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

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

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

Before you start validating, it is vital to be clear on your expectations. If it’s to provide a documented source of evidence to satisfy a regulatory body, you need to do it. But that shouldn’t be your sole motivation. Validation is not purely about procedures and scrambling to put the correct documentation in place. The objective of having an efficient process and repeatable high product quality should never be overlooked, as this is ultimately how you can avoid costly product recalls and cosmetic product defects.

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

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

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.

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.

Md Plastics is now marketing special Inject-EX versions of servohydraulic, two-platen injection presses from EdeX of Taiwan. (Photo: EdeX Technology Co.)

The validation process requires a step-by-step approach, working with each customer to break down each element of each injection moulding cycle and documenting every stage. Conducted by an engineer, the actual validation usually takes longer than actually building the tool itself. For this reason, the validation is often partially completed at the toolmakers’ facility by a senior engineer from the company as this allows issues to be addressed there and then on site, rather than shipping the tool back and forth. Ultimately, the final phases of the validation will be completed in-house on the specified equipment.

Portable, standalone data monitor replaces a laptop. Newest system uses melt thermal data to signal injection fill-to-pack switchover.

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.

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.

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

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

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

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

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.

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.

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.

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.

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

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.

The ‘DryerGenie’ marries drying technology and input moisture measurement with a goal to putting an end to drying based on time.

Durina also notes that the EdeX machines being sold here are built with provisions to accept Md Plastics’ special Temp-Sense melt-temperature sensor and the latest version of the Melt Profiler melt-temperature control system, called Melt iQ.

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

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.

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.

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.

Last year the European Commission issued its first update since 2001, causing more confusion. The new version of Annex 15 now requires manufacturers to ensure that “critical aspects” of their operation are validated throughout the product lifecycle. This includes any changes that could impact a product’s quality. Effective 1st October 2015, the amendment to EurdraLex Volume 4, Annex 15: Qualification and Validation closely mirror the FDA’s (U.S. Food and Drug Administration) lifecycle approach. There’s also a greater emphasis on risk management to reflect today’s manufacturing and regulatory environment.  So, how do these changes impact manufacturers?

Going back to the basics of why validation exists, it’s to ensure that injection moulders have a stable and dimensionally centred process that consistently produces high quality products. Validation is basically providing the scientific evidence that the machine and tool is repeatedly doing everything you expect it to do, every minute of every day.

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

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 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.

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

In accordance with ISO 13485 standards, ongoing documentation of the injection moulding process needs to be maintained. This is a continuous process, which is a significant change under the new directive.   From time to time, machine settings may have to be adjusted to compensate for changes in the environment or to address moulding issues, such as pulling, distortion, or aesthetic defects. The key areas that might impact a stable process include changes in pressure, temperature, flow rate and cooling rates, any of which may trigger a re-validation exercise.

At the Process Design stage you are looking to see if you have the proper sized machine - shot size and tonnage - and that the equipment is properly calibrated.

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.

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.

When it comes to product quality in injection moulding, machine and tool validation is fundamental to creating a stable manufacturing process and de-risking the project. Yet, it’s often bureaucracy rather than methodology that drives companies to validate. James Hines, Process and Training Engineer at Sumitomo (SHI) Demag goes back to the basics of why we validate and why this complex process shouldn’t be just regarded as a tick-box exercise to get the FDA or other regulatory bodies off your back.

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).

Also unique to this system, the entire screw/plunger barrel assembly moves forward to inject, emptying the melt chamber in front of the plunger through a Mini-Shut shutoff nozzle on the end of the barrel. This design is said to be simpler, more compact, and less costly than other two-stage designs.

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

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.

As stated by Michael Durina, president of Md Plastics, the Inject-EX plasticating system was developed “to ensure that each pellet is exposed to the exact same amount of energy during its journey from the hopper to the mold. The result is a melt that is more uniform and homogeneous than is produced by today’s reciprocating-screw systems.” He explains that as the conventional reciprocating screw retracts during recovery, the pellets entering the feed throat are exposed to a continuously changing L/D, so their shear exposure is inconsistent, which leads to viscosity variation. That effect is exacerbated by the fact that when the screw moves forward during injection, pellets fall from the hopper into the empty screw flights. Those pellets are not compacted efficiently during the next recovery cycle, creating further melt variability. Add to these problems the well-known issue in conventional machines of inconsistent shot volume due to inconsistent closing of the check valve at the end of the screw at the start of injection.

Like before, there are three key phases to process validation, only now the FDA categorises them as Process Design, Process Qualification, and Continued Process Verification. These reflect the focus on the manufacturing lifecycle and the need to provide scientifically sound data to verify that your injection moulding processes start and continue to remain stable.

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.

