CPL - April 2023

www.canplastics.com

APRIL 2023

TALL ORDER

Choosing the right storage silo

Checking in on PROCESS COOLING ALUULA COMPOSITES: From windsports to Mars?

Focus on new EXTRUSION technologies

contents APRIL 2023 VOLUME 82 • NUMBER 2

FROM THE ARCHIVES

The October 1995 issue of Canadian Plastics reported on a recent groundbreaking ceremony for a new plant for parts molder Mitchell Plastics in Kitchener, Ont. The 59,000-square-foot facility, which occupied 7.3 acres of land and was scheduled for completion by the end of that year, would initially be stocked with five Mitsubishi injection molding machines – with capacities ranging from 750 to 1,850 tons – for molding parts for the automotive, business machines, and electrical and electronics industries. The new plant would be Mitchell Plastics’ third facility in Kitchener.

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Number of the month:

1,024,462*

*Square footage of exhibit space sold at the NPE2024 space draw in Orlando, Fla. (See pg. 9)

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19

Cover Photo Credit: © weerapong/Adobe Stock

cover story 4

Editor’s View: What Seychelles tells us

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Ideas & Innovations: Making lifelike, 3D-printed microscopic creatures from smart polymers

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News: • Feds get pushback on ‘plastics registry’ plan • Changes at ABC Technologies • Magna makes major investments in Ontario • Supplier News and People

20 Technology Showcase Focus on extrusion 21 Advertising Index

10 RAW MATERIALS HANDLING: Tall order: Choosing the right storage silo

With an uncertain supply chain these days, you can’t have too much resin storage.

Which are where outdoor silos come in. And when selecting a new silo, determining your requirements in advance will help the supplier provide an efficient design and a trouble-free installation.

features

14 PROCESS COOLING: Very new, extremely cool

Process cooling is an important part of plastics processing because it maintains the quality of production and ensures the parts meet target dimensions. And in a competitive global market like now, it’s absolutely critical. Here are some of the latest developments in chillers, cooling towers, and TCUs.

18 COMPOSITES: Windsports and way beyond

Going from kitesurfing to landing on Mars is a giant leap, but it’s one that British Columbia-based Aluula Composites might be poised to take.

22 Technical Tips: How to reduce materials in injection molded auto parts

Visit us at www.canplastics.com April 2023 Canadian Plastics

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Canadian Plastics magazine reports on and interprets developments in plastics markets and technologies worldwide for plastics processors, moldmakers and end-users based in Canada.

editor’s view

www.canplastics.com

What Seychelles tells us

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new study co-authored by two Oxford University researchers sheds some valuable light on the serious and very high-profile problem of plastic waste in the ocean and where some of it comes from.

More than 1,000 kilometers southwest of Mahé, the main inhabited island in Seychelles – which is an archipelago of 115 islands in the Indian Ocean, off East Africa – lies a ring of coral islands called the Aldabra Atoll. The atoll is remote and uninhabited, but nevertheless a clean-up operation in 2019 removed roughly 25 tonnes of accumulated plastic waste from its shores.

The Oxford study modelled the flow of plastic debris in the Indian Ocean between 1993 and 2019 and traced it to its source, and found that none of the plastic was made on Seychelles, which has very little manufacturing.

So, where did it come from? According to the researchers’ model, some of it drifted from India, Sri Lanka, and the Philippines, which makes sense. But almost half of the plastic bottles that were collected were manufactured in China, which doesn’t make sense because ocean currents don’t flow directly between China and the western Indian Ocean. So, it’s exceedingly unlikely that they floated from China to Seychelles. But Seychelles is close to a major shipping lane that connects southeast Asia to the Atlantic, and the researchers conclude that the bottles were likely dumped en masse from container ships crossing the Indian Ocean.

As you can probably surmise, this isn’t supposed to happen. The Marpol Convention, written in 1983, prohibits discharge into the sea of nearly all forms of garbage, including plastic. As of 2023, 156 states are parties to the convention,

4 Canadian Plastics April 2023

being flag states of a whopping 99.42 per cent of the world’s shipping tonnage, so – in theory, at least – plastic items manufactured in China shouldn’t be washing up on Seychelles.

In reality, though, the effectiveness of ships to comply with the discharge requirements of Marpol depends largely upon the availability of adequate port reception facilities. Hence, Marpol also obliges signatory governments to ensure the provision of adequate reception facilities at ports and terminals for the reception of garbage without causing undue delay to ships.

It seems safe to assume, though, that at least some ports and terminals aren’t meeting this standard, since some ship operators are clearly jettisoning the plastic waste generated by their crews before reaching port, with ocean currents then carrying it to beach not only on Seychelles but also, as other studies have reported, on other remote islands. As the Oxford researchers conclude, better enforcement of Marpol would reduce the amount of plastic entering the Indian Ocean. And hopefully their study will advance the ball on this a little.

Which would be great for everyone on the planet, particularly those of us in the plastics industry in Canada and the rest of North America. Because, at present, we’re taking the heat for millions of tons of plastic pollution scattered around the world that we didn’t generate, with the possible result that our finger-to-thewind political leaders might someday act on this misinformation and do something drastic, ridiculous, and completely illogical like – Oh, I don’t know – ban single-use plastics items, or even declare the entirety of plastics manufacturing in Canada to be “toxic.”

Oh, wait…

Reader Service Print and digital subscription inquiries or changes, please contact Angelita Potal Tel: 416-510-5113 Fax: 416-510-6875 email: apotal@annexbusinessmedia.com Mail: 111 Gordon Baker Rd., Suite 400 Toronto, ON M2H 3R1 EDITOR Mark Stephen 416-510-5110 Fax: 416-442-2230 mstephen@canplastics.com ASSOCIATE PUBLISHER Stephen Kranabetter C: 416-561-5362 W: 416-510-6791 skranabetter@annexbusinessmedia.com MEDIA DESIGNER Lisa Zambri lzambri@annexbusinessmedia.com ACCOUNT COORDINATOR Cheryl Fisher 416-510-5194 cfisher@annexbusinessmedia.com AUDIENCE DEVELOPMENT MANAGER Serina Dingeldein 416-510-5124 sdingeldein@annexbusinessmedia.com GROUP PUBLISHER/VP SALES Martin McAnulty mmcanulty@annexbusinessmedia.com PRESIDENT/COO Scott Jamieson sjamieson@annexbusinessmedia.com PRINTED IN CANADA ISSN 008-4778 (Print) ISSN 1923-3671 (Online) Publication Mail Agreement #40065710 2023 SUBSCRIPTION RATES

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Mark Stephen, editor

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ideas & innovations

Making lifelike, 3D-printed microscopic creatures from smart polymers

I

Image Credit: C. Spiegel, Heidelberg University

n the age of smart cars and smart factories, smart polymers – which are high-performance soft materials that change according to the environment they’re in – are only natural. And a research team from Heidelberg University in Baden-Württemberg, Germany, has developed a new strategy for creating “living” 3D microstructures from smart polymers that grow in size and harden at will, opening up new opportunities in fields such as micro-robotics or biomedicine by using 3D printing.

The technique combines two-photon laser printing – which allows 3D printing to be performed at the micron and nanometer scale – with dynamic covalent chemistry, which is a process for making complex supramolecular assemblies from discrete molecular building blocks. In particular, the Heidelberg researchers designed an ink formulation such that a kind of dynamic covalent bond known as alkoxyamine units would be incorporated into the final printed structure – these alkoxyamine bonds could then be modified after printing to add more monomers or change the cross-linking density. Conventional inks don’t offer such features.

The researchers identified ink components that would produce so-called covalent adaptable microstructures (CAMs), and then optimized the components’ ratios to produce the desired mix of “living” features and to print successfully. Specifically, they made sure that the ink wouldn’t require overly high laser powers or lead to slow printing speeds. Next, the researchers used a commercial direct-laser-writing system with the novel ink

formulation to fabricate complex CAMs such as a sunflower, an octopus, and a gecko. A femtosecond-pulsed, near-infrared laser was focused on a tiny point within the ink solution and, through two-photon polymerization, transformed it into a solid.

With different chemical reactions, the team was able to successfully alter the mechanical properties of the CAMs postprint. For example, a reaction called nitroxide-mediated polymerization chain extension introduced new monomers to the CAMs, causing them to grow eight-fold in just a few hours and harden while maintaining their shape.

