Combat the skilled labor shortage using this comprehensive resource to train your own plastics processing experts.
Deep dive into the basics of blending versus dosing, controls, maintenance, process integration and more. Plastic sheet machine
This Knowledge Center provides an overview of the considerations needed to understand the purchase, operation, and maintenance of a process cooling system.
Learn about sustainable scrap reprocessing—this resource offers a deep dive into everything from granulator types and options, to service tips, videos and technical articles.
While prices moved up for three of the five commodity resins, there was potential for a flat trajectory for the rest of the third quarter.
By most measures, pricing for the five commodity resins appeared to be holding firm going into the third quarter.
Second quarter started with price hikes in PE and the four volume engineering resins, but relatively stable pricing was largely expected by the quarter’s end.
While the major correction in PP prices was finally underway, generally stable pricing was anticipated for the other four commodity resins.
Despite price increase nominations going into second quarter, it appeared there was potential for generally flat pricing with the exception of a major downward correction for PP.
First quarter was ending up with upward pricing, primarily due to higher feedstock costs and not supply/demand fundamentals.
Resin drying is a crucial, but often-misunderstood area. This collection includes details on why and what you need to dry, how to specify a dryer, and best practices.
Take a deep dive into all of the various aspects of part quoting to ensure you’ve got all the bases—as in costs—covered before preparing your customer’s quote for services.
In this collection of articles, two of the industry’s foremost authorities on screw design — Jim Frankand and Mark Spalding — offer their sage advice on screw design...what works, what doesn’t, and what to look for when things start going wrong.
In this collection, which is part one of a series representing some of John’s finest work, we present you with five articles that we think you will refer to time and again as you look to solve problems, cut cycle times and improve the quality of the parts you mold.
Gifted with extraordinary technical know how and an authoritative yet plain English writing style, in this collection of articles Fattori offers his insights on a variety of molding-related topics that are bound to make your days on the production floor go a little bit better.
In this three-part collection, veteran molder and moldmaker Jim Fattori brings to bear his 40+ years of on-the-job experience and provides molders his “from the trenches” perspective on on the why, where and how of venting injection molds. Take the trial-and-error out of the molding venting process.
Mike Sepe has authored more than 25 ANTEC papers and more than 250 articles illustrating the importance of this interdisciplanary approach. In this collection, we present some of his best work during the years he has been contributing for Plastics Technology Magazine.
In this collection of content, we provide expert advice on welding from some of the leading authorities in the field, with tips on such matters as controls, as well as insights on how to solve common problems in welding.
Mold maintenance is critical, and with this collection of content we’ve bundled some of the very best advice we’ve published on repairing, maintaining, evaluating and even hanging molds on injection molding machines.
Thousands of people visit our Supplier Guide every day to source equipment and materials. Get in front of them with a free company profile.
Almost 25 years ago, I stumbled into a career in the plastics industry in a most happy accident.
Processors with sustainability goals or mandates have a number of ways to reach their goals. Biopolymers are among them.
While the melting process does not provide perfect mixing, this study shows that mixing is indeed initiated during melting.
Additive technology creates air pockets in film during orientation, cutting down on the amount of resin needed while boosting opacity, mechanical properties and recyclability.
Aaron Industries added optical sorting to its operation, expanding capabilities to meet the color needs of customers.
Say “manufacturing automation” and thoughts immediately go to the shop floor and specialized production equipment, robotics and material handling systems. But there is another realm of possible automation — the front office.
Core Technology Molding turned to Mold-Masters E-Multi auxiliary injection unit to help it win a job and dramatically change its process.
While prices moved up for three of the five commodity resins, there was potential for a flat trajectory for the rest of the third quarter.
Across the show, sustainability ruled in new materials technology, from polyolefins and engineering resins to biobased materials.
Successfully starting or restarting an injection molding machine is less about ticking boxes on a rote checklist and more about individually assessing each processing scenario and its unique variables.
Topping five other entries in voting by fellow molders, the Ultradent team talks about their Hot Shots sweep.
