Canadian Plastics July/August 2008

CanadianPlastics www.canplastics.com

65th Anniversary issue

We’re not over the hill, we’re looking beyond it

INDUSTRY ROUNDTABLE

DISCUSSION What’s on the horizon

PACKAGING REPORT

Multi-layer blown film, new technologies & more

INJECTION MOLDING

The latest machines and processes

GRANULATORS

Best practices case studies

ADDITIVES

Getting greener JULY/AUGUST 2008

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contents

CanadianPlastics JULY/AUGUST 2008 VOLUME 66 NUMBER 7

Looking WAAAY back...

In August 1943, the first issue of Canadian Plastics reported on a meeting in Toronto between architects and technical experts from the plastics industry, which concluded there was a vast potential market for plastic products in construction. Extruded cellulose acetate strips were cited as an example of coverings for wallboard seams and joints without nails, adhesives or paint. Other possibilities raised at the meeting were thermoplastics wall coverings, plastic tubing and pipes, and hardware such as faucets, knobs and fittings.

page 20

Number of the month:

*$500,000

* Maximum fine for a Canadian corporation convicted of non-compliance under the Occupational Health and Safety Act. (see page 9)

page 10

page 26

Cover illustration by James Wardell

cover story 4 Editor’s View: • Pausing to reflect at 65 5 Ideas & Innovations: • A guide to Canada’s R&D facilities 6 News: • Auto parts suppliers caught in “perfect storm” • Remembering Art Painter • Royal Group’s De Zen and others charged with fraud 9 Executive’s Corner: • Understand safety codes when buying plastics processing machinery 32 Technology Showcase 35 Plastics Data File 35 Advertising Index 35 Classifieds 37 Design Ideas: • Celebrating unusual applications 38 View from the Floor: • Cooling considerations

PLUS: Jim’s Tip, Buzzword of the Month

10 ROUNDTABLE DISCUSSION: OBSTACLES AND OPPORTUNITIES “Perfect storm.” Roller coaster.” “Unprecedented situation.”

Everywhere you turn, it seems such terms are being used to describe the current state of plastics processing in Canada. But are they accurate?

To mark our 65th anniversary, Canadian Plastics invited a panel of industry experts to ponder this and other questions, in a debate over some of the most important issues affecting our industry.

features

14 PACKAGING REPORT With 11-layer blown film lines now available, does more layers equal more success? Also, a behind-the-scenes look at Plastilec Inc., a family-run Quebec cosmetics packager that’s taking on Chinese competition...and winning. PLUS: The latest in packaging technology!

21 INJECTION MOLDING: THE FUTURE IS NOW Faced with an ever-increasing demand for innovative and better quality parts, today’s injection molders rely more than ever on cutting edge technology to stay competitive. Inside, we survey some of the latest offerings from the heavy-hitters in the I/M machinery business.

26 GRANULATORS: FROM THE “GROUND” UP Canadian Plastics takes you to three different plants — a packaging blow molder, a Tier 2 auto parts maker, and a Toronto-based molder — to spotlight some “best practices” to follow when buying a new granulator.

29 ADDITIVES: BACK TO NATURE Green is the theme in everything these days, and plastics are no exception.

The good news for processors is that additive suppliers have unveiled a host of new, “all-natural” products, designed to boost performance of bipolymers, and add colour to enliven recycled resins.

Visit us at www.canplastics.com www.canplastics.com July/August 2008 Canadian Plastics 3

editor’s view

www.canplastics.com

PAUSING TO REFLECT AT 65

T

his is, in some ways, a bittersweet issue of Canadian Plastics.

First and foremost — and on the plus side — this is our 65th anniversary issue. The first issue of the magazine was published in August 1943, at the height of World War II. (It remained the only issue for quite some time, by the way; the second issue did not appear for another 16 months, due to warrelated paper shortages.)

It was a substantial production, even by inaugural-issue standards: almost 150 pages, including a seven-page directory.

In retrospect, it was altogether fitting that the magazine be launched during the war years, since the impetus for the application of plastics came about largely through material shortages created by the conflict. As well, a great many of the applications brought to market in that period were directed to the war effort.

To commemorate this anniversary, we put together a panel — composed of Canadian plastics industry professionals, selected to represent a broad spectrum of processes and regions — to debate some questions relating to the present and future of our industry. The intention was to touch on issues relating to each panel member’s specific segment, as well as overarching problems that affect — and may continue to affect — all of us. You’ll find our presentation of the panel discussion beginning on page 10. On behalf of the magazine, I’d like to thank each of the participants for giving over valuable chunks of their time to the project, and to remind them once again that it’s greatly appreciated.

Perhaps you may also have noticed that, graphically speaking, the magazine has undergone a slight redesign — not quite a 65th birthday facelift, but close.

The intent was to create a product with a more modern, unified look, without loss of 4 Canadian Plastics July/August 2008 www.canplastics.com

readability, and we hope we’ve succeeded.

(For the web-surfers among our readers, we’re also improving the layout of the online edition of Canadian Plastics, presenting each issue in the sequential, page-bypage format of the print version.)

That’s the good news.

On a different note, we were saddened this spring to learn of the passing of Art Painter, our magazine’s longtime publisher, at the age of 83. Judith Nancekivell, Art’s successor to the position, pays tribute to him on page six.

Along with everyone else in the industry, we’re also troubled by the succession of Southern Ontario-based auto parts suppliers forced to declare bankruptcy over the course of the summer. Tri-Star Plastics, Polywheels Manufacturing, and Progressive Moulded Products have all gone under within the span of a few weeks, a domino effect that’s shaken some people’s confidence in this segment of our industry. There are no quick fixes for what ails auto part suppliers, of course, but in future issues we hope to highlight possible longer term solutions, such as ways in which processors can either run leaner parts manufacturing processes, or transition to other types of non-automotive molding, or both.

Looking back over the course of 65 years, our industry has obviously changed a great deal, as has virtually every other aspect of Canadian life. In some ways, though, a 1943era processor — if he or she could be transported to the present for a few days — might find much that is recognizable, as well. The military battle, waged against various foreign nations, has been replaced by a less obvious economic conflict — but it’s still a conflict, involving some of the same foreign adversaries, namely parts of Asia and of Europe. And plastics are still being called upon to provide innovative alternatives to metal and other materials...and are still delivering.

I think our predecessor from 1943 would be both amazed and proud.

Mark Stephen, managing editor mstephen@canplastics.com

MANAGING Editor Mark Stephen 416-510-5110 Fax: 416-510-5134 E-mail: mstephen@canplastics.com technical Editor Jim Anderton 416-751-5749 E-mail: jimeditorial@yahoo.ca ASSISTANT eDITOR Umair Abdul 416-510-5112 Fax: 416-510-5134 E-mail: uabdul@canplastics.com art director Valerie Perrott Production Manager Steve Hofmann 416-510-6757 E-mail: shofmann@bizinfogroup.ca Print Production Manager Phyllis Wright Publisher & EDITORIAL DIRECTOR Judith Nancekivell 416-510-5116 Fax: 416-510-5134 E-mail: jnancekivell@canplastics.com Associate Publisher Bill Young 416-510-5124 Fax: 416-510-5134 E-mail: wyoung@canplastics.com Circulation Manager Diane Rakoff 416-510 5216 Fax: 416-510-6875 E-mail: drakoff@bizinfogroup.ca HEAD OFFICE 12 Concorde Place, Suite 800, Toronto ON M3C 4J2. 416-442-5600, Fax: 416-510-5134 Canadian Plastics is published 10 times a year by the Business Information Group, a division of BIG Magazines LP., a leading Canadian information company with interests in daily and community newspapers and businessto-business information services.

2008 SUBSCRIPTION RATES, 1 YEAR 10 issues Canadian Plastics, plus Dec. 2008 Buyer’s Guide: Canada: $67.95 plus applicable taxes.

USA: US$75.95; Foreign: US$118.95 Dec. 2007 Buyers’ Guide only: Canada: $99.00 plus taxes and shipping USA & Foreign: US$99.00 plus $5.00 shipping.

From time to time we make our subscription list available to select companies and organizations whose product or service may interest you. If you do not wish your contact information to be made available, please contact us via one of the following methods: phone 800-668-2374; fax 416-442-2191; e-mail: privacyofficer@businessinformationgroup.ca; mail: Privacy Officer, Business Information Group, 12 Concorde Place, Suite 800, Toronto, ON M3C 4J2.

The contents of this magazine are protected by copyright and may be used only for your personal non-commercial purposes. All other rights are reserved and commercial use is prohibited. To make use of any of this material you must first obtain the permission of the owner of the copyright. For further information please contact Judith Nancekivell, 416-510-5116.

For Reprints call RSiCopyright, Michelle Hegland, msh@rsicopyright.com USPS 745-670. U.S. Office of Publication, 2424 Niagara Falls Blvd., Niagara Falls, NY. 14304-0357. Periodical Postage paid at Niagara Falls NY USA. Postmaster: Send address changes to Canadian Plastics, PO Box 1118, Niagara Falls NY 14304-0357.

We acknowledge the financial support of the Government of Canada through the Publications Assistance Program towards our mailing costs.

PAP Registration No. 11035 CANADA POST – Publications Mail Agreement No. 40069240. Return undeliverable Canadian addresses to: Circulation Dept. – Canadian Plastics, 12 Concorde Place, Suite 800, Toronto, ON M3C 4J2.

RETURN POSTAGE GUARANTEED Indexed by CBPI ISSN 0008-4778 MEMBER: Canadian Business Press, Canadian Plastics Industry Association.

Editorial Advisory Board: Brian Read, president, Horizon Plastics Company Ltd. Tom Meisels, president, F.G.L. Precision Works Ltd. James Ellis, vice-chairman, CPI Plastics Group Ltd. Mark Lichtblau, vice-president, Haremar Plastic Manufacturing Ltd.

ideas and innovations

A guide to Canada’s R&D facilities

By Umair Abdul, assistant editor

S

ince last year, the Ideas & Innovations section of our magazine has been refocused to bring you the latest developments and innovations from Canada’s leading research groups. It was our hope to bring cutting-edge research to our readers and help create a link between industry and academia.

In celebration of Canadian Plastics magazine’s 65th anniversary, we bring you a guide to some of Canada’s leading An aerial view National Research Council’s Industrial Materials Institute in Boucherville, Que. plastics-related R&D facilities. This page Courtesy of NRC-IMI offers just a sampling of what’s out there, but it clearly illustrates that Canada has a Contact: Mohamed Hamed, Director, 905-525- Areas of research: polymer materials of lot to offer when it comes to innovation.

9140 ext. 26113, hamedm@mcmaster.ca controlled architecture; natural macroWebsite: http://mmri.mcmaster.ca molecules/biomedical polymers; oriented NATIONAL RESEARCH COUNCIL polymer materials; polymer materials at INDUSTRIAL MATERIALS INSTITUTE INSTITUTE OF POLYMER RESEARCH surfaces and interfaces.

(NRC-IMI) UNIVERSITY OF WATERLOO Contact: 418-656-3221, cersim@chm.ulaLocated in: Boucherville, Que. Located in: Waterloo, Ont. val.ca Areas of research: Bioplastics and biocom- Areas of research: Development of new Website: http://www.chm.ulaval.ca/cerposites; biomedical polymers; nanofabrica- polymers and monomers; coatings; adhe- sim/english/index.html tion; process diagnostics and simulations; sives; elastomers. process diagnostic instrumentation.

Contact: Alex Penlidis, Director, 519-888Contact: Nafez Melhem, Marketing Man- 4567 ext. 36634 ager, 450-641-5000, nafez.melhem@cnrc- Website: http://www.ipruw.com nrc.gc.ca MICROCELLULAR PLASTICS Website: http://imi.cnrc-nrc.gc.ca

CLICK ON...

Located in: Hamilton, Ont. • Centre for Advanced Polymer Processing and Design (CAPPA-D) Areas of research: blown film extrusion; injection molding (cooling circuit optimization); extrusion (flat die design, foaming, micropelletization); mixing; powder injection molding; rotational molding Contact: Elizabeth Takacs, Lab Manager, 905-525-9140 ext. 24100, etakacs@ mcmaster.ca • The Machining Systems Laboratory (MSL) Areas of research: machining of hardened molds; creation of molds; control issues Contact: Stephen Veldhuis, Associate Professor and Director, 905-525-9140 ext.

27044, veldhu@mcmaster.ca • The Thermal Processing Laboratory (TPL) Areas of research: heat treatment of molds for die production

MANUFACTURING LABORATORY (MPML) - UNIVERSITY OF TORONTO

Located in: Toronto, Ont. Areas of research: Microcellular foamed thermoplastics.

Contact: Dr. Chul B. Park, Director, 416978-3053, park@mie.utoronto.ca Website: http://www.mie.utoronto.ca/ labs/park/lab/labhome.htm

CENTER FOR APPLIED RESEARCH ON POLYMERS AND COMPOSITES (CREPEC) Located in: Montreal, Que. Areas of research: plastics; nanocomposites; high-performance composites; intelligent materials.

