Phillips noted that the biggest challenge was the logistics involved in delivering the mold. After the mold was built, it was disassembled and placed on a fleet of 15 trucks for shipping from Lansing, MI, to Winchester, KY.  A team of moldmakers was then sent to Kentucky to re-assemble the mold on Infiltrator's plant floor.

Bryan Coppes, VP of engineering at Infiltrator Systems, said, "Rounding out the successful IM-Tank product line was a high priority for Infiltrator. Franchino is our largest tooling vendor and with their experience with our other large-part molds it made them the right choice for this project."

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.

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

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.

From three machines in 1986 to 27 plants nationwide today, this family-owned processor has prospered through unwavering customer service, committed employees and dedicated service to its community.

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

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

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.

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.

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.

The world's largest low-pressure injection molding machine, designed and constructed by Infiltrator Systems at the company's Winchester, KY, manufacturing facility, took five months to engineer and nine months to build. However, today the machine is producing the Infiltrator IM 1530 Septic Tank product line being molded in a mold designed and built by Franchino Mold and Engineering of Lansing, MI. The mold installed in the press weighs 420,000 lbs. and molds a 15-foot long, 245-lb. polypropylene tank half, which the company claims is the world's largest molded part.

The mold is built with aluminum core and cavity, housed in a steel mold base in what is known as a "hybrid mold" and took more than 10,000 man-hours to build.  The cavity work was done using multiple Tarus 5-axis mills with table sizes of 114" x 120." It also contains the largest hot runner manifold system in operation in the world, explained Todd Phillips, VP of Franchino, which specializes the design engineering and manufacturing of very large molds to produce products that challenge the limits of injection molding. "This is the largest mold we've made to date," Phillips told PlasticsToday.

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 IACS offers a choice of two equipment types for exchanging cold air inside the part during the cooling cycle; both were exhibited by Farragtech at K 2019 in Düsseldorf. One is the Blow Molding Booster (BMB), the more economical choice, and also less powerful but less sensitive in terms of compressed-air quality, and also completely maintenance-free, according to the company. It produces a compressed-air temperature of about 5 C (41 F), eliminating the need to dry the compressed air. It requires only compressed air at 6 to 15 bar and a supply of cold, filtered water no warmer than 15 C (59 F). It comes in three sizes from 99.4 to 372.7 scfm, and generally affords production increases from 10% to 35%, according to Wittmann. Compact design typically enables installation right at the molding machine, keeping supply lines short.

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

Maker of one-stage ISBM machines will show off new sizes and styles of handled and stackable PET containers, including novel interlocking products.

A project of this magnitude certainly is a partnership, and Phillips commented that Infiltrator is a great partner with which to work. "They are such an innovative company and willing to take risks.  We love to have them as a partner," he added. "They've taught us a lot over the years, and through our input we've helped them find solutions as well. They like to challenge us and we enjoy meeting those challenges that result in success."

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.

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

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

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.

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.

Both IACS products utilize special Blow Valve Blocks (BVBs) that control flow of cooled compressed air through the core pin into the product and discharge of air from the product via controlled ventilation. Each blow molded product requires its own special core pin to provide the precise distribution of cooling air appropriate to its size and shape.

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

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

Franchino previously created what is now the world's second largest mold, Infiltrator System's IM-1060 tank in a mold to produce a part weighing 160 lbs.

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

Despite price increase nominations going into second quarter, it appeared there was potential for generally flat pricing with the exception of a major downward correction for PP.

The world's largest low-pressure injection molding machine, designed and constructed by Infiltrator Systems at the company's Winchester, KY, manufacturing facility, took five months to engineer and nine months to build. However, today the machine is producing the Infiltrator IM 1530 Septic Tank product line being molded in a mold designed and built by Franchino Mold and Engineering of Lansing, MI. The mold installed in the press weighs 420,000 lbs. and molds a 15-foot long, 245-lb. polypropylene tank half, which the company claims is the world's largest molded part.

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

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 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.

