Canadian Plastics May/June 2009

CanadianPlastics NPE2009 LEADER PREVIEW OF THE www.canplastics.com

YEAR

Westbridge PET’s Dave Birkby PLUS:

CANPLAST AWARDS

What to expect

HOT RUNNERS

The benefits of unitized systems

CHILLERS & TCUs New & cool

PRODUCT DESIGN

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contents

CanadianPlastics MAY/JUNE 2009 VOLUME 67 NUMBER 4

LOOKING BACK...

The October 1980 issue of Canadian Plastics reported on St. John’s, Nfld.-based PET processor Wometco. The sole holder of the CocaCola franchise in Labrador and Newfoundland, the company was also the first to produce 1.5 litre bottles in eastern Canada. Wometco, which used a Nissei machine to form the PET parison, credited the province’s lack of a policy regarding soft drink bottle returns for a surge in product demand.

page 29

Number of the month:

*31

*Number of companies that have joined new manufacturing consortium XAG Energy, as of press time. (See pg. 6)

page 10

page 37

Cover Photo Credit: Mark Mennie Photography

cover story 4

Editorial • “Made in Canada” — Worth bragging about

5

Ideas & Innovations • New strides in natural plastic bottles

6

News • Windsor manufacturers harness the winds of change • Arburg Technology Days 2009 • Plast 09 • People

9

Executive’s Corner • Preparing for the harmonized tax in Ontario

31 Technology Showcase 35 Advertising Index 35 Plastics Data File 36 Classifieds 37 Design Ideas • Earth, Wind & Fire 38 View from the Floor • Adsorbing Reading

10 CPIA LEADER OF THE YEAR Dave Birkby, president and CEO of Westbridge PET Containers, has spent virtually his entire working life in the plastics bottling business. Along the way, he’s obtained a couple of university diplomas, risen through the corporate ranks, moved halfway across Canada, bought a company...and still found time to volunteer for a variety of industry associations. No wonder he’s just been named as the CPIA’s 2009 Leader of the Year.

PLUS: Bios of the 2009 CanPlast Award winners.

features

16 NPE2009 PREVIEW With the economy in turmoil, and many plastics processors and manufacturers struggling to stay afloat, chances are this latest version won’t be your father’s NPE. Inside, we talk with a range of exhibitors to find out what they expect to encounter in Chicago this June.

PLUS: A look at some of the bioplastics developments you’ll see at the show.

22 PRODUCT DESIGN Wondering what an article about design is doing in a plastics magazine? Then you need to learn more about the importance of a good design in helping to sell your product. But don’t take our word for it — inside, we talk to the experts.

26 HOT RUNNERS These days, if you’re not using hot runners, you’re not making serious plastic parts — and buying an easy-to-install, easy-to-maintain unitized hot runner system just got easier.

29 CHILLERS & TCUs For processors looking for an edge — and who isn’t? — chillers and TCUs are more innovative and energy-efficient than ever. Canadian Plastics brings you the latest in process cooling.

Visit us at www.canplastics.com www.canplastics.com May/June 2009 Canadian Plastics 3

editorial

“Made in Canada” — Worth bragging about

R

ecently, we attended an annual open house at the headquarters of injection molding machine supplier Arburg Inc. in Lossburg, Germany. (A full write-up on the event is on pages 7-8 if you’re interested; a video of the visit is at http://www. canplastics.com/video/episode24.asp if you’re really interested.)

We had also attended last year’s open house at the same facility, and often speak with, and work with, many other European companies as part of our editorial coverage. Every time we speak with these manufacturers, I’m struck by how proud these companies — suppliers and processors alike — are of their unique local histories.

Many of the business leaders that we’ve worked with from across the Atlantic won’t hesitate to talk at length about how their companies came to be, and of the deep ties their corporation has with the region.

Having worked in the Canadian plastics industry now for a couple of years, I do have to say that this sense of national pride is a bit harder to find amongst Canadian manufacturers. Don’t get me wrong: we’re definitely very proud of where we come from. But when it comes to doing business, we just don’t seem to talk about our country, and cities there in the same way as some of our European friends.

As I leave the magazine — this will be my last issue as an editor for Canadian Plastics — the stories that stick with me the most are the company and leader profiles we’ve done over the last two years.

These pieces allowed us to present the local histories of companies and people, showing their deep ties to Canada.

By our very name, we are a magazine about plastics. But the first half of our magazine’s name, the “Canadian” part, is often implicit. We talk about Canadian companies, and cover the important issues that are of significance to Canadian manufacturers. But we rarely have the opportunity to talk about the importance of 4 Canadian Plastics May/June 2009 www.canplastics.com

being Canadian, and keeping production in Canada.

Let’s be straight: I’m not talking about being more protectionist here, though the recent wave of protectionism is definitely part of my thinking. As disgruntled consumers and laid-off workers redirect their anger at big business, companies like Toyota are running ads touting their Canadian production. What better time is there to be seen as a Canadian company, with local origins and strong regional ties?

This isn’t just about some romantic idea of nationalism. The European companies mentioned above do business internationally, but also talk about where they come from. And I believe that this is a part of what makes them so successful.

At an industry meeting last year, a marketing consultant put Canada on graphs with many of our competitors, rating us in areas like cost, quality, stability, et cetera.

Not surprisingly, Canada ranked high on almost all the counts.

Sure, maybe we can’t compete on cost against many low-cost regions, but we usually have them beat when it comes to technology and innovation. Our country has a strong infrastructure and a stable political climate, and we can provide significant inroads into the North American market.

On top of all of that, we have strong trade ties with almost every major international market, a qualified workforce, and a competitive dollar.

And despite this significant advantage, many companies still seem reticent when it comes time to talk about their history.

From where I stand, our strongest companies don’t just tell their customers that they are “proudly Canadian.” They use it as a selling point.

In parting, I’d like to thank everyone in this industry who shared their know-how and experience with me. But I’d especially like to thank the business leaders who taught me how important it is, at least from a manufacturing perspective, to be Canadian.

Umair Abdul, assistant editor

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

www.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 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 ADVERTISING SALES REPRESENTATIVE Brayden Ford 416-510-5124 Fax: 416-510-5134 E-mail: bford@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 8 times a year by the

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ideas and innovations

New strides in recycling natural plastic bottles

By Mark Stephen, managing editor

P

lastic bottles made from bioresins are no longer new. Nor, however, are concerns that natural plastic bottles are prohibitively difficult to sort from standard polymer bottles during recycling procedures.

Biopolymer supplier NatureWorks LLC now suggests this is a non-issue.

Following an extensive analysis of current technology, NatureWorks has concluded that automated systems being used today in the recycling industry are capable of sorting natural plastic bottles from other plastic bottles with an accuracy approaching 100 per cent — and that, therefore, there is no technological barrier to recycling bottles made from plants instead of oil.

“To become more sustainable, the packaging industry must lower the overall waste, energy consumed, and greenhouse gas emitted from the use of plastics, metals, and fibres,” said Steve Davies, NatureWorks’ director of communications and public affairs. “Demonstrating that natural plastic bottles can be brought seamlessly into the recycling steam through the use of automated sorting equipment available today is a major finding and another step towards greater sustainability.”

the equipment is programmable to identify Ingeo and sort with high accuracy.

Bolstering these assessments, WRAP, a not-for-profit waste reduction company based in the U.K., conducted an assessment of its own. Published in June 2008, Domestic Mixed Plastics Packaging Waste Options, WRAP concluded that, “NIR (nearinfrared) systems can effectively remove PLA bioplastic and carton board from a mixed packaging stream.”

“Accurate sorting is at the heart of making recycling an economically viable business because the recycling operation must be able to separate materials into pure streams — aluminum separated from steel or PET and HDPE plastics from other polymers,” Davies said. “Based on our own work and the analysis of WRAP, we know now that automated systems on the market today can sort natural plastics within industry accepted norms.”

NatureWorks LLC (Minnetonka, Minn.); www.natureworksllc.com; 1-800-664-6436

SURVEY SAYS...

During the past two years, NatureWorks has surveyed equipment manufacturers that have systems with the potential to sort biopolymers from such other plastics as PET, HDPE, PVC, and PS. These sorting systems are usually based on one or more of the following technologies: infrared, ultraviolet, x-ray, colour identification, and laser. NatureWorks has identified a dozen companies offering systems than can potentially sort bioresins and has worked closely with three to ascertain actual sorting accuracies.

Titech, an automated waste sorting manufacturer based in Norway, demonstrated the ability of its near-infrared sorting systems to eject concentrated amounts of NatureWorks Ingeo brand polylactic acid (PLA) plastic bottles in a PET sorting operation.

“Sorting efficiency in a single pass was found to be a minimum of 97.5 per cent accurate, a result that is consistent with sorting efficiencies for other materials the equipment ejects as contaminants or passes through as desired streams,” Davies said. German process analysis company Unisensor showed its laser technology was fully capable of sorting Ingeo flakes from desired PET flakes at efficiencies of 96 to 99 per cent, which is consistent with other plastics considered contaminants in the PET flake stream. And MSS, a Nashville, Tenn.-based supplier of automated sorting systems, tested Ingeo natural plastic in its Aladdin near-infrared system. According to Davies, the test confirmed that Ingeo emits a unique polymeric signature; that Ingeo comes up as “other plastics” in a system specifically designed to identify PET, PE, and other plastics; and that the “signature” of Ingeo means that

For complete product information Call Toll Free: Canada 1-800-263-1942 U.S.A. 1-800-263-7782 or VISIT OUR WEBSITE TODAY!

www.lorenz.ca www.canplastics.com May/June 2009 Canadian Plastics 5

news

Windsor manufacturers harness the winds of change

By Mark Stephen, managing editor

A

new cooperative venture spearheaded by two Ontario tooling industry veterans is hoping to go big by servicing North America’s growing renewable energy sector.

XAG Energy, founded by five Windsor, Ont. business leaders — among them Ed Bernard, formerly of Bernard Mould, and Cy McGrath, recently retired as Canadian general manager of Progressive Components — is intended to provide a single source of access to a network of Southern Ontario manufacturers, assemblers, construction professionals, and service providers capable of manufacturing such renewable energy products as wind turbines and other equipment.

According to Ed Bernard, now working for BDO Dunwoody identifying SR&ED tax refunds, the consortium is intending to take advantage of the skills and resources of existing moldmakers and others that have been hurt by the slowdown in the automotive industry. “Our network currently includes companies that specialize in moldmaking, metal cutting and forming, injection molding, composite forming, and many other specialties, as well as logistics capabilities, and service providers such as surveyors and contractors,” he said. “Also, we have access to extensive and surplus plant capacity for assembly of major and minor components, many with large overhead cranes and climate-controlled facilities.”

EARLY STEPS Bernard and the other founders of XAG Energy — “XAG stands for ‘ex auto guys’”, Bernard said — have set their sights on

6 Canadian Plastics May/June 2009 www.canplastics.com

Ed Bernard (left) and Dave Woodall pose with model wind turbine in the foreground. (The real ones are considerably larger.)

wind turbines business as an early area of interest. “The average utility-size turbine can have more than 8,000 separate parts, from enormous turbine blades made of plastic to small interior components made of metal, and each part offers manufacturing potential for any company that has experience making precision components for the auto industry,” he explained.

The decision to focus on wind turbines was dictated partly by market demand, and partly by geography, said Dave Woodall, another of the consortium’s five founders. “Wind power has amazing potential; the use of turbines in North America is doubling every year, but the vast majority of turbines used here are imported from Europe, and this gives domestic manufacturers a real edge,” he explained. “Also, the Windsor area is considered one of North America’s best regions for wind power, and is ideally positioned in respect to the Great Lakes shipping system.” Woodall’s construction company has already done concrete foundation work at an area wind farm, and has more work scheduled.

XAG Energy set up headquarters in Oldcastle, Ont. in late April in the facility formerly occupied by Bernard Mould.

Cy McGrath is the first full-time, albeit unpaid, employee. Over 130 companies have joined the consortium, Ed Bernard said, with 31 of these having signed contracts for exclusive representation.

The organization is making its presence known in a variety of ways. “We’re now members of CanWEA, which is the Canadian Wind Energy Association, and have volunteered to have XAG representatives active

within the CanWEA Manufacturing Caucus,” Bernard said. Organization officials have also met with Green Party leader Elizabeth May to explain their vision, and with wind farm investor representatives, and turbine and solar panel designers. “We’ve also been working closely with an agency that’s in the process of establishing Canadian quality and audit standards that meet global requirements.”

GROWTH INDUSTRY Given the potential volumes predicted for wind power, Bernard said, XAG Energy isn’t overly concerned about finding enough work. “Our combined capabilities should allow us to complete projects quickly and at low costs,” he continued.

“Getting ourselves organized before our U.S. competitors do is a genuine challenge, however, and one that we’re focussing on right now.”