Contact: Pierre Carreau, Director, 514340-4711 ext. 4629; crepec@polymtl.ca Website: http://www.polymtl.ca/crepec/ en/index.php

MACROMOLECULAR SCIENCE AND ENGINEERING RESEARCH CENTER (CERSIM) — LAVAL UNIVERSITY Located in: Laval, Que.

PLASTICS TV

CAN

MCMASTER MANUFACTURING RESEARCH INSTITUTE (MMRI)

for interviews with industry experts, coverage of plastics industry events, and more!

New episodes every two weeks.

These 5-minute informationpacked videos are produced by the editors of Canadian Plastics.

To view them, go to our web site,

www.canplastics.com and look in the upper right corner of our home page.

We're the first plastics magazine in North America to bring you regularly scheduled videos. www.canplastics.com July/August 2008 Canadian Plastics 5

news

Auto parts suppliers caught in “perfect storm”

T

he past few months have witnessed the demise of several Southern Ontario-based auto parts suppliers.

The assets for Tri-Star Plastics Corp., of Mississauga, Ont., were auctioned off in June. The company filed for bankruptcy in May, owing nearly $5 million to secured creditors and an additional $12 million to unsecured creditors. The company’s unsecured creditors consisted of a number of prominent industry names, including several well-known resin suppliers. Bankruptcy documents showed that the company’s assets were valued at just enough to cover its secured creditors.

Also in June, Vaughan, Ont.-based Progressive Moulded Products Ltd. filed for bankruptcy protection in an attempt to restructure its operations and reduce

its financial burden. Declining automotive sales, increased cost of commodities and materials, and pressure from manufacturers had put an immense strain on the company.

“When the company had filed for protection on June 20, we made clear our hope that negotiations would result in Laid-off workers of Progressive Moulded Products block the entrance to the solutions to its financial chal- Vaughan, Ont. auto parts factory on July 7. The workers were demanding the lenges that would be acceptable company give them a week of pay for every year of employment. to major customers and financial lenders,” said Progressive’s cant reduction in Progressive’s workforce. spokesperson Michael Daniher. However, At press time, the company had laid off those solutions would have taken time, and more than 2,000 workers at its Ontario and many of the company’s major customers U.S. facilities.

For now, it remains unclear if Progresdecided to move their work elsewhere.

The loss of work necessitated a signifi- sive will be able to restructure its operations

Oil to hit $200 a barrel: CIBC More bad news for the embattled automotive sector: CIBC World Markets is predicting that oil prices will hit $200 per barrel in 2010. And the unprecedented rise in commodity prices will carry broad implications for the auto industry.

“By 2012, there should be some 10 million fewer vehicles on American roadways than there are today — a decline that

Remembering Art Painter

The man known to many in Canada’s plastics industry as “Uncle Arthur” is no longer with us.

Art Painter, who died May 30 at the age of 83, was associated with Canadian Plastics for over forty years, working his way up from advertising sales representative to publisher to group publisher.

Art was an active volunteer in organizing industry events, serving on many Plast-Ex show and conference committees. His service to the industry was recognized in 1984, when he was given a CanPlast Award by SPI Canada (the precursor to the Canadian Plastics Industry Association).

I was fortunate enough to have Art as my mentor. He hired me as editor back in 1981 and later promoted me to publisher. Along the way, I learned a great deal about the plastics industry and about business from Art. 6 Canadian Plastics July/August 2008 www.canplastics.com

dwarfs all previous adjustments including those during the two OPEC oil shocks,” said the group’s chief economist and strategist Jeff Rubin.

CIBC World Markets also forecasted that gasoline at $7 a gallon will cause auto sales to drop to as low as 11 million units a year by 2012 — the lowest level since the early 1980s.

By Judith Nancekivell, senior publisher Art loved to sell. It was fun for him. In fact, when he took semi-retirement in the early 1990s, he stayed on with the magazine for several years on a part-time basis, with a sales territory covering his best buddies in the industry.

He took a real interest in his clients’ businesses and went out of his way to help them. Several of today’s industry equipment veterans got their start in the business because of Art’s encouragement.

Art was a master of relationships. He came from a time when people in business cared about each other. When there was time to have lunch, and to return phone calls. When people talked to each other face to face. A time before emails and Blackberries.

I mourn his passing, just as I regret the passing of that kinder, gentler way of doing business.

Art Painter

news

and bounce back. But, Daniher noted, “any time you lose 90 per cent of your business, it doesn’t bode well for the future.”

Recently, Oakville, Ont.-based compression molder Polywheels Manufacturing Ltd. also filed for bankruptcy protection under the CCAA. The company, which primarily made truck and SUV plants for Ford and GM, cited high oil prices and slowing demand as part of the problem.

However, founder, president and CEO Frank Milligan also said that the company approached the OEMs for some assistance over the summer. Instead, the OEMs decided to send trucks for their tooling and relocate their production elsewhere.

“We were forced to file for CCAA protection very quickly because of GM’s posture,” Milligan said in an interview with Canadian Plastics. “They said they were coming for their tools and they weren’t prepared to pay their payables.”

Polywheels’ future remains uncertain, but Milligan noted, “if the company is restructured, it won’t be automotive.”

Royal Group’s De Zen and others charged with fraud The Royal Canadian Mounted Police (RCMP) have laid fraud charges against Royal Group Technologies Ltd. founder Vic De Zen and other former executives of the plastic building products manufacturer.

The RCMP alleges De Zen and three other former executives defrauded the company of $27.4 million in a deal involving property north of Toronto.

De Zen and four other men, including two named in the other charges, are also alleged to have defrauded the Woodbridge, Ont.-based Royal Group of $2 million in the sale of a subsidiary. The alleged offences occurred during 1997 and 1998, and the charges come almost five years after De Zen stepped aside as chief executive officer.

“I am completely stunned by these charges,” De Zen said in a prepared statement. “For five years my name has been dragged through the mud with unfounded, sensational allegations leveled against me.

[These allegations are] without merit, and I intend to fight them vigorously in court.”

The alleged $27.4-million fraud relates to a deal in which land in Vaughan, Ont. is said to have been purchased by individuals closely associated with Royal Group and then sold to the company at an inflated price. In addition to De Zen, those charged include Douglas Dunsmuir, who was Royal Group’s general counsel and succeeded De Zen as president, along with two former chief financial officers, Gary Brown and Ron Goegan.

The alleged $2-million fraud relates to the sale of Royal Group subsidiary Steelwood Doors to Premdor Inc. The RCMP allege the warrant was not entered into Royal Group’s books and instead was exercised by senior executives for their own benefit. Charged in that case are De Zen, Dunsmuir and Goegan, along with Luciano Galasso, a former vice-president of Royal Group, and Gordon Brockle-

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news

hurst, former director of accounting.

Royal Group, which manufactures plastic pipe, window frames, outdoor furniture and other products, was founded by De Zen in 1970 as Royal Plastics Group.

NEWS BRIEFS The Canadian Plastics Sector Council (CPSC) has completed the first phase of its National Occupational Standards project, designed to establish a benchmark against which workers in the plastics industry can measure their skills and get training. Phase 1 consists of 33 bilingual standards for five major processes in the plastics industry: blow molding, fabrication, film extrusion, injection molding and profile extrusion.

The CPSC is working on Phase 2 of the project, developing additional standards for four other major processes: thermoforming, rotational molding, composites, and quality control. For more information, visit www.cpsc-ccsp.ca.

Que.-based IPL Inc. has introduced a new thin-walled round packaging container with in-mold labeling (IML) graphics, available in three different sizes. The project required a $4.3 million investment at the company’s Edmundston, N.B., facility.

Ball Corporation will close its packaging plant in Brampton, Ont. by the end of the third quarter of 2008. Production from the operation will be consolidated in the company’s other North American facilities.

Mississauga, Ont.-based PET bottle manufacturer MPI Packaging Inc. has opened a production facility in Riverside, Calif.

The new plant gives MPI 30,000 additional square feet of production space.

Trinity North America, Inc. has appointed Auxiplast Inc., of Ste-Julie, Que., as its representative for Quebec and the Maritimes. Trinity is a manufacturer of extrusion tooling and downstream extrusion equipment. The company is headquartered in Tongling, People’s Republic of China.

Husky Injection Molding Systems, of Bolton, Ont., will open a new, expanded 8 Canadian Plastics July/August 2008 www.canplastics.com

molding machines, died May 20. He had been ill with cancer for several years.

customer technical centre in Minami Machida, Japan by autumn 2008.

Sepro America has appointed Shadow Automation Inc., of Toronto, as representative of their line of robotics for Ontario.

Headed by Larry Bonehill, the company can be contacted at 416-464-2070.

Windsor, Ont.-based mold manufacturer Dieffenbacher North America Inc. is adding two CNC-controls machining centres and two gun drill machining centres at a cost of $8 million at its plant. The investment will allow the company to build presses with a capacity of 240 tons.

UVA and HALS producer Everlight Chemical Industrial Corporation has appointed Inortech Chimie Inc. as its exclusive Canadian distributor.

Perugia, Italy-based extrusion machinery manufacturer Torninova SRL Plastic Machinery is establishing a sales organization in Ronkonkoma, N.Y. to distribute bubble wrap machinery. They can be contacted at 631-676-7062.

Klöckner Pentaplast has purchased the entire rigid films product line of Tottenham, Ont.-based PMC Film Canada Inc. The company said that the acquisition included PMC’s formulations.

Switzerland-based Georg Fischer Ltd. is acquiring the business activities of Brampton, Ont.-based Alfa Plastics Inc. Alfa is a distributor of plastic pipes, fittings and valves for water treatment, chemical processes and other industrial applications, with annual sales of over $4.2 million.

PEOPLE

Steve Blomquist

Eurotherm, a global supplier of industrial controls and monitoring products, has named Steve Blomquis as President of Eurotherm USA, which is based in Leesburg, Va.

ZL Engineering Plastics Inc. has named David Dunn to the position of national sales manager for ZL East, responsible for growing stock shape sales to plastic distributors throughout Canada and the Eastern U.S. He will be based out of the company’s office in Peekskill, N.Y.

David Dunn

Pittsfield, Mass.-based engineering plastics supplier SABIC Innovative Plastics has named Charlie Crew as president and chief executive officer. Crew replaces Brian Gladden, who is leaving the company to become head of computer giant Dell Inc. Extrusion Dies Industries, LLC, of Chippewa Falls, Wis., has named Gary Oliver to the position of vice president of technology. He will be in charge of the company’s R&D program.

Pittsburgh, Pa.-based auxiliary equipment supplier The Conair Group has appointed Doug Brewster as its new national sales manager, responsible for all sales activity in Canada and the U.S.

Canadian Plastics Industry Association president and CEO Serge Lavoie will retire in early 2009. He joined the CPIA in 2003. A search for Lavoie’s successor will be underway when the organization’s restructuring is further along.

Ronald W. Mitchell has retired as president of CPI Plastics Group Limited effective June 30, 2008. He will continue to act as a consultant to the company, and will continue on as a member of the board of directors.

Keith Jackson, well-known in Canada’s plastics industry for his decades of work in servicing injection molding and blow

Calgary, Alta.-based Resin Systems Inc. has named Dimitrios (Jim) Leonidas as its chief financial officer.

executive’s corner

Understand safety codes when buying plastics processing machinery

by Simon Fridlyand, S.A.F.E. Engineering Inc.

I

n a modern processing plant, something needs to be fixed, installed, relocated or purchased every day. For decisionmakers, it’s very important in these cases to make the right decisions. But how do they do that?

The process begins by gathering information. It’s a well-known axiom that if everybody had all of the available information right at his or her fingertips, it would be easy to make the right decision all the time. However, gathering and assessing information is not that easy.

First, a person needs to know what questions to ask. Asking an incorrect question or a wrong person leads to inaccurate and wrong answers.

Incorrect information leads, in turn, to bad decisions. For example, my company, S.A.F.E. Engineering Inc., was recently asked to provide a Pre-Start Health and Safety Review (PSR) for an extrusion machine. There was an urgent need to get this machine operational. The original equipment manufacturer (OEM) had sold similar machines to our client in the past. Purchasing went ahead, and the client bought the machine. When we were called in, the machine was up and running. A quick PSR was expected from us. We discovered that the machine had an insufficient guarding arrangement and that the control system was not control-reliable as mandated by the machine guarding standards. The most important discovery, however, was that the machine had to go into a Hazardous Location Classified environment as determined by the Canadian Electrical Code.

The problems relating to the machine guarding issues could possibly be addressed through machine upgrade. Compliance to the Electrical Code, however, required changes to all electrical motors and other electrical equipment and wiring.

Fixing the machine at the job site became an impossible task.