The Heidelberg team’s technology actually crosses the line from 3D printing into 4D printing because it adds an extra fourth dimension, which describes how 3D-printed objects can change over time based on exposure to stimuli like air, water or heat.

“Manufacturing programmable materials whose mechanical properties can be adapted on demand is highly desired for many applications,” team member and Heidelberg professor Eva Blasco said.

CPL

Due to dynamic chemical bonds, the micrometric 3D structures can grow eight-fold and harden in just a few hours.

April 2023 Canadian Plastics CPL_Ensign_April23.indd 1

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2023-03-02 11:47 AM

news

Feds get pushback on ‘plastics registry’ plan

T

oronto-based automotive parts supplier ABC Technologies Holdings Inc. has made some recent changes in key leadership positions, and also sold its 50 per cent equity in its former joint venture with Inoac USA Inc. In mid-February, ABC named Barry Engle as chairman of the board, replacing James R. Voss, who remains on the board; and appointed Scott Roggenbauer as chief financial officer, replacing David Smith, who is leaving the company. And in

Barry Engle

Scott Roggenbauer

6 Canadian Plastics April 2023

Mark Decker

November 2022, ABC named Mark Decker as chief human resources officer.

ABC’s joint venture with Inoac USA, meanwhile, which had been called ABC Inoac Exterior Systems, is now a wholly owned Inoac entity after ABC sold its interest to Inoac USA. The independent entity has been renamed Inoac Exterior Systems.

The terms of the acquisition have not been disclosed.

The deal adds four facilities and 1,200 employees to Inoac USA, according to a Feb. 20 news release.

Troy, Mich.-based Inoac specializes in polyurethanes, polyolefins, elastomers, plastics, and composite materials for automotive interiors, exteriors, consumer products, medical, construction, and other markets.

ABC has approximately 9,000 employees worldwide, and 3 product groups: Interior Systems; Exterior Systems; and HVAC, Fluids & Other.

CPL www.canplastics.com

Photo Credits: ABC Technologies Inc.

Changes at ABC Technologies

the ministry concluded, “it’s difficult for Canadians to know how effective EPR is in helping to reduce plastic waste.”

The Canadian review process is in its early stages, with a formal proposal likely to be unveiled later this year and subject to additional public comment. A draft regulatory text for an EPR law is targeted for publication as early as mid-2023, the ministry said.

The federal government is also proposing stricter standards around recyclability and compostability labelling in Canada, which would require a package to be accepted by 80 per cent of collection systems to be called “recyclable.” The Feb. 17 report also summarized responses from a formal consultation on this plan. “Many stakeholders commented that the proposed 80 per cent threshold for acceptance in collection systems for recyclability labelling was too high,” the ministry said. “They also commented that a phased-in approach would better align with the adoption of EPR across Canada.”

The ministry also noted that industry groups have so far dominated both consultation processes, making up to two-thirds of the commenters on various topics, while environmental groups made up 13 per cent or less.

CPL

Photo Credit: © monticellllo/Adobe Stock

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he Canadian government said it’s getting pushback on its proposal to establish a federal “plastics registry” requiring annual reporting around how plastics are used in the Canadian economy and managed at their end of life.

Announced in July 2022, the plastics registry would collect data on the life cycle of plastics in Canada in accordance with an extended producer responsibility (EPR) law. The resulting database would require reporting on all major categories of plastic products, covering about 88 per cent of all plastics placed on the Canadian market, including packaging, construction, automotive, appliances, electronic and electrical equipment, textiles, and agriculture.

In a Feb. 17 report outlining feedback it was getting from the formal consultation, which ran from July to October 2022, the Environment and Climate Change Canada ministry said commenters expressed concerns about how the registry would work, how it would protect confidential business information, and how it could lead to competitive inequalities between the plastics industry and industries of other material types such as fibres, glass, and metals.

There was also disagreement about the timeline for implementing the registry. “Some stakeholders argued that the proposed timelines for implementing the registry were too long, and that all reporting should be phased in by 2026,” the ministry said. “Other stakeholders argued the opposite, stating that longer timelines are necessary to allow producers to build data collection systems and to allow EPR programs to mature.”

An area of agreement among the commenters related to carving out a small business exemption from registry reporting, the ministry said. “Stakeholders advised that the definition of small business and applicable thresholds require further consideration,” it said.

Given the lack of a precedent for a national plastics registry,

news

Magna makes major investments in Ontario

Image Credit: Magna International Inc.

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utomotive parts supplier Magna International Inc. plans to invest more than $470 million to expand its operations across Ontario, including a new battery enclosures facility in Brampton to support the Ford F-150 Lightning and future OEM programs.

In addition to the Brampton facility, Magna is growing in its locations in Guelph, Belleville, Newmarket, Windsor, and Penetanguishene. These expansions follow new business awards from various automakers in key product areas. They are also supported by $23.6 million in grants from the Ontario government.

The new and expanded operations are expected to bring more than 1,000 new jobs to Ontario over the next few years, officials with Aurora, Ont.-based Magna said in a Feb. 15 news release.

“The Brampton facility, coupled with investment and growth in five existing Ontario facilities, allows [us] to keep up with customer demands across several product areas,” said Eric Wilds, Magna’s chief sales and marketing officer.

The new Brampton plant will be a 490,000-square-foot leased facility to manufacture battery enclosures for electric vehicles (EVs), with operations to begin in the second quarter of 2023. In Guelph, Magna is adding e-coat, molding, and

welding capacity to its exteriors plant to support new EV production. In Belleville, Magna’s lighting plant is adding to its capabilities for printed circuit board assemblies and will start operations in the fourth quarter of 2023. In Newmarket, Magna’s mechatronics facility – which produces vehicle access systems, including side door latches and electronic control units – is growing its business and expects approximately 75 new jobs. In Windsor, Magna’s mechatronics plant is adding new business for powered aluminum tonneau covers. And in Penetanguishene, Magna’s mechatronics facility is growing its tailgate hinges production and more than 15 new jobs are planned.

CPL

A rendering of the new Magna Structures facility in Brampton.

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news

Nova launches circular solutions business, first mechanically recycled food-contact resin

SUPPLIER NEWS – Italy-based extrusion blow mold machinery maker AlphaMAC Italy is now being represented in North America through IMA Dairy & Food, which is headquartered in Leominster, Mass. AlphaMAC’s portfolio includes extrusion blow molding machines, extrusion blow molding molds, bottle design development and production optimization tools, and secondary packaging solutions robotics systems.

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PEOPLE

Photo Credit: Nova Chemicals Corp.

aterial supplier Nova Chemicals Corp. has opened a new business division focusing on lower-emission, recycled products; and launched its first portfolio of resins available through that business.

Called Nova Circular Solutions, the division was launched in February and is headed by Alan Schrob, Nova’s director of mechanical recycling.

And in March, Calgary-based Nova commercialized its Syndigo portfolio, made up of a range of lower-emission recycled polyethylene (rPE) and sold by Nova Circular Solutions. One of the new Syndigo resins is Syndigo rPE-0860-FC, Nova’s first FDAcomplaint, mechanically recycled food-contact rPE, suitable for use in rigid and flexible packaging applications.

The Syndigo portfolio also currently consists of three other resins, which can be used in a variety of non-food contact applications from e-commerce mailers to shrink to industrial films.

CPL

Michael Tassinari

Gordon Overs

Roberto Bischoff

Scott Bober

Lauren Scott

Mark Lippert

Trisha Conley

Norm Kukuk

Vincent Misiti

Marina López

– Automation supplier Barcoding, which has Canadian locations in Montreal, Toronto, and Vancouver, has named Michael Tassinari as chief revenue officer.

– Specialty chemical maker Barentz North America, headquartered in Avon, Ohio, has named Gordon Overs as operations manager for its coatings, adhesives, sealants, and elastomers (CASE) and plastics divisions.

– Thermoplastic resins producer Braskem SA, based in São Paulo, Brazil, has named Roberto Bischoff as CEO. – Woburn, Mass.-based material supplier CJ Biomaterials Inc. has named Scott Bober as global head of sales; and Lauren Scott as director, corporate affairs.

