Archive for Červenec, 2011

Polymera’s wood-plastic composite compounds not slated for decking

Polymera’s wood-plastic composite compounds not slated for decking

Located in a 160,000-square-foot former Diebold plant in Hebron, Polymera will make WPC compounds on three twin-screw Milacron extruders. At full production, the plant will be able to make more than 50 million pounds of compounds a year, and employ about 60 people, according to Herb Hutchison, vice president and general manager. The plant will employ 15-20 people when production begins in the fourth quarter of this year.

Polymera also will produce its own wood fibers on a Schutte-Buffalo grinder and hammer mill system.

The flexible, automated production operation includes a blending system than can add up to nine ingredients to a recipe.

The company is led by four industry veterans, including three with more than 25 years of experience at Crane Plastics Manufacturing Ltd. of Columbus, Ohio. Most recently, Hutchison was director of international business development at equipment maker Milacron Extrusion Systems.

Hutchison and other Polymera leaders described their strategy during a recent interview at the plant.

Decking will not be the focus of Polymera. Instead, Hutchison said the company will fill other needs in the wood-plastic composite industry. The major, large-volume decking extruders already do their own blending and compounding of wood fiber and plastic, but Hutchison said most lower-volume wood-composite users can’t afford to buy the equipment for just one or two products.

“It’s a very capital-intensive system and that’s limited other extrusion companies from getting involved. And if you look at injection molding, it’s even more limiting,” Hutchison said. “There hasn’t been a material out there — other than somebody that can blend a million or a half-million pounds a year, total — there hasn’t been a major player that can offer a raw material to the injection molding industry on a consistent basis. We have that capability.”

People in the WPC industry have talked about injection molded parts for years, but the sector has been slow to adopt wood-plastic materials. Polymera officials want to help change that.KraussMaffei targeting growth in Latin America

KraussMaffei Technologies has doubled its sales of new injection moulding machinery in Brazil to €18m this year, a senior official says.

The €18m worth of business in the South American country “is more than 50% up on 2010”, he said.

López is KraussMaffei’s head of injection moulding technology sales in Ibero-America.

Brazil, where 650 KraussMaffei injection moulding machines are installed, and Mexico are the German company’s two largest markets in Latin America, López said.

In Mexico sales of new KraussMaffei injection moulding machinery have totaled between €15m and €16m in 2011, slightly up on last year’s, he added.

By next year the company will have installed about 1,000 new machines, including both injection moulding machines and extruders, in Mexico in 15 years, according to Héctor Moreno, managing director of KraussMaffei subsidiary KraussMaffei de México.

“Our main business is still automotive, which is mainly injection moulding,” Moreno said in a separate interview, adding that, out of 185 KraussMaffei customers in Mexico, about 100 are in the automotive industry.

Its most recent sales include that of a 1,600-ton clamping force injection moulder, bought by Plásticos Panamericanos of Tultitlán, near Mexico City, which will use it to produce pallets for Fomento Ecónomico Mexicano (Femsa), of Monterrey, a leading soft drink and beer bottler.

Munich-based López said that, while Brazilian customers tend to purchase mainly very large injection moulding presses, in Mexico the clamping force demand is more varied, ranging from 50 tons to 4,000 tons.

“Argentina is always a surprising market, difficult, but they buy big machines. This year we sold six big machines (up to 4,000 tons clamping force) in Argentina and that’s not usual.”

“We get our machines out in two days. If you have your documentation in order, there’s no problem.”

KraussMaffei has not come across corruption in its dealings with private companies in Mexico either, he said. “We deal with a lot of companies, both national and international, and no money crosses hands.”

Moreno said a concern continues to be the importation of used machines. “60% of the machines coming into Mexico are second hand,” he said.

This year the company, which employs a full-time staff of 23, introduced a 240-hour diploma course to increase the knowledge of those working in the plastics industry and to help combat the importation of used equipment.

Better performance but lower cost in moulding

Better performance but lower cost in moulding

Developments in injection moulding processes continue to improve efficiency and precision and cut costs. European Plastics News looks at the latest advances in in-mould welding, inline sealing, mould steel and micro moulding.