BUYER BEWARE The Occupational Health and Safety Act (the Act) in Ontario requires owners of industrial machines and processes to make sure that machine, equipment or process is in compliance with the Act, and assigns the responsibility for compliance to the owner of the equipment and not to the OEM. The PSR process requires a professional engineer registered in Ontario to review and certify machinery, equipment or processes for compliance with the current and applicable standards.

In the above example a wrong decision cost the company a new machine, lost production time and lots of aggravation. PSR considerations, therefore, must be included in the decision-making process.

Also, to ask proper questions about compliance, one needs to understand various codes and standards. Understanding multi-disciplinary issues is not an easy task. An engineering firm conducting a PSR should be consulted before a purchasing decision is reached. The old adage about buyer beware is very much applicable to this situation.

A simpler way of insuring compliance is through the purchasing process. When purchasing documents are prepared, it’s easy to specify the OEM shall contact a company like S.A.F.E. Engineering Inc. We will advise the OEM of the requirements and, if necessary, help with design to achieve compliance with the current and applicable Canadian Codes and Standards.

A PSR report with a statement of compliance will be issued as soon as machine or process is installed at the client’s facility.

COSTLY PENALTIES Similar decisions shall be made when the machine or process is altered or relocated.

If a wrong decision leads to failures that result in a serious injury or fatality, the consequences are enormous. Under the Act, failure to comply with the requirements could result in prosecution and penalties for officers, directors, and engineers. A corporation convicted of noncompliance could face a maximum fine of $500,000 per count. For individuals, the maximum fine is $25,000 per count, plus a 20 per cent victim surcharge and or imprisonment for up to 12 months.

The bill for an Act to Amend the Criminal Code of Canada became law in 2004.

It’s known as Bill C-45, or The Occupational Health and Safety Criminal Negligence Bill, and it created the offence of occupational health and safety negligence.

According to Article 3, “everyone who undertakes, or has the authority to direct how other person does work or performs a task, is under a legal duty to take reasonable steps to prevent bodily harm to that person, or any other person, arising from that work or task.”

The fines in the Criminal Code have been increased from $25,000 per count to $100,000 for individuals. There is no maximum for corporations. Corporate representatives and senior officers face fines and imprisonment of up to 25 years, in addition to any fine or imprisonment that may be levied under the applicable provincial health and safety legislation On December 7, 2007 there was a first conviction under Bill C-45. Don’t let your company become another.

Simon Fridlyand, P. Eng., is president of S.A.F.E. Engineering Inc., a Torontobased company specializing in industrial health and safety issues and PSR compliance. He can be reached 416-447-9757 or simonf@safeengineering.ca.

For a videotaped conservation with Simon Fridlyand, visit http:www.canplastics.com/video/episode2.asp.

www.canplastics.com July/August 2008 Canadian Plastics 9

roundtable discussion

Dave Birkby

Dan Moynahan Sajjad Ebrahim

Serge Bragdon

OBSTACLES Mark Lichtblau

Tom Meisels

AND OPPORTUNITIES Q

How would you describe the present state of the Canadian/North American plastics industry?

Canada’s plastics processors are being challenged today as perhaps never before.

With this in mind, Canadian Plastics invited a panel of experts to explore some of the issues affecting our industry, as well as possible solutions for down the road.

Sajjad: The industry is facing the perfect storm — especially in Canada, as our raw material and freight costs are going up dramatically.

The high value of the Canadian dollar and increased competition from the U.S. manufacturers are making it very difficult to pass along any of these increased costs.

Serge: It’s definitely a perfect storm for us. Everything is against us: the oil price is going up dramatically, we have a strong Canadian dollar, there’s a manufacturing recession going on, and the rising gas prices are having an effect on people, which further slows down the economy.

Each of these things has happened in the past, but never at the same time.

Mark: I don’t like the “perfect storm” analogy, but I would say that we’ve witnessed the convergence of several significant issues. We’re asking for companies to

10 Canadian Plastics July/August 2008 www.canplastics.com

operate and function at the “speed of business.” We’re definitely at a critical point and we’re trying to find the equilibrium between globalization, a balance in fuel, oil and energy costs, and trying to see what will happen in the U.S. economy.

Dan: I would describe it as more of a roller coaster, but — at least for the moldmaking industry — I think the worst is behind us. The thinning out has been both at the Tier 1 and Tier 2 levels. The majority of the companies left standing at this point are pretty strong companies. They still have a lot to learn, but they understand what the problems are.

Tom: The present state of the industry is terrible, especially in Canada. With the dollar being as high as it is, and the U.S. economy being as bad as it is, none of our U.S. customers have any incentive to shop in Canada. The U.S. competition is so hungry that they’re giving away the work, and our high dollar makes it even more difficult to compete.

roundtable discussion

Participants: Dave Birkby, president and CEO, Westbridge PET Containers, Calgary, Alta. (PET preforms and bottle manufacturer)

Serge Bragdon, president and CEO, IPL Inc., St-Damien, Que. (Injection molder and extruder) Sajjad Ebrahim, president, Par-Pak Ltd., Mississauga, Ont.; 2008 CPIA Leader of the Year (Packaging supplier)

Mark Lichtblau, corporate vice president, Haremar Plastic Manufacturing Ltd., Toronto (Polyethylene film manufacturer)

Tom Meisels, president, FGL Precision Works Ltd., Toronto (Moldmaker) Dan Moynahan, president, Platinum Tool Technologies Inc., Windsor, Ont.; president, Canadian Association of Mold Makers (Moldmaker)

Dave: People and businesses are under stress from current economic conditions.

Our industry has also become a favorite target for environmental groups, particularly in North America. There have been a lot of acquisitions and consolidations in North America over the past few years, which has caused some industry confusion.

Q

In your view, what is the single largest obstacle confronting your business in the next five years? What plans do you have in place to overcome this challenge?

Sajjad: The single largest obstacle facing our business is the margin squeeze. We are looking at every cost and making changes to reduce our costs, including reduction in salary headcount, automation, and increasing the size of our business without adding overhead.

Dave: The single biggest challenge we have is lack of skilled labour. In Alberta, there’s just not a lot of labour available for anything.

Another challenge in this jurisdiction is deregulated electrical power. Since September, my company’s invoices for electrical power have gone from between $80,000 to $90,000 per month to $130,000 per month. It’s a bigger part of our costs than labour. Traditionally energy is not a major cost driver, but that’s completely changed.

We’ve been able to conserve some energy and sell it back into the “grid”, but unfortunately the grid price is very volatile and is currently lower than our three-year contract price. Not only do you have to be resin processor expert nowadays, you also have to be an energy management expert.

Tom: For us, the biggest handicap is still the Canadian dollar; my company exports about 85 per cent of its tooling.

Another challenge is government attitude towards manufacturing, especially in Ontario. Rather than coming to our aid, it’s almost as if the Ontario government is throwing more obstacles against us. For example, the SR&ED program is an incentive program being marketed as better and better, but at the same time the reviewers give you a harder time than ever, and deny us things.

A final challenge involves health and safety inspectors, who are very inconsistent as a group, and who are putting more and more costly, unrealistic demands on companies. I know of companies that spent $90,000 just to satisfy the demands of these health and safety people. They’ve got the power of God, and can shut you down in a second.

Serge: Several years ago we started adapting to lean manufacturing to reduce our costs. We’ve been able to reduce our costs dramatically, which has helped us get through the storm. Also, we’ve been managing our cash flow very strictly. We also made a decision to get out of the automotive industry, and are less vulnerable to changes in that industry as a result. Overall, we’re trying to move out of commodity projects and focus on value-added molding.

Q

Oil and gas prices have had a significant impact on several aspects of the industry, ranging from rising transportation costs to increasing raw material costs. What short-term and long-term effects do you think high prices will have on your operation or sector?

Mark: We’re dealing with increases in petrochemical and resin costs, and we’re being challenged by our ability to pass on these costs to the converters, and seeing if the converters can pass those costs on to the packagers, and then ultimately the retailers and consumers. We’re part of the chain, and of the absorption of costs through the chain. Regretfully, we don’t have as much control and power as the petrochemical companies to initiate these cost increases. We’re wrestling with the problem of absorbing costs, or passing them onto the converter, and it’s questionable who will be hurt more by this.

We may be able to pass on the costs to a converter, but we have to be sensitive to the direct impact it has on their markets and customers.

Sajjad: Our industry does not have pricing power, so we have to reduce our cost to be viable players in the long term. Our industry is suffering, and unless raw material prices come down soon there will be no choice but to increase prices and risk losing business. Prices came down to compete with offshore competition and the damage is done, and it’s very difficult to get prices back up.

Q

Speaking specifically about your business and sector, what growth opportunities do you see?

Dan: According to a Canadian Association of Mold Makers diversification study, for mold, tool and die makers the aerospace industry is the area we feel has the most opportunity. At present, we’re tripping over each other for the same work. If we diversify, in either automotive or aerospace or medical industries, that’s the key to the future.

Dave: The need to reduce freight costs has become somewhat of an opportunity for Western Canadian processors. Companies that were bringing in product from the East have suddenly realized the impact of high freight costs, and are taking a second look at manufactured goods supplied locally or at least regionally. www.canplastics.com July/August 2008 Canadian Plastics 11

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roundtable discussion

Sajjad: There’s a lot of emphasis on fresh and healthy eating and this is the major growth area for our business — more salads, more cut fruit, more prepared meals, and since we produce clear packaging the packaging of these products in our type of containers brings about impulse sales. We feel there is room to grow in this area for our industry.

Q

What strengths and advantages do you think Canadian companies have over Asian and other foreign competitors? What weaknesses and disadvantages do we have to struggle against?

Dave: I don’t think we have any advantages over the U.S. As North Americans, the only advantage we have is in our capability. Frankly, I think a big disadvantage for many Canadian firms is that we’ve been a bit fat and lazy in the past, mainly because the favourable exchange rate allowed it.

China has never been a threat for our type of beverage business and they are rapidly becoming a net consumer nation.

Serge: The advantages we have are more for when you work with very technical applications in short runs requiring speed to market. For a Canadian packager to work with commodity applications with large volume, you are very vulnerable. I don’t think the Asian packagers have our capabilities; but even if they get them, factors like transportation will impact their ability to compete.

Mark: I’d rather operate in Canada than anywhere else in the world. You can start up a company in many lower-cost, emerging countries, but you’re not guaranteed the political and economic stability you’ll find in Canada. At the same time, however, we’re being asked to manufacture products in Canada with a certain tax burden, and obeying various progressive environmental rules and regulations and labour codes. While simultaneously, in North America, we’re importing products from countries that are not complying with these types of regulations. Our true challenge is to outperform foreign competitors while complying with global best practice levels.

Tom: We have advantages, but they’re slipping away. I still think communication and proximity to the customer base is a big asset. If there is a 10 or 15 per cent cost benefit by going to China, the customer is not going to do it, because it’s not worth the aggravation, the communication difficulty, the distance, and warranty and maintenance issues. Being close to our customer base is still an advantage.

Q

Do you worry about the possibility of a shortage of skilled and professional workers in the future?

Dan: I believe this will be a real problem for the moldmaking industry. There will be a huge shortage of moldmakers in 10 to 15 years. As far as simple manufacturing goes, Ontario alone is projected to have a shortage of 400,000 skilled workers by 2025. This will trickle down into the moldmaking community. At present, there’s still a surplus of skilled workers in the mold, tool and die sector, who’ve been displaced and are looking for work, but they’re older. It’s very hard to get young moldmaking apprentices. The media, I believe, causes part of the problem. When young people read about plant closures, they ask themselves, “Why would I want to get into a situation like that?”

Mark: There’s definitely a shortage of skilled labour in Canada. The plastics industry has to embrace this challenge and develop its own skilled labour. Unfortunately, until the Canadian government decides to change the immigration policy and executes on that, the shortage will continue. As far as professionals, we have a great resource in the level of education in the population of Canada, but the message being communicated to professionals through both the media and the academic stream is that Canada doesn’t want to support manufacturing.

Q

In addition to contending with operational issues, the Canadian plastics industry has also had to deal with negative press and public opinion about plastics products. Do you believe these perceptions are having an impact on the industry’s well being? If so, what in your

view must be done to change plastics’ public image?

Dave: The bad publicity is a very big deal, in my opinion, and I’m very concerned.

At the moment, we’re not doing enough to counter the negative publicity, and part of the reason is that it takes a huge amount of funding. Organizations like the Canadian Plastics Industry Association (CPIA), the Plastics Film Manufacturers Association of Canada (PFMAC), and the Vinyl Council have raised hundreds of thousands of dollars to campaign against environmental groups, but it’s hard to get the message out without looking defensive. There’s an identity crisis in the industry in Canada, and people are aware of it and are throwing some money at it, but unfortunately there are numerous “free riding” companies not supporting the CPIA. They should all be ashamed. The urgency is better recognized in the U.S., where a large number of players commit to more significant funding.

