Canadian Plastics September 2015

Canadian Plastics www.canplastics.com

september 2015

Revolutionary Road:

challenges opportunities in vehicle lightweighting

BIOPLASTIC drink bottles are pouring into the marketplace Should you

automate your part packaging?

chantler packaging is going strong at

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The ENGEL CC300

as easy to use as a smartphone

Intuitive operation, simple navigation, smart user interface design: these are the characteristics of the ENGEL CC300 machine control. With features that make the experience effortless – as easy to use as a smartphone. A large full HD screen with excellent visual contrast makes it simple to read in all lighting conditions. Providing information at a glance – the operator can focus on the task at hand.

Ready for smart operation. ENGEL CC300.

ENGEL Canada Inc. | 550 Parkside Drive | Unit B12 | Waterloo | Ontario | N2L 5V4 | Canada phone 519 725 8488 | fax 519 725 8495 | sales.ca@engelglobal.com | www.engelglobal.com/CC-300

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contents

Canadian Plastics September 2015 VOLUME 73 NUMBER 3

LOOKING BACK...

Number of the month:

$370 billion*

* The estimated value, in U.S. dollars, of the global plastic packaging market by 2020. (See pg. 18)

16 Cover image: ©illcha/Getty Images/Thinkstock

Those with long memories might recall that in 1965 the Canada-U.S. Auto Pact was put in place, creating a duty-free North American market that — among other things — gave Canadian molders access to the U.S. auto parts market on the same terms as U.S. molders. Two years later, the November 1967 issue of Canadian Plastics surveyed the results by interviewing a variety of Canadian parts makers. The verdict? Two thumbs up.

“It took most of Canada’s plastics molders some time to find the best ways of obtaining business from the North American auto manufacturing giants, but the orders are now coming in in increasing numbers,” our man wrote. “There no longer seems any doubt that, overall, the pact has been beneficial to the Canadian plastics industry.”

12

24

cover story in every issue

12 AUTOMOTIVE: Lightweighting’s rough road to revolution

4 Editor’s View: As Ontario goes, so goes Alberta?

The automotive industry is under pressure to meet higher fuel efficiency, environmental, and performance demands at competitive costs. Plastics and polymer composites are no-brainers to speed them along, right? Not so fast…

5 Ideas & Innovations: Attention, rotomolders: your automatic weigh powder dispense system is here 6 News: • Canada’s first family of blown film is back with Cyber Plastic Machinery • P urging compound maker Sun Plastech acquires competitor Novachem • A rburg opens new U.S. headquarters • People 11 Executive’s Corner: How to sell your family business 28 Technology Showcase 35 Plastics Data File 37 Advertising Index 37 Classified Ads 38 Technical Tips: Know your part before sizing a blow molding machine and tooling

features 16 PACKAGING: Bioplastic drink bottles pour into the marketplace Driven by economics and the green movement, beverage producers from around the world are turning to bioplastics to bottle their products. But traditional PET isn't gonna go away quietly.

20 ROBOTS & AUTOMATION: Pack mentality If you think robots and EOAT are just an expensive substitute for competent machine operators, think again. When it comes to end-of-the-line parts packaging, they’re cheaper and more efficient than people. Here’s what to take into account before automating your line.

24 DOING IT BETTER: Chantler Packaging, food fighters After 85 years, this family-operated Ontario flexible packager is still mixing it up to stay current.

Visit us at www.canplastics.com www.canplastics.com September 2015 Canadian Plastics

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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.

As Ontario goes, so goes Alberta?

H

ere’s a statement with which I would have agreed wholeheartedly a few short years ago: “With some of the world’s largest supplies of, and lowest costs for, feedstock and electricity, as well as quality skilled labor, world class research institutions, and easy access to nearby markets, global companies choose Canada for chemicals and plastics.” Who said it? It’s an official statement from the federal government’s Canadian Trade Commissioner Service, intended to encourage foreign interest in our industry.

Today, I quibble with only one small part of that sentence: the bit about the lowest cost electricity. A few things have changed in recent years. In Ontario, home to the majority of the country’s plastics processors, the cost of electricity is now a major concern, having skyrocketed 16 per cent since 2013 and projected to climb another 13 per cent by 2020.

And it’s not like we need the supersleuths at CSIS to tell us why. Look no further than Ontario’s controversial Green Energy Act (GEA) of 2009, meant to expand renewable energy production — wind and solar power in particular — and perhaps best known for creating a number of feed-in tariff rates for different types of energy sources. Official data from Ontario’s Independent Electricity System Operator (IESO) shows that 80 per cent of the wind power produced under the GEA occurs at times and seasons so far out of phase with demand that the entire output is surplus and must be exported at a substantial loss.

The situation is already having serious negative impacts on the province’s manufacturing sector — witness Jaguar Land Rover Ltd. rejecting a site in Windsor, Ont. earlier this year and Volvo Cars choosing South Carolina as the location for an assembly plant that will supply North America. Which is why, in June, the Ontario Chamber of Commerce called on the provincial government to take steps to curb rising electricity prices, which it called “one of the most pressing chal4

lenges for Ontario’s economy”.

And which brings us, in turn, to Alberta and its new NDP government.

In September, said government released its Climate Leadership Discussion Document, a blueprint of sorts for future economic development. Aside from promising to pivot from oil sands development towards what they called “a knowledgebased, lower-carbon economy,” the Dippers announced big plans for Alberta’s electricity sector. As The Fraser Institute’s Kenneth Green wrote after analyzing the document, “Alberta gets the dubious privilege of following Ontario’s Green Power disaster, with feed-in tariffs to subsidize wind and solar power, tax credits and subsidies to producers of ‘green’ energy; Renewable Energy Certificates; and government-backed loan guarantees and power purchase agreements.”

If enacted, this legislation would be bad news by itself. But it would also have outsized symbolism. According to the federal government’s most recent statistics, 14 per cent of Canada’s plastics processors are in Alberta. It might not sound like much, but in some ways Alberta is at the heart of our industry, thanks to Nova Chemicals Corp., Canada’s largest player in the global chemical business. Calgarybased Nova is in the middle of a four-year, $900 million expansion project at its Joffre, Alta. site that will boost PE production by about 40 per cent. It’s a huge investment, and when it was announced as the Great Recession was winding down, it served as a symbol of sorts for the resurgence of Canada’s plastics industry — a big vote of confidence from a corporation with deep pockets.

It would be a shame to see Nova repaid with an increasingly gargantuan hydro bill that might make it less competitive. And it also raises the real possibility of would-be investors in Alberta deciding to check the rents in nearby, more business-friendly jurisdictions.

Like maybe Montana.

If you’re reading this, Premier Notley: don’t do it.

www.canplastics.com Editor Mark Stephen 416-510-5110 Fax: 416-510-5134 E-mail: mstephen@canplastics.com art director Andrea M. Smith Production Manager Steve Hofmann 416-510-6757 E-mail: shofmann@annexnewcom.ca Print Production Manager Phyllis Wright publisher Greg Paliouras 416-510-5124 Fax: 416-510-5134 E-mail: gpaliouras@canplastics.com Circulation Manager Anita Madden 416-442-5600, ext. 3596 Fax: 416-510-6875 E-mail: amadden@annexnewcom.ca Vice President annex business media east Tim Dimopolous 416-510-5100 tdimopoulos@canadianmanufacturing.com President & ceo Mike Fredericks mfredericks@annexweb.com 80 Valleybrook Drive, Toronto ON, M3B 2S9 416-442-5600, Fax: 416-510-5134 Canadian Plastics is published 7 times a year by Annex Printing and Publishing.

2015 SUBSCRIPTION RATES 6 issues Canadian Plastics, plus Dec. 2016 Buyer’s Guide: Canada: 1 Year $71.95 plus applicable taxes; 2 Years $117.95+ taxes; single copy $10.00+ taxes.

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The contents of this magazine are protected by copyright and may be used only for your personal non-commercial purposes. All other rights are reserved and commercial use is prohibited. To make use of any of this material you must first obtain the permission of the owner of the copyright. For further information please contact Greg Paliouras, 416-510-5124.

For reprints call RSiCopyright, Michelle Hegland, msh@ rsicopyright.com PAP Registration No. 11035 CANADA POST – Publications Mail Agreement No. 40065710. Return undeliverable Canadian addresses to: Circulation Dept. – Canadian Plastics, 80 Valleybrook Drive, Toronto ON M3B 2S9.

RETURN POSTAGE GUARANTEED Indexed by CBPI ISSN 0008-4778 (Print) ISSSN 1923-3671 (Online) MEMBER: Canadian Business Press, Canadian Plastics Industry Association.

We acknowledge the financial support of the Government of Canada through the Canada Periodical Fund of the Department of Canadian Heritage.

Mark Stephen, editor

mstephen@canplastics.com

Canadian Plastics September 2015 www.canplastics.com

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ideas & innovations

Attention, rotomolders: your automatic weigh powder dispense system is here

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worked through a number of different fabrication issues to make RotoLoad as costeffective and easy to operate as possible.”

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Introduced in June 2015 at the Plast-Ex trade show in Toronto, the RotoLoad automatic weigh powder dispense system with PLC is designed to provide exact dosing every time. The system is available in 50-, 150- and 300-lb models — with identical controls for each — and is exclusively distributed through Kent, Ohiobased sales agency Optimax Plastic LLC. “We don’t want to distract our own salespeople with a product that’s outside our core businesses,” Miller said.

And you can see why they might be distracted. “There are more than 500 rotational molders in the U.S. — including large shops such as Fischer-Price that have many machines each — and about 60 rotomolders here in Canada,” Miller said. “Every machine in every shop can benefit from RotoLoad.”

