Canadian Plastics June 2010

Canadian Plastics www.canplastics.com

LEADER of the

YEAR

Harvey Rosenbloom packager par excellence

+

Stewardship, Innovation award winners

JUNE 2010 CANADA POST PUBLICATIONS MAIL AGREEMENT NO. 40069240

Dryers

The latest technologies

Chillers

Strategies for saving energy

Moldmaking Report

• Lessons from a successful plant • PDx/amerimold showcase

CanadianPlastics

contents

JUNE 2010 VOLUME 68 NUMBER 3

LOOKING BACK...

“Eight thousand miles of polyethylene,” announced a headline from the October 1969 issue of Canadian Plastics. Turns out that Toronto-based extruder Indal Canada had just been awarded a $600,000 contract to produce polyethylene track for toy racing cars. Three newly purchased extruders, plus automatic feed equipment, would manufacture the track. Injection molded track loops and curves made by another Toronto shop were also included in the kit.

page 18

Letter/number of the month:

*R-22

* Universally popular chiller refrigerant that’s now been banned in Canada and the U.S. (See pg. 16)

page 21

page 10 Cover Photo Credit: Claude Roussel, Photo Zoom

cover story in every issue 5 Editor’s View: • In praise of manufacturing 7 News: • Canadian firms report opportunities from Plastimagen, Chinaplas • Alberta extruder named CPSC Employer of Choice • From pond scum to plastics: Algae might just be the next big bio-resin 9 Executive’s Corner: • The secrets to effective crisis management 24 Technology Showcase: • Spotlight on mold steel 27 Plastics Data File 27 Advertising Index 28 Classified Ads 29 Design Ideas: • Automotive applications 30 View from the Floor: • Mold cooling, part deux

10 CPIA LEADER OF THE YEAR: Harvey Rosenbloom, packager par excellence

As the owner of grocery bag manufacturer Hymopack Ltd. and polystyrene foam tray maker Dyne-A-Pak Inc., Harvey Rosenbloom has spent 30 years at the front lines of packaging innovation, in the process becoming a key player in moving plastics into the supermarkets. He’s finally ready for his close-up, and we’ve got it inside.

PLUS: Profiles of CPIA’s other 2010 award winners.

features

14 CHILLERS: Plant-wide approaches to energy savings

Process cooling is a critical stage of plastics manufacturing, and also one of the most energy-intensive. Cutting back on energy usage isn’t as simple as just plugging in a new piece of equipment—but that doesn’t mean it can’t be done. Some of the top cooling system manufacturers and vendors tell us how.

17 MOLDMAKING REPORT: Profiles, products and more

This time around, our Moldmaking Report is filled with almost more info than we could handle. Lessons from a successful mold shop, the latest technologies from the PDx/amerimold show, changes in rapid prototyping, and a big announcement from CAMM — it’s all here.

21 DRYERS: The latest efficiencies

This isn’t your grandfather’s plastics industry anymore, so why settle for his dryer? Nowadays, you’re looking for a dryer that also assists you in running a more cost-effective operation. Inside, we look at some recent offerings designed to help you trim expenses, get efficient, and open up new markets.

Visit us at www.canplastics.com 4 Canadian Plastics June 2010 www.canplastics.com

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

www.canplastics.com EDITOR Mark Stephen 416-510-5110 Fax: 416-510-5134 E-mail: mstephen@canplastics.com TECHNICAL EDITOR Jim Anderton 416-751-5749 E-mail: jimeditorial@yahoo.ca ART DIRECTOR Andrea M. Smith PRODUCTION MANAGER Steve Hofmann 416-510-6757 E-mail: shofmann@bizinfogroup.ca PRINT PRODUCTION MANAGER Phyllis Wright SENIOR PUBLISHER Judith Nancekivell 416-510-5116 Fax: 416-510-5134 E-mail: jnancekivell@canplastics.com ADVERTISING SALES REPRESENTATIVE Brayden Ford 416-510-5124 Fax: 416-510-5134 E-mail: bford@canplastics.com CIRCULATION MANAGER Diane Rakoff 416-510 5216 Fax: 416-510-6875 E-mail: drakoff@bizinfogroup.ca HEAD OFFICE 12 Concorde Place, Suite 800, Toronto ON M3C 4J2. 416-442-5600, Fax: 416-510-5134 CANADIAN PLASTICS is published 7 times a year by BIG Magazines LP, a div. of Glacier BIG Holdings Company Ltd., a leading Canadian information company with interests in daily and community newspapers and business-to-business information services.

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In praise of manufacturing

E

ver have someone express something you believe in better than you could yourself, reminding you in the process why you believe it?

This happened to me twice recently, first while reading a Harper’s Magazine article on the U.S. manufacturing industry, and then again while perusing a Statistics Canada report on Canadian manufacturing.

Appearing in the January 2010 issue, the Harper’s Magazine piece was written

by Alan Tonelson, a research fellow at the U.S. Business and Industry Council. The article challenges the idea, embraced by some, that America can cease being a manufacturer and thrive instead as a service provider. “For decades, America’s economics and business elites have been confidently assuring their countrymen that the alarming decline of the U.S. manufacturing sector was nothing to worry about,” Tonelson summarized. “They claimed the demise of manufacturing simply heralded the rise of alternatives better suited to modern circumstances—chiefly, the spectacular progress of information technologies and the impressive advances in the psychology and mathematics of finance.”

But that was then, before North America’s production-light economic expansion officially collapsed into the worst worldwide downturn since the Great Depression. “Today, the idea of maintaining genuine American prosperity without a vibrant manufacturing sector stands exposed as a fairy tale,” Tonelson wrote.

“Business leaders are beginning to understand that real, self-sustaining recovery and prosperity require a manufacturing base that is not only highly productive and innovative, but is a much larger share of gross domestic product.”

I hope Tonelson will forgive my impertinence, but his entire 3,000 word article can be boiled down to one conclusion: Economic prosperity comes from making things.

But that’s the U.S. Doesn’t apply up here in Canada, right? That’s certainly what some believe. In lockstep with their American cousins, Canadian commentators have long been saying that manufacturing can be outsourced and that we’ll do just fine, thank you very much, as a nation of hamburger flippers and call-centre

operators—a change that’s well underway, they add, as information technology and high finance shove a shriveling manufacturing sector off the stage.

Truth is, of course, Canada’s economic prosperity depends on manufacturing as much as—if not more— than on any other component. And, according to a July 2009 Statistics Canada analysis by economists John Baldwin and Ryan Macdonald, our manufacturing sector isn’t in decline, either. In terms of volume of output, they conclude, Canadian manufacturing production as a share of the economy hasn’t changed much in almost half a century.

So why does it often feel like it has?

The problem in assessing manufacturing by jobs and dollar measures, Baldwin and Macdonald suggest, is that these don’t accurately capture what’s going on in manufacturing output by volume. As productivity increased, and prices of manufacturing goods fell over the decades, Canadian manufacturing continued to produce. As with Tonelson’s article, the thrust of the paper can be summarized in a few words: Is Canada deindustrializing? No. The jury’s probably still out on this argument, but it’s welcome news if true, because—while the activists might gripe —there’s simply no better route to wealth creation and prosperity than a robust manufacturing sector that employs knowledge workers as well as traditional labourers, engages academic institutions in meaningful R&D programs, and pioneers new applications to serve new markets.

If you’re reading a business magazine like Canadian Plastics in the first place, chances are you agree. So why bother preaching to the choir? As mentioned above, it’s refreshing sometimes to have people with real facilities for words—Messrs.

Tonelson, Baldwin and Macdonald, that is, not yours truly—remind you of what you know to be true. So kudos to StatsCan for suggesting that our manufacturing industry isn’t in long-term decline, and to Tonelson for reminding us why this matters.

Mark Stephen mstephen@canplastics.com www.canplastics.com June 2010 Canadian Plastics 5

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news

Canadian firms report opportunities from

Plastimagen, Chinaplas

T

wo of the bigger international plastics trade shows took place recently, drawing Canadian Plastimagen, Chinaplas exhibitors and attendees. And they’ve returned with some insights about foreign markets.

April 19-22, attendance at the event reached 81,435—a 17.5 per First up was the four-day Plastimagen Mexico cent jump from last year’s total, despite volcano-related travel 2010 trade show, held from March 23-26 in Mexico City. disruptions that held down attendance from Europe.

The event attracted more than 28,000 visitors and generated To the surprise of no one, the show had a green theme, deals worth about $120 million, most involving machinery, with the spotlight on technologies and production processes materials and components for sectors including automotive, geared toward environmental protection, energy conservation, pharmaceutical, food and drink, petrochemicals, agriculture, resources saving, and after-use recycling. Packaging might the environment, and electronics. have been the industry segment of choice among attendees, “The Canadian presence at the Plastimagen was very and Canadian-based companies reported a healthy number of strong, which is important,” Harb Bhangu, vice president of packaging-related enquiries. “The Chinaplas 2010 show had manufacturing at Woodbridge, Ont.’s Compact Mould Ltd., a great turnout with some of the highest levels of attendance told Canadian Plastics. “Canadian shops and manufacturers we’ve ever seen, and our HyPET preform molding system who want to make connections in Mexico need to show up at and HyCAP 300 system for beverage closure manufacturing events like this to demonstrate their interest and commitment.” generated a lot of attention,” said Gerardo Chiaia, president One of the top low-cost manufacturing sources in the of Husky Asia, Europe, Middle East and Africa.

CPL world—ahead of both China and India— Mexico has a booming plastics industry, with an estimated 650 injection molding ALBERTA EXTRUDER machines purchased in 2009, which is NAMED CPSC three times the number sold in Canada.

EMPLOYER OF CHOICE Unsurprisingly, Canadian attendees came back with little doubt that Mexico holds Sheet extruder Orion Plastics real promise for partnerships and profits.

Inc., of Edmonton Alta., has “I was struck by the enthusiasm of the been named as the second-ever Mexican processors to collaborate with Employer of Choice by the Canadian organizations, which is excellent Canadian Plastics Sector Counnews for our industry,” said Pierre Fillion, cil (CPSC). president and CEO of the Quebec-based The Employer of Choice Left to right: Greg Maker, sales manager; Mike Federation of Plastics and Alliances award program was created in Orr, vice president, operations; Laird Kulak, Composites (FEPAC). “Mexican firms 2008 to recognize plastics com- president; Stephen Moore, production, materials manager; and Dhaval Ghandi, finance. panies who take steps to have have money to invest in partnerships, and their workers earn the CPSC’s can give Canadians access to markets in Certified Plastics Practitioner (or Cert.PP) designation. the southern U.S. and Latin America. The Almost 40 per cent of the positions at Orion Plastics that are eligible for main hurdle is that we have to be careful to certification are held by Cert.PPs, company president Laird Kulak said, with pre-qualify the companies that we’re going more still to come. “Orion Plastics has grown rapidly over the past 10 years to be dealing with.” in business with 12-fold growth,” Kulak said. “With capacity being added that PACKAGING IS HOT will allow us to double in size, this training is integral to our growth plans.”

