With Demand Surging 127% MoM, Plastic Injection Molding Market to Reach/With Demand Surging 127% MoM, Plastic Injection Molding Market to Reach

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With Demand Surging 127% MoM, Plastic Injection Molding Market to Reach

Author：gly Date: 2024-09-30

$513 Billion in 5 Years - plastic injection molding services

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.

Much like flight OD wear, root wear is typically most severe in these high-pressure areas. Wear is most extreme on the forwarding side of the flight vs. the trailing side. The severity of root wear is greatly impacted by the resin or resins processed. When processing abrasive fillers, such as glass fibers or calcium carbonate, it is possible to see severe wear in the feed section as pressure is developed by the forwarding side of the flight, with limited lubrication provided by the unmelted pellets. The amount of filler present and particle shape strongly influence the intensity of wear. Larger particles with sharper corners tend to wear more than smaller, rounder particles. Unfortunately, the desired physical properties of the molded part dictate the filler to be used. Since wear is more rapid (with fillers) in the solids-conveying section of the screw, it is common for fillers to be added downstream where the polymer is already molten to allow for better lubrication.

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.

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.

Many reputable screw suppliers state that a screw can be rebuilt only three to four times. The size of a screw and a number of factors that contribute to the severity of wear can greatly impact the life of a screw, but it is not uncommon for an experienced screw manufacturer to rebuild a screw many more times. With high-quality welding, careful consideration of the metallurgical aspects of screw manufacturing, and proper flight-profile reconditioning, the author has seen screws being rebuilt up to six to eight times.

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.

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

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

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.

Screw wear is generally a slow process that can go unnoticed until performance is greatly reduced. Minor wear will have little effect on overall performance, as machine parameters can be adjusted to maintain productivity. When the radial clearance between the screw flights and barrel wall increases, leakage flow is inevitable. The operator will typically see a reduction in throughput and an increase in melt temperature, forcing higher rpm and energy consumption to maintain the desired rate. With increased radial clearance, the screw is unable to develop necessary pumping pressure to maintain the intended output.

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

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

A pressure differential is needed to generate a force deflecting the screw, not a general high pressure. Metal-to-metal contact can occur, but it is a result of mechanical conditions and is a symptom of potentially larger problems: misalignment, gearbox damage, bent screw, bent barrel, inadequate foundation, etc. Abrasion testing performed across many industries shows that increased pressure and temperature leads to increased friction. Since the transition section and last few turns of the metering section typically experience the highest pressures and temperatures, we can predict that this is where the bulk of OD wear occurs. This rings true empirically after inspecting and rebuilding thousands of screws.

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

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.

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

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.

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 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.

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.

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.

As many processors will agree, downtime is the enemy of successful production. Many extrusion and injection molding plants rarely, if ever, pull screws to record wear. Tight production schedules and maintenance complications can force companies to squeeze every ounce of life from existing equipment. The cliché, “If it ain’t broke, don’t fix it,” comes to mind.

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.

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

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

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

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.

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.

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

Niigon was founded in 2008 by Robert Schad under the original name of Athena Automation Ltd.. Schad, of course, founded Husky in 1953. Schad was inducted in the Plastics Hall of Fame in 2006.

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

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.

Stephen Surley is the founder and president of SpiraMelt Technologies in San Marcos, Texas, a supplier of custom extrusion and injection molding screws, barrels, and front-end components. He has been involved with all types of extrusion and injection molding processing, specializing in feed screw design and optimization. Contact: info@spirameltgroup.com; spirameltgroup.com; (512) 522-2639. He was employed by R. Dray Mfg. when he wrote this article.

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

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

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

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

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.

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.

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

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.

Mixing sections and barrier flights also tend to wear, as their function requires resin to flow over their flight geometry. Dispersive-mixing designs incorporate some form of undercut geometry that imparts high shear forces on the resin to promote a more isothermal melt and uniform color. As the mixing design wears, there is a loss of adequate dispersion. Much like dispersive-mixing designs, barrier flights are undercut to help separate the melt pool from the solid bed. As the undercut flight wears, barrier designs can lose melting capacity and efficiency.

