Market Goals - all american injection molding 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.

•  So far this year, Flexcraft has made two significant additions. One is a sophisticated 500-ton central chiller system from Thermal Care. It’s large enough to support a future tripling of current machine capacity; but thanks to variable-frequency drive (VFD), the system uses only as much energy as the plant needs at any point in time. “That’s very important,” notes Smith. “A couple of large customers are looking for sustainability efforts by their suppliers.” The second key purchase is plant-wide air conditioning. “It provides a better work environment, and humidity changes can affect the molding process a lot,” says Smith.

EPET is another area of custom packaging where Flexcraft sees opportunity. Its multimillion-dollar development program with Bekum resulted in a version of Bekum’s model 607D with an oversized extruder capable of molding large, wide-mouth EPET containers in up to four cavities. Flexcraft’s first project in this area is a 160-oz jug with integral handle, designed to hold large quantities of dried spices used in restaurant kitchens. It is blow molded with a dome that is cut off to yield a very wide neck. The product is being converted from PVC to EPET, which is regarded as a more sustainable solution.

The company’s second ISBM machine is on order to take advantage of what is seen to be major growth potential in oriented PET bottles. Here, large, wide-mouth bottles are packed upside-down, a potentially labor-intensive task that is now handled by a cobot.

Flexcraft in New Jersey currently has 18 extrusion blow molding machines, 13 of them continuous-extrusion shuttles from Bekum, plus one single-stage ISBM machine from Nissei ASB Co. The Rhode Island plant has 14 extrusion blow machines built by Rocheleau.

You’ve probably heard of molders that start out in high-volume commodity products and then diversify to take on more high-tech, engineered custom applications. What you may not have encountered is a molder that does the reverse—starting from a base in highly engineered, lower-volume products and then expanding into high-volume consumer packaging, while retaining the custom focus and high level of customer service that made it successful in the first place.

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.

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).

•  2020 saw completion of a two-year project with Bekum to develop a large machine for the burgeoning field of extrusion blow molded PET, or EPET (see Jan.’19 Close-Up.) That year also brought in two more Bekum machines, plus an expansion of the cleanroom molding area, addition of a 50,000 ft2 warehouse, and automatic bagging and palletization on two molding lines.

For most of the last two decades, the firm has invested aggressively in technology and capacity expansion—continuing right through the COVID-19 pandemic:

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

Starting with a converted chocolate extruder, the firm now has two plants with 150 employees and around 40 injection and blow molding machines.

Husky Technologies, the industry’s leading technology provider of plastic injection molding solutions, has worked with Tan Hiep Phat since 1993 to provide high-end technology to install their first PET preform production system. Most recently, Husky enabled Vietnam’s leading beverage company to take a big step forward when implementing recycling and lightweighting initiatives.

Plans for capacity expansion continue apace. A former toolroom space is being converted to make room for four more blow molding machines. One additional Bekum machine cell with automated material handling was purchased, and a second ISBM machine is on order. A 12,000-ft2 cleanroom expansion is nearly complete, and the first machine to occupy it was due to arrive as this article went to press.

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.

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

The headquarters plant also has five older Hayssen accumulator-head machines, which are being phased out. Flexcraft has worked with Bekum to learn how to convert the larger parts made on the accumulator machines to run with continuous extrusion. An example is a large piggybank shaped like a classic Coca-Cola bottle and made of Styrolux styrene-butadiene copolymer from Ineos Styrolution. Flexcraft has made the “Bottle Bank” on accumulator-head machines for 13 to 14 years, but will be switching it over to continuous extrusion.

Flexcraft bought a blow-mold maker to give it in-house control over complex, tight-tolerance jobs that require multiple tool revisions.

Husky has become a trusted equipment supplier for many businesses in Vietnam. Many of these businesses are leading brands in the country. There are currently more than 110 Husky injection molding systems operating throughout Vietnam, producing about 7 billion parts per year (including preforms, closures, lids, and thinwall food containers).