One month later and half a world away, CanaOrangeville, Ont.-based manufacturer IMBC Blowmolding became the first dian exhibitors and attendees descended on company to receive the Employer of Choice designation in December 2009.

Shanghai for Chinaplas 2010. Running from www.canplastics.com June 2010 Canadian Plastics 7

news

From pond scum to plastics:

Algae might just be the next big bio-resin

E

Photo Credit: Cereplast Inc.

ven as the general appreciation for all things natural for further conversion into potential biopolymers. reaches stratospheric heights, most of us probably remain Cereplast isn’t the only company wading into the algae-based noncommittal about algae. On the one hand it’s great in plastics pool. In fact, it’s getting crowded. In August 2009, sushi, but on the other hand it chokes the boat propeller in London-based BP Amoco Plc contributed US$10 million to a shallow water. El Segundo, Calif.-based bioplasproject with Martek Biosciences Corp. of Columbia, tics maker Cereplast Inc., however, hopes Md., designed to bring large-scale algae biofuto turn these simple sea-borne organisms els to commercialization. Irving, Tex.-based into a game-changer for plastics manuoil conglomerate Exxon Mobil Corp. has facturers looking to go green. also jumped in recently with a whopThe company is planning to comping US$600 million investment in mercialize its first grade of algaealgae-based biofuels; the company is based resins by the end of the year, joining biotech specialist Synthetic intended to complement its existGenomics Inc., of La Jolla, Calif., ing Compostables and Hybrid resto research and develop next-genins product lines. eration biofuels produced from sunWith starches from corn, tapioca, light, water and waste carbon dioxwheat, and potatoes already used in ide by photosynthetic pond scum.

A plate-size prototype disc the manufacture of the Compostables In short, the word seems to be injection molded from and Hybrid materials, why bother addgetting out that feedstock like algae— algae-based biomass and polypropylene. ing another biomass to the mix? Because that’s unrelated to fossil fuels and to algae is cheap, plentiful, doesn’t take away the food chain—might be the next fronfrom the human food chain, and represents the tier for renewable plastics. “Commercial near-perfect closing of the renewable products algae resins represent a significant breakthrough loop, said Cereplast researcher William Kelly. “The use of in the greening of the plastics industry,” Kelly said. CPL algae as a feedstock for plastics allows us to go full circle,” he explained. “The very substance that can absorb and minimize CO2 and polluting gases from the industrial process can now PEOPLE also be turned into sustainable, renewable plastic products and — Auxiliary equipment supplier Hambiofuels while reducing our use of fossil fuels.” ilton Avtec Inc., of Mississauga, Ont., has appointed Al Watson as regional HEAT TOLERANCE? YES. FISHY SMELL? NO. sales manager for western Ontario.

How does it work? Algae from a photo-bioreactor is harvested Watson has over 30 years’ experience daily and can be treated as a biomass, Kelly explained. Cerein the extrusion and material handling plast dries the material at its new plant in Seymour, Ind. until industry, and can be reached at 416the biomass becomes a powder. To date, Cereplast has made a 578-6949. hybrid prototype, with organic ingredients and polypropylene Al Watson or other traditional resins mixed with between 35 and 50 per — Toronto-based plastics consulting cent algae powder using a proprietary process. The company firm SWM & Associates has named has also injection molded a test part made from the algae powYves Laroche as its representative in der and polypropylene.

Quebec and the Maritimes. Laroche is The algae-based biomass behaves like traditional starchbased in Montreal. based resins, Kelly continued, and also has a high heat toler— Trade association The Society of ance. And while the algae plastic had a strong fishy smell in Plastics Engineers, headquartered in the project’s early days, the company has mercifully found a Brookfield, Conn., has named Ken J. way to get rid of that.

Braney as its new president. Braney is Cereplast is currently in contact with several companies managing director of Thermoforming Ken J. Braney that plan to use algae to minimize carbon dioxide and nitrous Solutions Ltd., based in the UK. gases, and also with potential chemical conversion companies that could convert the algae biomass into viable monomers 8 Canadian Plastics June 2010 www.canplastics.com

executive’s corner

The secrets to effective crisis management

By Richard Martin, Alcera Consulting Inc.

C

risis management often gets a bad rap, as in, “That company/manager is always in crisis management mode.” There are no doubt plenty of people who have such poor management skills that they are constantly confronted by crises. Even the best-run organizations and the best leaders, however, can be confronted with a crisis at any time.

A crisis can be defined as any abrupt change that poses a vital threat to the viability or capabilities of an organization. The secrets to effective crisis management are intelligent preparation, information gathering, and cool-headed execution. Listed below are 10 principles or techniques you can use to better prepare and manage crises.

1

enior executives must be serious about crisis management S and must set an example by investing time and resources for realistic planning and organization.

2

rior to and after a crisis strikes, it’s critical to collect and P validate information about what is actually happening.

Remember, the first information you get is often wrong.

3 4 5

henever a crisis strikes, don’t overreact. Stay cool, and W put the contingency plans and procedures into effect.

6

ontingency planning involves making plans for situations C (contingencies) that are either highly likely or potentially very damaging to the organization, and that will allow you and your organization to spring into action when required.

7

reate procedures to deal with crises and other unforeC seen discontinuities in business or the environment. Preestablished procedures will help you navigate the crisis because they are common to the entire organization and they allow you to perform without panicking.

8

onsider the six P’s of crisis management: prevention, C planning, procedures, priorities, practice and people.

l iability, financial impact and the need to maintain business continuity.

9

ractise the plans and procedures before they’re actually P required—this allows for proper training and familiarization, as well as refinement through after-action review.

10

I n the final analysis, sound crisis preparation is about people. You must select and prepare your employees, managers, and senior executives for the contingencies that have been identified. Consider a training program based on technique #9. Also consider bringing in outside help to conduct the contingency planning and the training, either through temporary or permanent arrangements.

CPL

Richard Martin is the founder and president of Montrealbased Alcera Consulting Inc. He consults for both public and private sector organizations. He also speaks, teaches and writes on a variety of topics such as crisis management, leadership, planning, adaptability, resilience and performance.

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leader of the year

HARVEY ROSENBLO Plastics packager & leader par excellence

Photo credit: Claude Roussel, Photo Zoom

By Mark Stephen, editor

10 Canadian Plastics June 2010 www.canplastics.com

For over 30 years, Harvey Rosenbloom has been at the front lines of packaging innovation. As the owner of polyethylene grocery bag manufacturer Hymopack Ltd. and polystyrene foam tray maker Dyne-A-Pak Inc., he’s been a key player in moving plastics into the supermarkets, and in moving the supermarkets into a new age of consumer convenience. He’s now been selected as the CPIA’s 2010 Leader of the Year. Question: What took them so long?

leader of the year

I

t seems only fitting that Harvey Rosenbloom has been chosen as this year’s Canadian Plastics Industry Association (CPIA) Leader of the Year—he’s been a leader in the plastic packaging and bag making sectors for over 30 years now, anyway.

This just makes it official.

In 1977, the Rosenbloom group of companies acquired Toronto-based plastic bag manufacturer Hymopack Ltd., and Rosenbloom has been blazing a trail ever since. Under his guidance, the company first promoted the socalled “Thick-Thin, Wave Top Bag,” a sophisticated product that involved manufacturing a sheet of film with different thicknesses so that the handle could be thicker than the body of the bag. He then led the company and its customers through a transition from paper bags to low density polyethylene (PE) carryout grocery bags for the supermarket industry. Not done yet, he orchestrated Hymopack’s subsequent move to high density PE carryout bags, once again helping nudge the supermarket industry towards a new era of consumer convenience.

As if that’s not enough, Rosenbloom has been guiding two other manufacturing companies all the while: Aspamill Inc., a Montreal-based manufacturer of paper bags; and Dyne-A-Pak Inc., a manufacturer of polystyrene (PS) foam trays headquartered in nearby Laval. With Dyne-APak too, the pattern of innovation isn’t hard to spot: Under Rosenbloom’s watch, the company has been a key player in moving the industry from pulp trays to expanded PS foam trays for produce, fish and poultry.

OM

FROM PAPER TO PLASTICS For someone who continues to leave a large footprint in plastics packaging, it’s more than a little ironic that Rosenbloom got his start in the competing world of paper.

A Montreal native, Rosenbloom cut his entrepreneurial teeth in the early 1950s, working in the family business: an outfit called Rosenbloom Paper Supply Co., which manufactured and distributed carryout paper grocery bags. “In those days, plastic wasn’t an important part of the packaging world,” he said. “But this changed for me in 1977, when our company purchased Hymopack, which was then a small poly extruder and converting company.” Although Rosenbloom was by then taking notice of plastics, the majority of the packaging world still wasn’t. “At that time, the only successful users of plastic bags for retail were Marks & Spencer in the UK and Simpson’s in Canada,” he said. “We purchased Hymopack strictly as a learning experience, on the off-chance that either low or high density retail bags would start capturing a portion of the paper bag market.”

In truth, Rosenbloom said, the acquisition of Hymopack was less a vote of confidence in the long-term staying power of PE grocery bags than a natural sideways expansion. “By the late 1970s, our distribution company was

distributing plastic bags anyway; when Hymopack came up for sale, it just seemed a simple and natural step to buy it,” he explained.

The same logic led to the purchase of Dyne-A-Pak when that company was up for grabs in 1980. “Dyne-A-Pak had been our leading supplier of foam trays, so, again, acquiring the company when it became available was the obvious move,” Rosenbloom said.

KEEPING UP, GIVING BACK Cut to the present: Even as Hymopack and Dyne-A-Pak are firmly positioned as leaders in their respective packaging segments—and also as two jewels in the crown of parent company The Rosenbloom Groupe—neither organization is resting on its laurels. When a fire ravaged Dyne-A-Pak in September 2004, destroying approximately 40 per cent the 180,000-square-foot facility, including production and warehouse areas, the plant was quickly rebuilt; today, the company is leading the foray into bioplastic packaging with its fully certified, D6400-approved “Nature” line of compostable foam meat trays, made using cutting-edge biopolymers. Hymopack, meanwhile, continues to manufacture a wide variety of bag styles in high density, low density and co-extruded film.