Sonderhoff, the foamed-in-place foam gasket (FIPFG) system and materials specialist, has developed a new Mold’n Seal process that was shown at the open house at Arburg’s German headquarters at the end of March.

Sonderhoff says that compared with its earlier FIPFG systems, Mold ‘n’ Seal, as shown in Lossburg, has a relatively small footprint of 50m2 for the complete production cell. The cell consists of an Arburg 570S injection moulding machine, polyurethane MK600 mixing and DM402/403 dosing equipment, a 6-axis Kuka articulated part handling and gasket material application robot, and line balancing conveyor belt.

The system fully integrates the Mold’n Seal process with the injection moulding machine’s control system as one inline system. A particularly innovative feature is the cell’s use of just one 6-axis robot for part removal and PUR sealing material application. At the sealing stage, the residual heat from the moulding process reduces the curing time needed to form the in-place foamed gasket on the moulded part.

Sonderhoff marketing director Peter Fischer told European Plastics News that in the Lossburg demonstration, injection moulding, part removal and placement for seal application took around 45 seconds.

Following this, it only took another three minutes for the Fermapor K31 seal to become completely cured, eliminating the need for a long balancing belt.

Stoppages for mixing head cleaning are no longer required with the newly optimised K31 polyurethane material in an eight hour production run. During this time, 2,560 parts can be moulded, foam sealed and passed on for further downline processing.

The 40g cover produced in Lossburg was moulded in Tecnoprene A60 K6, a 30% glass fibre reinforced PP from Italian compounder PGroup.

A new means of welding together two injection mouldings within an injection mould has been launched as the Joinmelt process, developed by injection moulding machine producer Engel with mouldmaker Hummel-Formen and welding system specialist KVT. The process was given its premiere on the Engel and Hummel-Formen stands at the VDI plastics in automotive engineering conference in Mannheim in April.

Key to the process is the use of a patented KVT 400oC hot gas welding method under inert gas. The Joinmelt process itself has been patented by Hummel-Formen. KVT claims the process is suitable for all types of thermoplastics, in particular glass fibre reinforced polyamide media ducts in automotive engine compartments, without the bulges conventionally arising from use of other welding techniques.

In the process, two moulded halves are simultaneously produced on left and right sides of a mould. The mould opens after the cooling stage and the movable left half is slid to a position so that the two mouldings face each other. The hot gas heating element enters the open mould area between the cavities and heats the edges of the two mouldings, which are then welded together by renewed closing of the mould. On reopening, the complete welded part is released.

At the VDI conference, Hummel-Formen pointed out the advantages of using Joinmelt, including clean smooth parts free of particles, greater geometric freedom, lower production costs and weight reduction in a “simplification of the production process”.

In the mould making sector, stainless steel mould steel producer Deutsche Edelstahlwerke (DEW) launched its new Corroplast FM steel at the Euromold 2010 fair last December. The new steel addresses the needs of more precise machining capability when making stainless steel moulds, as the number of cavities increases in multi-cavity PET bottle preform moulds up to as many as 192-cavities.

Key to enhanced machining without compromising corrosion resistance has been two years of work spent in optimisation of the steel alloy’s chromium, nickel, manganese and sulphur contents.

According to Jens-Sebastian Klung of DEW’s development, material and process simulation department: “A particular challenge was homogenisation of the structure and the correct sulphur content, which has a positive effect on machining properties, but also decreases performance, especially in the transverse direction.”

The negative effects of the sulphur content were overcome by attention to melting, secondary metallurgical treatment, as well as by minimisation of embrittlement by delta ferrite through thermodynamic calculations. These measures achieved the required enhanced structural homogeneity.

DEW says that the new Corroplast FM steel, with its 290HB hardness and improved microstructure, is available in 1,000mm wide rolled or forged sheet in thickness of between 40mm and 400mm.

In a conference organised by the IVAM microtechnology trade association at the Compamed 2011 fair last November, examples of overcoming challenges in micro moulding medical device and drug delivery components were given by Paul Glendenning, business development manager micro_components and polymer optics at Micro Systems (UK).