Serendipitous Learning Opportunities at PTXPO Underscore the Value of Being Present.
Introduced by Zeiger and Spark Industries at the PTXPO, the nozzle is designed for maximum heat transfer and uniformity with a continuous taper for self cleaning.
Ultradent's entry of its Umbrella cheek retractor took home the awards for Technical Sophistication and Achievement in Economics and Efficiency at PTXPO.
technotrans says climate protection, energy efficiency and customization will be key discussion topics at PTXPO as it displays its protemp flow 6 ultrasonic eco and the teco cs 90t 9.1 TCUs.
Shibaura discusses the upcoming Plastics Technology Expo (PTXPO) March 28-30
Südpack’s Multifol Extreme film is well suited for greasy, protein-rich and frozen foods
Across all process types, sustainability was a big theme at NPE2024. But there was plenty to see in automation and artificial intelligence as well.
Exhibitors and presenters at the plastics show emphasized 3D printing as a complement and aid to more traditional production processes.
The Plastics Industry Association (PLASTICS) has released final figures for NPE2024: The Plastics Show (May 6-10; Orlando) that officially make it the largest ever NPE in several key metrics.
Discover how artifical intelligence is revolutionizing plastics processing. Hear from industry experts on the future impact of AI on your operations and envision a fully interconnected plant.
Sustainability continues to dominate new additives technology, but upping performance is also evident. Most of the new additives have been targeted to commodity resins and particularly polyolefins.
Mixed in among thought leaders from leading suppliers to injection molders and mold makers at the 2023 Molding and MoldMaking conferences will be molders and toolmakers themselves.
After successfully introducing a combined conference for moldmakers and injection molders in 2022, Plastics Technology and MoldMaking Technology are once again joining forces for a tooling/molding two-for-one.
Multiple speakers at Molding 2023 will address the ways simulation can impact material substitution decisions, process profitability and simplification of mold design.
When, how, what and why to automate — leading robotics suppliers and forward-thinking moldmakers will share their insights on automating manufacturing at collocated event.
As self-imposed and government-issued sustainability mandates approach, injection molders reimagine their operations.
August 29-30 in Minneapolis all things injection molding and moldmaking will be happening at the Hyatt Regency — check out who’s speaking on what topics today.
Get your clicking finger in shape and sign up for all that we have in store for you in 2023.
Molding 2023 to take place Aug. 29-30 in Minnesota; Extrusion 2023 slated for Oct. 10-12 in Indiana.
An overview on the use of chemical foaming agents (CFAs) to successfully foam single and multilayered rotational molding parts, this webinar will illustrate the multiple benefits rotational molders can achieve including reducing resin consumption, decreasing part weight, enhancing wall thickness and improving structural rigidity. Agenda: Charging the mold Dosing ratios Venting Optimal decomposition temperatures, cycle times and drop times for drop box applications Cooling considerations
The aim of this presentation is to guide you through the factors and the numbers that will help you determine if a robot is a smart investment for your application. Agenda: Why are you considering automation? What problems are you trying to solve? How and why automation can help Crunch the numbers and determine the ROI
Join this webinar to explore the transformative benefits of retrofitting your existing injection molding machines (IMMs). Engel will guide you through upgrading your equipment to enhance monitoring, control and adaptability — all while integrating digital technologies. You'll learn about the latest trends in IMM retrofitting (including Euromap interfaces and plasticizing retrofits) and discover how to future-proof your machines for a competitive edge. With insights from industry experts, it'll walk you through the decision-making process, ensuring you make informed choices that drive your business forward. Agenda: Maximize the value of your current IMMs through strategic retrofitting Learn how to integrate digital technologies to enhance monitoring and control Explore the benefits of Euromap interfaces and plasticizing retrofits Understand how retrofitting can help meet new product demands and improve adaptability Discover how Engel can support your retrofitting needs, from free consultations to execution