– Industrial equipment manufacturer Hamilton Caster & Mfg. Co., headquartered in Hamilton, Ohio, has named Mark Lippert as president.

– Houston-based polyolefins producer LyondellBasell Industries has named Trisha Conley as executive vice president of people and culture.

– Oconomowoc, Wis.-based bulk container maker Orbis Corp., which has Canadian headquarters in Toronto, has named Norm Kukuk as president.

– Specialty chemical and ingredient distributor Palmer Holland Inc., headquartered in North Olmsted, Ohio, has named Vincent Misiti as CEO. – Size reduction equipment maker Rapid Granulator Inc., headquartered in Leetsdale, Pa., has named Marina López as country manager for Mexico.

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www.canplastics.com 2023-03-14 2:07 PM

Photo Credit: Plastics Industry Association

NPE2024 space draw sets new record

Neutrex founder Arthur Haag dies

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ore than 1.02 million square feet of exhibit space for the NPE2024 plastics trade show was sold between Feb. 27 to March 3 at the in-person space draw held in Orlando, Fla. Officials with the Washington, D.C.-based Plastics Industry Association, which produces the show, said that 1,024,462 square feet of space was snapped up at the draw – a record high, they said, shattering the previous high of 982,000 square feet sold at the space draw for NPE2018.

More than 1,100 exhibitors selected space across 1,259 booths for the 2024 event, which is scheduled to take place May 6 to 10, 2024 at the Orange County Convention Center in Orlando.

The association sold more than 1.2 million square feet of exhibit space for NPE2021, but that event was cancelled due to the COVID-19 pandemic, making the 2024 event the first NPE in six years.

CPL

We Thought

rthur Haag, a plastics materials executive and inventor who founded purging compound supplier Neutrex Inc. and created Purgex purging compounds, died on Jan. 18 in Texas at age 93.

With a bachelor’s degree in chemical engineering from the University of Wisconsin–Madison, Haag started his career in 1953 at Stauffer Chemical as a research and development manager and plant manager.

In 1966, he founded PureChem Corp., a chemical company that made catalysts for the production of polypropylene. While at PureChem, Haag was co-awarded four U.S. patents for codeveloping new methods for making high-purity titanium trichloride. After PureChem was sold to Dart Industries in 1970, Haag managed all catalyst operations at Dart and later at Phillips Petroleum when the division was sold to them.

After retiring from Phillips, Haag founded Houston-based Neutrex Inc. in 1992 and developed Purgex-brand purging compounds, which are used to improve purging efficiency for injection molding, extrusion, and blow molding applications.

He served as Neutrex president until 2021, and continued to be involved as chairman after that. Haag’s son Ken and daughter Kathleen Jarvis are executives at the company.

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2023-03-14 1:50 PM

Photo Credit: Neutrex Inc.

news

raw materials handling

Choosing the right storage silo With an uncertain supply chain these days, you can’t have too much resin storage. Which are where outdoor silos come in. And when selecting a new silo, determining your requirements in advance will help the supplier provide an efficient design and a trouble-free installation.

By Mark Stephen, editor

T

he COVID-19 pandemic is over, but one of its legacies for plastics processors is the ongoing triple whammy of high resin demand, tight supply, and soaring prices.

Which are where outdoor resin storage silos come in. Silos have always been an integral part of large material conveying systems, but they have extra value nowadays as a hedge against current conditions. “Since there’s tremendous value in buying resin in bulk when prices go down, processors need bigger storage solutions, which silos provide,” said Jan Rickenbach, applications manager and regional sales manager for Canada with Motan. “This is why more customers want silos these days.”

10 Canadian Plastics April 2023

Silos also reduce the time and labour associated with handling and moving material in gaylords and bags; eliminate or reduce plant floor storage space requirements for bulk materials; eliminate the waste and disposal costs of packaging; and – when freshly painted and branded with a company logo – serve as a visual signpost for your plant, creating a good first impression for visitors.

So, what’s not to like about silos?

Absolutely nothing, provided you choose the right silo for your needs. This includes a design based on your specific application requirements, including the site location; seismic, wind, and snow loads; the material being stored; the material feed and discharge methods; transportation

THE BASICS

Probably the first question a silo supplier will ask is what type of resin the customer will be storing, since different pellets, flakes, and powders have different compacted bulk densities, flow characteristics, abrasiveness, and hygroscopicity. The answer will help inform not only the silo’s material of construction but also the angle of the cone-shaped bottom; and if the silo will require flow-aid devices such as bin activators, vibrators, aeration, or mechanical agitation to prevent common flow problems like bridging and ratholing.

Silos are built using either coated carbon steel, aluminum or stainless steel. Of these, coated carbon steel is the least expensive and – not coincidentally – the most widely used, suitable for virtually all pellet and powder applications. “The carbon steel panels used in silos must be protected from surface rust and corrosion, however, since these could potentially contaminate resin, so all carbon steel used in resin silos has a durable epoxy coating on the internal surface and a primed and enamel-coated surface on the exterior,” said A.J. Zambanini, director of product management with Conair Group.

Aluminum silos, meanwhile, typically have a higher starting price point than carbon steel but offer excellent long-term wear and corrosion protection.

And stainless steel silos may be required in certain food or pharmaceutical applications where product contact needs to be sanitary for the storage, processing, and conveying components throughout the production facility. The bad news? “Stainless steel tends to be at the top end of the price range for materials of construction for silos,” said Sean Dolan, plastics OEM regional sales manwww.canplastics.com

Photo Credit: © weerapong/Adobe Stock

TALL ORDER:

and on-site construction; and, of course, your budget.

Having a clear idea of what you want to accomplish will help you ask the right questions and manage your spending judiciously. When preparing your list of requirements, be sure to consider the following.

raw materials handling

ager with National Bulk Equipment.

Silos are constructed in one of three ways: bolted, welded or spiral. “Bolted silos are multi-piece units that are assembled on-site,” said Brian Davis, general manager of Maguire Products Canada.

“A bolted silo uses either gaskets, sealants, or a combination of the two to seal the joints between panels.” A critical rule is to ensure that the bolts have the necessary strength and corrosion resistance for your application – especially for sites located in damp climates – since a large bolted silo may have tens of thousands of bolts.

Welded silos have the simplest design, being one-piece factory-welded units, and are probably the most common silo style among plastics processors, and available from most suppliers.

Spiral-formed silos, meanwhile, are typically produced only in aluminum and are roll-formed at the factory, shipped in one piece, then erected onto a prepared foundation on-site. But you might look in vain for one in your area – while common in Europe, silo suppliers say, spiral silos are very rare in North America.

FROM TOP TO BOTTOM

Silos come in standard sizes of 9-, 12and 14-foot diameters and a range of heights from between 24 to 64 feet tall.

And they’re trending taller and wider these days. “We’re now commonly quoting 13.5- by 58-foot silos,” said Connor McCormack, technical sales with Wittmann Battenfeld Canada. “Because of material shortages, the consensus is that you need as much resin storage as you can get.”

The standard cone-shaped bottom of the silo, meanwhile, must be suited to material types to ensure proper flow. “A 45° cone is generally used for pellets, 60° for powders or hard-to-flow materials such as regrind, and a 45°/70° compound angle is used for PET pellets,” said A.J. Zambanini. Crucially, according to Brian Davis, a 45° cone angle will not work for processors that need precise lot and pellet traceability, like medical or pharmaceutical molders. “A 45° angle

creates ‘tunnel flow,’ where the centre portion of the resin in the silo collapses inward as it empties, like sand in an hourglass – when this happens, the material that goes in first may not come out until the fourth load, so there’s no way of tracing the material in the part. These shops require a 60° cone because they need mass flow – which is first-resin-in, firstresin-out – for traceability.”

Also at the bottom, the customer may want to add a skirt around the base for controlled access and weather protection of internal equipment. “A skirt adds to the cost, but it protects hardware like load cells and also gives some shelter to staff working at the base in bad weather,” Davis said. The alternative to a skirt is either structural legs or lugs.

The top of the silo, meanwhile, can have a sloped roof for maximum toploading of material, and usually has a manhole/vent combination.

Silo accessories such as filling lines, doors, hatches, dust collector flanges, connecting pipes, exhaust air filters, discharge devices, and other add-ons can be supplied according to the specific situation of the plant.

