
Toshiba builds-in Priamus Fill.
Toshiba machines may now incorporate the Priamus Fill system in their standard controls so that no additional computer is required.
Demag opens Indian expansion.
Demag's joint venture in India, L & T-Demag Plastics Machinery, has opened its new plant in Chennai which has increased its assembly capacity to 600 machines.
Milacron to migrate Mosaic control from electrics to hydraulics.
Ferromatik Milacron all-electric Elektra Evolution machines now have swivel touch screens and Mosaic control, which will also be introduced progressively on high performance hydraulic K-Tec and Maxima models up to 4,000 tonnes.
Stork adds large capacity packaging machine.
A 1,000 tonne model has been added to Stork's S range of packaging machines suitable for multi-impression tools making buckets, thin walled packaging, caps, closures and crates.
Big Billion gets a new lease of life.
The 10,000 tonne machine built by Billion in 1980, which has been running continuously since at Plastic Omnium in Langres, France, has been rebuilt for a further period of service. When it was built, this machine was claimed to be the largest in the world, and probably still is.
KM builds a turntable into the CX.
Krauss-Maffei has introduced multi-component versions of its CX series machines, fitted with an electric turntable which can rotate as the mould opens.
Chinese plant will give Engel large tonnage capacity in Asia.
Engel has released more details about the injection moulding machine factory it plans to build in Shanghai, China. It will complement the company's Korean plant, which builds small capacity machines, by producing large tonnage machines identical to those built in Austria and the USA.
The China Syndrome.
Like it or loathe it, China is now a significant influence on injection moulding in Britain. Chinese companies are competing with British moulders for work, and in the same way competing with British toolmakers but in ways which can benefit British moulders. Over the next couple of pages we report on some recent influences on the British moulding business from China, from moulding machines coming in, to moulding work going out. But first, a perspective on doing business in China from Brian Cox of Shelford Business Consultants. It's tongue-in-cheek, but there is a serious note inside.
UK contact for ISO 14001 moulder.
Lucky Star (Holdings), an injection moulder with two factories certified to ISO 9001 and ISO 14001, is working through a UK liaison office in Lancashire.
Straight from the shoulder pricing clinches Haitian sale.
It was the availability from stock and the price/specification combination which made Ultrafast Mouldings of Cannock buy a Haitian HTF300X 300 tonne toggle-locking machine.
China First holds your hand until you're ready to deal solo.
Assistance for companies planning to buy mouldings from China for the first time is offered by China First Plastics, which operates a brokering service with links with five major factories in China.
Chinese link up lets Mason Pinder concentrate on complex tools at Doncaster.
Toolmaker Mason Pinder has linked up with toolmakers in China to offer a global source service which includes concept support, design studies, process engineering, and physical 3D design with guaranteed issue control of CAD data.
China is not the only 'Chinese option'.
AKI Industries says that some companies have found that the real costs of dealing with China were not as advantageous as they had at first thought. So it has looked closer to home in offering low cost offshore moulding services - to the 'new economies' of Eastern Europe.
Powdered metal guide eliminates valve pin wear.
Günther has tackled the problem of wear to cavity insert gates caused by hardened and coated valve pins with a needle guide made in powdered metal that is claimed to eliminate valve pin stroke wear.
Cascade moulding without surface marking.
Portuguese moulder Interplastico is making a bumper grille insert using Synventive's cascade method of moulding with a needle shut off system, without flow lines or sawtooth pressure profiles.
Edge gate nozzles for side gating.
Two new Ultra edge gate hot runner nozzles from Husky are suitable for moulding polyolefin parts with side gating. Tips can be replaced in situ.
Ceramic insulation maintains critical temperature control.
Ceramic insulation is used by Männer of Germany on its new hot runner nozzles to ensure the precise temperature control valuable for critical materials and low shot weights involving long melt dwell times in the runner and nozzle.
Electric actuator adds precision to valve gate control.