However, the overlay to all this is that there’s an economic challenge at the same time, which has created a dual imperative for most manufacturing companies.

Mark: At times like this, I think we realize we’re very fortunate to have an industry association like the CPIA. Also we have the PFMAC and the Bag Task Force trying to address these issues. We’re seeing a global grass-roots movement against plastics and the various organizations mentioned are trying to battle this. I find it ironic that paper is being touted as a great replacement for plastics when 25 years ago it was the other way around.

The criticism against the industry is broad-streamed, but our response so far has been very targeted and strategic, trying to campaign and lobby decision-makers, at the municipal, provincial and federal level; and also positioned at educators.

Our industry is coming under attack, but so too did other industries, such as steel and paper, and they’ve survived and thrived. I think we will come out from this shadow, but we need more support and assistance for our whole industry membership. We have a lot to be proud of, and our industry achievements are significant and meaningful on a global scale.

CPL www.canplastics.com July/August 2008 Canadian Plastics 13

packaging report BE’s 11-layer SCD die Photo Credit: Brampton Engineering

LAYER

UPON LAYER

By Umair Abdul, assistant editor

I

f you have happened upon a blown film equipment manufacturer recently, you have probably heard them boasting about the number of layers they can offer on their lines. Although the fundamental technologies haven’t changed, most of the major players in the blown film field are either developing or currently offer 9-, 10-, or 11-layer blown film lines.

“Co-extrusion has been around for 40 years; what’s different is the quantity of layers that are being offered to clients,” noted Paul Waller, president of consulting firm Plastics Touchpoint Group. “And the reason for that is that there is a trend towards barrier structures.”

Traditionally, in sectors like food and pharmaceutical where barrier properties are essential, a smaller number of layers doesn’t do the trick. Waller uses the example of bacon wrap made with polyethylene (PE) and nylon, where a 3-layer structure wouldn’t work. The other option is to use a lamination process to achieve the necessary barrier structure.

“And that requires two machines, and it’s much more expensive,” he continued.

Which is where these new 9-, 10- and 11-layer lines come into the picture.

BREAKING THE BARRIER A few months ago, Brampton Engineering announced that it had shipped an 11-layer blown-film line, a world first, the company claimed. The company’s SCD multilayer streamlined co-extrusion die became the first successfully commercial 7-layer die, and BE has since shipped dozens of 7- to 11-layer systems.

“BE was the first one to go into market with 8, 9, 10 and now 11 layers,” said Adolfo Edgar, marketing manager for Brampton Engineering Inc. “The idea is that you can do the same structure better, or you could do the same structure cheaper.”

In addition to eliminating the need for

lamination, blown film experts note that multi-layer co-extrusion can help processors reduce their raw material costs.

“You can reduce the overall cost of that structure by 25 per cent, so there is an economic driving force that pushes you towards the layers,” said Waller.

For instance, processors can utilize a thinner film of their more expensive material without affecting the quality and properties of their final product.

“Co-extrusion can also give some savings on materials because people want to use additives with the multilayer structures, and these additives are very expensive,” added Felix Guberman, director of research and development at Macro Engineering and Technology Ltd. The company is currently making a 9-layer line at its Mississauga, Ont. plant after finishing a 7-layer line with an encapsulated layer, which allows for the production of a 9-layer film structure.

GROWING TECHNOLOGY Industry experts note that one of the key factors that has allowed suppliers to offer more layers has been the evolution of blown film technology.

“There’s been a learning curve...there have been developments in die technology and also in extruder screw designs that feed the resin to the die,” said BE’s Edgar.

Additionally, suppliers are more confident in offering this level of sophistication because they can produce very complex multi-layer lines with better quality products. For instance, there is less variation in thickness, less frequency of imperfections, and fewer problems with interfacial instabilities.

“The big improvement is that die technology is much better because we are using more and more sophisticated simulation processes to optimize the processing windows before we cut the steel,” said Waller.

14 Canadian Plastics July/August 2008 www.canplastics.com

ON THE CUTTING EDGE Brampton’s 11-layer line featured a unique extruder design to avoid a constricted dieextruder arrangement.

“From a production standpoint, it’s not a very good idea to have a cramped, hot section,” said Edgar. “We more or less kept a 9-layer configuration, and in a couple of those positions we piggybacked the extruders.”

BE’s SCD die allows the extruders to have different centre line heights, making the piggybacking of extruders possible.

Woodbridge, Ont.-based Alpha Marathon Film Extrusion Technologies Inc. has already delivered several 5- and 7-layer lines and is currently building a 10-layer fully automatic project to be shipped later this year. According to the company, the 10-layer line will feature a number of cutting edge technologies such as Gearless Direct Drive for all extruders, Alpha Dual Spiral Stacked co-extrusion die, Triton cool air ring with manual film gauge compensation mechanism, Advanced Water Ring and Accurate Layflat Controller, Horizontal Film Oscillator, and fully automatic winding with in-line sitters.

“The reason for Alpha Marathon to do this R&D and then design and build such a line is mainly based on our customers’ and the market demands, and to create a purely custom-made turnkey system to support the trendy market’s needs,” explained company president Domenic Marzano. CPL RESOURCE LIST Alpha Marathon Film Extrusion Technologies Inc. (Woodbridge, Ont.); www.alphamarathon.com; 905-265-2055 Brampton Engineering (Brampton, Ont.); www.be-ca.com; 905-793-3000 Macro Engineering and Technology Inc. (Mississauga, Ont.); www.macroeng.com; 905-507-9000 Plastics Touchpoint Group, Inc. (Thornhill, Ont.); www.plasticstouchpoint.com; 905-738-9742

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packaging report

FAMILY PACKAGE:

Plastilec Inc. Quebec’s Plastilec Inc., a family-owned

quickly,” said Sandrine Milante, custom molder, saw an opportunity to Plastilec’s director of operations. “They decided it was seize a cosmetics packaging account from worth paying a little more to China...and did it, through a combination of have the product made in Canada, in return for faster response engineering and manufacturing skills and to colour change demands and responsive business approach. daily delivery.”

The company now molds

By Mark Stephen, managing editor more than five million of the containers a year for this prodccording to Greek mythology, uct, in 14 different colours — a Prometheus once carried out the singular accomplishment, for impressive feat of stealing fire from reasons relating to the nature of the gods. For a Canadian plastics cosmetics packaging. “The cosprocessor, stealing business from China may metics business makes fancy products, but not be quite in that league, but it’s a good they are not overly hard to make, and quality is often not the most important aspect sign you’re doing something right.

Plastilec Inc., a custom molder in Cham- for the customer,” Sandrine said. “This bly, Que., recently took over an account gives the Chinese a real edge, and I don’t to mold containers for an all-natural skin know of any cosmetics products that aren’t cream that had previously been molded made in China — other than those we’re in China, after the customer encountered manufacturing.”

Plastilec is an example of that oldproblems with quality consistency and colour matching. “The customer, located est style of business operation, increasin Montreal, needed a company that is ingly rare in today’s industry: the famvery flexible and able to change colour ily-owned business. When Gaetan and Yvonne Milante purchased the company in 1995, it had just three machines. One year later, the Milantes bought the Plattsburgh, N.Y. plant of Twinpak Inc., an injection molding company specializing in the packaging business, and brought its machines into the Plastilec facility, then located in Longueuil, Que. By 2002, capacity and services expansions made it necessary to move to its present location in the 26,000 square foot Chambly plant. Today, Gaetan Ron Desjardins Milante is the managing direc-

A

16 Canadian Plastics July/August 2008 www.canplastics.com

Sandrine Milante

tor, while Yvonne Milante serves as president, said daughter Sandrine.

SECRETS TO SUCCESS As rare as is the company’s background, rarer still is its level of success; Plastilec has experienced approximately 10 per cent growth for every year it’s been in business, according to Sandrine. At present, the company currently employs approximately 30 workers, and houses 12 molding machines.

Cosmetics packaging makes up roughly 70 per cent of Plastilec’s business, and the needs of that particular industry are clearly reflected in the company’s philosophy. “Customers in the cosmetics industry are used to getting answers quickly, and to having their demands satisfied even faster,” said Ron Desjardins, business development manager. “Our own structure is well suited to this, geared towards thoroughness and a quick response time.

It’s simple: if a telephone rings here, we answer it, and also return calls as quickly as possible.”

Unlike other packaging suppliers, Plastilec mixes material per shift, not per batch or per order, Desjardins explained.

packaging report

“If a customer needs a certain amount of a particular colour right away, we simply make a work order and it’s taken care of by the next shift.” To guarantee this rapid response, he continued, the company operates 24 hours a day, with technicians on every shift, meaning production runs can begin at midnight, if necessary.

While cosmetics packaging is a company specialty, it’s not the only one. Plastilec is also involved in pharmaceutical and in precision medical molding, as well as molding for the electronics industry. In this latter area, the company recently kept another contract away from Chinese competition. “We had an electronics customer who wanted us to mold the part prototypes, with the bulk of the work then being sent to China,” Desjardins said. “We convinced him we could mold, paint, assemble, package and ship7/10/08 the parts just wellPage on our1 Compact/AB/CPL 2:24asPM own. Instead of this work going to China, it’s now staying in Canada.”

Plastilec Inc. (Chambly, Que.); www.plastilec.com; 450-658-9090

CPIA unveils “positive” packaging campaign

I

n light of the barrage of negative public press aimed at plastics, the Canadian Plastics Industry Association’s Environment and Plastics Industry Council noted that it plans on launching a constructive and positive campaign that tells the industry’s side of the story.

At an industry meeting in June, the CPIA detailed a new plan to respond to some of the negative and false criticism being leveled at the Canadian plastics industry.

“Today, we need to start being proactive,” noted Glen Armstrong of Brampton, Ont.-based thermoformer Par-Pak Ltd., who served as a host and moderator for the event.

The association is hoping to helm a campaign that will bring the environmen-

For blow molds, trust the experts

tal and public health benefits of plastic products and packaging into the public spotlight. EPIC has used a public relations firm called PR POST to develop a mainstream campaign that will target the full range of stakeholders — everyone from the general public to political decision makers to industry employees.

“It’s definitely offensive action by the plastics industry,” explained Cathy Cirko, CPIA’s vice president of environment and health. “What we have seen recently is a trend we don’t like, and we feel that we have to take control of our industry.”

But speakers at the June event noted that changing public perceptions of plastics is no easy feat. For instance, the plastics industry often has to contend with media reports of plastic products that may

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packaging report

packaging equipment – technology showcase Canadian Plastics spotlights some of the latest in packaging equipment

be “toxic” for children.

“We as an industry have to bring back the emotion of using plastics, and really tell the story from an emotional point of view of how valuable they are,” said Cirko.

To get the campaign up and running, EPIC is seeking financial support from industry members. The group has developed a guideline of suitable funding levels based on a company’s annual sales.

According to Cirko, sponsor logos and company profiles will also be placed on the packaging website, and donors will have access to an ambassadors program for employees.

“I think we’ve been silent for too many years,” said Par-Pak’s Armstrong. “The amount of money are looking for in funding is not a lot of money compared to the earnings of a lot of companies and members.”

For more information on the forthcoming packaging campaign and how you can get involved, contact Cathy Cirko at ccirko@cpia.ca.

Want more on this story?

CanPlastics TV goes behind the scenes at the CPIA’s June packaging campaign meeting, and also shows you other industry responses to bad press and environmental concerns.

Visit http://www.canplastics. com/video/episode7.asp

Large printing presses for packagers

print repeat length is 1,640 ft/min.

Windmoeller & Hoelscher Corp. (Lincoln, R.I.); www.whcorp.com; 800-854-8702

Winding stretch film rolls without a cardboard core The Heliostar S and the Miraflex C are two new printing presses made available for package printing by Windmoeller & Hoelscher Corp.

The Heliostar S can be fitted with up to 12 print stations which are designed for maximum printing speeds of up to 1,312 ft/min. This rotogravure press offers cost-effective printing of flexible packaging materials, such as plastic films or laminates. Maximum printing width is 51 inches with a print repeat of 36 inches.

The Miraflex C (pictured) offers a sleeve type nip roller before the first printing deck, which allows the nip roll to be changed from film to paper or to tube production quickly and easily. Manually operated bearing blocks allow fast, reliable plate and anilox sleeve changeover. The new flexo press can be supplied with eight or 10 colour decks with printing widths of 39 inches to 57 inches. The maximum

18 Canadian Plastics July/August 2008 www.canplastics.com

Italian stretch film equipment supplier NO.EL is making available in North America its exclusive, patented technology for creating standard stretch film rolls without the typical cardboard tube core inside.

Previously only available in Europe and Brazil, the new Coreless Rewinder II system will be available for installation

by North American stretch film producers beginning in the second quarter of 2008.

