A 360-degree look at resin conveying systems: types, operation, economics, design, installation, components and controls.
This Knowledge Center provides an overview of resin moisture and the drying process, including information on the best drying practices for your manufacturing facility. Pe Corrugated Pipe Machine
Everything you need to know about plastics compounding technology—from feeding solutions to application profiles and expert advice.
Combat the skilled labor shortage using this comprehensive resource to train your own plastics processing experts.
Deep dive into the basics of blending versus dosing, controls, maintenance, process integration and more.
This Knowledge Center provides an overview of the considerations needed to understand the purchase, operation, and maintenance of a process cooling system.
Learn about sustainable scrap reprocessing—this resource offers a deep dive into everything from granulator types and options, to service tips, videos and technical articles.
Flat-to-downward trajectory for at least this month.
A mixed bag, though prices likely to be down if not flat for all this month.
Trajectory is generally flat-to-down for all commodity resins.
Flat-to-down trajectory underway for fourth quarter for commodity resins.
Generally, a bottoming-out appears to be the projected pricing trajectory.
PS prices to see significant drop, with some potential for a modest downward path for others.
Resin drying is a crucial, but often-misunderstood area. This collection includes details on why and what you need to dry, how to specify a dryer, and best practices.
Take a deep dive into all of the various aspects of part quoting to ensure you’ve got all the bases—as in costs—covered before preparing your customer’s quote for services.
In this collection of articles, two of the industry’s foremost authorities on screw design — Jim Frankand and Mark Spalding — offer their sage advice on screw design...what works, what doesn’t, and what to look for when things start going wrong.
In this collection, which is part one of a series representing some of John’s finest work, we present you with five articles that we think you will refer to time and again as you look to solve problems, cut cycle times and improve the quality of the parts you mold.
Gifted with extraordinary technical know how and an authoritative yet plain English writing style, in this collection of articles Fattori offers his insights on a variety of molding-related topics that are bound to make your days on the production floor go a little bit better.
In this three-part collection, veteran molder and moldmaker Jim Fattori brings to bear his 40+ years of on-the-job experience and provides molders his “from the trenches” perspective on on the why, where and how of venting injection molds. Take the trial-and-error out of the molding venting process.
Mike Sepe has authored more than 25 ANTEC papers and more than 250 articles illustrating the importance of this interdisciplanary approach. In this collection, we present some of his best work during the years he has been contributing for Plastics Technology Magazine.
In this collection of content, we provide expert advice on welding from some of the leading authorities in the field, with tips on such matters as controls, as well as insights on how to solve common problems in welding.
Mold maintenance is critical, and with this collection of content we’ve bundled some of the very best advice we’ve published on repairing, maintaining, evaluating and even hanging molds on injection molding machines.
Thousands of people visit our Supplier Guide every day to source equipment and materials. Get in front of them with a free company profile.
Medical-component specialist LightningCath has carved a niche meeting the needs of small to medium-sized entrepreneurs with complex catheter designs … quickly.
Plastics Technology is closing in on its 70th anniversary. Here are some of Editorial Director Jim Callari’s observations to commemorate the occasion.
As with everything else, there are pros and cons, but more of the former. They provide processors higher rates while decreasing the temperature of the extrudate while enabling downgauging.
The drop in plastics activity appears to be driven by a return to accelerated contraction for three closely connected components — new orders, production and backlog.
Beginning the first of this year, 12 states are following EPA bans on potentially damaging cooling fluids. Chiller suppliers have adjusted equipment designs to accommodate the new regulations. Here’s what all this means to processors.
Pairing external big picture training with internal job-specific instruction can help your process technicians meet quality expectations as well as production targets.
In less than a decade in injection molding, US Merchants has acquired hundreds of machines spread across facilities in California, Texas, Virginia and Arizona, with even more growth coming.
Demand for bioresins is growing in molded goods, particularly as a sustainability play to replace fossil-fuel based materials, but these materials are not a drop-in replacement for traditional materials. Molds and hot runners need to be optimized for these materials.
There are many things to consider, and paying attention to the details can help avoid machine downtime and higher maintenance costs — and keep the customer happy.
