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Author：gly Date: 2024-09-30

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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

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.

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

In terms of physical space, individual employees and machine fleet, the two groups in this year’s benchmarking survey were virtually indistinguishable. The average floor space of a Top Shops entrant was 88,184 ft2, with the rest averaging 79,614 ft2. Total employees at Top Shops averaged 95 vs. 98 at other entrants, with workers directly involved in plant-floor operations coming in at 73 for Top Shops and 78 at all others.

Toshiba used two new 45-ton ECNII electric models to produce a golf-green repair tool of PBT overmolded with a soft-touch skin of self-adhesive LSR. A Toshiba SCARA robot transferred the part from machine to machine.

Niigata upgraded its MDVs-IV and MDVRs-IV lines of vertical all-electric presses (55 to 110 tons) with new software that enhances speed, responsiveness, and precision. Shuttle or rotary table response is improved 20% and table oscillation is down 20%. For lens molding, the presses can maintain injection speeds as low as 0.01 mm/sec and resin pressures down to 14.5 psi. A new nozzle-temperature control reportedly eliminates “cobwebs,” drool, and plugged nozzles. The operator panel is now a larger touchscreen with new screen layouts. The new injection unit features a wear-resistant screw tip.

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.

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.

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

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

PBT polyester was molded with a new self-adhesive LSR material on a 110-ton Engel electric E-motion Combi US. Integrated robotics transferred the part from the first to the second cavity.

At the start of 2021, as it does every year, Plastics Technology asked injection molders to look back on the year prior and take stock of their operations. The only difference this time: COVID-19.

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

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).

Exhibits in Chicago testified not only to the growing popularity of liquid silicone (LSR) injection molding but also to multi-shot molding of LSR with thermoplastics. Arburg molded ice scrapers from a self-adhesive LSR and PC on an 88-ton Allrounder A electric machine.

Engel has entered the field of direct in-line compounding and molding of long-glass thermoplastics by integrating PlastiComp’s Pushtrusion system atop an Engel machine. The device melts resin and then wets out continuous glass rovings, which are chopped and fed to the injection cylinder below.

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.

Husky also upgraded the CoolPik robot on its HyPET preform systems. The bladder-type transfer system was replaced by a vacuum transfer system to reduce maintenance and ease setup.

The new industrial event from the publisher of Plastics Technology will feature data, sourcing and technology updates for manufacturing businesses, including injection molders.

On the injection side, this firm deploys all-electric presses with integrated parts-handling robots and machine-monitoring systems that can run unattended. “We also mounted cameras strategically throughout our facility so remote operators can log in from their phones.”

Engel molded a two-color sunroof panel using its Glazemelt technology on a Duo 1650 US Combi-M machine. Unlike Milacron, Engel used a rotary stack tool from INglass of Italy.

Husky introduced its new HyPac line for thin-wall applications. The series will range from 300 to 600 tons and features several new technologies, including the new Ultra Packaging (UP) hot-runner system. A new direct-drive electric injection unit boosts acceleration rates to twice the industry standard, and maximum speed is 30% higher (300 g/sec), which allows for 10% lighter parts. There is also a new fast-acting pneumatic pin shutoff.

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.

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.

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.

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.

A smaller 720-ton electric unit demonstrated high-speed packaging at the show by producing a 20-liter container in under 8 sec.

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

Machine shops are natural inventors, but not necessarily suited to supporting and marketing a product. This Minnesota shop with an invention related to micromolding will share it through licensing.

Because of the wrinkle of the global pandemic, or perhaps in spite of it, Plastics Technology’s annual Top Shops survey received its best-ever response as injection molders seemed anxious to take a deep dive into operations that stayed open as essential businesses, while other segments of the broader economy faltered.

Meetings may be the bane of many in the business world, and certainly the running butt of a slew of jokes, but the communication, goal setting and goal measuring that well-designed and organized meetings facilitate are very much a part of Top Shops’ winning strategies.

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.

Ube Machinery said it is now offering its largest all-electrics (the biggest in the industry) in the U.S. Introduced last fall in Japan, the Ultima UN 2750- and 3300-ton models have up to eight servo motors and up to 400 oz shot size. The 3300-tonner was built to mold bumper fascias in under 30 sec.

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

NPE was also the North American debut for Krauss-Maffei’s Injection Molding Compounder (IMC) with a twin-screw extruder mounted over the injection press, which was first introduced at K 2001 in Germany. The 1000-ton system produced an automotive front-end carrier using 30% long-glass PP. Krauss-Maffei has sold more than 30 units globally, 10 of them for North American plants. Most systems are of 2700 to 3200 tons, though K-M is working on a 4000-tonner. Major applications are structural auto parts and shipping pallets.

While the melting process does not provide perfect mixing, this study shows that mixing is indeed initiated during melting.