The Coreless Rewinder II is a key enabling technology designed to help stretch film producers eliminate cost through supply chain simplification, and also helps the users of stretch film reduce their waste, since 100 per cent of the film on the roll

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What do you need?

packaging equipment – technology showcase

can be used for wrapping applications and leaves no cardboard tube to recycle.

Nuove Sales (Los Angeles, Calif.); www.nuovesales.com; 310-670-0576

Blow molding regulation system The Equinox system built into Sidel’s rotary blow molding 4/15/08 machines is1:56 designed ResinConfAd/AB186/CPL PM to ensure consistent, top quality PET bottle production for better overall bottling line efficiency.

Equinox monitors and corrects bottle

quality during production regardless of output rate. No samples are required because Equinox automatically measures the exact weight of every bottle base. If the system detects variations from the setpoint weight, it corrects the problem by adjusting certain blow Page 1 molding parameters. No machine shutdown is required.

Equinox automatically measures the exact weight of bottle bases using sensor

modules that emit infrared light. If the weight is beyond the tolerance limit based on the initial setpoint, the blow molding machine’s control algorithm is automatically triggered, and the operator receives a warning about the problem. Changes to preblow pressure regulate overall production on all stations, and modifying the start of pre-blow adjusts individual stations.

Sidel Canada Inc. (Laval, Que.); www.sidel.com; 450-973-3337

Don't Miss This Important Industry Event! 13th Annual Canadian Plastics Resin Outlook Conference

Thursday, October 2, 2008 Verdi Conference Centre Mississauga, Ontario (near the Toronto airport)

Hear forecasts from experts on supply, demand and pricing for the major resins.

Investment per person: Early Bird registration - register and pay in full by August 31, 2008: $395 + g.s.t.

Regular registration, after August 31, 2008: $495 + g.s.t.

50% discount for second & subsequent attendees from the same company Organized by Canadian Plastics magazine.

Endorsed by the Canadian Plastics Industry Association.

Conference details are on the Canadian Plastics website at www.canplastics.com/Conference/conference.asp

To register, contact Judith Nancekivell, Tel: 416-510-5116 Email: jnancekivell@canplastics.com

Here’s what delegates at last year’s conference said they gained from attending: • Long range forecasts re supply for resins • Resin pricing trends and networking • What future trends will be to ensure I can plan accordingly • Pricing trends in industry for next 1-5 years • Global consumption and market drivers • Update market trends • The outlook for global resin industry and its potential impact on our business • The economic review and a sense of the market expectations re price/supply/demand

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20 Canadian Plastics July/August 2008 www.canplastics.com

injection molding

INJECTION MOLDING:

THE FUTURE IS NOW T

here’s much that is new in allelectric machines, aimed at every segment of the market, from general-purpose to high-end. Not to be outdone, suppliers of hydraulic units continue to expand their range. Hybrids, too, are available in new designs ranging from essentially hydraulic machines having an electric screw drive to mostly electric machines that retain hydraulics for highpressure clamping or high-speed injection.

And this only scratches the surface.

More than ever, injection molders are looking for machines and processes that are reliable, energy-efficient and flexible enough for innovative applications. Canadian Plastics surveys some of the most recent offerings from the I/M machinery suppliers.

By Mark Stephen, managing editor

ALL ALL-ELECTRIC Sumitomo has introduced the new highspeed double shot SEHS-CI Series of all-electric machines, featuring advancements made on the company’s SE-HS Series. Available in two model sizes, the SE230HS-CI (253 US tons) and the SE280HS-CI (308 US tons), the machines offer cycle-time enhancements such as 180° mold plate rotation in 0.8 seconds, mold open and close speeds of 1,300 mm per second (51.2 inches per second), and reduced cooling times through optimal four-circuit temperature control piping.

The units are available with a choice of injection units, screw diameters and screw types for shot sizes ranging from 2.9 to 10.7 ounces. “The SEHS-CI com-

bines many of the advancements made in the high-speed SE-HS with double-shot capabilities and a new, faster rotating mold plate,” said Jeff Hicks, vice president, technical services for Sumitomo in North America. “Together with our SED-CI Series, we now have all-electric machines for double-shot applications from 83 to 308 tons.”

The Allrounder 570 A, the newest addition to Arburg’s Allrounder Series of allelectric injection molding machines, is not only the company’s largest model to date, with a clamping force of 2,000 kN, but also features a hybrid drive. In addition to the largest electric injection unit, size 800, a hydraulically actuated accumulator drive injection axis is available in conjunction with the size 1300 injection unit, permitting higher injection performance and injection speed, and making the model suitable for applications whose performance requirements exceed the capabilities of the size 800 unit. But the model still retains the energy efficiency of an allelectric unit, the company said, due to the other electric movement axes, for example on the clamping side.

Engel’s newest all-electric machine, the e-max, is designed to provide fast cycle times, precision and flexibility in a cost-

Arburg’s Allrounder 570 A is the company’s largest all-electric injection molding machine, with a clamping force of 2,000 kN, and features a hybrid drive.

Photo Credit: Arburg Inc.

www.canplastics.com July/August 2008 Canadian Plastics 21

injection molding

The new Mars Series hydraulic machines from Haitian combine a servomotor with a positive displacement gear pump, for delivery of the required flow and pressure as needed throughout the molding cycle.

Photo Credit: Absolute Haitian

effective package that fits a small industrial footprint. “The e-max is the all-electric solution for molders looking to reduce their plant energy costs while maintaining superior performance,” said Steve Braig, Engel North America president and CEO. Available in sizes from 55 to 200 US tons, the e-max has a footprint of 13 feet by 4 feet for the 110 tonnage model, a 1.4 second dry cycle time, injection units with peak pressures of up to 40,6000 psi, and injection speeds up to 17.7 inches per second. The e-max units are particularly well suited for such applications as medical, consumer, and electronic components and automotive, Braig said.

HIGHLIGHTING HYDRAULICS Demag Plastics Group has extended its Ergotech Dragon Series of hydraulic machines at the top end of the line with its Ergotech Dragon 100 and Dragon 160 models. With these additions, the company is now offering a machine range featuring clamping forces from 500 up to 2,000 kN. The Dragon’s fully hydraulic clamp has been purpose-trimmed for high productivity. Key features include two clamp cylinders and a flow-volume multiplier on the inner side of the anchor platen. According to Demag, this design reduces the overall length of the machine while providing ample space for larger molds. The Dragon Series is also available with customized added functions, auxiliary devices and modifications tailored to specific applications.

New from Haitian is the Mars Series hydraulic machines, designed to offer substantial energy savings over competitive units. The machines combine a servomotor

with a positive displacement gear pump, for delivery of the required flow and pressure as needed throughout the molding cycle.

“The Mars Series provide almost the same energy efficiency as an all-electric, and between 20 and 80 per cent savings over a conventional hydraulic machine,” said Glenn Frohring, vice president of sales and marketing with Absolute Haitian.

“The advantage of this concept is the dramatic reduction of wasted energy associated with conventional hydraulic systems,” he continued. “During the pressure holding period, the rotational speed of the drive is significantly reduced. During cooling, the output from the drive system is zero and there is almost no energy cost at all.”

NEXT STEPS IN HYBRIDS Toshiba Machine recently made available its new ED (Electric Direct-lock) Series hybrid machines, with models ranging from 650 to 3,000 metric tons. According to Toshiba, the units feature the newly developed hybrid direct-lock clamp, based on the hydraulic two-platen “DF” platform. The ED Series uses six high precision servomotors, plus synchronized hydraulic control; the servomotors provide the high speed clamp movement, while the hydraulic systems provide high clamp pressure and high pressure opening. The ED Series is designed to offer a small footprint, reduce oil requirements, and reduce mold maintenance, the company said.

Meanwhile, Nissei has developed the new X Series of hybrid machines, which the company claims offer energy savings of approximately 30 per cent over comparable hydraulic models. Available in sizes ranging from 40 tons to 460 tons, the units offer ramp-up times of 40 to

22 Canadian Plastics July/August 2008 www.canplastics.com

50 ms, which represents a high response on par with all-electric machines. The injection speed can be controlled over a wide range, from 1 mm per second to a maximum of 300 mm per second, the company said. Additionally, the X Series units are capable of sustaining high injection holding pressure longer than comparable all-electric machines, while using a maximum of 56 per cent less hydraulic oil than hydraulic models.

NEW SYSTEMS, MERGERS & CONCEPTS Husky Injection Molding Systems has introduced a system designed to improve cost-effectiveness and productivity for molders. The company’s HyPET 90 is a PET system featuring Flex Mold, a modular low cavitation PET preform mold intended for customers who use the same machine for multiple applications, and therefore need to change molds with minimal downtime — particularly converters producing smaller volumes of preforms.

With Flex Mold, the bodies of the cavities can be changed while the gate pad remains in the mold. The design of the mold eliminates the need to cool down and reheat the hot runner during a part changeover, the company said, reducing mold change times by as much as 75 per cent compared to a conventional mold.

Milacron has expanded its Servtek TCS barrel heating and cooling technology for injection molding machines, a move designed to save energy and improve processing. According to Milacron, the Servtek TCS injection unit barrel heater provides a high radiant energy release from an element that directs 100 per cent of the heat directly into the barrel. The encap-

injection molding

sulated barrel keeps all the heat inside, allowing a fast heat-up cycle. “The technology is simple and easy to use, and is quite different from old-fashioned ceramic heater bands, insulated heater bands and water-cooled systems that all must heat themselves up prior to delivering heat to the barrel,” said Rich Waterfield, Servtek product manager. “Presently, the heater bands are suitable for all machines except those with a barrel smaller in diameter than 5.75 inches.”

Following the purchase of Battenfeld by auxiliary supplier The Wittmann Group, the companies are working to integrate services. “Our goal is to complete and commercialize the integration by the end of 2008,” said Michael Wecker, CEO of Battenfeld of America. When finished, the integration will offer substantial benefits for injection molders, he said. “Traditionally, resin and finished product handling has been carried out separate from the machine molding process, and completely separate from the supplier aspect,” he explained. “We can now offer a seamless, one-stop shop, and this provides several advantages.”

Of particular importance, Wecker continued, is the linking of the injection molding machine with the automation through a complete integrated control panel. “Until now, a plastics processor employed a machine company to set up one controller, and an auxiliary supplier to set up another, and typically the two were not communicating efficiently,” he said. “Ultimately, we’ll be able to offer an entire system on one synergized, unified control panel.”

Krauss Maffei, meanwhile, has developed a new concept that cuts cycle times in the production of molded parts with integrated vibration damping, by linking injection molding with extrusion and reaction processing in a single manufacturing cell.

The process teams a Krauss Maffei injection molding compounder (IMC) with the company’s CX injection molding machine to produce 2C parts. With a crosslinking stage, the process delivers a product with the elasticity and resilience of natural rubber and other elastomers, with a cycle time of approximately 60 seconds. The crosslinking agent is added to the melt as a liquid polymer, the company said, and then mixed on the injection molding compounder, which

Krauss Maffei has developed a new concept that cuts cycle times in the production of molded parts with integrated vibration damping, by linking injection molding with extrusion and reaction processing in a single manufacturing cell.

Photo Credit: Krauss Maffei Corp.

yokes continuous extrusion and discontinuous injection in one machine. Because the extruder operates continuously, it ensures that the crosslinking agent is metered evenly into the melt and thoroughly mixed to produce a homogenous compound. The plasticized and homogenized material is injected via a heated runner and an injection piston into the mold.

Boy recently introduced the Procan ALPHA control, for injection molding machines with clamping forces below 1,000 kN. With a 15-inch full touchscreen system powered by a patented rapid UTX PC

hardware system, the control is designed to save time through effective processing of analogous signals. It reacts without delay and frees the PC from all time-critical tasks, the company said. The system also features the Iterative Learning Controller (ILC), designed to achieve actual values in a stable state. According to Boy, advantages of the ILC include the reduction of start-up and set-up times, and control of deviations common to continuous operation. Additionally, the profiles of actual and set values are largely approximated, thereby minimizCPL ing frequency peaks.