Flat-to-downward trajectory for at least this month.
Topping five other entries in voting by fellow molders, the Ultradent team talks about their Hot Shots sweep.
Serendipitous Learning Opportunities at PTXPO Underscore the Value of Being Present.
Introduced by Zeiger and Spark Industries at the PTXPO, the nozzle is designed for maximum heat transfer and uniformity with a continuous taper for self cleaning.
Ultradent's entry of its Umbrella cheek retractor took home the awards for Technical Sophistication and Achievement in Economics and Efficiency at PTXPO.
technotrans says climate protection, energy efficiency and customization will be key discussion topics at PTXPO as it displays its protemp flow 6 ultrasonic eco and the teco cs 90t 9.1 TCUs.
Shibaura discusses the upcoming Plastics Technology Expo (PTXPO) March 28-30
Sign up to attend North America’s leading trade show for plastics.
Ahead of the first NPE since 2018, PLASTICS announced that its triennial show will stay in Orlando and early May for ’27, ’30 and ’33.
New features of NPE2024 aim to “bring the whole plastics ecosystem together to innovate, collaborate and share findings.”
Hundreds of tons of demonstration products will be created at NPE2024 next spring. Commercial Plastics Recycling strives to recycle all of it.
After what will be a 6-year hiatus caused by the COVID-19 pandemic, registration is open for the triennial show, which will take place May 6-10, 2023, in Orlando, Florida.
The Plastics Industry Association has hired from within, elevating Matt Seaholm to CEO and Glenn Anderson to COO.
Mixed in among thought leaders from leading suppliers to injection molders and mold makers at the 2023 Molding and MoldMaking conferences will be molders and toolmakers themselves.
After successfully introducing a combined conference for moldmakers and injection molders in 2022, Plastics Technology and MoldMaking Technology are once again joining forces for a tooling/molding two-for-one.
Multiple speakers at Molding 2023 will address the ways simulation can impact material substitution decisions, process profitability and simplification of mold design.
When, how, what and why to automate — leading robotics suppliers and forward-thinking moldmakers will share their insights on automating manufacturing at collocated event.
As self-imposed and government-issued sustainability mandates approach, injection molders reimagine their operations.
August 29-30 in Minneapolis all things injection molding and moldmaking will be happening at the Hyatt Regency — check out who’s speaking on what topics today.
Get your clicking finger in shape and sign up for all that we have in store for you in 2023.
Molding 2023 to take place Aug. 29-30 in Minnesota; Extrusion 2023 slated for Oct. 10-12 in Indiana.
In today's manufacturing environment, robust processes that meet strict industry and regulatory standards are essential. With the advent of servo-driven ultrasonic welding technology, enhancing product quality and maintaining consistency has become remarkably effortless. Discover the fundamentals of ultrasonic welding, delve into vital components within these systems, explore how servo-driven ultrasonic welding enhances weld quality via advanced control features and gain insights into optimizing your assemblies for welding in these high-performing machines. Join Dukane to unlock the potential of ultrasonic welding in modern manufacturing for plastic devices and components. Agenda: Fundamentals of ultrasonic welding Key components in an ultrasonic welding system Using servo-driven ultrasonic systems to control your welding process Designing your parts and components for servo-controlled ultrasonic welding
This webinar will help you make informed decisions to confirm the equipment access stairs in your facility are OSHA compliant and meet the highest standards of safety and ergonomics. Agenda: Identifying opportunities to increase safety in the work place Utilizing space saving stairways Ensuring code compliance for equipment access