As reported in April, Arburg’s Allrounder C Golden Edition of horizontal hydraulic presses features improved controls and valve technology for greater accuracy. Sized from 44 to 220 tons, they have the “Selogica direct” controller with new 15-in. color touchscreen instead of a keypad.

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.

Engel showed a 300-ton model of its new Engel Speed accumulator-assisted hydraulic toggle series designed expressly for packaging. Engel will add a 440-tonner in the fall, followed next year with 550- and 710-ton units. They have a redesigned base, toggle, and moving platen.

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

Cincinnati Milacron rolled out the sixth generation of its Magna hydraulic toggle machine. The Magna MTg comes in four sizes from 170 to 450 tons and has a new injection unit, new hydraulics that are easy to service, new Mosaic control, and a compact footprint with fast-lockover clamp. It is designed for fast set-up and changeover. Proportional hydraulics yield a positioning accuracy of ±0.0014 in.

While this is technically a survey of injection molders, in reality, nearly all of its participants are more accurately described as contract manufacturers. A purchase order for molding a single component dropped from the cavity with nothing else done to it—inspection, decoration, assembly, packaging—is most definitely not the business model for today’s molders. Fully 78% of Top Shops and 81% of other shops provide assembly for customers, with 70% of Top Shops and 60% of the remaining survey respondents offering customers collaborative design services. Where Top Shops go even further is in shipping/packaging/labeling, with 87% of our honorees providing those services, compared with 66% of others.

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.

Compounding in-line with injection in order to incorporate longer glass fibers and reduce material cost was demonstrated by two machinery OEMs. Both systems involve a twin-screw compounder mounted on top of an injection machine. The twin screws pull in and chop continuous glass rovings. Husky has revived its development of this technology through cooperation with twin-screw extruder supplier Coperion Werner & Pfleiderer. Husky’s In-Line Compounding (ILC) cell mounts a Coperion ZSK70 extruder on a 2500-ton Quadloc two-platen press with a hot-runner system and robot.

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.

MHI also extended the size range of its direct-drive, all-electric MEII toggle series with a new 720-tonner that replaces a 610-ton model. It has two servomotors directly coupled to the injection screw. An on-board hydraulic power supply is used for nozzle-touch, core-pull, and valve-gate functions.

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

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.

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.

Fully 83% of Top Shops and 80% of other shops experienced a skills gap in 2020, with all participants looking to address the issue, just in different ways. On the people side, Top Shops outstripped other respondents in flexible schedules, mentor programs, and outreach at local schools by 18, eight and 26 percentage points, respectively. As for partnering with area schools for open houses or staff recruitment, 64% of Top Shops took that step, while only 28% of the other respondents did so.

Molders found more new choices in hybrid machines at the show. Toshiba announced its new ED two-platen series which ranges from 720 to 1950 tons.

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

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.

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.

The system is an alternative to the use of pre-compounded long-glass pellets. ILC allows flexibility in the material formulation, as well as improved mechanical properties at reduced material cost, says Jeff McDonald, Husky’s automotive v.p. A system is installed at a global Tier I automotive supplier. It can produce front-end modules, door-module carriers, and instrument-panel carriers.

“We listen to each others’ ideas to make the best choices and become closer as a team,” IEMSA’s Salazar says. “We also allow doubts and mistakes to happen—we let the learning process be part of our daily life—always taking care of the situation and solving the issues.”

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.

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.

“We think our coworkers have a feel for how our operation is doing and strive to maintain a high level of engagement in operational efficiency and quality,” Porter says, noting that PlastiCert has a monthly “all coworker” meeting, which has become two meetings an hour apart as the business grows. In these meetings, leadership communicates revenue trends, areas of operational interest, new internal developments, and items of interest in the surrounding community. “We also pick a customer to tell workers more about how what we do for that customer contributes to its mission,” Porter says.

Sumitomo introduced its mid-sized SE-HD line of all-electrics for heavy-duty applications such as thick-wall parts. These U.S.-built presses can handle long holding pressures at up to 31,718 psi. Sumitomo’s new SE-HS line of mid-sized all-electrics is suited to high-speed, thin-wall parts requiring a cycle time under 15 sec. It ranges from 242 to 385 tons and features injection speeds of 300 mm/sec and 25-millisec response. A new twin cylinder delivers high nozzle-touch force, with 0.3-sec pressurization or depressurization. It has the new SM screw for low-shear plastication and a constant-feedback clamp-force correcting system.

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.

As for their fleets’ clamp-force ranges, Top Shops and other entrants tracked closely in the 0-100, 101-500, and 501-1000-ton ranges, but only 9% of Top Shops utilized machines over 1000 tons, vs. 15% of other entrants. Top Shops also offered more specialty injection molding technologies, outstripping other entrants in providing two-shot, gas/water-assist, in-mold label and insert molding.