Although not a prerequisite for the automotive and packaging sector, validation can be good business practice for a large number of mass manufacturers of injection-moulded components. Think of it as a long-term investment. Essentially, it’s a risk assessment which, when executed professionally, can deliver efficiency gains and save your business time, money and resources by ensuring product integrity and reducing scrap volumes.

During the Process Qualification phase, you will move on to establish the range of process parameters. This involves conducting a selection of statistical and dimensional studies, enabling you to identify and investigate any deviations in the process. A process is not considered as validated if the variations have negatively impacted the finished product in any way.

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.

All these problems can be reduced or eliminated with two-stage screw/plunger systems, of which Inject-EX is a new variant. Like other two-stage systems, this one has a plasticating screw (Md Plastics’ Posi-Melt design) that is stationary with respect to the feed hopper and that feeds an injection plunger via a shutoff valve. What’s different about Inject-EX is that the screw and plunger are not housed within separate cylinders, but are directly coupled inline. The screw feeds melt through a channel or “inner barrel” in the center of the injection plunger, and the melt exits that channel at the front of the plunger. The valve between the screw and plunger sections is the same one used in Md Plastics’ Mini-Shut shutoff nozzle. This is a poppet valve that is spring loaded with Belleville washers. It therefore shuts immediately when the screw stops turning. This design provides true “first-in/first-out” melt inventory, unlike most other two-stage designs.

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

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

New system automatically cleans mold-cooling lines—including conformal channels—removing rust and calcium, among other deposits, while simultaneously testing for leaks, measuring flow rate and applying rust inhibitor.

Major repairs, changes, or improvements to the mould tool may require changes in the set up, and this would mean re-validating the process. This is also true of the moulding machines. Significant repairs or machine exchanges if not carefully managed and controlled may trigger a full validation of the process, which takes time and costs the moulder more money.

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.

Md Plastics, a supplier of screws, check valves, shutoff nozzles and other plasticating components, is now marketing its first injection press, built by EdeX Technology Co., Ltd. in Taiwan. EdeX (edex.com.tw) is a privately owned firm started in 2009, which builds around xx injection machines a year. It is mounting Inject-EX plasticating systems on a selection of press sizes from its ATOM and ATOP series of CE-certified, servohydraulic horizontal presses (see accompanying table). These are space-saving two-platen designs with four platen-mounted clamp cylinders, air-cooled hydraulics and INV7800A controls with 15-in. screen from LNC Technology Co., Ltd. (lnc.com.tw) in Taiwan. The company has built two-stage machines before, with an angled screw above the plunger barrel, a design used by a number of injection machine builders. A 70-metric-ton EdeX machine with Inject-EX system is newly arrived at Md Plastics’ plant in Columbiana, Ohio.

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

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.

Inject-EX machines incorporate Md Plastics’ inline two-stage injection unit, in which the fixed screw feeds melt through an inner channel in the center of the coaxial plunger to accumulate in front of the plunger. The entire screw/plunger assembly moves forward to inject and backward to recover the next shot. (Image: Md Plastics)

While the EdeX models initially offered by Md Plastics are designed for thermoplastics, Durina hopes to offer LSR versions in the future. (An Inject-EX system for LSR was shown at NPE2018). “They won’t need a screw at all,” Durina says. “The silicone material can feed directly into the inner barrel of the injection plunger where the end of the screw would normally be. And we can put a static mixer at that entry point, so there would be no need to premix the two LSR components in the feed system.”

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.

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

Novel inline screw and plunger are designed to overcome limitations of conventional reciprocating screws, in a system more compact and less costly than other two-stage configurations.

From a business perspective, validation will also address profit-driven challenges and design out production weaknesses. Functional tests can help operatives better understand what drives the machine, how fast it goes and the consequences if manufacturing procedures are not correctly followed. In some instances, ramping up to a faster cycle time won’t always be the most optimised process.

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.

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.

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

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

The final validation phase - Continued Process Verification - focuses on demonstrating that your process is consistently stable. It involves simulating different production runs using the same production equipment and the processes that you will be routinely using, ensuring repeatability of the set-up conditions throughout the machine’s full lifecycle.

For any plastics manufacturer, zero defects remain the target. In the medical industry, for example, there’s no wiggle room. You can’t shift the parameters to suit.  If you’re producing a medical device or a sterile implant, nothing less than 100 percent quality is acceptable.

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.

At NPE2018, Md Plastics showed off the prototype of a novel inline screw/plunger system called Inject-EX, designed to overcome the limitations of standard reciprocating-screw injection molding machines. Since then, the design has evolved, with an improved heating system and, most importantly, a Taiwanese machine builder has adopted the Inject-EX system for a series of presses to be marketed here by Md Plastics.

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.