The initial response to RotoLoad has been positive enough for Wittmann Canada to receive an Innovation Award from the Canadian Plastics Industry Association in June 2015, which drives home one point in particular: The company has opened up a big window, and at the moment it seems to have the landscape on the other side all to itself. “We believe RotoLoad is the only complete, off-theshelf powder dispense product available right now,” Miller said. “In the past, rotomolders have tried to piece systems together on their own that are similar to ours, with mixed results. Now they don’t have to.”

If you’re a James Bond fan, you could call it a view to a killing.

CPL Im

ou’ve probably heard the expression “When a door closes, a window opens.”

Maybe you dismiss it as a bunch of feel-good, Hallmark Card blather. Wittmann Canada Inc. doesn’t. When a big project in the Middle East went bust two years ago, the Vaughan, Ont.based equipment manufacturer persevered and developed RotoLoad, an award-winning powder dispense system now available for the global rotational molding market.

“We quoted a powder dispensing system for a large rotational molding facility in Oman in December 2013, with the intention of building a system using parts from our standard equipment with some fairly basic modifications,” said Wittmann Canada president Rob Miller. “In the end, the customer couldn’t get approval for the project, but it started a series of discussions with more local end-users about the need for a more accurate loading technology for the entire rotomolding industry — and they all told us they needed something new, because material dispensing was still a manual, labor-intensive process, done by weighing out batches by hand on platform scales, and using buckets and shovels.”

It wasn’t exactly precise, in other words. With a good grasp of the problem, Witmann Canada’s next step was to learn what the rotomolders did, and didn’t, require in a powder dispensing solution. “We considered every aspect — for example, what was the most cost-effective way to develop the control, and whether or not the operator pendant needed to be a push-button or an interactive touchscreen display,” Miller said. “We also considered factors like global shipping to ensure that the finished product was compact enough to be shipped on a single skid. We

www.canplastics.com September 2015 Canadian Plastics

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news

Canada’s first family of blown film is back with Cyber Plastic Machinery

S

ome families just seem drawn to certain activities. If your surname’s Wallenda, there’s probably a better-than-average chance you’ll wind up walking a high-wire at some point in your life.

For a Canadian plastics equivalent, consider the father/daughter team of Robert Krycki and Dawn Krycki-De Santis. Well-known as the founding family of the now-defunct blown film equipment supplier Future Design Inc., the pair is back with Cyber Plastic Machinery Inc. (CPMI), a Brampton, Ont.-based blown film equipment start-up with a distinct mission.

Founded in April, CPMI is designed to fill a hole in the blown film industry by servicing and Back in black and yellow: From left, Liviu Sas, Dawn Krycki-De Santis and Robert Krycki. upgrading all brands of existing equipment. And it’s a bigger hole than you might think. “There’s a large Krycki, director of R&D; and Future Design veteran Liviu amount of blown film machinery in need of refurbishing in Sas as operations manager.

North America, particularly in Canada — as U.S. firms have Repair and upgrade is a good way to get a foot in the encroached on Canadian blown film businesses, funds for door, but it’s not all that CPMI does. “We’re a full-service new equipment are usually the first things to get cut,” Robert environment, providing sales, engineering, consulting, and Krycki said. “We service all blown film equipment, upstream the design and manufacturing of new blown film equipand downstream, and there really are no other companies in ment — including servicing the Saturn air ring brand, which the blown film industry focusing on this now.”

Gloucester Engineering acquired from Future Design but no CPMI can perform straight machinery repairs, but that’s longer promotes,” Robert Krycki said. “Our first manufacjust the tip of the iceberg. “Our bigger goal is to improve turing project is a new air distribution manifold and air coolequipment, so that a customer will be capable of doing dif- ing ring. We’ll also build auxiliary equipment to support and ferent processes without the costs associated with new equip- enhance blown film production. Our goal going forward is to ment,” Krycki said. “If a processor wants to transition from design the products ourselves, outsource the manufacturing making linear trash bags to high density bags, for example, of most of the parts, and assemble and test the finished prodwe can change out the parts that are necessary — the die ucts in-house. We are also contacting various universities to gap, the screw, and the air ring configuration — for a frac- connect with students to help us improve our products — we tion of the price of a new machine. There’s a huge installed have experience building laboratory lines for the universities, equipment base out there, but many blown film shops haven’t and we’re going to draw on that heritage.”

Export is also a major part of CPMI’s mandate. “The curkept up with the times technologically because it’s such a customized industry, often customized to the resin used for a rent strength of the U.S. dollar has made us more competitive in a market that has imported so much equipment from particular application.”

Europe and Asia,” Liviu Sas said.

And the company’s progress is being covered in its own LEAN AND MEAN The company also believes it has found a way around a prob- “Cyber Buzz” monthly newsletter. “It brings our customers lem that’s tripped up more than one Canadian blown film up to date on our progress, as well as our new innovations equipment firm over the years. “Historically, it’s been very and equipment,” Dawn Krycki-De Santis said. “We also sell hard to keep blown film operations in business in Canada used equipment, and we cover that in the newsletter as well.”

That high-wire analogy we used at the outset? It’s not a bad without a streamlined operation and very low overhead,” Dawn Krycki-De Santis said. “CPMI jobs out as much of way to sum up the perils of the blown film industry in Canada, the work as possible to the professionals, including some unfortunately, but at least CPMI is off to a good start on its well-known blown film industry veterans. This helps keep own walk across the tightrope. “We’ve had a fantastic start-up, our own costs low, and we pass these savings along to the and have already shipped equipment to Asia and other parts customer.” No surprise, then, that the company’s staff size of the world,” said Liviu Sas. “Not many large OEMs in the — all of three people — is as stripped down as it gets: Dawn blown film industry are investing in R&D. We are, and I think Krycki-De Santis, executive sales and marketing; Robert this gives us an advantage.”

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Canadian Plastics September 2015 www.canplastics.com

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news

Purging compound maker Sun Plastech acquires competitor Novachem

I

n a development that consolidates two well-known manufacturers of purging compounds for the plastics industry, Sun Plastech Inc., the manufacturer of Asaclean compounds, has purchased the assets of competitor Novachem.

The terms of the deal have not been released.

Since its establishment in 1996, Parsippany, N.J.-based Sun Plastech has supplied a range of mechanical purging compounds sold under the Asaclean brand. According to Joseph Serell, vice president of Sun Plastech, the Novachem acquisition plugs a hole in the Sun Plastech product lineup.

“We wanted to start offering chemical purging compounds, which is something the market definitely requires,” he said.

“It was much easier for us to acquire Novachem’s product line — which had already been researched, product-tested, and accepted by the marketplace — than to invest time and treasure to develop a competing portfolio ourselves.

Novachem has a great name in the market — we didn’t just buy the technology, we bought the brand name and active customer base.”

Located in Bridgeport, Conn., Novachem was founded in 1989, and supplies chemical purging compounds under its NovaPurge and SuperNova product lines, as well as its InstaPurge line of mechanical purges, and its more recent Hybrid line of compounds that combines SuperNova technology with InstaPurge.

Guill Tool founder Roger Guillemette passes away

R

oger Guillemette, the founder of extrusion tooling supplier Guill Tool & Engineering Co., died in June at age 81.

Born in Providence, R.I., Guill’s parents were Canadian.

Guill founded Guill Tool in 1962, and held the position of CEO until recently. The West Warwick, R.I.-based company has long been a global leader in extrusion tooling.

“Roger was a fierce advocate for North American manufacturing,” Guill Tool said in a statement.

“Professionally, Roger was a longtime member of the Wire Association and of the Society of Plastic Engineers. Guill Tool, as a result of Roger’s leadership and drive, remains active in the Rhode Island Manufacturers Association, National Association of Manufacturers, National Institute of Manufacturing Skills, and the Rhode Island STEM Center.”

CPL

But as strong as the Novachem brand is, it won’t be around forever. “We will phase out the Novachem name eventually, as we don’t want the added expense of trying to maintain two brands,” Serell said. “In the short term, Novachem products will be identified in our portfolio as the “N” series of products. No decisions have been made yet about keeping or letting go existing Novachem staff; the Novachem office and warehouse in Bridgeport will be closed at some point, and absorbed into our infrastructure.”

And there’s also a Canadian angle to the deal. “Novachem didn’t have any warehousing in Canada, which sometimes made delivery difficult,” Serell said. “Sun Plastech has a warehouse in Mississauga, Ont. that we ship from, so Canadian customers will now have easier access to the Novachem portfolio — and, depending on where they’re located, possibly local delivery as well.”

So how big a deal is the acquisition in the purging compounds world? Think Coke buying Mountain Dew. “To my knowledge, a purchase of this scale hasn’t happened before in the North American purging compounds industry,” Serell said. “Sun Plastech can now offer its customers a wide array of products that meet almost any purging scenario.”

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news

Arburg opens new U.S. headquarters

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ust in time to mark its 25th anniversary of direct sell- testing and training purposes. “There is also plenty of space ing in the U.S. through its American subsidiary Arburg for setting up and dismantling complete turnkey systems, which are experiencing Inc., Germany-based injecrapid growth in demand tion molding machine maker in the U.S.,” said Arburg Arburg GmbH + Co. KG managing partner Friedofficially opened its new rich Kanz. “The building American headquarters in also features a compreJune 2015. hensive spare parts store, The 27,000-square-foot a machine store, as well building is located in Rocky as a special area for the Hill, Conn., just a few miles Freeformer additive manufrom the company’s longfacturing system.” time U.S. base in Newington, The U.S. is Arburg’s Conn. largest export market, The centrepiece of the new and Arburg said that an building is the showroom, installed base of 12,000 which Arburg said has sufArburg injection presses is ficient space for seven All- Cutting the ribbon at the opening, with managing partner Michael Hehl (third from left) and Bill Carteaux, president of SPI: The Plastics Industry molding parts in the U.S. rounder injection molding Trade Association (fourth from left). and Canada. machines that can be used for CPL Photo Credit: Arburg Inc.