The glass-filled, high-flow PBT/ASA carrier is shot first, and then the mold is rotated for injection of the second material in a “negative coining” (mold expansion) step with Engel’s Coinmelt process. The mold-opening stroke determines the thickness of foaming and hardness of the surface.

In-mold demonstrations abounded at NPE. Ferromatik Milacron demonstrated two-component molding and in-mold assembly of PP dispenser caps on a 275-ton K-Tec machine with a 48-cavity Foboha twin-turning-cube stack mold. Moldmaker Electroform showed off two-shot molding with black and white ABS, in-mold film decorating, and in-mold assembly. Its new tooling with twin rotating turrets ran on a 200-ton Engel tiebarless machine where it molded and snapped together the top, bottom, and four wheels of this model race car.

Two mammoth hybrid-electric machines, both with four direct-drive electric motors on the injection unit, were announced by Mitsubishi Heavy Industries (MHI) of Japan. As we reported last month, its 3300- and 3900-ton “em” models of hybrid-clamp, two-platen presses use low-speed/high-torque electric motors coupled directly to the ball screws.

Sodick Plustech Co. of Japan (represented here by Plustech, Inc.) offers its LSR series of machines in 44 and 88 tons. These hybrids have two-stage injection and hydraulic clamp.

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

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.

Taking an opposite tack, Demag demonstrated overmolding of dissimilar materials chosen so that they would not adhere to each other. Demag’s 120-ton Multi machine with two injection units produced a magnifying glass with protective case from optical-grade PC and glass-filled nylon. The two materials are combined by a flip hinge, and ran in a two-cavity mold with indexing plate in 20 sec. When cooled, the two materials do not stick, so the magnifying glass can rotate in and out of the case on pin-type hinges.

Nissei introduced a new all-electric press specially engineered for two-color or dissimilar materials. A horizontal 154-ton DCE140-9E Elject model with a servo-driven rotary table employs a new “shockless” rotation mechanism for higher precision and longer life. It indexes 180° in 0.9 sec. It uses two NEX-style electric injectors arranged side by side and a toggle clamp. Simultaneous motions allowed molding a two-color mug in two cavities in a 20-sec cycle. The system also has a new high-performance mold protection function.

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

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.

Looking more deeply into the numbers, while the Top Shops and the other respondents were very close in average fleet size, the presses on Top Shops’ floors had considerably less miles on them, boasting an average age of nine years compared with 14. The Top Shops ran horizontal machines exclusively, while 9% of the other facilities also had vertical presses in their plants. Top Shops operated slightly fewer hydraulic machines (62% vs. 71%) than other survey entrants; and far more all-electric presses (65% vs. 50%) and hybrid (50% vs. 26%) machines.

Markets served for both groups largely mirror each other, except for two sectors: medical/healthcare and building/construction. While 74% of the other respondents serve the building/construction market, only 35% of Top Shops generate business from it. And 74% of Top Shops have medical customers, vs. 54% of other survey respondents.

Krauss-Maffei showed its all-electric EX series for the first time in the U.S. The direct-drive injection unit provides up to 300 mm/sec speeds, and its three-platen, modified toggle clamp has just eight pivot points—half those of a conventional five-point toggle—bringing compactness and precision. The water-cooled motors reportedly can handle long holding pressure.

Negri Bossi rolled out its new 1500-ton Bi-Power two-platen hybrid model featuring electric injection, hydraulic clamping, and two traversing cylinders on the moving platen. A low profile and compact footprint allows for easier clamp access and integration of automation.

Milacron publicly demonstrated molding of automotive glazing for the first time, using a standard Maxima MG 1100 two-platen press. It injection-compression molded a fixed sidelight from clear polycarbonate overmolded with a black PC frame. The second injector was mounted on an angled sled affixed to the stationary platen above the primary unit. The system was done in partnership with Exatec, LLC, Wixom, Mich., which provided the mold with a retractable core. Shot weights were 2.15 lb for the clear PC and 8.4 oz for the black frame.

Plasticomp offers a portable Pushtrusion unit as a separate device, but Engel’s integrated system is said to have advantages: integrated control from the Engel operator panel and lower cost and smaller footprint since no separate power supply is needed for the Pushtrusion device.

Fully 70% of Top Shops perform regular, formal business reviews, compared with 54% of others, with 83% of Top Shops applying business-metric goal setting vs. 42% of others. And 87% of Top Shops have regular management meetings, compared with just 63% of others.

As we reported in June, at least 20 machinery suppliers exhibited systems for in-mold labeling and decorating (IML and IMD), anticipating growth of those technologies in North America. (IML, in particular, is already widespread in Europe.) A number of exhibits went for maximum visual impact in IML with lenticular films (in many cases supplied by Xtreme Graphics) that give a 3D animated effect. However, the most dramatic demonstrations were combinations of multi-shot molding with in-mold assembly and, in one case, IMD too. These applications showed off the multi-functional flexibility of stack-type molds with one or more rotating turrets between the fixed and moving platens.