Another possible consideration is appearance, since silos are usually visible to the public. “A silo is a great place for the processor to put its logo,” Davis said. Beyond that, painted silos need repainting, usually at great cost, while powder coatings are permanent and resist corrosion and weathering.

Finally, remember that the same factor driving up interest in silos – tight supply chains – is also affecting silo delivery, since steel availability is difficult to predict and often backlogged. “Anyone thinking of adding any type of silo to a building, especially a welded silo, should move quickly and be prepared for longerthan-expected lead times,” Connor McCormack said.

SENSORY OVERLOAD

Since storing large quantities of resin is the whole point of having a silo, the ability to measure the amount inside in order to schedule material deliveries is crucial.

The simplest method, with no moving

parts, is view windows. “Properly spaced view windows give a visual indication of the level of material in the silo, but it’s only a rough idea, since only material at or above a view window is visible,” Sean Dolan said.

Level sensors measure quantities with much higher levels of accuracy, generally within +/-0.2 inches. “The types of sensors best suited for plastics are immune to the noise and dust that occur when filling the silos,” said Jenny Christensen, vice president of marketing with BinMaster. “They report inventory levels in real-time and are highly reliable, with a long service life and minimal maintenance.”

And options vary. The most accurate – and most expensive – measuring method is load cells. “There are two types of load cells: one actually weighs the silo, and the other has compression load cells on the legs that measure the compression of the steel,” said Richard Maskobi, president of Smith Steel & Fabrication. “Clients with steady production tend to want load cells that tie directly into their computers, so they can keep exact track of resin used, down to the pound, for ordering.”

A cheaper option is the plumb bob, but it’s also less precise: it drops a weighted cable from inside of the roof of the silo and measures the distance to the material being stored, and it’s typically accurate to within five per cent of the actual material in the silo.

And a trend toward radar measuring systems is developing. “A dust-penetrating non-contact radar, like BinMaster’s NCR-80, is the go-to sensor for noncontact continuous level measurement,” Jenny Christensen said. “The advent of narrow-beam 80 gigahertz technology ensures reliable operation in dust and fast update rates. But there are other sensor technologies that may be better suited to the application or to the budget: A laser scanner that can measure multiple points on the material surface can account for surface variations of the resin in the silo as well as conditions such as cone up or down to account for irregularities when calculating volume.”

April 2023 Canadian Plastics

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raw materials handling

Also note if the silos are grouped in any way by location. “Silos grouped together physically can be addressed with wiring configurations, such as daisychaining,” Christensen said. “Silos distanced further from power can be good candidates for battery-operated sensors and wireless devices.” Whichever method is used, once a measurement is taken, modern software packages enable users to share readings and deliver material consumption reports easier than ever.

Overfilling a silo can be a costly and messy problem: material can get released into the environment, conveying lines can get plugged, and the discharge mechanisms – and even the silo structure itself – can become damaged. This is why a high-level sensor, typically equipped with either an audio and/or visual alarm, is recommended for the top of the silo.

CHECKING THE BOXES

It’s all-too-common at the start of a new silo project for the customer to underestimate the amount of red tape that has to be cut through, silo suppliers say, primarily around satisfying local building codes.

These can dictate – and even limit – your options for a silo, typically around height, given that some silos tower up to 80 feet tall. “Sometimes we can’t install a tall silo because of height restrictions in the neighbourhood, or because there’s an airport nearby, so we’ll use several smaller silos instead,” said Jan Rickenbach. “We also need to know if it’s a seismic area, or a heavy snowfall area, or prone to heavy winds; and we have to supply proper grounding for lightning protection.”

Since height guidelines tend to be

12 Canadian Plastics April 2023

UNDERSTANDING INSTALLATION

Once on site, the installation method will vary depending on whether the silo is bolted or welded, and whether the location is a greenfield site (new construction) or a brownfield site (adding to an existing facility). A greenfield site is a blank slate with no other equipment around, giving a clear foundation to build on, whereas a brownfield site may have tight quarters with height or space restrictions. For example, a welded silo, delivered in one piece, is the least expensive to install and can usually be erected by crane in a single day – provided there’s available room and/or height for

the crane. “Oftentimes, the ideal placement site for the silo happens to be where there are obstacles to the use of cranes, such as overhead lines or no road or level access,” Sean Dolan said. “These situations call for a bolted silo, which doesn’t need large cranes.” The catch is that bolted silos, which are delivered in pieces, take longer to construct. “A bolted silo typically takes between three to five days to erect and attach any required accessories and piping, although it can take longer for taller silos with bigger diameters,” Dolan continued.

And a silo can’t just be plunked down on the parking lot pavement. “Every silo requires an engineer-approved concrete foundation pad,” Brian Davis said. “In most jurisdictions in Canada, the pad is a minimum of four feet deep, below the frost line, and it can be five feet deep in northern regions.”

Finally, since this is Canada, the weather might impact some parts of assembly. “No matter where in Canada we install a silo, we expect extreme swings in temperature and lots of rain and snow, so we take extra care when installing sensors, piping, and flanges, including gaskets,” Connor McCormack said.

GO WITH THE FLOW

Once a silo is installed, consideration must be given on how resin delivered by the supplier will be conveyed into the silo on the first delivery and going forward, and to make sure there’s sufficient silo capacity available when a delivery arrives. “A typical truckload of plastic resin pellets weighs roughly 45,000 pounds, and a railcar carries approximately 185,000 pounds,” said Sean Dolan. “And since you want to size the silo to have excess capacity, the truckload silo should be sized to a minimum of 60,000 pounds and the railcar should be sized to a minimum of 200,000 pounds.”

Whether receiving material by truck or railcar, the material is usually blown into the silo under pressure. Silos that are filled by bulk trucks usually have equipment for safe and efficient silo loading, including automatic filling control systems, but problems can still arise. “Somewww.canplastics.com

Photo Credit: BinMaster

BinMaster’s NCR-80 non-contact radar sensor offers continuous resin level measurement.

municipal rather than state or provincial, they can vary from one town or city to another; and so too can the yardstick for calculating the exact height of the silo.

“A height restriction can refer to the silo’s eave line; or the safety railing on top, which can be another 42 inches; or the piping at the very top, which can be another 5 feet,” said Richard Maskobi.

“We need to know which it is beforehand.” In any event, don’t expect your municipality to approve your silo installation overnight. “Depending on where a plant is located, the permit process can take a long time – sometimes years to attain if the plant backs onto a protected environmental area,” said Brian Davis.

Transporting the silo to the customer’s site can also be a challenge, and should be planned – and approved, if necessary – well in advance. “A silo with more than a 12-foot diameter requires a transportation permit, which adds time and cost in logistics,” Richard Maskobi said.

Last but definitely not least, silo safety features such as personnel ladders with safety cages, rest platforms, fall arrest systems, perimeter guardrails, and more are mandated by Occupational Health and Safety (OH&S) standards in Canada and the Occupational Safety and Health Administration (OSHA) in the U.S.; both of which also mandate adding certain modern safety features to older silos.

Silo suppliers also recommend placing locks on all entry points to keep unauthorized people from climbing the silo or entering the skirted silo hopper area.

raw materials handling

Photo Credit: Novatec Inc.

times the truck driver conveys the material into the silo too fast because he’s in a hurry, which can cause damage like streamers in soft materials like polypropylene or polyethylene,” said Jan Rickenbach. “The simplest solution is to give the driver a minimum time limit – don’t let him unload in less than 30 minutes, for example.”

For silo-filling from railcars – which is overseen by the processor, and can involve operators having to make multiple trips between the railcar, silo pad, and unloader to check fill levels and unloading conditions – Novatec has developed RailSense, a system that monitors the condition of the major components in railcar unloading systems, and then diagnoses problems and recommends corrective actions which users can view using a PC, tablet or smartphone. The system also alerts operators via text message when a railcar compartment has been emptied and it’s time to shift the unloader to a new compartment.

RailSense can move as much as 30,000 pounds an hour, Novatec said, can be equipped with the ability to supply as many as 12 different silos, and is available as a retrofit.

For conveying material from the silo into the plant for production, you’ll need to know the horizontal and vertical distances to the destination and the rate required, which determines the size and type of conveying equipment needed.