In the end, Bernard and Woodall see alternative energy manufacturing as more than merely a way of keeping tooling shops and others busy while they hope for the auto market to recover. “This is a market that has enormous potential for growth, and it’s looking for suppliers,” Bernard said. “The collapse of the automotive sector in North America was a perfect storm for us in the negative sense; the opportunity for Southern Ontario shops that serviced the Big Three automakers to transition into manufacturing for the wind-power sector is a perfect storm in the positive sense. We have the skills, the resources, and the location to grab a huge share of the North American alternative CPL energy market.”

news

Canadian plastics processors impressed by Plast 09 The Plast 09 trade show in Milan, Italy drew almost 56,000 visitors — among them a group of Canadian plastics processors traveling at the invitation of the Italian Trade Commission, and the Italian Plastic and Rubber Processing Machinery and Molds Manufacturers Association (ASSOCOMAPLAST).

The show, held in the Milan Fairgrounds from March 24 to March 28, is the second largest plastics and rubber processing technology event in the world, after Germany’s triennial K trade show. This year’s edition of Plast 09 was held simultaneously with IPACK-IMA, a trade show catering to the packaging industry. Two other international trade shows took place at the same time and venue: the Grafitalia 2009 show for printing machines, and the Converflex Europe 2009 show for converting technology. Taken together, the events offered visitors a broad view of complementary and ancillary technologies.

Arburg holds Technology Days event In the presence of over 4,000 customers and other industry insiders from throughout the world, injection molding machine supplier Arburg Inc. opened its new Customer Center in Lossburg, Germany, and also introduced new machinery lines.

The company’s 2009 Technology Days event, held from March 19 to March 21 in

Lossburg, marked the official opening of the 2,100 square meter Customer Center.

“At our Customer Center, we are now able to highlight the products and applications which have long featured in our range but have not yet been adequately presented,” said Michael Hehl, managing partner at Arburg. “The Center’s focal points will be customer tests and

WEIMA’s shredding, grinding and briquetting equipment can help your company reduce both its landfill footprint and bottom line.

Canadian processors, Italian Trade Commission members, and ASSOCOMAPLAST employees at the Plast 09 show.

Representatives from Canadian companies IPEX Inc., Plastic Packaging Comp. Inc., Stratus Plastics International Inc., Plastic Age Products Inc., and Go Plastics attended the event, and reported finding a wealth of new technologies and business contacts.

“I was very interested in downstream automation, especially automated bundling and packaging of pipe,” said Chris Ciszek, plant manager at IPEX Inc. “There were several world-class manufacturers of this type of equipment in Italy at the show, and this is something we definitely would be looking to put in our pipe plants in the future.”

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www.canplastics.com May/June 2009 Canadian Plastics 7

news

The new Arburg Customer Center.

personalized consulting on applications technology.”

Arburg also used the occasion to launch its new Allrounder H/Hidrive line of injection molding machines. According to Arburg, the units combine servo-electric and hydraulic components to offer reduced cycle times and energy savings of up to 40 per cent.

The company also announced the addition of two new sizes to its Allrounder A series injection molding machines. The Allrounder 270 A is the smallest size in Arburg’s range of electric machines, with a clamping force of 350 kN and size 70 injection unit. Additionally, the Allrounder 720 A has a maximum clamping force of 3,200 kN and a size 800 injection unit.

Want more on this story? Check out CanPlastics TV, at http://www.canplastics.com/video/episode24.asp

 ☛

PCS Company comes to Canada A wide range of people from the Windsor, Ont. tooling and plastics processing communities gathered on April 16 to attend a product showcase staged

by PCS Company, a Fraser, Mich.-based supplier of mold bases, pins and components, hot runner systems and special-made components. The company, which recently named Brian Campbell as PCS Company general manager Ed Mohrbach (left) and vice president of sales and marketing Len Harold. its sales manager for Canada, is in the process of expanding its presence in the Canadian marketplace.

AlphaMarathon sells 10-layer blown film line in China Woodbridge, Ont.-based blown film equipment supplier AlphaMarathon has sold a 10-layer water quenching blown film system to a Chinese packager. According to company president Domenic Marzano, the system uses Alpha Glacier technology, which involves a combination of water and air to create stability and cooling of the bubble, thereby achieving a gauge variation of between two and four per cent across the web.

8 Canadian Plastics May/June 2009 www.canplastics.com

Plast-Ex gets new home in 2010 The Plast-Ex 2010 trade show, to take place from May 4 to May 6, 2010, will be staged at the new Toronto Congress Centre North, the Canadian Plastics Industry Association (CPIA) has announced.

“After 35 years at [Mississauga, Ont.’s] International Centre, it was time for a change, and the Congress Centre has much to offer,” said the CPIA, which owns and operates the show. “The 500,000 square foot Congress Centre North facility prides itself on providing a technologically-advanced meeting space that is allergy free, has reduced energy consumption, and superior air quality.”

Plast-Ex 2010 will occupy over 300,000 square feet of exhibit space in three contiguous halls, the CPIA said.

Information on the new venue can be found at www.torontocongresscentre.com. Details about Plast-Ex 2010 will be available on the Plast-Ex website, www.plast-ex.org, in early July.

PEOPLE

Paul Caprio has taken over as president of Florence, Ky.-based KraussMaffei Corporation, responsible for the U.S. activities of all technology divisions.

Laurent Tainturier has been appointed president of Mississauga, Ont.-based BASF Canada.

Chemical distributor L.V. Lomas Ltd., of Brampton, Ont., has named Jeff Baumann as technical sales representative, specialty business unit in Western Canada. The company has also appointed Tom Mouharemis as sales manager, filtration.

Paul Caprio

Ampacet Canada has appointed David Toguri as account executive responsible for customer sales in Ontario.

Gefran Inc., a Winchester, Mass.-based supplier of systems and components for industrial automation, has named Eric J. Kirleis as its new general manager. The company also announced the appointment of Paul G. Pedro, controller, as part of its new management team.

Jamplast Inc., an Ellisville, Mo.-based distributor of raw plastic materials and biopolymers in North America, has named Ted Kunkel to the position of business manager, and Joe Hart to sales manager.

Ed Dineen

Robert Davies

LyondellBasell Industries has named Ed Dineen as its chief operating officer.

Synventive Molding Solutions has appointed Robert Davies as its new chief executive officer. Davies will be based at the company’s headquarters in Peabody, Mass.

Correction: The colour matching article in the April 2009 issue of Canadian Plastics wrongly identified the Canadian representative for X-Rite.

The correct representative is Manutrol, which can be contacted at 877-626-8876.

Canadian Plastics regrets the error.

executive’s corner

Preparing for the harmonized tax in Ontario What manufacturers should be doing before the new HST system is introduced

A

fter 18 years of maintaining a retail sales tax alongside the federal GST, Ontario is making a bold move to modernize sales tax in the province.

Effective July 1, 2010, Finance Minister Dwight Duncan announced that Ontario will “harmonize” its sales tax system with the Goods and Services Tax (GST). This means instead of a five per cent federal GST and an eight per cent Ontario Retail Sales Tax (RST), the province will have a single 13 per cent Harmonized Sales Tax (HST). Newfoundland and Labrador, Nova Scotia, and New Brunswick have used this system since 1997.

Most economists will observe this decision as a step towards improving the productivity and competitiveness of Ontario’s economy. However, it will have a different impact on the province’s industry sectors, including manufacturing. Although manufacturers are permitted to buy materials and production equipment exempt from RST, numerous purchases by manufacturers, from office equipment to delivery vehicles, are subject to RST — a significant cost.

WHAT THE HST MEANS, INSIDE AND OUTSIDE ONTARIO Under the HST, manufacturers will pay more tax on their purchases but, like the GST, they will be able to recover the HST by claiming input tax credits on their GST/ HST returns. Therefore, the removal of the non-recoverable RST will lower costs and improve the competitiveness of Ontario manufacturers.

Many of the systems businesses now use to comply with the GST can be used, with appropriate modifications, to handle the HST. In addition, the transition to the HST

By Brian Wurts, PricewaterhouseCoopers Canada

will give rise to many of the same issue the implementation date — such as longthat arose with the GST rate reductions on term leases, equipment rentals, and fixedJuly 1, 2006, and on January 1, 2008. price contracts.

Although the HST in Ontario will substantially mirror the GST, there are certain Brian Wurts is a senior manager, Indidifferences that will require systems modi- rect Tax Group, at PricewaterhouseCoofications. In particular, during the first eight pers Canada. The company provides years of the tax, large businesses (annual industry-focused assurance, advisory, 4/21/09 8:10 private, AM Page 1 and tax services to public, and taxable sales in excess of $10 million)PFS will Ad/AB/CPL face restrictions in claiming input tax cred- government clients in all markets. For its for certain categories of expenditures, more information, visit www.pwc.com. such as energy (other than for producing goods for sale), telecommunications, food, beverages and entertainment, and road vehicles weighing under 3,000 kg (including repairs, parts, and fuel).

Manufacturers outside Ontario may also have to modify their systems to apply HST, rather than GST, on sales to Ontario customers.

ACHIEVING

NEW STANDARDS

in vacuum pumping after 80 years

POSTPONE PURCHASES? Apart from systems issues, Ontario manufacturers should plan for the removal of the RST from prices and make purchase decisions accordingly. In particular, it may be desirable to postpone certain major purchases until after the implementation of the tax. For example, delaying the purchase of new computer hardware and non-custom software (unless used directly in the manufacturing process) until after the RST is removed may result in tax savings.

In some instances, the savings may be less obvious. Although the RST does not apply directly on construction projects, RST on the building materials is incorporated into the contractor’s price. Therefore, it will be necessary to carefully review the price charged to ensure that the savings from the removal of the RST are passed on.

Experience suggests that transitional rules will apply to transactions straddling

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leader of the year

DAVE BIRKBY:

A LIFETIME IN PLAST I

Over the past three decades, Dave Birkby has worked his way from being a technologist with Shell Canada to heading up Calgary, Alta.-based PET bottle and preform supplier Westbridge PET Containers.

Despite taking a lot of chances along the way, he never thought he’d done anything outstanding.

The CPIA begs to differ.

Canadian Plastics spotlights the 2009 Leader of the Year.

By Mark Stephen, managing editor

10 Canadian Plastics May/June 2009 www.canplastics.com

t’s a long and winding road from the quiet of rural Ontario to the high rises of downtown Toronto to the sprawling city of Calgary near the beginning of the Rocky Mountain range.

For Dave Birkby, the president and CEO of Calgary’s Westbridge PET Containers, the only constants in his trip along this road were a willingness to take risks, and an ever-increasing involvement in the plastics industry. Cut to the present, and it’s a road that led to his being selected as this year’s Canadian Plastics Industry Association (CPIA) Leader of the Year Born and raised in Chatham, Ont., Birkby began his business career in Toronto with Shell Canada, working as a chemical engineering technologist. A transfer into the company’s polymer division was to prove life-altering. “I realized that I didn’t know much about polymer chemistry, and that it was important that I should,” he said. “I enrolled in, and graduated from, the polymer chemistry program at Toronto’s Ryerson Polytechnical Institute.”

Finding satisfaction in the world of polymers, but tiring of the commute to and from Toronto after 17 years with Shell, Birkby took a job with plastic bottle supplier Plax in Burlington, Ont. After Plax was taken over in the mid-1980s by Graham Packaging, also a plastic bottle molder, Birkby moved up through the company, eventually becoming manufacturing manager for Graham’s three Canadian plants: Burlington, Mississauga, and Montreal.

LEARNING THE BUSINESS OF BUSINESS Graham Packaging marked another crucial point in Birkby’s career. “I became more interested in the overall operation of running a business, and decided to take a two-year business certification course at McMaster University in Hamilton, Ont.,” he said. “I came to realize that business itself was interesting, and that I wanted to learn as much as I could about the different aspects to running a business, such as accounting, sales, marketing, and human resources.”

Looking back, Birkby stresses the importance of his studies at McMaster to his later career. “Too often, someone tries to run a business with only an accounting background, or only a sales background, without a real understanding of the many other elements involved,” he said. “My time at McMaster helped in rounding out my background. I learned that you can’t run a business without knowing something about each of the elements that make up that business.”

ALBERTA BOUND In 1997, after 10 years with Graham Packaging, Birkby received an offer that he might not have been able to accept at an earlier time: to pull up stakes in Burlington and work as the general manager with PET bottle processer Yorkbridge Packaging in Calgary. A determining factor for him and Sherry, his wife of 40 years, was that their two children were adults by that point.

Even so, the decision wasn’t easy. “All

leader of the year

ICS PAYS OFF

TAKING CHANCES Birkby’s first step was to put together a business proposal. The second step was more difficult: finding a partner with enough money to help purchase the company. Through a business connection, Birkby’s plan had reached the ears of a Chicago entrepreneur named Carlos

Photo Credits: Mark Mennie Photography

of our roots — our family and friends — were in Southern Ontario,” Birkby said.

“But we decided to begin a new adventure by trying a five-year plan in Calgary, and then hopefully retiring back to Ontario.”

Having settled with his wife in Calgary, Birkby rose through the ranks again, and after three years was managing not only the PET plant in Calgary, but also similar facilities in Mississauga and Pennsylvania.

Then, in 2000, disaster struck: the merchant bank that owned Yorkbridge Packaging went into receivership. “I was devastated,” Birkby said. “My five-year plan went down the drain; also, I was in my fifties by that point, which is an awkward age to be at risk of losing a job.”