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.

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

Chen Hsong of Taiwan announced that it had developed a press series with a direct-drive electric injection system and hybrid clamp. An electric inverter motor is used for plasticating. The first model is the SM-180HC with 180-ton clamp. The company also plans to launch soon a new 460-ton hybrid with servo-electric plasticating and injection.

A new factor in direct in-line long-fiber compounding and molding is Engel, which is now working with PlastiComp to offer PlastiComp’s patented Pushtrusion technology on Engel’s Combi press (licenses are included in the purchase).

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.

Nissei debuted its new FNX presses with servomotor-driven, variable-volume hydraulic X-Pump. Machine sizes are 88 to 198 tons. They use the same direct hydraulic clamp as Nissei’s FN series. The hybrid design delivers the combined capabilities of hydraulic clamping with most of the energy savings, quick response, high position repeatability, and fast injection of an all-electric. Injection response is 40 millisec, and maximum injection speed is 300 mm/sec standard. The servo motor runs the pump only when needed, requiring 55% less oil and 40% less energy than Nissei’s fully hydraulic FN units. Part-weight variation with FNX is only one-third as much as with the FN series.

Netstal pushed the limits in PET preform molding with its Pet-Line 660-ton machine running the first 192-cavity tool capable of a 7.3-sec cycle—90,000 preforms/hr. The tool comes from MHT in Germany and employs a narrow-pitch technology that reduces cavity spacing. Netstal has sold one 192-cavity system.

Ningbo Haitian Group of China, known in the U.S. now as Absolute Haitian, also introduced its first all-electric line—HTD machines from 64 to 396 tons. Injection speed is 150 mm/sec standard, 300 mm/sec optional.

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.

On the equipment side, the average fleet size for Top Shops and the other respondents registered at 21 and 20 injection molding machines, respectively. So, we are looking at basically the same amount of workers utilizing the same amount of machines in the same amount of space for the two groups, but there are also some key differences.

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.

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

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.

A nearly identical number of all survey participants said their facilities featured an in-house tool room (78% of Top Shops and 77% of all others), with both groups utilizing them in equal measure for mold building (rather than just repairs)—44% of Top Shops and 41% of other entrants. While 36% of Top Shops’ molds featured hot runners, only 22% of tools at the other facilities applied this technology. Only 9% of the Top Shops’ tools and 8% of the other entrants’ molds had more than 16 cavities.

The Boy XS E, successor to the XS series, features servodriven pump drives and different clamp configurations, as well as a special mold holder for optional micromolding operation.

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

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.

The Pushtrusion Direct In-Line Compounding unit is a small extruder unit and glass-roving feed system that is mounted atop the feed throat of the primary injection press. The system melts the resin and forces it through the Pushtrusion die, where it wets out continuous glass rovings. The melt pressure coming through the die pushes the glass into the system, where an internal knife chops the material to desired lengths of 2 to 10 mm. The chopped material is fed into the throat of the Engel press fitted with a special screw designed for low shear and little mixing.

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.

Materials run by our survey entrants largely tracked along similar lines, with other shops running slightly more polyolefins than Top Shops (63% to 52%), while Top Shops processed more engineering resins (87% to 76%). Only in LSR and bioplastics was the gap noticeably wide, with 9% of Top Shops running LSR and 17% bioplastics, compared with 2% and 7%, respectively, for other plants.

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

Dima also announced its new DCI series of vertical-clamp/horizontal-injection presses in sizes from 35 to 70 tons. Two machines can be mounted on one rotary table for multi-shot uses.

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.

Husky challenged this achievement with a new and larger model of HyPET preform machine and unveiled the world’s largest PET perform mold, a 216-cavity tool that it developed in partnership with Amcor PET Packaging. Husky’s new 715-ton HyPET 650 model features a new injection unit capable of throughputs up to 3960 lb/hr. The mold makes PET preforms with thread diam. up to 30 mm. It is configured with 60-mm spacing between the cavities rather than the 50-mm pitch common to molds for this size of preform. The larger-pitch allows for a more rugged and longer-lasting design, Husky says.

As reported in April, Negri Bossi USA launched its new Canbel VE all-electric machine series of 77 to 935 tons, redesigned and upgraded from its previous Elma line for faster injection, more precise and repeatable movements, and reduced maintenance. Negri Bossi now also uses direct drive on the toggle clamp and injection unit of all sizes (previously only on smaller models). Direct drive provides higher clamp speeds than before on the larger presses.

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

Sumitomo rolled out a 7.7-ton all-electric unit for micro-molding. The SE7M has direct drive on the toggle clamp, plasticating, and ejection. New control software reportedly delivers 25-millisec response. New synchro-plast control mode for screw position and backpressure can be used with low-viscosity resins or uneven pellet sizes. At the show, the machine molded 0.035-g connectors from LCP in four cavities with a 3.3-sec cycle.