Credit: https://vietnamtimes.org.vn/joining-forces-with-the-worlds-leading-partners-tan-hiep-phat-improves-recycling-and-green-production-capacity-69971.html

One of the leading enterprises in Vietnam that Husky has worked with is the Tan Hiep Phat Group. Husky and Tan Hiep Phat have worked together since 1993 when Tan Hiep Phat purchased the company’s first PET preform molding system.

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

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.

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

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.

Agreement between Eastman and Ethicon will put copolyester derived from recycled materials in sterile barrier applications.

“We wanted in-house mold manufacturing because a lot of our programs, especially tight-tolerance jobs, require multiple mold trials and tooling adjustments.”

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.

High clarity, easy incorporation of handles, and recycling resin code No. 1 are the principal drivers for converting to EPET resins for extrusion blow molding.

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

A new Automation group focuses on making processes more consistent. Team members Adrian Mendez, technical manager (l.), and Kevin Izworski, plant engineer, design and build devices like this indexing box filler.

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

This year, Flexcraft decided to approach the need for automation more systematically by forming an in-house Automation group, consisting initially of one employee from engineering and one from maintenance. Their charge, as Smith describes it, is to “focus on line improvement and automation to make processes more consistent.” They are considering potential use of autonomous mobile warehouse robots (AMR’s) to improve material flow through and between buildings. They are also investigating more automated quality-assurance inspection equipment to improve consistency of data and allow a greater quantity of samples to be analyzed more quickly.

Automation is a must-have for molders of pipettes. Make sure your supplier provides assurances of throughput and output, manpower utilization, floor space consumption and payback period.

That growth has indeed been impressive: around 20% annually for the past five years. This was accomplished without a full-time sales force. “We’ve grown by word of mouth and reputation,” says Smith. “Our customers’ engineers get to know us, and when they move to new companies, they recommend us as a supplier. We make things easy for them—offering engineering, tooling, molding and secondary operations like surface treatment, printing, sleeving, labeling and more.”

Since its founding, Flexcraft has been devoted mainly to complex parts for medical and biosciences, often using engineering resins. Examples of current applications in that field include custom diagnostic reagent bottles, PC vacuum chambers for medical equipment, large flasks of PC and EPET for COVID vaccine production, a flexible TPE pump for bariatric surgery, and a TPE inflatable medical device.

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

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

“In the past five years, we have diversified to compete in high-volume custom bottles for consumer packaging, food and beverages,” says Smith. One example is growing investment in ISBM. “We see a lot of applications going to PET for food and beverage packaging, so that will be a focus for us going forward.” Examples include custom long-neck bottles for fuel additives and a 1-gal, wide-neck food container.

Looking ahead, Smith foresees adopting coextrusion for personal-care packaging, where cost savings can be achieved by using only a thin external layer of colored resin over a virgin internal layer.

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.

Low-cost and easy-to-program collaborative robots are a new solution to bottle handling, trimming and packing automation.

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

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.

Husky’s solutions have helped Tan Hiep Phat successfully implement its own packaging production strategy, contributing to reduced production costs and increased competitiveness in the market. For this reason, Husky has become a leading strategic supplier of Tan Hiep Phat over the years.

Another effort toward sustainability is Flexcraft’s plan to reuse every bit of its internal scrap, much of which is reground and reused at the press. A new shredder will allow purgings such as these to be reclaimed, too.

Flexcraft built its reputation on highly customized, tight-tolerance medical components, such as these, made of polycarbonate and PE.

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.

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.

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 prices moved up for three of the five commodity resins, there was potential for a flat trajectory for the rest of the third quarter.

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 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

The cooperation between Husky and Tan Hiep Phat has helped both companies become industry leaders in Vietnam with a focus on continuous improvement and technological innovation. At the same time, both companies share common values in delivering safety and sustainability in essential products to consumers.

That’s the evolving strategy of The Flexcraft Co., a custom blow molder headquartered in Neptune, N.J. To accomplish this, the firm has invested in a broader arsenal of blow molding technologies, as well as automation and employee development. Ben Smith, CEO, explains the strategy: “We don’t want to become a commodity blow molder. We’re not looking to the be the cheapest option. We offer value—customization in design, packaging and labeling. We’re a regional blow molder, so we offer freight savings to local clients. We’ve invested so much in our people and technical capabilities—more than $15 million in new equipment since 2015. We can offer what the larger guys do, but customer service is where we shine. We react fast. As we’ve grown, we have stayed true to the importance of every customer.”