Resource List Absolute Haitian Corporation (Worcester, Mass.); www.absolutehaitian.com; Shadow Automation (Uxbridge, Ont.); 416-464-2070 Lutek Plastic Equipment Inc. (Dorval, Que.); 888-505-8835 Arburg Inc. (Newington, Conn.); www.arburg.us; 800-221-0712 DCube (Montreal); www.dcube.ca; 514-272-0500 Dier International Plastics Inc. (Unionville, Ont.); www.dierinternational.com; 905-474-9874 Battenfeld (Wittmann Canada Inc.) (Richmond Hill, Ont.); www.wittmann-canada.com; 888-466-8266 Boy Machines Inc. (Exton, Pa.); www.boymachines.com; 610-363-9121 Barway Plastic Equipment Inc. (Vaudreuil-Dorion, Que.); www.barway.ca; 450-455-1396 Plascon Plastic Machinery Inc. (Toronto); 416-491-8450 Demag Plastics Group (Strongsville, Ohio); www.dpg.com; 866-491-1045

24 Canadian Plastics July/August 2008 www.canplastics.com

Stephen Sales Group (Markham, Ont.); 905-940-5577 Husky Injection Molding Systems Ltd. (Bolton, Ont.); www.husky.ca; 905-951-5000 Engel Canada Inc. (Guelph, Ont.); www.engelglobal.com/na; 519-836-0220 Milacron Inc. (Cincinnati, Ohio); www.milacron.com; 513-487-5000 Accuplast Solutions (Kirkland, Que.); www.accuplast.com; 866-630-0808 Cincinnati Milacron Canada Ltd. (Burlington, Ont.); 905-319-1919 Nissei Plastic Industrial Co. Ltd. En-Plas Inc. (Toronto); www.en-plasinc.com; 416-286-3030 Krauss Maffei Corp. (Florence, Ky.); www.kraussmaffei.com; 859-283-0200 Sumitomo Plastics Machinery (Norcross, Ga.); www.sumitomoPM.com Plastics Machinery Inc. (Newmarket, Ont.); www.pmiplastics.com; 905-895-5054 Toshiba Machine Co. America (Elk Grove Village, Ill.); www.toshiba-machine.com; 888-593-1616

E X P O P L A S T 2 0 0 8 Roadmap to a Sustainable Future!

Expoplast only takes place every three years, it’s your absolute best opportunity to see and interact with the products and services you’re going to need to compete and prosper in an increasingly competitive world.

This event is loaded with educational opportunities, business development initiatives and features celebrating innovation and achievement in the Canadian plastics industry. This is the event you can’t afford to miss.

Visit the website for information and to register to attend.

Palais des congrès Montréal • October 20-21, 2008

www.expoplast.org

granulators

“GROUND” RULES B&C PLASTICS LTD. 905-427-3324; www.bcplasticsltd.com

Processors shopping for a new granulator will find that they have several options, and there is no “one-size-fits-all.” Bearing that in mind, Canadian Plastics spoke with three different manufacturers — a blow molder, an automotive molder, and an injection molder of electrical components — to discuss the grinding equipment they purchased, and why it best suits their needs.

Although each processor opted for a different grinding solution, they help illustrate some of the best practices when approaching the market. Let’s call them the ground rules of grinding.

By Umair Abdul, assistant editor

Founded in 1983, Pickering, Ont.-based B&C Plastics Ltd. serves a wide range of industries — everything from food and beverage to automotive and agriculture.

Based out of a 50,000 square foot facility, the company runs six blow molding machines to produce high-density polyethylene (HDPE) bottles and jars.

Each machine at B&C’s plant is fitted with a 25 horsepower press side granulator from Hosokawa Polymer Systems. The first one was purchased in 1985 when the company first started production, and the most recent was added a few years ago.

Vice president and general manager Corey Gambon Jr. notes that a beside-the-press configuration made sense because each machine runs a different colour.

B&C’s machines are automated, and each bottle produced at the plant is inmold deflashed. The flash is then dropped onto an angled conveyor below, which goes right to the mouth of the granulator.

The Hosokawa grinders are also used to introduce defective bottles back into the process.

“All bottles are 100 per cent leak tested and visually inspected,” explained Gambon Jr. “Those are just manually fed by the operator.”

The company opted for six mm screened units because they needed equipment that wouldn’t allow excess dust into the process. B&C isn’t a 24-hour operation, and the screened machines allow for fast start-up and no cleanout on the next business day.

“There is no dirt that gets in there,”

26 Canadian Plastics July/August 2008 www.canplastics.com

noted Gambon Jr. “We just shut them down and start back up.”

The screened granulators also allow B&C to achieve a very small pellet size — six millimetres — that is the optimum size for remelting.

Regrind is metered back into the process, and the Polymer units have allowed the company to have a five per cent scrap rate on their new bottles.

“It’s helped us reduce raw material costs,” said Gambon Jr. “We are not throwing away resin, we try to reuse all our scrap plastics.”

Additionally, the press side granulators allow for easier material changeovers. The whole process — which includes hopper and filtration cleanout and line purging — takes an hour, reducing downtime.

“All of the openings are large enough,” continued Gambon Jr. “And they are very safe, they have a lot of safety switches.”

According to Gambon Jr., one of the benefits of going with a Hosokawa Polymer Systems granulator was that B&C got a turnkey system through supplier Plastics Machinery Inc. of Newmarket, Ont. “We had explained and visually shown them what we wanted to do and they were able to supply the whole thing,” he said.

“They sold us the granulator and the conveyor system that we needed, sized to fit.”

Hosokawa Polymer Systems (Kensington, Conn.); www.polysys.com; 860-828-0541 Plastics Machinery Inc. (Newmarket, Ont.); www.pmiplastics.com; 905-895-5054

granulators

ADVENTEC MANUFACTURING INC. 905-648-3345; www.adventec.com

Since 2000, Ancaster, Ont.-based Adventec Manufacturing Inc. has been manufacturing Tier 2 automotive parts for leading suppliers to global OEMs. The company runs parts on 10 servo-electric injection machines up to 200 tons, and nearly each one — nine, to be exact — has been outfitted with a beside-the-press screenless granulator from Wittmann Canada Inc. According to technical services manager and business partner Dan Valerio, one of the first criteria when the company was shopping for granulators was that the units have a low rotor speed to prevent dust.

“We needed low RPM because our parts are so dimensionally stable,” he explained.

In other words, dust particles could damage the integrity of the part.

On several of the company’s closedloop production lines, a pick-and-place robot drops a sprue and any defective parts directly into the Wittmann grinder. Vacuum take-out allows for the regrind to be reclaimed almost immediately, with material being proportionally metered back into

the process when the hopper calls for it.

Valerio notes that feeding reground scrap back into the process cuts out the costly step of drying regrind.

“It’s just coming from the processed system, whereas regrind has to be dried,” he explained.

Several of Adventec’s molded parts include metal inserts, which presented a major problem when trying to reclaim defective parts. On some of the machines, Adventec has installed three bunting magnets into the chute to prevent finished insert molded parts from falling into the grinder.

Valerio notes that the beside-the-press granulators have rendered the plant’s central grinding room and regrind storage nearly obsolete. And although regrind may occasionally get contaminated with metal, a press-side system helps contain that problem to only a small amount of material on just one production line.

“It still happens, but it doesn’t contaminate 15,000 lbs of regrind,” he said. “[The machines] have probably paid themselves off on the regrind. Regrind inventory could easily be as much as $100,000, which is equivalent to us adding another machine to our plant.”

Wittmann Canada Inc. (Richmond Hill, Ont.); www.wittmann-canada.com; 888-466-8266 www.canplastics.com July/August 2008 Canadian Plastics 27

granulators

IPEX INC. 416-751-3820; www.ipexinc.com

Molder Ipex Inc.’s Toronto-based plant on Bermondsey Road mostly works with polyvinyl chloride (PVC), producing parts for the electrical, industrial, construction and retail industries. Ipex keeps the plant running 24 hours a day, 7 days a week, with 38 injection molding machines in total on the plant floor.

The Bermondsey plant recently upgraded its grinding setup, sourcing two shredders, conveyor systems and a grinder through Vecoplan LLC. Prior to the upgrade, the plant was using two grinders to manage its scrap.

“We had a small grinder and bigger unit,” said plant technical manager Rod Huels. “It was all manually fed, we had three or four operators in the workroom, and we had to grind all the time.”

In order to improve output and reduce the manpower needed to keep up with the plant’s grinding needs, the company created two grinder lines. The first line, for smaller parts, tilts a full gaylord of parts into a shredder. Once the sprues and parts

are shredded into manageable 3/4 inch pieces, they are transported by a conveyor to one of the old grinders Ipex had before the upgrade. The end of the conveyor is outfitted with a magnetic roller to prevent any metal from getting into the grinder.

The second line has a similar design, but is meant for larger parts and includes a new grinder from Vecoplan with a larger throughput at the end of the line. Huels noted that the company occasionally has eight-inch “T”-shaped parts — weighing in at about 32 pounds — that need to be reclaimed.

“Now we basically have half of one operator, someone who does material changes,” explained Huels. Plant operators can simply dump a full gaylord of their largest and heaviest parts into the shredder and walk away, with no need to meter feed the product.

One of the benefits of adding a shredder to the process is that the grinders can keep up with Ipex’s throughput levels without using up more floor space.

“Our plant doesn’t have a lot of room, it’s really congested here,” said Huels.

28 Canadian Plastics July/August 2008 www.canplastics.com

“Before, when we really only had one grinder, [scrap] would pile up...the whole room now uses the same footprint.

“If we went directly into the grinder, we’d have one huge grinder and the throughput wouldn’t be as fast,” he continued. “Now we can just put the big parts directly through, and even go bigger.”

When the plant had been looking to upgrade its grinding room, Huels notes that the choice came down to between the company’s previous supplier and Vecoplan. Although he notes that both company’s make top-notch grinders, Vecoplan’s solution was easier to automate and came from one supplier.

“They put together a package, you have the conveyor, the shredder and the grinder,” he explained. “It was more a matter of convenience...we have one supplier of one full system, so they have more ownership over the product.”

Vecoplan, LLC (High Point, NC); www.vecoplanllc.com Greg Parent (Toronto); 416-678-0154

additives

ADDITIVES GO

GREEN T hese days, it seems everyone wants to be seen to be “green,” and, given increasing demand from consumers for products that are biodegradable, renewable, and less dependent on fossil fuels, plastics processors are certainly no exception.

The high expectations shared by processors for biopolymers — materials derived at least in part from biological activity — are being satisfied by a slew of new bio-based or “all-natural” additive masterbatches, fillers and colourants, designed for use in biopolymers such as polylactic acid (PLA), as well as other eco-friendly plastics.

GETTING TOUGH ON PLA

With environmentalism on a rapid rise, more and more plastics product developers are seeking additive masterbatches that are both biodegradable and renewable.

Suppliers are responding with products designed to improve the strength and processibility of biopolymers, as well as brighten up recycled materials.

By Mark Stephen, managing editor

Stiff, strong and clear, bio-based and biodegradable PLA is a popular choice among processors and end-users looking for environmentally friendly plastics. The material also poses problems, however. Brittle and offering low heat resistance, it has low melt strength and high sticking tendency during processing, and can degrade quickly in the presence of moisture.

Several additives firms have recently introduced products to address these concerns.

Clariant Masterbatches offers several different functional ingredients its new CESA-natur product line, which is designed to improve PLA melt strength and allow larger and more stable bubbles during extrusion, even at higher line speeds. According to Clariant, the product also produces smaller and more resilient cells in foamed PLA. CESA-natur uses a chain extender called CESA-extend to re-link polymer chains broken by degradation in PLA. The additives can also be formulated for use in conventional polymers as alter-

natives to non-renewable additives.

CESA-natur masterbatches include slip/antiblock agents, UV/light stabilizers, antioxidants and antistatic agents, and feature a biopolymer carrier resin. According to Clariant, CESA-natur slip additive masterbatches are based on naturally occurring waxes, and perform well in PLA film applications, with only a marginal influence on transparency.

The company’s CESA-natur light masterbatches, meanwhile, are designed to provide light stabilization in both conventional resins and biopolymers, and can also function as UV filters to protect the contents of packaging made of PLA. Based on aromatic molecules, CESA-natur light additives use naturally occurring ingredients, and Clariant claims to offer improved UV protection with this masterbatch series.

“In the past, the natural compounds chosen for UV protection have been coloured and usually show low thermal stability at processing temperatures above 200°C,” the company said. “The newest CESA-natur light masterbatches, however, are formulated from light-coloured substances that are substantially more heat stable and offer UV protection comparable to conventional synthetic UV absorbers.”

Arkema is also attempting to tackle problems relating to the processing and performance of PLA. The company recently released two impact modifiers based on familiar core-shell technology, designed to double the toughness of PLA. Biostrength 130 and Biostrength 150 are core-shell impact modifiers for PLA. Biostrength 130 is intended for use in translucent or clear applications, while Biostrength 150 is a higher efficiency modifier for use in opaque applications.

www.canplastics.com July/August 2008 Canadian Plastics 29

additives

According to Arkema, both additives double the Gardner Impact at loadings as low as two per cent.

The company’s Biostrength 700, meanwhile, is a clear acrylic copolymer that enhances processability of PLA for use in sheet extrusion, calendering, blow molding, thermoforming and foamed applications, and also doubles the melt strength at four per cent loadings. Improved melt strength and melt elasticity provide a wider processing window for extrusion, reduce parison thinning in blow molding, assist deep-draw thermoforming, and provide a more consistent cell structure in foams.

PolyOne Corporation recently launched two new additives for biopolymers, one of which is also designed to enhance PLA. OnCap BIO Impact T is a transparent impact modifier masterbatch for PLA intended to increase the impact resistance of the base polymer while maintaining transparency.