Despite having fallen into receivership, the business continued to run — and after sober second thought, Birkby realized that, far from a disaster, this development represented a possible golden opportunity.

“I realized that I knew the customers, the manufacturing plants, the equipment, and the people, and that the receivership afforded me the prospect of buying the business,” he said.

leader of the year

“Having a good relationship with — and a good understanding of — one’s employees is absolutely critical for any business.”

Nardo, who contacted Birkby and — after having performed the necessary due diligence — became his partner. “We outbid several other interested parties, and Carlos wire-transferred me his share of the money, still without having met me or seen the facilities,” Birkby said. “For my part, I cashed in all of my RRSPs and mortgaged our house. My wife was horrified, because this was our life savings, but we were willing to take the gamble.”

With Birkby at the helm, the company — operating as Westbridge PET Containers — carried on profitably enough. The next stage in Birkby’s evolution came three years ago, with the announcement that Amcor PET Packaging was closing its Calgary plant. “We were able to pick up some of Amcor’s contracts, equipment, as also as some of their employees,” Birkby said.

“Nowadays, Amcor functions as a type of ‘big brother’ to us; there’s no financial interest or ownership, but we have a five-year agreement with them, and a very good relationship.”

As part of that agreement, Westbridge PET moved out of its old plant two years ago and into the 155,000 square foot Amcor facility. “It was a very expensive move that almost crippled us, but we needed the increased floor space,” Birkby said.

PUTTING PEOPLE FIRST Today, Westbridge PET supplies PET preforms and bottles for the edible oil, liquor, beverage, and syrup industries. The company currently employs approximately 55 workers, a lean workforce that exemplifies the philosophy towards managementemployee relations that Birkby has refined over the past 30 years.

“Having a good relationship with — and a good understanding of — one’s employees is absolutely critical for any business,” he said. “Putting the right people in the right jobs, and keeping them motivated, goes a long way towards laying the groundwork for success.” In March 2009, for example, Birkby shut down the Westbridge PET facility for an entire day to carry out a business update and training program with all employees together. “We treat our employees with respect, and try to send them the message that we care about them and their training,” he said.

The value of cultivating good relations with workers is particularly important in the booming province of Alberta, where skilled labour has been in short supply. “Like most Alberta shops, we’ve had to learn to get the most out of the staff count that we have,” he said. “Although my wife is a teacher by trade, as human resources manager she’s helped me tremendously with an employee-focused culture that has allowed us to retain the best and brightest.”

For a PET bottle and preform supplier, there are advantages to being located in Alberta, as well. “We’re a mid-sized company, but there’s nobody in our size range west of Toronto,” Birkby said. “At one time, I was afraid that being in Alberta might pose a geographic disadvantage, but now — with the number of players in decline — I see it as an advantage. We have the ability to sell bottle preforms in Ontario, for example, without being perceived as a threat by Ontario firms.”

GIVING BACK In addition to running Westbridge PET, Birkby — a grandfather of three — also balances his time between family, friends, and work on behalf of the Canadian plastics industry. A former chairman of the Western chapter of the CPIA, Birkby served as the chairman of the CPIA’s Board of Directors until May 2009. Currently, he serves as the only representative of the plastics industry on Calgary’s Manufacturing Action Committee, a business lobby group dedicated to establishing common purpose between manufacturing sectors in the region.

After close to a lifetime in the industry, Birkby seems both humbled and surprised to find himself the recipient of the CPIA’s award. “Being selected as the 2009 Leader of the Year is a real honour, and was totally unexpected,” he said. “I don’t consider myself to have done anything earth-shattering. I attribute whatever success I’ve had to family support, doing my best to look after customers and employees, and being respectful to our valued vendors.”

CPL

T H E I N T E R N AT I O N A L P L A S T I C S S H O W C A S E 22–26 June 2009 • McCormick Place • Chicago, Illinois USA

W E

S P E A K

Co-located Events

Technology exchange will dominate discussions among thought leaders as NPE2009 co-locates with the following events:

international competition

Y O U R

L A N G U A G E.

All in one week, under one roof, experience the world’s most comprehensive event for the plastics industry supply chain.

• Source 2,000 plastics suppliers exhibiting on nearly 100,000 square meters • Conduct business with 75,000 professionals from 120 countries • Learn from over 900 technical presentations & peer-reviewed papers, seminars and forums • Sharpen your skills in business development and training workshops

• Meet with leading contract and captive OEMs, from the packaging, bottling, automotive, air, space and medical industries • Compete in the first International Plastics Design Competition • Discover new and emerging technologies • Participate in industry sustainability discussions

Join the conversation. You can’t afford to miss the one event that brings the global plastics industry together.

produced by

Register Today! www.npe.org

canplast awards

CANPLAST: THE AWARDS GO TO...

CanPlast Awards have been given out by the CPIA on a continuous basis since 1977, to honour those that contribute time, energy, and expertise to improving the competitive and environmental performance of the Canadian plastics industry.

Sally Damstra

Mark Lichtblau

Judith Nancekivell

If you’ve spent any time at a plastics trade show in Canada, chances are you know Sally Damstra, director of international trade and shows at the CPIA. What you may not know is that Sally’s road to plastics was anything but direct: Iranian-born of British parents, and trained for the theatre at the Guildhall School of Music and Drama, University of London.

Sally moved to Canada in 1967, and worked in marketing, advertising, and public relations for a variety of organizations. She managed the Arthritis Society’s Research and Education program for several years, and liaised with medical departments at Canadian universities to provide peerreviewed sub-specialty training and research programs. Following that, Sally and husband Bill ran a group of five international import companies servicing the shoe, leather goods, and clothing industries.

Sally joined SPI Canada — now the CPIA — in 1993. In 1994 she was appointed Show Director of the PlastEx and Expoplast trade shows, and had responsibilities for office management, machinery council, and international trade.

“When the Federal Government withdrew from the provision of Canadian pavilions at international trade shows in 1994, I made a commitment to provide pavilions at events targeted as most important by the industry,” she said. “Now, in 2009, the Trade Promotion Unit has innovated rotating exhibit areas and organized information desks, mini- and full-sized pavilions, plus missions at over 40 events around the world, each providing opportunities for a large number of Canadian companies to expand their export horizons and broaden customer bases.”

Currently the corporate vice president at Torontobased mono- and multilayer film supplier Haremar PlasticManufacturing,Mark Lichtblau studied plastics at the feet of two industry members eminently qualified to instruct him: his parents. Saul and Fela Lichtblau started the company in the mid-1960s with two extruders, and Mark felt the pull at an early age: during his school years, he worked part-time in the company’s warehouse, on the production line, and in the office.

Following his graduation from Ryerson Polytechnical Institute with a degree in accounting and finance, Mark spent two years as a category manager at Loblaw — an experience that proved surprisingly relevant to his later career. “The parallels between coffee-handling at Loblaw and resin-handling are very close,” he said.

“Both have basic and specialty grades, and both are transported by vacuum loading systems. Loblaw turned out to be my preeducation on resins.”

After obtaining an MBA from Clarkson University in New York state, Mark began at Haremar in 1997 — a time that coincided with his father’s failing health. “My father died of cancer after my first year at Haremar, and this resulted in a very demanding 12 months,” he said. “Knowing that he was sick, he had the desire to teach me all that he could in a limited time, and I had the desire to learn as much as I could from him.”

In addition to his duties at the 100 employee-strong Haremar, Mark has served on the CPIA’s Board of Directors, and is a past chairman of the PFMAC. “It’s an honour and privilege to be a recipient of the CanPlast Award, but I’m only doing what my parents have taught me,” he said.

The publisher of Canadian Plastics magazine, Judith’s involvement in the industry stretches back three decades — long enough to remember events in which the moderator would acknowledge her presence by saying “Welcome, lady and gentlemen...”

Armed with an Honours BA in urban studies, Judith was hired by SPI Canada in 1979 as division manager for the group’s Plastic Film Manufacturers Association, and also worked as staff manager for the Commercial Bottle Division.

Judith came to Canadian Plastics magazine as associate editor in 1981. “I had never worked in journalism before — other than working on my high school yearbook — but the group publisher, Art Painter, took a chance on me.” Promoted to publisher six years later, Judith has been responsible for such achievements as the 1999 startup of Plastiques et Moules, the first French language plastics magazine published for Quebec; and for the revival of the Canadian Plastics Resin Outlook Conference, which had been discontinued for a number of years in the late-1980s and early-1990s. Currently, she’s involved in organizing an upcoming webinar with the CPIA and Export Development Canada, designed to present Ontario plastics manufacturers with financial assistance information.

Other industry activities include participation in a number of Plast-Ex and Expoplast trade show advisory committees, serving on the award selection committees for SPI Canada product design events, and a stint on the SPE Ontario Board of Directors.

“Looking back, I’m fortunate to have had wonderful mentors like Art Painter,” she said. “I still love the plastics business, and enjoy getting to know a whole new generation of manufacturers.”

AND ONE MORE...

Joe Giglio Joe Giglio is president of flexible packager Tempo Plastics Limited, in Innisfil, Ont. Canadian Plastics was unable to contact Mr. Giglio by press time.

14 Canadian Plastics May/June 2009 www.canplastics.com

HELP IS OUT THERE. We’ll help you find it.

By signing up for this FREE one-hour webinar, you’ll get an overview of government programs available for the plastics industry.

Presenters from: • Export Development Canada • Business Development Bank of Canada • Ontario government will explain what programs are available and the eligibility criteria. There will be ample opportunity to ask questions.

Given the new fiscal stimulus programs coming from government, this will be important and timely information.

Time: Tuesday, June 9 1:30 - 2:30 p.m. EDT For registration, please visit:

www.plastics.edc.ca (ENG) www.plastiques.edc.ca (FR) There is no charge to participate.

This webinar is brought to you as a no charge service from the Canadian Plastics Industry Association, Export Development Canada, and Canadian Plastics magazine.

Canadian Plastics After the initial webinar, we’ll survey participants to find out which programs are of most interest. If demand warrants, we will then schedule more detailed webinars that will drill down and tell you exactly how to apply and how to fill out the application forms. Stay tuned.

NPE2009 preview

THE INSIDERS PREDICT...

Q Unless you’ve been hiding out in a resin bin lately, you’ll know that the NPE2009 trade show is right around the corner. Taking place between June 22 to June 26 at Chicago’s McCormick Place, the triennial show has always been not only one of the world’s biggest showcases for new products, but also a kind of thermometer for measuring the current health of the plastics industry. With this year’s show taking place during a period of particular economic uncertainty, Canadian Plastics asked a wide range of equipment suppliers to give us their two cents’ worth on what they expect to see.

WHAT GENERAL TRENDS DO YOU EXPECT TO SEE AT NPE2009?

Steve Braig, Engel North America I think there will be a natural focus on such growth market segments as the medical and packaging industries, with a view on expanding operations to cover a broader range of industry markets. The difficult economy means that everyone attending or exhibiting at NPE2009 will want to get extra value for every dollar they spend.

Adolfo Edgar, Brampton Engineering Suppliers will be focused on efficiency — for example, less energy consumption and scrap generation. Given the current state of the economy, the focus will be on those market segments that will continue strong in spite of the recession, like the food and medical packaging industries.

Bruce Kirby, CDS Extrusion machinery manufacturers will not completely ignore the housing and automotive markets, despite the current state of the North American economy. For instance, although decking demand is stagnant, demand is expected to double within the next five years for wood-plastic composite materials.

16 Canadian Plastics May/June 2009 www.canplastics.com

In general, I think there will be a greater focus on medical, industrial tubing, and pipe applications.

Rob Miller, Wittmann Canada There are some industries, like medical, packaging — especially consumer packaged goods — and aerospace, that are not seeing the significant declines experienced by other industries. We expect the show will attract customers from these and other industries looking for new ways to enhance their operations.

Carrie Shoemaker, Motan In this current economy, I expect most companies to focus on how and where their customers, or potential customers, can save money.

Q

WHAT DO YOU EXPECT THE MINDSET OF THE ATTENDEES TO BE? Steve Braig, Engel North America Those making the investment to attend the show will be looking for added value in every exhibit, in every technical session, and in every presentation or discussion. We believe that in the machinery segment, attendees will be looking for machines that offer the lowest operating costs and provide them with enabling technology to differentiate them-

NPE2009 preview

PARTICIPANTS:

Steve Braig, president and CEO, Engel North America, York, Pa. (Injection molding machines) Doug Brewster, national sales manager, The Conair Group, Cranberry Township, Pa. (Auxiliary equipment) Adolfo Edgar, marketing manager, Brampton Engineering, Brampton, Ont. (Blown film systems) John Fleischer, vice president of sales and marketing, Universal Dynamics Inc., Woodbridge, Va. (Auxiliary equipment) Bruce Kirby, marketing chief, CDS- Custom Downstream Systems Inc., Lachine, Que. (Downstream extrusion machinery) Robert Koch, president, Boy Machines Inc., Exton, Pa. (Injection molding machines) Rob Miller, president, Wittmann Canada Inc., Richmond Hill, Ont. (Auxiliary equipment and injection molding machines) Jim Murphy, president, Davis-Standard LLC, Pawcatuck, Conn. (Extrusion equipment) Larry Pascucci, general manager, Negri Bossi Inc., Mississauga, Ont. (Injection molding machines) Carrie Shoemaker, marketing communications, Motan Inc., Plainwell, Mich. (Material handling systems) selves from their competitors through leading-edge processing technology solutions. They’ll want to see energy savings, lower cost of operation, versatility and flexibility, and ultimate reliability.

