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

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.

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.

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

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.

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

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 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.

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 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.

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).

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

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.

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.

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

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.

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.)

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 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.

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

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

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.

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.

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.

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.

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.

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.

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 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.

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.”

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.

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

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.

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.

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.

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

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

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.

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

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.

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.

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.

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.

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.

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

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.

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

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.

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.”

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.

“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.”

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

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.

“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.

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

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.

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.

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

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

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

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.

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.”

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

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.

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

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.

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.

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.

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.

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.

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

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.

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.

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.

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.

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.

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.

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.

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.

“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.”

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.

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.

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.

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.

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).

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

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

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

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.

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.

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.

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

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 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.

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.

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

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.

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

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 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.

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.

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.

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

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.”

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.

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

“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.”

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

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

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

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

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.

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

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.

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.

•  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.

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

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.

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.

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

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.

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.

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

•  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.

“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.”

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

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

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

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

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.

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.

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.

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.”

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.

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.

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.

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

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.

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.

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.

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.

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

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

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.

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 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.

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.

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

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.

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.

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

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.

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.

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.

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

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

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.

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.

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 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.”

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.

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.

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

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.

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.”

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.

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

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.