As befits two heavy hitters like Hymopack and Dyne-APak, key company personnel have volunteered their time to industry associations, sometimes at Rosenbloom’s gentle behest. Senior staff members have served on several committees with the Plastics Film Manufacturers Association of Canada over the years. Most recently, Rosenbloom encouraged Gerry Maldoff, president of Hymopack, to chair the CPIA’s Plastic Bag Task Force.

The streak of philanthropy extends into Rosenbloom’s own personal life. He currently sits on the Foundation Board of Montreal’s Jewish General Hospital, and is also an active fundraiser for Alzheimer Groupe (AGI) Inc.’s programs for patients and their caregivers in his community.

TAKING STOCK OF THE PRESENT But to return to plastics: Rosenbloom is confident that plastics packaging in general will remain a growth industry in the years to come, despite encroaching legislation and a level of bad press unimaginable when he began making his mark in the boom years of the 1970s and 1980s. “The question for critics of plastics is, ‘What do you propose as an alternative?’ ” he said. “As someone who also supplies and promotes paper bags, I can tell you that paper isn’t any more user friendly as an alternative, and also has the same issues with disposability.”

This isn’t to say suppliers of front-end plastic bags and other packaging formats won’t have to make compromises going ahead, he continued. “If we want to survive, the packaging industry is going to have to accept new compromises with retail stores that limit the use of, or charge a fee for, carryout plastic bags,” he said.

CPL www.canplastics.com June 2010 Canadian Plastics 11

CPIA awards

PLASTICS STEWARDSHIP AWARD

Designed to honour companies that have contributed to the enhancement of the Canadian plastics industry’s stewardship and sustainability.

PAR-PAK LTD. No stranger to the spotlight—company president Sajjad recycled 319 tons of cardboard, packaging material and metal Ebrahim was CPIA’s Leader of the Year in 2008—packaging pipes in 2008, and 300 tons in 2009. supplier Par-Pak Ltd. is back in public view, this time as one Moving along to energy conservation, Par-Pak has made of two Stewardship Award winners. significant changes to their operations to cut Looking for just one reason why? You won’t energy use, and employs a designated find it. The Brampton, Ont.-based company energy specialist to look for everwas instead selected for having succeeded newer ways to trim consumption. with a slew of sustainability goals.

To date, the company has reduced Let’s start with its recycling policy. energy consumption in lighting by “We recycle 100 per cent of our internal 65 per cent by retrofitting fixtures trim scrap and have a program with our in office and production areas with customers who buy our sheet to buy high-efficiency bulbs, installed tube Plastic container back their trim scrap,” said Sajjad Ebraheaters in production and warehouse from Par-Pak. him. “Also, we installed a state-of-the-art facilities that use two-thirds less energy, purification and filtration extrusion line and peland reduced water usage in its production letizing process in 2009 that lets us decontaminate and purify plant through a new closed loop water cooling system that post-consumer recycled PET to be utilized back into food allows reuse of water. packaging. The system also helps us reduce CO2 emissions, Finally, Par-Pak is an active member of the National Assothe material going into landfill, and the energy required to ciation for PET Container Resources (NAPCOR) and the make recycled PET versus virgin PET.” The company also Association of Post-Consumer Plastic Recycler (APR). CPL

NESTLÉ WATERS CANADA

to lightweight our various bottles,” Challinor said. “Since 2007, we’ve been able to reduce our plastics requireLightweighting—designing a product to use the thinments by 4.59 million kilograms annually, our C02 emisnest material that will still meet specs for strength sions by eight per cent annually, and our high pressure and appearance—is the ultimate green manufacturcompressed air consumption by 40 per cent.” ing “two-fer,” reducing both carbon footprint and The company is also on a continual hunt for production costs. It’s also a mantra at beverways to trim secondary packaging materials— age manu­facturer and distributor Nestlé Waters and, as with plastics, with notable results. “We’ve Canada, CPIA’s second Stewardship selection. eliminated cardboard side walls from the majority Case in point: the company’s new Ecoof our 24-packs of bottled water, for example, and Shape(R) 500 ml PET bottle. Weighing just 9.16 downsized our paper labels since 1998,” Challinor grams on average, the bottle contains 27 per said. “The current label is 35 per cent smaller than cent less plastic than its predecessor Eco-Shape its immediate predecessor, and saves approxibottle from 2007; and 60 per cent less plastic mately 20 million lbs of paper.” than the company’s original, pre-Eco-Shape 500 As befits a Stewardship Award winner, the ml PET bottle from 2000. company’s green activities also extend to helping This latest version of the Eco-Shape 500 ml fund Canada’s municipal recycling infrastructure bottle—currently rolling out in the company’s across the country, and playing a role in introducPure Life and Montclair brands—is 100 per cent ing Canada’s first public spaces recycling program recyclable, said John Challinor, director of corin Quebec in 2008. “A similar program is schedporate affairs with the Guelph, Ont.-based comuled to be unveiled in Manitoba later this year, pany; target end uses as recycled material include Nestlé Pure Life and a successful pilot program has recently been carpeting, automotive parts, toys, and clothing.

PET bottle. completed in Ontario,” Challinor said.

CPL “Beginning in 2006, we made a determined effort

12 Canadian Plastics June 2010 www.canplastics.com

CPIA awards

PLASTICS INNOVATOR AWARD

International Trade Fair No. 1 for Plastics and Rubber Worldwide

Designed to honour individuals who have contributed to advancing plastics technology in Canada.

WERNER AMSLER

Swiss-born Werner Amsler cut his teeth in plastics back in 1970, when he joined the former Premier Plastics in Toronto as a moldmaker before rising to plant manager. Following a five-year stint with Bekum Plastics Machinery’s Canadian office, Amsler opened blow molding company Swissplas Ltd. In 1990, he started R&D and technical consulting firm W. Amsler Enterprises Inc. Four years later, W. Amsler Equipment Inc. was founded, and began manufacturing all electric PET blow molding machines and accessories. The company now operates from a 16,000-square-foot plant in Richmond Hill, Ont., and this is where we find Amsler today, as the first recipient of CPIA’s newly minted Plastics Innovator Award.

Amsler said he decided early on to make fully electric machines instead of standard hydraulic presses—and with the fully electric unit as its guiding light, his company has spent the past 15 years pushWerner Amsler (second from right), staff and ing the boundaries of blow molding machine on the shop floor. stretch blow molding technology. With machines in over 10 countries, the lineup now ranges from one to six cavities for container sizes between 50 ml to 23 litres, and for outputs exceeding 9,000 per hour.

There’s no sign of a slowdown, either: a new two-cavity machine, for instance, can produce bottles from 50 ml to five litres, with output of the five-litre unit an impressive 2,400 per hour. A three-cavity convertible machine, meanwhile, can produce 500 ml bottles at 4,500 per hour utilizing all three cavities, two-litre bottles from two cavities at 3,600 per hour, or five-litre containers from a single cavity at 1,000 per hour.

True to the modern ideal of green technology, the three-cavity machine has 50 per cent more output than its two-cavity counterpart but an energy usage increase of only 12 per cent.

And that’s not all: Other innovations from 2009 include a fully automatic loading system for wide mouth preforms up to 89 mm, a flexible PET machine series allowing for adjustable cavitation on PET blow machines, and a modular semiautomatic palletizer with optional fully automatic operation through the purchase of additional modules.

CPL

k-online.de Buy your ticket now +++ at an attractive price +++ in the Online Ticket Shop +++ at www.k-online.de/2130

The mostt importtant trad de fair for you – worldwide !

“It’s K time” means that about 3,000 exhibitors from over 50 countries present the latest products and concepts – from standard solutions to high-tech results. With its first-class range of exhibits, both quantitatively and quali tatively, K is the worldwide most important business and contact platform for the industry. In 19 halls, the future of the industry across every sector is represented – from market leaders to niche market suppliers.

Be there when the world class of plastics and rubber suppliers meet in Düsseldorf !

Canadian German Chamber of Industry and Commerce Inc. Your contact: Stefan Egge 480 University Avenue, Suite 1500 Toronto, ON, M5G 1V2 Tel: (416) 5 98 - 15 24 Fax: (416) 5 98 - 18 40 E-mail: messeduesseldorf @germanchamber.ca

www.canplastics.com June 2010 Canadian Plastics 13 kmd1002_AZ_106x277_M1_CA_US_Lae_OS.indd 1

12.05.2010 9:44:14 Uhr

chillers

CHILLERS

Think PLANT-WIDE for energy savings Cooling is a critical, and sensitive, stage of plastics manufacturing, where many manufacturers rack up significant energy costs. But unlike firing up an energy efficient new I/M machine, slashing energy usage on chilling systems involves a broader approach. Doesn’t mean it can’t be done, though.

Here’s some ideas from cooling system manufacturers and vendors.

By Mark Stephen, editor

W

hen it comes to saving energy with chillers, it’s important to realize one thing from the start: treat it like a piece to a puzzle.

“There’s no single magic bullet to achieve an energy efficient chilling system,” said Don Berggren, president of Berg Chilling Systems.

“Instead, the process requires a plant-based approach that looks at the whole picture.”

Why isn’t it as simple as just buying energy efficient chillers? “From an energy efficiency perspective, chillers haven’t progressed much over the years because the focus has tended towards reducing ozone-depleting refrigerants, not cutting energy consumption,” said Ziggy Wiebe, owner of Chillers Inc. Achieving energy savings with chilling systems is difficult, then...but not impossible. Luckily, operating in a northern country like Canada gives processors an opportunity right off the bat: free cooling, which is the use of “free” lower external ambient air to assist—or bypass entirely—the mechanical cooling systems during winter months.

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“Free cooling of a chilled water system during winter and even into part of spring is an effective way to cut power consumption,” said Don Berggren.

“In a regular cooling system, chilled water loops cooled by mechanical refrigeration operate continuously. Using free cooling, refrigeration compressors can be turned off in the winter to save energy.”

14 Canadian Plastics June 2010 www.canplastics.com

It gets better: Many newer models combine a central chiller and outdoor free cooling in one unit to allow process cooling water to bypass the chiller when outside temperatures are low enough.