Doug Brewster, Conair Canadian processors are always looking for an edge; they’re cost-conscious, but not afraid to innovate. This year, more than ever, I think Canadian visitors to NPE will be looking for technology that gives them better, more complete control over their operations. They’re going to be looking at ways to understand their process more completely, tighten their operating set-points, reduce energy consumption in all equipment, and make better and more efficient use of scrap — all while still making quality product.

Adolfo Edgar, Brampton Engineering I think the mood will be one of cautious optimism, as processors will have had time to evaluate where the opportunities may lie in the current business environment.

Processors will be looking for features and technologies that allow them to differentiate themselves from their competition, with the intention of providing value-added products to their customers.

Processors don’t want more of the same,

they want machinery suppliers that are able to work with them to generate new ideas and make them a reality.

John Fleischer, Universal Dynamics If the show attendees are optimistic about the future, and if they have both the money and the need for more equipment, the NPE show will be a good time for them to buy, probably at lower prices than in normal circumstances.

Bruce Kirby, CDS As OEMs and their customers struggle to deal with the harsh new business climate, the typical showgoer will be attending NPE2009 with the future in mind.

They’ll be taking into consideration the long-term trends of those products they make. They’ll be attending to see more of the latest innovations in product development, and how these products might be able to help them to open up new markets in the future.

Robert Koch, Boy Machines We think the attendee mindset will be focused on technology that will save them time, money, floor space, and energy.

Rob Miller, Wittmann Canada Attendees will be asking themselves how

they can get the most for their time attending NPE, and that means looking at new equipment and how it can offer them the greatest ROI (return on investment). Equipment suppliers will need to clearly show the advantages their equipment offers and how it improves the bottom line with solid data and not wild claims. Processors that are to remain successful will continue to look at how to take cost out of the process with automation, which is much more than just robots and includes all areas of the process, especially that of resin handling given the significant cost savings opportunities available.

Jim Murphy, Davis-Standard Visitors to NPE2009 are going to be very focused on getting value in their investments at the show. I think the attendees will be looking for the best equipment and suppliers, and they’ll want to make sure they get some tangible takeaways.

Carrie Shoemaker, Motan Attendees will definitely be looking to save money where they can.

Q

What do you think

the equipment trends will be for some of the various processing technologies?

Bruce Kirby, CDS In extrusion machinery, we expect European and North American manufacturers to concentrate on those applications that are the focus of most government-approved stimulus packages: industrial tubing, and piping.

Robert Koch, Boy Machines We think the general trend in injection molding will be towards energy efficiency, as well as smaller machines and reduced cavitation.

Rob Miller, Wittmann Canada Energy savings are only one area to consider when purchasing equipment. There are many other areas, like simple controls, easy operation, low maintenance, resin savings, and scrap reduction that contribute to the true operating cost and ultimately the ROI. www.canplastics.com May/June 2009 Canadian Plastics 17

NPE2009 preview Larry Pascucci, Negri Bossi The common theme for the injection molding machines we’ll be showing will be molding material specialization, speed of operation, centralized information, energy efficiency — and, of course, service.

Q

Briefly, what

will be your company’s focus as an exhibitor at NPE2009?

Steve Braig, Engel North America Engel North America will be ‘electrified’ at NPE2009, with a range of injection molding machines, automation, and Engel technology, focusing on all-electric machines and energy savings. Also, Engel will introduce its latest two-platen machine model, as well as an energy calculator that allows operators to choose the machine settings to provide the most energy-efficient mode of operation.

Doug Brewster, Conair Conair’s focus will be on controls that give users more information about their process, whether it involves drying, blending, material handling, or heat-transfer. Several new approaches to reducing energy consumption — particularly in the drying process — will also be introduced.

Adolfo Edgar, Brampton Engineering Our company is positioning itself as a partner to its customers. We use our technology and our customers’ requirements to engineer and manufacture the equipment that will produce the value-added blown films that our customers need to satisfy the requirements of their markets.

John Fleischer, Universal Dynamics In addition to drying products and granulators, Universal Dynamics will be showing our Factory Acquisition Control System (F.A.C.S.), a Windows-based, plant-wide control and monitoring system for plant material conveying.

Bruce Kirby, CDS Aside from our standard machinery for pipe, profile, and tubing applications, we’ll be putting an emphasis on machinery

for small tubing applications. Also, we’ll be showing our new medical downstream equipment line, which will have several features new to the medical market.

Robert Koch, Boy Machines Boy Machines will be demonstrating energy-efficient machines, and the benefits of small footprint and single-cavitation machines.

Rob Miller, Wittmann Canada The concept of integrated control, and of one-stop shopping for robots, automation, auxiliary equipment, and injection molding machines will be an important area for Wittmann Canada at NPE2009, in the Wittmann Battenfeld booth. We will feature our comprehensive product offering with many new additions and developments since the last NPE. Attendees will be looking at everything from a single loader or dryer to a fully integrated automated work cell complete with machine, robot, and all auxiliaries. Wittmann Canada will be at the show to provide them with the best possible solution for their application.

Jim Murphy, Davis-Standard Generally, our products are very engineering-intensive, and there’s lots of give and take between the customer and our sales and engineering teams to take the basic technologies and apply it to the line or equipment the customer needs to convert. One thing we’ll be doing more of at NPE2009 is utilizing more advanced multimedia type displays; our equipment can be very large and it can almost be impossible to run at a trade show.

Larry Pascucci, Negri Bossi Negri Bossi will be focusing on what we see as growth areas: high-speed applications, liquid silicone resin (LSR), multimaterial molding, and plant monitoring and Internet-based service.

Carrie Shoemaker, Motan Motan will be showing our latest in gravimetric blenders, coupling stations, and mixing and dosing units. One of the highlighted attractions at our booth will be media kiosk — attendees can take control with their own hands and operate our WEB-compatible units.

CPL

NPE2009 preview

Teknor Apex

gets greener with Canadian technology

M

aterial supplier Teknor Apex is licensing an innovative starch-blend technology from Canadian-based Cerestech Inc. Developed by Dr. Basil Favis, who founded Cerestech as a spinoff company from Montreal’s École Polytechnique, the technology is based on blending relatively low-cost thermoplastic starch (TPS) with synthetic polymers or other bioplastics, and makes it possible to combine other polymers with TPS from vegetable sources like corn, wheat, or potato without losing key performance properties.

Pawtucket, R.I.-based Teknor Apex will use the technology to produce both masterbatches and ready-to-process compounds under the brand name Terraloy, to be commercially unveiled at NPE2009.

According to Dr. Robert Brookman, vice president for business development at Teknor Apex, the Cerestech technology overcomes a critical handicap inherent to other bioplastics.

“Normally when you mix starch with plastics, the properties of the plastics deteriorate rather badly,” he said. “The Cerestech process allows the starch to be dispersed very uniformly within the host plastic, resulting in mechanical properties that are very similar to the host plastic. They exhibit lower levels of sensitivity to moisture than many other starch-containing plastics, are translucent, printable, and sealable, and can be formulated for biodegradable applications.”

Teknor Apex has already begun installation of a pilot plant, capable of producing up to one million pounds of Cerestech per year, at its world headquarters in Pawtucket.

“We see great growth potential in bioplastic products,” Brookman said. “While it remains a boutique market in North America — unlike Europe, where it’s growing much faster — we believe the market will increase quickly in years to come, and we’re positioning ourselves to capitalize on that.”

CPL

www.canplastics.com May/June 2009 Canadian Plastics 19

NPE2009 preview

Bioplastics grow at NPE2009

Photo Credit: BASF

W

e all know that bioplastics have become a fast-growing business for marketers and technologists in the plastics industry mainstream — and the organizers of NPE 2009 want the show to provide a bright spotlight for its continued growth.

According to show owner SPI, NPE2009 will feature three raw materials companies reporting on new ventures for manufacturing bioplastics, as well as 39 companies, agencies, and industry consortia making conference presentations on bioplastics technology and business strategy.

“The dawn of the era of sustainability has brought with it a worldwide industry consensus on the need to proactively address issues such as resource depletion,” said SPI president and CEO William R. Carteaux. “Bioplastics have emerged as one of the most promising means for companies to carry out this strategy while operating profitably. Besides enabling businesses to comply with mandates for renewable resources, these exciting new polymer families will help ensure the longterm viability of our industry by providing an alternative to traditional raw materials.”

While the majority of plastics will continue to be fossil fuel-derived for years to come, current research to improve the properties and reduce the cost of bioplastics will result in rapid growth in the marketplace, according to Melissa Hockstad,

SPI vice president in charge of the Material Suppliers Council and the Bioplastics Council. Hockstad identified three ventures into production of bioplastics that will be commercial or nearly so at the time of NPE2009. The first, Cereplast Inc., expects early-2010 completion of a new manufacturing plant to produce bioresins made from starches derived from tapioca, corn, wheat, and potatoes. Telles, a joint venture of Metabolix and Archer Daniels Midland Co., has announced plans to start up a plant for its Mirel resins, produced from plant sugars in a process that involves

chemical transformation by microorganisms. Teknor Apex Company will use NPE2009 to introduce its new Bioplastics Division and the first commercial compounds in its Terraloy range, consisting of blends of thermoplastic starch with other bioplastics and with conventional polymers like polypropylene. (see pg. 19) According to the SPI, the 39 conference presentations dealing specifically with bioplastics will take place in four educational programs co-located with NPE2009.

These will include ten presentations in the Business of Plastics conference; 26 in the ANTEC 2009 technical conference; two in the PET Strategies Plus conference; and one in the Spanish-language Seminario Latinoamericano.

Additionally, bioplastics will be one of four technologies to be the focus of exhibits in the Emerging Technologies Pavilion, with DuPont Company as the major pavilion sponsor, and Dow Chemical Company as sponsor of a sector on sustainability.

“At the last NPE in 2006, bioplastics were still something of a curiosity, but at NPE2009 literally dozens of organizations will have something important about bioplastics to say or demonstrate,” Hockstad said. “There will be implications for every major plastics market, from appliances and automotive, to electronics and medical, to CPL sporting goods and packaging.”

Conferences, competitions, and pavilions

NPE2009 is expected to draw some 75,000 industry professionals.

Here’s a brief look at some of the many events that await them.

ANTEC @NPE2009 The world’s largest plastics technical conference, ANTEC is co-located with NPE2009.

Produced by the Society of Plastics Engineers, it will include at least 650 original, peer-reviewed presentations.

SPI’s Business of Plastics

this program will include an exhibit of product entries by designers, processors, moldmakers, and OEMs.

Emerging Technologies Pavilion The pavilion will spotlight four sectors: sustainability, bioplastics, nanotechnology, and energy.

Specialized Technology Pavilions

An educational program that will address marketing, human capital management, finance, environmental issues, regulation, global economic trends, and other business management issues.

The seven multi-exhibitor pavilions will include New Technologies, SPE Thermoforming World, Compressed Air World, Fluoropolymers World, North American Contract Processors, North American Moldmakers, and TPE-Elastomers.

International Plastics Design Competition

MoldMaking Expo Trade Show and Conference

Produced by the Alliance of Plastics Processors, 20 Canadian Plastics May/June 2009 www.canplastics.com

Featuring an educational program that will

include technical presentations, panel discussions, workshops, and keynote speakers.

Time Compression Conference and Expo This new technical event is designed for professionals looking for technologies to accelerate product development.

PET Strategies Plus Conference A conference intended for professionals involved in packaging applications of PET and other plastics.

Coatings for Plastics Conference A conference designed for industry professionals who specify and use coatings on plastics, as well as coating manufacturers and raw material suppliers.

HOW MUCH WILL YOU BE PAYING FOR RESINS IN 2010?

Find out at the 14th Annual Canadian Plastics Resin Outlook Conference Wednesday, October 7, 2009 NEW VENUE: Toronto International Centre 6900 Airport Rd. Mississauga, ON

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

Investment per person: Early Bird Registration – register and pay in full by Aug. 28 $395 plus g.s.t.

Regular Registration – after Aug. 29 $495 plus g.s.t.

Group Registration – 50% discount for second and 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/

Here’s what delegates at last year’s conference said they liked about last year’s conference: • Provided us with lots of info in a short period of time • Broad range of topics covered the majority of resins purchased by my company, with potential for new materials for new products.

• Always a great conference, with key attendees present.

• Good cross section of speakers.

• Insights into various resins and the variables that control the pricing of these commodities • Gained knowledge and confidence • Networking opportunities.

For more information, contact:

Judith Nancekivell, Tel: 416-510-5116, Email: jnancekivell@canplastics.com SPONSORS TO DATE:

“Earning your trust one stripe at a Cantec time.”