This also requires an understanding of how the material flows in your process, silo suppliers say, which determines whether a pressure or vacuum system is the better option. Ensign Equipment’s

high-capacity live bottom bins can be integrated underneath a silo to control the feed rate of non-free-flowing materials such as films, flakes, and powders into downstream vacuum, pressure, and/ or screw conveying systems.

Silos can also be filled from inside the plant if materials come from other sources, such as bulk bags and gaylords.

In these instances, silo suppliers say, the material can be discharged in the plant and then pneumatically or mechanically conveyed to the silo fill line.

A related danger lies in changing the material type stored in the silo. “From shell thickness to anchoring, a silo is designed for a certain bulk density of material per cubic foot and a certain capacity, and altering that – going to a heavier material, for example – could create a structural problem,” Richard Maskobi said. “Always check the engineering drawings before making that change, and consult the silo supplier if you’re unsure.”

AN OUNCE OF PREVENTION

Silos are long-lived assets, with lifespans measuring in decades, which makes maintenance all the more important. A well-designed silo has easy access to internal components for inspection, repair, and replacement, and in most cases it’s a good idea to conduct at least an annual inspection of the roof (looking for signs of cracking or peeling in the roof coating), exterior surfaces (delamination of silo walls, and corrosion or buckling of metal silo components), and the interior (regular checks of airflow systems; checking the epoxy lining; a routine professional cleaning; and regular, complete silo emptying). And sometimes cleaning inside the silo is necessary beyond just annual maintenance.

“Most commonly, if the material stored in the silo is changed and there’s a risk of product cross-contamination, the silo should be cleaned,” said Sean Dolan.

“Lack of cleaning will likely lead to Novatec’s RailSense system monitors the condition of the major components in railcar unloading systems, diagnoses problems, and recommends corrective actions.

material flow problems within the components or piping of the plant; and with powdered product, the interior of the silo can develop a crust that can also cause conveying issues or cross-contamination.”

Outdoor silos have always made good sense for storing large amounts of resin, but today’s supply chain woes make them virtually indispensable for many shops.

Creating a list of your application’s specific requirements and checking your local regulations allows the silo supplier to provide an efficient, cost-effective design and a smooth delivery and installation.

Done properly, acquiring the right silo doesn’t have to be a tall order.

CPL RESOURCE LIST BinMaster (Lincoln, Neb.); www.binmaster.com; 402-434-9102 Cancoppas Ltd.(Mississauga, Ont.); www.cancoppas.com; 905-569-6246 Conair Group (Cranberry Township, Pa.); www.conairgroup.com; 724-584-5500 Dier International Plastics Inc. (Unionville, Ont.); www.dierinternational.com; 416-219-0509 Industries Laferriere (Mascouche, Que.); www.industrieslaferriere.ca; 450-477-8880 Turner Group Inc. (Seattle, Wash.); www.turnergroup.net; 206-769-3707 Ensign Equipment Inc. (Holland, Mich.); www.ensigneq.com; 616-738-9000 Maguire Products Canada Inc./Novatec Inc. (Vaughan, Ont.); www.maguire.com; 905-879-1100 Motan Inc.(Plainwell, Mich.); www.motan-colortronic.com; 269-685-1050 D Cube (Montreal); www.dcube.ca; 514-272-0500 National Bulk Equipment (Holland, Mich.); www.nbe-inc.com; 616-399-2220 Lutek Equipment Plastique Inc. (Dorval, Que.); www.lutek.ca; 514-421-8963 Promat Engineering Sales Inc. (Mississauga, Ont.); www.promatengineering.com; 877-567-7819 Smith Steel & Fabrication (Atwood, Ont.); www.smithsteel.ca; 519-356-2802 Wittmann Battenfeld Canada Inc. (Richmond Hill, Ont.); www.wittmann-group.com; 905-887-5355 April 2023 Canadian Plastics

13

process cooling

VERY NEW, EXTREMELY COOL

Process cooling is an important part of plastics processing because it maintains the quality of production and ensures the parts meet target dimensions. And in a competitive global market like now, it’s absolutely critical. Here are some of the latest developments in chillers, cooling towers, and TCUs.

By Mark Stephen, editor

14 Canadian Plastics January/February 2021

from the chiller to the process, and this cool fluid removes heat from the process and the warm fluid returns to the chiller.

As an alternative, evaporative cooling towers remove heat from water that’s discharged from a condenser, and are an extremely energy-efficient cooling source for hydraulic systems, chiller condensers, and higher temperature molding applications.

Proper temperature control, meanwhile, is vital to plastic processing: molds that are heated to the right temperature are instrumental for manufacturing better parts with improved quality and lead times. Unlike a chiller that mechanically removes the heat, a TCU can raise the temperature with internal heaters and cool by directly exchanging with lower temperature water or through a heat exchanger. TCUs provide control of process temperatures, servicing a single process at any one time, and are designed to be moved between process applications as the need requires.

And precisely because heat removal and temperature control are so important to plastics processing, new advances in chillers, cooling towers, and TCUs are always being made available. Here’s a look at some of the latest.

PRESENTING CHILLERS AND TOWERS

ACS Group recently launched an Industrial Internet of Things (IIoT) service that collects and analyzes data using cellular technology instead of WiFi or Ethernet networks. Called MiVue, the service was two years in the making and provides real-time condition monitoring of production on the conglomerate’s equipment – which includes AEC chillers, as well as the Sterling and Cumberland brands – so manufacturers can essentially see inside their equipment and operations to predict and prevent problems. “MiVue will help plastics processors increase their uptime, reduce costs, and improve aftermarket support,” ACS Group senior product manager Michael Gersmeyer said. The service gathers data from a chiller’s controller and a router sends it through a cellular technology signal to the cloud, where it’s stored; the data can then be accessed remotely nearly anywhere in the world on any device with an internet connection.

MiVue also will send email and text alerts to any web-enabled device. The software will eventually work with all industry products, Gersmeyer added.

Delta T Systems has introduced a new line of modular chillers featuring redundant variable-frequency drive pumps.

Photo Credit: Frigel

I

t’s an unfortunate fact that no industrial process, machine, or motor is 100 per cent efficient. Heat is the most common byproduct of this inefficiency, and if it isn’t removed from a manufacturing process it will accumulate over time, causing reduced production rates, equipment shutdowns, and even premature machinery failure.

Which is why it’s necessary to incorporate cooling into plastics production.

And this is where chillers, cooling towers, and temperature control units (TCUs) come in. A chilling system cools the hot plastic that’s either injected, blown, extruded or stamped, and can also cool down the equipment that’s used to create plastic parts – the hydraulics of the molding machine, and gear box and barrel of the extruder – to save on energy and wear and tear on the machine itself. Chiller systems range vastly in size and design, and are available as small, localized or portable chiller units for smaller applications, or large central chillers designed to provide cooling for entire processes.

There’s something a bit misleading in the fact that, contrary to their name, chillers don’t actually create cold – they remove heat – but otherwise the principle is straightforward: a pumping system circulates cool water or a water/glycol solution

process cooling Opposite page: Frigel displayed a chiller from its new Ecodry MDK range at K 2022.

Photo Credit: Advantage Engineering Inc.

Each chiller comes with a four-inch touchscreen with adaptive controls that are Industry 4.0-ready, and support remote monitoring. Users can assign a single main control to direct up to 14 units in parallel, providing a maximum cooling capacity of 840 tons. Available in both water-cooled and air-cooled systems, benefits include lower upfront costs and energy usage – the expense of adding a separate pump tank is eliminated thanks to the combination of variable-speed technology and an auto-tank-leveling algorithm proprietary to Delta T, which can also cut electricity consumption by as much as 50 per cent compared to fixedspeed units. The modular design of the new chillers allows for a smaller system footprint and simplifies installation, company officials said, and the use of nonferrous materials prevents corrosion.

Introduced at the K trade show in Germany in October 2022, Frigel’s Ecodry MDK range expands its adiabatic cooling system family, borrowing some of the technological advances introduced with the company’s earlier, larger LDK range, such as a high-efficiency humidification system; electronically commutated fans; and a compact, modular design. Built from 304L stainless steel, the units are available with single- and dual-fan row designs, with up to 10 fans per row, and all fans are equipped with safety switches.