Glendenning identified these key micro mould tooling success factors: machining and alignment accuracy, preferential use of three-plate mould systems for auto-degating, and attention to venting. He pointed out that 0.050 - 0.200mm pin gates are used for injection, “unless an attached runner is needed for part handling”.

A new Wittmann Battenfeld MicroPower 15 machine ran on the Micro Systems (UK) stand at Compamed 2011, producing a medical clip as a development part with overall size of 1.5 x 2.6 mm and tooth pitch of 0.3mm. A clip was also produced on the Wittmann Battenfeld stand at the Medtec 2011 fair in Stuttgart in March. The POM part weighed 0.003g and was produced with 4s cycle time in a four-cavity mould supplied by Microsystems (UK).

Micro Systems (UK) has successfully moulded parts with 0.2mm diameter holes in 1.5mm and 0.32mm diameter holes in 7mm thickness “at a compound angle”. Holes as small as 0.04mm diameter have been achieved in thin moulded filter meshes, Glendenning stated.

Applications described by Glendenning included a micro-moulded drug-delivery caplet involving overmoulding in a two-cavity mould of bio-resorbable material. He also described a catheter tip development for a cardiac operation fluid delivery tube in which Pebax plastic is moulded onto a Pebax tube, followed by post-moulding laser drilling to produce a hole in the tip and 600 holes in the Pebax tube walls. Total cycle time amounts to 20s for two catheters.

Dental surgery was represented among Glendenning’s application examples by DFRP’s Smartseal ProPoint obturation device used in root canal treatment. The device applies hydrophilic polymer instead of conventional Gutta Percha, resulting in the first-ever lateral expansion within the root canal to form a complete 3D seal, claims DFRP.

The 43mm long, 0.18mm diameter ProPoint tip is made of a 60% mineral filled polymer that is “radio-opaque” to X-rays in a two-cavity tool. The tip was developed with Bradford University that has received its first MicroPower machine from Wittmann Battenfeld.

Microfluidic and bio-photonic applications were also addressed by Glendenning, with micro-moulding facing challenges as more features are integrated into microfluidic devices, such as use of diffractive optics to shape laser or LED light in, for example, cell interrogation.

With surface nanostructures being used to control wetting ability, “design know-how is needed at the nano level to create functional surfaces on specific materials”, Glendenning concluded.

Wittmann Battenfeld has been active in other application developments with the earlier MicroSystem 50. This has included micro metal-plastic hybrid part moulding, developed together with the packaging technology business unit of roll-clad metal strip producer Heraeus.

But the new MicroPower machine can be equally well integrated as part of a complete production cell producing items such as LED lead frames by overmoulding thermoplastics onto roll-fed metal strips. With cycle time of 5s, the company claims that cost savings of 30 to 50% can be achieved compared to conventional injection moulding machinery used for this purpose.

Injection service to be used extensively

Injection service to be used extensively,easy to find what you want

Drawer Mould Injection moulding is identified getting a type of producing and is also ordinarily employed to create small plastic material things that come going to be huge in number. For example, a car institution would use this method to create every one of the small components which consists of seatbelt holders, caps for fluid reservoirs and several different other small plastic material products.

Most using the time, a institution will only use this sort of producing if they create lots of small dietary supplements that come going to be especially the same. So, in other words, once the institution should create a massive assortment of duplicate things then injection moulding could be the excellent solution.

The complete method is quite potent and quite fast and that is why it’s so popular. a massive apparel does most using the purpose however it will need supervision from employees and possibly a technician. The complete method is quite fast but is straightforward to understand.

To start with, a feeder spots the granulated plastic material into what they phone call a hopper also it is then fed through the use of a heated barrel which melts the plastic. after it is melted it could be mixed with other components and options which consists of color or what ever else is needed.

Once the plastic material has melted and mixed it may then be fed to the mould element using the machine. after every one of the product or company is inside the mould, the apparel cools this place to set up the mould. You will then be in the carry out using the method and will possess the important thing of lots of plastic material dietary supplements created.

A complete large amount of other factors are enclosed in sustaining the apparel operating – for example, consuming water is practically usually employed to awesome the plastic material even although it’s inside the mould. There are also a assortment of shapes and sizes offered using the mould and most firms are required to create these moulds themselves.