Polymers INC.

product design

DESIGNING FOR SUCCESS When it comes to crafting products that stand out from the competition, too many plastics manufacturers in Canada are flying — and designing — blind. But it doesn’t have to be this way. There’s a slew of industrial design firms out there ready to help take your product design to a new level.

By Umair Abdul, assistant editor

22 Canadian Plastics May/June 2009 www.canplastics.com

product design

A

sk a Canadian manufacturer about the key to his business’s success, and they will easily come up with a number of reasons: the efficiency of the production, the quality of the finished product, or even the competence of the sales staff. Chances are, though, that “good design” will hardly ever make the shortlist.

However, more brand owners are finding that a well-designed product is the make-it-or-break-it factor in an increasingly saturated market. In recent years, industrial designers argue, product design has taken a front seat when it comes to capturing the public’s imagination — and, in turn, a larger part of the market.

“I think it’s safe to say that we’ve experienced a global ‘design boom’ in the last several years,” said Sandro Zaccolo, head of Sandro Zaccolo Industrial Design Inc. Industry leaders point to companies like Umbra Concept Store, firms that place a strong emphasis on design and engineering. A design studio with graphic artists, industrial designers and engineers are at the heart of the Umbra’s head office, focused on new product design. The company also uses computer-assisted design (CAD), and a prototyping lab to breathe life into its new product concepts.

Despite the availability of such companies as these, however, most designers maintain that Canada lags behind other industrialized countries when it comes to cutting-edge products. “Unfortunately, the reality is that Canada has very little design-cultured companies such as

Umbra, Bombardier, and MEGA Brands, compared to other nations such as Italy, Sweden, Japan and South Korea,” said Aldo Balatti, the principal and design engineer director, plastic applications specialist for Evolve Design Solutions, Inc. “Also, let’s not ignore the fact that many industrialized countries have government design programs to help their companies with R&D, innovation and design. Unfortunately, Canada cancelled its Canadian design program in early 1980s.”

“INDUSTRIAL WHAT ”?

Nearly every brand owner, in the plastics industry and elsewhere, could benefit from the services of an industrial designer, but designers are mostly used on projects aimed at consumer use.

“An OEM for an under-the-hood part won’t care about finding an aesthetic designer,” said Doug Clark, president of DC Design. “But if you’re making a product that’s going to sit on a desk, and is looked at constantly, this can be visibly appealing to someone.”

Outside of that, the possibilities are endless. Industrial designers are brought in to work on a range of products, covering many different sectors.

“To date, we haven’t been commissioned by many automotive and packaging groups,” said Sandro Zaccolo. “We’ve been busy the last several years with safety products, consumer products, equipment, household goods and a range of hardware.”

The word “design” may bring images of fashion designers and interior decorators

to mind for many people, but an industrial designer’s role goes far beyond the aesthetic. In addition to making a product aesthetically appealing and in keeping with the latest styling trends, industrial designers also ensure that the product is structurally well-designed and easy to produce. Also, with consumer products, designers have to take other use factors into consideration when designing a product.

“Typically, manufacturers work closely with mechanical engineers and marketing people who don’t necessarily possess industrial design training and skills,” Zaccolo continued. “As creative problem-solvers with a good base knowledge of manufacturing and materials, we plug various other components into the design formula, which may include ergonomic human factors, consideration for proper disposal or breakdown of a product after it’s life cycle, and perceived quality in addition to the engineering quality.”

Essentially, a good industrial designer’s job is to marry design appeal with function, and help a company create a utilitarian product with mass appeal. Aldo Balatti uses the example of Apple’s iPod MP3 players, which feature a sleek design, but also have a functional interface and user experience that set them apart from competing products.

WORKING WITH PLASTICS For plastics manufacturers looking to take advantage of design opportunities, it’s important to find a designer with experi-

DESIGN EXAMPLE:

Evolve Design Solutions’ hearing aid Evolve Design Solutions was chosen to design a compact and ergonomic plastic wireless handheld remote control for hearing instruments, manufactured by Smart Control. “The main objective was to create an innovative and distinctive new design which would appeal to an older group of end-users,” said Aldo Balatti.

“Since low eyesight, loss of fingertip sensation, and arthritis are common factors associated with the end-users’ age group, the design had to incorporate tactile elastomeric user interface

touch areas, a large button keypad, colour and graphics contrast, as well as an illuminated keypad.”

The Smart Control housing components utilized a new decorative plastic resin system called EF technology from Sabic Innovative Plastics. “The user interface touch areas are produced by inserting the top housing in a mold and overmolding the elastomeric substrate onto the plastic housing,” Balatti continued. www.canplastics.com May/June 2009 Canadian Plastics 23

product design

DESIGN EXAMPLE:

Sandro Zaccolo Industrial Design’s construction hardhat “We have an on-going project with an occupational safety equipment manufacture, for whom we developed a new construction hardhat,” said Sandro Zaccolo.

The shell was designed to convey a new styling within a very traditional end-user group, predominately the construction worker. “We introduced a slight duck-bill into the front visor in order to work with the ventilation we were incorporating for summer use,” he explained. “The shell had

ence with molding environments.

“Generally, we get involved with the plastic processors and suppliers as early as possible, for review and discussion of the part design regarding its design features, mold design, ease of moldability, cooling and ejection, as well as material selection and post-operations,” said Balatti, who noted that his expertise in injection molded part engineering and development has been gained with over 500 parts.

very pleasing, hard-edged lines which were both styling cues and geometry to reinforce the shell structure, while also contributing to the product’s ability to deflect falling construction tools, and help to route rain water away from face and help provide sun protection.”

The company also incorporated a ratchet adjustment mechanism with a contoured pad fitting the rear of the head, and dial ergonomics for the glove-covered hand.

According to Balatti, plastics industry professionals looking to bring an industrial designer into the fold should ensure that the firm has a sound knowledge and experience with plastic materials selection, plastic part design and engineering and tooling design.

Additionally, Sandro Zaccolo suggests that that manufacturers look for a strong sense of methodology. At his firm, for instance, the product design process is

Add On Injection Unit

broken into four seamless phases.

Overall, designers note that perhaps the most important decision is to get someone involved with the project in the early stages. Doug Clark noted that a good designer, who is well-versed in plastics, and uses prototyping or CAD, could identify immediate structural improvements that can result in significant cost savings.

“A lot of times, the cost-saving alteration can be wall thickness changes, or increasing

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product design

drafts, or adding more ribs if the product feels too flexible,” he explained. “That one minor change performed at the CAD stage can cost multiple thousands of dollars if it has to be made to the actual tool design.”

BREAKING THE MOLD Clark noted that an industrial designer can get involved in a project that is “anywhere from an existing part that is being redesigned, to sketches on a napkin.” Designers are also often approached by manufacturers or inventors who have a concept, but need the services of someone who is industrially-proficient enough to execute the design, he continued.

But Clark also noted that manufacturers with an innovative idea that they want to bring to market should be aware of new and competing products that are probably available. “New product designs can often be a tough sell, because there’s already too much junk on the market already,” he said. “By that measure, it can be hard to bring a new design to market unless you’ve got something that is absolutely extraordinary,” he said.

And while it may indeed be tough sell, industrial designers can often help plastics industry professionals turn their concepts into reality. Sandro Zaccolo is himself a great example of someone who took an idea and turned it into a viable, marketready product. In addition to his industrial design services, Zaccolo is the co-founder and VP of design at Effbe International Inc., a new design manufacturing company that has started a line of garbage and recycling products. According to Zaccolo, he used his background as an industrial designer to create an innovative floating bin bracket. Much like floating shelves, the floating bin bracket mounts on a wall and is designed to organize standard blue recycling bins on a wall. The ABS-molded part can support up to 50 lbs., while only requiring one wall stud as a main anchoring point. The product is now being sold through Canada’s Lee Valley Tools, a woodworking and hardware supplier.

For a plastics product manufacturer, partnering with an industrial designer on a new project offers the real possibility of creating an innovative product made from advanced materials. “I don’t think most

consumers realize the number of good Canadian designs on the market,” Zaccolo said. He pointed to several clients who have used strong design to forge ahead and blaze their own path. One of them, a racing bicycle manufacturer, has designed one of the best frames in the world, according to Zaccolo. Another, a supplier of golf and fishing equipment, is presently making

a fishing rod with a biopolymer made of extracted carrot fibres.

CPL RESOURCE LIST DC Design (Campbellville, Ont.); www.dcdesign.ca; 905-854-3747 Evolve Design Solutions Inc. (Ottawa, Ont.); www.evolve-designsolutions.com; 613-482-9626 Sandro Zaccolo Industrial Design, Inc. (Toronto); www.szid.ca; 416-364-1039

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hot runners

HO TH T E

: S T R I N E FU N N O U R ISE R

S M E T S Y S D E Z I

Husky’s fully configurable PRONTO hot halves.

Photo Credit: Husky Injection Molding Systems

P

These days, if you’re not using hot runners to make plastics parts, you’re just not cool.

And unitizing hot runner systems to reduce machine downtime, increase production, and avoid the pitfalls of multiple sourcing can make your life a whole lot simpler, as well.

By Mark Stephen, managing editor

26 Canadian Plastics May/June 2009 www.canplastics.com

robably the key word in “hot runner systems” is “hot” — as in becoming more popular all the time.

Nowadays, hot runners are being used more frequently for the production of injection molded parts than ever, as they permit parts to be produced more rapidly with improved quality, making production more cost-efficient overall.

And, as practically any plastics processor will tell you, cost-efficiency is king in today’s economic climate.

Hot runners also have a technical advantage: some of the most widely-used forms of injection molding — such as insert, coinjection, and multicomponent molding — would be impossible without hot runner systems.

But there’s a slight downside. “Hot runners have to bring together time, temperature, flow, and the pressure of plastics operating on rapid cycles, and this makes them inherently complex,” said John Schmidt, hot runner, sales with PCS Company. And it probably doesn’t help that hot runners are self-contained, and hidden — incorporated entirely within the injection mold — with tasks and functions

that are completely different from those of the mold itself.

No wonder more than one processor has referred to the process as a “black art”.

Many are choosing to overcome any difficulties caused by this complexity by ordering state-of-the-art hot runner systems to be supplied in ready-assembled form as injection halves — or unitized.

According to some hot runner system suppliers, this can prevent installation errors, simplify connection of the system, and reduce the amount of time required for installation in the mold.

And it’s a service that they’re increasingly happy to provide.

THE IMPORTANCE OF BEING COMMUNICATIVE For processors that decide to order a unitized system, good communication with the hot runner supplier is — not surprisingly — crucial. “The key thing that needs to happen is a good communication stream with the customer,” said Mike Brostedt, director of market development with Gammaflux L.P. Information that the hot runner system

hot runners

supplier needs to know includes the mold dimensions, information about the interface, the nozzle length, the part weight, and the type of resin to be used. Injection time is also necessary to calculate the melt channel sizing, and information about the injection molding machine itself can also be helpful. “We want to know whether there are any pressure limitations in the molding machine, for example,” said Martin Baumann, business manager, hot runners with Husky Injection Molding Systems. “Also, if there’s too much pressure being used in the hot runner system, there may not be enough left to fill the part.

Most injection molding machines have at least 30,000 psi available, but some don’t, and this is important information.” Suppliers will also want to know the radius of the injection nozzle, Baumann continued, so that the interface between the hot runner and the machine nozzle fits properly; and the tie-bar spacing, so that the system fits within the given envelope.

Ordering a unitized system, some suppliers say, can prevent some of the pitfalls that can be inherent in a mold obtained from multiple sources, since both the hot half and the mold base are coming from the same source. “Finding a hot runner supplier that integrates both the hot half and the mold base into a single mold package is an alternative approach to multiple sourcing, and can avoid the ongoing design changes, errors, and miscommunication that often result in significant manufacturing rework, and unbudgeted costs,” said John Schmidt.

From the point of view of design, a unitized system can make it simpler to configure such things as electrical and hydraulic connections to customer specification. “The hydraulic mechanism driving the valve gate also can be mounted directly on the system, making the injection mold more flexible, and enabling it to be used on machines without additional control valves,” said John Blundy, vice president, business development with Incoe Corporation.

Mold-Masters Ltd., for example, offer

ready-to-use hot halves that feature stainless steel plates, and come ready to bolt directly onto a cavity plate with no further machining, wiring, or fitting required.

Positioning can also be optimised.

“Unitized systems are centred in the injection mold with minimal contacts made of materials that are poor heat conductors, and do not require any clamping or pretensioning of the mold plates,” said John Blundy. “The minimal contact in unitized systems provides highly accurate and stable temperature profiles, with energy consumption substantially below that for conventional systems.”

TESTING, TESTING...

Usually with unitized hot runners, the systems undergo electrical continuity, temperature, and pneumatic or hydraulic tests prior to delivery. “If a customer buys an Altanium temperature controller from Husky, for example, we’ll test the system before it’s shipped to make sure it’s electrically-wired properly, so that each nozzle tip reads the temperature accurately,” said

quick, too. For example, D-M-E Company’s unitized hot runners can be ready to ship in as little as three weeks, the company said.

