There’s nothing small, however, about the capacity of these molding machines. Conrad says the first model on the market can mold parts weighing up to 70 lb and measuring 24 in. wide × 36 in. tall × 1 in. thick. Conrad likes to “spec” his machines conservatively. This month, he says, Omachron Plastics will mold PE parts up to 140 lb. The firm also has orders for parts measuring 12 × 12 × 6 in. And an accompanying photo shows molded HDPE 2 × 4 in. planks 4 ft long.

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

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

Conrad notes that besides molding huge parts, his process also ensures accurate reproduction of part surface features down to micro scale—for example, capillary microstructures measuring only a ten-thousandth of an inch (0.001 mil).

Wheeler adds that using the ultrasonic method also allows mold technicians to multi-task. “While some mold components are in the ultrasonic tank, they can clean the mold base, which makes the job faster and results in higher quality parts.”

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.

Injection molds require a huge capital investment, as any piece of machinery does, which means that the care and maintenance of molds is extremely important. A company founded by Bob Sandor, Tovatech is described as a company created by PhDs to provide top-level science expertise and support for customers looking for the right solutions in ultrasonic cleaners, digital scales, medical refrigeration, flow meters and moisture analyzers. Tovatech is the U.S. distributor of Elma Brand ultrasonic cleaners for scientific and industrial applications.

Omachron’s commercial motto is “The Power of Small,” referring to empowering small businesses to tackle big projects with low capital investment, using small-footprint machines with lower power consumption. Such machines make possible “distributed manufacturing” close to customers for the machines’ output, even in rural areas.

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

NPE2024: Absolute Haitian says Generation 5 of the servo-hydraulic Haitian and electric Zhafir machines lines emphasize efficiency, performance and intelligence.

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.

It can mold 70-lb parts 1 in. thick using 100% regrind, and it can reproduce micro surface detail. Add to that its small size, frugal energy consumption, and zero upfront cost.

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.

Any molder will tell you there’s a difference in working with electric vs. hydraulic drives. Servohydraulic is still hydraulic; a hybrid machine is something different. Imprecise use of terms causes needless confusion.

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.

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.

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

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

PAM Injection Molding uses the Elmasonic X-tra Basic 550 industrial ultrasonic cleaner with a 15-gallon tank. “We often take in molds from other molders and find that these molds are in poor condition,” said Wheeler. “We take them apart and clean them thoroughly before putting them in our presses to ensure good part quality.”

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

NPE2024: A slimmed-down version of Engel’s all-electric, e-mac injection molding machine is among eight displays, which also include LSR micromolding, quick mold changes and a cube mold.

In addition to frequency and pulse, the operating panel allows operators to set the cleaning cycle time and solution temperature. Set and actual parameters are displayed. The unit will start when the set temperature is reached and can operate continuously with auto shut-off at 12 hours or if the solutions temperature reaches 90° C. PAM Injection Molding selected an insulated tank lid to muffle noise during the cleaning cycle and to reduce cleaning solution evaporation.

PAM Injection Molding molds a variety of products for the automotive, household, and lawn and garden markets, among others, using 20 presses ranging in size up to 950 tons. “A lot of our molds have interchangeable modules to make different part numbers. We can pop the modules out, take the back off, loosen the inserts and put the mold in the tank, so we can thoroughly clean around the inserts, and loosen the deposits and gas,” Roger Wheeler, Tooling Manager at PAM Injection Molding, told PlasticsToday.

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.

Until she retired in September 2021, Clare Goldsberry reported on the plastics industry for more than 30 years. In addition to the 10,000+ articles she has written, by her own estimation, she is the author of several books, including The Business of Injection Molding: How to succeed as a custom molder and Purchasing Injection Molds: A buyers guide. Goldsberry is a member of the Plastics Pioneers Association. She reflected on her long career in "Time to Say Good-Bye."

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

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

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

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.

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

That also partly accounts for Omachron’s success in molding 100% regrind. For example, Conrad says his machines molded reground PVC plumbing fittings into new fittings that were 15% stronger than the originals, due to low molded-in stress. After five regrind cycles, the molded fittings still retained 10% higher strength than the virgin originals, owing to the low thermal stress of intrusion molding—without introducing any additional stabilizer additives.

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.

The secret to all this is a process sometimes called “intrusion molding,” whereby the mold is filled by extrusion rather than by injection of a pre-plasticated shot of melt. According to Conrad, this method has the benefit of low pressure, low melt temperature, and very low molded-in stresses. Typical filling pressures are 100 to 300 psi, and final packing pressures run 600 to 900 psi. Conrad cites the example of molding ABS with typical process temperatures 5° to 15° C (9° to 27° F) lower than is recommended by the material supplier—“And we still get perfect parts.”

PAM Injection Molding appreciates that the Elmasonic X-tra Basic 550 allows users to select a 25- or 45-kHz ultrasonic frequency based on the extent and tenacity of burned-on plastic residues. “For really tough deposits, our operators can activate what is called the ‘pulse mode’ that sends a more powerful blast of cleaning action into the bath,” Wheeler said. “Pulse is also activated to de-gas fresh ultrasonic cleaning solutions in order to quickly remove cavitation-inhibiting trapped air.”

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

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.

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

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.

Conrad says Omachron is building its first 10 commercial machines, which occupies its full production capacity right now. But next year it expects to expand to production of 50 to 100 machines.

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

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.