Join KraussMaffei for an insightful webinar designed for industry professionals, engineers and anyone interested in the manufacturing processes of PVC pipes. This session will provide a comprehensive understanding of the technology behind the production of high-quality PVC pipes: from raw material preparation to final product testing. Agenda: Introduction to PVC extrusion: overview of the basic principles of PVC pipe extrusion — including the process of melting and shaping PVC resin into pipe forms Equipment and machinery: detailed explanation of the key equipment involved — such as extruders, dies and cooling systems — and their roles in the extrusion process Process parameters: insight into the critical process parameters like temperature, pressure and cooling rates that influence the quality and consistency of the final PVC pipes Energy efficiency: examination of ways to save material and energy use when extruding PVC pipe products
Join Wittmann for an engaging webinar on the transformative impact of manufacturing execution systems (MES) in the plastic injection molding industry. Discover how MES enhances production efficiency, quality control and real-time monitoring while also reducing downtime. It will explore the integration of MES with existing systems, emphasizing compliance and traceability for automotive and medical sectors. Learn about the latest advancements in IoT and AI technologies and how they drive innovation and continuous improvement in MES. Agenda: Overview of MES benefits What is MES? Definition, role and brief history Historical perspective and evolution Longevity and analytics Connectivity: importance, standards and integration Advantages of MES: efficiency, real-time data, traceability and cost savings Emerging technologies: IoT and AI in MES
In a time where sustainability is no longer just a buzzword, the food and beverage packaging industry is required to be at the forefront of this innovation. By adopting circular packaging processes and solutions, producers can meet regulatory requirements while also satisfying consumer demand and enhancing brand reputation. Join Husky to learn more about the broader implications of the circular economy — as well as how leading brands are leveraging this opportunity to reduce costs, increase design flexibility and boost product differentiation. Agenda: The cost and operational benefits of embracing circularity Key materials in circular packaging — including rPET and emerging bioplastics How to design a circular food and beverage package Strategies for selecting sustainable closures to future-proof packaging solutions Optimization and streamlining of production processes for enhanced efficiency How Husky Technologies can enable your sustainable success
Plastics Technology’s Tech Days is back! Every Tuesday in October, a series of five online presentations will be given by industry supplier around the following topics: Injection Molding — New Technologies, Efficiencies Film Extrusion — New Technologies, Efficiencies Upstream/Downstream Operations Injection Molding — Sustainability Extrusion — Compounding Coming out of NPE2024, PT identified a variety of topics, technologies and trends that are driving and shaping the evolution of plastic products manufacturing — from recycling/recyclability and energy optimization to AI-based process control and automation implementation. PT Tech Days is designed to provide a robust, curated, accessible platform through which plastics professionals can explore these trends, have direct access to subject-matter experts and develop strategies for applying solutions in their operations.
Formnext Chicago is an industrial additive manufacturing expo taking place April 8-10, 2025 at McCormick Place in Chicago, Illinois. Formnext Chicago is the second in a series of Formnext events in the U.S. being produced by Mesago Messe Frankfurt, AMT – The Association For Manufacturing Technology, and Gardner Business Media (our publisher).
While the melting process does not provide perfect mixing, this study shows that mixing is indeed initiated during melting.
The melting process for plasticating, single-screw extruders is also an excellent mixing process. A low level of mixing can occur during pellet blending before being placed in the hopper. But the first major mixing process occurs during melting.
Figure 1 – ABS resin in the transition section after a Maddock solidification experiment. The feedstock mixture was 200 parts white ABS and one part black ABS in pellet form. Source: M. Spalding
This mixing is obvious by studying the photograph in Figure 1. Here the feedstock was a mixture containing 200 parts of a white ABS terpolymer to one part of black ABS, both in pellet form. The cross section was taken from a Maddock solidification experiment where the feedstock was extruded and then the screw rotation was stopped. Next, full cooling was applied to the barrel.
After the ABS was solidified and at room temperature, the screw and plastic were pushed out of the barrel, and the plastic was cut off the screw. The areas that are white were solid, compacted pellets when screw rotation was stopped. The melting process occurred mostly in a thin melt film between the solid bed and the barrel wall. The molten resin was then conveyed to the melt pool by the rotation of the screw.