Emile said: “Tan Hiep Phat is one of the largest beverage companies in Vietnam with a dynamic and ambitious leadership team that finds every way to improve and innovate to meet the needs of customers and international standards. We also support Tan Hiep Phat in delivering on its commitment to sustainability and the circular economy through the implementation of recycling and lightweighting initiatives.”

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.

This family-owned firm is broadening its range of blow molding technologies to expand into new markets, while maintaining the strong service philosophy that has made it successful.

Choosing a supplier who is a leading reputable enterprise is a wise step for Vietnamese businesses looking to reach demanding markets through improving capacity and developing high quality products.

For a new EPET application that requires large bottles to be packed upside down, Smith says the labor requirement was especially large, so the job was automated with a collaborative robot (“cobot”) from Universal Robots.

“We work hand in hand, based on professionalism and support. This will continue in the future,” Emile Haddad, Sales General Manager – Rigid Packaging SEA shared.

Recognizing the growth potential, Husky began entering this developing market in 1993. At the time, Vietnam was seen to have a stable political environment, a young and growing population, and a strategic geographical location to promote development. Its industries are also thriving with stable growth rates over the years.

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.

A new 500-ton central chiller will support a future tripling of machine capacity, but variable-frequency drive continuously tailors the energy consumption to the immediate load. Large customers are said to be looking for such sustainability measures from their suppliers.

Two generations of Smiths—Russ Sr. (third from l.), who co-founded the company with his father, with sons (l. to r.) Russ Jr., Ben, Dan, Tucker. Behind them is a special machine they developed with Bekum to produce the large, wide-mouth EPET containers that they’re displaying, which represent part of the company’s new thrust into high-volume packaging.

Teel Plastics opened new plant in record time, partnering with AEC & Aqua Poly Equipment Co. to expand production of swab sticks to fight pandemic.

Join Wittmann for an engaging webinar on the transformative impact of manufacturing execution systems (MES) in the plastic injection molding industry. Discover how MES enhances production efficiency, quality control and real-time monitoring while also reducing downtime. It will explore the integration of MES with existing systems, emphasizing compliance and traceability for automotive and medical sectors. Learn about the latest advancements in IoT and AI technologies and how they drive innovation and continuous improvement in MES. Agenda: Overview of MES benefits What is MES? Definition, role and brief history Historical perspective and evolution Longevity and analytics Connectivity: importance, standards and integration Advantages of MES: efficiency, real-time data, traceability and cost savings Emerging technologies: IoT and AI in MES

In this collection of articles, two of the industry’s foremost authorities on screw design — Jim Frankand and Mark Spalding — offer their sage advice on screw design...what works, what doesn’t, and what to look for when things start going wrong.

In 2015, Russ Sr.’s four sons acquired the company (flexcraft.com) and moved it to the 210,000-ft2 Neptune City plant, which today employs 150 people. Besides Ben Smith as CEO, the firm is operated by his brothers, Russ Jr, president and CFO; Dan, COO; and Tucker, program manager. Dan and Tucker run the factory floor.

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.

Husky Technologies is a world leader in injection molding technologies, solutions and services. Providing optimal production solutions, Husky collaborates with many of the world’s leading brands and producers.

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

Krones adds PET preform injection molding to its bottle blowing and filling capabilities, as well as cap molding and expansion into medical, food and other markets.

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.

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.

Flexcraft has also grown through acquisitions. In 2003 and 2005, it absorbed two smaller blow molders, gaining new customers and some additional machines. In 2019, Flexcraft purchased another blow molder active in similar high-tech custom markets, Blow Molded Specialties in Pawtucket, R.I., whose 30,000-ft2 plant with 40 employees is now operating as a second Flexcraft facility. “This acquisition helped build our technical depth and provided additional cleanroom molding capacity,” says Ben Smith. “It also helped us to diversify our customer base in medical and specialty products. They have experienced people and the same basic operating philosophy and capabilities as us. But they have smaller machines, which are good for smaller parts with tight tolerances.” (See PT’s May ’13 profile of Blow Molded Specialties.)