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REGENERATIVE BLOWERS (VACUUM PUMPS) FOR DRYERS, PNEUMATIC CONVEYORS, VACUUM SYSTEMS, ETC. FEATURES • • • • • • •

1/4 to 30 HP Air Flow to 950 SCFM Pressure to 11.5 psi Vacuum to 12”Hg Oil & Odor-free Single or 3-Phase Quiet: 53 to 81 db(A)

43

Viton seals suitable to 500°F protects the motor windings

Corrosion resistant aluminum materials used for blower and motor housings, conduit box

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Class H insulation rated to 355º F.

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Removable flanges allow blower change without disassembly of pilings.

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All-Star Regenerative Blowers (Vacuum Pumps) offer an alternative to traditional high pressure blowers and pumps.

The regenerative blower is suitable for applications where positive displacement (PD-type) blowers and pumps have been used. It’s simple design permits the units to be used as a blower or vacuum pump - without added parts.

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High temperature bearing lubricant melt point 385°F.

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CPL Sept15 p06-10 News.indd 9

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news

PEOPLE John Blundy

Doug Borgsdorf Gerardo Chiaia

Terry Elliott

Clive Martell

Access

Dale Walker

– J asper, Tenn.-based color masterbatches and custom compounds supplier O’Neil Color & Compounding has named Canadian Plastics Doug Borgsdorf as its new president. Borgsdorf replaces 1/2 pg 4c horizontal outgoing president Mark Bruner, who is retiring from the No Booth Number industry.

– T he Netherlands-based chemical supplier Royal DSM has named Roeland Polet as the business group director of DSM Engineering Plastics. The company has also appointed Atul Thakrar to head its bio-based products and services unit.

– Bolton, Ont.-based Husky Injection Molding Systems has appointed Gerardo Chiaia as president of its global beverage packaging organization.

– Munich, Germany-based plastics processing machinery and systems supplier KraussMaffei Group has appointed Frank Stieler as its CEO. He replaces outgoing CEO Jan Siebert.

V-ECO 900

V-ECO 900

•

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•

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•

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V-ECO 1700

•

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•

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V-ECO 2100

•

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V-ECO 900

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Easy access to shredding room

Frank Stieler

– Global engineering technologies company Renishaw has appointed Clive Martell as head of its global additive manufacturing division.

–T erry Elliott, the general manager of plastics color and additive concentrates supplier Ampacet Canada, has been elected as the new chair of the Board of Directors of the Canadian Plastics Industry Association. Elliott, who will serve a two-year term, replaces the immediate past chair Amir Karim, of Polykar Industries Inc. •

Atul Thakrar

– Grand Rapids, Mich.-based hot runner supplier HRS-Flow Hot Runner Systems has named John Blundy as president of its North American division.

FEatUrES

•

Roeland Polet

– Size reduction equipment maker Weima America, headquartered in Fort Mill, S.C., has appointed Dale Walker as a sales engineer with a primary focus on waste-to-energy markets and on applications that require a two-stage system.

FEatUrES opt.

• • •

•

Screen change Quick and easy during maintenance or on demand for different input material

Access

Rotor bearing Large distance between rotor and rotor bearing for long-life of bearing

V-ECO 900

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V-ECO 900

opt.

V-ECO 900

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•

•

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Easy access to shredding room

Wear High durability due to wear resistant steel on machine bottom and pusher

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•

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•

Cutting rotor cutting rotor with optimized cutting geometry for maximum performance and reduced generation of heat

FEatUrES OUtStaNDING FEatUrES •

opt.

• • •

• • • •

opt.

• • •

opt.

• • •

Screen change Quick and easy during maintenance or on demand for different input material

V-ECO 900

•

V-ECO 1300

•

V-ECO 1700

•

V-ECO 2100

•

Rotor bearing Large distance between rotor and rotor bearing for long-life of bearing

OUtStaNDING FEatUrES Access Easy access to shredding room

Machine design compact machine design for smooth operation and lower noise

Wear

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Quick and easy during maintenance or on demand Hydraulic aggregate for different input material Hydraulic aggregate standard with shock valve to avoid hydraulic shocks

Hydraulic aggregate Hydraulic aggregate standard with shock valve to avoid hydraulic shocks

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15-08-21 10:39 AM

executive’s corner

How to sell your family business

By Mark Borkowski, Mercantile Mergers & Acquisitions Corporation

S

elling a family business is a major decision, and the reasons for selling are many — retirement, loss of skilled employees, very high capital expenditures. Once you decide to sell, your next step is to prioritize your objectives and consider your exit alternatives. You can choose to work with your accountant and then bring in professionals, or with a mergers and acquisitions broker. If you choose the latter, ask for references from their clients.

If the business is sold to a family member to ensure family harmony and to minimize tax liability for all parties involved, an accountant should be consulted prior to the sale, and a plan put in place if the seller remains involved financially with the business, such as through a retiring allowance. A mergers and acquisitions professional can coordinate this arrangement.

The most common non-family buyer is a strategic buyer who knows the business and knows what they’re buying — the process, equipment, et cetera. The second most common is the private equity buyer, followed by an individual buyer.

There are several methods to value a business. The valuation by financial statement method will base value on your company’s financial statements, examining the cash on hand, equipment, real estate, debts and investments, and obligations. The liabilities will be subtracted from the total assets to establish the business’s theoretical value. This method has disadvantages: it may not take into consideration the current values of assets, for example, and instead assign them their costs at the time they were acquired.

A second method, called valuation using multiples or comparable company analysis, looks at what public companies similar to yours are being traded for. This method is best applied to larger businesses. The disadvantage here is that no two companies are completely alike in terms of products, size, and growth potential, so if your business produces a specialized product or service, making a precise comparison can be difficult.

Third, the comparable transaction method looks at recent sales and purchases of similar but privately-owned businesses. The business valuator will determine which businesses are appropriate to use as a comparison to yours, and will apply valuation methods such as price-to-earnings (P/E) or Enterprise Value (EV) to EBITDA to determine your company’s value.

Discounted cash flow analysis is a fourth method. As the value of the cash received at present is not the same as cash received at a future date, the cash flow must be discounted to assess the cash’s current value. This is a complicated process — involving estimates such as how much your company will grow, and what costs and profits can be expected over the next few years — and is best undertaken by an experienced valuator.

The sale of your business will also affect your employees…and possibly your legal obligation to them.

In an asset sale, for example, the seller will be liable for the severance costs associated with employees who decline, or are not offered, employment with the purchaser. These costs will depend on many factors, among them whether or not the employees have written employment agreements specifying their entitlements on termination. No matter what, the seller of a business is obligated to disclose employee contracts to the potential buyer in most transactions.

In the end, selling your business is more than just a sale of machinery — it’s a complete lifestyle change. Working with your accountant, business valuator and/or corporate lawyer will bring some much-needed objectivity into what can be a CPL stressful, emotional process.

Mark Borkowski is president of Mercantile Mergers & Acquisitions Corporation, a Toronto-based brokerage firm that specializes in the sale of privately-owned, mid-market companies. He can be contacted at www.mercantilemergersacquisitions.com.

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CPL Sept15 p11 Exec Corn.indd 11

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automotive

The automotive industry is under pressure to meet higher fuel efficiency, environmental, and performance demands at competitive costs.

Plastics and polymer composites are no-brainers to speed them along, right?

Not so fast…

By Mark Stephen, editor

Lightweighting:

The rough road to revolution

H

ollywood celebs aren’t the only ones obsessed with shedding unwanted pounds. Faced with growing concerns about the impact that automobiles have on the environment, coupled with ambitious new mileage targets set by the U.S. government, automakers and their suppliers are exploring every possible avenue to reduce vehicle weight.

Arguably the most influential force in the North American automotive market right now is the joint Corporate Average Fuel Economy (CAFE) standards set by the National Highway Traffic Safety Administration and the U.S. Environmental Protection Agency, which set emissions and miles per gallon (mpg) requirements for model year 2025 vehicles to more than 50 mpg. And

the automakers aren’t exactly resisting. Ford Motor Company, for one, has gone on the record saying it wants to lighten its cars by 200 to 700 pounds in the coming years.

But this rapid mpg increase has the automotive industry searching for ways they can cost-effectively drop more and more weight from vehicles while maintaining quality and safety.

Part optimization/consolidation only gets them so far — the other half of the equation is materials substitution, which is why OEMs are embracing the use of lighter weight materials in automotive components and parts. For the steel industry, advanced high-strength steel (AHSS) can provide weight-saving improvements at an incremental cost of $0.30 per pound of weight saved. Combined with the ability to be produced with existing high-volume manufacturing infrastructure, AHSS is gaining use in the automotive world, albeit largely as a replacement material for conventional steel.

THE PRICE OF PLASTICS

Polymer wheel rims made with BASF’s Ultramid long fibre reinforced polyamide provide a potential weight reduction of up to 30 per cent compared with metal rims. The products are the first polymer wheel rims suitable for mass production, BASF said.

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A potential source of even more significant savings is plastics and their composites. But don’t take our word for it. “By 2030, the automotive industry and society will recognize plastics and polymer composites as preferred material solutions that meet, and in many cases set, automotive performance and sustainability requirements,” the American Chemistry Council (ACC) noted in a December 2014 executive summary. It’s a projection that current growth trends support. According to market analyst IHS Automotive, the global market value for lightweight materials used in the transportation industry is expected to grow to nearly US$125 billion in 2015, up from an estimated US$95 billion in 2010, for a five-year compound

Canadian Plastics September 2015 www.canplastics.com

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chillersinc_Innovation_Chillers:Layout chillersinc_Innovation_Chillers:Layout1 1

automotive

these factors and that are accepted by the automotive industry, hindering its ability to demonstrate lifecycle cost savings in a way that’s accepted by automakers. The good news? The recent boom in U.S. shale gas production has the potential to aid the industry in its search for cost-effective ways to produce these materials.