An electric servo actuator for injection valve gate control has been introduced by Tol-O-Matic of the USA as a replacement for bulky hydraulic valve manifolds. The new ServoGate eliminates variables in fluid power systems and delivers precise gate control, says the company.
Horizontal tips for direct side gating.
The new Mold-Masters Melt-Disk hot runner system provides simple horizontal hot tip processing for direct side gating applications such as for pipettes, syringe barrels and needle shields. The controlled heating element on the disc portion optimises heating in the gate area and ensures that heat is applied right up to the hot tip seals.
Hot runner manufacturers open plants in China and Brazil.
Hot runner systems supplier Synventive Molding Solutions has opened a manufacturing plant in China, Husky's Brazil Technical Center has become fully operational and Mold-Masters has invested more than Eur 2 million in expanding facilities at its European headquarters in Baden-Baden, Germany.
Synventive improves multi-cavity nozzles.
Small nozzles for multi-cavity moulding have been introduced by Synventive to replace its 10 years old CA nozzle.
HR controller can have automatic fallback from thermocouple failure.
The new DMS-Diemould HRCX series low cost hot runner controller can run six or 12 zones and incorporates many features of the company's MTS control.
Modular design of hot runner makes application of angled gates simpler.
Modular design of new MHT hot runner systems is claimed to confer various advantages as the manifolds are made of individual carrier bars and can be converted to the requirements of individual moulds, and there is extensive freedom to position angled gates.
Cascade filling is improved with new control units.
HCS-TS hot runner control units from Männer have pin monitoring and sequential pin control for valve gate nozzles, overcoming previous difficulties of filling cavities evenly which called for workarounds including setting individual temperatures for cascade or multi-component moulding and for separate stack mould cavities.
Small parts go into production sooner.
Small parts previously made in multi-cavity tools on a standard injection moulding machine can now be brought into production much sooner on a Babyplast machine at Hereford-based AKI.
Negri Bossi adds chillers to complete total supply package.
The last link in Negri Bossi's machine-mould-material handling-automation-cooling chain has been added through a strategic alliance with Aqua Cooling Solutions to provide chiller systems.
40 Ferromatiks for the Playmobil people.
German toymaker Geobra Brandstätter, which makes the Playmobil series of toy figures, has placed a single order for 40 Ferromatik Milacron machines to be supplied to its new injection moulding plant in Dietenhofen during the first quarter of 2006.
MES system automates reporting to FDA requirements.
Shopfloor-Online manufacturing execution system has been implemented by a major international manufacturer of moulded components for medical devices to meet the traceability and certification requirements of the US Food and Drug Administration.
Portola puts down pencils and picks up Plantmaster.
Portola Packaging has outgrown the manual production monitoring and scheduling system at its Doncaster plant and has ordered a Barco Plantmaster with the aim of improving factory efficiency and reducing scrap.
ROTATIONAL MOULDING
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Leonardo is 'the fastest roto moulding machine in the world'.
Italian manufacturer Persico has introduced a fully automated rotational moulding system that works without an oven, and one of the first machines has been installed at a British moulder.
PIPE & PROFILE
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In-die embossing cuts cost by switching from injection moulding.
The cost of a component used in car roof racks has been reduced by 40 per cent by converting it from an injection moulding to an extrusion using the Markram in-die embossing process. It had been injection moulded because conventional post-extrusion embossing/machining processes were unable to produce a sufficiently sharp edge.
Dual coiler keeps pipe more manageable in the field.
Maillefer has developed a fully automatic dual pipe coiler with intermediate strapping for large coils. It produces two or more coils with each coil strapped independently, and also strapped in the coil wound round it.
Quick change pipe system now from Cincinnati.
Cincinnati Extrusion is the latest company to offer a quick change system for pipe diameter. Its IntelliChange system works out around 5 per cent cheaper than buying a set of dies and reduces the downtime for each pipe dimension change by about 90 minutes.
Wood extrusion packages from Milacron and Reifenhäuser.
