Canadian Plastics September/October 2009

CanadianPlastics www.canplastics.com

BRUISED, NOT BROKEN Auto parts suppliers adapt to survive

NANOTECHNOLOGY The next big thing

RAW MATERIALS HANDLING The newest equipment

MOLDMAKING SURVEY

Facts & figures

ULTRASONIC WELDING Troubleshooting tips

COLORANTS The hot trends

SEPTEMBER/OCTOBER 2009

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contents

Canadian Plastics SEPTEMBER/OCTOBER 2009 VOLUME 67 NUMBER 6

LOOKING BACK...

The October 1971 issue of Canadian Plastics reported on an agreement between Gifu Die and Mold of Japan and a Bolton, Ont.based company then known as Husky Manufacturing and Tools Works. Under the agreement, Gifu would manufacture Husky’s pre-engineered molds. Gifu was to pay an initial lump — amount undisclosed — to Husky, plus payment of a licensing fee on every piece sold. Our report noted that the agreement was “a bright spot in all the gloom surrounding [then U.S.] President Nixon’s 10 per cent surcharge on imported products.”

page 24

Number of the month:

*21.1%

* Percentage of respondents to our Moldmaking Survey that expect good business conditions in 2010. (see pg. 21)

page 10

page 29

cover story 4 Editor’s View: • Under GM’s hood?

The North American dream 5 Ideas & Innovations: • Electrically conductive plastic set to give processors a jolt 6 News: • The latest intelligence on resin buying • FEPAC begins government lobbying 9 Executive’s Corner: • How to benefit from the SR&ED program 26 Technology Showcase 27 Advertising Index 28 Plastics Data File 28 Classified Ads 29 Design Ideas: • Earth, asphalt & sky: vehicles at work 30 View from the Floor: • Pareto problem-solving

10 AUTOMOTIVE UPDATE Bankruptcy protection, “Government Motors”, “Cash for Clunkers”. It’s been a year unlike any other for the North American automotive industry. But while the troubles of the Big Three have been well publicized, there hasn’t been much attention focused on Canada’s auto parts molders...until now.

Inside, we look at how some shops are weathering the storm.

features

12 RAW MATERIALS HANDLING EQUIPMENT In today’s business environment, any problems in getting your resin to your processing machines mean that you’re already behind the competition. But with a wealth of new raw materials handling equipment hitting the market, there’s never been a better time to upgrade.

16 ASSEMBLY & BONDING Okay, you’ve made your part to spec...but if it still needs ultrasonic welding, you’re not done yet. And unfortunately, there’s more than one way to run into trouble with your ultrasonics. Canadian Plastics asked some of the experts to identify and solve the most common problems.

19 MOLDMAKING REPORT Because you asked for it, we present the results of our first ever Moldmaking Survey. If you’re looking for the sizes, markets, buying habits — and more — of Canada’s moldmakers, you’ve come to the right place.

22 COLORANTS Brand owners don’t take trends in colorants lightly, so why should the plastics processors that service them? Inside, we give you an advance look at what to expect in 2010. Can you really afford not to know?

24 NANOTECHNOLOGY Nanotechnology involves understanding and controlling at dimensions as small as one billionth of a meter. But what’s in it for plastics processors?

Plenty. Find out about the next small thing to hit the industry.

Visit us at www.canplastics.com www.canplastics.com September/October 2009 Canadian Plastics 3

editor’s view

Under GM’s hood?

The North American dream

T

o be honest, I’ve never liked the way that people always talk about the American love affair with cars.

I’ve always thought it would be more accurate to call it a North American love affair. In other words, count us Canadians in.

A country steeped in American influences — not to mention possessing some of the most wide open highways anywhere — Canada has just as much of a car culture as our neighbor to the south.

That’s why whatever happens to any of the Big Three automakers matters to us...and not just in an economic sense, although that’s certainly an important consideration. (For a look at how the troubles of the Detroit automakers are impacting Canadian parts manufacturers, check out our “Automotive Update", beginning on pg. 10) For those of us that grew up surrounded by domestic cars, the economic problems of GM, Ford and Daimler Chrysler matter on an emotional level, I think — in much the same way that it would bother us to see the old Mom’n’Pop store that we hung out in as kids go out of business.

The fact that these companies brought many of their problems on themselves might blunt our compassion, but probably doesn’t destroy it completely.

Anyone who feels even a lingering affection for the Big Three will probably find a new book called Why GM Matters to be an entertaining and instructive read. Written by business journalist William J. Holstein, Why GM Matters (subtitled Inside the Race to Transform an American Icon) gives the reader keyhole access to the ins-and-outs of the history of the venerable auto giant: its glorious rise, the beginnings of crisis, the slow slide into bankruptcy, and the recent sacking of chairman and chief executive George Wagoner, Jr.

Without downplaying GM’s failures, Holstein does a good job of reminding the anti-car advocates (not that they’d ever read his book, of course) of the importance of GM and other auto giants. “It’s hard to imagine a healthy technology industry without an auto industry to buy from," he said. Seen in this light, Holstein continued, GM “is not a dinosaur left over from the previous century, but a crucial piece of America’s effort to revitalize its economy and sustain its position in the world for the next century.” A chapter on the development of the Chevy Volt backs up this claim by offering an interesting glimpse not just of the future of GM, but into the future of driving in North America.

In the end, Holstein makes a convincing argument for the continued centrality of GM to the so-called American dream, despite the transplantation of foreign car production onto American soil.

(He also offers the interesting theory that GM’s own awareness of its role in the American dream led, at least in part, to its downfall: the gargantuan employee benefits burden that put GM at a competitive disadvantage to foreign carmakers was an outgrowth of its self-image as the personification of everything good in America — according to which, what could be better than giving working men and women a decent retirement?)

Early in the book, Holstein asked the question, “Should anybody care if GM survives?" Putting the volume down, I found myself thinking that its survival does matter — to me and probably to millions of others, not just to the car owners and jobholders.

It used to be said that what was good for GM was good for America. I think it still is, although with the following modification: what’s good for GM is good for North America.

Mark Stephen, managing editor mstephen@canplastics.com

4 Canadian Plastics September/October 2009 www.canplastics.com

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

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ideas and innovations

Electrically conductive plastic set to give processors a jolt

M

ost of us don’t think about our car battery until we have to replace it.

And at that point we realize how heavy it is, and probably pause to wonder why — with plastic car parts becoming lighter by the day — the battery still feels like something that Arnold Schwarzenegger would have trouble lifting.

The short answer is that, because of the electricity coursing through it, there’s never been a way to make a lightweight car battery from plastic.

Until now, that is.

A new moldable conductive plastic called ElectriPlast, being brought to market by development company Integral Technologies Inc., has the potential to replace traditional material like lead or stainless steel in a car battery, reducing the weight by up to 30 pounds.

According to William Robinson, Integral’s chairman and CEO, ElectriPlast’s ability to conduct electricity results from a blend of small single pellets designcompounded with metal fibres. The technology was six years in the making, and wasn’t achieved without false starts. “In the end, the key was to find a polymer that had a low dielectric loss tangent,” Robinson said. “We’ve now patented not only the pellet, but also the process of having it under one pellet.”

FIRST STEPS The use of ElectriPlast as a weight-saving replacement to lead and steel in car batteries is about to be tested. “We’re working with a battery manufacturer to change the weight factor within a car battery by making the body completely from plastic,”

Robinson said. “The project has advanced sweat equity are about to pay off. “We’ve to the CAD drawing stage, and can ulti- got the material; it’s just a matter of findmately help the auto industry reach the ing companies that are aggressive and goal of having the same amount of power, want to move forward,” he said. “If we can but with a lower load factor.” get our foot in the door, I think that people will look at4/21/09 us very seriously.”

With a shift towards a “green” econPFS Ad/AB/CPL 8:10 AM Page 1 That wouldn’t exactly come as a shock. omy in North America, Robinson believes that ElectriPlast’s characteristics, such as Integral Technologies Inc. weight savings, cost savings, design flex- (Bellingham, Wash.); ibility, conductivity and non-corrosiveness, www.itkg.net; 1-888-666-8833 could lead to the product becoming an important part of new transportation trends.

And this may be just the beginning.

Integral is currently working to apply its technology toward the creation of antennas, apparel, appliances, computers, electrical and heating systems and more, Robinson said, and at present there are already Travaini’s innovations and experience in almost 120 patents filed around Electrimanufacturing liquid Plast and its use.

ACHIEVING

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in vacuum pumping after 80 years

PARTNERSHIP PAYS OFF A key element in developing ElectriPlast has been Integral’s partnership with Jasper, Ind.-based fabricator Jasper Rubber Products. “They’re our sole manufacturer, and their involvement allows us to remain focused on developing the science behind the ElectriPlast material,” Robinson said.

And the fruit of this development is a product with very simple operating instructions for processors. “The ElectriPlast pellet can be custom made for any use, regardless of how simple or complex the application, or of the ratio of metal-to-polymer required in the pellet,” Robinson said. “The material is available as either an additive or resin, and the customer doesn’t have to do anything other than convey it to the processing machine.”

Robinson has no doubt that the years of

ring vacuum pumps have driven the industry to new standards.

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www.canplastics.com September/October 2009 Canadian Plastics 5

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news

THE LATEST INTELLIGENCE ON RESIN BUYING Q&A with Bill Bowie, chief operating officer, Resin Technology Inc.

Q A

Can you give us an overview of the industry at present?

The resin industry is going through a transition, just as we all are. With polyethylene, for example, currently close to 30 per cent of the North American production in 2009 has gone offshore.

Domestic producers keeping inventory levels low here in North America have allowed them to push through some of the price increases we’ve seen most recently.

In general terms, on the polyolefin side, we’ve seen the peak now with shutdowns in the summer; producers have slowed down their reactors, and we will see prices come off during the second half of the year. We believe we’ve seen the peak in resin markets in North America.

Q A

What changes will be brought about by large capacities of Saudi Arabian resin coming on stream shortly?

As that production comes on stream, the 25 to 30 per cent of North American production that’s been going offshore is going to have to find a home here, and it will put tremendous pressure on the North American producer to rationalize this older production, in that it might not be quite as efficient as the new production. We’re going to see total reorganization of the producers, in that those producers that were domestic producers will now become global producers in joint ventures with Middle East countries.

Q A

What will this mean for North American processors?

It’s an interesting time in that, as we’re seeing less opportunity for a producer in North America, there’s great opportunity that continues to present itself in Asia and the Middle East. As those reactors come on stream and go online, there’s new opportunities being presented to North American processors to look more globally for their resin supply.

 ☛

Q A

What’s your prediction for resin pricing trends in the next 12 months?

We’re not through the difficulties we have yet.

