PMT: An Emerging Plastics Power | Plastics Technology

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. Automatic Thermoformer Machine

PMT: An Emerging Plastics Power | Plastics Technology

Everything you need to know about plastics compounding technology—from feeding solutions to application profiles and expert advice.

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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.

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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.

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Thousands of people visit our Supplier Guide every day to source equipment and materials. Get in front of them with a free company profile.

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.

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

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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.

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Get your clicking finger in shape and sign up for all that we have in store for you in 2023.

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Key technologies — such as multicolor molding, film molding and PUR overmolding for both exterior and interior applications — are at the forefront of this transformation. Join this webinar to explore the vast potential of eMobility in molding large components — including those with fiber reinforcements — thereby driving the need for large injection molding cells with a clamping force of up to 11,000 tons. You will also gain insight into Engel's innovative two-stage process, a solution for future recycling processes. This webinar will provide an in-depth overview of challenging applications, production concepts and best practices, including: BMW iX front panel production cell Smart rear panels concept based on IMD and 2C molding Sustainability concepts based on two-stage process Large tonnage equipment for battery moldings

Fast facts SPE International Polyolefins Conference 2024: The Preeminent Polymer Conference in the World dedicated to Polyolefins since 1975 The conference will in-person and virtual The powerful software platform for the conference will allow access to all papers on-demand, even several months after the conference, access to the program, access to virtual exhibitor/sponsor booths, and easy communication with speakers and other participants In-person participants can download a mobile or web app for the conference to access all the features of the software platform for the conference We anticipate over 900 people from around the globe to participate in-person or virtually The improved layout of the exhibit floor offers easy access and flow for the 60+ companies that we anticipate to exhibit Over 20 sponsors expected 150+ Technical papers, Sunday afternoon Tutorial Student Poster Competition 2 Networking Socials Meeting rooms available for rent to meet with customers and suppliers Exhibits from Monday through Wednesday until noon The Conference is organized by the SPE South Texas Section, the SPE Polymer Modifiers and Additives Division, the Thermoplastic Materials and Foams Division, the Engineering Properties and Structures Division, the Building and Infrastructure Division, and the Flexible Packaging Division.

Following a rapid series of acquisitions, Plastic Molding Technology now undertakes an integration process as the first step on a path to its goal of becoming a world-class plastics processor.

In a span of just five months over the second half of 2021, Plastic Molding Technology (PMT), Centennial, Colo., completed four acquisitions of injection molding, moldmaking, thermoforming and extrusion operations in Colorado and Texas, creating the basis for what it hopes will eventually be a plastics processing power located in the western U.S. but with reach well beyond that geography.

Targeted for strategic fit and core competencies, with a requisite nod to financial health, the newly acquired companies are now undergoing integration into PMT’s corporate vision — voted upon and agreed to by its employees — as it seeks to build, in the words of CEO Michael Engler, a “world-class organization.”

Engler says, “We actually did a survey inside our business across all employees that got us to agree on what we want our real mission and vision to be. From that high-minded effort to forge and share a corporate philosophy, PMT’s integration work extends to the more mundane as well: create a uniform quoting process and upgrade IT and back-office technologies, including establishing a shared CRM (Salesforce) and ERP (DELMIAworks, formerly IQMS).

All of these activities fall under an integration initiative. In a second-story conference room overlooking the company’s most recently created molding floor at a facility southeast of Denver, Engler spins around his laptop to share the down-to-the-bullet-point assimilation plan. Located in the appendix of a slide deck, the scheme applies to PMT’s marketing, sales, assets, management team, accounting/finance, operations and systems.

“When I talk about integration, I see it as a very structured process,” Engler says, “It’s not happenstance.” Each business aspect is scored with a radar chart where blackened quadrants denote progress, although integration is never really completed. “Think of it like 5S,” Engler says, referencing the lean manufacturing methodology that calls for continuous improvement: “You’re never done.”

PMT undertook a classification of the working status of all its equipment, including injection molding machines. (Photo: PMT)

To begin to satisfy the asset portion of the process, PMT classified its roughly 100 injection molding machines across all sites. At that time, those included two facilities in Colorado — Altratek Plastics in Longmont and Pikes Peak Plastics in Colorado Springs — as well as Plastic Molding Technology in El Paso, Texas, which was the final acquisition in the 2021 shopping spree and whose name was adopted for the new combined company. Presses were catalogued with A, B or C rankings. “’A’ machines are top of the line, ready to run,” Engler explains. “’B’ machines are maybe getting a little older but have no major issues, and ‘C’ machines are targets to replace.” PMT didn’t stop at injection molding machines, however, as the equipment review extended to everything on the shop floor, from temperature-control units and robots to forklifts and air compressors.

“When I talk about integration, I see it as a very structured process. It’s not happenstance.”

“Why is that important?” Engler asks. “Now we work the plan. Each year when we’re developing our budget, there are no secrets,” so that C machines are targeted for replacement with an eye on improved productivity, as well as the customer’s best interests. “If I have ‘C’ machines that are highly utilized,” Engler says, “I’m putting my customers at risk. So maybe my business process is to buy a new piece of equipment and then start to mitigate risk.”