Infiltrator Systems, a Graham Partners portfolio company, employs approximately 280 people at its facility. Through its subsidiary, Champion Polymer Recycling, Infiltrator is a leading purchaser of "green materials" including post-consumer and post-industrial recycled plastics used in the manufacture of Infiltrator products.

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

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."

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.

Coppes added that the ability to mold septic tanks of this size "opens up a lot of doors" for the company in this marketplace. He noted that there is more demand for polymer septic tanks as replacements for concrete tanks because of the greater strength of the polymer tanks as well as the ease of installation and the fact that no large equipment is required.

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

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.

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

Franchino employs 85 people currently, but that will change as the company's expansion plans evolve. Phillips noted that the company recently purchased another 62,000-sf facility behind a current plant and the two buildings will be connected. "We're going through the building modifications now and moving equipment in, which will include a 50-ton crane to accommodate the larger sizes of the molds we build," he said.

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.

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 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

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

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.

Wittmann’s Blow Air Chiller (BAC) is the top-of-the-line IACS offering. It’s said to provide production increases of 35% to aboe 50%. In some cases, blowing and cooling time can even be cut by two-thirds, the company says. This system is more complex; it requires high-quality compressed air at 7 to 15 bar with a residual oil content of 0.01 mg/m3 (0.01 ppb) and a pressure dewpoint of 5 C at 7 bar or less. Inside the BAC, compressed air is fed through the internal Pressure Air Dryer (PAD) with a molecular sieve desiccant, which regenerates itself simply by means of dry compressed air. The PAD lowers the dewpoint of process air to -40 C/F. Like the BMB, the BAC requires a cold water supply at 15 C/59 F or lower at a pressure of 3 to 8 bar.

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

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

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.

Second quarter started with price hikes in PE and the four volume engineering resins, but relatively stable pricing was largely expected by the quarter’s end.

Formnext Chicago is an industrial additive manufacturing expo taking place April 8-10, 2025 at McCormick Place in Chicago, Illinois. Formnext Chicago is the second in a series of Formnext events in the U.S. being produced by Mesago Messe Frankfurt, AMT – The Association For Manufacturing Technology, and Gardner Business Media (our publisher).

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

What's happening across the country is that the cost of expanding sewer plants has risen and a lot of the federal grant money for these infrastructure projects has dried up," Coppes explained. "That means more people and communities are looking at septic systems rather than sewer systems."

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.

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.

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.

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.

Once viewed by injection and blow molders as a necessary evil, machine vision technology today can continuously monitor and improve production while reducing costs.

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.

Each shot is a mirror image of itself with a cutout in the top for tank access. "Other than that the tanks are symmetrically the same," said Coppes. One half has gaskets and the halves are sealed together. The parts handling and finishing stations utilize what Infiltrator believes is the largest six-axis robot in the world.

Franchino has many years (16-18) of experience with building aluminum and hybrid aluminum and steel tooling for very large parts. Phillips said that some of those molds the company built have one to two million shots on them, a testament to the longevity of aluminum tooling in many large-part molding applications.

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.

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

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

Coppes told PlasticsToday that the company's success with its 1000-gallon septic tanks led the market to demand tanks in a 1500-gallon size. Infiltrator is the world's largest septic products company. Molding a tank this large required a 6,000-ton low-pressure injection molding machine. "We brought in a lot of resources to help us redesign and engineer a press to make it suitable for our needs," Coppes explained. Infiltrator molds its own product and parts requirements in-house, and also has a number of regular injection molding presses to mold its other 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.

Blow molding production increases from at least 15% to more than 50% are promised with Internal Air Cooling Systems (IACS) from Wittmann Battenfeld. These systems were formerly marketed by Farragtech of Austria, which was acquired by Wittmann Group in late 2019. These systems cool the inside of the blown part with chilled compressed air, while the outside of the part is cooled conventionally by the water-cooled mold. This dual-surface cooling not only speeds cycles, but is said to reduce internal stresses compared with cooling on just one side of the part, allowing for thinner walls and weight savings of up to 10% while still passing the same leak, drop and strength tests. As a result, ROI for these systems reportedly is well under a year.