PERFORMANCE ANXIETY A second potential problem has to do with performance. While today’s plastics and polymer composites offer exceptional performance that can withstand the rigors of many demanding applications, some operating conditions — such as high temperatures, corrosive chemicals in fluids and lubricants, electric currents, weather variations, or minerals from roadways — are still too harsh for some plastics and polymer composites to withstand over a vehicle’s life. These conditions can have long-term effects on the durability, performance, and aesthetics of the materials in automotive components. The solution is obvious: develop materials with improved properties and performance — stiffness, strength, fatigue, environmental resistance, creep, energy management, and temperature capability. The hard part, of course, is doing so without sending costs halfway into the stratosphere. Call this one a work in progress.

“

Some consumers are wary of plastics and polymer composites being used in structural applications.

“

annual growth rate of 5.6 per cent. The consumption of these materials is projected to grow to 67 million tons in 2015 from its 2010 figure of 46 million tons.

“Polymer composites” refers to material systems that combine a plastic resin (the raw material used in plastics and polymer composites) with a filler material to produce improved properties. Filler materials can be talc, short glass or carbon fibres, long glass or carbon fibres, or long continuous glass or carbon supports. Resins in such composites can be thermosets or thermoplastics. One type of polymer composite in particular — carbon fibre reinforced composites — presents major lightweighting opportunities for structural vehicle components. At a weight 50 per cent lighter than conventional steel and 30 per cent lighter than aluminum, more automakers are taking notice: for example, BMW uses the material as the body structure of its electric city car, the i3, which went on sale in North America in 2014.

So with advantages that align directly with the automotive industry’s needs, plastics and polymer composites can be a major part of the solution for automakers. But there are hurdles to be overcome before the industry wholeheartedly embraces these materials.

One of the biggest — and stop us if you’ve heard this before — is cost. “Carbon fibre reinforced composites are still costly, discouraging many automakers from using them extensively in vehicle fleets,” the ACC said.

Some plastics, and especially polymer composite materials, are more costly on a mass or part basis compared to materials such as steel, aluminum, and glass when purchased at medium and even high volumes.

Such lightweight fillers as glass beads and alternative glazing materials also face costrelated challenges that limit their use in today’s vehicles. “While these materials may offer greater value than alternative materials throughout the vehicle lifecycle, OEMs typically focus on material and component pricing instead of considering whole system cost, which includes the cost of materials, part fabrication, vehicle assembly, warranty maintenance and repairability, and the cost of energy throughout the lifecycle of the material,” the ACC noted. Adding to the problem, the plastics industry currently lacks verified cost models for many plastics and polymer composite applications that include all of

Related to performance is another challenge: processing times. To enable greater use of plastics and polymer composite materials in vehicles manufactured at high volumes, it’s critical for the plastics and polymer composites industry to reduce manufacturing cycle times. Without this advancement, the use of polymer composites, particularly thermoset-based composites, in new applications risks being limited to niche vehicles. Here’s the problem in a nutshell: The increased complexity of these www.canplastics.com September 2015 Canadian Plastics

CPL Sept15 p12-15 AutomotiveV4.indd 13

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automotive

Photo Credit: Ford Motor Company

The MMLV lightweight concept, with lightweight components identified with colored graphics.

Magna & Ford collaborate to lighten up

Like two plus two equaling eight, the right partnership can create a supercharged result: think Dean Martin and Jerry Lewis, for example, or Lennon and McCartney. In the same vein, Aurora, Ont.-based auto parts maker Magna International Inc. and Ford Motor Company have partnered on a new multi-material lightweight vehicle (MMLV) concept that uses advanced material solutions to achieve a whopping 25 per cent weight reduction compared to the current production vehicle.

Co-funded by the U.S. Department of Energy (DOE), the project includes engineering, prototype vehicle build, and selected validation testing associated with a new aluminum-intensive passenger vehicle design architecture — an extensive use of advanced lightweight and high-strength materials that offers environmental and fuel economy benefits.

The MMLV concept is based on the production version of a 2013 Ford Fusion, Ford said, and defines a new aluminum-intensive passenger car structure. The concept reduces the weight of the Fusion to that of a 2013 Ford Fiesta, making the weight of a C/D segment family sedan approximately equal to that of a subcompact B-car — two vehicle segments lighter — without compromising performance or occupant safety.

“Our goal was to investigate how to design and build a mixedmaterials, lightweight vehicle that could potentially be produced in high volume, while providing the same level of safety, durability, and toughness as our vehicles on the road today,” said Matt Zaluzec, Ford technical leader of global materials and manufacturing research. “There isn’t a one-size-fits-all approach to lightweighting.

The research vehicle gives us the platform to continue to explore the right mix of materials and applications for future vehicles.”

The MMLV project is part of the DOE’s Vehicle Technologies Office lightweight materials project portfolio, which addresses future CAFE fuel economy legislation. Vehma International, an engineering and prototype division within the Cosma International operating unit of Magna, manufactured and integrated the multi-material body-inwhite, closures, chassis, and bumper components. Ford supplied the vehicles and weight-optimized powertrain, tires/wheels, suspension, interiors, glass, and seating.

In the end, it might just be a more fuel-efficient way to travel the long and winding road.

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polymer composites, particularly continuous-fibre composites and composites using thermoset resins, increases their curing time and makes them more difficult to mold than metals. As a result, thermoset composites currently have long cycle times, which hinders high-volume production of polymer composite parts.

A fourth challenge is to surmount operational conditions — which is a fancy way of saying that the automotive infrastructure and workforce that has evolved over the past 100 years is designed to accommodate steel and glass, a fact that creates barriers to plastics and polymer composites. Assembly plants operate at temperatures that hit 200°C or higher for electrocoating, which can be difficult temperatures for plastics and polymer composites. “The current automotive manufacturing infrastructure that can fully capitalize on the unique capabilities of plastics and polymer composites is limited because many automotive production and assembly processes have been optimized for historically traditional materials like steel and glass,” the ACC said. “This entrenched infrastructure — representing billions of dollars in capital investments by Tiers and automakers that will remain in place for years or decades — means automakers seeking to use plastics and polymer composites in new automotive applications should find ways to accommodate these materials in metals-oriented systems, often with suboptimal results.” Making the hurdle that much higher, because the infrastructure is in place for producing metal components, the path from prototype to manufactured part is better established for metals than for plastics and polymer composites.

A fifth problem is the lack of standardized material properties databases, particularly in the composites universe. “Designers and engineers lack access to standardized material properties and performance data for many classes of plastics and polymer composites,” the ACC said.

“Without a materials characterization database with verified property and performance data, it’s difficult for engineers and designers to select the best plastic or polymer composite for an application. Developing such databases, however, will be costly and will therefore require significant investment from material developers, Tiers, and OEMs.” As with so many other challenges, it’s a cost that’s just going to have to be borne.

PERCEPTION PROBLEM Saving one of the most challenging problems for nearlast, one big barrier to advancing plastics and polymer composites is for material developers to gain a complete understanding of the material properties desired by OEMs for specific automotive applications. Different OEMs, and even different automotive engineers at the same OEM, want different material properties — usually combinations of temperature, strength, stability,

Canadian Plastics September 2015 www.canplastics.com

CPL Sept15 p12-15 AutomotiveV4.indd 14

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automotive

ductility, and other requirements that are difficult to achieve at an acceptable cost. Once again, this a problem without a magic-bullet solution.

Finally, consider the delicate issue of consumer perception.

As the ACC report noted, some consumers do not perceive plastics and polymer composites as a premium product, and have misconceptions about the health, safety, and environmental impact of the materials. While comfortable with plastic drink bottles, they may be wary of plastics and polymer composites used in structural applications, and are concerned about the ability for these materials to serve the same functions as metals.

Taken together, these major challenges might seem insurmountable. They’re not. The bottom line is, the lightweighting drivers the automotive industry is facing offer significant opportunities for plastics and polymer composites, provided the industry works together and with automakers to achieve greater efficiency, performance, and value. “We are pretty bullish on the impact that materials can have on lightweighting, and new solutions continue to be introduced,” said Jeff Sternberg, technology director at DuPont Automotive. “But materials alone are not enough when it comes to reducing vehicle weight in the 10 to 15 per cent range. Those big opportunities require fundamental changes in design, manufactur-

Sarlink ME-2600 series compounds from Teknor Apex Company are part of the Sarlink range of automotive TPEs for window encapsulation and other injection molded automotive sealing applications, and offer the potential for weight savings because of their low density.

ing, and assembly. These more ‘disruptive technology’ developments are taking longer, but the work is moving forward.

High-volume adoption by 2025 may be optimistic for some of them, as we are just a little more than two vehicle model cycles away, but I am confident we will see an impact.”

And unlike with those crash dieters in Hollywood, this weight is staying off.

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packaging

Bioplastic drink bottles

are pouring into the marketplace Driven by economics and the green movement, beverage producers from around the world are turning to bioplastics to bottle their products. But traditional PET isn’t gonna go away quietly.

By Mark Stephen, editor

T

here isn’t much that we Canadians can’t explain with a hockey metaphor. In that spirit, let us suggest that bioplastics are the Connor McDavids of the drink manufacturing world.

In the same way that number one draft pick McDavid is the NHL’s new “It” boy, bioplastics — polymers made from renewable biomass sources such as vegetable fats and oils or cor n starch — are the go-to materials for use

16

by nearly all major bottlers around the world, from Coca-Cola, PepsiCo and Nestlé on down.

Coca-Cola, the world’s largest beverage company, was first out of the gate in 2009, when it introduced PlantBottle packaging, said Coca-Cola’s new PlantBottle design, made from 100 per cent plant-based plastics.

Photo Credit: Coca-Cola

to be the first-ever fully recyclable PET plastic bottle made with 30 per cent plant-based polymers. In the ensuing years, Coca-Cola distributed more than 35 billion bottles to nearly 40 countries.

PlantBottle packaging now accounts for 30 per cent of the company’s packaging volume in North America and 7 per cent globally, making the company the world’s largest bioplastics end-user.