Many people these times overlook injection moulding but it’s in reality extensively employed by lots of huge producing firms all through the world. the important thing aim that this method is so well-known is merely since it is fast, exact and quite uncomplicated to set up up – after you possess the machine, you merely should preserve it.

Injection moulding products could be quite huge so you’ll undoubtedly need a warehouse, but probabilities are, if you’re a producing company, you presently possess a massive warehouse in place. an extra aim why this type of producing is so well-known is merely because it’s cost effective as well.

Obviously, you do possess the original cost of buying the apparel but they cost quite small to run and so are ordinarily quite stable in conditions of not breaking decrease or malfunctioning. they are able to help save lots of your time and bucks inside the prolonged run.

You must acquire in a location to locate injection moulding products within of a assortment of shapes and sizes as well as you can both purchase them, used, from other firms who no lengthier need them, or you can purchase them brand name new from the producing apparel specialist.

You have to undoubtedly do some investigation past for you purchase something merely since it could be considered a tad of the complicated process. Obviously, getting a massive producer you’ll most possible possess the ability to create utilization of your contacts to acquire your do it yourself an superb offer for just about any amount of products and apparel options.

Some Points About Plastic Injection Molds

Some Points About Plastic Injection Molds

Some blessings of plastic injection molds are high tolerances. High production rates, low labor prices and minimal scrap losses. There are completely different injection molds techniques accessible to accomplish this as well as rotational molding, injection molding, blow molding, and compression molding to call simply some. Every technique has its edges and is best fitted to the creation of specific things. In contrast to the olden days solely when solely contemporary plastic materials were molded to helpful product, nowadays with environmental awareness on the increase, plastic injection concentrates on using recycled materials. Moreover, the advancements in plastic injection technology have created it potential to manufacture product in any sophisticated shapes. There are many companies which provide manufacturing services like lavorazione plastica milano and Stampaggio materie plastiche milano.

Several terms are commonly used for injection molding. Ejection pins are rods that push the half out of the mildew. This force keeps the mildew closed throughout the injection method. Tonnage will vary from but five tons to 6000 tons, with the upper figures employed in comparatively few producing operations.

In broad terms, the method of plastic molds consists of feeding raw material granules and additives like color, into a hopper situated on the molding machine. The raw material enters a heated barrel with reciprocating screw and therefore the molten plastic is then injected at considerable force into a 2 half mould tool specific to the item being made. The method of plastic injection molds typically begins with an industrial designer or engineer who styles a product. For best manufacturing and production services you can go for lavorazione materie plastiche Piemonte and progettazione stampi milano.

This can be followed up by the work of a toolmaker or mould maker who makes the mould to suit the look created. When molten, they’ll then be manipulated to a brand new form. When shaped to their new form they have to then be cooled to solidify them.

Choose For Your Plastic Bottles Requires The Right Blow Molding Machin

Choose For Your Plastic Bottles Requires The Right Blow Molding Machine

Blow molding machine a€“ choose plastic bottles you need the right equipment, casting is a manufacturing blow molding machine has played a leading role in machinery production. process of thermoplastics for the manufacture of hollow objects.

Two types of machines used in a variety of plastic injection molding machine and blower. Choosing the right rapid prototyping machine is first introduced in last yeara€?s. difficult task in the early 90s into the country, if you are not familiar with the concept of hitting.

Entrepreneurs, such as beauty shop owner, pharmaceutical manufacturers and others should do in their daily lives for plastic bottles and the standerd engine blowing. According to China blowing machine plastic injection molding, and large market for this option, it is very difficult from the best manufacturers of equipment. There are options that can be entered in the secret blow, injection machines. It includes an extruder with an extrusion head. It must have a minimum closure. Two deaths were particularly welcome. Query specifications and key features. For example, the barrel, so the ideal screw should be set up steel and nitrification. Extrusion machine structure will be adjusted automatically. PET bottle materials is a relatively small amount of hope for the development and sale of polyester products, heat-formed into a plastic bottle blow molding. PET bottle embryo is usually available in different shapes and sizes. We provide high quality ball you, please contact us. The decisions are high-speed PET plastic bottle blow molding machine is heated preform to hire. The resulting plastic bottles used for various applications, including carbonated beverages, alcoholic drinks, liquid laundry detergent, body lotion, prescription medicines, cosmetics and personal care products. Plastics can be non-metallic compounds. It can be molded into different shapes. As the plastic pipes, toys, bottles, kitchen utensils, protective caps, plastic bottles commonly used mold. Plastic molding process includes several. It is important to understand the various processes that I have. Injection molding and is therefore an integral part of plastic molding. The former includes causing a matrix, which melts the plastic, the product, we can provide you with complete ceramic films can make your kitchen clean. turn format. When cooled mold can be removed. This is a common standard or large-scale production data from the choice of caps, furniture, apart from all of the body. The latter is the same injection molding. Output products embrace plastic bottles, containers and pipes. High quality casting machine to get the final plastic models you.