The potential of free cooling can best be realized when combined with variable frequency drives (VFDs), which can be installed to reduce fan/pump motor speed to 80 per cent full speed, in turn reducing a cooling system’s energy consumption by as much as 50 per cent. “VFDs are important in allowing motors to run at a lower speed, which saves energy usage,” said Balbir Anand, vice president of Freeze Co. Systems. “There’s a cost to installing VFDs, of course, but processors usually find that it will be paid back relatively quickly.”

The only real drawback to free cooling is— you guessed it—temperature fluctuations. “If the weather isn’t conducive, free cooling won’t provide much in the way of energy savings, particularly when temperature fluctuations cause energy spikes,” said Don Berggren. “The differing demands of each manufacturing system play a role here: Processors who are running molds at lower temperatures will have shorter periods of time to take advantage of free cooling than will those with higher mold temperatures.”

HEAT RECLAIMING AND BEYOND A second energy saving strategy is heat reclaim.

In a traditional chilled water cooling system, heat is transferred from the indoor coil to the

chillers outdoors. “Not only is this heat wasted, but energy is consumed at the cooling tower and condenser-water pumps in the process,” Ziggy Wiebe said.

Whether or not a heat reclaim system is feasible for your shop boils down to whether or not it can accommodate continuous and peak hot water demand while still providing a controlled source of service hot water. If so, a heat reclaim system might be a valuable energy saving addition.

A way to further build on these savings is to include a heat reclaim chiller, a device that generates highpressure refrigerant that can be used to produce higher temperature condenser water.

And although it sounds obvious, proper sizing and application of equipment shouldn’t be overlooked— but often is. “Too many chilling systems are oversized, resulting in higher than necessary power and energy consumption per ton of cooling delivered,” said Henry Van Gemert, president of Regloplas Corporation. “By better matching current loads with chiller units, processors can get better performance and energy efficiency.” Modular chillers are particularly well suited for this; they can be installed in hard-to-reach places, require a only small footprint, and make it easier to better match current and future cooling demands.

Other recent chiller technical developments can also help.

Piovan’s new PET chiller, for example, is designed for energy efficient performance for chilled water systems. Developed for PET perform production lines, the unit is equipped with inverter controlled compressors for self tuning of the refrigeration capacity necessary to provide cooling to the utilities.

Another energy efficient technical development is Advantage Engineering’s new Maximum portable chillers with digital scroll compressors. Combined with Advantage’s proprietary control, the digital scroll compressor modulates cooling capacity from 20 to 100 per cent, while also consuming less energy than traditional portable chillers that use hot gas bypass capacity control. “Portable chillers are often applied to a wide range of load profiles, making energy efficient capacity control an important feature,” said Ziggy Wiebe.

It doesn’t hurt to reiterate that these developments remain a piece of the bigger puzzle. “In the end, a processor has to be prepared to examine its entire process and make changes anywhere in the system to get the best cooling efficiency,” Wiebe noted.

CPL RESOURCE LIST Advantage Engineering Inc. (Greenwood, Ind.); www.advantageengineering.com; 317-887-0729 Chillers Inc. (Newmarket, Ont.); 905-895-9667 Berg Chilling Systems Inc. (Toronto); www.berg-group.com; 416-755-2221 Freeze Co. Systems Limited (Brampton, Ont.); www.freezeco.com; 1-800-339-8982 Piovan Canada Ltd. (Mississauga, Ont.); www.piovan.com; 905-629-8822 Regloplas Corporation (St. Joseph, Mis.); www.regloplasusa.com; 1-888-799-4110 Plastics Machinery Inc. (Newmarket, Ont.); 905-895-5054

QUEBEC PROCESSOR GETS “AIR BLAST,” ENERGY AND WATER SAVINGS THE SITUATION A major plastics processor in Quebec had to satisfy a temperature requirement within the range of 7° to 25°C with chilled water cooling. Looking to trim energy costs, they determined that most of the load could successfully operate at higher supply temperatures, which would allow the majority of the load to be satisfied by ambient-produced cooling rather than high horsepower mechanical cooling.

As a result, they calculated that only 22 per cent of the load would require a chiller supplying mechanical cooling at 7°C, while the balance—78 per cent—could be satisfied with cooling at 30° to 35°C.

THE CHALLENGE The most energy efficient solution, they realized, would be to utilise ambient-based cooling equipment, and the most environmentally friendly solution would be a sealed air blast fluid cooler that consumes no water. Also, there would be no evaporative cooling requiring water make-up as required by an evaporative cooler, no need to introduce water for temperature trimming, and no need for the constant attention of chemical treatment. Problem was, such a system wouldn’t be able to attain and maintain the lower temperature requirement during the hot summer months.

To meet the 7°C requirement, they knew, a chiller would have to be used in conjunction with the fluid cooler.

THE SOLUTION The processor contacted Berg Chilling Systems. Berg supplied an Eco-Wise system that integrated both the air blast cooler and a chiller. Equipped with Berg’s Eco-Trol controls, the system automatically allows for a transfer between the air blast cooler and the chiller. The air blast cooler satisfies the process demands for most of the year— even taking advantage of cooler spring and fall nights— while the chiller takes over to supply the portion of the process that requires 7°C when ambient temperature rises above 2°C.

THE RESULTS The customer now stands to save approximately $100,000 annually through reduced energy and municipal water usage and chemical treatment savings. The system payback? Less than two years.

CPL www.canplastics.com June 2010 Canadian Plastics 15

chillers

The RACE

Copeland, is saying that R-410A is the refrigerant they’ll use in their digital scroll compressors,” said Ziggy Wiebe, owner of Chillers Inc. Chiller manufacturers such as Advantage Engineering, for example, have already released new chiller models—in this case the Maximum portable water chiller—that use R-410A, as has Thermal Care with its’ NQ line of air-cooled portable chillers, and Mokon with the new Iceman portable and central chillers.

to REPLACE

R-22

SECOND PLACE: R-134A

For chiller manufacturers, 2010 represents the dawning of a new age: effective January 1, the industry’s most widely used refrigerant­—R-22—was history. Under the terms of the Montreal Protocol, it’s now illegal to make, import or sell chillers in Canada and the U.S. that use R-22.

With process cooling’s across-the-board standard gone, the onus is on equipment suppliers to come clean with their customers. “The fact is, we don’t know which replacement refrigerant will come out on top, if any,” said Don Berggren, president of Berg Chilling Systems. “For this reason, we direct our clients to choose the refrigerant that best suits a particular application.”

With this caveat in mind, here’s a quick look at three leading PCMExpoR-22 1/2 replacements.

Ad 5/17/10 1:31 PM Page 1

Not so fast, however. “Because R-410A operates at significantly higher pressures than R-22, many components must be more robust than is standard in conventional chillers.” said Balbir Anand, vice president of Freeze Co. Systems. “Also, R-410A can’t be used to retrofit existing R-22 equipment, due to significantly high operating pressures By comparison, the low-pressure R-134A refrigerant can replace R-22 with minimal adjustments to the chiller.” In addition to Freeze Co., another manufacturer embracing R-134A is The Conair Group: The company’s EarthSmart portable chiller product actually uses both R-134A and R-410A refrigerants.

THIRD PLACE: R-407C

Another alternative to R-22 is R-407C. “We’ve standardized on the R-407C, which has been very popular in the European chilling industry for some time,” said Henry Van Gemert, president THE FRONTRUNNER: R-410A of Regloplas Corporation. The company’s air- and water-chilled The early favorite to replace R-22 has to be the non-ozone-deplet- Reglochill units, for example, use R-407C, as do larger chillers ing R-410A. “The largest compressor manufacturer in the world, offered by Advantage Engineering.

CPL

THE ONLY PLASTICS SHOW IN CANADA IN 2010

PCMEXPO

Plastiques, Composites et Moules Expo Plastics, Composites and Molds Expo

A tabletop show and technical seminars produced by

Canadian Plastics

plastiques et moules Supplément de la revue Canadian Plastics

Thursday, September 23, 2010 10 a.m. to 4 p.m.

Loews Hôtel Le Concorde Québec City, Québec

The publishers of Canadian Plastics and Plastiques et moules announce the launch of a tabletop show with technical seminars presented by exhibitors.

We are partnering with the industry association FEPAC (Federation of Plastics and Alliances Composites) whose Forum Canada conference and Awards Gala will take place the next day, at Loews Hôtel Le Concorde.

A jointly sponsored PCMExpo/FEPAC cocktail reception from 4:30 – 6:00 p.m. after the tabletop show, will provide an excellent networking forum.

This one-day show provides an opportunity for you to market your products and

services in a productive and constructive sales environment. Meet over 200 potential customers in an approachable, buying atmosphere.

Cost effective. Exhibit space costs as little as $795 for a table.

To book your exhibit space or receive more information, contact your Canadian Plastics sales representative: Judith Nancekivell, Senior Publisher Tel: 416-510-5116 Email: jnancekivell@canplastics.com Brayden Ford, Sales Representative Tel: 416-510-5124 Email: bford@canplastics.com

www.plasticsandmoldsexpo.com 16 Canadian Plastics June 2010 www.canplastics.com

Moldmaking TESAN MOULD:

REPORT

Step by step to success

M

aking it in today’s manufacturing climate is a bit like climbing up a ladder—you can’t miss a step. And for moldmakers, these steps include location, focus, equipment, manpower, flexibility— and the right products, of course.

Concord, Ont.-based moldmaker Tesan Mould Inc. seems to have ascended the ladder better than many, which might explain why business is booming. ForBins and containers (left) made with molds like this one (right) from Tesan Mould. merly heavily invested in—what else?—the automotive industry, the 30-year-old company has transitioned into designing and mak- take advantage of the highway infrastructure: the 400, the 401 and ing molds for a variety of other sectors: thin wall food packaging, in the 407,” said assistant manger Lucas Tesan. particular, as well as medical components, and containers and trays.

A second step involves maintaining high levels of awareness and specialization. “These days, the cheap, dirty molds have LOCATION, LOCATION, EQUIPMENT all disappeared. The future lies in doing difficult components Founded by company president Riccardo Tesan, Tesan Mould and taking on jobs that few others can, but without making arrived at its current level of success by making the most of its the mistake of thinking that you can do it all,” Lucas Tesan opportunities over the decades, beginning with logistics. “We used said. “Presently, we’re restricting ourselves to designing and to be located in the heart of Toronto, but moved north to Concord in manufacturing medium to large molds, with a typical tonnage the late 1990s to be in the middle of our customer base, and also to of between 150 to 1,000 tons, but we’re diversified within that range, making both stack and IML molds.”