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.

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

With baseline data, wear-monitoring procedures, and an understanding of what is happening to the screw, maintenance and engineering departments can significantly reduce downtime and increase their bottom line. Replacing high-performance feedscrews can be expensive, but an experienced screw manufacturer can rebuild worn screws to like-new condition for a fraction of the cost in less time.

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).

Trouble is, these types of practices can leave a processor in limbo when screw wear can no longer be ignored. Remember: Screw wear is a gradual process that can go unnoticed until scrap rates spike, energy consumption soars, or in extreme cases, catastrophic failure results. To save downtime and costs associated with buying and installing new equipment, many processors spend a fortune on the hidden costs of increased energy consumption and material waste. When a screw is finally pulled for inspection it may not be salvageable, forcing longer downtime waiting for new equipment.

Obviously, the amount of radial clearance is a key variable in leakage-flow calculations. A common “rule of thumb” considers a flight clearance four times the original tolerance to be the cutoff point for screw replacement, but it is important to consider the viscosity of the resin processed. A resin with higher viscosity will provide less loss of output than will lower-viscosity resins with the same radial clearance. These rules of thumb should be viewed only as guidelines.

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

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.

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.

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.

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

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

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.

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.

If careful consideration of wear monitoring is ignored, screw wear can be so extreme that it is difficult or even impossible to repair reliably. Typically, the cost of rebuilding a screw depends on the severity of wear and the amount of work required. An experienced screw manufacturer can inspect worn equipment and processing performance to determine if the current design is worth salvaging. In some cases, a new, optimized screw can greatly increase overall profitability rather than relying on the original, less-efficient design. Often the worn screw can even be re-cut, improving the performance vs. scrapping the old screw. To improve abrasive and corrosive wear resistance, hardfacing and surface treatments can be improved to extend the overall wear life of a screw.

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.

A homogenous melt is required for consistent part quality, but achieving it requires balancing a number of factors, including barrel usage and temperature as well as screw speed, backpressure and residence time. Learn how to prepare your melt for molding success in this two-part series.

Feedscrew wear in both extrusion and injection molding is similar; the majority of wear occurs in areas of high pressure--in particular, the transition section and last few turns of metering. Processors and suppliers commonly theorize that wear in these areas is caused by metal-to-metal contact between the flight OD and barrel ID, due to screw flexion under these high pressures. This theory is unlikely because the internal pressure is generally the same all around the screw.

Infinity Asset Solutions has been authorized to liquidate the two state-of-the-art manufacturing facilities that had been operated by Niigon Machines Ltd., the Toronto-based injection molding machinery and automation company that last month filed for bankruptcy and is now in receivership.

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

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.

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

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.

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.

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

Hobson and Rutkowske did a great job demonstrating how to diagnose excess screw wear by monitoring quality and performance issues. Now that we have some idea of what our extruders are “telling us” from a processor’s point of view, the next step is to explore what is happening to the screw and what can be done about it. In this article we will look at how screw wear affects melt quality and at the cost-effectiveness of rebuilding vs. replacing worn equipment.

Being in tune with your film extrusion equipment will allow you to identify issues before they start impacting production.

Root wear generally creates pockets and areas for material to hang up and degrade. This is observed as black specs in molded parts, and surging. Material degradation can become a serious concern when processing resins like rigid PVC. PVC tends to generate hydrochloric acid at elevated temperatures, leading to extreme corrosive wear on equipment. In extreme cases of root wear, the sides of the flights can become washed out, leaving little substrate to support the welded hardface inlay, as seen in Fig. 1. With no support, the brittle hardfacing material easily chips away, leaving rough edges, reduced flight width, contaminated extrudate, and potential damage to downstream components.

