thin-walled PET containers - polyethylene terephthalate injection molding

First quarter was ending up with upward pricing, primarily due to higher feedstock costs and not supply/demand fundamentals.

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.

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

With Micro-AM, designers can directly translate their digital designs into physical objects with minimal lead time. This capability accelerates the product development cycle, allowing for rapid iterations and design improvements. Additionally, the lack of expensive tooling requirements and reduced material wastage compared to traditional manufacturing methods significantly lowers prototyping costs. As a result, even small businesses and start-ups can explore innovative ideas without breaking the bank.

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.

Chesshier noted there was no real cost push from any of the key feedstocks, including styrene monomer, ethylene and butadiene, with continued lackluster demand for PS resins. Reported Barry, “Supply remained ample amid a generally gloomy demand outlook. The implied styrene price based on a 70% benzene/30% ethylene spot formula was down 1¢/lb by end of December.

As Micro-AM matures as a process, not just for prototyping but for true production, there is an excitement about what the future may hold for medium-to high-volume manufacturing.  There has recently been increased interest in using Micro-AM for the production of mould tools themselves, so called Direct Rapid Soft Tooling (DRST). DRST is especially well suited to scenarios when the goal is small series production where the cost of a traditionally manufactured tool is prohibitive, and it is also much easier and inexpensive to apply design changes. In addition, increased tool complexity can be accommodated at no extra expense.

Across all process types, sustainability was a big theme at NPE2024. But there was plenty to see in automation and artificial intelligence as well.

Barry noted that Nova Chemicals has begun PE production at the new 992 million lbs/yr AST2 unit near Sarnia, Ontario, with initial output of wide spec injection molding homopolymer HDPE. Eventually it is expected to produce a range of octene copolymers, including film grades. Shell was restarting the ethane cracker at its Monaca, Pennsylvania, site on the evening of Dec. 25, according to a social media post, while Baystar was in the process of starting up a production unit at Pasadena, Texas, on the afternoon of Dec. 28, according to a flaring notification.

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.

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

Greenberg characterized spot PE prices as selling at deep discounts through December, and reported that transactional prices were well below levels reflecting the 9¢/lb increases reported by the major indices in 2023. Quoting November supply/demand results from the ACC (American Chemical Council), he reported, “PE production was almost identical to October, as reactors again ran just shy of 85% capacity and PE exports were above 2 billion pounds for the seventh straight month and comprised nearly 47% of total PE sales.”

In just over a year´s time, Microsoft will stop supporting Windows 10. I foresee that a lot of businesses (that tend to run slightly older hardware)...

Exhibitors and presenters at the plastics show emphasized 3D printing as a complement and aid to more traditional production processes.

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.

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.

In recent years, additive manufacturing (AM) has made significant strides in transforming traditional manufacturing processes. Among the various applications of 3D printing, micro additive manufacturing (Micro-AM) has emerged as a disruptive force in the production and prototyping of micro plastic products and components. This technology has the potential to revolutionise the way manufacturers design and manufacture miniature plastic parts for a wide range of industries, including electronics, medical devices, aerospace, and more.

How the development of new catalysts—notably metallocenes—paved the way for the development of material grades never before possible.

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.

Prices of the five commodity resins were heading into 2024 at a lower point, but typical moves to reverse the overall downward trend of the fourth quarter were underway. This was particularly the case for PE and PVC, with suppliers issuing early first quarter price hikes. Such attempts are facing slowed domestic and global demand, higher supplier inventories and generally lower prices of key feedstocks. PET resin prices might differ just a bit if key raw materials move up.

Polyethylene prices in December appear to have dropped by 3¢/lb while suppliers cancelled their 3¢/lb increases and issued new 5¢/lb increases for January, according to David Barry, PCW’s associate director for PE, PP and PS, The Plastics Exchange Greenberg, and resin pricing expert Robin Chesshier. They view this latest move by suppliers as intended to stop any further price erosion.

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Polystyrene prices dropped another 3¢/lb in December, following a 4¢/lb drop the previous month, but flat prices for the January-February time frame were ventured by both PCW’s Barry and resin pricing expert Robin Chesshier. This scenario is primarily attributed to improved benzene supply due to plenty of Asian and European imports underway. Barry did add that while there was a likelihood of January benzene contracts dropping 10-20¢/gal, it would translate to only 1-2¢/lb for PS resins.

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.

Multiple speakers at Molding 2023 will address the ways simulation can impact material substitution decisions, process profitability and simplification of mold design.

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.

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).

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

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.

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.

Join Engel in exploring the future of battery molding technology. Discover advancements in thermoplastic composites for battery housings, innovative automation solutions and the latest in large-tonnage equipment designed for e-mobility — all with a focus on cost-efficient solutions. Agenda: Learn about cutting-edge thermoplastic composites for durable, sustainable and cost-efficient battery housings Explore advanced automation concepts for efficient and scalable production See the latest large-tonnage equipment and technology innovations for e-mobility solutions

Coverage of single-use plastics can be both misleading and demoralizing. Here are 10 tips for changing the perception of the plastics industry at your company and in your community.

