Signal Plastics, based in Washington, has recently acquired a state-of-the-art Yizumi 700-tonne injection moulding press. This strategic acquisition aims to bolster production capabilities and meet the increasing demand from an existing customer as part of their production ramp-up. Equipped with a Sepro robot for demoulding and a conveyor belt to enhance productivity, the new 700-tonne press will significantly contribute to meeting customer requirements efficiently and effectively.

Over the past five years, the group has added seven additional injection moulding machines, significantly expanding its injection moulding machine capacity from 23 to 30 machines, ranging from 40T to 1,300T. Further significant investments have been made in warehousing, and material handling systems to support the additional moulding capacity.

The trial cell is equipped with two injection moulding machines, including a 40-tonne machine and a 100-tonne machine. This dedicated resource ensures optimal flexibility and precision during tooling validation processes, enhancing the overall customer experience.

Another advantage of the PP-UMS foam resin–based panel is its impact resistance. In addition, panels using the Sabic foam resin can be repaired easily if damaged and are durable because the foam resin does not react with water.

Sabic PP-UMS foam resin’s processing versatility allows PP foams, subject to user testing, to be used in structural cores for sandwich panels in delivery vans, trucks, and recreational vehicles (RVs), and to provide structural and insulative properties in blow-molded air ducts. Examples of these applications, on display at the Sabic booth, illustrate the suitability of this foam resin for broad use in transportation components that can benefit from significant weight reduction and potential cost optimization.

Blow-molded PP foam produced with Sabic PP-UMS foam resin can be used in automotive air ducts to help reduce weight and simplify the mounting process in the vehicle. The foam resin creates a mono-material part for easy recycling in existing waste systems. An air duct, approximately 60 inches long (pictured at the top of this article), is in commercial use and can be viewed at the Sabic booth.

The trial cell offers a dedicated area for comprehensive testing, allowing for analysis of key characteristics such as fill patterns, thermal imaging, gate freeze studies, cycle time efficiencies, and their direct influence on final product quality. By introducing this dedicated trial resource, Omega Plastics can support customers by providing insights and expert validation of tooling solutions.

Sabic PP-UMS foam resin is a new-generation, long-chain branched PP material with a melt strength greater than 65 cN to enable very low foam densities (20 to 200 kg/m3). It offers a broad processing window using various methods — foam extrusion, foam injection molding, foam blow molding, particle foaming, and foam blown and cast film. Sabic supports its materials with the resources of the Foam Innovation Center in the Netherlands. The center provides leading-edge technologies and a platform for collaboration with customers and organizations across the foam industry value chain.

Besides weight savings and recyclability, this air duct offers additional functionality, including insulation properties that can save energy and help extend the range of electrical vehicles. This inherent insulative capability and smart design help manufacturers avoid the need to add insulation to the part. The results are additional savings on weight and cost (labor and material).

The PP foam produced with Sabic PP-UMS foam resin can function as a strong, insulative core material for sandwich panels in trucks, delivery vans, and RVs, replacing metal, wood, and competitive foams. Panels with PP foam cores produced from Sabic PP-UMS resin can reduce weight and help lower carbon dioxide emissions.

Peter Sayer, group commercial director at Omega Plastics Group, said: "At Omega Plastics Group, our mission is to provide high-quality plastic injection mould tooling, components, assembly, and technical solutions on time and with exceptional customer service. These recent expansions and investments in our capabilities and resources demonstrate our commitment to our customers, ensuring we continue to exceed their expectations and deliver innovative solutions."

Omega Plastics Group, an integrated plastic injection moulding group has announced the addition of new injection moulding press capacity at both Signal Plastics and Omega Plastics.

“This distinctive foam resin with exceptional melt strength enables the extrusion of PP foam with very low density, which can help the transportation industry advance lightweighting goals by replacing heavier material combinations ranging from metal and wood to solid polymers,” said Amanda Roble, director, Advanced Consumer Solutions. “But Sabic PP-UMS foam resin does even more. Its purity and cleanliness address the most stringent automotive emission regulations, while its processing flexibility and blendability make it adaptable to many different applications. We look forward to working with the transportation value chain to develop new and innovative foam solutions.”

A sample composite PP sandwich panel from an RV floor, comprised of a glass fiber–reinforced PP face sheet and foam core, is on display at the Sabic booth.

Structural cores for sandwich panels in delivery vans, trucks, and recreational vehicles can be made from Sabic PP-UMS foam resin. Image courtesy of Sabic.

Stephen has been with PlasticsToday and its preceding publications Modern Plastics and Injection Molding since 1992, throughout this time based in the Asia Pacific region, including stints in Japan, Australia, and his current location Singapore. His current beat focuses on automotive. Stephen is an avid folding bicycle rider, often taking his bike on overseas business trips, and a proud dachshund owner.

Sabic is spotlighting two diverse transportation applications that demonstrate the potential benefits of Sabic PP-UMS (Polypropylene – Ultra Melt Strength) foam resin at NPE2024 (Booth S19005). The material features high melt strength for high levels of foamability and enables the extrusion of PP foams with very low density, good impact resistance, and compliance with VDA 278 emission regulations.

In addition to the press expansion, Omega Plastics based in Gateshead, has established a dedicated tool trial cell to support its UK toolroom and in-house tool manufacture, operating independently of planned production activities. This specialised validation facility enables Omega Plastics to test and validate new tools without any impact on ongoing production processes.

These recent investments in additional injection moulding capacity and dedicated tooling resources are part of Omega Plastics Group's ongoing commitment to continuous improvement and customer satisfaction.

Across the wide press range, Omega Plastics Group can produce components with shot weights ranging from less than 1g to 4kg. The group has capability to mould complex technical hand loads and overmoulds through to fully automated robot demoulding with integrated conveyor systems.

The Sabic foam resin is typically combined with other PP materials to produce the foam core. Adding a glass fiber–reinforced PP face sheet results in a mono-material part that is easier to recycle than a mix of material types. Furthermore, foam produced with Sabic PP-UMS foam resin can be thermally bonded to the PP face sheet, avoiding the need for adhesives.

During that time investments have also been made in the toolroom, including the acquisition of a Puma GT 2100 CNC Lathe, a new surface grinder, an Agie Carmilles EDM drill and a Fanuc ROBOCUT wire EDM, as well as in metrology software and capabilities. These investments allows Omega Plastics to aim to consistently meet customer demands and provide cutting-edge tooling solutions.

Sabic is exhibiting two transportation applications at NPE that demonstrate the lightweighting, processing, and sustainability features of its PP-UMS foam resin.