Over the last five years, CocaCola said, its adoption of the technology has eliminated the equivalent of approximately 240,000 metric tons of CO2 emissions. PlantBottle packaging has also resonated with consumers, helping boost sales of brands like Dasani; won sustainable and inno-

Canadian Plastics September 2015 www.canplastics.com

CPL Sept15 p16-19 Packaging.indd 16

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packaging

vation awards; and captured the collective attention of the suppliers and the scientific/academic and investor communities. During a Capital Hill hearing in Washington, D.C. earlier this year, PlantBottle packaging was even singled out by the U.S. Senate Committee on Agriculture, Nutrition and Forestry for helping to fuel the bio-based manufacturing boom.

In 2011, PepsiCo unveiled a bottle made entirely of plant material, which it said bested the technology of its competitor Coca-Cola. The bottle is made from switch grass, pine bark, corn husks, and other materials. Ultimately, PepsiCo plans to also use orange peels, oat hulls, potato scraps, and other leftovers from its food business.

Coca-Cola, meanwhile, was investing in three leading biotech companies — Virent, Gevo, and Avantium — to speed the commercialization of a PET plastic bottle made entirely from plants.

Recently, the company made an additional investment in Virent’s development and commercialization of its biobased technology. The payoff came in June 2015, when Coca-Cola unveiled a new PlantBottle made 100 per cent from sugar cane plastic. The sugar cane comes from Brazil, and the new bottles also contain waste products from India that are left over from processing sugar cane. Though those are currently the only two sources of materials for its PlantBottles, Coco-Cola said it’s also looking at converting fruit stems, peels, and bark into plastic in the future. The company didn’t say when it would start shipping Coke in the new bottles, but noted that it will partner with biotechnology firms to move from lab to commercial scale in producing a 100 per cent plant-based plastic bottle.

GREEN ALL OVER Probably to the surprise of no one, green of a different sort — money — is perhaps the biggest motivator for companies in the fiercely competitive soft drink industry. Most plastic bottles today are still made from fossil fuel

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packaging

One reason for this, he said, is concerns about polylactic acid (PLA) — which is one of the most promising bio-based polymers for eco-friendly applications due to its biodegradability, processability, lightness, and transparency — contaminating the PET recycling stream.

“The two materials don’t mix well, and it takes very little PLA to make PET nonviable if you want to recycle it back into a bottle, which is a big concern for plastic reprocessors,” he explained. “Also, PLA simply doesn’t make a good water bottle compared to PET. PET is a superior product: marginally better

SHOWDOWN: PET VS PLA But traditional petroleum-based PET still has its advantages — which is why it enjoys a hammerlock on the water bottle industry. “Currently there is very little use of biopolymers in water bottles,” said John Moisson, president of Manchester, Mo.-based bioplastics supplier Jamplast.

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cost-wise, but much better performancewise, with better vapour transmission properties than PLA.” That’s not to say some beverage producers haven’t given PLA a try. Beginning in 2010, Green Planet Bottling and Keystone Water Company both launched 100 per cent plant-based water bottles. Both eventually pulled the products from the marketplace and replaced them with plastic bottles made from 100 per cent recycled content. A small Austrian packaging supplier called Naku is a more recent entry, with a PLA water bottle that is just now being introduced to the European market. The

Global plastic packaging market to reach $370 billion by 2020: report Driven by a rising demand for plastic packaging in the healthcare sector, the global plastic packaging market was valued at nearly US$260 billion in 2014 and is expected to reach US$370 billion by 2020, according to a new report from U.S.-based research firm Transparency Market Research.

Overall, the market is expected to grow at a compound annual growth rate of five per cent over the forecast period between 2014 and 2020, the report said. And as more and more regulations are being set in place regarding pharmaceutical packaging in regards to maintenance of hygiene, reduction of fraudulent drugs, and increased retention of medicinal properties of packaged drugs, healthcare packaging is expected to undergo the fastest growth from the medical application segment over the next few years.

Industry growth will also be fueled by the expansion of the food and beverages market, which — although expected to decline slightly ­­— is still currently the largest sector for plastic packaging. The food and beverages sector received more than 65 per cent of the market share as recently as 2013, the report said.

The report also noted that R&D activities on plastic packaging technologies have opened up opportunities for the use of nanotechnology in the formation of films and printing.

The lowest cost and most widely-used plastic film for food packaging across the globe is still PE, the report said, but PP is becoming a big contender. Bioplastics are expected to increase in demand and open up new growth avenues for packaging applications.

The report also noted potential downsides for the plastic packaging market, chief among them the volatility of crude oil prices, which affects the prices of its downstream chemicals.

Asia-Pacific accounted for the highest demand for plastic packaging in 2014, at over 35 per cent of the market share. This trend is expected to continue over the forecast period on account of rapid economic development in this region resulting in the growth of industries such as food and beverages, personal care products, and pharmaceuticals.

©shakzu/Getty Images/Thinkstock

hand, beverage producers want to show environmentally-conscious consumers that they’re serious about reducing their carbon footprint because doing so is good for their image and good for sales.

On the other hand, they don’t have a whole lot of choice, as governments around the world — especially in industrialized nations — are approving rules and regulations to force manufacturers to reduce their carbon dioxide emissions.

One of the most widely-used bottling materials today is, of course, PET. According to industry experts, the material is ideal for soft drinks with carbonation, which requires durability. It’s also colorless, which is important for selling many drinks.

Problem is, it normally has a high petroleum content — although efforts are underway to change that.

Coca-Cola, for instance, has developed a bottle made with a PET resin that contains bio-based monoethylene glycol (MEG). Currently, the bottle consists of up to 30 per cent MEG and 70 per cent purified terephthalic acid (PTA). The company is working on technology to develop PTA from plants, but doesn’t expect a commercial breakthrough for a few more years.

The Brazilian company Braskem has developed an alternative bioplastic product it calls “green polyethylene” or Green PE. The product, obtained from sugarcane ethanol, has many performance features of traditional fossil fuel-based PE, but not all of them. “It is highly recyclable, up to 10 times, and can be used in lightweight bottles,” said Marco Jansen, European commercial director for renewable chemicals at Braskem. “But, unlike PET, it is translucent.”

Canadian Plastics September 2015 www.canplastics.com

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packaging

Canada’s Macro Engineering installs a big order in Europe

Mississauga, Ont.-based film and sheet extrusion machinery supplier Macro Engineering & Technology has just installed a state-of-the-art 9-layer system in Europe.

The 1.8-metre-wide line — installed for an undisclosed European plastics packager — uses 9 extruders and a 9-layer die design to produce various barrier structures for the packaging industry to make film and bags. The line is also equipped to run 18-layer structures, and can handle a variety of materials, including barrier resins such as polyamide, EVOH, and PETg. The winding system handles film thicknesses from 20 to 300 microns.

According to Macro Engineering, the surface winder has zero fold-back roll starts, and can auto-cut and transfer in both directions. It includes automatic shaft and roll handling, and automatic shaft extraction.

The company also said the installed control system includes a “ready-run” feature, which allows it to restore frequently-used recipes at the push of a button, reducing changeover times and improving the consistency of the products.

Finally, the line is equipped with Macro Engineering’s “Green Energy” technology, which improves energy consumption during the heat and cool process.

bottle is being hyped as needing only between 35 to 90 days to biodegrade, compared to 350 years for a traditional PET bottle. But there are still challenges. When initially developed, the bottle was about 20 euro cents more expensive than a petroleum-based plastic bottle, although it has become more costcompetitive over the past year.

Another challenge is its durability, which company founder Johann Zimmermann said is between six to eight months, compared to about a year for conventional bottles.

Not to jinx him or anything, but there’s always the chance that Connor McDavid might disappoint when he finally hits the ice. Biopolymers, on the other hand, are already scoring big with the beverage producers.

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robots & automation

PACK MENTALITY

By Mark Stephen, editor

S

ince long before the Terminator went on its killing spree in the 1986 movie, robots have gotten a bad press. Take any sci-fi story with a robot in it and odds are it`s bent on destroying the humans. Go from fiction into a reallife manufacturing situation and the narrative holds…only instead of taking people’s lives, popular wisdom goes, the robots are eliminating their jobs.

It’s a bum rap, however, at least in the manufacturing scenario. Robots can definitely pack less expensively and more efficiently than people and can work around work-force shortages — but rather than rendering the workers redundant, this actually frees them to work where they’re most needed.

But there’s a right way to approach the idea of robotic automation for endof-the-line packaging of plastic parts.

Here’s a look at some factors to be evaluated to ensure that your switch to automation will provide the competitive edge needed to cut costs and boost profit.

NOT A NO-BRAINER First, consider whether or not you need robotic automation at all. Repeatable runs are a key determinant. “Analyze runtimes and product quantities to assess whether automating an end-ofthe-line packaging system will improve pack efficiency and reduce costs,” said 20

Photo Credit: Fanuc

If you think robots and EOAT are just an expensive substitute for competent machine operators, think again.

When it comes to end-of-the-line parts packaging, they’re cheaper and more efficient than people. Here’s what to take into account before automating your line.

Bengt Stom, global business line manager with ABB Inc. “People can be very efficient at packaging small, short, oneof-a-kind runs, so robotics may not be the best choice for a product that will only run once, or if different products run every day.”

On the other hand, it doesn’t hurt to put yourself in your operators’ shoes, especially if it means feeling their pain.

“Even if a cycle time is slow enough for comfortable manual packaging, it can be difficult for an operator to handle a very large part,” Stom continued. “Also, repetitive motions such as lifting, bending, labeling, inspecting, and orienting can be physically fatiguing for workers, to the point of impacting their ability to do the job effectively.”

Assuming a processor gives a thumbs up to installing robotic automation, the specifics of the system will be determined by a series of factors, beginning with the properties of the parts being handled. So-called part behaviour is a big one, in that differences in the physical characteristics of plastic parts — such as round, square, or tacky — can affect the performance of a packaging system.