4.0, EUROMAP, OPC, OLE, QC, DSN, SQL, VNC, MES, ERP, FTP, CMS, SPI — are you confused by all buzzwords being tossed around in the plastics industry? Not convinced the data collection is necessary? Or are you unsure of how it could be implemented and improve your molding processes? Wittmann has been on the cutting edge of the data collection push for nearly 20 years. In this webinar, take a step back from the idea of the manufacturing facility of the future and discuss what you can do today to improve your process. Using readily-available technology, Wittmann can help reduce downtime, limit scrap and wasted material, and predict required maintenance. Let the experts at Wittmann help you understand: what data can be collected, what that data can be used for, what systems are used, and how to implement them. Agenda: Demystifying the terminology Tracking the material flow and lot information through the material handling system The data available from various auxiliary equipment, such as: dryers, blenders, mold temperature controls and robots Automating the process through changes in the data collected at the machines during production Adding visualization to increase productivity
Learn how targeted, modular, dosing and blending solutions — covering powders, granules, regrinds and liquids — provide plastics processors of all kinds with best-in-class accurate dosing while delivering significant raw material savings and ensuring highest quality. Agenda: Introduction to Movacolor Blending in plastics applications Movacolor feeding and dosing technology Hybrid blending to combine high material throughput and dosing accuracy
This presentation will explore the in-situ polyurethane (PU) overmolding of injection-molded and composite parts, allowing for direct out-of-mold class "A" surfaces. KraussMaffei will review the process and equipment required. It will also discuss tooling types currently available for PU systems for this process. KraussMaffei will compare the pros and cons of this technology over currently-available coating and painting systems. Agenda: Introduction and evolution of the ColorForm technology Overview of the ColorForm process Equipment required Tooling and PU systems Benefits of the system compared to typical spray-applied coatings Pros and cons of the technology
Consistent quality is paramount within the production of pipe and tubing applications. Additionally, significant material savings can be obtained by tightly controlling product dimensions with the correct process equipment. In this webinar, Conair will cover gravimetric control of an extruder and production line speed to ensure optimal quality and cost savings are achieved in your product run. A detailed discussion of the upstream material handling system includes: blending resins upstream of the feed throat, detection of the extruder rate at the throat, control of the extruder rpm and control of the product itself in feet per min — all accomplished with a simple recipe configuration which includes product weight per length desired and production line speed.
The global plastics industry has been navigating through what is arguably the most volatile period in decades. Unprecedented amounts of new production capacity are scheduled to start in North America, Europe, and China in the near term and compete for demand during a period of economic challenges. How will trade flows shift? Will this lead to regional cost disparities and rationalization? Energy transition and sustainability targets continue transforming the plastics market and increasing the competitive landscape. As the market evolves, what impact will new technology, policy, regulation, the growing role of chemicals versus fuel and other factors have on industry restructuring and business models? At GPS 2024, leading global experts will come together to discuss pivotal impacts and initiatives shaping the plastics industry. Join us and participants from across the globe to gain the latest insight and deep analysis as you connect with your peers and industry professionals. This year’s conference will explore the theme Disruptive Global Dynamics Reshaping Plastics and include a full day workshop focused on the Global Plastics Business and Plastics Transition to Circularity, 1.5 days of expert content and numerous networking functions.
Every three years, leaders from almost every major industry gather at NPE to advance their businesses through innovations in plastics. The largest plastics trade show in the Americas, NPE offers six technology zones, keynote speakers, workshops and opportunities to build partnerships.
The 3D Printing Workshop @ NPE2024 – The Plastics Show, is an immersive, half-day workshop focused on the emerging possibilities for part production via 3D printing and additive manufacturing. Presented by Additive Manufacturing Media, Plastics Technology and MoldMaking Technology, the 3D Printing Workshop will build upon a successful model first introduced at IMTS 2014. Attendees will benefit from a program focused on practical applications of 3D technologies related to plastics processing. This event will conclude with a 3D Printing Industry Reception sponsored by Additive Manufacturing Media.