If the unitized system has been properly built to specifications, its value can become apparent as early as during installation, some suppliers maintain. “The design of unitized systems makes it possible to install pre-wired hydraulic connections directly on the system, independent of the mold to be used,” said John Blundy.

“The hydraulic mechanism driving the valve gate also can be mounted directly on the system, making the injection mold more flexible, and enabling it to be used on machines without additional control valves.”

On unitized systems, the nozzles and manifold blocks constitute a single drop-in unit. The melt channel runs from the manifold block directly to the nozzle without any potential misalignment or dead spots.

“Any potential for plastic leakage between the nozzles and the manifold block is eliminated since the nozzles are inserted within the manifold by a thread connection,” Blundy continued. “This eliminates the tendency for plastic leaks between the nozzles and manifold, which can occur during heat expansion of conventional bushing-type system designs, causing production interruptions.”

“With a bolt-on hot side system, the customer doesn’t need to make any adjustments, just put it next to the cold half and turn on the temperature switch,” said Tony Brusca, president of Alba Enterprises.

“Within 20 to 25 minutes, depending on the size of the system, they can make their first shot.”

Benefits of a unitized hot runner system continue once it’s running, suppliers say, beginning with routine maintenance.

“While conventional injection halves also allow some maintenance to be performed when in the molding machine, it’s limited to the very front of the nozzle area due to the retainer plate. Servicing beyond this point requires the hot runner manifold system to be removed from the machine

If the unitized system has been properly built to specifications, its value can become apparent as early as during installation.

Martin Baumann. “If the customer has not bought the controller from us, we’ll still test it, as well as inspect all the key dimensions, and provide the customer with a test report”. The end result, Baumann said, is a checked, ready-to-install system that can be easily assembled in the mold and brought directly into operation.

Other suppliers offer similar services.

For example, Hasco’s new Hot Base comes tested, assembled, and ready for installation of cavity and core plates or inserts, according to Louis Hebert, president of Hasco Canada. “The unitized Hot Base can be configured for speciality designs like side-entry, multi-material, high-cavitation, and stack molding,” he said.

Despite this complexity, the construction of a unitized system can be relatively

www.canplastics.com May/June 2009 Canadian Plastics 27

hot runners

in order to expose the manifold system, and this involves a considerable amount of work, with a renewed risk of assembly and installation errors,” said John Blundy.

“Maintenance can be performed on an integrated system without removing the system from the molding machine.”

Then there’s the question of inserts.

Inserts can easily be interchanged. Since the hot runner system remains firmly attached to the stationary plate during this work, the mold can be repositioned again immediately after the service work is complete, and can be ready for production again in just a few minutes. Integrated systems can thus save several hours — or in large systems perhaps days — during routine hot runner system maintenance.

Also, unitized systems can provide a considerable contribution to reducing the number of errors and saving2:09 timePM for mold Rotogran 3-AB-CPL 2/13/09 Page manufacturers during the manufacturing and sampling of new molds. In addition, integrated systems permit additional savings for injection molders by reduc-

ing downtime during injection molding production.

WHEN NOT TO Does it always make sense to order a unitized hot runner system? Not necessarily, some suppliers say. Many molders of large auto parts, for example, prefer the do-ityourself approach. “For large parts molders, the hot runner system still tends to be pieced together by them, or the moldmaker is tasked with the responsibility of piecing it together,” said Mike Brostedt. “It’s done for the same reason that a house is typically built on-site: it’s simpler that way, and makes a great deal of sense.”

There are also many moldshops that will handle the assembly or the wiring of any hot runner system in-house because they’re willing, and technically capable, to 1do the procedure themselves — which is fine with hot runner suppliers, too. “We’ll certainly provide them with a drawing and enough information so their designer can handle the job,” said Tony Brusca.

“Whether or not a customer wants a unitized system, hot runner technology will continue to play an increasing role in injection molding production, and it’s our job to make this transition as inexpensive and convenient as possible.”

CPL Resources List Alba Enterprises Inc. (Rancho Cucamongo, Calif.); www.albaent.com; 1-800-432-6653 D-M-E of Canada Ltd. (Mississauga, Ont.); www.dme.net; 1-800-387-6600 Gammaflux L.P. (Sterling, Va.); www.gammaflux.com; 703-471-5050 Control Solutions (Brampton, Ont.); 905-458-8382 Hasco Canada (Toronto); www.hasco.com; 416-293-5044 Husky Injection Molding Systems (Bolton, Ont.); www.husky.ca; 905-951-5000 Incoe Corporation (Troy, Mich.); www.incoe.com; 248-616-0220 Mold-Masters Ltd. (Georgetown, Ont.); www.moldmasters.com; 905-877-0185 PCS Company (Fraser, Mich.); www.pcs-company.com; 1-800-505-3299 (Windsor, Ont); 1-800-521-0546

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chillers

THE BIG CHILL

During economic downturns, many processors look to their operations for cost reductions and efficiencies.

When it comes to chillers and temperature control units, suppliers are coming up with new, innovative ways to maximize efficiencies and minimize footprints — ecological or otherwise. With everything from eco-friendly refrigerants to variable frequency drives to new chillers, Canadian Plastics has all the latest developments in process cooling.

By Umair Abdul, assistant editor DESCRIPTION: High capacity, small footprint INFO: The new Model SB-420 from Delta T Systems offers a compact footprint and a lot of capacity, for when space is at a premium.

The unit measures in at 15”W x 20”D x 14”H, and is equipped with a 1/2 HP pump (20 gpm at 15 psi), and 9kW heating capacity.

According to Delta, the unit’s small size makes it a very efficient system. All wetted surfaces on the unit are non-ferrous, and the unit includes a stainless steel pump, piping and heater tanks.

The unit is controlled through a microprocessor-based PID controller, and all the unit’s components are commercially available.

CONTACT: Delta T Systems. Inc. (Richfield, Wis.); www.deltasys.com; 1-800-733-4204 Spaltech International (Halton Hills, Ont.); www.spaltech.com; 866-592-1442 DESCRIPTION: New rotary screw central chillers INFO: Thermal Care is releasing their MX Series R-134A rotary screw central chillers. MX Series Central Chillers use Copeland compact rotary screw compressors for greater reliability, energy efficiency and noise reduction.

Each unit consists of one refrigeration circuit with a brazed plate evaporator for greater chiller reliability and reduced size.

Thermal Care’s approach to modularity, with a straight-forward mechanical design and an Allen-Bradley compact Logix PLC, provides a solid performing chiller to meet industrial requirements with the added benefit of easy access to controls and components.

The chillers are available from 50 tons to 125 tons in water-cooled and remote condenser models. Additionally, the modular design allows multiple circuits — up to four — to be linked together with a common control system.

CONTACT: Thermal Care, Inc. (Niles, Ill.); www.thermalcare.com; 888-828-7387 Dier International Plastics Inc. (Unionville, Ont.); 905-474-9874 D Cube (Montreal); 514-272-0500

DESCRIPTION: Expansion of Hydrotherm II line INFO:Mokon is expanding its Hydrotherm II circulating water temperature control system line for heating capacities up to 24 kW. The Hydrotherm II is now available in standard heating capacities from 3 to 24 kW, ratings from 208 to 600 volts, pump sizes from 1/2 to 3 hp, and flow rates from 15 to 60 gpm.

The expanded line offers a slightly larger cabinet to allow for higher capacities, energy saving automatic high-low heat selection for the 18kW and 24kW designs, additional options, and larger casters to allow for easier portability.

To improve serviceability, the heaters are easily removed from the back to allow improved tool access.

The overall number of fasteners has also been greatly reduced to minimize service time and to strengthen and stability the unit, the casters have been moved toward the back of the cabinet.

The Hydrotherm II features hybrid-epoxy powder coated cabinetry with a 14 ga. base and 16 ga. electrical enclosure. Mokon’s heating design utilizes low watt density heating elements and a two pass stainless steel heating canister via a flow diverter.

The result, according to the company, is a small hold up volume, turbulent flow, and water channeled over the heating elements to enhance the heat transfer efficiency and extend the heater life.

Additionally, the Hydrotherm II features an operator-friendly and easy-to-use microprocessor-based controller delivering precise temperature control.

CONTACT: Mokon (Buffalo, N.Y.); www.mokon.com; 716-876-9951 En-plas Inc. (Toronto); www.en-plasinc.com; 416-286-3030 www.canplastics.com May/June 2009 Canadian Plastics 29

chillers DESCRIPTION: Flexible centralized modular chilling station INFO: Frigel has added the Ecoflex, a centralized modular chilling station, to its line of process cooling products.

Frigel describes the Ecoflex as a high-efficiency unit that incorporates Turbocor variable speed centrifigual technology.

The station is supplied cooled water from the company’s Ecodry System, and includes all of the same eco-friendly benefits as other Frigel products such as free-cooling capabilities.

According to Frigel, the unit is compact and can be fully integrated into a processor’s cooling system through an intelligent microprocessor controller.

Frigel noted that the product is the company’s most energy efficient to date. Ecoflex is ideal for for use in injection molding applications where individual press side units are not required, such as in packaging where a common temperature is used throughout the plant and flow is regulated locally by TCUs. It also works well for other industrial applications where central chillers are required.

The Ecoflex compressor operates using centrifugal technology and oilfree magnetic bearings. It has superior part load efficiencies, and a soft start, conserving energy.

CONTACT: Frigel North America (East Dundee, Ill.); www.frigel.com; 847-540-1060 Plastic Automation Engineering Inc. (Toronto) ; 416-237-1307 Anplast Inc. (Anjou, Que) 1-800-387-4590 DESCRIPTION: Small footprint, environmentally friendly INFO: With what’s described as one of the smallest footprints in the industry, the GP Series 5-15 HP portable chillers from AEC Inc. utilizes environmentally friendly R410a refrigerant.

Designed to offer a leaving coolant temperature range of -7.5 C to 21 C, the GP Series offer easy-to-read LCD display showing system operating status, Set Point and To-Process temperature, and remote mount without special configuration.

Air-cooled units feature aluminum fin tube condensers with on/off, washable air filters. The off-the-shelf modular controller is accurate to within +/- 0.6 C. AEC said.

No tools are necessary to access the mechanical cabinet, and the units come standard with a one-year compressor and labour warranty; two-year parts warranty; and three-year limited controller warranty.

The units have branch motor fusing, are equipped with water regulating valves with tube-in-tube condensers, and come standard with a multiple screen, 20 character by eight line display, and NEMA 12 electrical enclosures.

The stamped, stainless steel, horizontally mounted pump assures reliability. Also, the non-fused disconnect switch offers a single point power connection.

CONTACT: AEC Inc. (Schaumburg, Ill.); www.aecinternet.com; 847-273-7700 Equiplas (Toronto); 416-407-5456 Lutek Plastic Equipment Inc. (Dorval, Que.); www.lutek.ca; 514-421-8963 Shaw Equipment Technologies (Vancouver, Wash.); 1-800-528-8011 30 Canadian Plastics May/June 2009 www.canplastics.com

DESCRIPTION: Variable frequency drives save money, prevents mechanical problems INFO: Designed to save energy and electrical costs, and prevent damage to heat transfer equipment operating at less than full capacity, Conair now offers variable-frequency drive controls (VFD) that can replace standard fixed-speed motor controls on central cooling pumps.

A VFD can also be used on the process pump motor of a portable chiller or Thermolator temperature control unit, reducing flow and pressure to match system loading and save energy.

The VFD controls from Conair allow the speed of the pump motor to be varied as the cooling load fluctuates.

Operating a pump in this fashion reduces energy consumption and the high pressure spikes that can cause piping damage. Because the relationship between pump speed and power consumption is cubic rather than linear, Conair notes that huge savings are possible.

The VFD can also be programmed for a “soft start,” ramping up to the desired speed over a user-selectable time span (30 sec, 1 minute, or 2 minutes, for example). This limits or even eliminates damaging water-hammer and also can reduce electric power rates by avoiding the high inrush current that fixed speed pumps draw when starting up.

VFDs also have good power factor, which also contributes to lower electrical costs.

Additionally, the company noted that a variable frequency drive can also be cost-effective in cooling towers.

A temperature sensor placed in the tower water can provide feedback to the VFD fan controller, ramping fan speed up and down as needed to maintain a consistent, economical water temperature.

The fan draws less electricity, power factor is improved, and there is less of a need to adjust water temperature using power-hungry chillers or mold-temperature controls elsewhere in the plant.

CONTACT: The Conair Group (Cranberry, Pa.); www.conairnet.com; 724-584-5500 Hamilton Avtec (Mississauga, Ont.); www.hamiltonavtec.com; 1-800-590-5546

technology showcase

AUXILIARY EQUIPMENT

Auger-fed granulator

Wittmann’s new MAS2 Auger is based on the MAS2 series beside-the-press conventional granulators, but has an auger feed cutting chamber that can be used directly under the molding machine because of its low height.