Collaborations to produce packages of equipment for wood extrusion have been put together by extruder manufacturers Cincinnati Milacron and Reifenhäuser. Cincinnati Milacron has joined forces with B & P Process Equipment of the USA to develop a new co-rotating parallel twin screw extruder and Reifenhäuser is collaborating with Kosche to produce complete lines.
REACTION PROCESSING
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PU battery cover is stronger than metal sheet.
German PU moulding specialist Thieme has produced a one-piece battery compartment cover in Bayer's Bayflex for American fork stacker manufacturer Crown.
KM to expand its rapidly growing reaction processing division.
Krauss-Maffei is to add tooling to its Reaction Process Machinery division to become a full system machinery supplier.
FILM & SHEET CONVERSION
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Feedback control for the forming process.
Austrian thermoforming automation and tooling specialist Mould & Matic has developed a new control system for thermoforming enabling supervision of every phase of the forming process.
Mould design project aims to reduce forming times and costs.
A project is being undertaken across Europe to develop a predictive mould design and manufacturing system intended to reduce throughput times and enhance right-first-time production in thermoforming tooling.
Cutting rules intended for deepcutting applications.
Dieflex Hard High cutting rules augment the range from Sandvik Diecutting Products and are intended for deep cutting applications such as sandwich packs, food, cosmetics and toy packaging.
Knife holder thrust is calibrated to reduce knife wear.
Simplex-Turbulo is UK agent for new Mario Cotta Gold Series pneumatic knife holders for cutting flexible materials up to 450 g/m² at speeds up to 1,450 m/min.
FILM & SHEET PRODUCTION
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Polishing rolls have adjustable crowning.
Brückner Formtec has developed a hydraulically-adjustable crowning technology to enable polishing rolls to be adjusted for film and sheet production in a wide range of materials and thicknesses.
Macchi adopts AC direct drive motors.
Macchi now equips its COEXFlex coextrusion lines with AC synchronous direct drive motors.
New adhesives for film lamination.
Lotader 4403 and 4503 are two new multi-purpose adhesives produced by Arkema for extrusion lamination. Granules are insensitive to moisture and bonds can be made to polar and non polar materials including plastics, metals and woven and non woven substrates without need for a primer.
PROCESS SCRAP RECLAMATION
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Rear feed gives granulator access for clean-down.
Feeding the granulator from the rear has enabled UPM to build an integrated system for use on blow moulding machines at Polimoon's Thetford and Beccles sites.
New heavy duty machine from Hellweg.
A heavy duty granulator has been introduced by Hellweg Maschinenbau as the new top end of its range.
Optical sorter also includes a metal detector.
The Spektrum optical colour sorter developed by S+S Inspection is primarily intended for the separation of coloured PET from PVC reclaim, and for other granular or shredded plastics with a particle size less than 5 mm.
Granulator design influences energy consumption.
Tria has identified seven characteristics of granulator design that, when correctly implemented, can reduce the energy consumption of a granulator.
Granulators for press-side or central applications.
The Wanner Technik granulators now available in the UK from Jenco are intended for in-line recycling of production waste from injection moulding and extrusion processes.
Dreher pitches at blow moulders - at least for now.
The latest Delta 2641 granulator from Dreher has been designed for blow moulding use, with a low slung cutting chamber to enable bulky scrap to be fed. Since Kautex shut up shop in the UK the agency has been taken over by Proma Machinery.
When Wittmann rotors stop they stay stopped.
A safety brake is fitted as standard on Wittman's Master MC granulators to prevent imbalances in the rotating mechanism causing it to tilt or rotate, and risking operator injury.
RECLAMATION & RECYCLING
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Brominated FR polymers could and should be separated from WEEE scrap.
An interim report has been published showing that polymers containing brominated flame retardants in mixed waste electrical and electronic equipment would be better separated and treated to remove the additives than for them to be disposed of or even incinerated with energy recovery.
Coke and Boots put RPET bottles on the shelves.
Packaging containing recycled PET is now being used by Boots and Coca-Cola Enterprises as part of a project to evaluate the technical feasibility and customer acceptance of recycled PET in retail packaging.