Prices for resin are going to drop for the balance of this year, and then in the first and second quarter of 2010, when people start getting called back to work, we’ll see natural gas and oil prices increase, and then resin prices follow that. It may be difficult, but I think that it’s a positive indicator that we’ve turned the corner, and that our economy is going to change.

Q A

What are the main difficulties confronting processors today in sourcing their resins?

The old saying that knowledge is power is very true here. My advice to clients is to know more than the person siting across the table from them.

Understand what’s driving the resin prices, understand what the right price is for your business, and pay your bills on time. If you need 60 days to make payment, negotiate 60 days — but pay by day 59, because when a processor is negotiating, that’s what will give them an advantage and empower them with the supplier that they’re dealing with.

What most purchasers in plastics processing companies don’t realize when dealing with a resin supplier is that they, the processor, are really selling themselves as being an advantage for that supplier to deal with.

Q A

What general resin buying advice would you give today’s plastics processors?

More than ever, it’s important to know what’s impacting your resin price when you’re about to make a purchase, to understand what the markets are doing, and what that producer’s position is in the market. How does he fit? Is he a low cost producer, does he have extra production, is he financially struggling himself? These are key things to understand when you’re sitting down to negotiate.

For the complete interview with Bill Bowie, check out http://www.canplastics.com/video/episode31.asp

6 Canadian Plastics September/October 2009 www.canplastics.com

news

FEPAC begins government lobbying

The Federation of Plastics and Alliances Composites (FEPAC), the Montreal-based association of plastics processors, has announced plans to undertake a new phase of its action plan.

According to executive director Pierre Fillion, the plan consists of “officially presenting different projects and programs developed over recent months to different strategic groups, and both federal and provincial governmental agencies.”

“Since January 2009, all the resources were devoted to mobilise different actors and industry partners around FEPAC’s vision

and action plan,” Fillion continued. “Results are above expectations, and we are very proud of the outcome of our efforts and the level of engagement from all leaders and decision-makers of the industry.”

According to Fillion, FEPAC’s major initiatives are intended to provide the different-sized players in the plastics and composites sectors with powerful leverage to improve their competitiveness and global performance.

Approximately 70 members have joined FEPAC since the beginning of 2009, Fillion said.

PEOPLE Extrusion machine and equipment manufacturer CDS - Custom Downstream Systems, Inc., of Lachine, Que., has named Todd Messick to the position of senior sales account manager for the U.S.

Craig Farrell

Color and specialty additive masterbatch producer Optima Colour, of Cambridge, Ont., has appointed Claude Faubert as account executive for Quebec and Eastern Canada.

Mike Hicks has been appointed vice president of precision standardized components and ancillary products supplier DMS North America, in Oldcastle, Ont.

Caton Morris

Calgary, Alta.-based Nova Chemicals announced that Larry A. MacDonald, its senior vice president and chief financial officer, will retire effective December 31, 2009.

Fort Worth, Tex.-based resin pricing consultants Resin Technology Inc. (RTi) has named Craig Farrell to position of new international vice presiRick DePew dent, while Caton Morris and Rick DePew have been appointed as vice presidents of business development.

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www.canplastics.com September/October 2009 Canadian Plastics 7

SPONSORED FEATURE

the long term solution to price volatility It has been a challenging and a reflective time for the plastics industry since this time last year. Polypropylene and polyethylene prices have shown high levels of volatility. Just shy of $2000/ mt ($0.89/lb) in July 2008, the LME price for PP North America fell 70% to $610/mt ($0.28/lb) in December, rising to $1000/mt ($0.45/lb) recently.

What does this mean for the polymer industry? How can market participants forecast costs, revenues etc? We’ve all seen the impact on major producer financial statements since Q4 of last year. Demand destruction has meant that crackers, plants have been shut down for extended maintenance periods and less cost-effective capacity has been permanently removed from the market.

An ExxonMobil executive is quoted recently (“ExxonMobil waiting out global recession, preparing for recovery”, Plastics News, Aug. 13, 2009) “…high prices aren’t the problem. All the materials that polymers compete with are up even more. What hurts is volatility. How do you plan? You can’t lock in to six-month contracts because polymer prices and crude [oil] prices aren’t good to the end of the year.”

Yes you can. Volatility in polymer prices is leading to a re-think of current business models and strategies. For the London Metal Exchange (LME; London) this has meant increased interest in hedging using its Polypropylene (PP) and Polyethylene (LLDPE) futures contracts. Volumes have been steady and there is open interest (an indication of forward business) well into 2010.

Frustration with existing price indexes tied to price reporting services is also driving interest, according to LME member firms and LME executives.

L M E P R I C E S M O R E A C C U R AT E T H A N I N D U S T RY S U R V E Y S

An exchange-derived price is transaction-based - one of the most effective price discovery mechanisms available. It increases transparency and does not rely on phone rounds of industry participants. According to a North American polypropylene producer recently quoted in Chemical Week, the “LME cash settlement prices are more accurate than industry surveys as an indicator of polypropylene pricing.” (Chemical Week August 3/10, 2009, page 27).

LME prices should be referenced in sales and purchase agreements when using the futures market for hedging.

Over-the-counter (OTC) activity (a derivative transaction that is neither standardised nor transacted on an exchange) is often a precursor to on-exchange trading. This now represents more than five times the on-exchange business and will move on exchange in due course.

These financial tools enable volatility to be managed or

‘hedged’. An equal and opposite cash flow to the normal sale or purchase is created which offsets any movement in the price of the underlying product. This provides the ‘hedger’ with a known cost in a similar way to a fixed rate loan from a bank.

The LME has persevered with highlighting the importance of its services and is seeing real progress. Introducing pilot hedging programmes into organisational strategy is the way forward. One

By Robert Sheldon step at a time has been the mantra, and Business Manager - Plastics steadily organisations, where resource can be allocated, are seeing the benefits. Some North American organisations have reported taking market share from competitors during the downturn.

SUCCESS IN CHICAGO

North American industry continues to be the most responsive. This was reflected in the recent workshop the LME held at NPE in Chicago where the majority of attendees were converters and large end consumers from the USA and Canada. The interest is clearly there, and that was apparent at the team-based workshop which was run by practitioners from LME member firms; MF Global, RBS Sempra, Société Generale and Macquarie Bank. Due to the workshop’s interactive nature numbers had to be restricted to 60 places. Over-subscribed by 50%. Most of those not participating were happy to watch proceedings from the remaining seats in the auditorium.

There is still conservatism towards futures contracts and many myths still abound. Many producers suggest that a futures market will commoditise their business, but ask yourself how many produce commodity grades and how many had their financial statements impacted by the collapse in the price of polymer last year?

The prospect of allocating resource to a new product or formulation can be perceived as risky. It is true, this is not an undertaking to be entered into lightly. A pilot scheme; hedging small volume initially and gaining experience gradually is the proven way forward. As the saying goes, seeing is believing or in this case doing is believing.

For more information on managing volatility: email: info.plastics@lme.com; web: www.lme.com/plastics

executive’s corner

How to benefit from the SR&ED program

By Sol Algranti, Northbridge Consultants

W

atching my manufacturing company thrive for the past 30 years, even throughout the latest recession, I’ve learned some valuable lessons that helped me keep my businesses successful. One of the primary ways I discovered to do this is by going against the grain.

We developed new products and technologies when most companies stopped all their development activities, with help from Canada Revenue Agency (CRA) and its Scientific Research and Experimental Development (SR&ED) program. The SR&ED program can help a manufacturing company recapture up to 41.5 per cent of its costs. Each year, the SR&ED program provides over $4 billion to more than 18,000 claimants. The downside is that only about one-half of the manufacturing companies in Canada are taking full advantage of this program.

LESSENING FINANCIAL RISK The plastics industry has evolved tremendously in order to stay competitive, keep up with trends, and build higher quality products for consumers. The revolutionary development of the entire plastics processes, including tool making, has forever changed manufacturing, and it’s safe to assume that the plastics industry will continue to evolve in order to reflect the changing needs of customers.

This evolution of new technologies and new product development activities can bring about experimentation to determine if what we’re trying to accomplish is actually viable. It may also prompt us to change our products and/or processes slowly over time. Either way, we take what we know and build upon it to make a better product or a better way of producing that product.

With new product development comes risk. The possibility of failed projects, and the uncertainty of the results, could prove to be a costly venture for a business in this economy. This is where the SR&ED program can be of great assistance.

The CRA recognizes the risks that are involved in the development of new or improved products or processes. The outcome of new product and technology development is not easily predictable, and can cost significant time, materials and resources. The CRA developed the SR&ED program to help compensate for some of the costs incurred through innovation. This compensation is granted in the form of a tax credit or cash refund. By investing in domestic research and development, the SR&ED program improves Canada’s competitiveness in the global market, stimulates domestic economic growth and creates more employment opportunities.

According to CRA estimates, approximately 50 per cent of eligible companies are not claiming SR&ED. Often, companies fail to claim because they don’t realize that they’re always involved in some sort of technology development activities in order to survive beyond to their normal day-to-day work. The development of new product and technology activities will often involve sufficient experimentation that is eligible for SR&ED. In fact, we’ve seen new products, improved and/or modified products, and new and/ or improved processes all accepted for the SR&ED program.

cles and technological content. Technological advancement means going beyond the current industry knowledge in your field. Technological obstacles are any uncertainties that you must overcome, and any problems that can’t be solved with current industry knowledge. Lastly, technological content (or systematic investigation) is the actual work that is done on a project — the investigation, experimentation and/or analysis.

So, what does this mean for the plastics industry? It means we can grow with the trends, and can embrace new technologies and new projects, knowing that there is a program that can help recover the costs that these changes and innovations can bring about.

What have you done to take advantage of the SR&ED program?

Sol Algranti’s entire career evolved in the plastics industry. He has held various advanced engineering and management positions and had 35 years of experience in the plastics manufacturing industry prior to founding Cambridge, Ont.-based Northbridge Consultants.

Northbridge specializes in assisting companies to maximize their SR&ED claims. For more information about Northbridge’s services, please go to www.northbridgeconsultants.com.

HOW TO QUALIFY But how do you know a project qualifies as SR&ED? It must meet three criteria: technological advancement, technological obstawww.canplastics.com September/October 2009 Canadian Plastics 9

automotive update

BRUISED, T

Bankruptcy protection, “Government Motors”, “Cash for Clunkers”.

The North American automotive industry has been on a roller coaster for the past year, and auto parts suppliers have been taken along for the ride.

And it’s not over yet.

Canadian Plastics takes a look at how Canada’s auto parts molders have fared so far.

he French Revolution, Charles Dickens once wrote, was the best of times and the worst of times for the people involved.

For Canada’s auto parts manufacturers, the past few years have definitely been among the worst of times. The global economy went into a tailspin, GM and Chrysler both scaled back production during their recent bankruptcy protection revamps, and dealers also cut back for fear they may get stuck with cars and trucks no one wanted.