Additional benefits include efficient, resource-conserving cooling – Frigel said the MDK series consumes up to 15 per cent less energy, and provides up to a 95 per cent savings in water consumption compared to traditional cooling towers.

Its modular design allows for easy on-site

assembly and capacity expansion, the company said, simplifying the addition of more units to run in parallel. A single unit offers cooling capacity of 1.4 megawatts as an adiabatic cooler, and up to 700 kilowatts as a dry cooler. The units provide easy access, simplifying maintenance procedures. The MDK series’ patented CoolPad adiabatic chamber is said to pro-

vide exceptional cooling and humidification rates, and is Greenguard Gold-certified.

Also unveiled in 2022, Advantage Engineering’s third-generation Power Tower evaporative cooling tower is designed to improve on the product’s 34-year performance history, with new features such as a one-piece seamless bot-

HOD 55mm

Closure solutions for Home & Office Delivery Containers

Novembal’s Home & Office Delivery (HOD) one-piece closures, are designed for 3-5 gallon water containers with a 55mm neck finish.

Explore our long, short and linerless HOD closures, which incorporate non-spill features required by the producers and the market to tackle the supply chain challenges.

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Advantage Engineering’s third-generation Power Tower evaporative cooling tower features an all-new design.

April 2023 Canadian Plastics CPL_Novembal_April23.indd 1

15

2023-03-13 9:23 AM

process cooling

TALKING ABOUT TCUs

Rounding out Conair Group’s line of TCUs, and complementing its top-of-theline TW-T unit, two new Thermolator TCUs – the mid-range TW-E series and basic TW-B series – feature upgraded mechanical and electronic components for improved durability and control, plus a new panel layout designed to improve airflow and cooling for easier inspection, reduced maintenance, and maximum operating life. The TW-B series aims at cost-efficiency for basic temperature control applications, Conair said, and features a simple, easy-to-use LCD control panel with multiple readouts and indicator lights, a maximum setpoint of 120°C or 250°F, and a choice of three-quarter- or two-horsepower (hp) pumps. And the TW-E has all the standard features of the TW-B units plus an enhanced LCD digital control, a modulating cooling valve that automatically adjusts flow and temperature to serve varying mold sizes and process needs, an adaptive maximum setpoint, auto-pressure relief, pump sizes up to 10 hp, and digital pressure transducers that eliminate analog gauges while providing real-time system pressure readings on the digital display.

Designed to fit in tight spaces, Mokon’s new HTF 400 series circulating-oil TCU meets process heating requirements ranging from 50° to 205°C or 125° to 400°F, and can be used to continuously regulate the temperature of molds, dies, and poly-

16 Canadian Plastics April 2023

Conair Group’s new mid-range TW-E series (pictured) and basic TW-B series units round out the company’s line of TCUs.

mers. They feature a microprocessorbased controller that shows both the process fluid setpoint and actual temperature.

Standard features include an energy-efficient insulated heater manifold with steel heating elements, an automatic air purge function, a sight glass, a powder-coated carbon steel cabinet, and heavy-duty casters. Options include audible and visual alarms, an emergency stop, overhead piping kits, timers, and nitrogen purging.

The new Easytherm EP TCU from Piovan is designed for user-friendliness, flexibility, and reliability in injection molding, blow molding, and extrusion processes. The versatile unit has a new interior and exterior layout and redesigned ergonomic control, Piovan said, and operates at temperatures up to 180°C or 355°F. The large 4.3-inch TFT high-contrast display is tilted for easy reading, and navigation in the submenus is managed thorough a conveniently-placed knob. Easytherm EP is suitable for use in Industry 4.0 environments, with communication protocols that include the OPC UA platform, Piovan said, and is Winfactory 4.0-ready.

The Aquatherm RQT line of TCUs from Thermal Care has three versions – Standard, Premium, and Advanced – depending on user needs. The Premium and Advanced units monitor data and trends, with the Premium units equipped with a colour touchscreen to display the information. Other features include password protection for the Premium units and electrical-phase-alerts, available as standard on Premium units; and optional on the Advanced units. Also, because of their data tracking capabilities, the Pre-

mium and Advanced units are said to offer greater accuracy than standard meters found on other temperature controllers. The RQT series is available in single- and dual-zone configurations, the company said, with power capacities of 0.75 to 10 hp.

Heat removal technologies like chillers, cooling towers, and TCUs will always have outsized roles in plastics processing.

Which is what make these latest developCPL ments not only cool, but critical.

RESOURCE LIST ACS Group (New Berlin, Wis.); www.acscorporate.com; 262-641-8600 Auxiplast Inc. (Sainte-Julie, Que.); www.auxiplast.com; 450-922-0282 Equiplas (Toronto); 416-407-5456 Shaw & Christler Equipment Technologies (Vancouver, Wash.); www.shawequiptech.com; 800-528-8011 Advantage Engineering Inc. (Greenwood, Ind.); www.advantageengineering.com; 317-887-0729 Chillers Inc. (Newmarket, Ont.); www.chillersinc.com; 905-895-9667 Aquatech/Piovan Canada Ltd. (Mississauga, Ont.); www.piovan.com; 905-629-8822 Conair Group (Cranberry Township, Pa.); www.conairgroup.com; 724-584-5500 Dier International Plastics Inc. (Unionville, Ont.); www.dierinternational.com; 416-219-0509 Industries Laferriere (Mascouche, Que.); www.industrieslaferriere.ca; 450-477-8880 Turner Group Inc. (Seattle, Wash.); www.turnergroup.net; 206-769-3707 Delta T Systems(Richfield, Wis.); www.deltasys.com; 262-628-0331 Frigel North America (East Dundee, Ill.); www.frigel.com; 847-540-0160 Injection Depot Group (Markham, Ont.); www.injectiondepot.ca; 705-627-5456 Mokon (Buffalo, N.Y.); www.mokon.com; 716-876-9951 En-Plas Inc.(Toronto); www.en-plasinc.com; 416-286-3030 Thermal Care Inc. (Niles, Ill.); www.thermalcare.com; 847-966-2260 D Cube (Montreal); www.dcube.ca; 514-272-0500 Tantus Corp.(Pickering, Ont.); www.tantuscorp.com; 647-258-9657 www.canplastics.com

Photo Credit: Conair Group

tom that eliminates the risk of water leaking through a glued bottom seam, a galvanized steel base on single cell models, and an external perimeter drip gutter to minimize water loss. But they kept other features, company president Jon Gunderson said, including the same proven fan, fan motor, fill, and nozzles as the previous legacy tower cells. The new generation Power Tower is available in 45-, 85-, 105-, 135-, 170-, 210-, and 270-ton nominal cooling capacities, Gunderson added, and has a galvanized steel base on the 170-, 210-, and 270-ton models. The old legacy cooling towers, meanwhile, are still fully supported with available replacement parts.

JUNE 2023 ISSUE

Here’s a look at what’s inside the upcoming

80th anniversary issue of Canadian Plastics magazine in June: A special feature article will look back at the biggest news stories and trends that we’ve covered over the past 80 years: the early years after World War II, the boomtimes of the 1960s and 70s, the rise of recycling in the 1980s and 1990s, and the current era from the aughts to the pandemic.

In addition, we’ll also feature articles on • How to choose between granulating or shredding in size reduction • The latest developments in dryers • The rise of automation in thermoforming

eNewsletters Sign up for our free enewsletters to stay up-to-date Scan QR code

Subscribe to Canadian Plastics Magazine Reading someone else’s copy of Canadian Plastics magazine? Get your own copy by subscribing here.

Scan QR code

Looking to market your company to Canada’s plastics industry, contact: Stephen Kranabetter, Associate Publisher | skranabetter@canplastics.com | 416-510-6791

composites

WINDSPORTS AND WAY BEYOND

Going from kitesurfing to landing on Mars is a giant leap, but it’s one that British Columbia-based Aluula Composites might be poised to take.

W

hen you think of kitesurfing and wingsurfing, two slightly different but increasingly popular windsports that use kites to pull riders across the water, you probably think of sun-drenched places like Florida or Hawaii. But British Columbia has countless beaches that can be surfed virtually year-round – including within Vancouver itself – which may help explain the origins of Victoria, B.C.-based advanced materials technology firm Aluula Composites.

And how Aluula might come to play a role in a NASA mission to the Moon or even Mars someday could be an even bigger story.