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.

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.

Compounders face a number of processing challenges when incorporating a high loading of low-bulk-density mineral filler into polyolefins. Here are some possible solutions.

DRST opens up the possibility of small and even medium and high-volume batch manufacturing depending upon part size and geometric complexity. Manufacturers can produce numerous replacement tools at extremely low cost. For the cost of one aluminium precise mould, which costs about $10K, it is possible to manufacture 500 soft moulds, each producing hundreds of shots, leading to large amounts of final parts through a significantly faster process. In addition, each tool can be adapted as required, opening up the possibility of speed to first part out, and the ability to correct during the manufacturing process according to market and customer needs.

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.

PVC resin prices dropped by another 1¢/lb in December, following a similar drop the previous month, but suppliers were out with January price increases ranging from 2¢/lb to 5¢/lb, according to Paul Pavlov, RTi’s v.p. of PP and PVC and PCW’s senior editor Donna Todd. The former ventured that prices in the January-February time frame were likely to remain flat, noting, “These price initiatives are a knee-jerk reaction and aimed at stemming the bleeding.” He saw potential for some uptick in March.

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.

Polypropylene prices in December were flat, in step with propylene monomer; this despite that the anticipated recovery of monomer tightness had yet to occur due to two unplanned shutdowns, according to PCW’s Barry, Spartan Polymers’ Newell and The Plastic Exchange’s Greenberg. Said Newell, “As long as monomer inventories remain tight, there’s some volatility.” He notes that domestic PP demand ended badly in 2023, and he expected suppliers would likely have to further cut production rates from the low 80s percentile to the mid-70s for an improved supply-demand scenario.

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.

This month’s resin pricing report includes PT’s quarterly check-in on select engineering resins, including nylon 6 and 66.

Across the show, sustainability ruled in new materials technology, from polyolefins and engineering resins to biobased materials.

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.

I tend to agree, based on my experience with every single piece of consumer electronic or electrical equipment I´ve purchased over the last 20 years...

With Micro-AM, designers are no longer constrained by the limitations of conventional machining or moulding processes, which often restrict the shapes and geometries that can be produced. Instead, Micro-AM enables the creation of highly intricate and complex designs, such as lattice structures, interlocking parts, and miniaturised features. This newfound design freedom empowers engineers and designers to explore unconventional concepts, experiment with novel shapes, and push the boundaries of what is possible. As a result, product development becomes an iterative and creative process, encouraging the generation of innovative ideas and driving the evolution of products and technologies.

PET prices in December dropped 1¢/lb, following drops of 2¢/lb and 4¢/lb the two previous months driven primarily by lower raw material formulation costs as well as seasonal slowed demand for PET in the Northern Hemisphere, according to Mark Kallman, RTi’s v.p. of PVC, PET and engineering resins. He anticipated a bit of a rebound in PET prices of 1¢/lb to 2¢/lb in the January-February time frame as a result of forecasted increases in key raw materials. Kallman continued to characterize the market going into first quarter as domestically well supplied along with continued attractively priced imports.

Some of the most advanced Micro-AM hardware systems available on the market enable designers and manufacturers to exploit the ability that exists through 3D printing to build complex parts in small, medium, and high volumes in a timely and cost-effective fashion.

While the major correction in PP prices was finally underway, generally stable pricing was anticipated for the other four commodity resins.

Reported Todd in December, “With January increases of 2¢/lb, 3¢/lb and 5¢/lb, customers were wondering how the price would be implemented and at what level.” She also noted that Westlake, with the lower price hike, announced that it would issue another price increase for February. “As such, it appeared that the January price uptick will be limited to 2¢/lb, with a further increase of undetermined size in the cards for February. Some PVC converters think the January price hike would be pushed back and implemented in February.”

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.

Historically, producing prototype runs of micro plastic products has involved expensive and time-consuming processes, such as micro-injection moulding or micro-machining. These traditional manufacturing processes typically require the creation of specialised moulds or tooling, making it impractical for small-scale production or rapid iteration. Micro-AM, however, introduces a cost-effective and “rapid” prototyping solution for micro plastic components.

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.

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.

This Knowledge Center provides an overview of the considerations needed to understand the purchase, operation, and maintenance of a process cooling system.

Ultradent's entry of its Umbrella cheek retractor took home the awards for Technical Sophistication and Achievement in Economics and Efficiency at PTXPO.

When, how, what and why to automate — leading robotics suppliers and forward-thinking moldmakers will share their insights on automating manufacturing at collocated event.

Citing ACC results going into December, Greenberg reported that PP suppliers ran their reactor a bit higher in November, at about 80%. He noted that exports were a bit stronger, but representing only 6.6% of sales. “Domestic processors were turned off by the steep cost-push price increase last month (November) and slowed their purchases to only 96.5% of the trailing 12-month average,” Greenberg added. “Total production outstripped the weak sales and consequently, upstream inventories built for the second straight month back to levels not seen since April.”

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.

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.

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

Additive technology creates air pockets in film during orientation, cutting down on the amount of resin needed while boosting opacity, mechanical properties and recyclability.