This has translated into considerably less business for part molders, to say the least.

But with the Bank of Canada declaring that the recession is over, and with all three Detroit automakers boosting the volumes of vehicles they make over the third and fourth quarter of 2009 thanks to federal incentives, is it safe to say that times might finally be getting — at least a little — better?

Not necessarily, according to at least some of Canada’s auto parts suppliers.

It turns out, in fact, that there are a host of problems still to be faced — and the only comfort may be that many of the parts suppliers still operating have probably already made the changes that will be necessary to see them through future crises.

GOOD NEWS, BAD NEWS The first problem might seem surprising, at first glance. Someone, 10 Canadian Plastics September/October 2009 www.canplastics.com

somewhere, once said that good news can be bad news...and they weren’t just being clever. Some of the parts molders that used up their cash reserves to remain solvent over the past few months may find out that there’s some truth to the adage when they’re unable to afford to restart production. Simply put, while part orders may come in, these shops may not have the funds necessary to spend on materials and capital expenses.

And they probably shouldn’t look to the banks for help. “From a supply standpoint, the banks don’t like the automotive industry at present,” said the global marketing director at a Southern Ontario parts molder, who wished to remain anonymous. “A lot of the suppliers that are teetering on the edge may find that the banks will decide to close them down rather than help them to refinance.”

Small wonder, then, that Southfield, Mich.-based automotive consulting firm AlixPartners estimated recently that 24 per cent of all auto suppliers globally are in risk of going out of business within the next two years — a 25 per cent increase from just 12 months ago.

And even those suppliers that can afford to begin new production runs aren’t guaranteed to actually receive any orders. “The Big Three are evolving, studying what the foreign competition is doing, and adapting,” said Brad Wright, vice president, sales and engineering, at Toronto molder Innotech Precision Inc. “In awarding a contract, they

automotive update

NOT BROKEN

By Mark Stephen, managing editor and their customers are now looking at all of the facets that make a strong supplier, in particular a low debt-to-equity ratio.”

In a notable instance of good news, Innotech was able to score a coup recently by successfully bidding to mold parts for the new hybrid electric Chevrolet Volt.

“We secured this contract because we were relatively strong financially, but also because we’ve proven ourselves in the past,” Wright said. “We’re an engineeringbased firm, too, which is a quality that more and more customers are demanding of their part suppliers nowadays.”

should be allowed to weigh cost, quality, reliability and risk regardless of short-term political considerations”, said Dave McCurdy, president and CEO of the Washington. D.C.-based Alliance of Automobile Manufacturers. “Technological development is inherently unpredict-

do survive will be a lot leaner and better educated, which might be the only good things to come out of this situation,” said the global marketing director at the Southern Ontario firm. “The industry will have a long memory, and we’ll deploy capital better and not necessarily get forced into situations by the OEM customerbase whereby they bully us into making investments.”

But this last point might breed a problem of its own, he continued. “Some of the R&D costs might get pushed back to the OEMs, which could wind up hurting the suppliers, since there’s no guarantee that the OEMs will be willing or able to pay these costs, either,” he explained. “This could cause otherwise viable projects to go overseas.”

On the job front, meanwhile, many of the positions that were lost over the past year may never come back. “Outside of the plant level, there may prove to be a jobless recovery,” the global marketing director said. “Even if the industry does bounce back to previous levels of unit orders, I suspect that there will still be 25 per cent fewer jobs, mainly as a result of leaner manufacturing processes.”

To return to Dickens, it’s clear that the good times haven’t come back just yet for Canada’s auto parts suppliers. But while many shops have definitely been bruised by recent events, they haven’t been broken — or lost their optimism. “It’s still an exciting industry, and people are excited about new possibilities when the market does rebound,” said Innotech’s Brad Wright.

“We’ve all had to work that much harder to survive, but many of us will emerge stronger, leaner, and better at what we do.” CPL

“The industry will come back, but not as strong as before.

There will be fewer suppliers, but more strategic suppliers.”

GOVERNMENT STEPS IN But isn’t the success of the Obama administration’s “Cash for Clunkers” program — responsible for a distinct rise in U.S. auto sales — something for Canada’s parts suppliers to celebrate? Yes and no, some say, in that the short-term benefits might be outweighed by damage done in the longer term. “It’s true that production forecasts over the next six months are up, but a large portion of that — maybe as much as 75 per cent — is simply pulling forward future demand,” said the global marketing director of the Southern Ontario firm. “The industry will pay a price for this at some point in the future, perhaps even into 2011.”

On the topic of government and the auto industry, there are worried voices saying that the rebirth of GM as the so-called “Government Motors” — of which the governments of Canada and Ontario share 11.7 per cent ownership — will not be the cure-all that many hope.

Primarily, there is concern that politics, not technological advancement, will drive decision-making. “The market

able, and the best policies will encourage a range of technologies to develop and enter the market.”

The results of government intervention for Canada’s auto parts suppliers? “It’s possible that some of the OEMs might have difficulty raising the capital they need to fund new development and introduce new models, and there might be some fallout from that a few years from now,” said the global marketing director at the Southern Ontario firm. “The bailouts and the GM takeover kept the Big Three alive and cleaned up their balance sheets, but it didn’t address the problems that got them into trouble in the first place, and I’m not convinced that they’ve learned anything.”

A NEW LANDSCAPE Trying to map out the emerging landscape facing Canada’s auto parts suppliers is difficult, but a few broad features can be seen. Clearly, there will be fewer auto parts molders around, which has the potential to offer more work to those that have survived. “The industry will come back, but not as strong as before,” said Innotech’s Brad Wright. “There will be fewer suppliers, but more strategic suppliers.”

The survivors will have learned some valuable lessons, too. “The molders that

www.canplastics.com September/October 2009 Canadian Plastics 11

raw materials handling equipment

HANDLING IT (YOUR RAW MATERIALS, THAT IS) Problems getting your resin to your processing machines quickly and efficiently?

Then you’re already behind in the game. But with a wealth of new raw materials handling equipment hitting the market, there’s never been a better time to replace whatever it is that’s not working properly at your shop.

By Mark Stephen, managing editor DESCRIPTION: Distributed I/O 10/80 controller INFO: The distributed I/O 10/80 controller from AEC Inc. — the newest member of the VacTrac Series — is designed to offer fast, easy and flexible solutions for the general conveying process with control of up to 10 vacuum conveying pumps, 80 loading stations and 80 purge valves. Featuring a distributed I/O network, the 10/80 provides a series of options per block to ensure maximum efficiency, allowing them to be tailored to fit a specific process.

An Allen-Bradley CompactLogix controller with 10-inch color touchscreen operator interface with enhanced graphics is standard.

The easy-to-follow graphical touchscreens provide total navigational control of the central vacuum system. The setup screen, for example, allows for the naming of loading stations, pumps, purge valves and material sources so you know exactly what is in each hopper and where it’s located.

The touchscreen display provides an icon-based platform for easy maintenance, operation and troubleshooting. Easy-to-read diagnostics, operation and installation instructions as well as spare parts information are all available from the touchscreen.

Manifold sharing capabilities allow the 10/80 to reduce the cost for tubing and purge valves, and can stage and sequence six vacuum pumps per manifold line. The 10/80 can assign each loading station to any of the pumps connected to the same manifold.

CONTACT: AEC Inc. (Schaumburg, Ill.); www.aecinternet.com; 847-273-7700 Equiplas (Toronto); 416-407-5456 Lutek Plastic Equipment Inc. (Dorval, Que.); 514-421-8963 Shaw Equipment Technologies (Vancouver, Wash.); 1-800-528-8011 12 Canadian Plastics September/October 2009 www.canplastics.com

DESCRIPTION: Dual-hopper gravimetric feeder adjusts color to match regrind rate INFO: Designed to accurately add both regrind and color to natural resin, the Dual TrueFeed gravimetric feeder from Conair has two material hoppers and a control system that adjusts color percentages if regrind percentage varies. If no regrind is involved, the second hopper could also be used to stage a second color for quick changeover.

The color and additive feeders use gravimetric (loss-inweight) metering technology that improves accuracy and makes the units simpler to operate. Unlike volumetric feeders, which have been standard in the plastics industry for years, gravimetric feeders are self-calibrating, adjusting automatically for changes in material type, bulk density or pellet geometry.

The control system tracks material dispensed and compares it to the programmed feed rate, adjusting continually to maintain the correct proportion of ingredients. When feeding color and regrind, the color side of the feeder can be slaved to the regrind side so that more or less color is dispensed, depending on how much regrind (which is already colored) is being used. An optional communications package is available to deliver material usage data to a central host computer for inventory control or process documentation.

No calibration is required for consistent metering, and the operating parameters can be stored in memory for recall the next time the same job is run. The system can store up to 1,500 set-ups.

CONTACT: The Conair Group (Cranberry, Pa.); www.conairnet.com; 742-584-5500 Hamilton Avtec (Mississauga, Ont.); 1-800-590-5546

raw materials handling equipment

DESCRIPTION: Clean, versatile flexible screw conveying INFO: FlexFlite Flexible Screw Conveyors from Cyclonaire Corporation use steel augers and flexible tubes up to 100 feet long to move materials at rates as high as 3,600 lbs/hour.

The spiral auger is the only moving part that contacts the conveyed material. It is coreless to minimize clogging, and has an oval cross-section to ensure positive movement of material through the delivery tube and metering accuracy. Close pitching of the spiral allows increased flexibility, a tighter bending radius, and operation at lower speeds.

FlexFlite is easy to run and maintain. The in-line, geared electric motor rotates the spiral and can be set at speeds suited to the density of conveyed materials, the angle of inclination, and distance and rate of transfer. Fully enclosed construction ensures contamination-free operation.

The head housing provides access to the drive shaft for maintenance.

The conveyors are readily portable and ideal for conveying product from bags, bins, hoppers, or weigh stations.

Rated capacities for the three FlexFlite models are 100, 300, and 400 cubic feet per hour.

CONTACT: Cyclonaire Corporation (York, Neb.); www.cyclonaire.com;800-445-0730 Con-V-Air (Mississauga, Ont.); 905-285-9934 (St-Hubert, Que.); 450-462-5959

DESCRIPTION: Diverter valve orients from any direction INFO: The new Swivel-Port Diverter Valve from Lorenz, which automatically selects from up to 10 sources to destination, has been designed to solve a multitude of material conveying problems.

Made from heavy duty machined aluminum, the unit connects with rigid pipe, instead of flex hose, to orient incoming lines from virtually any angle or direction. Each segment can be rotated to suit an incoming pipe.

With a small footprint, it can be installed in minimal floor space, saving installation labor and maintenance costs.