Boy introduced its 60.5-ton 55 Ae model with servo-electric plastication and hydraulic injection and clamping. Its dual hydraulic pumps permit ejection on the fly for 10% faster cycles.

Husky introduced other HyPET improvements that reportedly trim cycle times up to 25% compared with three years ago. These include improved in-mold and post-mold cooling (through the addition of a fourth stage of cooling) plus faster dry cycling and hot-runner refinements. For example, a HyPET 300 system produced a 14.5-g preform for a 500-cc water bottle in a 72-cavity mold in 6.5 sec, while a HyPET 500 molded a 20-oz carbonated soft-drink bottle in a 144-cavity mold in 10.5 sec.

Niigata also developed the MD-W series, similar to the MD-X but in 200- and 385-ton sizes with 11% wider tiebar spacing and 100- to 110-mm increase in minimum mold height.

Engel also rolled out its new CC200 touchscreen controller. It features an intuitive control panel, said to permit faster initial set-up and synchronized movements. All Engel automation is fully integrated into the control using the RC 200 robot control.

Krauss-Maffei showed its new CX line of two-platen machines in 385, 880, and 1760 tons, which replace its C series. Clamp length is 30% shorter, and it has improved hydraulics for better performance. Access to the clamp is easier, too. The CX line has an electric screw drive as standard. For clean-room applications, CX models incorporate a new drive system that retracts the clamping unit from the clean room for mold changing or maintenance. In addition, K-M’s new MC 5 control is standard.

While the melting process does not provide perfect mixing, this study shows that mixing is indeed initiated during melting.

Nissei upgraded its FN series of fully hydraulic presses with a longer screw and barrel, optimized hydraulics, reduced sliding resistance, and the TACT controller for high-speed injection control and repeatability. There is also a new oil heat-up function to ensure quick starts. The upgrade results in one-third shorter set-up time, 50% less part-weight deviation, and 30% energy savings. Eight models range from 89 to 501 tons.

In-mold technologies for labeling, decorating, painting, and assembly were another major theme at NPE. Another was the integration of long-fiber compounding and injection into a single machine as a way to combat rising materials costs. Other timely market needs were addressed by the latest developments in automotive glazing, multi-component presses, and higher-volume PET preform systems.

Netstal and Husky pushed the productivity limits for PET preform molding: Netstal operated a new 192-cavity mold in a Pet-Line machine, and Husky displayed a brand-new 216-cavity tool.

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

The 2019 Plastics Technology Top Shops Survey shows that for its highest-rated respondents, injection molding is just one element in a growing suite of services and capabilities offered to customers.

Where the gap between the groups widens further is the volume of resins processed, with Top Shops nearly doubling the other entrants’ poundage, running an average of 22.3 million lb of material in 2020 vs. 12.5 million lb average for the others. In addition to more material, our honorees processed more kinds of resins. Top Shops ran an average of 43 different material categories, compared to 18 for the remaining survey participants.

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

With advocacy, communication and sustainability as three main pillars, Seaholm leads a trade association to NPE that ‘is more active today than we have ever been.’

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

And for a totally different type of in-mold finishing, Ube Machinery announced that the first U.S. machine with its new Imprest in-mold painting technology (developed with Sherwin-Williams) will arrive next spring for a large, non-automotive application. In Japan, Ube has sold several in-mold painting systems for automotive and appliance jobs. The system was developed for ABS, but Ube and Sherwin-Williams are testing nylon and PP.

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

Processors with sustainability goals or mandates have a number of ways to reach their goals. Biopolymers are among them.

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

Those challenges, just like the virus, didn’t stop at the border. Aida Cecilia Mercado Salazar of Mexican Top Shop molder and moldmaker IEMSA in San Luis Potosi, said her company had to adapt to and embrace how the pandemic changed day-to-day life and work. “The first big challenge was to get used to the new normal,” Salazar says, citing the two most recognizable aspects of the pandemic: masks and uncertainty. “In the beginning, we were scared because we didn’t know how safe we actually were.” Ultimately, IEMSA, like so many of the molders we surveyed, never halted operations and came through the crisis even stronger. “We became a closer team, and because of that trust it was easier to overcome the challenges in the way.”

PRD’s Murphy says his company has thrown people and automation at the skills gap, which is “by far the biggest challenge. We have implemented automation where possible, increased wages, and gone out of our way to ensure our employees know how much we appreciate them,” including discretionary bonuses. “Unfortunately, I don’t hear anyone with a good answer to the predicament we find ourselves in. Everyone talks about the end of extra unemployment benefits, and while they do not help the situation, I am not convinced this well be the solution.”

Start by picking a target melt temperature, and double-check data sheets for the resin supplier’s recommendations. Now for the rest...