“Bottles molded from PET can exhibit static ‘cling’, which can cause them to stick, jam, or travel down the line in an unpredictable manner; and static can also be an issue with in-mold labeling,

which can introduce static into the injection molding machine,” said Michael Mravyan, president of Minatech Inc. “Solutions include using an antistatic spray system to blow charged air onto the bottles, or grounding strips or plates on the machine to help dissipate static buildup, and possibly changes in conveyor belt material to lessen the friction.”

It’s a question in particular for endof-arm tooling (EOAT) providers. “The physical characteristics of what you’re picking up mean everything to the EOAT design,” said John Westbeld, engineering manager with SAS Automation LLC. “Vacuum cups and/or mechanical grippers can be tweaked according to the stickiness of the material in the finished part.”

HANDLE WITH CARE Product handling requirements — including FDA rules for handling food containers, as well as other regulations — can also dictate which areas of the part can come in contact with a tool, which may in turn impact EOAT design.

“Robotic EOAT, including new types of 3D printed EOAT, can be designed to achieve very specific movements or placement, and can easily be replaced as the products or procedures for packaging change,” Westbeld continued.

“These tools are capable of complex

Canadian Plastics September 2015 www.canplastics.com

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robots & automation

picks and motions that would not be possible or safe for a person.“ Once the properties of the part have been factored in, you need to consider where and how the robotic automation will physically fit into the plant. “The packaging system provider should examine the floor layout, where the customer wants the product to come into the work cell from, where it will exit, where the regrind will go, and where the rejects will go — these are key design decisions to make, and it’s easier to make them at the outset with the customer’s input,” said Michael Mravyan. “A robot can be integrated with technology from any start point to any final destination, regardless of physical layouts and space limitations, as long as the space has enough clearance for the robotic components.”

But just because the system fits doesn’t mean you’re done. Robots pack efficiently and also contribute to a clean

environment by lowering the risk of contamination — a particularly big deal for medical parts molding — but they still require a quality control process. Quality control on a manual packaging line is often performed by an employee on the line; putting in an automated line, however, requires something new. “Options range from a simple leak checker to something as high-tech as a vision system or other sensor,” said Brad Lemieux, sales manager at En-Plas Inc., which represents Yushin. “Vision-guided robotics can now verify product position, check the placement of a label, and inspect the printing on the label for correct content simultaneously, as well as weeding out defects, short shots, and/or missing or misplaced inserts that the human eye can miss.”

If you’re worried about the added energy costs of a robotic automation system, you probably shouldn’t be. Just

make sure that your new packaging equipment includes energy-saving provisions — even small features like auto shutoff and standby modes can add up to substantial energy savings over time. ”Wittmann introduced EcoMode with its W8 robot series,” said Christian Weiss, technical sales manager, robots and automation with Wittmann Canada Inc. “EcoMode automatically reduces acceleration, deceleration, and speeds to minimize power consumption, and utilizes the full dynamic range of the robot only if it’s truly needed.”

REAL-WORLD EXAMPLE Umpteen molders have made the transition from manually packaging parts to varying degrees of plant-wide, lights-out automation systems. Take injection molder Vision Plastics of Delavan, Wis., for example. “We’ve always put our money where we could

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www.canplastics.com September 2015 Canadian Plastics

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robots & automation

get the biggest bang for the buck, usually a molding machine,” said CEO Craig Hubertz. “Cost-justifying a robot was more difficult.” But when a customer that made architectural and outdoor lighting products wanted to produce bigger lenses for new LED products requiring brass sleeves molded into the corners of the lenses, Vision Plastics contacted Sepro America LLC and got busy automating. In the resulting process, an automated feeder orients the sleeves first and then the Sepro robot goes to work. The EOAT on the vertical arm picks up eight sleeves and prepares to load them into the mold. When the cycle ends and the mold opens, the vertical arm descends and pulls two finished lenses out of the mold cavities. Then the EOAT rotates 90° so that it can place the brass sleeves into the mold. As a

new cycle begins, the robot offloads the finished parts. “All of this runs lights-out, so I don’t have to put a dedicated operator on each machine, and we’ve been able to deploy all our operators on more interesting and higher paying jobs, without having to downsize anyone,” Hubertz said.

In the end, if you’ve determined that your line meets the criteria for installing robotic automation, get ready to reap the benefits. “Robots can give you repeatability, consistency, a cleaner environment, and happier employees,” said Brad Lemieux. And on their end, the ability to specify how a product should be handled, along with the ability to streamline the process for the client, is what the system provider brings to the table. By opening up endof-the-line solutions that can pay dividends for years to come, they`ll make

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CPL RESOURCE LIST ABB Inc. (Brampton, Ont.) www.abb.ca; 905-460-3000 Minatech Inc. (Woodbridge, Ont.); www.minatech.ca; 905-264-0411 SAS Automation LLC (Xenia, Ohio); www.sasgripper.com; 855-396-6797 MSJ Sales & Distribution (Toronto); www.msjsales.ca; 416-577-1801 Sepro America LLC (Pittsburgh, Pa.); www.seproamerica.com; 412-459-0450 Dier International Plastics Inc. (Unionville, Ont.); www.dierinternational.com; 416-219-0509 Industries Laferrière (Mascouche, Que.); www.industrieslaffiere.ca; 450-477-8880 Wittmann Canada Inc. (Richmond Hill, Ont.); www.wittmann-canada.com; 866-466-8266 Yushin/En-Plas Inc. (Toronto); www.en-plasinc.com; 416-286-3030

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doing it better

CHANTLER PACKAGING: After 85 years, this family-operated Ontario flexible packager is still mixing it up to stay current.

By Mark Stephen, editor

FOOD

FIGHTER A

lot of family-run operations aren’t exactly blueprints for harmony. The third generation of the Kennedy political clan should be in the thesaurus as a synonym for “train wreck”, and it only took two generations for the Corleones of Godfather movies fame to start bumping each other off.

Things have unfolded much more successfully at Chantler Packaging Inc., a Mississauga, Ont.-based flexible packager now in its fourth generation of family ownership and operation. The company, which turns 85 this year, provides services and solutions that are used to package and ship food for buyers, distributors, and grocery retail chains throughout Canada, the U.S., Mexico, Spain, and South America. And with a new and innovative service under its belt and a rebranding effort currently underway, the firm has no plans to slow down.

TAILORED BEGINNINGS

Then and now: The original Chantler brothers strategizing in the 1930s (top); Ian Ferguson (left) and Grant Ferguson with the silver award for Brandcheck’s Competitor Comparison service.

24

The company was incorporated in 1930 as Chantler & Chantler in Toronto’s so-called Garment District (now China­town) by two brothers who were pioneers in the emerging plastics field. “The company sold some of the first injection molding machinery imported to North America, and soon began molding plastic replacement items for such wood or horn-based consumer goods as combs, handles for shaving brushes, buttons, and other products typical of the time,” said Grant Ferguson, Chantler Packaging’s vice president of sales and marketing and a great-grandson of one of the original Chantler brothers. “Our first injection molding machine is now on display at the Canadian Museum of Science and Technology in Ottawa.”

In the 1960s, under the second generation of family leadership, the company transitioned from producing replacement items to making flexible packaging for industrial, agricultural, and floral markets, creating a range of innovative products. One of them was its Sealtite retail brand.

“Sealtite consisted of resealable plastic packages for home and commercial use, window coverings for storm windows, industrial covers for equipment, a line of Sealtite pool covers — even a covering used to protect the field for an early Grey Cup final,” Ferguson said. “We changed the marketplace with Sealtite.”

And that wasn’t all that changed. “The name change to Chantler Packaging Inc. also came at that time, and we moved to our current headquarters in Mississauga in 1971,” Ferguson said.

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doing it better

In the 1980s, with third-generation family member Roy Ferguson in charge — he now serves as the firm’s CEO — the company added film extrusion and printing to its list of capabilities, and after the turn of the millennium it underwent a strategic reorientation to focus on food packaging. “This led us into high-quality printing, food-friendly materials, and more export sales,” Grant Ferguson said. “We also developed our PrimePro modified atmospheric packaging, which absorbs ethylene gas to extend the shelf life of fresh produce.”

scores clients’ packaging against a set of North American and global peers.

“This benchmarking process shows clients how their packaging measures up to the packaging used by the competition,” Ferguson said. “It also identifies white space — areas where no competitor has a clear advantage.

Seizing that white space and adding packaging features that consumers want can lead to higher impulse sales and more engaged consumers.”

Impressive? Innovative? The PAC Plant manager Abe Looy with packaging product Packaging Consortium thought so, and on the shop floor. in April 2015 it awarded Brandcheck’s Competitor Comparison the silver award in the sustainability and service category of its PAC Global Leadership Awards.

WASTE NOT Along with the company’s EnduroPouch product — a package with strong handles manufactured using minimal materials — CHINESE FOOD PrimePro reflects Chantler Packaging’s ongoing interest in But if you think they think they’re home free, think again. The addressing concerns about food waste and carbon footprints. flexible packaging business is no cakewalk, and despite Chantler “We’re proud of the different areas that PrimePro participates Packaging’s long string of successes, pressures remain. “Food in,” Ferguson said. “It allows vice president Ian Ferguson to packaging may be recession-proof to an extent, but it isn’t losswork with the PAC Packaging Consortium, and other different proof — it’s a very competitive market, even ultra-competitive,” food waste reduction agencies around the world, to help developing countries to export their food product to gain access to further, more affluent markets. Low packaging costs cannot simply be the only concern for stakeholders — decreasing food waste and lowering carbon footprints are significant factors that save food, the environment, and overall costs in the long run.”