The Society Plastics Engineers (SPE) Extrusion Division and the SPE Eastern New England Section will co-host the Screw Design Conference-Topcon on June 19-20, 2024 @ UMass Lowell in Lowell, MA. This highly technical program will focus upon screw design principles for single and twin screw extruders with wide ranging topics relating to screw designs for feeding, melting, mixing, venting and pumping plastics products and parts. Areas of focus will include screw designs for melt temperature and gel management, gel minimization, bioplastics, recycled materials and foaming. In addition to the technical sessions, a tour of the UMass Lowel Plastics Processing Laboratories will be integrated into Day 2 of the event. This program is not just for screw designers, but to help anyone responsible for any type of extrusion operation to evaluate existing extrusion equipment; and also to prepare for future projects. Price to attend: Less than $1000! Registrations will be accepted in early 2024. Call for papers – To be considered to give a presentation, please submit a talk title and abstract on or before December 15 to: Technical Chair: Eldridge M. Mount III, e-mail emmount@msn.com Corporate sponsorships - A limited # of corporate sponsorships (15) are available on a 1st come basis. Included is a 6’ tabletop display (must fit on table), denotation in all promotional activities, and 1 no charge registration. To become a sponsor contact: Charlie Martin, Leistritz Extrusion, e-mail cmartin@leistritz-extrusion.com, cell 973-650 3137 General information: A reception on Day 1 and a tabletop display area will allow the attendees to meet and discuss state-of-the-art screw technologies with industry experts. The SPE Extrusion Division will issue a “Screw Design Certificate” to all participants who have attended the program. Students are encouraged to attend and will receive a discounted rate. For additional information contact: Program Chair: Karen Xiao, Macro Engineering, KXiao@macroeng.com
Debuting in 2010, the Parts Cleaning Conference is the leading and most trusted manufacturing and industrial parts cleaning forum focused solely on delivering quality technical information in the specialized field of machined parts cleansing. Providing guidance and training to understand the recognized sets of standards for industrial cleaning, every year the Conference showcases industry experts who present educational sessions on the latest and most pressing topics affecting manufacturing facilities today. Discover all that the 2022 Parts Cleaning Conference has to offer!
Presented by Additive Manufacturing Media, Plastics Technology and MoldMaking Technology, the 3D Printing Workshop at IMTS 2024 is a chance for job shops to learn the emerging possibilities for part production via 3D printing and additive manufacturing. First introduced at IMTS 2014, this workshop has helped hundreds of manufacturing professionals expand their additive capabilities.
When investigating compound quality defects or determining the root cause(s) of processing problems, look for spatial and/or temporal patterns to provide clues. The strategy to identify an assignable cause and cure is to first determine whether the problem is chronic or transient.
You can draw a parallel between diagnosis of twin-screw compounding extruders and of the human anatomy. When you go to a physician to diagnose your ailment, the first question is designed to lead the investigation in one of two directions: “How long have you had this problem?” If you respond that the problem started when you were a child, this will lead the doctors down the “disease” pathway, eliminating the possibility that this is a temporary situation. If you reply that the problem started yesterday, this will limit the investigation to your activities within the past 48 hr only.
Chronic compounding problems are like diseases—they are always present, and the cure requires extensive treatment, while transient problems can be thought of as “illnesses.” An illness is temporary, and the treatment is relatively simple (e.g., take some medication and rest for 24 hr).
We identify problems in compounding as “chronic” if the results are the same every time a particular formulation is run—every lot produces the same results: poor physical properties, black specks, strands dropping, die holes freezing, vent ports fouling, etc. In these cases, the problem cannot be the result of a particular lot of raw materials, worn extruder components or any other temporary condition. The symptoms of chronic problems suggest that the process itself is the problem: improper screw/die design and/or operating conditions. For these problems, the treatment requires redesigning the screw configuration or modifying the compounding process. This is the only way to cure such problems.
We identify problems in compounding as “chronic” if the results are the same every time a particular formulation is run.
On the other hand, if a particular compound has been produced successfully in the past, and today it runs differently—this is the symptom of a temporary illness. Now we must determine why the current condition exists and whether it is causing compound quality problems or processing problems. Illnesses are most commonly associated with specific lots of raw materials, mechanical failures (burned-out heater, leaky solenoid valve, etc.), environmental conditions, operator error or machine wear—all of which appear over different time periods.
Most modern compounding lines continuously log all the process data, which can be graphically displayed as trend curves over some defined time interval. When viewed in this way, it becomes obvious that there is a pattern to the variation … or not. These patterns are not readily seen when viewing numerical information on the extruder control screens. The most common temporal (time-based) and spatial (relative to one specific area) patterns observed during compounding operations are described below with typical root causes.