Reclaim line dedicated to toner cartridges.
A compact line for the reclamation of toner cartridges has been developed by Herbold Meckesheim.
Tyre crumb ousts polyurethane for street bollard production.
Reclaimed tyre rubber is now being used exclusively by Bollards International to make street bollards instead of a customised polyurethane elastomer as previously.
BLOW MOULDING
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Amcor assesses biodegradable bottles.
The potential for compostable bottles made from polylactic acid corn-based polymer has been increased with the possible entry of Amcor into the market.
Plasma treatment could bring more cost-effective barrier coatings.
Barrier coating of PET bottles through the application of an external silicon oxide coating under an open air plasma is under development by Plasmatreat.
Mini preforms meet anticipated demand for single serve bottles.
To meet the demand by drinks suppliers for 200 ml single dose PET bottles PET Engineering in Italy has developed a bottle blown from a special preform.
What a difference a gram makes.
SIG Corpoplast's Bottles & Shapes service has developed what it claims as 'a new benchmark for light weight bottles': 12 g for an 0·5 litre non-carbonated water bottle.
Bottle bagging companies combine.
The two principal players in the automation of bottle handling for dairies have become one, with the take over by Dassett Process Engineering of BottleTech Solutions.
Kautex Maschinenbau pulls out of the UK.
German blow moulding machinery manufacturer Kautex Maschinenbau has closed its UK subsidiary Kautex Machinery Sales (UK) in Milton Keynes.
ENGINEERING MATERIALS
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Polycarbonate makes more headway in vehicle glazing.
Approval from the US Department of Transportation for the use of Bayer/GE's Exatec polycarbonate glazing in cars opens the way for worldwide acceptance of the system. The latest Exatec product, 900vt, is being used by Inalfa Roof Systems to make 'a new generation of polycarbonate automotive roof systems' while Bayer's Makrolon has been used for the rooflight of the Mercedes B Class.
Engineering foams range is broadened.
Zotefoams is working on an energy-absorbing viscoelastic foam as an addition to its Zotek series of engineering plastics crosslinked foam sheet materials.
Frosted acrylic can be moulded or extruded.
New grades of Altuglas Frosted acrylic materials have been produced by Altuglas International. They can be moulded or extruded.
Rosehill pitches at synthetic grass.
Rosehill Polymers has invested £1·5 million over two years in a high capacity extrusion line to manufacture a thermoplastic vulcanisate for use as a granular infill and topping for synthetic grass sports pitches and multi-use games areas.
COLOUR MANAGEMENT
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'No limits' liquid colouring from Degussa.
New developments in liquid colouring are being promoted by Degussa Colortrend.
No minimum order for Clariant Omnicolor masterbatches.
Clariant Masterbatches UK has joined forces with its local distributor Colourmaster of Oldham, to offer its Omnicolor masterbatch product with no minimum order level.
GretagMacbeth puts colour matching on-line.
GretagMacbeth has launched on-line versions of its recently-introduced Color iMatch and Color iQC colour formulation and quality control software giving centralised colour data management with secure shared access from remote locations over the internet.
Universal masterbatch for 1 - 2 per cent let down.
The new UniColor range of universal masterbatches from RTP can be used to colour all polymers, including engineering plastics, in concentrations typically of 1 to 2 per cent.
In-line colour quality control system does away with sampling.
Thermo Electron Corporation has integrated an in-line quality control system for colour inspection into the new Haake PolyLab OS torque rheometer platform.
Blue is the new black.
Shepherd Color has added a blue shade of black to its Arctic line of infrared reflecting pigments.
PACKAGING MATERIALS
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New technologies improve PP and PE.
Borealis is expanding the property potential of its polyolefin materials with an agreement to use metallocene single-site polypropylene technology and a new multi-modal polyethylene tailoring process.
Wake up and smell the chocolate.