Individual positive seating valves open on demand to allow a smooth flow of both material and air through the valve to the outlet and back into the conveying air stream.

After the conveying cycle is completed, the valve is resealed and, if necessary, a purge cycle is activated to ensure that the valve is completely clean before the next material is conveyed.

CONTACT: Lorenz Conveying Products (Cobourg, Ont.); www.lorenz.ca; 1-800-263-1942

DESCRIPTION: See-through vacuum loader gives full view of loading INFO: The GlassVu GVL loader from Maguire Products is a self-contained unit designed to offer a full view of loading for easy setup and monitoring.

A slanted hinged lid at top provides easy access for cleanout and filter changing. The cylindrical body of the loader has a center section of borosilicate glass.

The cylinder shape extends all the way down to the discharge area, eliminating the conventional cone-shaped bottom, whose narrow section can cause agglomeration or bridging of material.

Located at the base of the loader body, the discharge assembly controls the flow of materials with a pneumatically driven, positive-seal discharge valve that prevents vacuum leaks associated with flapper valves. The material drops into a hopper through a mechanical, counterbalanced level switch, which automatically returns to its normal position once material is evacuated.

The discharge area design also makes possible flush mounting of the loader onto a hopper by means of a mounting flange at the base of the loader. For mounting directly onto a processing machine, Maguire supplies a glass hopper, which is contained within a sturdy frame that supports the loader. The hopper pivots out of the frame for easy draining of residual material.

Other features include a rotating inlet that allows 360째 access for hoses, a blowback system that cleans the entire surface of the filter with one blast, and a handle for easy portability.

CONTACT: Maguire Canada/Novatec Inc. (Vaughan, Ont.); www.maguirecanada.com; 1-866-441-8409 www.canplastics.com September/October 2009 Canadian Plastics 13

raw materials handling equipment

DESCRIPTION: Low-leakage rotary valves INFO: Pelletron is introducing a new low-leakage rotary valve series for pneumatic conveying of granular products, designed to provide low leakage of air, continuous product flow, and high filling efficiency.

The company’s GRM Series is intended for medium

pressure applications, while the GRH Series has been built for high-pressure applications.

The rotor design features expanded tips at the end of the rotor blades; also, expanded vanes at the ends result in lower air leakage.

In combination with the special rotor design, the number of rotor blades could be increased as well, which also contributes to a lower leakage rate.

More vanes also provide more pockets, and result in an improved continuous product flow at higher filling rates.

The new rotary valves are available for various pressure applications, from a medium differential pressure of 22psi (1.5 bar), to a high-pressure version for 50psi (3.5 bar). The valves are available for conveying capacities of 4,500 lbs/hour (~2t/h) up to 220,000 lbs/hour (~100t/h), depending on the bulk density of the conveyed product. A quick-clean version for adhesive products or for easy cleaning during product change over is available as well, called GQM Series.

The housing is made in stainless steel or hard-coated aluminum, and the rotor is always made in stainless steel.

CONTACT: Pelletron Corporation (Lancaster, Pa.); www.pelletroncorp.com; 717-293-4008

DESCRIPTION: Fully automatic material selection system INFO: The standard version of Motan’s fully automatic coupling station, Metrolink, supplies up to 15 processing machines automatically with up to 16 material options.

Due to the modular construction, the capacity can easily be expanded and the compact, sophisticated design of the material distribution system enables spacesaving integration into the process.

Using the Metrolink in production plants with numerous processing machines, manufacturing will continue even if there is a malfunction within the system, and all machines will continue to be supplied with material. Moreover, when a material change is required, this can be done manually.

Unlike conventional automatic distribution systems, the Metrolink is only in action when the material is changed, and not whenever a conveying point needs material. The system throughput can also be increased using the Metrolink, since several machine lines can be fed with material at the same time.

CONTACT: Motan Inc. (Plainwell, Mich.); www.motan.com; 1-800-991-9921 Dier International Plastics Inc. (Unionville, Ont.); 905-474-9874 D Cube (Montreal, Que.); 514-272-0500

DESCRIPTION: Precision feeding of most materials INFO: The new AccuMeter continuous loss-in-weight feeding system from Sterling is designed to handle most pellets, regrind, powders and liquids, even at very low levels (>50 grams/hour).

The AccuMeter series features a modular, compact design that provides complete flexibility for changes in your process. Pellets, micro-pellets, powders, liquids, and regrind are all accurately metered, while twin-screw feeders and special agitators are also available for non free-flowing materials. Self-calibration eliminates the need to take manual weight samples or calibrations.

The refill system is designed for up to 40 refills per hour, which can reduce system size and cost, especially when used with integral conveying systems. The vacuum receiver can also be used as the refill hopper to further reduce the overall height of the system. Smaller components allow quick changeover, since less material needs to be drained and fewer components need cleaning.

The AccuMeter can feed from 50 grams/hour to 16,500 lbs/hour (7,500 kgs/hour) and can accommodate up to eight precision feeders per extruder. All components are continuously dosed, and the material flow is constantly monitored and controlled.

The system has a cumulative dosing accuracy of ±0.5%, and is driven by variable speed DC drive motors.

CONTACT: Sterling Inc. (New Berlin, Wis.); www.sterlco.com; 262-641-8610 CN Smith Machinery Sales Inc. (Georgetown, Ont.); 416-917-3737

14 Canadian Plastics September/October 2009 www.canplastics.com

raw materials handling equipment

DESCRIPTION: 4-way line diverter for dry bulk solids INFO: The new Quantum Series 4-Way Wye Line Diverter from Vortex Valves has been engineered to handle dry bulk solids in pneumatic conveying systems with vacuum or positive pressures up to 15 psig (1 barg).

Available in two-inch to six-inch (50 mm to 150 mm) pipe or tube, the system can direct dry bulk material from one source to four destinations, or converge from four sources to one destination.

The Quantum Series provides positive shutoff of air and material improving process efficiency, minimizes cross contamination, and eliminates material buildup beyond the closed port.

Vortex Valves (Salina, RotogranCONTACT: 3-AB-CPL 2/13/09 2:09 Kan.); PM Page 1 www.vortexvalves.com; 785-825-7177 (Mississauga, Ont.); 905-607-5200 (Edmonton, Alta.); 780-432-3612 (Dorval, Que.); 514-684-0058

DESCRIPTION: Vacuum loader with intelligent design INFO: The new FeedMax B, the latest generation of the FeedMax Series material loaders from Wittmann, features a complete construction redesign.

By slanting the cylindrical part of the center section, a greater cross sectional area of the loader is achieved, ensuring easy access for thorough cleaning, long operating life, and efficient use.

The FeedMax B units feature connections to the material inlets and vacuum outlets that can be adapted to fit various system tubing diameters. By means of a modular kit consisting of two different cylinder segments, the loader can be configured for any desired throughput.

The units are suited for dedicated as well as common material line conveying. Also, loaders can be equipped as an option with a triple-shielded capacitive level sensor in order to avoid programming and faulty entry of loading times.

Unchanged from the previous series, the FeedMax B loaders employ a pneumatically-actuated material discharge bell. By pneumatically actuating the discharge bell, atmospheric pressure differences between the interior of the loader and the discharge cone have no influence on the function of the unit. This also eliminates the need for a filter in the cone that would otherwise need to be cleaned after material changes.

CONTACT: Wittmann Canada Inc. (Richmond Hill, Ont.); www.wittmann-canada.com; 1-866-387-4590 Anplast Inc. (Anjou, Que.); 1-800-387-4590

FOR YOUR NEXT GRANULATOR GET THE BEST OF BOTH WORLDS:

Canadian Built and Priced Right for Today’s Economy R

Rotogran granulators are internationally recognized for their superior design, efficiency, durability, and competitive pricing.

We are the size reduction specialists for the processing and recycling industry.

Our rugged equipment is precision manufactured to meet individual customer needs.

• Complete range from press side to central • The fastest change-over in the industry • Chamber construction second to none • Custom applications our specialty

AS ALWAYS, YOU PRODUCE IT…WE’LL REDUCE IT. INTERNATIONAL INC.

3 Bradwick Drive, Concord (Toronto) Ontario Canada L4K 2T4

For your area rep. or quotation, please call: Tel: (905) 738-0101. Fax: (905) 738-5750 www.rotogran.com

26 years of manufacturing in Canada

www.canplastics.com September/October 2009 Canadian Plastics 15

assembly & bonding

ULTRASONIC WELDING: A TROUBLESHOOTING GUIDE

By Mark Stephen, managing editor

Your part may have been manufactured to spec, but if it needs ultrasonic welding, you’re not home free yet. And unfortunately, there’s more than one way to run into trouble with your ultrasonics. Canadian Plastics asked some of the experts to identify and solve the most common problems.

A

ccording to Murphy’s Law, whatever can go wrong, will. It’s an important maxim to keep in mind for the end stages of plastics production. In other words, the fact that a part has been molded or extruded to spec doesn’t mean that the chances for mishaps are over. Many parts still have to go through a last step: ultrasonic welding, a process that involves the use of high-frequency mechanical vibrations to generate a frictional heat build-up at an interface between thermoplastic parts. Sounds simple, right? But while ultrasonic welding may be the last step, it’s definitely not the least — there’s a whole host of problems just waiting to arise.

Here are solutions to some of the most common ultrasonic weld problems, provided by several leading suppliers of ultrasonic welding equipment. The problems have been grouped into two categories: problems that can afflict new applications, and problems that can develop with long-running applications.

✓ SOLUTIONS:

PROBLEMS WITH NEW APPLICATIONS

Depending on their thickness, parts require either a little or a lot of support during welding (Rule of thumb: the thicker the part, the less support it needs). Thin, unsupported sections of a part may vibrate or flex during welding. If the flexing is severe, it may cause a hot spot in the material, or even a hole in the part.

⌦ PROBLEM: USING IMPROPER/UNEVEN AMPLITUDE CAUSES:

Usually the result of either processor error or damage to the horn (the part of the ultrasonic system that connects the parts to be joined; amplitude is the motion of the horn during welding, measured as the peak-to-peak motion at the horn’s face).

“Processors may be using the wrong material for a certain amplitude, or they may have started out with one material and then changed to another that requires more amplitude,” said Miranda Marcus, applications engineer with Dukane Corporation.

16 Canadian Plastics September/October 2009 www.canplastics.com

“One solution is to use a larger ratio booster to increase amplitude,” Marcus said. “Processors must also understand that the length of the weld will affect the amplitude to be used.”

A second solution lies in employee training.

“Training is one of the biggest areas that I try to promote,” said Brian Gourley, technical services manager with Sonics & Materials, Inc. “Amplitude is big variable within the welding process, and it’s very difficult to understand without proper education.”

