The ColorForm process effectively works by combining injection moulding and polyurethane processing. The multi-component injection moulding procedure is the foundation of this process. After injection moulding of the thermoplastic mould base body, the body is flow-coated with polyurethane (PUR) or polyurea (PUA) as the surface material in a second cycle.

How the development of new catalysts—notably metallocenes—paved the way for the development of material grades never before possible.

Polypropylene prices in April signaled the beginning of a big downward correction, after rising another 8¢/lb in March, in step with propylene monomer, according to PCW’s Barry, Spartan Polymers’ Newell, and The Plastic Exchange’s Greenberg. These sources expected PP contract prices to drop by 11¢/lb in step with April monomer contract prices. Initial projections for May were for another 5¢ to 7¢ drop. Two suppliers had issued 3¢ and 6¢/lb “non-monomer” (i.e., profit-margin) increases for May, which were expected to go nowhere.

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.

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

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

(Left to right) - Peter Giessmann (KraussMaffei), Eric Jan Frijters (Techniplas), Philipp Strasser (KraussMaffei), Michael Fuchs (KraussMaffei), Rene Rudolf (Techniplas), Sarah Seidel (Techniplas)

Baystar's Borstar technology is helping customers deliver better, more reliable production methods to greenhouse agriculture.

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

PET prices dropped by 1¢/lb in April in step with feedstock costs paraxylene/PTA and MEG. Prices for May-June were likely to be flat to fractionally lower, according to Mark Kallman, RTi’s v.p. of PVC, PET and engineering resins. He characterized demand as slowed, with plenty of domestic supply and continued good availability of imports that are typically lower in cost and now benefit from improved transit logistics.

These sources also noted that new capacity from Baystar and Nova Chemicals would also make an impact on the market, even though the Shell Polymers Monaca 3.5 billion lb/yr HDPE/LLDPE capacity was reported to be completely shut down until the third quarter. One of the three PE units, a slurry process HDPE blow molding line, was not expected to restart until first-quarter 2024. Among the reasons reported were cracker issues restricting production of on-spec ethylene monomer. Barry said this had made the spot PE market a bit tighter.

Heading into May, the price trajectory for commodity resins was projected to be largely downward, with PP expected to face a double-digit correction and more modest declines for other volume resins. These are the views of purchasing consultants from Resin Technology, Inc. (RTi), senior analysts from PetroChemWire (PCW), CEO Michael Greenberg of The Plastics Exchange, and Scott Newell, executive v.p. for polyolefins at  distributor/compounder Spartan Polymers. Their predictions, of course, do not account for any unforeseen major production disruptions or a spike in crude oil and natural gas prices.

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.

Addressing polyolefins, in particular, The Plastics Exchange’s  Greenberg summed it up this way: “This weaker price direction comes amid looser availability for both major resin groups (PE and PP) as producers contend with plentiful inventories that regrew in the first quarter, making the impact of current force majeures – four for PE and two for PP – pretty much irrelevant.”

Driven by brand owner demands and new worldwide legislation, the entire supply chain is working toward the shift to circularity, with some evidence the circular economy has already begun.

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.

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.

Newell noted that the current 42.7 days of inventory was one of the highest levels in over a decade, compared with 32 to 34 days for a balanced market. Barry reported that PP exports were gradually seeing more activity, but some resin suppliers did not think it worthwhile to sell prime resin in the low 30¢/lb and low 40¢/lb range needed to gain offshore interest. Greenberg characterized spot PP activity as good, with more interest in copolymer than homopolymer, and prices dropping as they got a head start on the anticipated decline.

These sources noted that suppliers had increased plant operating rates to 90%, even while supply inventories mounted by triple digits and domestic demand rose only 1%. Chesshier saw April prices staying flat with a potential drop in prices in May-June. “There is no cost -push for suppliers in making PE; and based on supply/demand fundamentals, prices ought to come down,” she commented. Barry ventured that prices would be flat in May and could drop in June. He noted that demand in some market sectors, like HDPE pipe, fared better than others, while demand for stretch film was estimated to be off by about 10% year-over-year. Though demand for food packaging has been steady versus 2022, it is still “a stark departure from robust double-digit growth in recent years,” he said.