Based on 100 per cent renewable resources, the company’s OnCap BIO Anti-fog T, meanwhile, is designed to prevent the occurrence of fogging on the surface of film packaging, enhancing the shelf appearance of chilled, pre-packaged foods. Also, by preventing the formation of small water droplets, the additive can extend product shelf life by preventing food deterioration, PolyOne said.

COLOUR CONCERNS Another traditional challenge of molding with PLA has been achieving bright, lasting colours. Here, too, improvements are on offer.

Teknor Color Company recently released three series of colourants for use with PLA resins and blends, designed to help manufacturers of packaging, bags, liners and other extruded or injection molded products that are biodegradable and based on renewable resources. The company’s PLA-carrier concentrates are for use in all biodegradable applications; the biodegradable co-polyester-carrier concentrates have a petrochemical carrier resin and are recommended for biodegradable blown film and other applications requiring greater flexibility than is produced by 100 per cent PLA formulations; and its PETek polythylene terephthalate (PET)-carrier

FLAME RETARDANTS, WPCs AND MORE

Teknor Color Company recently released three series of colourants for use with PLA resins and blends, designed to help manufacturers of packaging, bags, liners and other extruded or injection molded products that are biodegradable and based on renewable resources.

Photo Credit: Teknor Color Company

concentrates are for non-degradable applications where use of a biopolymer base resin such as PLA is desired, such as toys or housewares.

Concentrates in all three series are available as customer formulations in a wide range of colours, according to John Politis, director of marketing.

Clariant Masterbatches is also stepping up to the challenge of colouring PLA, as well as other biopolymers. The company’s RENOL-natur colour masterbatches are designed not only for PLA, but also for polyhydroxyalkanoates (PHAs) and starch-based materials. According to the company, the RENOL-natur Series contain only natural, renewable and completely biodegradable resins and colourants derived mainly from plants. The colours include red (derived from the cochineal insect), orange (derived from the turmeric spice plant), yellow (derived from a tropical flower) and green (derived from chlorophyll and other plant sources).

The RENOL-natur line complements the company’s Enigma colour and masterbatches, aimed at removing the murky grey colour that often comes with recycled resins, particularly in bottles using high levels — up to 100 per cent — of post-consumer recycled (PCR) high density polyethylene (HDPE). Available in translucent blue, red pearl and green pearl, these additives are designed to product bright colour with high PCR levels.

30 Canadian Plastics July/August 2008 www.canplastics.com

Also dipping a green toe in the water is Chemtura Corporation. Under the slogan “Greener is Better”, the company has introduced several new bio-based additives.

Mark OBS (organic-based stabilizers), intended for flexible polyvinyl chloride (PVC) automotive and flooring applications, are described as the industry’s first non-heavy metal heat stabilizers, and as being more cost-effective as a stabilizer than calcium zinc.

The company’s Weston NPF 705 is a drop-in liquid replacement for tris(nonylphenyl) phosphite (TNPP), an industry-standard secondary antioxidant used in linear low-density polyethylene (LLDPE) and HDPE applications such as consumer and industrial packaging, and household goods.

Naugard 300-E styrene monomer inhibitor, which uses dinitro-type polymerization inhibitor (DNBP) for scavenging of radicals, is designed to control and improve the efficiency of styrene monomer processing, especially compared to Tempo-based products.

In the realm of flame retardants, the Firemaster 800 Series for flexible PU foam are 10 per cent more efficient than the company’s predecessor additives. Each has been designed to provide a good environmental profile and is non-scorching in such applications as automotive and furniture manufacturing.

Chemtura is also tapping into the growing wood plastic composite (WPC) market with its Polybond 1103 and Polybond 3029 coupling and lubricating agents, designed to allow the use of more recycled wood in CPL the composite.

Resource List Arkema Canada Inc. (Oakville, Ont.); www.arkemagroup.ca; 800-567-5726 Chemtura Corporation (Middlebury, Conn.); www.chemtura.com; 203-573-2000 Canada Colors & Chemicals Ltd. (Toronto); www.canadacolors.com; 905-454-6900 Clariant Masterbatches (Toronto); www.clariant.masterbatches.ca; 800-265-3773 PolyOne Distribution Canada Ltd. (Mississauga, Ont.); www.polyone.com; 888-394-2662 Teknor Apex Company (Pawtucket, R.I.); www.teknorapex.com; 800-556-3864

Lonza, The Additives Edge

速

The Edge in Plastics: For more than 50 years, Acrawax速 C has been the lubricant of choice for a variety of plastics, providing an exceptional balance between internal and external lubricity, improving process throughput and reducing energy requirements. Acrawax速 C is also widely used as a dispersing aid for pigments and other additives, and as a lubricant for Wood-Polymer Composites.

The Edge in Wood-Polymer Composites: Glycolube速 WP-2200, an improved all-organic lubricant for Wood-Polymer Composites, provides increased extruder output with excellent surface appearance, and can be used in conjunction with coupling agents without the interference that comes from metalcontaining lubricant systems.

Contact your local Lonza representative for more information.

Lonza Inc., 90 Boroline Road, Allendale, NJ 07401 Technical Service: 800.365.8324 Customer Service: 800.631.3647 www.lonza.com

technology showcase

AUXILIARY EQUIPMENT

Dryers available with energy rating Wittmann has introduced a comprehensive testing program to establish energy ratings for their Drymax dry air dryers.

Developed after several years of research, this standardized rating method is based on stringent test conditions that provide repeatable results for the actual energy use.

Traditionally, establishing the energy consumption for many plastics processing products means using internal company measuring methods that naturally differ from each other, and can be overtolerant when it comes to interpreting data.

Wittmann’s system, in contrast, looks at internal moisture content of the resin and the ambient conditions, and uses airflow as the common property. This allows the company to define the actual energy rating as the basic energy consumption per mass flow of air.

To further test the validity of the result, Wittmann compared actual test results with theoretical values.

Once tested, every dryer model will be labeled with an Energy Sticker showing the measured test result in terms of kWh per unit weight of dry air.

Wittmann Canada Inc. (Richmond Hill, Ont.); www.wittmann-canada.com; 888-466-8266

Expanded line of single-axis actuators Misumi USA, Inc. has announced a major expansion to its line of singleaxis actuators, designed to provide precision linear motion to packaging, medical, semiconductor, automotive and other automated assembly operations.

On the LX Series, Model LX30 is now available with or without a motor bracket, with one or two short blocks, or one or two long blocks. All the configurations are available in a covered version, as well. In addition, a new Model LX45 was introduced in July, 2008, with or without a cover, with or without a motor bracket and in the same block configurations as the LX30. The LX45 further features a 15mm or 20mm lead and a maximum length up to 590mm. Maximum stroke length is 497.9mm for one short block. Brackets are now available on LX Series single-axis actuators to allow a combina32 Canadian Plastics July/August 2008 www.canplastics.com

tion of two units on a different axis. LX Series models will be available in 1,000 possible configurations, up from 200 in the original series.

Misumi USA, Inc. (Schaumburg, Ill.); www.misumiusa.com; 800-681-7475

ROBOTS & AUTOMATION

Seven-axis robot arm Motoman’s new SIA20 (slim, individual arm) robot features a seven-axis design with best-in-class wrist performance characteristics that enables freedom of movement, coupled with the ability to maneuver in very tight areas.

The compact SIA20 has a 16 per cent smaller footprint than the previous IA20 model, as well as five times faster acceleration for improved cycle times, and is ideal for assembly, injection molding, inspection, machine tending and a host of other operations.

The SIA20 robot features a 20 kg (44.1 lb.) payload, 1,498mm (59 inch) vertical reach, 910mm (35.8 inch) horizontal reach and a repeatability of ±0.1mm (0.00 4 inches). It can straighten vertically to take up only one square foot of floor space and is just 330mm (13 inches) wide at the widest point.

Short axis lengths and motion flexibility allow the slim manipulator to be positioned out of the normal working area (i.e. floor-, ceiling-, wall-, incline- or machine-mounted) without limiting the motion range of any axis. Mounting the SIA20 robot between two machine tools provides open access to the machines for fixture maintenance, adjustment or testing. Additionally, the operator has clear access to the machine operator station for entering offsets, maintenance or other operations.

The SIA20 robot is controlled by the Motoman NX100 robot controller that features a robust PC architecture, Windows CE programming pendant, and easy-to-use INFORM III programming language.

Yaskawa Motoman Canada Ltd. (Mississauga, Ont.); www.motoman.com; 905-569-6686 (Pointe Claire, Que.); 514-693-6770

EXTRUSION

Slitter for film and sheet extrusion Parkinson Technologies Inc. announces the release of its new model DRS dual razor slitter for film and sheet extrusion applications.

The new DRS features numerous improvements over other commercially available slitters. It’s a low-maintenance, costeffective alternative to more complex and typically expensive

technology showcase

dual-slitter designs.

The new Parkinson DRS has a design ensuring the dual blades are completely guarded whether they are retracted or extended, greatly reducing the chance of operator injury.

Additionally, either of the two blades can be installed or removed simply and without tools, as the DRS is designed so the blades are held in place magnetically. Also, the blades can be changed without interrupting the slitting process.

The DRS mounts on a standard dovetail bar, so it can be used as a retrofit slitter on other non-Parkinson winders. It can also accommodate other mounting options.

With a lower profile and more compact design than previous Parkinson slitters, the DRS is also designed to slit as narrow as 1.5 inches.

Parkinson Technologies Inc. (Woonsocket, R.I.); www.parkinsontechnologies.com; 401-762-2100

MATERIALS

Glow-in-the-dark plastics for rotational molding Chroma Rotational Molding has introduced a new light stable photoluminescent material, designed to enhance and differentiate rotationally-molded life safety applications through custom tailoring for glow longevity and brilliance.

Offered in a mini-pellet form that can be introduced directly into the mold, Chroma Glow has been measured at over 32 hours of glow, in testing performed by independent laboratories.

Suitable for both indoor and outdoor applications, products in the Chroma Glow line are currently available in blue or green glow, and can be custom formulated to comply with select photoluminescence glow standards.

Chroma Rotational Molding Division Inc. (McHenry, Ill.); www.chromarmd.com; 815-385-8100

Agreement launches special effect masterbatches A recent North American sales and marketing agreement joins Clariant Masterbatches’ effects technology with the unique ClearTint transparent colourants from Milliken & Company, and makes those masterbatches available even in small lot sizes.

The Milliken colourants will be offered under the ENIGMA

brand name in a wide range of transparent colours and in combination with reflective special effects.

These include iridescent pearls and Spectrachrome, a high-end multicolor flip technology incorporating complementary or contrasting color particles.

To mark the announcement of this marketing agreement, Clariant will be producing molded samples using three distinctive ClearTint colours: bright green, dark purple and fuchsia.

Each colour will be presented using the colour alone, with iridescent pearl effect, and with Spectrachrome.

Clariant Masterbatches Division (Toronto); www.clariant.masterbatches.com; 416-847-7000

MOLD TECHNOLOGY

Temperature sensor for inside mold cavity RJG Inc.’s new Press Fit Cavity Temperature Sensor is designed 1:45 PM tochillersIncTowerAd:towerCellAd work in conjunction with RJG’s eDART2/12/08 Process Control Sys-Page

Fiberglass Construction for Long Service Life

TC-405F, 405 ton multi cell shown TC-45F, 45 ton single cell shown

Advantage cooling towers feature UV stablized fiberglass construction, stationary PVC water distribution header, ABS wet deck, large size inspection covers and structural steel base.

Call for more information.

Chillers, Inc. is the exclusive Canadian representative of

Advantage Engineering, Inc. 525 East Stop 18 Road Greenwood, IN 317-887-0729 fax: 317-881-1277 website: www.AdvantageEngineering.com email: sales@AdvantageEngineering.com

1228 Gorham St. Unit 11 Newmarket, Ontario Canada L3Y7V1 905-895-9667 fax: 905-895-5177 website: www.ChillersInc.com email: sales@ChillersInc.com

www.canplastics.com July/August 2008 Canadian Plastics 33

1

technology showcase

of the part can show problems with nonuniform cooling.

RJG Inc. (Traverse City, Mich.); www.rjginc.com; 231-947-3111 Dier International (Unionville, Ont.); www.dierinternational.com; 905-474-9874 KLA (Kitchener, Ont.); 519-894-0164

tem to assist molders in diagnosing processing problems relating to temperature issues inside the actual mold cavity.