The transition into a food packaging supplier also involved a change in business philosophy. “To flourish as a food packager, we had to move beyond the idea that we were just a packaging manufacturer and actually become a problem-solver for all aspects of the supply chain,” Ferguson said. “We work with the brand owners, like Europe’s Best and Dr. Oetker; with brands within the retail sphere such as President’s Choice; and with companies that are between food growers and food distributors, such as Burnac Produce and Gambles Ontario Produce. Our goal is to help them with packaging solutions, and also to create brands and market position to promote their own businesses and branding goals.”

This latter objective took a giant step forward last year, with the launch of the company’s Brandcheck packaging consultancy division, headed by Ian Ferguson. “We saw a need in the market for an advisory service to help brand owners improve the fit between brand strategy and packaging,” Grant Ferguson said. ”One reason why some food products fail on the shelf is because the packaging doesn’t align with the brand strategy. Brandcheck develops brand and product family strategy through strategic analysis, name generation, innovation mapping, and consumer intercepts. All of these services come together to create new strategies and analyze existing ones to better focus the brand.”

The Brandcheck “Competitor Comparison” is a service that www.canplastics.com September 2015 Canadian Plastics

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The EnduroPouch.

PrimePro bags in action.

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Ferguson said. “In Canada, there are a limited number of food producers, made even smaller by ongoing amalgamations — Loblaw Companies and Shoppers Drug Mart, for example — that increase a customer’s purchasing power.”

The rise of foreign competition doesn’t help, either. “To be honest, packaging suppliers in China, Vietnam, and India are starting to catch up on the needs of the North American market,” Ferguson said. “We fight back by constantly innovating and thinking about our products and brands in new ways — Brandcheck is an example of that. Also, instead of benchmarking to create a product like our Sealtight three-sided resealable pouch, we chose to reverse engineer it to give it even more value: faster production, shorter lead times, and speed to market.”

These headaches notwithstanding, Chantler Packaging seems to have found its sweet spot for the time being. “Our mantra is to constantly strategize and reinvent, not simply to benchmark,” Ferguson said. Suiting the actions to the words, an ongoing rebranding effort is part of the company’s latest growth strategy, as is the expansion of its Brandcheck division. Fortunately, one thing that doesn’t need expansion — yet — is the company’s home base. “Our Mississauga facility has 20,000-square-feet of space, which is enough for our needs at the moment, and we also have warehousing facilities locally. While we also use a network of partner companies that help with other production, we look forward to growing in scale,” he added.

In the end, that whole family-owned thing almost seems like an afterthought. “We’re probably the longest privately-held plastics manufacturer in Canada, but we don’t really think about it,” Ferguson said. “In fact, we don’t think of ourselves as a family business at all — we think of ourselves as a business that happens to be owned and operated by a family, but that also includes a tremendous collection of non-family members. Some family-operated companies structure the management team according to genealogy, but we haven’t done that. We look for the best available people anywhere we can find them, because that’s the best way to get new perspectives.”

It’s a strategy the Corleones, for one, should have followed.

CPL They might have avoided that whole Fredo fiasco.

Canadian Plastics September 2015 www.canplastics.com

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technology showcase

AUXILIARY EQUIPMENT

Gravimetric control boosts accuracy for dosing liquid color The new Riverdale Gravimetric Stand (RGS) from Riverdale Global is designed to make liquid color as easy to handle as pelletized color concentrate.

The RGS uses gravimetric metering to hold color-delivery tolerance to within 0.1 per cent, preventing overcoloring and making it possible to reduce costs while maintaining target color levels.

In the RGS, a liquid color drum is mounted on a self-calibrating loss-in-weight scale that continually reports the weight of the contents to the controller as a means of ensuring that the target let-down ratio is maintained. Flow is modulated through an airregulated actuator connected to the liquid color pump. The pump

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is located inside the sealed drum.

The RGS also eliminates the urethane delivery tube required for the peristaltic pump in a volumetric system.

With each RGS, Riverdale Global provides sealed delivery tubes with quick disconnects. The tubes are available in custom lengths, and a custom-design feed throat adapter is also supplied.

Riverdale Global also supplies software that allows the RGS to be networked for central control and monitoring.

In addition, the RGS tracks real-time consumption data so that inventory levels can be monitored and re-order points can be flagged when low levels are reached.

Riverdale Global (Aston, Pa.); www.riverdaleglobal.com; 610-358-2900

Low profile, versatile granulator

With a castered base that provides a low profile, the new U series thermoforming granulator from Cumberland is well-suited for under-the-press or in front of the press applications.

For easy clean out and maintenance, two swing-open doors allow easy access to the screen cradles and screen, while two pivoting doors offer complete access into the bottom of the cutting chamber. The rotor and bedknives can be accessed from the eight-inch pneumatic upper hopper by tilting open the upper chamber.

The U series features a three-blade open rotor with Twinshear cutting geometry, providing a quieter, cooler operation, making it ideal for handling PP. With three model sizes available, the U series offers a horsepower range of 20 to 50 hp, and throughput capacities of 1,800 to 3,000 lbs per hour.

A 12-inch cutting circle, high-angle rotors knives, reversible bedknives with D2 construction, and NEMA 12 controls come standard; five-blade open rotors are available options.

Cumberland (New Berlin, Wis.); www.cumberland-plastics.com; 262-641-3885 Auxiplast Inc. (Ste-Julie, Que.); www.auxiplast.com; 866-922-2894 New Tech Machinery Inc. (Brampton, Ont.); 905-456-2968 Precision Mold Supplies Ltd. (Delta, B.C.); 604-943-7702

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Canadian Plastics September 2015 www.canplastics.com

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technology showcase

INJECTION MOLDING

Micro press features 12-mm in-line screw The new NPX7 Advance compact hybrid injection molding machine from Nissei Plastic Industrial Co. Ltd. has a 69 kN (7.7 US ton) clamping force and is equipped with a 12-mm in-line screw, making it well-suited for repeatable molding of micro parts.

The machine is also equipped with a Nissei-original material feeding device called the Smart Feeder (sold separately) that prevents insufficient resin feeding and stabilizes the melting/plasticizing of the resin.

The most distinctive feature of the NPX7 Advance is said to be its innovative, energy-efficient hybrid X-Pump system, which saves about 40 per cent in power consumption compared with hydraulic types. The system also delivers rapid injection ramp up response and wide-ranging injection performance from low through to high-speed range.

The clamping unit employed is a direct hydraulic type with linear guides on the die plate. Since this mechanism opens and closes the mold with stable clamping force, the force is transmitted evenly to the mold. Low-pressure clamping precision is also high, allowing for a stable precision molding process.

The NPX7 Advance is outfitted with the TACT IV highend controller, featuring a larger screen that displays two windows, convenient and easy-to-use advanced software, and a newly designed operation panel that offers improved workability and operability.

Nissei Plastic Industrial Co. Ltd./En-Plas Inc. (Toronto); www.en-plasinc.com; 416-286-3030

Customer portal makes ordering parts easier and faster Engel’s new e-connect customer portal is designed to make processing service requests and ordering spare parts easier, faster, and more transparent.

With e-connect, injection molders can now request quotations and place orders online at any time, with-

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out needing to know the exact designation of the required spare parts. In the system, all machines and manufacturing cells that Engel has delivered to a respective company are documented along with the corresponding parts lists. There are animated 3D models of many machine components, so the part that must be replaced can be found quickly and easily, and selected with just a click. In addition, the online catalog contains the current part price and availability information.

Immediately after an order has been placed by the user, the request is automatically sent to the respective service team and processing can begin without delay. The system also provides the service technicians with access to the complete history of the plant, which speeds up their search for the solution.

Engel Canada (Waterloo, Ont.); www.engelglobal.com/na; 519-725-8488

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technology showcase

BLOWN FILM EXTRUSION

High-level performance, greater processing flexibility The new dsX flex-film line for blown film applications from Davis-Standard LLC allows greater processing efficiency in such target applications as films for laminating and converting, bag making shrink film, hood shrink film, collation film, multi-unit packaging films, roll stock, and surface print films.

Available in 1,900 mm, 2,200 mm, and 2,500 mm sizes, the line supports speeds up to 180 meters per minute, and film thicknesses ranging from 20 to 180 microns. Advantages include die designs with among the fastest formulation changes in the industry, options for multiple end-use applications, proven control systems and screw designs, flatter films with nip flattening enhance-

ments, and U.S.-centred support and service for a faster response and shorter lead times.

Options for modifying equipment are based on application, film thickness, and other processing factors. The UpJet air ring is an option for increased output capacity.

Surface winders can be upgraded to include centre assist, gap winding, and reversible winding direction on a single winder with integrated nip; or back-toback, or face-to-face winders with a secondary nip. Screw designs can be upgraded from X100 liner and Colmonoy 56 screw facings to more wear-resistant X800 barrel liners and Colmonoy 83 screw flight facings.

The line can be delivered and installed in as little as six months from order to acceptance.

Davis-Standard LLC (Pawcatuck, Conn.); www.davis-standard.com; 860-599-1010 Auxiplast Inc. (Ste-Julie, Que.); www.auxiplast.com; 866-922-2894

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technology showcase

BLOW MOLDING

Compact accumulator head unit for small industrial parts A new accumulator head blow molding machine from Graham Engineering Corporation offers a small shot size and space-saving footprint, onehour color and material change, precision process control, and is designed to be well-suited for molding a wide range of small industrial parts.

Available in three shot sizes — 2.5 lbs, 5 lbs, and 8 lbs (1.13, 2.25, and 3.63 kgs) — the new Mini Hercules blow molder has a footprint of approximately 15 by 11 feet (4.6 by 3.4 meters) and a height of 15 feet (4.6 meters). It is available in single- or dual-head configuration, and with bottom or side discharge. Platens are designed for easy mold removal. A 75-mm smooth extruder and two auxiliary hydraulic valves are standard, with a 90-mm smooth or grooved extruder and additional valves as options.

The spiral paths in the diverter are rheologically engineered to create a “first in, first out” material flow and selfcleaning action as new material replaces old. While many conventional systems require several hours to complete a head cleanout, the Mini Hercules blow molder purges most colors or materials in less than one hour.