High stress levels will create premature cracks in a horn, Gourley continued, making it difficult, if not impossible, to get a proper level of amplitude. “Processors can either have the horn repaired or replaced, depending on the degree of damage,” he said. ⌦ PROBLEM: PART NOT SUPPORTED PROPERLY CAUSES:

✓ SOLUTIONS:

“Without proper part support, the welder loses control of the process,” said Brian Gourley. “To solve this problem, we prefer to build not only the horn, but also the nest and the fixture at the same time. By doing the complete package, the customer will have a greater chance of getting a repeatable process.”

If the parts have thin walls that might bulge

assembly & bonding

BEFORE: FEA (Finite Element Analysis) computer modeling shows uneven amplitude across

AFTER: That’s better! The horn with uniform amplitude activity. The horn was modified with

the face of a horn (all the different colors indicate different values, with blue the minimum and

an increase in the surface area of the face, addition of undercuts, and a change in the configura-

red the maximum).

tion of the slots.

Image Credits: Sonics & Materials, Inc.

under pressure, it’s advisable to support the part up to the joining zone. Reducing the amplitude of vibration can also help with thin parts.

Also bear in mind that shear joints — which involve trying to melt the material together on the edges of the part — generally need more support than energy directors, Miranda Marcus said.

“The shear joint also tends to impart sideways motion into the part, so the side walls should be well supported by the nest or holding fixture,” she said. “If necessary, the fixture can be split to permit easier loading and unloading of the parts.”

welding equipment suppliers say. “As far as the ultrasonic process goes, there are two basic resin categories: amorphous and semi-crystalline,” Brian Gourley said. “Amorphous is tolerable of ultrasonics, and can withstand different conditions and still weld easily.” Semi-crystalline resins in general require higher ampli-

⌦ PROBLEM: DIFFICULT PART FEATURE CAUSES:

Sharp corners may fracture or melt when exposed to ultrasonic vibration. Also, sizeable holes or bends within the part can create difficulties because the ultrasonic energy may be deflected, leaving a section with little or no fusion. ✓ SOLUTIONS:

For small, easy welds, processors can try to fix the problem by using more amplitude. (Warning! Too much amplitude can crack the horn, so be careful.)

For tougher problems, corners and edges can sometimes be radiused to make them easier to weld, according to Brian Gourley.

“In some cases, it’s necessary either to thicken the part, lightly clamp it, or, if possible, use a higher frequency welding machine to reduce breakage,” he added. ⌦ PROBLEM: USING REGRIND OR “DIFFICULT” RESINS CAUSES:

Problems can arise when processors use a percentage of regrind that’s too high for the allowable process. Also, different virgin resins create different ultrasonic energy requirements; some materials are just tougher to bond ultrasonically, period. ✓ SOLUTIONS:

Know your resins, and how they react to ultrasonic welding.

It sounds simple, but processors don’t always understand this,

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 September/October 2009 Canadian Plastics 17

assembly & bonding

tude and energy levels, Gourley continued, due to polymer structure, higher melt temperatures, and heat of fusion. “Semicrystalline is harder to weld; the tolerance for welding is very narrow, and the procedure is generally more difficult,” he said.

Beyond this, it gets really tricky. For example, impact modifiers such as rubber can affect the weldability of a material by reducing the amount of thermoplastic available at the joint interface, foaming agents can reduce a resin’s ability to transmit energy, and mold release agents can inhibit welding by interfering with surface heat generation and fusion.

Regrind, meanwhile, should be regulated to +/- 10 per cent per part, for proper control.

Rather than memorize all of these variables — and more — a simple way to avoid resin-related difficulties in the first place, Miranda Marcus said, is by involving both the equipment supplier and the resin supplier in any new part application requiring ultrasonics.

PROBLEMS WITH LONGRUNNING APPLICATIONS ⌦ PROBLEM: DECREASED WELD STRENGTH CAUSES:

In an weld application that’s been running flawlessly for a period of time, a loss of weld strength is usually caused either by wear and tear or damage to the welder or horn. It’s an unseen problem, and tip-offs include increased wattage draw, a change in the sound of the weld, and overloading. ✓ SOLUTIONS:

Four words: record keeping and maintenance. “The first step in eliminating unseen problems is to record your welding setup,” Miranda Marcus said. “Make a ‘Weld Process’ sheet that includes information such as your weld parameters, manual settings, and the critical dimensions of your part. Also include photos of the welder, showing the alignment and design of the horn and fixture.

Refer to this document when problems arise; it may save you a lot of time and trouble.”

Ultrasonic welding isn’t always gentle,

making good maintenance crucial. “If a processor has a vibrating horn against hard, glass-filled plastic, it will wear the face off rather quickly,” said Brian Gourley. “But if processors are conscious of preventative maintenance — which involves calibrating the equipment on an annual basis — their welders can last for decades.”

Also, don’t forget that problems with the upstream equipment will come to light during ultrasonic welding, if not sooner: one of the most frequent causes of problems in a long-running process is wear on the mold that produces the parts to be joined. “This is a slow, but sure, event in any molding process,” Marcus said. ⌦ PROBLEM: ENVIRONMENTAL CHANGES CAUSES:

Not only is climate change tough on the ice caps, fluctuating temperatures in your factory can be bad for your resins, too, eventually causing problems for ultrasonic welding.

“Humidity is a particular concern if you’re using hydrophilic material such as nylon, polycarbonate or polysulfone,” said Miranda Marcus. “Very cold temperatures can cause polymers to become brittle, which might cause them to crack rather than weld at a normal welding pressure. High heat can lead to longer solidification times, causing problems if you’re working with short hold times.” ✓ SOLUTIONS:

“Some materials are less sensitive to process changes,” said Miranda Marcus. “Try switching to an easily welded material, like ABS, to achieve greater consistency in your process.”

If the material can’t be substituted, the processor can try to protect it from the elements. “If the humidity level is high, for example, we advise customers to keep parts from being exposed by storing them in double lined polybags with desiccant material,” said Brian Gourley. “If they can’t do that, we usually recommend that they increase the amplitude or pressure to try to overcome that moisture.”

CPL RESOURCE LIST Dukane Corporation (St. Charles, Ill.); www.dukcorp.com/us; ; 630-797-4900 P&J Distribution Services Inc. (Toronto); 416-798-8440 Sonics & Materials Inc. (Newtown, Conn.); www.sonics.com; 1-800-745-1105 18 Canadian Plastics September/October 2009 www.canplastics.com

Moldmaking R

E

P

O

R

T

THE 2009 MOLDMAKING SURVEY:

JUST THE FACTS

Every year, Canadian Plastics conducts benchmark surveys on injection molding and pipe & profile extrusion...so why should our MTDM readers settle for anything less? Our first ever Moldmaking Survey sheds some valuable light on the sizes, markets, buying habits — and more — of Canada’s moldmakers. If you’re looking for a snapshot of an industry responding to tough economic times, this is it.

By Mark Stephen, managing editor

H

ere’s a question: why bother taking surveys?

The short answer is that, since long before European explorers began mapping the New World, the practice has been recognized as one of the best ways of gathering, displaying and comparing information.

The first Canadian Plastics Moldmaking Survey has these goals in mind: to give you, the reader, a look at some of the broad characteristics of Canada’s moldmaking industry, while also setting a standard against which data from future surveys can be measured to track changes over time.

We all know that the past year has been a rough one for the plastics industry, and that the moldmakers have taken their share of the lumps. Hopefully, the survey results will give a useful snapshot, including both the good and the bad, of where some of Canada’s moldmakers are today.

THE BASICS Before getting into some of the actual survey results, it’s important to understand the size and scope of the respondents. To begin, almost 100% of respondents are located in

Ontario: 48% are in the Windsor area, 20% in Toronto, 35% situated throughout the rest of Ontario, and the remaining 5% in Quebec.

When asked how many employees work at their plant, the answers varied from five to 250 people. Almost 50% of respondents are with firms that employ between 20 to 50 workers.

The vast majority of respondents — 85% — manufacture molds and dies for injection molding applications. Forty per cent also made die cast molds, 30% also work on compression/transfer molds, and another 30% on structural foam molds.

Despite the well-known troubles facing the automotive industry, the responses suggest that it’s still a huge source of business for the vast majority of moldmakers: eighty-five per cent of respondents said that they manufacture molds for auto parts suppliers. Equally, 85% also made molds for consumer goods and housewares. Onehalf supply molds for appliances, 35% for sporting good products, and 30% for toys. Thirty per cent report doing work for the rapidly growing medical parts market, 15% for the aerospace industry, 15%

for the electrical parts market, and 10% for the packaging industry. Twenty per cent reported making molds either for the construction, lawn equipment, lawn and garden, or alternative energy markets.

All of the respondents offer custom machining, 86.7% have an EDM facility, 86.7% offer mold repair and/or mold cleaning services, 66.7% offer mold prototyping, 60% have mold polishing capabilities, 53.3% offer CNC duplicating, 53.3% perform engraving works, and 26.7% do in-house mold testing and/or tryouts.

BUSINESS: PAST, PRESENT & FUTURE Asked to describe the current state of the MTDM industry, respondents gave a variety of answers. Slightly more than 10% described business conditions as “good”, almost 15.8% described it as “fair”, almost 31.6% called it “poor”, and 42.1% described it as “bad”. Perhaps not surprisingly, none of the respondents described their business as “excellent”.

The numbers took a slightly more positive turn on the question of business

To view the full survey results, go to http://www.canplastics.com/survey/moldarchives.asp The survey, consisting of 33 questions, was emailed in July 2009 to 192 moldmakers across Canada in the Canadian Plastics database, as well as to members of the Canadian Association of Mold Makers (CAMM). We received 20 completed surveys. www.canplastics.com September/October 2009 Canadian Plastics 19

WHAT MARKETS DO YOU SERVE? Response Percent 15%

Aerospace

Response Count 3

Appliance

50%

10

Automotive

85%

17

Consumer good, Housewares

85%

17

Electrical/Electronic

15%

3

Medical

30%

6

Oil & Gas

0%

0

Packaging

10%

2

Sporting Goods

35%

7

Toys

30%

6

20%

4

Other 0

20

40

60

80

100

Answered Question

20

WHAT SERVICES DOES YOUR PLANT OFFER? Response Percent 53.3%

CNC duplicating

Response Count 8

Custom machining

100.0%

15

EDM facilities

86.7%

13

Engraving

53.3%

8

In-house mold testing/try-outs

26.7%

4

Injection molding of parts

13.3%

2

Jigs and fixtures manufacturing

46.7%

7

Mold repair/cleaning

60.0%

9

Prototyping

86.7%

13

66.7%

10

SLA modeling 0

expectations for the next 12 months. While none of the respondents expected excellent business, 21.1% hoped for good conditions, 36.8% for poor conditions, and only 5.3% predicted a “bad” forecast.

