Because the process uses a low-pressure system, a 40% reduction in clamp tonnage can be achieved, and a 15% cavity pressure reduction. Additionally the process allows molders the possibility to propose embossed containers without extra tooling costs and there are no extra set-up costs for the embossing modifications.

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."

With supply and demand upstream returning to balance once planned cracker outages are over, HDPE output will also get back to normal. European HDPE buyers expect new production to be available to them as early as the third quarter 2017, but that product will only be available in volumes sufficient to affect the market materially by the end of 2017, beginning 2018.

The unusual situation of 2015 continues to have an impact in HDPE pricing and buying activity. An unprecedented series of force majeures in 2015 meant converters did not have enough product to continue keep all lines running. Apocryphal stories told of empty bottles being airlifted into European sites, and prices soared. The events of 2015 led to many converters changing their buying methods. Security of supply became more important than pricing, and imports have become an integral part of HDPE supply in Europe.

The supply/demand balance in the European HDPE sector has changed significantly in the past three years, following some definitive planned closures that took place between the end of 2012 and 2015. Closures were made as profitability has been poor in this sector, and producers reacted to the increase of low-cost imports by closing older non-competitive plants.

Suppliers have lost some of the spread built up between ethylene and HDPE in 2016, but it remains well above what it was at the end of 2015, and it has been stable to slightly higher in 2017, with some grades such as HDPE pipe, gaining a little more ground than other HDPE grades.

Meanwhile, much depends on how Asian markets fare. Low prices in Europe have deterred importers, but falling levels in Asia, coupled with firm contracted pricing in Europe – and new capacity coming on stream – is leading to expectations of more imports into Europe, even before the onslaught of the new North American shale-based material.

Now that the exclusive agreement that Trexel had with Unilever has expired, the company is free to offer this technology to other brand owners, who want to differentiate their products by its unique visual appearance and soft touch effect to packages. In addition to offering a special look and feel to packaging, the 3D IML offers a 10% improvement in thermal insulation.

Spot upstream ethylene is still strong, and some HDPE output has been reduced for the lack of ethylene, but when the cracker outages end, a normal balance is expected to return to the market.

Strawbridge pointed out in his presentation that when the MuCell process was first commercialized, more than two decades ago, the technology was used to reduce weight by reducing the density of the molded component. The wall sections of components such as those used in consumer electronics and automotive parts, tended to be thicker, thus offering good opportunities for weight reduction using MuCell.

An increase in import duties from the major importing region of the Gulf Cooperation Council on 1 January 2014, from 3% to 6.5%, combined with a later crash in crude oil prices and also a crash in the value of the euro against the dollar, meant that some European HDPE buyers were unable to get hold of all the HDPE they needed from local sources. Europe subsequently became a net importer of some HDPE grades.

Over the past few years, the MuCell Microcellular foaming technology has been used in some very unique applications, and the IML 3D label certainly fits that bill. The 3D in-mold label was originally developed for the Paccor/Unilever 500g polypropylene margarine tub. It won the DuPont Silver Award in 2013 as well as the Emerging Technology award in SPI's International Design Competition at NPE2012.

Buyers have built up stock, as they feared potential shortages because of a series of planned cracker maintenance outages. No production issues have occurred to interfere with HDPE supply, however, and by the end of the first quarter, they were using up stock. Lower prices have been offered for spot imported volumes, while contracted prices have remained relatively firm.

European HDPE producers have managed to keep hold of much of the margin they gained in 2015. Fear of more supply disruption saw 2016 contract prices rise, and again 2017 contracts were tougher for many buyers as weak prices in Europe left imported volumes low.

The 3D IML is processes with an injection-molded tub made of expanded polypropylene to incorporate selective masking, creating areas without adhesion. The MuCell process controls the introduction of nitrogen into the polymer. Where there is adhesion between the label and the polymer, the nitrogen migrates through both structures. Where there is no adhesion (by design behind the blue lettering), the nitrogen accumulates between the polymer substrate and the label. The process creates bubble patterns for a multi-sensory experience. This also provides the possibility to do Braille for the visually impaired.

High-density polyethylene (HDPE) is used extensively in blow-moulded products such as milk bottles, packaging containers, drums, car fuel tanks, toys and household goods. Film and sheet are widely used in wrapping, refuse sacks, carrier bags and industrial liners. Injection-moulded products include crates, pallets, packaging containers, housewares and toys. Extrusion grades are used in pipes and conduit.

By April 2017, more imports were being offered from Asia and Mexico among others, as Asian prices faltered and European contracted levels rose. Demand in Europe is said to be running at a modest increase over 2016.

New supply is coming on stream in North America, and while delays mean that growth will have some time to catch up with supply, an impact from new capacities is expected by the end of 2017/beginning 2018, according to sources.

First-quarter spot prices have not been buoyant in the blowmoulding and injection sectors, however. Film prices have held up better, in line with spot prices in associated polyethylene (PE) film markets.

Trexel Inc. recently made its global introduction of its MuCell 3D in-mold labeling (IML) process for packaging applications. Brent Strawbridge, vice president of sales, presented this unique, award-winning label at the recent IMLCON in Phoenix. The MuCell process creates a 3D label with the look of embossed labeling on the package without any need for additional tooling costs.

Trexel Inc. recently made its global introduction of its MuCell 3D in-mold labeling (IML) process for packaging applications. Brent Strawbridge, vice president of sales, presented this unique, award-winning label at the recent IMLCON in Phoenix. The MuCell process creates a 3D label with the look of embossed labeling on the package without any need for additional tooling costs.