OUTDOOR ORIGINS

Founded in 2019 by a group of chemists and engineers with a passion for outdoor sports, Aluula uses a proprietary fusion technology that bonds films at a molecular level to an ultra-high molecular weight polyethylene (PE) – or UHMWPE – core, resulting in a new generation of performance composite fabrics that deliver

18 Canadian Plastics April 2023

unique and superior performance results.

An offshoot of research and development in ultralight fabrics at Ocean Rodeo Sports Inc. – a kiteboarding (the dry version of kitesurfing, done on land) and windsurf company also headquartered in Victoria – Aluula’s initial objective was to improve the performance of kiteboarding kites through material science. “Kiteboarding was established more than 20 years ago, and has seen some big advancements in rider safety, product handling, and control, but the standard legacy materials and seaming techniques, originally adopted from the sail industry, hadn’t changed and were stalling the sport’s technical advancement,” said Greg Falck, Aluula’s senior materials scientist. “We wanted to develop ultralight materials that could withstand the rigors of a kite’s pressurized airframe, and were intrigued by the properties of UHMWPE fibre and wanted to find a way to create a fabric that could utilize it.”

Getting the chemistry right was the first order of business, since UHMWPE

fibre is difficult to glue to and the properties of adhesives are affected by ultraviolet (UV) light and water exposure. “We developed a molecular fusion process called Aluula Fuse that bonds the fibre to various technical films without using heavy glues,” Falck said. “After a series of trial runs and combinations, the material achieved our goal in the kitesurfing and wingsurfing market.” Early testing also revealed the performance increase wasn’t restricted to the lighter weight, Falck continued, since the higher modulus of UHMWPE fibre made for more responsive, higher performance airframes that were less prone to deformation under load.

The resulting product line is a new family of composite materials built from components with eight times the strengthto-weight ratio of steel and yet lighter than nylon, polyamid or aramid; and that are easily fabricated into a multitude of products across a wide range of markets. Aluula’s trademarked fabrics include Aluula Gold GC-82, used within windsports for www.canplastics.com

Photos Credit: Allula Composites, © viperagp/Adobe Stock

By Mark Stephen, editor

Photo Credit: Allula Composites

composites lightweight, rigid airframe structures; Aluula Durlyte, for ultra-durability and high-performance inflatable structures; Aluula Aeris, for ultralight canopy, spinnaker, and pack applications; Aluula Graflyte, which has been designed specifically for the ultralight pack market; and Aluula Atom, a bladder film and bladder design that’s 50 per cent lighter, has twice the resistance to puncture, and is three times more UV-resistant when compared to standard polyurethane films.

Beyond the performance of the fabrics themselves, Aluula products also have the benefit – unique in the world of composites – of being recyclable, since most of the fabrics are 100 per cent PE and are all fused without glue.

Aluula receives its UHMWPE from a variety of international partners that weave the fibre into different configurations, depending on customer needs. “We can adjust the balance of the fabric for strength in various directions to optimize the strength-to-weight ratio for an application,” Falck said. “We source our UHMWPE from both China and the U.S., while our technical films come from all over the world. Our patented fusion process is done exclusively at our Vancouver Island facility.” Aluula runs a streamlined manufacturing operation, Falck continued, with a production process that utilizes self-contained “pods” to produce the end-product, as opposed to a larger in-line manufacturing system. “The pods give us the scalability to handle large fabric orders while also maintaining the flexibility to create small batches of new materials for other customers,” Falck said. “The sailing industry is already very technologically adept, and we’re completing a software program that generates predictive models of the attriA sample heat welded cylinder made of Aluula Durlyte composite.

butes of any combination of our materials and weaving technologies to meet the various demands of sail design teams.”

TAKING OFF

Within windsports, Aluula’s materials are said to be half the weight of traditional materials, and also stiffer and stronger than existing composite options. For the uninitiated, kite and wing airframes are built by sewing patterned pieces of fabric together to create 3D shapes, and an internal bladder is then installed and inflated at high pressure to create the kite’s structure and rigidity. According to Falck, surfers using a lightweight Aluula composite kite can fly in much lighter wind, while the increased stiffness delivers better performance in stronger winds.

Aluula’s first customer was its parent company Ocean Rodeo, but its fabric has since been commercialized by other kitesurfing suppliers including Duotone, said to be the sport’s biggest brand.

“Wingsurfing and kitesurfing were already high-end sports, and we only make high-end products, so we’re wellpositioned to claim a very good market share – maybe as much as 30 per cent of the kitesurfing sector within the next few years,” Falck said.

And beyond windsports, Aluula is now working with industry partners to develop next-level materials for applications in aerospace, outdoor gear, sailing, and defense markets. “We quickly realized that this was a soft materials technology that wasn’t going to be limited to kitesurfing – there are many possibilities

because we can incorporate different films with our UHMWPE formulations and also have different weights, distributions, and directions of weaving,” Falck said. “With backpacks, for example, we want to replace nylon and polyester materials currently being used; and we’ve had inquiries from the commercial aerospace sector about lightening fabrics without sacrificing strength and durability.”

Most recently, Aluula’s composite materials have been selected by Chilliwack, B.C.-based technology developer Thin Red Line Aerospace to support its development of cutting-edge, critical application hardware for future NASA lunar and Mars missions. “Thin Red Line is responding to a NASA requirement, and our material uniquely met their need,” Falck said. “The project is still in the early stages: Thin Red Line has ordered batches of our materials for product development, and we’ll see where it goes, but it’s a vote of confidence in our fabric and a really exciting possibility.”

Going forward, Aluula will continue developing cross-linking technology with its chemistry partners, Falck said, and is working with the University of British Columbia to create compression molded hard composite panels from offcuts and end-of-life products. Aluula is also exploring additional manufacturing techniques, including heat welding, steam taping, and molding in the development of air- and water-tight structures.

With Aluula becoming established as a high-performance brand and its composite materials on the cusp of wider commercialization, the company is right where it wants to be. “We’re targeting high-tech applications that require a soft structural fabric, not everyday consumer items,” Falck said.

“We’re already involved in all of the high-performance niches we want to be, so the goal going forward is to expand in these areas. We offer a process, not a product, and this allows for a wide range of iterations to meet a broad range of applications.”

And with the potential of landing one or more of its materials on the Moon or even Mars, not even the sky, CPL apparently, is the limit.

April 2023 Canadian Plastics

19

technology showcase

FOCUS ON EXTRUSION

Cutters for extruded PVC and polyolefin plastic pipe

Large die cart with crosshead Guill Tool’s new die cart can be easily assembled and disassembled, and features a high-volume, adjustable-centre accumulating crosshead that’s designed to produce a smooth linear bore and provide jacketing over various substrates.

The crosshead’s maximum through core is 18 inches, while its maximum die ID is 23 inches.

Built to handle thermoplastic applications, the crosshead also includes an isolation sleeve.

Additionally, the tooling section features quadrant heating. Guill’s crosshead stand is equipped with an integral alignment station and a concentric roll guide. The stand is also an integral cleaning station, so processors don’t need to remove the crosshead for cleaning.

Additionally, the crosshead has an on-the-fly catenary adjustment feature, and can be easily maintained with simple hand tools.

Guill Tool & Engineering (West Warwick, R.I.); www.guill.com; 401-828-7600

New PipeMaster planetary cutters from Conair Group are designed for continuous, distortion-free cuts in extruded PVC and polyolefin pipe in diameters from 0.630 to 24.9 inches, at line speeds up to 82 feet per minute, and with no chips or waste.

Available in six sizes, the cutters have a seven-inch colour touchscreen HMI for simple management of speed controls, alarm capabilities, production recipes, and communications with all upstream and downstream equipment. Other key equipment positioning and adjustments are motorized for operator ease and convenience.

The cutter also has full guarding for safety, including safety tunnels and interlocks on all opening doors.

Conair Group (Cranberry Township, Pa.); www.conairgroup.com; 724-584-5500 Dier International Plastics Inc. (Unionville, Ont.); www.dierinternational.com; 416-219-0509 Industries Laferriere (Mascouche, Que.); www.industrieslaferriere.ca; 450-477-8880 Turner Group Inc. (Seattle, Wash.); www.turnergroup.net; 206-769-3707

Automated lip adjustment system Nordson’s new EDI Prodigi automated lip adjustment system for its EDI extrusion and fluid-coating dies relies on motorized actuators to control the lip adjustment, and is designed to achieve saving tolerances four times faster than conventional thermal bolt systems.