Having the latest in CNC machinery, 3D-prototyping equipment—and more—is critical here.

“We perform a lot of five-axis machining work, The Canadian Association of MoldMakers (CAMM) and own a large five-axis machine, which is continues to go big. rare,” Lucas Tesan continued. “The machine is On the heels of its strategic partnership agreement busy virtually 24 hours a day, and we have a with Quebec’s Federation of Plastics and Alliances small night shift working with it, grinding, drillComposites (FEPAC), Windsor, Ont.-based CAMM ing, and doing other mold services around the has established a new Toronto chapter, to be headed clock. Most of our employees have been with

by Natalia Stephen, president of functional coater us for over 10 years, and are happy to put in the Compound Metal Coatings in Mississauga, Ont. extra work because they understand that the days “I’m honoured to run CAMM’s new Toronto chapof working from 9:00 to 5:00 are over.” ter,” she said.

“Our goal is to add value for all of our CAMM president members by growing the membership in the greater Dan Moynahan Toronto area. This will give us a stronger voice to ADIOS TO AUTOMOTIVE WORK with Natalia Stephen. lobby government, a bigger presence at national and The willingness to take on mold repair work, refurinternational trade shows, and a better overall forum for spreading inforbishment and engineering changes doesn’t hurt, mation about new technologies and innovations that will keep Canadian either. “We repair other molds that our customers moldmakers and related industries competitive on a global level.” have acquired from other shops, and even from other

CAMM opens Toronto chapter

See Tesan Mould, page 20 www.canplastics.com June 2010 Canadian Plastics 17

PRODUCT SHOWCASE: PDX/AMERIMOLD

One of the biggest events on the moldmaker’s calendar for 2010, the PDx/amerimold trade show was held from May 11-13 in Cincinnati, Ohio. Here’s a sampling of some of the technologies on display.

HOT RUNNER SYSTEMS DESIGNED FOR ANY INJECTION MOLDING APPLICATION

IMPROVED MOLD ANALYSIS SOFTWARE

The new Quick-Flo (QF) system from Incoe Corp. is used with commodity grade resins for caps/ closures, medical disposables, and pharmaceutical packaging applications which demand maximum output, repeatable part quality and superior cosmetics. With up to 375g shot weight capacity, complete hot half systems are included with nozzles available in flow channel diameters of three mm, five mm and eight mm.

The QF system is available with Opti-Flo manifolds featuring Beaumont Technologies’ MeltFlipper technology, which can provide improved cycle times and processing capability.

Incoe Corp. USA (Troy, Mich.); www.incoe.com; 248-616-0220 Anplast Inc. (Anjou, Que.); 1-800-387-4590

The new version 3.0 systematic mold balance analysis software from Beaumont Technologies is designed for additional runner layouts and improved functionality with data entry.

The five-step process provides users with a systematic mold balance analysis that facilitates the mold debug and diagnostic procedures. This is accomplished through automatic “flow grouping” of cavities, which helps separate the main sources of mold filling and part quality variations.

The new 3.0 version includes several new runner layouts, custom scaling of the report graphs, and “shot manager” for multiple data entry on one analysis page.

Beaumont Technologies Inc. (Erie, Pa.); www.beaumontinc.com; 814-899-6390

ELECTRIC VALVE GATE AND SEQUENCER FOR MEDICAL APPLICATIONS The first product introduced as part of the new strategic partnership between D-M-E Company and Plastic Engine­ering & Technical Services, Inc. (P.E.T.S.) is an electric valve gate system well suited for highprecision, cleanroom molding applications.

Advantages for molders include higher speeds, better part quality and material savings, design enhancements, variable speeds, and fast mold changeovers.

In addition, the P.E.T.S. electric valve gate can be paired easily with the user-friendly P.E.T.S. valve gate sequencer, which offers real-time, section-views of each valve gate, with the capability of digitally, precision positioning each valve pin independently, in .001inch increments.

D-M-E Company of Canada Ltd. (Mississauga, Ont.); www.dme.net; 1-800-387-6600

18 Canadian Plastics June 2010 www.canplastics.com

DOVETAIL COLLAPSIBLE CORE REDUCES PART WEIGHT

Roehr Tool Corporation is unveiling its Dovetail Collapsible Core (DT Core), intended to offer added flexibility in design, as well as reduced part weight.

The DT Core also offers simplified mold design and less maintenance time, customizable collapse angles for gradual release from undercut, part design flexibility, and deeper undercuts.

Additionally, it can eliminate secondary operations like cutting TE Bands or gluing liners, as well as special core pull circuits or the common ejector plate sequence, resulting in considerable cycle time reduction.

Roehr Tool Corporation (Hudson, Mass.); www.roehrtool.com; 1-877-563-1912

Want the latest in MOLD STEEL? See our special Technology Showcase section on pg. 24.

Additive manufacturing

gets standardized I

(BUT DOES IT MATTER?)

t’s been called rapid technology, rapid prototyping, rapid tooling, and layered manufacturing, but—by whatever name—the long debate over what the process involves is about to be clarified.

Through a collaborative effort between the Society of Manufacturing Engineers (SME) and standards organization ASTM International, rapid tooling now has a universal name—“additive manufacturing”— and a universal language.

The move is an effort to eliminate confusion among moldmakers and their customers over terminology, design, testing methods, materials and processing differences. In addition to coining the additive manufacturing phrase, 25 terms have been standardized.

The result is the publication, “Standard Terminology for Additive Manufacturing Technologies,” now available for purchase online.

will allow manufacturers to compare and contrast the performance of different additive processes and enable researchers and process developers to provide repeatable results.”

WHAT’S IN A NAME? Without taking anything away from Committee F42’s obvious hard work and good intentions, here’s a question, though: how many in the moldmaking community will care? “On paper, the change is a good idea, because ‘rapid prototyping’ was too big a descriptor, and allowed shops that weren’t true rapid toolers to claim that they were,” said Todd Grimm, a rapid tooling veteran

and president of Edgewood, Ky.-based consulting firm T.A. Grimm & Associates.

“In reality, however, I don’t think either the moldmaking industry at large or their customers will care about something as rudimentary as a name change, or even a clarification of standards.”

It’s a statement echoed by some of the moldmakers themselves. “Changing the name from rapid tooling to additive manufacturing doesn’t really matter to us,” said Andrew Stewart, account manager of Wallaceburg, Ont.-based AarKel Tool and Die, a shop that’s been performing classic rapid/prototype tooling since its inception in 1977. “Many of the moldmakers that only offered rapid tooling have disappeared anyway because they’re not diversified enough, so we no longer need a terminology change to set us apart.”

A LOST ART? It just might be a moot point anyway.

“The rapid tooling process itself may be Continued on page 20

CLARIFICATION = CONSISTANCY (MAYBE) “In the past, rapid prototyping has meant different things to different manufacturers.

It meant quick prototyping to one and layered manufacturing to another,” said Brent Stucker, PhD, a member of SME’s Rapid Technologies and Additive Manufacturing (RTAM) Community and an associate professor of mechanical and aerospace engineering at Utah State University. The new terminology “will help clarify communications,” Stucker continued, especially in industries like medical manufacturing and aerospace where consistency is a must.

In addition to fixing the terminology, the advisory panel formed by SME and ASTM to implement the name change—called Committee F42—will also develop other key standards. “Test methods will more than likely be our next effort, but additive manufacturing industry design, materials, and processes are also in the works and will be developed in parallel,” said Stucker. “The new standards www.canplastics.com June 2010 Canadian Plastics 19

Additive Manufacturing, from page 19

Tesan Mould, from page 17

KShow

countries,” Riccardo Tesan said. “It’s a service our customers definitely appreciate, especially now, when they’re beginning to get busy again and need molds that are up to new jobs. It’s cost-effective for them and works very well for us.”

Even with these strengths, it’s doubtful the company would be maintaining its present size and scale without a transition away from making automotive molds. “We spent years phasing out of the automotive sector, and are pursuing what we regard as better avenues, such as molds for food packaging, medical parts, rigid containers and trays, and pails and lids,” Lucas Tesan said. “The automotive sector is a tough one to be in, and we’re glad not to be over-invested in it.”

While there are no guarantees, Tesan Mould can probably stand as a blueprint for adapting and surviving in a brave new world.

“It’s definitely been a rough few years—probably the worst I’ve ever seen—but we’ve stayed strong by trying to adjust changes before1/13/10 they become widespread,” Ad 1/2topg-AB-CPL 2:34 PM Page Ricca1 rdo Tesan said. “It sounds simple but it’s not, and there’s really no other way to succeed these days.”

Tesan Mould Inc. (Concord, Ont.); www.tesan.com; 905-738-9056

on the way out, for the simple reason that there are very few situations where it’s worthwhile anymore,” Todd Grimm said. “Originally, rapid tooling was defined as the ability to generate core and cavity inserts as a product of a rapid prototyping technology, and had the advantage of communicating complex designs quickly, clearly and concisely. Nowadays, though, everyone is in the same speed category, and the term—by whatever name—will probably continue to lose its distinction.”

This isn’t to write the newly-named additive manufacturing off entirely, though. “Shops like AarKel that perform true rapid tooling still have a significant cost edge over those who do not have this as part of the business model, because the process allows for dedicated tool building techniques and for specific testing to be done before the customer invests in a production tool with the same team, transferring knowledge from one to the other,” said Andrew Stewart. “Also, having a group of dedicated rapid tooling workers gives true rapid toolers a technical edge.”

Nevertheless, Stewart acknowledged a decline of sorts in the demand for rapid tooling. “A lot of OEMs, looking to shorten project time, are eliminating the rapid tooling step by involving the tool builders in the project from the feasibility stage onward,” he said.

“This is where the value of diversification comes in—as AarKel has done—so that a shop has other skills to offer.”

CPL

TURBO CHARGE YOUR BUSINESS WITH A VISIT TO K 2010!

BE PART OF THE OFFICIAL CANADIAN DELEGATION Canadian Plastics and Plastiques et moules is partnering with FEPAC (Federation of Plastics and Alliances Composites) to bring Canadians to the K Show as a whole group. This program will create a unique dynamic among participants, enhancing future collaborations and partnerships for a stronger Canada to compete in global markets.

We’ve teamed up with Carlson Wagonlit to bring you an unbeatable travel package: • SPACIOUS ROOM FOR 6 NIGHTS AT THE MARRIOTT COLOGNE (4 STARS +).