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 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.

“Our ColorForm system is used to produce parts using the injection compression moulding process, which are given a high-quality, transparent PUR surface for a special depth effect. Another line for the project is currently being commissioned,” said Luckner.

“Our customers, major OEMs from the automotive industry, place the highest demands on quality. There must be no defects larger than 0.2mm on the entire transparent component. With the MXW 1000 in combination with the RimStar Flex for PUR metering, we fully meet these requirements,” added Toni Luckner, process developer at Techniplas in Treuen.

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

Noted Chesshier, “Supply is outpacing demand since the seasonal PS demand has yet to materialize — partially due to conversion to other plastics or paper and the impact of lower-priced PS imports.” Moreover, production rates were increased by suppliers to about 70% capacity utilization from the low of mid-50% level, which reportedly resulted in supplier inventory buildup. Chesshier ventured that the likelihood of a decrease in PS prices in May-June was favorable as benzene prices typically fall during this period and benzene imports were increasing. Barry noted that demand remained weak and “suppliers saw little chance of stimulating additional sales by lowering prices more aggressively.” He characterized the spot market as having limited buying interest and flat-to-lower prices.

"ColorForm technology offers great potential for a lower CO₂ footprint in the production of components with a noble, multifunctional surface," said Michael Fuchs, global application owner surface and lightweight at KraussMaffei. By consolidating the process down into one step, the user saves time and resource on intermediate storage, painting, and reworking of components. By using a transparent polyurethane surface treatment, Techniplas can also achieve ‘depth effects’ on the final component. The company uses the MXW 1000 ColorForm system at its Treuen, Saxony site.

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.

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

Techniplas has used the ColorForm process for several years – although the manufacturer refers to it as “ColorFuse” technology. There are four ColorForm systems in Treuen and one in Rüti, Switzerland. An in-house technical center in Treuen also uses two further systems.

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

Both Newell and Barry ventured that April was just the start of a PP contract-price correction and that it would take a bit more time than a drop in spot-market prices. They also noted that the gap between contract and secondary market prices was very wide — 15¢/lb or more.

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.

PVC prices moved remained flat in March-April, though three suppliers issued increases of 4¢ to 5¢/lb, according to Paul Pavlov, RTi’s v.p. of PP and PVC, and PCW senior editor Donna Todd. Pavlov ventured that prices for the May-June period could continue flat but had the potential to drop by 2¢ to 5¢/lb.

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.

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

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.

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.

“We produce under cleanroom conditions in the process. Thus, when the mould is open, no grain of dust can get between the coating and the substrate surface. We thus achieve very low reject rates,” Luckner said.

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.

"There, all necessary equipment is available on-site, and commissioning at the TechCenter was also completed on schedule – both for the injection moulding machine and for the PUR technology, that is, for the RimStar Flex with two MK 5-2K CCM mixing heads for simultaneous production of two components. This cannot be taken for granted under the current basic conditions determined by the pandemic," says Luckner.

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

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.

The MXW 1000 was not just retrofitted for ColorForm technology. Its control system was also completely upgraded to KraussMaffei’s MC6 control system, and a new ORCA cooling system was installed. "The system performs a contact-free temperature measurement, which minimises maintenance. The technology allows us to control the twenty cooling circuits of the MXW precisely and thus makes a critical contribution to the high, uniform quality of the components," explained Luckner.

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

The RimStar Flex ColorForm reaction process machine, which was designed specifically for this process, and the mixing head, feed the surface material (PUR/PUA) directly into the cavity. “RimStar systems take up very little space and meter even small amounts precisely and at a high cycle frequency,” said Philipp Strasser, global application owner, RPM and automotive at KraussMaffei.