A package that releases the smell of the contents from the surface of the lid has been developed by Eastman Chemical in association with compounder Rotuba from the USA, scent manufacturer Eurofragrance from Spain, and South Korean moulder EJ Pack.
Polyolefin packaging innovations from Basell.
Basel has introduced a clutch of new polyolefins to serve a broad spectrum of film, blow moulding and injection moulding applications. The new grades expand the existing performance profile normally associated with polyolefins and are said to deliver significant cost and performance advantages for processors alongside new design opportunities.
Dow film grades offer better processing and performance.
Dow Chemical Company has produced two new grades in its Versify line of plastomers and elastomers which offer film converters better processing and improved product performance.
Sabic claims first for high impact clear PP.
SABIC has introduced a range of high impact clear polypropylenes that is said to be the first of its kind in the market, combining the transparency of a random copolymer with the impact performance of a block copolymer.
DuPont lights the way to new packaging concept.
Self-illuminating packaging has been devised by DuPont, combining know how from its electronics and packaging materials businesses. It is intended for use in the cosmetics industry to add shelf appeal.
Lower-cost Ticona COCs for flexible packaging.
A new and more cost-effective grade of Topas COC (cyclic olefin copolymer) for packaging applications has been introduced by Ticona.
New food packaging grades from Nova.
Nova Chemicals has introduced two new materials for food packaging. The first is an addition to its Zylar line of clear acrylic copolymers. The second material is the latest addition to its Dylark line of styrenic copolymers.
ADDITIVES
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DuPont modifier toughens PBTs.
A new toughening agent from DuPont improves the impact strength of polybutylene terephthalate by up to 12 times while largely preserving the engineering and processing properties.
Nanotube polymer blends simplify handling and use.
Belgian company Nanocyl has introduced the first of a planned line of high-concentration nanotube polymer blends. The new product consists of a high concentration of carbon nanotubes pre-dispersed in a polymer.
PVC-specific masterbatch is patented.
ColourTone Masterbatch has been granted a patent on its Vynacol colouring technology, described as 'the world's first and only polymer-specific colour masterbatch that makes it as easy to colour PVC as any other plastic material'.
CPVC performance enhancer for PVC improves heat and flame resistance.
Arkema has developed a grade of chlorinated PVC that is designed to blend easily with, and enhance the performance of standard PVC in all rigid and plasticised applications.
MoldWiz makes PPS more predictable to mould.
Since its trials earlier this year with the use of a new grade of Axel MoldWiz processing aid in polycarbonate injection mouldings, UK distributor Genie Kenraw has been assessing its performance in polyphenylene sulphide and has found improvements beyond those achieved in PC.
Ciba additive boosts scratch resistance of automotive PP/TPO compounds.
Ciba Specialty Chemicals has introduced a new additive to boost the scratch resistance of automotive components moulded in polypropylene/thermoplastic olefin (PP/TPO).
PolyOne introduces masterbatches for low voltage cable insulation...
Two and three component colour and additive masterbatches for low voltage cable insulation from PolyOne simplify metering arrangements by combining constituents.
...and stays on top of impending EC requirements.
The new range of OnColor colour masterbatches for the wire & cable industry are compliant with both the RoHS (The Restriction of Hazardous Substances in Electrical and Electronic Equipment) and WEEE (Waste Electrical and Electronic Equipment) directives from the European Parliament.
Antifog masterbatch for PE food packaging films.
Italian company Viba has followed up its Vibatan Food Antifog masterbatch for polypropylene films with a new variant designed specifically for polyethylene films.
MATERIALS HANDLING
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Vertical screw improves feeding performance.
Brabender's new ScrewDisc feeder has a vertical metering screw mounted on a rotating disc arranged in a specially shaped transparent PU outlet giving 'outstanding' feeding performance.
Materials handling options increased by Sandretto.
Sandretto UK has introduced the HLV20 vacuum hopper loader, a volumetric doser without a screw, designed to overcome dosing variations caused by screw position at the end of a cycle, and a dehumidifying drier which requires no cooling water.
Compressed air type dryer added by Colortronic.