• ROUND TRIP AIR TRANSPORTATION FROM TORONTO or MONTREAL (departures available from other cities at a nominal surcharge)

• 4-DAY ADMISSION TO K2010 and EXHIBITORS CATALOGUE. • DAILY BUFFET BREAKFAST. Departure October 26; return November 2 $3650.00* (*double occupancy; single occupancy available for a surcharge)

To reserve your K 2010 travel package, contact :

• FIRST CLASS PASS FOR ALL TRAINS between Cologne and Düsseldorf and LOCAL TRAM from the main Düsseldorf train station to the K2010 site.

• WELCOME DINNER in local brauhaus.

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• EXPERT ASSISTANCE ON SITE provided by Carlson Wagonlit and FEPAC staff.

OTHER PACKAGES AVAILABLE INCLUDING A MIX OF BUSINESS AND PLEASURE.

André Houle, General Manager CARLSON WAGONLIT TRAVEL

20 Canadian Plastics June 2010 www.canplastics.com

Toll Free Tel: 1-888-378-7208; Fax 1-866-880-1121 Email: ahoule@voyagelm.ca

DRYERS

dryers

The latest efficiencies In the old days, you bought a resin dryer because you were processing resins that took on moisture, and that moisture would mess up your end product. Today you’re buying a resin dryer for the same reason, but it has to provide a slew of other benefits to help you run a more cost effective operation, beginning with energy efficiency. Here’s a brief look at some recent dryer offerings that fit the bill.

By Mark Stephen, editor

IT’S THE ENERGY SAVINGS, STUPID In any discussion of plastics processing, energy consumption isn’t the elephant in the room—it’s more like Godzilla: a major issue for PET processors, including drying, and a headache for everyone else. Not surprisingly, virtually every new dryer introduced today is designed to cut energy usage to some extent at least. For some units, slashing hydro bills is unequivocally the prime directive.

Case in point: Wittmann’s new Drymax Aton desiccant dryer.

According to Rob Miller, president of Wittmann Canada Inc., the Drymax Aton has three separate processes that use existing heating energy of the drying process to cut energy consumption.

“First, the dryers have a chamber in the centre of the drying wheel that takes the radiation of excess heat from the wheel and uses it for the pre-heating of regeneration air,” he said. “Second, the radiation of heat from the inner heater tube is used to pre-heat the regeneration air; and third, the wheel is regenerated by reverse flow process for efficient cooling of the desiccant, further minimizing the heat energy used.”

The units also come standard with the company’s ECO-Mode technology. “If the moisture load on the dryer is lessened, the wheel regeneration can automatically operate similarly to a tower dryer,” Miller explained. “The regeneration is done sequentially during operation, which creates a lower water load, further reducing energy consumption.”

Since January, Italy-based Piovan SpA has been shipping its new

Photo Credit: Wittmann Canada Inc.

I

f you were forced to sympathize with one plastics machinery manufacturing segment in particular during this so-called Great Recession, it might just be the dryer suppliers. With plastics processors fighting a two-front war against resin-destroying shop floor moisture on the one hand, and increased competition on the other, they’re demanding more from their dryers than ever before: smaller footprint, easier cleanout, all-stainless construction, increased drying speed and efficiency, equipment for new markets like medical parts molding, topped off by—what else?—the constant craving for energy savings.

Rather than throwing up their collective hands, though, dryer manufacturers are digging deep to come up with new units designed to satisfy all of the above criteria.

Wittmann’s Drymax Aton dryer features three processes that use the existing heating energy of the drying process to reduce energy consumption.

Genesys PET dryer in North America, billed as a self-adjusting system that delivers very low energy consumption. Genesys has an automatic airflow control and adjustment to cut energy use by 35 to 55 per cent below today’s conventional resin dryers, the company said. Another feature of Genesys is the capability to stabilize the airflow in the drying hopper for better optimization of the energy utilization. Genesys also recovers between 50 to 80 per cent of energy used during regeneration of the desiccant material.

As a hypothetical, processing systems producing PET performs that consume resin at a rate of 1,000 kg/hr can save as much as 220,000 kW/h per year, the company said.

Universal Dynamics recently brought out its first desiccant wheel dryers, the Titan TR series, with throughputs of between 15 to 250 lbs/hr. The units are described as having a special wheel design that allows for high-temperature regeneration with dry air, resulting in lower dewpoint and energy savings of up to 30 per cent over conventional rotary wheel drying systems. Housed in a stainless steel enclosure, the series also features a heat recovery www.canplastics.com June 2010 Canadian Plastics 21

dryers and filtration system designed to trim energy usage even further, allowing the dryers to run dust-free and cost-effectively for drying resins in small quantities for medical applications.

FROM LARGE TO SMALL

SAB

Available in sizes from 600 cfm to 3,000 cfm, Sterling’s SDA large dryers are also meant for energy efficiency. Improved thermal efficiency is said to lower energy costs by 10 to 15 per cent, and reduce regeneration time to less than one hour. Available in three temperature ranges and sizes up to 3,000 cfm, SDA dryers are said to operate effectively either centrally or beside the machine, achieving a -40°F dewpoint even in high humidity. For even greater energy efficiency, an SDAG version incorporates gas-fired heat exchangers for both process and regeneration.

Also from Sterling is the compact SCD10 series dryer, which can be located on the floor or directly on the drying hopper. Air enters through a solenoid and is filtered through a large-particle compressed-air filter before it moves through the heating element. Another new dryer, the SDF series dryer, delivers low dewpoint dehumidified air for medium throughput Ad/AB/CPL 1/22/10 10:07 AM Page 4 drying applications.

An energy efficient conditioning cycle is said to reduce energy consumption up to 40 per cent over traditional carousel-style designs, and virtually eliminates temperature and dewpoint spikes.

AEC has also weighed in with a compact, energy efficient drying solution. The company’s HRS Heat Recovery System is said to save up to 30 per cent of the annual heating energy cost associated with high-temperature drying. “The process uses the hot air leaving the drying hopper to preheat the cool air leaving the dryer prior to it being heated by the process air heater,” said Tom Thompson, AEC’s technical sales manager.

“The return air from the dryer gives up heat and becomes cooler by as much as 40 to 80°F, which reduces the cooling load necessary to cool the air entering the desiccant bed by up to 30 per cent.” The process air takes on heat and becomes warmer by as much as 40 to 80°F, he continued, which in turn reduces the load on the process air heater by up to 30 per cent.

“The result is an exchange of energy that would otherwise have been lost,” Thompson said.

OTHER EFFICIENCIES, NEW MARKETS If you haven’t guessed by now, energy efficiency is a highranking concern—but it isn’t the whole ball game for plastics processors looking maximize their dryer efficiencies. Here’s a different efficiency: The Conair Group’s TouchView dryer controls, available on the company’s larger Carousel Plus dryers, offer an autostart function that makes it possible to begin predrying material hours before the start of production. “Also, correct settings can be locked in and saved for instant recall,” said

ADVANCED TECHNOLOGIES FOR PRODUCTIVITY IMPROVEMENTS

Servo robots with highly accurate positioning.

Custom designed automation cells.

High-precision, all-electric injection molding machines, 35T–1,000T Environmentally friendly: no oil, no noise, energy-saving.

Hot runner control systems, sequential valve gate systems, production monitoring systems and Mold temperature controllers (water and oil).

The most technologically advanced, closed loop, process cooling systems, Chillers with free cooling capability and thermolators for precise control of the process parameters .

For your solution, contact: Automatisation S.A.B. Inc, Varennes, Que. 450-652-9767 www.automatisationsab.com Plastic Automation, Toronto. 416-938-3648, email: pae.inc@rogers.com 22 Canadian Plastics June 2010 www.canplastics.com

dryers Jamie Jamison, Conair’s general manager for PET and packaging. “Once set, the Optimizer Mode controls will automatically adjust air flow, temperature, and dewpoint to maintain a stable temperature profile in the hopper, regardless of changes in throughput, material temperature, or ambient conditions.”

And in case you’re wondering, there’s an energy efficiency component to the TouchView controls, too. “The controls finetune the air temperature, flow and dewpoint to consume just enough heat and mechanical energy to produce the optimum temperature profile,” Jamison said. “Too much air flow wastes energy, while too little air flow results in poor drying. Similarly with temperature, except that too much heat is not only wasteful but can overdry or degrade the material.”

Ask an ambitious processor about new market possibilities and medical parts molding is likely to top the list. Problem is, materials used within the medical industry have become more demanding to effectively process, to say nothing of the energy waste associated with running a high throughput machine for low throughput rates. Can newer dryers provide a more cost effective approach? You bet. The Precision Micro dryers line from Dri-Air Industries is designed specifically for medical parts molding. The units can handle from two pellets to 20 lbs/hr, the company said, with drying temperatures from 70 to 400°F. Configurations range from compact all-in-one drying systems that can fit on extruders or molding machines, to separate systems

with two-ounce hoppers and stand-alone dryer packages.

Wittmann is also dipping a toe into the pool with the release of its new Drymax Micro F2 unit. “With a drying capacity of two lbs/ hr, the F2 is well suited for micro molding,” said Rob Miller. “The dryers have integrated compressed air feeding, two-stage silos for a wide range of residence time, and are easy to clean.”

CPL RESOURCE LIST AEC/Equiplas (Toronto); www.aecinternet.com; 416-407-5456 The Conair Group (Cranberry Toownship, Pa.); www.conairnet.com; 1-800-654-6661 Hamilton Avtec Inc. (Mississauga, Ont.); 1-800-590-5546 Dri-Air Industries Inc. (East Windsor, Conn.); www.dri-air.com; 860-627-5110 Plastics Machinery Inc. (Newmarket, Ont.); 905-895-5054 Piovan Canada Ltd. (Mississauga, Ont.); www.piovan.com; 905-629-8822 Sterling (New Berlin, Wis.); www.sterlco.com; 262-641-8610 CNSmith Machinery Sales Inc. (Georgetown, Ont.); 416-917-3737 Wittmann Canada Inc. (Richmond Hill, Ont.); www.wittmann-canada.com; 1-866-466-8266 Universal Dynamics Inc. (Woodbridge, Va.); www.unadyn.com; 703-490-7000 Piovan Canada Ltd. (Mississauga, Ont.); 905-629-8822 Resource Polytec Inc. (Vancouver); 604-454-1295

Summer’s on its way it’s time to check your dryer!

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www.canplastics.com June 2010 Canadian Plastics 23

technology showcase

SPOTLIGHT:

The Latest In Mold Steel Overstating the importance of steel to the moldmaking industry is like overstating the importance of gin to a G&T—it can’t be done. Here’s a look at some recent offerings.