CEO Ben Smith displays a large Styrolux “Bottle Bank” piggybank that has been blow molded on an accumulator head for more than a decade but will be transitioned to a continuous-extrusion process.

Smith voices a complaint heard widely throughout the industry: “There’s a massive labor shortage, and it’s even worse in technical personnel.” Flexcraft is addressing that on two parallel tracks. On the one hand, says Smith, “We want to use automation to minimize the human element that can cause variation.” Almost all lines have fully automated material handling, and the toolroom has built several items of downstream automation, such as trim-and-transfer tooling that orients bottles upright on conveyors, and a box filler that counts bottles packed and indexes the box when it reaches a preset count.

In 2010, Flexcraft made a different sort of acquisition—Primus Mold in Middlesex, N.J., a maker of blow molds. “We wanted in-house mold manufacturing,” Smith explains, “because a lot of our programs, especially tight-tolerance jobs, require multiple mold trials and tooling adjustments. We need flexibility to try new ideas ‘outside the box.’ This way, we can dictate the shop schedule.” Flexcraft now has six people dedicated to the toolroom, which builds about 10% of the company’s molds and also performs maintenance and repairs and builds downstream automation equipment.

In 2020, Flexcraft scored a win by working with a large packaging distributor to reshore from China a dual-chamber HDPE bottle for Green Gobbler Drain Clog Dissolver, a major feature of which is inline shrink sleeving of the label, which was a challenge to orient on such an irregularly shaped bottle (see photo). Flexcraft came up with an unusual approach—inverting the bottle for the sleeving operation so that the label could cover the container’s base. Flexcraft built the tooling and sleeving system for this bottle, which won three packaging awards in 2020. The application runs 5-7 million units/yr.

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

Over the next 25-30 years, Flexcraft built a reputation as a highly technical blow molder for medical and biosciences applications. In 1980, the firm tackled a large metal-to-plastics conversion project, replacing 18 stainless-steel parts with a single polysulfone blow molded component. In 1985, Flexcraft claimed credit for being the first to extrusion blow mold Allied-Signal’s Halar ECTFE (now supplied by Solvay) and, in 1989, the first to blow mold GE’s Ultem PEI (now supplied by SABIC).

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.

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

This year, Flexcraft also enhanced its ability to recycle internal waste. Trim scrap is already reground and blended at the molding machines; a brand-new shredder allows reclaiming purgings, too. “Our goal is to reprocess 100% of our scrap within the next three years,” notes Smith. He adds, “We’ve been using a lot of HDPE post-consumer reclaim for going on six years, but right now there’s a crazy shortage of PCR availability and extreme volatility in pricing.” He says the firm is also looking into additives that make PE and PP biodegradable. “We see the demand coming, and we want to be ready—to know we can process it.”

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

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.

Flexcraft was founded in 1971 by the late George Smith together with his son Russ Smith Sr. George was a former GE Plastics engineer who hankered to make products from the resins he had spent his career developing. The Smiths bought a chocolate extruder from Hershey and converted it to a blow molding machine. For their first customer, they molded thick-walled polycarbonate and polysulfone vacuum canisters for medical equipment. Flexcraft still molds for that customer today.

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.

Flexcraft is broadening its focus to include custom, high-volume consumer packaging, such as the award-winning, dual-chamber HDPE drain cleaner package at left; EPET restaurant spice container (center); and stretch-blown PET fuel-additive bottle at right.

While automation can free people from simple, repetitive tasks, Flexcraft is also working to develop its personnel for more challenging activities. “We want to help people build careers in molding,” explains Smith. “So this year, we made a massive investment in a complete Paulson Training package for injection and blow molding. It will allow us to track employees’ progress through the program. And we are transitioning one person into a full-time trainer.”

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

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.

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.

Also in New Jersey are six injection molding machines of 35 to 310 tons, used to mold caps, closures and other packaging components.

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.

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

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.

Sharing Husky’s upcoming plans in the Vietnamese market, Emile mentioned they will continue to work with leaders in the market. Husky is committed to providing manufacturers with industry-leading technology, services and support.

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