A 110-ton model at the show molded polycarbonate light guides 0.4-mm thick x 2.7 in. long using its optional 400-mm/sec injection speed with injection response time under 38 millisec. A 180-ton ECNII-4A showed a new LAP feature for overlapping molding functions to shorten cycle times. It produced PP coasters in a four-cavity mold in under 5.5 sec. A 20-tonner molded thin-wall (0.4-mm) PC parts using optional 550-mm/sec injection speed.

Sumitomo introduced its SE-DU line of U.S.-built direct-drive all-electrics from 20 to 198 tons. They use four direct-drive Sumitomo AC servo motors with closed-loop control and digital sensors for plasticating, injection, toggle clamping, and ejection. New PC-based N-9 control provides faster response, full SPC/SQC, and machine-optimization functions.

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.

Nissei applied its X-Pump technology to its new vertical hybrid machine, the 118-ton Ecoject TNS100RE18E with horizontal injection, hydraulic three-tiebar clamp, and high-speed rotary table (180° in 1.6 sec). All operations except clamping and nozzle touch are electric. TNS models less than 75 tons will remain all-electric.

Thousands of people visit our Supplier Guide every day to source equipment and materials. Get in front of them with a free company profile.

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

Now in its fifth year, this benchmarking survey of injection molders queries participants on demographic data, performance indicators, and business and process strategies. A selection of those performance metrics are then scored, with the highest scoring companies named Top Shops for 2021 based on their 2020 operations. The Top Shops display some stark contrasts with all other entrants, but in many ways they are quite similar.

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

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

Milacron rolled out vertical/vertical Magna V machines from 15 to 130 tons. Offered in stationary, shuttle, or rotary-table designs, they have a C-frame clamp, digital positioning, and overlapping functions for maximum speed and precision.

In addition, Demag Plastic Group offers a direct-drive injection unit with certain sizes of its IntElect electric press.

Meiki America molded a prototype two-component roof panel on a new a 3400-ton model in its Meiki Dynamic Injection Press (MDIP) series for large, thin-wall parts. The press was designed in cooperation with Japan’s Teijin Chemicals, which makes special PC grades for auto glazing. The MDIP-2100-HR2 is said to be the world’s largest two-component rotary injection-compression machine. Platen parallelism is said to be within ±25 microns. Platen movements are controlled with hydraulic servo valves. The machine has 2100 x 2100 mm tiebar spacing and the 1900 x 1900 mm rotary table is indexed hydraulically.

Milacron’s Powerline NT550 all-electric press at the show featured a new high-capacity (54-oz) direct-drive injection unit. It uses a single roller-screw to reduce noise and inertia and eliminates having to synchronize two actuators. It is also five times faster than a ball screw, and delivers up to 20,600 psi at 41 in.3/sec with certain screw designs. A servo motor drives the toggle clamp and allows the toggle to relax during part cooling to eliminate the wait for tonnage release before opening the clamp. Other features include Milacron’s new Mosaic control, the global standard now for all Milacron presses, as we reported in June.

Sumitomo also introduced the iii-System, its new real-time production and quality monitoring system. Up to 50 machines can be connected, and the unit can store up to 60,000 shots of data and burn it onto a CD or DVD.

Meanwhile, Boy introduced to the U.S. its new 60.5-ton 55 M VV vertical/vertical hydraulic machine. It has Boy’s standard two-platen clamp turned 90°, shot weights up to 5.6 oz, and Procan CT color touchscreen control.

In fact, average plant-floor employee age, plastics/manufacturing experience, turnover rate and hourly wages were nearly identical for all survey participants—41/40 yrs; 17/16 yrs; 17/16% ; and $17/$16—for Top Shops/Others in all those categories, respectively.

“We are very open and honest with our employees and communicate frequently on the state of our business and outlook,” Murphy says. “We have always had a great culture at PRD where everyone feels like family. For some it is just a job, but many feel ownership and accountability for our success. We try to provide clear production goals, learn from our mistakes and celebrate our successes.”

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.

NPE2024: Wittmann is featuring five injection molding machines incorporating its range of robotics and auxiliaries, with all products employing industry 4.0 communications, energy measurement and a brand-new red color.

Milacron rolled out a new Fanuc Roboshot S2000i-B series from 55 to 330 tons featuring 330-mm/sec injection speed with 36-millisec response standard. A new moving-platen design produces more equal pressure distribution across the mold face. Fanuc’s new 310iS CNC control is said to deliver faster control, higher acceleration, faster injection, and simultaneous sled-forward and clamp-close motions. A 110-ton model at the show demonstrated a coining process to produce ultra-thin-wall medical parts.

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

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.

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.

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.

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.