NEW GRADE FOR SHORT, MEDIUM PRODUCTION RUNS

Bohler Udde­holm has developed M303 Extra (pictured), a stainless martensitic chromium steel, offering excellent toughness, corrosion and wear resistance.

Characterized by improved machinability and polishability, the Extra M303 grade was developed for improved homogeneity ensuring good usage properties.

The grade is designed to give good polishability without having to be remelted, saving on cost for the alloy.

The homogeneity of M303’s chemistry yields a major advantage over 1.2316, in that no delta ferrite forms in the matrix, meaning that mechanical properties like fracture resistance are unaffected. M303 is pre-hardened to 32-36 HRC, and is primarily for prototyping and for short and medium production runs.

Bohler Uddeholm Canada (Mississauga, Ont.); www.bucanada.ca; 1-800-665-8335

FOR MOLDS WITH LARGER DIMENSIONS

With a delivered hardness up to 38 HRC, the new ThruHard Supreme from Buderus Specialty Steels is designed to satisfy the growing need for molds with larger dimensions.

Available in regular grade 31 HRC and in HighHard grade 36 HRC, the new steel offers good product quality due to etch grain and mirror finish reliability, and high gloss polishability in the HighHard grade for applications such as producing transparent parts.

The steel can significantly increase mold service life due to uniform hardness through to the core, even with the largest dimensions.

Also, high strength, good toughness and low internal stress provide resistance to costly tool damage.

Buderus Specialty Steels/Dan Coll Agency (Windsor, Ont.); 519-562-6651

TWO GRADES OFFER DISTORTION-FREE MACHINING Two new grades of Toolox prehardened tool steel plates are now available from Hasco America Inc. These low-carbon steels offer low residual stresses, which helps achieve nearly distortion-free machining, and their high cleanliness (close to ESR levels) facilitates polishing and etching.

They need no heat treatment and their high-heat tolerance of 1,094 F (590°C) allows them to be gas nitrided and PVD coated.

Toolox 33 is prehardened to 29 HRC and tempered, but can still be machined more easily than competing steels. Toolox 44 is prehardened to 45 HRC with the same hardness throughout.

Hasco Canada Inc. (Toronto); www.hasco.com; 1-800-387-9609 24 Canadian Plastics June 2010 www.canplastics.com

technology showcase

AUXILIARY EQUIPMENT

Stainless steel water heater for accurate temperature control Shini Technology’s STM-MW model all stainless steel water heater features a multi-stage P.I.D. temperature control system that can reach 120°C while maintaining the mold temperature to within an accuracy of +/- 1°C. Multiple safety devices can automatically detect abnormal performance, and indicate this via visible alarm, including over-temperature alarm, low liquid level protection, and pump overload protection.

The heater has a magnetic pump to ensure long service life, and comes standard with compulsive cooling function, seven-day automatic start/stop timer, and default and reverse phase protection.

An RS485 communication function and an external analog temperature setting function are optional.

Shini Plastics Technologies (Canada) Inc. (Mississauga, Ont.); www.shini.ca; 905-565-1602

sensor signal, from either the machine or the mold.

Six mold signals are available in standard configuration, with up to 20 controlled valve gates and five openings and closings per injection cycle, memorization of all injection cycles, and cycle-per-cycle display of mold and machine parameters.

The IS’Tech connects to a computer with standard USB cable, and has an enhanced Windows-operated monitoring system and real-time data display, and can store up to 48 mold files.

S.I.S.E. Plastics Control Systems, Inc. (Atlanta, Ga.); www.sis.fr; 404-784-8676 Plastic Automation Engineering (Toronto); 416-938-3648 Automatisation S.A.B. (Montreal); 514-968-2825

Real-time production monitoring and analysis

The Shotscope NX from Husky Injection Molding Systems provides real-time monitoring and analysis to help manufac-

Welding tool for plastic fabrication The Triac BT hot air indoor welding tool from Leister Process Technologies is now available for plastic fabrication.

The TRIAC BT features intuitive controls, including a rotary switch that allows the user to easily regulate temperature during the welding process and signals the user if the power supply has been interrupted.

With a weight of only one kg, the welding tool is easy to handle and comfortable to control. Specialized grip sections on the ergonomic handle help to ensure a firm grip while welding and helps reduce strain.

Packaged in a sturdy carrying case, the Triac BT comes in a complete kit ready for use. Each kit contains a Triac BT with 40 mm fixed nozzle, a manual silicon pressure roller, a replacement heating element, and room for more accessories.

Stanmech Technologies Inc. (Burlington, Ont.); www.stanmech.com; 1-888-438-6324

INJECTION MOLDING

Valve gating system triggered by any sensor signal The new IS’Tech sequential valve gating system from S.I.S.E. Plastics Control Systems is capable of being triggered by any

Providing a full line of fluid circulating products with tailor-made microprocessor controls for reliable and effective control of your process temperatures. www.AdvantageEngineering.com • Get Equipment Specifications and Pricing • Contact Sales & Service • Download Literature & Manuals • Learn About New Products & Technology

Advantage Engineering, Inc. 525 East Stop 18 Road Greenwood, IN 46142 317-887-0729 fax: 317-881-1277 e-mail: sales@AdvantageEngineering.com

Chillers Inc. is the exclusive Canadian representative for Advantage Engineering.

www.ChillersInc.com

905-895-9667

Chillers, Inc. 1228 Gorham St. Unit 11 NewMarket, Ontario Canada L3Y 8Z1 phone: 905-895-9667 fax: 905-895-5177 email: sales@ChillersInc.com www.canplastics.com June 2010 Canadian Plastics 25

technology showcase turers control processes and improve productivity while minimizing scrap and downtime.

The system collects all of the shot variables from every cycle and retrieves them for later analysis using run charts, histograms, X-bars, R charts and scatter diagrams. Run charts permit the review of process parameters and part attributes for up to 100,000 shots on one chart. Scatter diagrams are used to relate process variables to physical part measurements for the purpose of establishing process limits. To determine interaction, users can simultaneously display and compare up to four parameters shot-by-shot.

Also, Shotscope NX is able to exchange information with other plant management systems (MRP and ERP) and enables users to configure, analyze and report information to support the unique requirements of different organizations.

The system’s remote log-in capability allows multiple plants to be monitored from a single location.

Husky Injection Molding Systems (Bolton, Ont.); www.husky.ca; 905-951-5000

Choose a Single Component or a Turnkey System!

EXTRUSION

New units for cleanroom, controlled-environment production The new Compact MD series extruder from American Kuhne is designed for cleanroom and/or controlled environments.

Providing reduced machine width and reduced floor space, the units have low profile control panels that enables the operator’s unobstructed view across the clean room production area.

The ergonomically designed rotating operator control station can include simple discrete controls or the customer’s choice of three levels of AKcess touch screen control solutions.

The Compact series extruder is also available with an option to include the entire main frame and safety guards to be made entirely of stainless steel in place of standard painted steel. The Compact Series is offered in 0.5 inch (12.7 mm) to 1.75 inch (44 mm) sizes.

The Compact MD extruder is also available in an optional “Modular” variation where the barrel diameter and/or L/D can be quickly and easily changed to achieve different output ranges and/or simply to accelerate changeover and cleanout time.

American Kuhne Inc. (Ashaway, R.I.); www.americankuhne.com; 401-326-6200 Romark Technologies–Div. of Ontor Ltd. (Toronto); 416-781-5286

From a single loader to a fully integrated work cell – the choice is yours!

BATTENFELD Injection Molding Machines FEEDMAX Material Handling Equipment DRYMAX Dryers GRAVIMAX Blenders

Technology working for you.

26 Canadian Plastics June 2010 www.canplastics.com

SILMAX Hoppers TEMPRO Water Products WITTMANN Granulators WITTMANN Robots and Automation

WITTMANN CANADA Inc. 35 Leek Crescent | Richmond Hill, ON L4B 4C2 T (905) 887-5355 | Toll Free 1-888-466-8266 F (905) 887-1162 www.wittmann-canada.com

ROBOTS & AUTOMATION Flexible controller with user friendly training program

Designed for robots with the “W8” designation, Wittmann’s new CNC8 robot control comes with improved software functions and features, including the TeachBox R8 program that offers a short training program and easy use.

The control system offers three levels of operator interface as standard: the Graphical Editor for creation of standard routines, the Tooling Editor for the modification of

technology showcase a few select commands, and the Text Editor for ultimate programming freedom.

With USB connection, the TeachBox R8 also has an improved disconnect ability to avoid misuse.

Additionally, TeachBox programs can either be saved via the integrated USB port—on the memory stick provided—or on an integrated flash card memory.

Wittmann Canada Inc. (Richmond Hill, Ont.); www.wittmann-canada.com; 1-866-466-8266

MOLD TECHNOLOGY

Key benefits include an electronic design with a 10-year installed base; easy access for servicing; and a full color, 10.4-inch full-size touch screen for ease of operation.

The touch screen software includes the latest software improvements and controls for up to 240 zones. Technical advances are combined with good pricing for this new controller series.

Mold-Masters Ltd. (Georgetown, Ont.) www.moldmasters.com; 905-877-0185

MATERIALS

Modular controller for high zone counts The new K-Series modular controllers from Mold-Masters are designed to be compact and economical, especially for applications with 60 or more control zones.

plastics data file

Biopolymers for automotive applications Targeting the auto industry, Royal DSM N.V. has launched two

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

Now for LARGE molds —

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.

the New LIME BUSTER XL™ Mold Water-Passage Cleaner with 30 gallon tank capacity. Mineral deposits in a mold can reduce its heat transfer rate; increase cycle times; and can even cause a loss of temperature control in parts of a mold. The LIME BUSTER XL is designed to slowly circulate a mild acid through a mold to dissolve deposits and flush them away.