Shift: We describe this first pattern as a “shift”—when the measured parameter moves up or down to a new equilibrium position and remains stable at the new level (Fig. 1). Measured parameters can be any process variable (percentage torque, die pressure, melt temperature, etc.) or any product quality attribute (melt flow index, percentage ash, color, tensile property, etc.). We should also consider the time frame over which the shift occurred—e.g., gradual change over hours or rapid change within a few minutes—to assist in identifying possible causes.
FIG 1 In a “shift,” the process changes to a new equilibrium position and remains stable thereafter. (All images: CPM Extrusion Group)
Which parameters can change like this? Over what time scale? Raw-material lot changes can appear like this, changing the rheology in the extruder as soon as the new lot enters the machine. The process (and product) moves quickly to a new and stable condition. The affected parameters can include motor load (percentage torque), discharge melt temperature and pressure, product melt-flow rate.
Changes in environmental conditions (ambient temperature and/or relative humidity) can influence raw-material temperature, for example, if the resin feedstock is stored in outside silos. Significant changes in ambient temperature can occur within 12 to 24 hr, for example, but generally not in less time than this. As a result, the process will shift gradually over this time frame until reaching a new equilibrium.
Trend: Nearly every aspect of twin-screw compounding exhibits some degree of short-term variation—e.g., barrel temperatures, motor load, die pressure, feeding rate. However, the average value remains constant. In the case of a trend pattern, the average value is increasing or decreasing continuously over some longer time frame (Fig. 2).
We can rule out some variables: For example, raw-material lots do not change in one direction only. Common variables that do tend to trend include barrel temperature caused by cooling-valve failure; pellet size and shape caused by die-hole freeze-off (e.g., caused by a burned-out heater); product porosity caused by vacuum-system fouling (accumulation of material over time in vacuum piping).
FIG 2 While there are clear signs of variability in a trend, the overall value of the parameter is moving up or down over a larger time scale, similar to the stock market’s short-term fluctuation underlying longer-term growth.
The source of change (e.g., failed component like a cooling solenoid valve) must remain in the failed state throughout the remainder of the production lot for the trend pattern to continue.
Nearly every aspect of twin-screw compounding exhibits some degree of short-term variation.
As opposed to looking for a trend from a single production lot, we could look at many different lots in sequence to see the trend from screw or barrel wear, as this time scale is months or years.
Oscillation: What is an acceptable amount of variation, for example, for barrel temperature? How much variation in percentage torque or melt pressure is normal?
Regular variation is to be expected for most of the process parameters and product properties, as there is inherent “noise” in most measurements and also variation associated with PID control loops (Fig. 3). Some acceptable tolerances:
• Temperature control: ±5° C (10° F).
• Motor load/amperage/torque: ±2-3%.
• Feeding rate: ±1-2%.
• Ash content: ±1-2% (should be same as feeding rate).
• Melt pressure: ±2-3%.
For variation greater than “normal,” search for the underlying causes. In the case of feeder variation, for example, if the speed of rotation of the metering screw is too slow, that results in surges of material being discharged from the feeder. These surges then induce variation in motor load and melt pressure in the extruder. In the case of barrel-temperature control, we must look at PID parameter tuning and adjustment of cooling valves (e.g., barrel cooling-water flow-control valve settings), When these manually adjusted cooling valves allow too much water flow, this results in large fluctuation in barrel temperature.
FIG 3 During oscillation, the process parameter or product-quality attribute (e.g., percentage ash) is moving up and down at some regular frequency. How much variation is normal? What is the frequency? What is the root cause of the variation?
The frequency of fluctuation will depend on the source of variation (e.g., pulsation associated with screw feeders; opening of barrel-cooling solenoid valves) but is typically within seconds or minutes. When looking at longer time scales, we could also see the variation in environmental temperature or humidity from day/night—or even seasonal changes—having some influence in the compounding operation.
Many plant managers see the effect of shift change (e.g., regular variation every 8 to 12 hr), suggesting that the extruder operator influences the process measurements or product quality.
Upset: Upset conditions are extremely hard to diagnose since the parameter always returns to the initial equilibrium condition following the upset (Fig. 4). There is no pattern or regularity for the time between upset conditions or the amount of deviation during the upset condition. Such isolated incidents could be triggered by external influences, like incoming power surges, which must be included in the investigation.