At the 200:1 ratio noted, the concentration of black pellets was so low that not a single black pellet is observed in the white region of Figure 1. The rotation of the screw causes energy to be dissipated in the melt film via high shear rates and shear stresses. The thickness of the melt film is between 0.010 and 0.020 inches. The energy dissipated conducts into the solid bed and melts the resin at the solids-melt film interface. The high shear stresses cause the mixing process to occur in the melt film. The melt pool where the freshly melted resin accumulates is relatively uniform in color, indicating the effectiveness of the mixing process during melting.
As shown, color striations between gray and black bands exist, indicating that mixing is not perfect. But going from a feedstock of mostly white pellets to a melt pool that is essentially black indicates the melting process is a great mixing process.
The excellent level of mixing occurs because the melt film is very thin, causing a high level of material elongation during melting. For example, the velocity of the solid bed is on the order of a few cm/sec in the downstream direction. When melting at the interface occurs, the molten material is stretched and accelerated in the cross-channel direction at a velocity nearly 10 times higher. Moreover, materials from many pellets are accelerated and mixed at the same time. Statistically, about 1/220 of the area at the melt film-solid bed interface would have a black pellet, yet the material at the entire surface at the barrel wall is tinted black once melting has started, as shown by Figure 2.
Figure 2 – A screw from a Maddock solidification experiment.
In this figure, the first three diameters of the screw do not contain any plastic. Here the pellets were at ambient temperature and very low pressure such that the pellets would not compact into a solid bed. They fell off the screw and to the floor when the screw was removed from the barrel. At diameter 4, the pellets were compacted but have not started to melt as indicated by the white color. That is, no melting and no mixing. By diameter five and all diameters downstream, the outside surface of the plastic was tinted black due to mixing during melting.
The melting process, however, does not provide perfect mixing, as shown by the melt pool in Figure 3. As melting occurs in the melt film, it is dragged over into the melt pool. The material entering the melt pool from the melt film creates a recirculation flow counterclockwise, creating color striations. These striations are clearly visible in Figure 3. For many applications, these striations would cause color defects in the final product. This imperfect mixing can be completed using a secondary mixing process such as a Maddock mixer positioned near the discharge of the screw. Operation and design of Maddock mixers was discussed in the March 2024 issue of Plastics Technology.
Figure 3 – Blowup of the melt pool in Figure 1 with the counterclockwise flow shown by the arrow.
The Maddock solidification experiment presented here clearly shows that primary mixing occurs during the melting process. The mixing occurs because of the thin melt film between the compacted solid bed and the barrel wall where the shear rate and shear stress are high. A secondary mixing process is needed downstream to guarantee a homogenous extrudate before forming the final product.
About the Author: Mark A. Spalding is a fellow in Packaging & Specialty Plastics and Hydrocarbons R&D at Dow Inc. in Midland, Michigan. During his 39 years at Dow, he has focused on development, design and troubleshooting of polymer processes, especially in single-screw extrusion. He co-authored Analyzing and Troubleshooting Single-Screw Extruders with Gregory Campbell. Contact: 989-636-9849; maspalding@dow.com; dow.com.
With cavity steel or alloy selection there are many variables that can dictate the best option.
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Performing fundamental maintenance inspections frequently assures press longevity and process stability. Here’s a checklist to help you stay on top of seven key systems.
You can better visualize the melting process by “flipping” the observation point so the barrel appears to be turning clockwise around a stationary screw.
Plastics processors are finding applications for 3D printing around the plant and across the supply chain. Here are 8 examples to look for at NPE2024.
Driven by brand owner demands and new worldwide legislation, the entire supply chain is working toward the shift to circularity, with some evidence the circular economy has already begun.
Implementing a production monitoring system as the foundation of a ‘smart factory’ is about integrating people with new technology as much as it is about integrating machines and computers. Here are tips from a company that has gone through the process.
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