IMS Industrial Molding Supplies 10373 Stafford Road, Chagrin Falls, OH 44023-5296; Tel. 1-800-537-5375; www.imscompany.com

advertising index Advertiser

Page

Arburg 6 Automatisation S.A.B. Inc. 22 Auxiplast 2-3 Canadian Plastics Resin Outlook Conference 31 Chillers Inc. 25 Hamilton Avtec 23 Haremar 9 K Show 13 K Show travel 20 Maag Pump Systems Textron Inc. 23 PCMExpo 16 PCS Company 19 Process Heaters Inc. 30 Tempco Electric Heater Corp. back cover Vortex Valves 24 Wittmann Canada Inc. 26

Telephone 860-667-6500 450-652-9767 866-922-2894 416-510-5116 905-895-9667 800-590-5546 905-761-7552 x 204 416-598-1525 866-880-1121 888-622-4872 416-510-5116 800-521-0546 877-747-8250 800-323-6859 785-825-7177 888-466-8266

E-mail

Website

usa@arburg.com info@sabgroupe.com info@auxiplast.com jnancekivell@canplastics.com sales@chillersinc.com sales@hamiltonavtec.com info@haremar.com messeduesseldorf@germanchamber.ca ahoule@voyagelm.ca maaginfo@maagusa.textron.com jnancekivell@canplastics.com sales@pcs-company.com proheat@processheaters.ca info@tempco.com rbarragree@vortexvalves.com info@wittmann-canada.com

www.arburg.com www.automatisationsab.com www.auxiplast.com www.canplastics.com/conference/ www.chillersinc.com www.hamiltonavtec.com www.haremar.com www.k-online.de www.maag.com www.plasticsandmoldsexpo.com www.pcs-company.com www.processheaters.ca www.tempco.com www.vortexcanada.com www.wittmann-canada.com

www.canplastics.com June 2010 Canadian Plastics 27

technology showcase bio-based plastics, with both thermoset and thermoplastic blends boasting more than 50 per cent of its content from plant-based materials.

Palapreg ECO is composed of 55 per cent renewable resources, making it the composite resin material with the highest bio-based content available on the market today. Industry testing has proven that DSM has been able to achieve this high renewable content without making any sacrifice to product performance or production speeds.

EcoPaXX is a high-performance polyamide that combines

the benefits of a high melting point (approx.

250°C), low moisture absorption and excellent resistance to various chemical substances, including road salt. Approximately 70 per cent of the material is based on building blocks derived from castor oil, a renewable resource.

DSM has already made and shipped 12 tons of Palapreg, which is being tested by customers currently.

EcoPaXX will be available commercially in early 2011.

DSM Engineering Plastics Inc. (Evansville, Ill.) www.dsm.com; 1-812-435-75 00

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PROCESSORS/MOLD MAKERS

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design ideas • automotive applications

Oil pan lightens up

New design turn for steering wheels SABIC Innovative Plastics is putting a new spin on the traditional steering wheel with an injection molded design featuring its Lexan EXL copolymer resin.

There are two versions of the glass-filled, polycarbonate-siloxane resin design: one is injection molded in two parts and finished with a leather wrap, the other is injection molded in one part and then overmolded with polyurethane. Both are attached to the steering column with a small metal hub.

“It’s high time for a new direction in steering wheel design, and SABIC has made a 180-degree turn with our two-part molded design,” said V. Umamaheswaren, director of products and marketing. “Tough new demands on steering wheels—from integration of features and weight-out— require an entirely new approach.”

Unveiled at Chinaplas 2010, the new steering wheels cut system costs by up to 20 per cent and reduce mass by up to 40 per cent compared to traditional magnesium or aluminum alloy models, he said.

In addition, injection molding Lexan EXL is a more environmentally friendly process than die casting magnesium alloy because it reduces CO2 emissions. “Compared to die casting 1.1 kg of magnesium alloy, which generates nearly 70 kg of carbon dioxide, manufacturing 1.0 kg of Lexan EXL copolymer resin only generates 7.6 kg, about one-tenth the emissions,” Umamaheswaren explained Using Lexan EXL also allows for greater design flexibility and part consolidation through integration of items such as the airbag attachment and horn mechanism, he added.

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

When it comes to carving weight out from a vehicle, it’s easy to overlook the underthe-hood components—but we shouldn’t.

Case in point: a new car oil pan made from a grade of DuPont’s Zytel nylon resin that’s approximately 40 per cent lighter than its aluminum counterpart.

Manufactured by German automotive supplier ElringKlinger, the part design involves the single-stage production of not just the pan (measuring approximately 550 mm long, 400 mm wide and 300 mm high) but also sections of the pipeline for suction of oil from the sump, the fastening flanges for the pressure pipelines to and from the oil filter, and the oil filter flange with a directly encapsulated oil filter thread.

The nylon selected by ElringKlinger— Zytel 70G35 HSLRA4—is reinforced with 35 weight per cent glass fibers, making it very stiff, and creep- and hydrolysis-resistant. It combines high-impact resistance over a wide temperature range with a high resistance to

lubricants and road salts, and also affords heat stabilization to enable the long-term usage of the material at temperatures of up to 150°C. Finally, the low warpage behavior of the material ensures a durable and reliable seal along the circumference of the oil pan.

“Our selection of the 70G35 HSLRA4 meant that we were able to manage the long flow distances at a comparably low injection pressure, and despite some very low wall thicknesses,” said Ralf Franz, development engineer at ElringKlinger. “This, in turn, reduces cycle times, helps preserve the tool, and keeps energy costs low.”

E.I. DuPont Company (Mississauga, Ont.); www.plastics.dupont.com; 905-821-5193

Bumpers go soft to meet safety standards In a piece of good news for Europe’s jaywalkers, the new Opel Astra hatchback and the Opel Meriva minivan are now equipped with bumpers that meet the latest legislated standards in pedestrian protection.

Unveiled at the Geneva Motor Show in March 2010, both vehicles feature a lower bumper stiffener (LBS) made of BASF’s Ultramid CR polyamide, optimized by BASF specifically for crash applications.

BASF developed the LBS via computer with the aid of its ULTRASIM simulation program, which allowed for shape optimization during design calculations, making construction of multiple and costly prototypes largely a thing of the past. The result: two completely different styling concepts for the two front ends, doubling the buying pleasure for stylistically picky consumers.

Opel is happy too. Comparison with a production LBS made of impact-modified polypropylene (PP) from another automaker shows that the LBS made from Ultramid CR for the Opel models are about 50 per cent lighter than the PP LBS (1 kg compared to 1.6 kg) and 50 per cent narrower at its widest spot, and also exhibit almost three times the stiffness and energy absorption. “Considering the cost of the material, an LBS made of Ultramid CR offers the end-user a weight advantage of about 66 per cent for the same costs and energy absorption,” an Opel spokesperson said.

And for clumsy pedestrians, meanwhile, it’s the next best thing to having down-filled pillows taped to the cars’ front ends.

BASF Canada (Mississauga, Ont.); www.basf.ca; 1-866-485-2273 www.canplastics.com June 2010 Canadian Plastics 29

view from the floor

Mold cooling, part deux

By Jim Anderton, technical editor

R

eaders with long memories might recall that I started a very preliminary look at mold cooling in the February 2010 issue of Canadian Plastics.

The subject is phonebook-thick if you want to really understand it, but fortunately, the most important cost aspects of cooling the mold don’t require an engineering degree to understand.

Cooling is by far the longest portion of a typical mold cycle for commodity resins, so it’s natural that it’s also the best place to shave seconds off when looking to gain productivity. The temptation is to oversize the chiller and crank up the flow rate for the lowest possible outlet temperature. Colder is better, right? In theory, yes; in the real world, it’s a little more complicated.

The actual flow of heat from the molten resin goes through the metal of the mold cavity and then into the cooling water flow...but the proper way to think of it is as a one-step process, from the part to the mold wall. The water’s job is to keep the mold from heating up, which may seem to be the same thing, except for one important fact: Unlike a direct heat flux from part to coolant, the effect of lowering the water outlet temperature doesn’t automatically translate into noticeably faster cooling in the cavities.

Cranking up the flow rate can actually decrease cooling efficiency if it upsets the turbulent flow needed for efficient heat transfer at the walls of the cooling channel. Then there’s the shrinkage issue. Part cooling actually starts the instant the shot hits the cavities, and for common resins like PP and PE it will shrink noticeably. The hold time serves not only to fill the mold, PROCESSHEATERS CPL.qxd 2:45 PM Page 1this but also to keep the part5/19/10 pressurized to counteract

shrinkage. Shrinkage control is often the key quality issue, and it isn’t a given that colder is better.

The blow molding community, for example, commonly uses oil—and hot oil, at that—as a cooling medium, so there’s more to optimizing cooling than lowering the set temperatures. And then there’s my favourite: ejection temperature. In a perfect world, you’d open the mold at the instant the parts are solid enough to hold their shape, which is generally somewhere between Tim Hortons’ double-double hot and blister-your-fingers hot. Why? Post-mold cooling is essentially free, and, in any case, they’re going to sit in those Gaylords for some time in even a captive molding/assembly operation.

But if you optimize this part of the cooling cycle, keep in mind a couple of factors. First, any press-side dimensional checks won’t be at the comfortable airconditioned temperature of the QA lab or office; this means there will be a temperature gradient between the parts at the top of the bin and at the bottom, so make sure your SPC police dig down into the pile to grab a true sample.

Second, don’t forget the operator. After-mold cooling can make the press side environment damn hot, and few plant engineers I’ve met consider this when laying out the production floor. I once built a “cool cab” for a miserable operator, basically an open-ended phone booth with a small residential A/C unit blowing cool air onto her as she worked the mold. Wasteful, yes, but check out how many bathroom breaks your crew takes when working in hot environments and you might find that stopgaps like that can pay. Sometimes you need to cool the people as much as the parts!

CPL

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30 Canadian Plastics June 2010 www.canplastics.com

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Call toll free 1-877-747-8250 • Email: proheat@processheaters.ca • www.processheaters.ca

Resin supply, demand and pricing forecasts

ON TARGET!

Since resin accounts for up to two-thirds of your manufacturing cost,

you can’t afford to miss the mark.

Get the information you need by attending the

15th Annual Canadian Plastics Resin Outlook Conference Wednesday, October 6, 2010 Doubletree Airport Hotel, Toronto, Ontario Hear forecasts from experts on supply, demand and pricing for the major commodity and engineering resins: polyethylene, polypropylene, PVC, styrenics, PET, nylon, polycarbonate, plus biopolymers.

NEW! Conference delegates may attend, at no extra charge, a half-day workshop on the afternoon of October 5th at the Doubletree: “Hydrocarbons to Polymers, an overview of how plastics are produced from wellhead to finished product.”

A full conference agenda and registration form is on the Canadian Plastics web site at: www.canplastics.com/Conference/

REGISTER NOW AND SAVE $100!

Investment per person: Early Bird Registration – register and pay in full by Aug 31: $395 plus H.S.T. Regular Registration – after Aug. 31: $495 plus H.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 A limited number of sponsorships and tabletop displays are still available.

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.