These answers can help explain machine utilization rates. Asked for their average machine utilization rate for the past 12 months, none of the respondents reported using all of their equipment. Almost 11% of respondents reported using between 90-70% of their machinery, roughly onehalf said that they used between 69-50%, roughly 22% used between 49-30%, and about 17% said that they utilized less than 30% of their equipment.

Not surprisingly, the global economic meltdown has had an effect on quotations

20

40

60

80

for new business among our respondents.

Only 5.3% of respondents said that they have had substantially more new quotes this year than last year. Twenty-six per cent of those surveyed reported a moderate increase compared with last year, while 16% reported the same or slightly lower levels than last year. Almost 37%, however, said that the number of their quotations was down substantially from 12 months ago.

According to 52% of the respondents, less than 10% of the jobs that they have quoted on are expected to result in new contracts. At the other end of the spectrum, 10% of respondents reported a 50% or better success rate when quoting for new business. The remaining respondents fell in between these two groups.

20 Canadian Plastics September/October 2009 www.canplastics.com

100

Answered Question Skipped Question

15 5

PURCHASING, TRAINING & R&D When it comes to buying new moldmaking machinery, the respondents were clear... and the results aren’t good for machinery sales firms. The vast majority of respondents — almost 90% — said that they have no plans to buy any new equipment in the next 12 months. Slightly more than 55% of respondents, meanwhile, have acquired new equipment within the past 12 months.

Understandably, money to spend on employee training seems to be scarce nowadays: 46.7% of respondents said that their shops devoted just 1% of annual budgeted expenses for training. Twenty per cent of respondents reported having no expenses at all set aside for training, meanwhile,

PROJECTION FOR BUSINESS CONDITIONS IN 2010 Excellent 0.0% Bad 5.3% Good 21.1% Poor 36.8%

Fair 36.8%

WHAT TYPE OF PRESENCE DO YOU HAVE OUTSIDE CANADA? Working relationship Joint venture 7.1% with a local firm 21.4% Manufacturing facility 7.1% None 57.1%

while 13% have budgeted 4% or more of their plant’s expenses for this purpose.

Thirty-three per cent of the respondents are with facilities that have budgeted 4% or more of annual expenses for R&D, 26.7% of respondents have set aside 2% of annual expenses for R&D, 20% have budgeted 1% for R&D, and 20% reported having no money budgeted in this area.

When it comes to formally implemented policies and programs, however, most respondents aren’t scrimping. Almost 70% reported having safety programs at their facility, 46.2% follow preventative or predictive maintenance programs, 30% have training programs, and another 30% are with shops that have adopted cost reduction policies.

FOREIGN RELATIONS For years now, we’ve been hearing that a key to business prosperity is in building

Sales office 7.1%

relationships with foreign companies. Is this message getting through to Canada’s moldmakers? According to the respondents, almost 54% do not yet have a business presence outside of Canada. Thirty per cent have a presence of some kind in China, while 15.4% have connections in the U.S. Of these foreign connections, 21.4% have of respondents have joint ventures with a local firm, 7.1% operate a manufacturing facility, 7.1% have a sales office, and 7.1% have at least a “working relationship” with a foreign firm.

Of the respondents that do not have a presence outside of Canada, 90% have no plans to initiate one within the next two years. But this isn’t to say that they don’t do business with foreign firms at all; almost 54% of respondents said that they purchase and/or fine-tune molds manufactured in China.

CPL www.canplastics.com September/October 2009 Canadian Plastics 21

colorants

LIFTING THE LID ON NEW

COLORS FOR 2010

By Mark Stephen, managing editor

With 2009 already drawing to close, brand owners are once again looking ahead to the color palettes expected to make the biggest impact with consumers next year.

Canadian Plastics knows what they are.

Now you can too.

I

f you’re looking for an example of how not to add color, just check out any of the early classic black and white movies that were colorized in the 1980s to make them appeal to a younger audience. If you’re wondering why Humphrey Bogart looks green enough to play the Incredible Hulk, that’s the reason.

Fortunately for processors, today’s color suppliers are working with a much greater degree of sophistication to perfect the science of adding color to plastics packaging and parts.

And equally important to developing quality colors is developing colors that reflect current market trends, hopefully drawing consumers to products like the proverbial moths to the flame.

A good indication of what the trends and hot colors will be in 2010 can be found in Clariant Masterbatches’ ColorForward 2010 color trend and analysis guide. As part of its annual ColorForward research, Clariant examines several years’ worth of color matches, and uses the information to confirm its predictions about what’s most likely to happen in colorant trends a year or more in the future. “By looking at it systematically, there are trends that become apparent,” said Norzihan Aziz, head of Clariant ColorWorks in Singapore. "There are broad color trends, and we can also incorporate nuances from cultural and regional trends.

Most trends go by feelings, and fashion can go by who shouts the loudest.”

SOFT & UNDERSTATED So, what do the feelings and the shouts portend for 2010?

According to ColorForward 2010, the latest color trends demanded by end users will include hues that are soft and understated, while also deeper and more complex.

Major changes in the palettes from 2009 will 22 Canadian Plastics September/October 2009 www.canplastics.com

include organic colors becoming deeper, the guide continued. With beige and brown coming into focus, the primary colors are expected to all but disappear, while yellows, blues, reds and purples will remain popular.

Digging a little deeper, Clariant predicted that yellow will trend towards green, blues will become lighter and fresher, reds will move more towards pink, and purple will shift toward violet and lilac.

Green is forecast to be a particularly popular choice, due to its connection to all things environmental. “Green is still there from 2009, but it’s becoming more complex," explained Clariant ColorWorks designer Cristina Carrara. "There are changes on the surface, and in how we interact with the color.”

Clariant has identified four sociological themes that it believes will affect consumer color choices in 2010, each linked to Clariant colors: “Reinventing Happiness”, based around consumer desire to create a peaceful home environment, reflected in Clariant’s Goldiva dark chocolate brown color; “Tech It Easy”, where society is more open to technology’s ability to meet our needs; “Embracing Gaia”, using shapes, forms, functions, colors and visual effects drawn from Mother Nature; and “Age Shock”, as aging baby boomers continue to enjoy active lifestyles while young people look for ways to display their style and sophistication, reflected in a fuschia color called Transition.

But these aren’t the only color trends forecast for 2010. “Functional colors, put in the package to protect the contents, are coming into style,” said Dwight Marshall, sales and marketing manager with Holland Colours Americas Inc. “Amber color is used for beer, for example, while white colors are found in dairy packaging.”

According to Marshall, Holland Colours has designed a special white colorant for use in

colorants Photo Credit: Clariant Masterbatches

monolayer PET in ultra high temperature (UHT) milk packaging. “With the use of Holcomer UHT, packaging manufacturers can now utilize the premium appearance and the mechanical strength of PET, along with processing efficiency in preform and bottle production,” Marshall said.

GETTING TOUGHER It’s not enough for today’s new colorants to simply look good on the store shelf.

Long lasting colors on packaging that’s stored for longer periods of time, or under difficult conditions, send a message about the quality of what’s inside the packaging — which is why brand owners want colors that can stand up to the elements.

The Arctic Infrared Reflective Pigments line from Shepherd Color is designed to withstand the toughest conditions by reflecting the sun’s energy away from an object to keep it cool, preventing warping and distortion by reducing thermal expansion and contraction. According to Shepherd Color, the pigments are suitable for all types of polymers, and are typically used in PVC, engineered resins and polyolelins. “Arctic pigments can be used in a vast array of applications including siding, fencing, railing, decking, window profiles, roofing membranes, polymeric

roof tiles, automotive interior and exterior parts, patio furniture, outdoor playsets, and recreational items such as kayaks and pools,” the company said.

BIOPLASTICS NEED COLORS, TOO In addition to improving standard pallettes, colorant suppliers are continuing to delve into one of the biggest new markets of all: bioplastics.

The increased use of biodegradable resins offers a new generation of materials, colorant suppliers say, with new properties compared with traditional plastics. The main advantage of these materials is that they can be organically recycled through composting. Different biodegradable resins are commercially available, including starch, PLA, PHA, PHBV, PBS, PBAT, and blends of these different polymer families. A particular challenge, however, lies in developing colorants that will meet the wide range of industry requirements and legislation surrounding the bioplastics industry.

According to PolyOne, their OnColor BIO colorants for biodegradable polymers have been designed with these criteria in mind, while still offering a full range of color choices. Based on sustainable raw materials, these color concentrates meet

several global industry and composting standards, PolyOne said, including EN 13432 (European Union), ASTM D6400 (U.S.), BPS GREENPLA (Japan) and DIN CERTCO (Germany). Each of these color concentrates is based on biopolymer carriers, and can be used at normal loadings and dosed in the standard way.

OnColor BIO colorants can be processed by injection, extrusion and blow molding processes, and are used in a wide variety of end-use applications.

“The OnColor BIO line is designed to enable processors and product designers to deliver sustainable products with low environmental impact,” PolyOne said.

The company also offers OnColor Smartbatch BIO concentrates, which combine OnColor BIO colorants and OnCap BIO additives into a single masterbatch.

Telles, meanwhile, has collaborated with Teknor Color Company to develop new color concentrates for use with Mirel resin. Telles is a joint venture between Metabolix and Archer Daniels Midland Company that has already developed a family of bioplastic materials, called Mirel, which it claims has the physical properties of petroleum-based resins.

According to Metabolix, the new color concentrates are formulated for use with Mirel base resins, and meet ASTM D6400 and EN 13432 standards for compostability and biodegradability.

The new Mirel colorants are designed for use on a wide range of injection molding, sheet, film and thermoforming applications.

And there’s no doubt where the demand for bioplastic colorants is coming from. “Teknor developed this series of color concentrates for use with Mirel PHA in direct response to consumer demands for a wider range of bioplastic colorants,” said John Wood, technical manager with Teknor Color.

CPL RESOURCE LIST Clariant Masterbatches Division (Toronto); www.clariant.masterbatches.com; 416-847-7000 Holland Colours Canada Inc. (Toronto); www.hollandcolours.com; 1-800-723-0329 PolyOne Canada Inc. (Mississauga, Ont.); www.polyone.com; 905-405-0003 The Shepherd Color Company (Cincinnati, Ohio); www.shepherdcolor.com; 513-874-0714 Teknor Color Company (Pawtucket, R.I.); www.teknorapex.com; 1-800-556-3864

www.canplastics.com September/October 2009 Canadian Plastics 23

nanotechnology

NANOTECHNOLOGY: With a diameter of 250 to 300 nanometers, the pictured nanofibers are a thousand times finer than a human hair.

Nanotechnology involves understanding and controlling at dimensions as small as one-billionth of a meter. Scientists throughout the world consider it to be one of the world’s most

F

Photo Credit: BASF

THE NEXT BIG THING ALL SM

or many of us, nanotechnology is probably a bit like Einstein’s theory of relativity: we’ve heard of it, we know it affects us, but we don’t really understand how.