The cutting chamber dimensions of 247 mm x 255 mm (9.7” x 10”) and the open rotor concept are identical to that of the MAS2. The direct drive gear reduction provides a reduced rotational speed of 240 rpm to guarantee a more uniform regrind with minimal fines. The MAS2 Auger is equipped as standard with a large auger trough measuring 600 mm x 280 mm (23.6” x 11”) that is ideal for larger sprues. An additional knife located above the screw is designated to prevent large, soft runners from wrapping themselves around the screw.

Like the MAS2, the MAS2 Auger is equipped with an open rotor with three rotating and two fixed knives. By using the knife gap pre-adjustment fixture that is included with each unit, the rotor knives can be adjusted easily and accurately for faster knife changes. This also guarantees a continuous cutting diameter for more uniform regrind. The open rotor enables optimal air circulation and prevents jamming of warm sprues and parts. The 4 kW (5.4 hp) motor results in an average throughput of 70 kg/h (154 lbs./hr.).

Wittmann Canada Inc. (Richmond Hill, Ont.); www.wittmann-canada.com; 888-466-8266 Anplast Inc. (Anjou, Que.); 1-800-387-4590

Horizontally-fed granulator Herbold Meckesheim’s horizontally-fed SB Series granulators are designed for

quiet and efficient size-reduction.

The five new models granulate containers made of PET and other recyclable plastics at rates of up to seven tons per hour.

The horizontal feeding screws of the SB units force materials from the hopper to an adjacent cutting chamber at a steady, even pace instead of depending on the materials to fall directly into the blades. One result is higher throughput - an improvement of 30-50 per cent compared with same-size gravity-fed cutting chambers.

Other benefits include less power consumption, quieter operation, no fly-back, reduced wear to the cutting blades, and reduced fines and dust (since granulated particles spend less time in the cutting chamber).

SB series granulators are suitable for dry or wet operation and can also be used for secondary size reduction of pre-shredded plastics.

Herbold Meckesheim USA (Smithfield, R.I.); www.herboldusa.net; 401-232-3354

inate from the electric Allrounder A series, and are complemented by hydraulic injection units from the Allrounder S advance.

This combination is further enhanced by performance-adapted hydraulic accumulator technology.

Servo-electric drives optimize energy use, and offer up to 40 per cent in energy savings, because in addition to the servoelectric drive and braking energy recovery, the hydraulic accumulator is also driven with the minimum amount of installed pump capacity and by motors of efficiency class EFF1.

Arburg Inc. (Newington, Conn.); www.arburg.us; 1-800-221-0712 Dier International Plastics Inc. (Unionville, Ont.); 905-474-9874 D Cube (Montreal); 514-272-0500

Injection moldinggrade resin

INJECTION MOLDING

High performance machine for reduced cycle times The new Allrounder H injection molding machine from Arburg is designed to combine high performance with energyefficient drive technology, making it wellsuited for thermoplastics processing with reduced cycle times.

The abbreviation “H” also stands for the machines’ hybrid drive concept: the powerful combination of electric and hydraulic machine components integrated in the Allrounder H. The servo-electric clamping units orig-

MonoSol LLC is introducing MonoPol, a new family of injection molding resins based on water—soluble polyvinyl alcohol, a safe, non-toxic, biodegradable polymer.

MonoPol can be used for various lost core applications where it can form a temporary structure around which other materials are formed. The water-soluble structure can then be dissolved away, leaving a hollow finished article. www.canplastics.com May/June 2009 Canadian Plastics 31

technology showcase

The MonoPol family reflects the variety of formulations that are used to create films of differing performance. The material can be tuned to work at different fabrication speeds and different temperatures. Molding also allows structures to be customized by changing wall thickness and dimensional strength.

MonoPol is currently available in four different grades: ColdWater Soluble (from about 10°C) to very Hot Water Soluble (above 70°C). MonoPol is MoldFlow-certified and each grade is available in a full range of colours. Mechanical properties can be adjusted and customized for specific applications.

MonoSol LLC (Merrillville, Ind.); www.monosol.com; 219-762-3165

EXTRUSION

Extrusion die for foam insulation boards KraussMaffei Berstorff GmbH has developed the new wide extrusion die 600 for foam insulation boards with a width of 1,200 mm.

The die is tailored for Schaumtandex twin-screw/single-screw extruder combinations ZE/KE featuring an output capacity of more than 1,000 kilograms per hour.

Optimum flow channel geometry inside the extrusion head ensures even melt distribution over the entire width. At the discharge from the die, the material expands to a width of 1,300 to 1,350 mm and is subsequently calibrated to the desired board thickness in a special calibrating unit. The board thickness can be freely varied within a range of 30 to 60 mm; a solution for major thickness is currently in the development phase. The corresponding downstream equipment is designed to cool, cut and mill the boards to the desired dimensions.

The Schaumtandex configuration composed of a co-rotating ZE twin-screw extruder and a KE single-screw extruder ensures optimum product quality and is suitable for processing all blowing agent systems used world-wide.

KraussMaffei Corporation (Florence, Ky.); www.kraussmaffei.com; 859-283-0200 32 Canadian Plastics May/June 2009 www.canplastics.com

Control developments for extruders

REACT is included with the new EPIC. Davis-Standard LLC (Pawcatuck, Conn.); www.davis-standard.com; 860-599-1010 Auxiplast Inc. (Ste-Julie, Que.); 1-866-922-2894

CONTROLS

User-friendly machine operator interface Two new control developments from Davis-Standard’s Extrusion Systems Group — the DS-eTPC and REACT systems — offer processors more options while improving processing efficiencies.

The DS-eTPC touch-panel control system has been improved to include coordinated one-line drive control and new features to support customers across all product lines, including elastomer, while maintaining pricing comparable to discrete controls.

Advantages include temperature control of up to eight barrel heating and cooling zones per extruder and a “Historian” package for viewing and storage of process variables. The expanded temperature control enables the system to be used on larger extruders, with sheet systems and for the majority of recycling/reclaim applications.

Customers can name the temperature zones and drives for a more user-friendly operator interface. With the “Historian” option, the controller can be connected to any PC running Windows( Internet Explorer( so that temperature profiles, drive conditions, and pressure conditions can be saved in a report format for future analysis.

The REACT (REmote ACcess Technology) system, standard on all new EPIC III systems, is designed to reduce downtime and lost production. It enables Davis-Standard process engineers and technicians to support customers worldwide in real-time without a service call. Conditions at a customer’s plant can be viewed remotely and immediately during a production run via a secure, high-speed Internet connection without the need to stop the line.

All required hardware and software for

Standard-Knapp is introducing the new Operator Interface, a graphically driven interface that can be customized to each Standard-Knapp machine, and that utilizes colour touch-screen technology to offer a new level of intuitive machine control.

Through computer-aided fault recovery, it reduces Mean Time to Recover (MTR) and increases efficiency for challenging 24/7 applications in the food and beverage industries.

The main screen of this innovative solution contains a speedometer that tracks the speed of the machine in number of cases packed per minute. The centre of the speedometer contains a colour-changing button that switches from green to yellow to red to indicate the presence of machine faults and errors.

A product selection screen displays a photograph of each product and allows the operator to easily choose the specific product to be packaged, eliminating costly errors and jamming. With a simple push of the touch-screen image, the machine electronically aligns itself to the size and requirements of the specified product. Further simplifying the process, the corner of each product image contains a coloured box that corresponds to the colour-coded change parts needed to package each product.

Standard-Knapp (Portland, Conn.); www.standard-knapp.com; 860-342-1100

technology showcase

Accurate high performance controller RKC Instrument announces the release of the FB100 high performance temperature/process controller with an accuracy of 0.1 per cent.

The 1/16 DIN is housed in a panel saving 74 mm short case which has NEMA4X and IP66 waterproof and dustproof protection.

Sampling time can be selected as 50 ms, 100 ms, or 250 ms, depending on the application. A special start-up tuning feature calculates optimum PID values and eliminates time that conventional autotuning requires at start-up. The operator can select from autotuning, advanced autotuning, or a more advanced Brilliant II autotuning feature which allows selectable PID control.

The FB100 has universal input, up to five digital inputs, three digital outputs, A multi-memory area function stores up to eight sets of control parameters and may be set easily through front key operation, DI, or communications. The multi-memory area may be used to create up to 16 segments of ramp/soak control.

A loader port comes standard to permit communication with a PC using its USB port. Win-UCI software is provided to make data monitoring/logging easy in setting control parameters or copying parameters to another FB series controller via PC. Communication capabilities include RS-232C, RS-422A, RS-485 and Modbus.

RKC Instruments (South Bend, Ill.); www.rkcinst-usa.com; 547-273-6099 Acetronic Industrial Controls Inc. (Mississauga, Ont.); 1-800-803-8871

Non-mercury melt pressure transducers Gneuss Inc. has recently developed the new NTX non-mercury melt pressure trans-

ducers and transmitters, offering premium performance and longer life compared to existing mercury, NaK (sodium potassium), and other alternative fill-mediums.

The NTX series meet current high demand for measurement sensors incorporating superior performance and are environmentally safe, having no disposal limitations regarding hazardous waste.

Additional benefits include excellent response, repeatability, and available with higher accuracy up to 0.15 per cent. The sensors are rated to temperatures of up to 930°F, and are also very suitable for use

in the pharmaceutical and food processing sectors.

The NTX series sensors are interchangeable with other brands, offering most typical configurations regarding flexible capillary, combination melt temperature, electrical outputs, and popular connector options.

Gneuss Inc. (Matthews, N.C.); www.gneuss.com; 704-841-7251

TESTING & MONITORING EQUIPMENT Third-generation vision sensor

Cognex Corporation has added the Checker 3G Series to its Checker vision sensor product line. With simple setup, integrated part detection, lighting, I/O and job change all in a rugged IP67 housing, Checker 3G is designed to offer easy and reliable verification of all products or parts on the line.

With Checker 3G, the user chooses whether to configure the sensor as a presence sensor or measurement sensor.

Presence sensors verify that features are present. Measurement sensors verify that

features are the correct height, width and/ or diameter. In either mode, there is no limit to the number of part features that a single Checker can “check”. Checker is also able to detect and track over 6,000ppm in varying positions along the production line, overcoming imprecise part positioning and delivering consistent, precisely timed pass/fall results.

The new Cognex offering does not require a PC for setup. Instead, the SensorView Teach Pendant, with its “one-click” setup technology, allows the user to set up jobs right on the line and has them running in a matter of minutes.

Cognex Canada Inc. (Lachine, Que.); www.cognex.com; 514-728-7158

Sensors monitor pistons in pneumatic cylinders For automated equipment where piston position must be closely monitored, Baumer Inc. has introduced a new line of magnetic T- and C-slot cylinder sensors that provide discrete output regarding the end-of-stroke position of pistons in pneumatic cylinders.

Compact and economical, these noncontact sensors offer precise, repeatable switching behavior with defined and tested activation sensitivity.

The sensor’s rugged, IP67-rated plastic housing provides reliable operation in harsh and wet end-use environments. Five different, universally applicable standard C and T-slot sensors are available for use in round cylinders and cylinders with tierods. Baumer Magnetic Cylinder Sensors are designed for quick and easy installation. Available in both NPN and PNP outputs, these sensors feature cable or flywww.canplastics.com May/June 2009 Canadian Plastics 33

technology showcase

SOFTWARE

lead connectors and a wide, 3-30 volt OC supply range.

Baumer Inc. (Burlington, Ont.); www.baumer.ca; 905-335-8444

Software for flexible packaging industry

HOT RUNNERS

CPL

Mold Hotrunner Solutions Inc. introduces the new Rheo-Pro CV08 moldmounted valve gate sequence controller, a compact and user-friendly solution for accurate fill control of injection molded parts.

Designed for balancing family molds and stack molds, the CV08 provides timebased control of up to eight pneumatic valve gate circuits. Units are available with up to 64 valve control zones. The controller is mounted directly on the mold to minimize setup time and to eliminate the risk of plumbing errors during mold setup.

Conventional valve sequence controllers are bulky stand-alone units with air or hydraulic hoses connecting to the mold.

The plug-and-play CT05 touch screen interfaces with the CV08 controller for Digital Ad 1\2 4/28/09 AM Page hand-held operation, while11:35 the programming unit simplifies machine setup

and can be detached during production.

LED’s on the CV08 provide real-time visualization of the valve gate open or close position.

The CV08 does not require special options from the molding machine other than a simple start signal for the injection cycle. The controller has an internal memory which stores numerous process program setups with an automatic mold identification.

Mold Hotrunner Solutions Inc. 1 (Georgetown, Ont.); www.mhsinc.ca; 905-873-1954

Plastisoft Corporation is releasing PSQuote, its first offering in a suite of software tools designed exclusively for the flexible packaging industry, designed to allow packagers to deliver accurate quotes within minutes.

PS-Quote is a software program that allows manufactures of flexible packaging to cost and quote their products from extrusion through to printing, laminating, and converting. Users of the software can construct custom or stock product specifications including raw materials, run and scrap rates, as well as labor and overhead costs.