As opposed to automated lip adjustments achieved by using thermally actuated bolts – which are highly influenced by external factors – the EDI Prodigi system has installed actuators that smoothly translate motor rotation into precise linear movement to locally open and close the lip; accomplishing this away from the hot die, at a user interface, creates a process that’s much faster, safer, and more energy-efficient.

Customers will save significant time and be able to exactly repeat their production cycles. This will create much less scrap and add more productive time, since final tolerances are achieved so quickly.

Nordson Corp. (Duluth, Ga.); www.nordsonpolymerprocessing.com; 770-497-3400

20 Canadian Plastics April 2021 PCS_MoldCompenents_CP_3-475x4-75_031523.indd 1 CPL_PCS_April23.indd 1

www.canplastics.com 3/15/23 11:53 AM 2023-03-16 2:30 PM

technology showcase

Control upgrade for cast film, extrusion coating, and aqueous coating

Designed for cast film, extrusion coating, and aqueous coating processes, the new Integrator PRO+ control upgrade from Davis-Standard supports the DS ActivCheck digital transformation platform, which offers a robust suite of analytical tools, cloud and local data storage options, and process and equipment technology algorithms.

An upgrade to Davis-Standard’s Integrator PRO humanmachine interface (HMI), the Integrator PRO+ offers recipe recall, intuitive interface and control functions, custom reporting and line drive functionality, as well central control of all production parameters, process data analysis to assist with overall equipment effectiveness (OEE), and compatibility with obsolete controls installed on legacy Davis-Standard machinery.

In addition, the Integrator PRO+ doubles data storage compared to Integrator PRO, with process data collection and trending screens also doubled.

Davis-Standard LLC (Pawcatuck, Conn.) www.davis-standard.com; 860-599-1010 Auxiplast Inc. (Sainte-Julie, Que.); www.auxiplast.com; 866-922-0282

PAM device automates adjustments Reifenhäuser’s new PAM automation option – which stands for Precise, Autonomous, Mechatronic – is designed to make work easier for machine operators by automatically calibrating coextrusion adapters and dies, thereby increasing productivity and improving quality.

Equipped with two automated screwdrivers that adjust the manual bolts, the PAM system controls the flex lip, restrictor bar, external and internal width adjustment, and lip gap of extrusion tooling.

The feedblock and die can be adjusted mechatronically much faster than when done manually, and the line operator can also already make the next work step during this time. As a result, the PAM option enables faster startup of good production, higher output, and improved OEE. And because calibration with the PAM device is contactless, operators no longer run risks by working on hot components.

Reifenhäuser Inc. (Maize, Kan.); www.reifenhauser.com; 316-260-2122

More efficiency with lower energy consumption New from Coperion, the ZSK Mc18 extruder is designed to significantly simplify extrusion, compounding, and recycling processes.

The machine has a 70-millimeter screw diameter and highspecific torque of 18 Nm/cm3, making it especially suited for efficient compounding of plastics at very high throughput rates and with comparatively low energy consumption.

The ZSK extruder is equipped with a ZS-B easy side feeder as well as a ZS-EG side devolatilization unit, both of which can significantly reduce the time needed for recipe changes or maintenance tasks, since they can easily be removed from the process section in just a few steps.

And the gearbox of the ZSK can be equipped with a condition monitoring system that detects irregularities in the operation of the extruder gearbox at an early stage, to avoid potential damage and allow for service calls to be scheduled in advance.

Coperion Corp. (Sewell, N.J.); www.coperion.com; 856-256-3175

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To apply, please submit your resume to: careers@poundsofplastic.com April 2023 Canadian Plastics

21

technical tips

How to reduce materials in injection molded auto parts

By Ken Fassett, RJG Inc.

W

e’re all feeling the pains of material supply issues as they ripple across the globe, especially those in the plastic injection molding industry. The solution is simpler than you might think: use less plastic. It sounds both obvious and difficult, but believe it or not, the majority of injection molders are packing way more plastic into their parts than necessary.

This additional material leads to a slew of hidden costs, both on your finances and on the part’s performance, including machine downtime, the cost involved with each scrapped part, and damage to the mold and machine due to improper shot sizes or flash (and we all know how costly mold damage can be).

Not to mention the time wasted by managers on figuring out problems when they could be doing more important things to improve the organization. And finally, let’s not forget the cost of shipping bad parts to customers.

And for the end-product, lighter automotive components put less load on the battery systems, resulting in longer range for the vehicle – saving the final user money and frustration; increasing car sales; and increasing your customer’s faith in you, which ups the odds of grabbing more long-term partnerships and more continuous revenue.

There are many ways to reduce how much material is in your automotive parts, some easier than others. Here are nine of them.

to make it as efficient as possible.

1. SELECT MATERIAL TYPE WHEN DESIGNING THE PART

6. USE FOAMING AGENTS

The material type should be decided upon and taken into consideration in tandem with designing the part. The type of material will greatly affect how it performs inside the mold and what features need to be present in the design in order

22 Canadian Plastics April 2023

2.USE GOOD MANUFACTURING PRACTICES DURING DESIGN

from the inside out, resulting in much lighter parts. This process is also known as low-pressure molding.

Design is key, and a bad design can sink a project before it even begins. Techniques such as coring out thick sections when applicable to reduce part weight should be taken into consideration. The runner and gate size and location are vital as well.

7. USE GAS ASSIST MOLDING

3. CONDUCT MOLD SIMULATIONS

8. TRAIN YOUR TEAM

4. USE PROCESSING TECHNOLOGY

9. USE DECOUPLED MOLDING PROCESSING

Mold simulations allow for inexpensive investigations into potential part designs before the mold is built. The risk of altering a part design is lowered when the process capability is simulated beforehand.

The utilization of a process control system and in-cavity pressure sensors allows you to see what’s happening inside the mold before the part is ejected. This means you can create consistent processes that result in high-quality parts again and again, without the need to sort through scrap.

5. USE SEQUENTIALLY VALVE GATED HOT RUNNERS

A valve gated hot runner system, in most cases, removes the scrap of a cold runner system due to the gate located on the part surface. Eliminating this sprue from every part produced adds up very quickly.

Foaming agents are a category of chemical additives mixed into the plastic resin. When the resin or foaming agent is injected into the mold, the foam expands to create hollow cellular structures inside the thicker regions of the part. This essentially packs the part

Gas assist is a process by which pressurized nitrogen is injected into a thick part to hollow it out, making the part lighter by packing from the inside out, creating a hollow channel in the interior.

Training gives processors knowledge to optimize the molding processes. This can result in avoiding costly processing strategies (or lack thereof) that needlessly increase part weight.

Decoupled molding separates pack from hold in the injection molding process, eliminating the effects that viscosity shifts can have on the process and building consistency in part quality. It streamlines the process to make it as efficient as possible in all ways, including finding the perfect balance of material for each part.

If you were able to reduce material volume in your injection molded parts by – to pick a number – 4.5 per cent, what would your annual savings be? What could you use that money on to grow your business, empower your team, or invest in your equipment? It’s easy to see that the return on these improvements will be big, and potentially even huge.

CPL Ken Fassett is director of global sales with RJG Inc., a Traverse City, Mich.based training and consulting company that specializes in injection molding. Visit www.rjginc.com for more. www.canplastics.com

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Same resins, different gaylords, different moisture levels...

Why dry them the same?

The pellets look the same, but intragranular moisture is often not the same, and most dryers don’t know the difference. So, if the input moisture is different for the very same resin, time-based drying will also have different end results!

Wasting energy. Sometimes making bad parts—unknowingly.

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The patent-applied Genie is available exclusively for Novatec dryers produced 2016 onward.

> Make more parts in less time > Use less drying energy > Make parts that are always dry, but not over-dried

© Copyright 2023 Novatec, Inc.

Sold & Serviced in Canada by Maguire Products Canada, Inc. 905-879-1100 l info@maguirecanada.com www.maguirecanada.com Moisture & Drying > Conveying > Blending

www.novatec.com 800-237-8379 | genie@novatec.com