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

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.

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.

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 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

With advocacy, communication and sustainability as three main pillars, Seaholm leads a trade association to NPE that ‘is more active today than we have ever been.’

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

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.

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

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.

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.

Polyethylene prices in March rose unexpectedly by 3¢/lb, with suppliers attributing the move to a combination of increased demand and force majeure actions, according to Greenberg; David Barry, PCW’s associate director for PE, PP and PS; and Robin Chesshier, RTi’s v.p. of PE, PS and nylon 6 markets. Greenberg noted that while suppliers were announcing increases of 5¢/lb for April, the market would likely remain flat, “holding onto the 6¢/lb  increase implemented during the first quarter, which includes 3¢/lb that somehow managed to take hold in March.”

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

Tobe Packaging’s breakthrough was to create its Ecolefin PE multilayer film that could be applied with a specialized barrier coating.

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.

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

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.

Using ColorForm tech means Techniplas doesn’t need to transport and paint components, or invest in a painting plant. The finished components are also ready for installation when they’re discharged from the automated production cell, saving on buffer storage and drying.

In this three-part collection, veteran molder and moldmaker Jim Fattori brings to bear his 40+ years of on-the-job experience and provides molders his “from the trenches” perspective on on the why, where and how of venting injection molds. Take the trial-and-error out of the molding venting process.

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

August 29-30 in Minneapolis all things injection molding and moldmaking will be happening at the Hyatt Regency — check out who’s speaking on what topics today.

Plastics Technology’s Tech Days is back! Every Tuesday in October, a series of five online presentations will be given by industry supplier around the following topics:  Injection Molding — New Technologies, Efficiencies Film Extrusion — New Technologies, Efficiencies Upstream/Downstream Operations Injection Molding — Sustainability Extrusion — Compounding Coming out of NPE2024, PT identified a variety of topics, technologies and trends that are driving and shaping the evolution of plastic products manufacturing — from recycling/recyclability and energy optimization to AI-based process control and automation implementation. PT Tech Days is designed to provide a robust, curated, accessible platform through which plastics professionals can explore these trends, have direct access to subject-matter experts and develop strategies for applying solutions in their operations.

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.

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.

Polystyrene prices in March moved up by 2¢/lb and then dropped the same amount in April in step with benzene contract settlements. However, benzene spot prices were on the rise — 20¢/gal above April contract levels –  along with an 8% rise in crude-oil prices, which was likely to lead to a May PS contract price increase, according to PCW’s Barry and RTi’s Chesshier. Barry confirmed that at least one supplier had nominated a 4¢/lb price hike for May, but that implied styrene costs based on a 30% ethylene/70% benzene formula were down more than 3¢/lb at April’s end as spot benzene values dropped sharply.

All three sources referred to preliminary data from the American Chemistry Council (ACC), which showed March PP operating rates to be 6% lower than February on a daily output basis, and March PP sales to be lower again on a daily average basis, resulting in an accumulation of just over 50 million/lb of supplier inventory.

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

Todd reported, “While there have been no official announcements that the April price increase has been rescinded, the fact that one supplier (OxyVinyls) never supported it, and the continued erosion of export prices, plus a market forecast of flat pricing for April, have pretty much sounded its death knell.” She noted that buyers would resist any increase, barring a major supply disruption. Both sources characterized demand as sluggish.

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.

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.

Pavlov noted that first-quarter demand showed an uptick month-to-month, primarily due to exports, but demand year-to-year was down more than 15% for PVC pipe and more than 20% for all other PVC market sectors.

ColorForm is KraussMaffei’s combination of injection moulding technology and surface finishing with polyurethane in a single step. The technology is designed to make large-scale production of high-quality components more economical and sustainable.

A new system has recently been put into operation, for which Techniplas used an existing MXW 1000 injection moulding machine from KraussMaffei as the basis. Techniplas had the MXW retrofitted at its manufacturer's main factory in Munich's Allach neighborhood.