Also, the unit’s XBM Navigator PC-based control offers proportional hydraulics combined with closed-loop position

control, and 100-point parison programming, for precise control over wall thickness.

Graham Engineering Corporation (York, Pa.); www.grahamengineering.com; 717-505-4813

RAW MATERIALS HANDLING

Improved MVP system for superior conveying Conair has updated its Material Vision Proofing (MVP) system to include upgraded camera and shuttle mechanism and advanced controls for even simpler operation.

The MVP uses advanced machine-vision technology to provide automatic 100 per cent validation that the correct material is being conveyed to the right destination. With the next-generation version, a motorized camera is installed on a track behind a Conair table-top resin selection station manifold. When setting up a job, an operator designates the source and destination in the standard FLX or ELS material handling system. Then, animation on the four-inch color touchscreen display shows exactly where the correct connection is to be made. No text instructions are needed. The interface is 100 per cent graphical for the benefit of workers with limited language or reading skills.

Before any resin is conveyed, however, the machinevision camera traverses behind the selector table and posi-

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Easiest to Use Mobile Wheel Dryers Standard Dry Air Conveying Package

Standard LED Alarm Light...Matsui Charges Over $250!

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We Include It. Matsui Charges an Extra $900!

Exclusive Overdry Protection Ideal for Nylon and Other Sensitive Materials

Very Smart Upgraded Software Senses Faults…

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Standard Conveying Blower Package Pictorially Guides You in a Solution

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Sold as Options Everywhere Else! www.novatec.com/dryers

Standard 5-Year Warranty | Sold & Serviced in Canada by Maguire Products Canada, Inc. T: 905-879-1100 | F: 905-879-1101 | info@maguirecanada.com | www.maguirecanada.com © Copyright 2014 Novatec, Inc.

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SCHMOLZ + BICKENBACH broke the mold when they introduced products like Formadur PHX Super-clean, not to mention their entire line of Plastic Mold Materials. With over 160 years of steel production backing their brands, SCHMOLZ + BICKENBACH is not only a pioneer, but also a market leader in specialty steels. Their comprehensive range of products allows you to choose the ideally suited mold material for your application. In addition, an extensive range of value added services provides you with more alternatives from one source, SCHMOLZ + BICKENBACH.

CPL Sept15 p28-37 TechShow.indd 34

Mold Materials: Formadur 2085, 2083 Superclean, Corroplast FM, 2311, 2316, 2344 Superclean, S7 Mold Quality, P20 Modified, P20 High Hard, Holder Block, MoldMAX速 Grades

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technology showcase

tions itself between the appropriate rows of ports, confirming to the material handling system control that the correct connections have been made. Only then will the control allow material to be conveyed. The entire validation process takes just seconds to complete.

The Conair Group (Cranberry Township, Pa.); www.conairgroup.com; 724-584-5500 Dier International Plastics Inc. (Unionville, Ont.); www.dierinternational.com; 416-219-0509 Industries Laferrière (Mascouche, Que.); www.industrieslaferriere.ca; 450-477-8880

TESTING EQUIPMENT

FlexPak leak detector control package New from Flex Essentials Inc., the FlexPak semi-automatic (FPSA) control package for the FlexPak package leak detection system is designed to allow operators

to set two independent or successive vacuum level setpoints for bubble emission tests, vacuum tests, altitude tests, and dry chamber tests.

The FPSA consists of a stainless steel independent panel complete with operator interface and designed for washdown environments, and a PLC to control the vacuum setpoints and test times. Operators can program each test with a countdown timer setting for the length of time required to

plastics data file Wittmann Innovations

Innovations — Wittmann’s quarterly newsletter — offers plastics processors detailed insight into ways to improve their businesses with news and application stories covering Robots and Automation, IML, Injection Molding Machinery, Material Conveying, Drying and Blending, Granulation and Temperature Control. It is available in print and on-line.

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

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technology showcase

perform the test.

The FPSA can be retrofitted to all FlexPaks or similar competitors’ vacuum style, bubble test, and package leak detectors.

Benefits of the FlexPak FPSA unit will be realized by many industries such as those in the manufacture of packaging and end-user food packages, and also any non-food packaging items where package integrity is critical.

Flex Essentials Inc. (Caledon East, Ont.); www.flexessentials.ca; 905-584-6369

MATERIALS

Nucleator for HDPE boosts resin performance and processing Milliken & Company has unveiled a new nucleating agent for injection molded HDPE applications that improves the mechan-

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ical performance of HDPE to levels approaching those of PP impact copolymers, giving molders attractive new processing options for packaging and material handling applications.

The Hyperform HPN 210 M nucleator — which specifically targets material handling applications such as waste containers, totes, crates, and pallets — has been tested by the American Society for Testing Materials (ASTM D790-00) and shown to increase stiffness (modulus) of up to 50 per cent compared to standard HDPE. This stiffness can enable thinner wall designs, contributing to weight reductions of the final part.

Hyperform HPN 210 M also improves HDPE’s heat resistance and offers other processing benefits, including higher productivity due to shorter cooling times.

It can also reduce shrinkage and part warping for an improvement in the overall quality of large, complex parts, opening the window for PE to become a potential material of choice in molds that traditionally run PP, without the need to re-tool.

Milliken & Company (Spartanburg, S.C.); www.milliken.com; 864-503.2020

To place your classified ad here, contact: Greg Paliouras, Associate Publisher at 416-510-5124 or gpaliouras@canplastics.com www.canplastics.com September 2015 Canadian Plastics

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technical tips

Know your part before sizing a blow molding machine and tooling

By Robert Slawska, Proven Technology Inc.

T

oday’s industrial blow molding machines are highly efficient and predictable, and can generally be relied on to produce sophisticated parts from the first shot. But it’s still wise to brush up on some basic guidelines to help you get started, especially if you’re making a particular part for the first time.

First, determine the specifications of the actual parts you’ll be running. Will it require flash only on the top and bottom of the part, or flash all the way around? Project the actual finished weight of the part, and then estimate the shot size, taking the flash into account. Flash only on the top and bottom of the part will mean a complete shot weight about 25 to 40 per cent more than the final trimmed part weight. If the flash is all the way around, this could increase the shot weight by upwards of 60 per cent. In most cases, flash can be recycled back into the parts.

Shot size and cycle time will also influence the output requirement for the extruder. To make sure the machine is sized properly, a rule of thumb is to project the needed output capacity of the extruder at 80 per cent of its maximum screw speed. The extruder must be working well to ensure a low melt temperature. The hotter the material, the longer the cycle time.

The finished wall thickness of the part also plays an important role in cycle time. If the part wall thickness is 0.060 inches or less, the cycle time will be in the area of 40 to 50 seconds. A wall thickness of 0.080 to 0.100 inches will result in a cycle of around 60 to 70 seconds. Very thick parts with walls of 0.120 to 0.180 inches could result in cycles from 90 to 180 seconds. (Be careful, however, as these are only estimated guidelines.)

Another matter to consider is the size of the accumulator head that your part and process will require. Here are some guidelines:

1.

Determine necessary head tooling size. You might require larger head capacity than output needs alone would indicate, in order to get proper head tooling size for the part.

2.

Find out the parison layflat needed based upon top/bottom or all around part flash. (Layflat = tooling diameter x 3.14 ÷ 2) This equation does not consider die swell or parison preblow inflation.

3.

Factor in parison die swell. Normally, larger tooling diameters have smaller parison swell. Small tooling produces a larger percentage of swell.

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4.

5.

Remember that competitive heads may produce different parison sizes for a given tooling size.

Determine if there is a limit on how much regrind can be put back into the finished part. Some flash requirements might be more that the weight of the finished part.

6.

Based upon maximum shot size, determine head capacity needed. Consider what other parts might be run in this machine and to what specifications.

7.

Select tooling size based on head size. Determine if converging or diverging head tooling is needed. If using dual heads, determine the required head centre distance.

8.

Identify the actual size of the mold, including any outriggers, cylinders for split molds, water connections, and blow pins. This is extremely important in case you’re running dual heads with side-by-side molds on a fixed head centre line. The platens must be sized to fit the molds on the head centre line.

Now you’re ready to determine the clamp tonnage required to mold your part. I use the following resin guide: HDPE: 500 to 600 lbs of force per linear inch; HMW-HDPE: 600 to 700 lbs of force per linear inch; PP homopolymer: 500 to 600 lbs of force per linear inch; and PP copolymer: 600 to 700 lbs of force per linear inch.

Next, calculate the pinch clamp force needed to seal the parison: length of pinch x lbs of force per linear inch ÷ 2,000. Find the blowing clamp force (to keep molds closed during air blow): projected area of blown section x blowing pressure (around 100 psi) ÷ 2,000. Finally, remember that once you clamp up, the pinch clamp force ends and the blowing clamp force takes over. Don’t add these two values together.

CPL Robert Slawska has more than 50 years’ experience in blow molding. His firm, Proven Technology Inc., located in Hills­borough, N.J., provides engineering/consulting services and equipment to industrial blow molders. Contact him at 908-359-7888, email him at rslawska@aol. com, or visit www.industrialblowmolding.com.

Canadian Plastics September 2015 www.canplastics.com

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has a solution you can depend on. Engineered to perform. Built for reliability. Backed by the best parts and service support in the industry.

Share in our knowledge and experience.

Call 800-654-6661.

Represented in Canada by: Dier International Plastics l Greg Reid l 416.219.0509 Industries Laferriere l Francois Laferriere l 450.477.8880 l Injection Molding, Quebec F M Mecanique l Jocelyn Fournier l 514.953.5307 l Extrusion, Quebec The Turner Group l Chuck Roehm l 206.769.3707 l British Columbia and Alberta 1.800.654.6661 • 724.584.5500 • info@conairgroup.com • www.conairgroup.com

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