Nissei also unveiled the AN1 series prototype hybrid press based on its NEX all-electric toggle press but using the hydraulic X-Pump for plasticating. It is designed for high-speed plasticating and fast-cycle molding of PP and PE. Sizes will be 300 to 500 tons. A 397-ton AN1 model at the show molded thin-walled PP lids in a 16-cavity tool in 4.9 sec. The X-Pump raised the plasticating rate to 794 lb/hr, 70% higher than a standard NEX unit.

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.

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

Toshiba’s new ECNII line of all-electric machines have a new low-inertia injection motor and mechanism for quick response. Like the ECN series the size range is from 5 to 950 tons, but the toggle clamp has been improved for “shockless” opening/closing and the new Injectvisor-V30 controller has touchscreen data entry and expanded memory to store data on up to 300 molds and 1000 shots.

Netstal’s new Elion all-electric press made its U.S. debut. The new line will be offered initially in four models from 55 to about 200 tons. They feature a new toggle-clamp design that makes the ma chine considerably shorter and has closed-circuit, oil-free lubrication. A new “combi” gearbox integrates plastication and injection functions into a single transmission. Three different plasticating systems are offered: high-speed, high-torque, or a blend of the two. The unit can deliver injection speeds of 250 to 450 mm/sec, depending on which option is selected. The moving platen rests on a new linear guide system rather than the tiebars. Netstal says the machine achieves a dry-cycle time of 1.2 to 1.4 sec. Elion also uses Netstal’s DSP/3 and Sycap closed-loop control with 15-in. flat-screen touch panel.

Niigata’s new MD-X series of all-electric toggles comes in 55, 85, and 110 tons. The new injection unit, servomotor, and control reportedly allow holding pressures as long as 60 to 100 sec at 19,575 psi for molding thick parts. Injection response time is 55 millisec.

Five industry pros with more than 200 years of combined molding experience provide step-by-step best practices on mounting a mold in a horizontal injection molding machine.

A still more elaborate demonstration by moldmaker Electroform showed off its brand-new twin-turret tooling technology by combining two-shot molding, IMD, and in-mold assembly of a toy race car. Using a 200-ton Engel tiebarless machine, the process starts with robotic insertion of a preprinted, preformed ABS film from Serigraph into the mold cavity. That film is backed up with injection of white ABS to form the top of the car. Black ABS is injected separately to mold the bottom chassis and four wheels. Then all six parts are snap-fitted together in the mold. Moving slides are used to snap on the wheels perpendicular to the direction of joining the car’s top and bottom halves. Cycle time at the show was 22 sec, but Electroform president Wade Clark hopes to get that down to 15-16 sec.

The FNX model also demonstrates a new Nissei concept called “Eco Molding” that uses the X-Pump to automatically adjust clamp force to just the amount needed to counteract the filling pressure. This saves energy by avoiding over-clamping and prevents flash from under-clamping. The concept allows for bigger parts to be molded on smaller machines, says Nissei president Hozumi Yoda.

PlastiCert’s Porter says his company’s location in a small, rural farming community in Minnesota situated between two large cities equates to a shallow talent pool. Its answer to that geographic challenge: “First and foremost, we have created a desirable and accommodating workplace environment, resulting in turnover being practically negligible,” Porter says. The company has also sought to raise its visibility in the community and to partner with a nearby state university for a stream of interns.

Engel also demonstrated integration of RJG’s eDart process monitor with the CC200 controller—the first such move by an injection machine OEM. This allows users to program separate profiles for the three phases of filling, packing, and holding and to use cavity-pressure monitoring as the changeover between the phases. RJG eDart screens appear on the CC 200 display.

MHI rolled out the next generation of its MetII all-electric series, ranging from 35 to 300 tons. It incorporates Super Resin Control (SRC) II metering system, which ensures consistent part weight and density by applying packing pressure to the melt with the screw after recovery.

“The biggest challenge was the unknown,” explains Mark Murphy, president of molder and moldmaker PRD Inc. in Springville, Ind.—one of PT’s 23 newest Top Shops. “We had gone for so many years with growing sales and a growing economy. We knew this could probably be the event that brought it all to a halt.”

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

On the non-people or robotic side, 52% of Top Shops increased automation in 2020, compared with 35% of the rest of the shops surveyed. Those investments add to an already sizable fleet of robots for top shops, fully 96% of whom said their facilities used automation, compared with 68% of others.

Battenfeld introduced its upgraded HM series two-platen presses, showing 28- and 450-ton models. Upgrades include injection pressures up to 42,630 psi and injection speeds up to 300 mm/sec.Demag beefed up its Titan two-platen line with new 1500- and 1760-ton models.

New electric vertical presses and models for LSR, multi-component, and micro-molding also made debuts. And even hydraulic systems followed the trend with servo-driven pumps.

Processors with sustainability goals or mandates have a number of ways to reach their goals. Biopolymers are among them.

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.