The press-fit cavity temperature sensor is simple to install, by drilling a small hole for the wire, and a flat-bottomed pocket with the tolerance necessary to press fit the device in from the cavity face. Locate the sensors near areas where short shots, dimensional errors or warp are likely to occur. Placing sensors in different areas

34 Canadian Plastics July/August 2008 www.canplastics.com

TESTING EQUIPMENT

and storage of up to 600 test results. A backlit LCD displays instructions for the test in a variety of languages as well as the results. An RS-232 interface allows connection to a computer for downloading of results or for fully automated software control using NEXYGENPlus PET. Ametek Test & Calibration Instruments (Albany, N.Y.); www.ametektcia.com; 518-689-0222

Lloyd Instruments, a unit of Ametek Measurement & Calibration Technologies, has launched the Davenport PETPlus intrinsic viscosity measurement instrument, a compact stand-alone unit designed to determine the intrinsic viscosity (IV) of moisturesensitive PET polymers, avoiding both the costs and the environmental hazard of handling and disposal of toxic solvents.

The PETPlus also measures the degradation factor and provides the mean and standard deviation for each batch.

The PETPlus can test polymers at virtually all stages of the production process to provide greater overall control. Tests can be completed in as little as 20 minutes on incoming resin, powder, dry granules, molten polymer, pre-forms, bottles, films and even re-ground material to eliminate scrap.

The microprocessor controlled standalone system provides high accuracy measurements, temperature control to + 0.1째C

The Computrac MAX 5000XL from Arizona Instrument LLC is the next generation of bench top moisture and ash analyzers, featuring a new temperature controlled balance and high temperature lift compensation algorithm that provides users with more stable and accurate measurements.

The new instrument also features a temperature ramp control feature that allows the MAX 5000XL to be used for qualitative analyses that were previously only possible using a thermogravimetric analyzer (TGA).

The new MAX 5000XL features the same intuitive user interface and rugged design as its predecessor t h e MAX 5000. Improvements to the design and high temperature performance of the balance system of the MAX 5000XL now make it possible to accurately analyze materials with ash concentrations of as little as 0.5 per cent.

The calibrated, instrument specific, high temperature lift compensation algorithm replaces the static lift compensation factor of previous models, resulting in more precise readings during ash / L.O.I. analyses.

Arizona Instrument LLC (Tempe, Az.); www.azic.com; 800-528-7411 Tracelogix Inc. (Richmond Hill, Ont.); www.tracelogix.com; 905-882-8000

Measurement Next generation instrument for moisture-sensitive PET moisture analyzer

plastics data file

Get free information from the companies that interest you most.

Contact the company directly using the telephone number, e-mail address or web site listed below

GRANULATORS

The Lorenz In-Line Angel Hair Trap Designed to mount in the material stream to collect “angel hair�, “streamers or “snake skins� while allowing the pellets to pass through. r 5IF DMFBS WJFXJOH DPWFS GPS MFWFM JOEJDBUJPO DBO CF RVJDLMZ SFNPWFE GPS DMFBO PVU r 'PS VTF JO WBDVVN MJOFT QSFTTVSF DPOWFZJOH systems r 5ISFF TUBOEBSE CPEZ TJ[FT BSF u u u XJUI MJOF TJ[FT GSPN PE VQ UP u PE r #PEZ DPOTUSVDUFE PG HBVHF TUBJOMFTT TUFFM r $POOFDUT UP UIF MJOF XJUI DPNQSFTTJPO DPVQMJOHT

High performance low speed screenless granulators and compact conventional granulators offer the highest quality regrind, superior safety features and performance.

A wide range of models ensure the best granulator for your application.

Wittmann Canada, Inc., 35 Leek Crescent, Richmond Hill, ON L4B 4C2; Tel. 1-888-466-8266; www.wittmann-canada.com

Lorenz 1-800-263-1942 or 905-372-2240 Email: sales@lorenz.ca www.lorenz.ca

advertising index Advertiser Arburg Canadian Plastics Resin Conference CanPlastics TV Chillers Inc. Clariant Masterbatches Compact Mould Ltd. CPIA APAC CPIA Expoplast Haremar Hosokawa Alpine American Kreator Lonza,Inc. Macro Engineering & Technology Inc. Polyone Shini Plastics Technologies (Canada) Inc. Rotogran International Inc. Vortex Valves Weima America Inc. Wittmann Canada Inc.

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Telephone

E-mail

Website

860-667-6500 usa@arburg.com 416-510-5116 jnancekivell@canplastics.com 416-510-5116 jnancekivell@canplastics.com 905-895-9667 sales@chillersinc.com 888 621-1282 905-851-7724 info@compactmould.com 450-641-5923 dlacas@acipquebec.cd 905-678-7748 ext 283 tsockett@cpia.ca

905-761-7552 info@haremar.com 508-655-1123 519-941-7876 sales@kreatorequipment.com 800-777-1875 contact.allendale@lonza.com 905-507-9000 sales@macroeng.com 888-394-2662 905-565-1602 sales@shini.ca 905-738-0101

info@rotogran.com 785-825-7177 rbarragree@vortexvalves.com

803-802-7170 info@weimaamerica.com 888-466-8266 info@wittmann-canada.com

www.arburg.com www.canplastics.com www.canplastics.com www.chillersinc.com www.clariantmasterbatches.com www.compactmould.com www.apacinternational.net www.expoplast.org www.halpine.co www.kreatorequipment.com www.lonza.com www.macroeng.com www.polyonedistribution.com www.shini.ca www.rotogran.com www.vortexcanada.com www.weimaamerica.com www.wittmann-canada.com

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MAchinery & equipment

MAchinery & equipment INJECTION MOLDING

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4/8/08

1:33 PM

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design ideas • celebrating unusual applications

Polyethylene dinosaur hits the road

Polyurethane coating helps art stand up to tough critics It’s one thing to protect a work of art in the controlled environment of a museum. It’s another when the art is on outdoor display on a resort beach.

And it’s harder still when the sand itself forms the artwork.

When the European Union staged an art exhibit along the Belgian coast of the North Sea, sculptor Santiago DeWaele used lightweight Styrofoam to create a huge sand sculpture on one beach in the town of Oostende. He also turned to Chemthane 7000, a spray-applied twocomponent polyurethane coating, to provide a layer of protection to the object.

Designed to provide long term durability and high impact resistance, Chemthane 7000 forms a hard, chemical, moisture and fire retardant shell when spray-applied directly over the Styrofoam. The material dries to the touch within 10 seconds, and adds almost no extra weight to the substrate when cured.

“After several months of constant exposure to sand abrasion, wind, rain and the activity of playful children, Chemline 7000 did not crack, dent or crumble,” said DeWaele.

Chemline Inc. (St. Louis, Mo.); www.chemline.net; 314-664-2230

After 77 million years, a mummified dinosaur is slated to go on tour this year for display at museums throughout the U.S., thanks in part to multifunctional and hybrid resins from Huntsman Advanced Materials.

The exhibit is a high-quality stereolithography model of a rare 22-foot-long fossil of a mummified duck-billed dinosaur that was unearthed in Montana and dubbed “Leonardo”. Consisting of 30 different polymer blocks, the model was created from data produced by a white light scan of the dinosaur, accurate to 0.25 mm, and includes intricate details such as skin, scales, muscle and foot pads.

Among the materials used for the model are Huntman’s RenShape SL 7510 multifunctional resin and RenShape SL 7800 and SL 7810 hybrid ABS-like photopolymers. According to Huntsman, the SL resins allow for replication of intricate fossil details as small as a grain of sand. Additionally, the amber-coloured SL 7800 and white SL 7810 resins reduced processing time with good green strength.

When assembled, the painted polyurethane dinosaur will be virtually indistinguishable from the mummified Leonardo fossil, and will be tough enough to withstand the rigours of shipping and handling during the multi-location tour.

Huntsman Advanced Materials (The Woodlands, Tex.); www.huntsman.com; 888-564-9318

Acrylic sheet brings people and chocolate together They say you are what you eat. M&M Chocolates has gone one better; using acrylic manufactured by Cyro Industries, they’ve now made it possible to resemble what you eat.

When M&M’s World New York opened its doors in Times Square last fall, it featured as its centrepiece the so-called “Make-Your-Mix” Colour Mood Analyzer. An interactive display designed to match a visitor’s personality to one of the hundreds of specialty M&Ms’ colours, the Colour Mood Analyzer incorporates the Confetti pattern from the Sterling Collection of Cyro’s Acrylite acrylic sheet.

Equipped with a digital scanning tool, the analyzer scans the participant’s body, projecting their video image onto a large screen. The analyzer then displays the person’s customized M&M’s colour, complete with a descriptive statement about their personality.

The effect was made possible by the reflective metallic-looking properties of the Confetti sheet. “We clamshelled large cylindrical pieces of the Confetti sheet around a large structural column, measuring three feet in diameter, which was covered in a wooden frame,” explained Brian Shafley, managing engineer of the project. “In addition to adhering well to the frame, the acrylic material is also lightweight and can be easily shaped, providing an advantage over alternative materials like prismatic glass lenses, which are difficult to mold.”

Cyro Industries (Parsippany, N.J.); www.cyro.com; 800-631-5384 www.canplastics.com July/August 2008 Canadian Plastics 37

view from the floor

Cooling Considerations

By Jim Anderton, technical editor

P

lastics is a simple business...add heat, squeeze into your desired shape and take heat away. One of the consequences of the Laws of Thermodynamics (which, if you’re lucky, you will never have to know) is that putting heat into things is an easy task. Electrical resistance adds heat, as does friction between resin and barrel/screw as well as the heat rise from the compression of the melt in the barrel.

Ever rub your hands together on a hot day to cool them off? That’s the dark side of thermodynamics: as easy as it is to put heat in, it’s a little harder to take heat out...in fact in engineering terms, it’s impossible.

You can, however, move it from place to place, which is the job of chillers. For one of the more controllable variables in the molding process, it’s a little underappreciated, although there are ways to create needless cost and frustration for the careless or unaware. Inconsistent cooling or inadequate mold cooling is, surprisingly to many, rarely caused by a breakdown in the chiller itself.

Chillers can fail, but they’re simple machines at heart and as most suspect, they’re

38 Canadian Plastics July/August 2008 www.canplastics.com

Jim’s Tip of the month:

Most “mother” and driver boards on modern computer-controlled equipment use phenolic cA fin comb is a simple, cheap hand tool that lets a tech quickly restore the contour and separation of condenser fins without damage. Clean the condenser, and then work gently from an undamaged section into the flattened area, rocking the tool slowly from side-to-side.

The key is to manipulate the aluminium as little as possible during straightening, to prevent the metal from work hardening and breaking or tearing. A few cracks in fins are nothing to worry about, but if major sections are missing, cooling performance will be compromised.

Condenser replacement needs a refrigeration tech; most plant maintenance personnel can’t do it in this age of licensing for ozone-depleting substances, so a little care at the condenser can save lots of money and aggravation later.

related to process cooling as well as food refrigeration equipment. So how come your home fridge never needs maintenance, lasts 25 years and only costs $600?

Because it’s similar, but different. The main difference is that the refrigerant loop cools a working fluid, which in turn cools the mold. The obvious question is, where do you look when the mold won’t cool properly? I start simply...with my eyeballs.

How much fluid leakage is acceptable?

None, yet I’ve seen bonus-hungry operators tie a rag around a bleeding manifold and keep going rather than call me for a repair.

The fluid loop must have adequate volume to transfer heat properly. The second common mistake I’ve seen involves portable chillers. Remember where I said that you don’t remove heat, you move it?

Where it’s removed is a radiator-like component called a condenser. Push the chiller up against a wall, stack cartons against it or block the air flow through the unit and you will have poor cooling performance.

Similarly, the tiny fins of the condenser are easy to clog with dirt and grease, also blocking cooling air. The solution is simple: clean the condenser.

In a perfect world, I’d flush with a garden hose from behind, but there is enough electronics in the cabinet these days to make this a really bad idea. Compressed air (from the

inside out!) and spray solvents designed for electrical work are good, as is a small stiff bristle brush. Clean is good, but so is straight. The tiny fins aren’t there for show; each one is a tiny radiator, rejecting heat to the ambient air. Smash the fins flat and they can’t get the flow of air needed to surround every square millimetre of fin surface area.

This is more common than most molders realize and it gets worse if the millwright or mechanic fails to replace the guard after service or cleaning. If your fins are beaten up, there’s a simple tech tip below to get them working again. Chiller manufacturers have made the guts of their units so robust that many jobs shops treat their portable chillers like the forklift...out of sight, out of mind, but see what happens when you don’t have one available! cpl

JIM’S BUZZWORD OF THE MONTH: Dielectric Strength (dyeee-lek-trik strength)

The property of a material that describes its resistance to electrical breakdown or “shorting out”. It’s a key parameter for insulating materials and it’s dependent of the material properties, thickness and the way the test electric field is applied. For electrical applications, it’s possibly the most important property.

4QFDJ¾DBUJPOT TVCKFDU UP DIBOHF XJUIPVU OPUJDF 1SPEVDU OPU TIPXO BDUVBM TJ[F

for more information.

• Call 1- 888-466- 8266

• Fits beside the press.

• High quality regrind.