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

Omachron’s machines are available for lease, not sale, so there is no upfront investment (except for molds and perhaps auxiliaries like water cooling). Typical monthly lease costs are $5000 to $6000 (USD).

“For some molds, we have to take out each individual insert and clean it. Some are easier to clean than others. The materials we’re running and the type of mold determine how far we have to take it apart to put it in the ultrasonic cleaner,” says Wheeler.

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.

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

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

Molds are made of aluminum, which reduces weight, cost, and time for machining. (The molds for the 4-ft planks mentioned above were built, and initial parts produced, only five days after receiving the order.) Some molds are ceramic-based with a flame-sprayed nickel coating for heat transfer and corrosion protection.    Molds can be mounted on a pushcart for installation—“One person can do it safely,” Conrad asserts.

If that sounds like an attractive proposition, those are just a few of the benefits cited for a new line of low-pressure injection molding machines being launched by Omachron Technologies in Pontypool, Ont., a new name in plastics extrusion and molding machinery, headed by Wayne Conrad, who calls himself “chief scientist and also president.” Omachron recently came out with a line of small extruders (see last month’s Keeping Up section) that also serve as the plasticating section of its molding machines. After seven years in development, the first commercial models of those presses are being built now for a handful of initial customers. The company is expanding capacity to serve a broader molding audience by the end of the year.

Another benefit of the intrusion molding process is that it greatly reduces the equipment size needed to mold large parts. Three extruders are available for the plasticating section—1 in. diam., 18:1 L/D and 1.25 in., 24:1 or 36:1 L/D. With optimized screw designs and electric motors, they require only 2 to 5 hp to produce from 10-25 lb/hr for the smallest size up to 100-120 lb/hr.

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

Low power requirement also characterizes these machines, which can run on single-phase, 220V/80-89A power (or three-phase if desired).

PAM Injection Molding, based in Kernersville, NC, has found that cleaning molds using the ultrasonic method saves time and does a much better job of mold cleaning than other techniques. Plastic injection molds must be cleaned on a regular basis to remove all burned-on deposits from the surface as well as residual plastic in vents without damaging the tooling. The image below shows a mold before (left) and after ultrasonic cleaning.

The clamp and mold are typically much larger than the extruder. The machine is all-electric with a proprietary, ballscrew-driven clamp design. The clamp has 144 tons of closing force and 5 tons of opening force. “No individual part of the machine weighs more than 60 to 70 lb,” says Conrad. “And it’s totally modular, so parts are easy to replace.”

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

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.

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.

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).

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.

Ultrasonic cleaning uses a process called cavitation—the implosion of billions of microscopic air bubbles—against surfaces immersed in a cleaning solution. Bubbles are created by generator-powered transducers bonded to the underside of a stainless-steel tank. When excited, the transducers vibrate at ultrasonic frequencies measured in kilohertz (kHz) per second. This causes the tank bottom to act as a membrane creating the bubbles.

What if you could satisfy short- to medium-run injection molding needs with the capability of a 500-ton press, in a machine that uses one-tenth as much energy and can fit on a large office desk? What if you could do that with no capital investment for the machine? And what if that machine would allow you to mold 100% regrind into parts that are stronger than the virgin originals?

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.

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

Omachron’s machines have molded LLDPE, HDPE, PP, rigid PVC, ABS, nylon, acetal, UHMW-PE, PEEK and PPS. Conrad says it’s possible to mold ABS, PVC and HDPE to very nearly the same dimensions in the same tool, regardless of the different materials’ shrinkage. That’s because his machines fill continuously during packing, through a heated inlet, so as to compensate for shrinkage during cooling in the mold.

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

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

Omachron Technologies (omachrontechnologies.com) is the machine-building and moldmaking arm of Omachron Science, Conrad’s 30-year-old R&D company with 750 patents in fields as diverse as satellite communications, personal watercraft, and appliances (omachron.com). Another subsidiary is Omachron Plastics, which acts as a test bed for the company’s machinery, using it to produce the Plasti-Block line of machineable sheets, rods, tubes, blocks and custom shapes (plastiblocks.com).

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.

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.

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.

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

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 machine with mold is about 3 × 7 ft—or about the footprint of a large office desk—and weighs around 2.5 tons without the mold. This is so compact that a molding operation can be established in a facility of 1000 to 2000 ft2, according to Conrad.

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.

On the other hand, these machines are not for fast-cycle molding. For large, thick parts, molding cycles can range from 10 min to 1 hr.

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.

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.

Time saving is the biggest benefit of the ultrasonic method, according to Wheeler. “Hand cleaning a mold is time consuming, and there are little areas that are tough to reach,” said Wheeler. “Frankly there’s no way that manual cleaning, not matter how carefully applied, can access complex shapes, vents, dumps and other mold surface configurations. We use a bio-degradable, water-soluble fluid that gets into the cracks and crevices to loosen the debris and gas. It makes my job a lot easier. The ultrasonic equipment does the job in about 30 minutes average—a task that could take hours if done manually.”

“Longer injection mold life depends on not only keeping them clean but conducting mold-cleaning operations in such a way that extends their life by maintaining surface finish specifications,” Wheeler added.

Ultrasonic equipment slashes the time it takes to thoroughly clean molds, according to PAM Injection Molding (Kernersville, NC), which has adopted the technology.

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.

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

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.

Implementing a production monitoring system as the foundation of a ‘smart factory’ is about integrating people with new technology as much as it is about integrating machines and computers. Here are tips from a company that has gone through the process.