It turns out, though, that nanotechnology is already having an impact on the plastics industry.

For the processor, a key benefit is this: through nanotechnology, special nanocomposites can be created that, when applied to plastics, create parts that are better in a variety of ways, yet cheaper to manufacture.

And that’s just the beginning.

exciting fields of research. WHAT’S A “NANO”, ANYWAY?

If you’re not quite sure what nanotechnology is,

But what’s in it for the don’t worry — you’re not alone. “A lot of very plastics industry? Plenty. intelligent people don’t understand nanotechnology,” said Don Rosato, a senior research analyst, plastics, at Frost & Sullivan in Concord, Mass.

“They see the prefix ‘nano’ — which is Greek for dwarf — and know that it involves something very small, but beyond that the whole process seems mysterious.”

Nanotechnology is, in fact, a very broad, highly heterogeneous field of technology. As an enabling technology, it sets the stage for various innovations in many fields, ranging from the automobile industry to the electronics industry to the pharmaceutical industry. The word “nanotechnology”

24 Canadian Plastics September/October 2009 www.canplastics.com

By Mark Stephen, managing editor

describes materials, structures and technologies involving the creation or presence of a spatial dimension smaller than a hundred nanometers. “A single nanometer is one millionth of a millimeter,” Rosato said. “To put that in perspective, the diameter of a human hair is about 50,000 nanometers.”

At this very tiny level, the chemical, physical and biological properties of materials are different than when in their bulk form, and often behave differently compared to traditional materials, including polymers. For the manufacturing world, here’s where it gets exciting: the special properties of these microscopic particles can be used to develop materials that offer significant advantages in our macroscopic world, including improved strength, mechanical toughness, UV resistance and barrier thermal electrical conductivity.

For the plastics industry, nanotechnology basically means nanocomposites that are compounded into a plastic. “The big advantages to using nanomaterials in plastics products involve getting more performance at lower cost and more efficient loading levels,” said Rosato. “The ability to give higher performance than is possible with traditional material properties is already well known. For example, if you put a nanoclay in an auto running board or bumper, you’ll get more impact resistance for a longer period of time at a lower loading level than materials like TPOs can offer.”

nanotechnology

MORE THAN JUST TOUGH Toughness isn’t the only benefit of nanotechnology. According to a recent report on nanoscale science by the Committee on Technology, National Science and Technology Council, many plastic applications currently in use can be reduced further in size while improving efficiency. “Memory chips the size of a postage stamp, yet capable of holding the data equivalent to 25 DVDs, are on the horizon through the use of nanotechnology,” the report said. “Similarly, solar panels that can be manufactured at a much lower cost than they currently are may be able to be produced with nanotechnology.”

Plastic nanotubes are also being created with nanotechnology. These nanocomposites are generally 50 to 150 nanometers in diameter, and are used to conduct electricity. While these nanotubes have the current carrying capacity of copper, they’re extremely flexible, lightweight and durable. This technology is expected to be able to lead to the creation of conductive paints, caulks, coatings, sealant, fibers and adhesives. The thick sheets and tubes are also considered to be potentially valuable to the automotive, aerospace and chemical industries.

Finally, special nanocomposite foams have already been created. Over time, these foams will likely replace solid plastic because they’re much lighter, yet look the same as solid plastics.

Potential uses for foam nanocomposites include coffee cups, fast food containers, home insulation, carpet padding, disposable diapers, seat cushions and packaging material.

Nanotechnology is also a hot topic with government and academic researchers. “It’s an area that receives a good deal of government funding,” said Don Rosato. “Most universities, including several in Canada, are doing research with nanotechnology.”

MATERIAL SUPPLIERS GET ONBOARD This growing acceptance is reflected in the large number of plastics material suppliers delving into the field. “There might have been 200 end use plastics products made through nanotechnology available in 2006,” Rosato said. “Today, there are approximately 600. Among the global material suppliers, all of the heavyhitters — BASF, Bayer, DuPont, Dow, Sabic Innovative Plastics, Lanxess, DSM and Clariant — are getting more involved.”

To use just one example, Clariant Masterbatches is currently cooperating with several German companies in a project designed to use carbon nanotube technology (CNT) to help reduce the cost of environmentally friendly, low temperature fuel cells. “Applications that involve carbon nanotubes have been experiencing enormous growth because of the material’s unique properties, which include exceptional electrical conductivity, strength and stiffness,” said Dr. Ralph Rutte, head of production and technology, Clariant Masterbatches Division, Muttenz, Switzerland. “Using CNTs in place of conventional graphite fillers and carbon black in fuel cell plates is expected to provide better conductivity. The benefit for the plastics manufacturer is that, by processing the CNT material compounds on

standard injection molding machines, they can reduce production costs while increasing productivity.”

But if the future of nanotechnology in plastics appears unlimited, it turns out that there are still some hurdles to jump. For example, critics of nanotechnology maintain that certain substances may become toxic when manipulated at such a small scale. There’s also fear that some of these manipulated substances might cause harm to the immune system if inhaled, absorbed through the skin, or otherwise digested — a possible blow to medical molders hoping to incorporate nanocomposites into their products. “There is a potential for nanoparticles in medical applications to cross the blood/ brain barrier,” said Don Rosato. “It’s a problem that researches are working on, but don’t yet know how to solve.”

These challenges notwithstanding, there’s no doubt that decision-makers in the plastics materials industry have already embraced nanotechnology with open arms. As Dr. Andreas Kreimeyer, a member of the board of directors at BASF, put it, “The deeper understanding of relationships at nanodimensional level enables us to use new effects systematically and safely, and to develop products that even more effective for continued profitable growth in expanding markets and as a basis for tapping into new markets.”

CPL

Make Money through DeDusting of plastic pellets THE PROBLEM

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After

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to help you.

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Pelletron Corporation 499 Running Pump Rd Lancaster, PA 17601, USA T. 717.293.4008 info@pelletroncorp.com www.pelletroncorp.com

www.canplastics.com September/October 2009 Canadian Plastics 25

technology showcase

AUXILIARY EQUIPMENT

Screenless granulator with small footprint Wittmann’s new SJ914 C, a compact version of their SJ914 screenless granulator, requires approximately 45 per cent less floor space simply by changing the gearbox design to allow the motor to be mounted at 90° to the rotor shaft.

With a cutting chamber size of 9.4 inches by 13.6 inches (240 mm by 346 mm) and a throughput of 44 lbs/hour (20 kg/hour), the SJ914 C is designed for the granulation of bigger sprues and parts made of hard, filled plastics. The reduced footprint makes it ideal for beside-the-press operation without compromising throughput.

The SJ914 C has a low rotor speed of 32 rpm, for quiet operation with minimal fines and no longs — an advantage for beside-the-press operation. The hardened, reversible knives provide double the life and reduce maintenance costs. The staggered breaker knives are designed to cut thick cross-sectioned parts.

The stainless steel feed hopper allows for easier cleaning and is available with an optional magnet to help capture ferrous metal contamination. The regrind collection bin is made of stainless steel to eliminate corrosion and improve material flow.

Wittmann Canada Inc. (Richmond Hill, Ont.); www.wittmann-canada.com; 1-866-466-8266 Anplast Inc. (Anjou, Que.); 1-800-387-4590

Environmentally friendly portable chilling Colortronic is introducing their first “green” portable chilling line with the GP Series, which offer R410a refrigerant designed to meet new regulatory requirements taking effect in 2010.

R410a refrigerant, is chlorine-free, which complies with the Environmental Protection Agency’s newest, most stringent guidelines. The benefits to R410a include improved system efficiency as well as higher capacity rates.

An electronic modulating capacity control maintains leaving fluid temperature to within 0.1°F, and electronic sensors with digital readout include leaving and entering fluid temperatures, compressor suction pressure, compressor discharge pressure, condenser inlet temperature, superheat, sub-cool, pump pressure and tank level. Monitoring the conditions of the chiller provides “adaptive control”, where the operator can adjust the operation of certain components with the chiller approaches an alarm condition in an effort to keep the chiller running with minimal to no downtime.

Optional web access to the controller will allow a Colortronic or other qualified technician to diagnose alarms and see real time data without having to go directly to the site. The controller 26 Canadian Plastics September/October 2009 www.canplastics.com

includes alarm history and capacity profile information.

Colortronic North America Inc. (Flint, Mich.); www.colortronicna.com; 810-720-7300 Ontor Limited (Toronto); 416-781-5286 Auxiplast (Boucherville, Que.); 1-866-922-2894

ROBOTS & AUTOMATION Easy-to-use robot controller

The latest robot controller from Sepro America, the Visual 2, brings together several digital technologies to create a powerful, yet easy-to-use interface to Sepro Generation IV robots.

The Visual 2 controller offers users several different options for setting up a robot program. The pick and place module allows users to create a robot program just by answering a few basic questions posed by the system. The results are presented immediately in three-dimensional video. EPS (Embedded Program Source) programming uses freely programmable templates and on-screen prompts that lead the operator through the process of ‘teaching’ all relevant robot positions. Direct programming of even the most complex routines can be completed on the Visual 2 pendant or off-line. Programming can be uploaded to the control via Ethernet, Wi-Fi or USB connection.

Sepro America LLC (Pittsburgh, Pa.); www.seproamerica.com; 1-877-737-7610 Shadow Automation Inc. (Uxbridge, Ont.); 905-649-2652

Full-servo robot with shorter take-out times The newest line of full-servo takeout robots from Yushin, the RC Series delivers up to 13 per cent shorter take-out times and ensures increased productivity for its owners.

The unit comes with the new E-touch II controller, with audible help guidance, animated iconbased charts, and more. Newly programmed motions may be simulated and checked on a 3D screen on the controller or another PC. This valuable function streamlines operation time, improves safety, and shortens setup time. Edge protectors on both sides of the controller cushion the controller case if dropped. Housing has IP44 rating for protection from particulates and moisture.

The RC units are also equipped with vertical axis and kick axis servo motors a full size larger than the previous robot line.

The standard-equipped “ECO Vacuum” feature reduces the amount of compressed air needed for product suction during takeout, providing energy-savings and lower running costs.

Yushin Precision Equipment Co. Ltd./En-Plas Inc. (Toronto); www.en-plasinc.com; 416-286-3030

technology showcase

HOT RUNNERS

Valve gates for micro parts

Mold Hotrunner Solutions Inc. introduces a new Rheo-Pro multi-tip valve gate hot runner, designed for molding direct gated micro parts with crisp, clean gate marks.