A compressed air-operated dryer recently introduced by Colortronic has a choice of either a 15 litre or a 30 litre drying hopper.
Control module combines control and motor drive.
The new K-Tron SmartConnex KCM control module integrates control and motor drive directly on the feeder, with remote mounting optionally available.
Gravimetric blender for high throughputs.
A high capacity version of the Multi Weigh gravimetric blender from K-Tron Colormax is designed to provide blending and synchronized screw-less feeding of up to four materials at significantly higher rates than the standard Multi Weigh in single-screw extrusion and moulding processes.
Conair adds equipment to increase its market position.
Conair is introducing three product ranges to Europe, the Carousel Plus rotary wheel dryers, Access hopper loaders, and TrueBlend gravimetric blenders.
ENERGY EFFICIENCY
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Processors need double digit price rises to survive.
The European Plastics Converters Association warns that energy and raw material costs mean that plastics processors need to push up the prices of their products by 'tens of percentage points' to survive while a group of nine trade associations in the UK have urged the Chancellor of the Exchequer to take action on five key points to prevent energy prices crippling British polymer processors.
Urgent action needed on energy issues to save the European plastics industry.
RECIPE - Reduced Energy Consumption in Plastics Engineering - has been established to persuade the plastics industry to measure its energy-use performance and change for the better.
Capital equipment selection: changing the rules.
As polymer processors face massive increases in the costs of gas and electricity we begin a new series of Carbon Trust energy efficiency factsheets to help processors reduce costs through energy efficiency, written by Dr Robin Kent in association with the Polymer Machinery Manufacturers and Distributors Association.
Add-on control improves efficiency of big old injection machines.
Motor energy efficiency of older types of hydraulic injection moulding machine can be improved by 35 to 55 or even 70 per cent by retrofitting one of its motor control units, claims NRG Control.
Economiser hangs on to reactive power and saves money.
Krauss-Maffei has developed a unit known as the Economiser to enable reactive power to be used for injection moulding machine operation and reduce electricity costs.
TEMPERATURE CONTROL
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Off-the-shelf chillers can still be supplied as specials.
The ADV range of chillers introduced at Interplas by Tricool Engineering represents a departure for the company in that chillers are being kept for ex-stock delivery, while Tricool traditionally builds to order.
Performance feedback for cooling units.
Feedback on the performance of Comfort-controlled TopTherm cooling units is provided by the new Rittal RiDiag II fault finding software package.
New chiller series cuts energy consumption.
Evolution chillers introduced by ICS Cool Energy incorporate scroll compressors which save 18 per cent of energy and reduce noise by up to 2 dB(A), says the company.
Miniature heaters have high Watt densities.
A miniature version has been added to the Watlow range of Firerod cartridge heaters.
Regloplas goes hotter with economy water controller.
What is described as 'the first low-cost temperature control unit for pressurised water up to 140 degC' has been introduced by Regloplas alongside a new range of higher performance temperature controllers for oil and water.
Nozzle heaters keep going if a circuit fails.
Friedr Freek of Germany has introduced Tandem nozzle heaters with a so-termed 'limp home' mode. They have two separate heating circuits designed so that one circuit is able to heat the nozzle without the other.
SOFTWARE
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Moulding made crystalline clear.
Clive Maier revisits a pure 3D injection moulding simulation program which has now acquired the ability to predict variable crystallisation through a part, and is more in tune with multi-component moulding.
Application database aids material choice.
The application database built into the Material Data Center, the internet information portal run by M-Base Engineering + Software, shows examples of materials at work with the data sheet for the material available at the click of a button.
Moldflow upgrades Plastics Advisers.
Version 7.2 of Moldflow Plastics Advisers software provides plastics flow simulations directly from 3D CAD models of the component.
MatWeb data now exports to ALGOR FEA.
MatWeb, the on-line library of data sheets for plastics, metals, ceramics and fibres, can now export material property information in ALGOR library format, in addition to the existing SolidWorks and Excel formats.
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