With proper baseline data and wear-monitoring procedures in place, and an understanding of what is happening to the screw, maintenance and engineering departments can develop a robust maintenance program to greatly reduce downtime and increase profitability. It is important to monitor screw wear before scrap rates and energy consumption soar. Don’t be too quick to throw out worn equipment. Consulting with an experienced screw manufacturer on the potential of rebuilding screws can not only reduce downtime but the cost of rebuilding tends to be a fraction of the cost of a new screw.

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.

As resin leaks over the screw flights, the material experiences excessive shear rates. This raises melt temperature, which is only compounded by the higher rpm needed to maintain output, as noted previously. Higher melt temperatures can lead to major quality concerns, as molded part physical properties are greatly reduced at these excessive temperatures. When processing amorphous resins, these high shear forces can easily burn and degrade the extrudate, leading to high scrap rates.

FIG 1 Extreme root wear, primarily on the forwarding side of the flights, causes severe chipping of welded hardface inlay.

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

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.

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 prices moved up for three of the five commodity resins, there was potential for a flat trajectory for the rest of the third quarter.

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

A collaboration between show organizer PLASTICS, recycler CPR and size reduction experts WEIMA and Conair recovered and recycled all production scrap at NPE2024.

After a screw is ground to a uniform undercut diameter, the flights must be rewelded to utilize the higher-hardness hardfacing alloys that provide maximum wear resistance (Fig. 2). After hardfacing, the screw OD must be ground to original tolerances (Fig. 3). The leftover overhanging weld must be profile ground to provide minimum flight-width loss. In many cases, poor practices reduce the effective flight width during this process, potentially affecting screw performance and complicating future rebuild potential. To help alleviate these complications, some screw manufactures opt to reduce the width of weld. When these screws are ground to original tolerances, the welded hardface does not encompass the full flight width. This negatively impacts wear performance due to the exposed softer base material.

To help better predict the effect of diametrical wear, you can calculate leakage flow by considering overall clearance, flight width, lead, head pressure, viscosity, and melt density. These calculations can become quite cumbersome when trying to accurately predict throughput; but fairly accurate estimations can be generated that predict potential rate loss. To help processors and maintenance departments predict this loss of productivity, the author has developed a rate-loss calculator that estimates the potential loss of rate due to screw wear. This tool helps conceptualize the severity of wear and helps teams develop a plan for screw replacement or repair.

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.

Good rebuilding practices should allow for screws to be salvaged many times, passing on major savings in maintenance cost. A robust planned maintenance program rooted in baseline data, wear monitoring, and a basic understanding of screw wear is far better than reactive maintenance.

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.

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.

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

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.

Infinity says featured items include nine new and demo injection molding machines; paint spray and wash booths; clean room; resin drying and handling equipment; material handling and rolling stock; chiller systems; air-management systems; electrical testing equipment; plant support and maintenance; and more. There are ongoing negotiations with potential end-user buyers, according to Infinity.

This tool was used to generate the results shown in Tables 1 and 2, which reveal the estimated rate loss for PP and PE under the same conditions. Notice that the more viscous PE suffers less rate loss than does PP. When processing other shear-sensitive resins such as PVC and PC, minimal wear can adversely affect quality due to the increase in melt temperature from excessive shear

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.

Feedscrew and barrel wear is a serious matter for maintenance and engineering departments in both extrusion and injection molding, and rightfully so. Excessive wear in a plasticating unit poses a litany of serious performance issues, naturally affecting cost and overall quality. In an article that appeared in Plastics Technology’s February 2018 issue, “What Is Your Extruder Trying to Tell You?,” authors Wes Hobson and Mike Rutkowske from The Dow Chemical Company illustrated the need for baseline data and wear-monitoring procedures to avoid excessive loss in productivity.

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

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 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.

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.

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.

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

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.

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

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

Addressing hot-runner benefits, improvements, and everyday issues from the perspective of decades of experience with probably every brand on the market. Part 1 of 2.

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