Advances in electric drive technology were evident in nearly every injection machine builder’s booth in Chicago. New electric and hybrid models sported direct-drive motors for injection and other functions, and direct drives showed up on bigger presses, too. Thanks to these drives, several electric machine lines can now mold thick parts with long hold times.

Thousands of people visit our Supplier Guide every day to source equipment and materials. Get in front of them with a free company profile.

Direct-drive servo-electric motors replaced belts and pulleys on a number of new machines, such as Sumitomo’s new U.S.-built SE-DU all-electric line. Direct drive is said to give higher speeds, faster response, higher precision, and lower maintenance.

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.

The process takes place in one Engel Duo two-platen machine with the multi-component Combi M configuration and Trexel’s Mucell microcellular foaming process. Dolphin uses a rigid carrier of PBT/ASA alloy (BASF’s Ultradur S) and a special copolyester thermoplastic elastomer called Pibiflex from P-Group of Ferrara, Italy. Pibiflex can be foamed with the MuCell process yet delivers a high-class surface—unlike most TPEs—and bonds well to PBT.

Engel and a group of partners developed the new “Dolphin” multi-component process to produce auto interior trim such as instrument panels with integral thermoplastic foam skins. This avoids secondary operations such as slush molding and post-trimming, as well as non-thermoplastic urethane foam. Recyclability is thus enhanced.

Husky also developed a new split sprue-bar (SSB) system that keeps the mold area clear for free-drop parts or robot access and eliminates drool and stringing when running stack molds. The split sprue bar is offered in an in-line or offset configuration. A HyPac unit produced a 19.5-g deli container in a 24-cavity tool in 3.8 sec.

“The biggest challenges were maintaining operations, assuring customers that we were taking steps to sustain their order flow, and keeping our coworkers safe,” says Craig Porter, president and owner of another Top Shop, PlastiCert in Lewiston, Minn. “As a small manufacturer, keeping track of COVID legislation, mandates and programs around finances for the company and our employees was a full-time job for people that typically already wear multiple hats.”

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.

Ferromatik Milacron, for example, molded two-color PP flip-up dispensing closures on a 275-ton K-Tec machine with a 48-cavity Foboha “Twin-Cube” turning-stack mold that was jointly developed with Milacron and introduced at NPE. It has two four-face center turrets that rotate 90° on each cycle. The two parts of the closure were snapped together in the mold.

JSW Plastics Machinery showed two models in its new J-AD Advantage series of electric toggle presses. It will range from 40 to 1800 metric tons (44 to 1980 U.S. tons). The new line will eventually replace JSW’s ELIII series and has controls with response times as short as 62 millisec vs. 250 millisec for the ELIII. The controller also has a new 15-in. touchscreen. Injection rate up to 350 mm/sec is standard, 550 or 800 mm/sec optional. The new clamp design accommodates larger molds while also reducing platen deflection. Clamp and ejector speeds also have been increased. A 121-ton model at the show produced a 1.25-in.-diam. helical gear with 28 teeth using injection-compression molding.

The wave of new direct-drive electric machines, in which ball screws are coupled directly to the motor shaft, is prompted by the ability to achieve faster response, higher speeds, greater precision, and reduced maintenance by eliminating belts and pulleys. Some sources say direct drive is also cleaner because belts generate particulates as they wear.

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

Plastics Technology’s 2020 Top Shops benchmarking survey reveals that the most effective molders are, not surprisingly, the most efficient, accomplishing more than their peers from a smaller manufacturing footprint.

The medical device contract manufacturing company with eight facilities globally has purchased the Riverside, California-based micromolder.

Jim Goerges, president of Precision Tool Technologies Inc. (PTT) in Brainerd, Minn., another Top Shops honoree, says that even before the pandemic, the company had a goal of unattended machining through all 168 hr in a work week, investing in lights-out capable machines over the years to get there. “Our investment in the right automated machining technologies put us in a strong position to navigate the issues related to increased social distancing during the pandemic,” Goerges says.

Dima plans to bring its hydraulic DTC line for two-component molding to North America. It has a rotary turntable and integrated second injector.

A U.S. molder ordered the first ET-90HR4 all-electric vertical-clamp/horizontal-injection press from Toyo/Maruka. The new four-station rotary table indexes 90° in about 1 sec. Toyo/Maruka also showed its new 90-ton vertical/vertical electric press, the ET-90VR2. This toggle press joins a 45-ton model and allows users to set up separate injection profiles for different molds on the same table.

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.

Examining other key metrics more closely, we see that Top Shops had more active molds (398 vs. 219) that molded more total parts (73 million vs. 32 million) for more active customers (102 vs. 56). Ultimately, it is that ability to wring maximum production from every person, every square foot, every tool and every machine that is part of what characterizes a Top Shop.

Toshiba’s new ED series of two-platen hybrid presses ranges from 720 to 1950 tons and combines electric plasticating and injection with hydraulic clamping.