The M05VG can direct valve gate micro parts with a weight of less than five mg. It delivers crisp, clean gate marks of 0.7-mm to 1.0mm diameter with zero gate vestiges. Traditional thermal gating and hot tip gating experience inherent problems with micro parts because of cold slugs below the surface and gate vestige on the surface. These methods often fail to achieve the part quality required for precision micro parts, particularly in medical applications.

Precision shut off pins guarantee the ultimate gate control. The valve actuators are synchronized with millisecond accuracy throughout all gates to deliver a completely balanced melt flow. The M05VG nozzle is especially suited for commodity materials, but performs well with engineering and high temperature polymers.

Mold Hotrunner Solutions Inc. (Georgetown, Ont.); www.moldhotrunnersolutions.com; 905-873-1954

Software balances hot runner manifolds RJG’s new Balance Viewer software provides a tool for users to visually balance hot runner manifolds.

Most molders try to adjust the balance by running a series of fillonly parts and adjusting the tip temperatures until the parts are about the same size or weight. With an eDart process controller and cavity pressure or cavity temperature sensors in every cavity of a mold, you can use the data to balance the tip temperatures. The eDart computes cavity fill times that directly reflect the fill imbalance. This optional software tool uses the data to make the visual process of balancing much simpler. You look at the high or fast filling cavities and lower those temperatures while raising the tip temperatures for the lower

bars until they all come into balance.

Selection buttons on the software allow you to check the balance of other parts of the process: filling and packing, pressurization and mold temperature. If the mold has only temperature sensors (no pressure) you can see the balance of the time to reach the sensor and the mold temperature at that point. The viewer tool automatically sets up and scales the bars for the number and range of sensors found. Once a tool is balanced any odd behavior, such as material build-up or clogging, can initiate a warning system and will not be masked by automatic control adjustments.

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

HYDRAULIC LUBRICANTS

Lubricant can cut energy costs Shell Lubricants has added a state-of-the-art lubricant to its high quality Shell Tellus hydraulic oil range that could help increase the energy efficiency of hydraulic systems.

Shell Tellus EE, formulated in response to customers’ concerns over energy usage and associated costs, has been shown to help companies reduce the energy consumption of their hydraulic machinery by an average of eight per cent while also providing exceptional equipment protection and the capability of extending oil maintenance intervals.

Shell Tellus EE is Shell Lubricants’ first synthetic hydraulic fluid that has been specifically designed to help improve the energy efficiency of the machinery in which it is used. The fluid contains a unique and patented additive technology, and has undergone extensive laboratory tests and field trials that have demonstrated its ability to help improve a machine’s energy efficiency. With hydraulics being at the core of many production processes, Shell Tellus EE has the potential to contribute to the goal of reducing an organization’s energy costs.

Shell Lubricants (Burlington, Ont.); www.shell.ca; 905-335-5577

advertising index Advertiser Arkema Canada Inc. Canadian Plastics Resin Outlook Conference Hapco Canada Ltd. London Metal Exchange Lorenz Conveying Products PCS Company Pelletron Corp.

Premier Fluid Systems Process Heaters Inc. Rotogran International Inc. Vortex Valves Weima America Inc. Wittmann Canada Inc.

Page 2 31 18 8 17 21 25 5 30 15 9 7 back cover

Telephone

E-mail

Website

800-567-5726 416-510-5116 800-345-9353 44 20 7264 5555 800-263-1942 800-521-0546 717-293-4008 800-461-2611 877-747-8250 905-738-0101 785-825-7177 803-802-7170 888-466-8266

polymers.canada@arkema.com jnancekivell@canplastics.com sales@bak-ca.com info.plastics@lme.com sales@lorenz.ca sales@pcs-company.com info@pelletroncorp.com info@pfspumps.com proheat@processheaters.ca info@rotogran.com rbarragree@vortexvalves.com info@weimaamerica.com info@wittmann-canada.com

www.arkema.ca www.canplastics.com/Conference/ www.bak-ca.com www.lme.com www.lorenz.ca www.pcs-company.com www.pelletroncorp.com www.pfspumps.com www.processheaters.ca www.rotogran.com www.vortexcanada.com www.weimaamerica.com www.wittmann-canada.com

www.canplastics.com September/October 2009 Canadian Plastics 27

plastics data file

Get free information from the companies that interest you most.

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

ONE STOP SHOPPING

Innovative automation and auxiliary equipment — from autonomous work cells to central systems. Products include Battenfeld injection molding machines, robots and automation, in-mold labelling, material handling systems including blenders, dryers and loaders, granulators, water flow regulators and mold temperature controllers.

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

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MATERIALS

MACHINERY & EQUIPMENT

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

design ideas • earth, asphalt & sky: vehicles at work

SKY: Film meets new aircraft insulation requirements

We’ve all seen airplane disaster movies; few of us mind, therefore, when safety standards for commercial aircraft are improved. But what we don’t often realize is that meeting these new standards in a cost-effective manner can pose real challenges to the airplane manufacturers.

So when the Federal Aviation Administration (FAA) announced a new fuselage “burn-through” barrier requirement for all new aircraft manufactured after September 1, 2009, Victrex’s APTIV PEEK-based covering film became a hot item.

“APTIV film laminates meet FAA radiant panel testing which mandates the improved resistance to flame propagation for thermal and acoustic insulation blankets,” said John Walling, global aerospace marketing manager at Victrex. “In addition, APTIV films can be laminated to specialized burn-through barrier systems, resulting in a complete system that will meet the new FAA requirements.”

The APTIV film is also lightweight, an important factor in reducing aircraft weight and increasing fuel economy. “APTIV film can be produced at 6µm (micron) thickness, offering significant weight savings versus the existing 12µm PVF insulation systems,” Walling said.

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

ASPHALT: Lexan sheet protects Toronto bus drivers It’s a problem that Ralph Kramden, the bus-driving hero of the 1950s sitcom The Honeymooners, never had to worry about: being attacked by a passenger.

In modern-day Toronto, however, assaults on Toronto Transit Commission (TTC) operators now average one per day. The TTC turned to Sabic Innovative Plastics for help, and Sabic responded with a new, high-tech shield to enhance driver protection.

Consisting of a 31-inch by 38-inch rectangular enclosure with a lower metal door, the new operator protection is made of Lexan sheet and coated with the Exatec E900 advanced plasma technology at Exatec’s facility in Wixom, Mich. The high impact strength and optical clarity of Lexan sheet combines with the abrasion resistance of the Exatec coating to form a formidable protective barrier.

While protection of the driver was a primary objective of the TTC bus retrofit, the glazing solution also had to meet stringent regulatory requirements for optical clarity (driver visibility) as set forth by the National Highway Transportation Safety Administration.

“Our close collaboration with the TTC and their suppliers helped us to quickly understand their requirements, and develop the material and coating combination needed for the high performance protection shield quickly and cost-effectively,” said Stephen Shuler, chief technology officer for Exatec, LLC, at Sabic.

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

EARTH: Polymer blend brings tractors into modern era For most people, tractors probably seem like the epitome of old fashioned living; something your grandfather — if not your great-grandfather — might have used, but definitely not the place to look for an example of new technology.

The Same Deutz-Fahr Group, an Italian manufacturer of agricultural tractors, is determined to drag the venerable machine into the 21st century, however...with a little help from BASF. BASF’s new Terblend N NG-02 EF, the company’s latest glass fiber-reinforced ABS/PA offering, is being incorporated into both large and small parts used for Same Deutz-Fahr’s newest line of tractors because — guess what? — tractor manufacturers have the same concerns about weight savings, processability and scratch resistance as auto manufacturers.

Providing ease of processing (the “EF” in the product name stands for “excellent flow”) with mechanical stability, the new Terblend offering is used to mold small, lightweight panels for the interior of the tractors, which traditionally presented challenging requirements, especially in terms of the flow length-to-wall thickness ratio. The easy-flowing Terblend material provides high surface quality on the one hand, and allows sturdier interior panels on the other.

Other, larger interior and exterior components can be easily molded as well, offering even greater weight savings.

And with high resistance to both impact and chemicals, the new Terblend will keep tractor parts looking newer for longer, regardless of tough outdoors conditions.

Definitely not your grandfather’s tractor.

BASF Canada (Mississauga, Ont.); www.basf.ca; 1-866-485-2273 www.canplastics.com September/October 2009 Canadian Plastics 29

view from the floor

Pareto problem-solving

By Jim Anderton, technical editor

I

n the 20th century, there were two gods of quality assurance: Drs. Edward Deming and Joseph Juran.

Everyone knows about Deming, but Juran is often overlooked...although he shouldn't be. Juran focussed on the management approach to quality, but one of his most important contributions was his discovery — or more accurately, rediscovery — of Italian economist Vilfredo Pareto.

An economist? Yes! Juran's application of Pareto is the origin of the principle that 80 per cent of a problem is created by 20 per cent of the causes. Juran called this principle "the vital few and the useful many", to remind us not to forget about the other 20 per cent.

Interesting, but why should we care? Well, one application of Pareto's work is the "Pareto diagram", a very simple, very powerful tool for tracking down problems. Here's how it works:

50

A PARETO CHART

40 30 20 10 0

A

B

C

D

E

dominant (highest) bar, and the process repeats again. To use it optimally, the charting process would never end and a running series of charts would give a manager a sense of which problems Classify the different types of non-conformity or failure into repeat most often and how effective the fixes are.

The beauty of the Pareto method is that it's simple and visual; groups, then label them, say, “A” through “G”. Put this on the there's no massaging the data with mathematics, and no ambiguhorizontal line of a regular bar chart, spreadsheet or paper. ity about the hot problems. Another bonus is that non-technical personnel can draw it up...as long as the initial classification of On the vertical axis, put dollar cost of non-conformities or the failure types is established; the rest is just counting the nonsimply the number of non-conformities. I like both, on sepaconformities. It can be as simple as making a series of labelled rate charts. boxes and having inspectors put the bad parts in each box. Each box's contents make a bar of the chart.

Collect the data and group it by the type of non-conformity And there's another, hidden benefit: you don't have to use it for and then assemble the bars of the graph. production only! You choose the failure classifications; it could Voila, you have a Pareto chart. Do this simple bar chart and be order entry mistakes, missed phone calls, or the amount of toiyou can instantly see which types of failures account for the most let paper used in each washroom, but the principles are the same. lost production or profit, the "vital few", giving your engineerIt's faster to do it than explain it, so go ahead and make a ing team the correct problem to fix first.

After a period of time, Pareto chart and play with the values, especially the failure clasPROCESSHEATERS 1-AB-CPL 2.qxd 8/26/09 2:54 PM Page 1 the process is repeated, and another type of failure becomes the sification types. You may surprise yourself!

CPL

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30 Canadian Plastics September/October 2009 www.canplastics.com

09 RESIN CONF AD

7/3/09

10:58 AM

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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.

Wittmann/AB/CPL

8/18/09

9:13 AM

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