Most common upset conditions are related to accumulation of raw material (e.g., powder buildup in feed hoppers) that eventually avalanches into the extruder, causing torque spikes. There is no regularity to the frequency of occurrence, and may be related, for example, to environmental conditions. Consider the case where the accumulation of powder only occurs when a specific filler type is run and when there is also high relative humidity.
FIG 4 Upset conditions are extremely hard to diagnose since the parameter always returns to the initial equilibrium condition after the upset. There is no pattern or regularity for the time between upset conditions or the amount of deviation during the upset condition.
Identifying the root cause for upset conditions often requires review of multiple lots over a much longer time scale (e.g., months apart) to determine if environmental conditions or machine wear has any influence.
Most common ‘upset’ conditions are related to accumulation of raw material that eventually avalanches into the extruder causing torque spikes.
Spatial patterns: When a product quality problem appears at a specific location or position (e.g., only on the outer portions of the die), we can isolate the possible causes by considering how the extruder interacts with the die forming operation (Fig. 5).
For twin-screw compounding extruders, the melt leaving the screw tips is fairly well mixed prior to arriving at the die entrance. To illustrate this, if you drop one black-colored pellet into a light-colored polymer through the vent port that is typically located at the very end of the extruder, the black color will be well dispersed across the entire die opening. The screws that are usually installed after the vent port are only conveying screws without any mixing elements—yet the color is well mixed throughout. What this implies is that any defect in the material exiting the screws will be very well distributed across the entire die; unmixed filler or unmelted polymer will not prefer to flow to one part of the die versus another.
FIG 5 Spatial patterns are associated with product-quality defects as well as processing variables. Why does the product flow differently throughout the die plate? Why is the product hotter in the center of the die?
Understanding that there is no mixing after the screw tips, any problems that appear within a specific area of the die cannot be caused by the extruder: poor flow from specific die holes, darker strands or black specks that appear only on certain strands (Fig. 6). In these cases, the problems are created after the screw tips in the adapter, screen changer or die body.
FIG 6 Are voids in the pellets of different sizes and randomly distributed (suggesting a problem with degassing in the extruder), or are they all the same size and always located in the center of the pellet (“shrink voids” usually associated with insufficient cooling downstream of the extruder)?
Bottom line: teach your staff to look at trend curves (a “history” feature is available on most extruder control screens that provides graphs to track specific parameters over time) for patterns that can quickly lead to or eliminate specific root cause(s).
Along with staff training, a good preventive-maintenance program is also required to eliminate some of the “usual suspects” from causing most problems related to mechanical failures.
ABOUT THE AUTHOR: Adam Dreiblatt has more than 35 years’ experience with twin-screw extrusion as a consultant, teacher and practitioner. He is currently dir. of process technology for CPM Century Extrusion, which supplies compounding extruders and replacement parts. He provides technical support to the sales organization and customer base, as well as technical support for sister company Ruiya Extrusion in Nanjing, China. Contact: 231-421-6896; dreiblatta@cpm.net; centuryextrusion.com.
Compounds must be free of voids and volatiles or else the material will cause subsequent processing problems. Here’s how to ensure your venting is effective.
Over the past several years, significant innovations have occurred in the area of polypropylene nucleation.
Newer specialty slip masterbatches go beyond traditional capabilities to provide greater thermal stability, reliability, and ability to hold COF steady during laminating.
Start by assessing the status quo, as well as defining future needs. Develop a five-year projection of materials and required capacities. Short-term solutions very often prove to be more expensive and less satisfactory after a period of time. Most of all, know your options.
The metering equipment, twin-screw extruder and downstream systems all must work in concert to control the properties of the final part and manage the process of mixing.
The concept of troubleshooting in compounding can be defined in terms of a problem (or problems) with compound quality or as a problem with the compounding process.
A twin-screw compounding extruder is a single piece of equipment divided into distinct unit operations. Thinking of each unit operation as part of a toolbox can help determine what can be added or improved to process best-quality color masterbatches.
Mixer Plastics Technology covers technical and business Information for Plastics Processors in Injection Molding, Extrusion, Blow Molding, Plastic Additives, Compounding, Plastic Materials, and Resin Pricing. Learn More