US Toolmakers need start training now before it’s too late!

US Toolmakers need start training now before it’s too late!

Big shortages are expected in the toolmaking fields, Tool and Die, Mold Making, etc. The average age of toolmakers is about 60 years old in the industry right now. Michigan the state that employs the largest number of these workers employs about 16,000. That’s down about a third from what it was a few years ago due to globalization and the recent recession. The country as a whole is down about 25%. The number of workers right now isn’t expected to rise dramatically over the next 10 years or so, but the number of people retiring from the field will be immense. The exodus has started as worker take early retirement and buyout packages. This threatens the industry far more than competition from China or anywhere else. The number of apprentices graduating are about 250 a year in Michigan. Nowhere near the future demand that will be created. Parts of the country have already seen wages top $30/hour with the average being about $25 for a Tool and Die Maker for the rest of the country. Michigan has been able to keep theirs to about $20 due to it’s lagging economy but that to is showing signs that it is finally turning the corner.
The industry suffers from alot of bad press due to the downturn in manufacturing and the false assumption that these jobs are old economy. The industry has changed tremendously in the last few years due to economic pressures. Gone are the days of dank and dirty sweat shops, replaced by high tech and advanced manufacturing run by computers and high speed machining.
Many small shops decided to quit training and ended their apprenticeship programs because of large corporate customers were raiding their programs of their 2nd, 3rd year and recent card carrying apprentices.

Plastic Injection Moulding: How Does it Work?

Plastic Injection Moulding: How Does it Work?

A lot of people go through life with no real interest in the ‘behind the scenes’ stuff. They don’t want to know where their dinner came from, they just want to know it’s in front of them. They have a similar opinion on everything from how their car works to the physics that drive our reality. There is nothing wrong with this kind of person, it takes all kinds to make up the world. There is another type of person, however, and this type of person likes to know the back story of everything. This type of curious individual loves watching documentaries about how things are built, behind-the-scenes features on how certain films are shot, and is usually the type of person who takes things apart to find out on their own what makes it tick. It if for these inquisitive creatures that we’ve created this article, a brief look at the way in which plastic injection moulding works. While most of our homes are filled with items that came into existence through plastic injection moulding, many of us have no idea how it works. Allow us to explain…

Manufacturing Process

Basically, injection moulding requires whatever material (plastic, in this case) to travel through a heated barrel (thus liquefying it) and then into a pre-made mould wherein it hardens again. While this is an industrial engineering and manufacturing process, it has a lot in common with the art of pastry cooking! Scoff though you may, the principles of heating a material and then injecting it into a mould for it to set conjures up many an image of culinary art.

Materials

The material used in plastic injection moulding is thermoplastic. Thermoplastic is a polymer, and it is also known as thermosoftening plastic because of the softening effect heat has on the material. The properties of thermoplastic allow it to liquefy at an elevated temperature and then set into a solid once it cools. The exciting thing about thermoplastics is that they can repeat the melting/freezing process many times, making them valuable for a wide range of uses, especially when it comes to injection moulding.

There are several parties involved in the manufacturing of goods through plastic injection moulding. The moulds themselves are created by mould makers out of metal, and the product design is conducted by industrial designers or engineers. At this stage the injection moulding takes place, and the soft plastic is driven through to the mould by a plunger-like part.

From entire bodies of vehicles to tiny little buttons, plastic injection moulding is responsible for many of the products we see every day.

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