As PMT worked to create a cohesive whole from its collection of acquisitions, Engler knew the company would need a headquarters facility. It found that structure, and additional core competencies in Plastics Design & Manufacturing (PDM), Centennial, Colo. Acquired in May 2021, PDM is located south of Denver in what’s known as the Tech Center. In business for more than 40 years, the custom heavy-gauge thermoformer, which also has a profile extrusion operation, operates in an 80,000-ft2 space.

Upon taking over, PMT brought in 10 injection molding machines, including five brand-new presses, putting the first machine on the floor before there were even electrical utilities in place to run it. When Plastics Technology visited last month, two more injection machines were on their way, joining nine new Yushin robots, including two 6-axis Fanuc models. Mold racks, new overhead cranes and a jib crane were also installed, and PMT is still awaiting delivery of two material silos and a cooling tower.

PMT CEO Michael Engler (left) and John Hunt, vp and general manager Colorado for PMT, stand in front of the company’s newest press — an all-electric Toyo running a renewable-energy application. (Photo: Plastics Technology)

At this time, the plant uses two portable chillers to supply process water, and it goes through 50,000 to 60,000 lb of resin a week, with each press burning through two gaylords daily, as PMT anxiously awaits its silos and, eventually, a centralized material-handling and drying system. The first four machines on the molding floor — all-electric Toyo’s — are committed to one customer and run six dedicated tools for a renewable-energy project. Once the six-axis robots are integrated, PMT’s plan is to make this machine group fully “4.0,” running nearly lights-out, with only one material handler managing the floor.

All this injection molding is new, but the legacy thermoforming and extrusion operations at the facility are not. The thermoforming footprint includes 12 machines with capabilities in drape, vacuum and pressure forming, including two- and three-station rotary and two-station pressure-forming shuttle and single-station machines. Molds as large as 10 × 10 ft can be run, and the operation includes three- and five-axis CNC machining for post-forming finishing, as well as in-house toolmaking using epoxy, wood and aluminum forms. Certified AS 9100 for defense and aerospace work, the operation also boasts a paint room and the ability to add EMI shielding.

PMT’s custom thick-sheet thermoforming operations supply the medical business, among others, and offer painting. (Photo: PMT)

When Plastics Technology visited, parts in production varied from components for communications, including an 80-in. telecom dome and various 5G parts (with 7G already being quoted), as well as components for an autonomous vehicle and various helicopter applications, including floors, being retrofitted into decommissioned Blackhawk helicopters that are being converted to help combat forest fires.

“Buying four companies in less than one year was very stressful. Now we need to make some money and pay some bills.”

On the extrusion side, parking targets — extruded and cut profiles that are adhered to a garage floor to indicate to a driver when a vehicle is properly situated — were running last month. The facility has six single-screw extrusion lines targeting open and closed profiles, as well as pipes, including parts for hydroponic farming. The parking target application actually allows PMT to run zero landfill with company-wide plastic scrap reincorporated into the black profiles. Depending on the scrap mix, PMT alters the adhesive used to secure the parts to the garage floor on the basis of compatibility.

PMT’s extrusion capabilities include custom plastic profile and pipe extrusions. Photo Credit: PMT

One hour north in Longmont, Colo., PMT operates an additional injection molding and moldmaking operation. Featuring 14 all-electric Toyo injection machines from 55 to 400 tons that are just six years old or newer, this molding operation specializes in highly glass-filled parts, with many applications destined for sporting goods. All the machines feature sprue pickers, and there are brand-new three-axis robots on two of the presses. Including the tool shop that’s five minutes down the road, the two facilities cover 18,000 ft2. The toolmaking operation has three moldmakers on staff and offers full design, fabrication and repair, as well as sampling capabilities from a lone press. It built 20 tools in 2022.

PMT’s three-man tooling operation in Longmont, Colo., built 20 tools in 2022, including this mold which it will run in-house. (Photo: Plastics Technology)

Across the three sites in Colorado and Texas, PMT has just under 250,000 ft2 of space and more than 100 vertical and horizontal molding machines, ranging in clamp force from 20 to 500 tons, with insert, overmolding and two-component capabilities. The company also bought out the lease of the company that was using the other half of the building it purchased in Centennial, giving PMT another 40,000 ft2 to move into as it expands. PMT also owns the land, offering further expansion opportunity. Featuring 33-ft ceilings, two office areas and two shipping and receiving docks, the site gives PMT an anchor point as it continues to establish what Engler calls a “beachhead of competencies.”

With the backing of California investment firm Tide Rock (Cardiff by the Sea), which has deployed close to $350 million in capital over the last two years, PMT will at present focus on continuing to incorporate its acquisitions. Beyond strictly plastics plays, Tide Rock’s 2022 acquisitions included two metal operations, Accu-Fab and Fabcon; and Adura LED Solutions, which manufactures custom LED modules, PCBs and Chip-on-Board (COB) LEDs.

“When you buy four different businesses with four different teams, four different cultures, and four different ways of doing business, you need integration and stabilization of those processes,” Engler says, noting that if an acquisition opportunity presents itself in the coming year, the company will consider it, but the present moment might call for something else. “Right now, buying four companies in less than one year was very stressful,” Engler says laughing. “Now we need to make some money and pay some bills.”

PMT has more than 100 injection molding machines across three sites, with plans to replace aging equipment and build out additional capacity going forward. (Photo: PMT)

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