PCW’s Barry, somewhat in contrast, ventured further price correction of PP and the monomer through January and February, noting that spot monomer prices were well below contract prices and that domestic PP resin tabs were still too high compared to global prices. Characterizing 2024 as a year of “market share battles,” he reports that with no anticipated near-term uptick in demand, some traders were positioning for PP prices to move lower in first quarter.

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.

DRST unlocks new business possibilities for mould makers and manufacturers who up until this point have been restricted to the use of long lead time and expensive traditionally manufactured mould tools for the achievement of any volume of moulding, from prototype runs all the way through to mass manufacture. Positive results today stimulate the business case for a process chain that includes DRST, with a dramatically shorter lead time of around a few hours from file to injected part and at costs reduced from thousands of dollars to tens.

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.

Chesshier ventures that PE prices in January-February could either be flat but with potential for an increase, particularly if the exports market strengthens. Similarly, Barry saw potential for an increase, as he expected exports to pick up, but was not quite certain of domestic demand. He noted that processors had stocked up due to lower pricing at the end of 2023. These sources also point to the impact of new capacity, particularly from major new player Shell as well as NOVA Chemicals and Baystar, leading Barry to say, “2024 will see a “market share battle.”

Core Technology Molding turned to Mold-Masters E-Multi auxiliary injection unit to help it win a job and dramatically change its process.

While price initiatives for PE and PVC were underway, resin prices had rollover potential for first two months of 2024, perhaps with the exception of PET.

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.

Micro-AM's ability to produce functional prototypes with complex geometries also facilitates the validation of designs before full-scale production. Engineers can test various designs, dimensions, and tolerances without incurring substantial costs or long lead times. This iterative approach enhances the quality and reliability of final products by identifying and rectifying potential issues at the early stages of development.

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.

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.

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.

By reducing the time spent on traditional manufacturing setup and tooling, Micro-AM minimises production delays. This capability is particularly valuable in industries where fast response times are crucial, such as consumer electronics and aerospace, enabling companies to bring products to market swiftly and efficiently. Micro-AM also enables "just-in-time" production, where components are fabricated exactly when and where they are needed. This lean manufacturing approach reduces the need for extensive inventory management, leading to cost savings and improved supply chain efficiency.

It is usually the case that when AM produced DRST and traditional injection moulding are compared, the savings in terms of product development time and cost are seen as the most compelling benefits for using AM. However, the fact that AM is agnostic to complexity means that AM produced DRST could also stimulate innovation in product design and manufacture. As mentioned, AM can achieve very complex geometries at zero added cost and geometries impossible using conventional processes, and as such is positioned as a key enabling technology driving the production of cutting-edge products as well as shortening the product development cycle. This is because it is quite often the case that product design updates are shelved by manufacturers due to the cost of new traditional moulds.

The time and cost associated with the fabrication of conventional micro tooling for micro injection moulding has led to a sustained focus on the creation of Micro-AM produced DRST for short run production parts and functional prototypes. Indeed, via our own Fabrica line of 3D printers, we have fine-tuned the manufacture of DRST through a combination of design optimisation, material improvements in respect of temperature resistance and strength, and process improvements (focusing on improving the impact pressure and stiffness of the printed soft tool). The aim is the handling of tougher injection conditions and a bigger array of injected materials.

A collaboration between show organizer PLASTICS, recycler CPR and size reduction experts WEIMA and Conair recovered and recycled all production scrap at NPE2024.

These are the views of purchasing consultants from Resin Technology Inc. (RTi), senior analysts from Houston-based PetroChemWire (PCW), CEO Michael Greenberg of The Plastics Exchange, Scott Newell, executive v.p.  polyolefins at distributor/compounder Spartan Polymers, and resin pricing expert Robin Chesshier.

Some industry insiders anticipate the first quarter may well see commodity resin prices relatively flat and perhaps a bit down. Certainly in the case of PE and PP, some of these pros see 2024, at least for the first half, as being a buyer’s market or as one put it — “anticipate market share battles.”

Furthermore, Micro-AM facilitates the production of custom designs tailored to specific applications, enabling personalised solutions that were previously unfeasible. This customisation potential extends to a wide range of industries. In electronics, for example, custom Micro-AM components can be designed to fit complex electronic assemblies or integrate seamlessly into miniaturised devices. This design freedom fosters a culture of innovation, where products can be optimised for specific purposes, leading to enhanced performance, efficiency, and user experience.

Plastics Technology covers technical and business Information for Plastics Processors in Injection Molding, Extrusion, Blow Molding, Plastic Additives, Compounding, Plastic Materials, and Resin Pricing. About Us

With Micro Additive Manufacturing continuing to establish itself as the go-to technology option for manufacturers, Ziki Peled, GM – Additive Division at Nano Dimension, looks at its potential to transform the way miniature polymer parts are designed and produced.

In some highly competitive market niches, time-to-market is a critical factor for success. Micro-AM expedites the product development and manufacturing process, giving companies a competitive edge. As micro-AM allows for rapid prototyping and low-volume production on-demand, companies can quickly respond to changing market demands and emerging trends.