PS-Quote is capable of costing film substrates with up to 10 layer blends. This sophisticated costing tool provides analysis by margin, price or net profit with a push of a button as well the ability to automatically incorporate any future raw material costs. The software’s integrated quoting module enables the user to create and email detailed quotes for multiple

Introducing Canadian Plastics Digital Editions

Providing Readers With An Interactive Version of The Magazine ● ● ● ●

GO TO:

Choose Digital, Print or Both Keyword Searches of Digital Edition Archives Quick Easy Links to Advertisements Instant Online Access

http://digital.canplastics.com

technology showcase

quantities and in various units of measure.

Plastisoft Corporation (Toronto); www.plastisoft.com; 416-223-8166

applications.

PolyOne Distribution Canada (Mississauga, Ont.); www.polyone.com; 1-888-394-2662

MATERIALS

Heat-stabilized vinyl powder compounds PolyOne Corporation is introducing a new family of Geon flexible vinyl powder compounds that offer an expanded processing window for better fluidized bed manufacturing cost performance and efficiency.

At the high temperatures required to flux ordinary vinyl powder, a processor using exterior fluidized bed vinyl powder formulations typically has little time before the powder begins to thermally degrade. PolyOne has developed a new

series of vinyl powder compounds that process at lower temperatures and offer exceptional heat stability.

Processors using the new compounds can reduce manufacturing costs and improve efficiency through shorter cycle times, reduced energy consumption, reduced scrap rates, and lower costs in recovery or replacement of hooks and other hangers.

Typical applications include wire goods, pipe, fencing, grilles, conduit or similar parts, with a focus on outdoor

Colours for PEEK materials Clariant Masterbatches has developed a range of colour masterbatches that are formulated specifically for use with PEEK materials. In addition, Clariant Masterbatches is also producing specialty compounded pre-colored PEEK materials, which are available in small and large quantities.

Clariant’s RENOL colour masterbatch series includes more than a dozen standard colours designed specifically for use in PEEK polymers. Standard-colour masterbatches can

advertising index Advertiser Alba Enterprises Inc. Arburg Arkema Canada Inc. CPIA/EDC/Canadian Plastics webinar Canadian Plastics digital editions Canadian Plastics Resin Outlook Conference Canadian Plastics Sector Council Lorenz Conveying Products Macro Engineering NPE2009 PCS Company Premier Fluid Systems Rotogran International Inc. Vortex Valves Weima America Inc. Wittmann Canada Inc.

plastics data file

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E-mail

Website

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800-432-6653 860-667-6500 800-567-5726

info@albaent.com usa@arburg.com polymers.canada@arkemagroup.com

416-510-5116 613-231-4470 800-263-1942 905-507-9000

jnancekivell@canplastics.com info@cpsc-ccsp.ca sales@lorenz.ca sales@macroeng.com

800-521-0546 800-461-2611 905-738-0101 785-825-7177 803-802-7170 888-466-8266

sales@pcs-company.com info@pfspumps.com info@rotogran.com rbarragree@vortexvalves.com info@weimaamerica.com info@wittmann-canada.com

www.albaent.com www.arburg.com www.arkema.ca www.plastics.edc.ca http://digital.canplastics.com www.canplastics.com/Conference www.cpsc-ccsp.ca www.lorenz.ca www.macroeng.com www.npe.org www.pcs-company.com www.pfspumps.com www.rotogran.com www.vortexcanada.com www.weimaamerica.com www.wittmann-canada.com

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

HM SERIES IMM’S OFFER SHORTEST FOOTPRINT

The fully hydraulic Battenfeld HM Series injection molding machines are available from 50 to 730 US tons and offer high precision along with the shortest footprint. The advanced UNILOG B6 control is based on Windows XP and offers many basic features as well as a long list of additional functions. Contact us to discuss your specific requirements.

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

ROBOTS, AUTOMATION & AUXILIARY EQUIPMENT

Complete overview of the company, its history and the relentless product developments that have made it the leading manufacturer for plastics processors worldwide. Its innovative products include robots and automation systems, auxiliary equipment for resin conveying, blending, drying, granulating, heating and cooling. Contact us today to discuss your specific requirements.

Wittmann Canada Inc., 35 Leek Crescent, Richmond Hill, ON L4B 4C2; Tel. 1-888-466-8266; www.wittmann-canada.com www.canplastics.com May/June 2009 Canadian Plastics 35

technology showcase be delivered in five to seven business days, and custom colours are also available. All meet the stringent requirements of high-performance applications in markets like aerospace, automotive, electrical devices, military, and medical applications.

To meet the requirements of medical applications, RENOL MD masterbatches and RENOL MC compounds are produced under stringent “Clariant HSMP Guidelines” (consistent with

the FDA’s GMP-good manufacturing practices).

Pigments used have been tested and certified compliant with United States Pharmacopeia (USP) Class VI standards, and drug master file (DMF) authorizations can be provided for medical applications.

Clariant Masterbatches Division (Toronto); www.clariant.masterbatches.com; 1-800-265-3773

classified ads MATERIALS

MACHINERY & EQUIPMENT

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SCRAP BUYERS 25 YEAR VETERAN Email: domino@domplas.com • Fx 631-642-1771 631-642-1995 Website: www.domplas.com domino@domplas.com Phone: (631) 751-1995 Fax: (631) 751-9396 www.domplas.com

MOLDS

Aluminum Mold & Pattern Ltd. CAD design, patterns, 5 axis CNC, fixtures Locations in Toronto and Mexico Tel: 416-749-3000 Fax: 416-749-4701 www.seatmold.com 36 Canadian Plastics May/June 2009 www.canplastics.com

NPE2009 Booth # S4014-5013

SERVICES INTEGRITY TESTING LABORATORY (ITL) INC.

20 years in service of major plastics, packaging & recycling industries iso 9001:2000 and cgp registered

Comprehensive analysis, testing, R&D of plastics and polymers. Q.A./Q.C. - troubleshooting, customer returns; failure analysis; manufacturing process control, reverse engineering, case studies. RoHS, environmental, physical, chemical, mechanical testing. All major test procedures: glass transition, degree of curing, OIT, viscosity, surface/roughness analysis, microhardness, Vicat, etc.. DSC/TGA/TMA, SEM/ EDS, ICP, FTIR, XRF, UV-VIS,QUV, X-ray imaging analysis, Auger, optical interferometry (WYCO system), most ASTM standard tests, etc..

80 Esna Park Drive, #7-9, Markham, Ontario, L3R 2R7, Canada tel: (905) 415-2207; fax: (905) 415-3633; website: www.itlinc.com; e-mail: info@itlinc.com.

design ideas • earth, wind & fire

EARTH: Thermoplastic drill component handles the pressure

In the hostile environment of deep drilling, it’s not unusual to encounter temperatures ranging between 180°C and 200°C, in the presence of hydrogen sulfide, methane, carbon dioxide, salt water, and crude oil.

It goes without saying, then, that deep drilling equipment must be capable of operating under the most extreme pressures — often up to 20,300 psi - and have the ability to withstand the most extreme mechanical forces. That’s why, when micro molder CG Tec Injection, of Frasne, France, wanted to completely encapsulate a miniature sensor used in the drilling equipment, it chose Victrex’ high performance thermoplastic PEEK polymer.

The sensor, measuring 100 mm long by 3 mm in diameter, is formed using a twostage duplicate molding process. With the high rigidity, dimensional stability, and ease of processing of the PEEK material in mind, CG.TEC developed the mold and regulated it at high temperatures to guarantee good crystallinity of the polymer.

“Victrex PEEK polymer offers a good combination of mechanical and tribological properties at the elevated temperatures found in deep drilling operations,” said Robert Navo, global applications manager for oil and gas at Victrex. “Because of its range of high performance characteristics, PEEK polymer is also being used in deep drilling equipment as an insulating and encapsulating material for connector insulators, condenser housings, potentiometers, and coil frames.”

Victrex USA Inc. (West Conshohocken, Pa.): www.victrex.com; 484-342-6001

WIND: Sheet panels designed to weather the storm

The return of warmer weather also marks the return of something slightly less welcome in many regions of North America: the hurricane season.

Fortunately, home- and shopowners in storm-plagued sections of the continent can now turn for partial relief to Lookout Clear Storm Panels, manufactured with Sabic Innovative Plastics’ Lexan sheet.

Constructed by Calhoun, Ga.-based Lookout Shutters, which teamed with Sabic for the project, the easy-to-install panels are designed to provide impact strength greater than half-inch plywood against wind and windborne debris during storms.

The panels are also between 30 to 50 per cent lighter than metal panels, and — unlike metal — will not corrode or rust. They also meet code approvals for high-velocity hurricane zone, ICC, and TDI. Additionally, the panels are designed to be left up all season, and offer UV protection on both sides, as well as letting in natural light and enhancing the attractiveness of a home or store front.

“Our goal is to make sure that the technology and enhanced product attributes are there to meet the needs to builders, along with home and business owners, in these at-risk locations,” said Tammy Rucker, global product manager at Sabic.

Sabic Innovative Plastics Canada (Toronto); www.sabic-ip.com; 1-800-323-3783

FIRE: Clear view under heat

It’s hard to exaggerate the importance of having a clear field of vision when you’re battling against a burning building.

For this reason, the PAB Company — a Buzet, Croatia-based manufacturer of safety equipment — selected the new high performance Ultrason E2010 HC polyether sulfone, supplied by BASF, for the visor of its FIRE HT 04 heat-resistant firefighter’s helmet.

In developing this new Ultrason variant, BASF was able to reduce the typical inherent yellow colour of the plastic, allowing for good visual purity. Together with its ability to withstand temperatures of 250°C for 30 minutes without being damaged — and even temperatures of 1000°C for 10 seconds — the material was a good fit for use in the visor, BASF said, and the visor represents its first incorporation in a commercial application.

The helmet and visor can be produced by injection molding so that even complex shapes with integrated functions can be easily achieved.

The toughness of this transparent plastic makes it break-resistant even under extremely rough conditions, BASF said; also, the material is lightweight enough that the helmet weighs only 1.2 kg, making it comfortable to wear.

BASF Canada (Mississauga, Ont.); www.basf.ca; 1-866-485-2273 www.canplastics.com May/June 2009 Canadian Plastics 37

view from the floor

Adsorbing Reading

By Jim Anderton, technical editor

W

hen it comes to making money in the resin processing business, I prefer to take as much of the production process in-house as possible. This means serious attention to “second op” processes, but pays dividends in quality and on the bottom line.

Last month, I described the property of “surface energy”, and what it means to virgin and engineered materials.

That’s great, but why do we care? Mainly because, since few high-value resin parts are big money makers as they come from the mold or die, adding them to assemblies boosts value. And making assemblies with resin parts cost-effectively frequently involves bonding.

I’ve talked in the past about welding, and mechanical fastening using inserts, but what about good old fashioned glue? Sticking parts together is cost-effective, controllable, and can be a design “ace in the hole” where single molded assemblies

JIM’S BUZZWORD OF THE MONTH:

Adsorption (adz-orp-shun)

The deposition of a gas or liquid onto a (usually solid) surface. Adsorption is almost impossible to eliminate from energetic surfaces, but can be minimized by quick assembly or coating of the surface after treating or cleaning. Adsorption isn’t necessarily a bad thing; it’s the basis of desiccant-type low-cost compressed air dryers.

are prohibitively complex in a single shot.

This is where the surface energy comes in. Every surface of any material has an associated energy, and the amount or value of that energy drives the material to either minimize the surface area, like a spherical droplet of molten solder; or maximize it, like naphthalene (mothballs) that try to become all surface by sublimating directly into the air.

Again, so what? It turns out that controlling the surface energy of your resin part controls the ability of a liquid adhesive to wet the part’s contact surface, since the surface energy fights the liquid’s energy of cohesion (the force that tends to pull the liquid together like a water drop on a waxed car fender). Treating the surface can involve anything from gamma rays to a gas flame to acid dips, but the key is to avoid adsorption. Adsorption (not absorption, which requires a porous material) is a process where stuff sticks to the energetic part surface, reducing overall energy.

There’s a ton of physics here, but from a production standpoint, the important thing to remember is that any surface that has to be modified to get it to stick is vulnerable to contamination by the dirt floating in the air of almost every shop floor, and at a speed much faster than an untreated surface. If you’re using a treating technology, or even if you’re simply washing the parts to take off adsorbed contaminants, the clock is ticking and you need to stick your stuff together as soon as possible. If it’s a critical bond, it might be worthwhile to experiment with the time between treating/cleaning and assembly to see if there’s a strength compromise by delay.

Naturally, the adhesive matters, but if you find that surface contamination is killing your bond, don’t automatically assume that you need cleanroom conditions. I once encountered a problem with dust and dirt contamination that defied all attempts at housekeeping. It turns out that in ventilating the line properly to draw off the fumes from the adhesive, we were drawing dustladen air from adjacent lines over the parts, then up the fume hoods. The solution was simply to add a “make-up” air duct channelling clean air into the “glue station” to pick up the fumes without sucking up dust.

Cleanliness may be next to godliness, but I’ll take positive CPL pressure any day.

Check out Jim Anderton on CanPlastics TV, at http://www.canplastics.com/video/episode22.asp

38 Canadian Plastics May/June 2009 www.canplastics.com

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