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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.

FIG 5 Following a purging, material remains in the barrier screw’s flights, getting darker as it gets closer to the tip. Photo: Joe Cascarano

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.

Not all the pellets melt, and the resulting solids bed breakup provides for poor melt uniformity, as well as several of the previously listed problems. It is also common for the plastic to stagnate where the flights mate with the root diameter. This stagnation causes discoloring, degradation and solids bed breakup.

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This article focuses on only one aspect: No. 4: Processing/Molding. Specifically, we’ll look at obtaining a uniformly melted shot of plastic to form a functional part. This is critical for the part to perform, yet grossly overlooked by most processors. Typically, most molders use the stock “General Purpose” (GP) screw. See Figure 1.

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

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.

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).

Also, note it gets darker as you get closer to the screw tip. Because this is after purging, you can understand that this material stays there during production and will degrade over time. You get even more degradation and black specks. So, if a barrier screw is not the answer, what is?

Xaloy is investing in a new R&D Facility for plasticizing equipment in northeast Ohio with aid from JobsOhio R&D Center Grant.

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.

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

“The collaboration with Insit is a special one,” explained Fabio Bonfiglietti, the account manager who supports Insit. “Luigi Galgani has a vision for how he wants to run his company, for it to be innovative and to continue improving its sustainability. He keeps us on our toes with new developments, and he supports us when the materials are ready for testing and validation. His is a fun company to support.”

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 is a proud dachshund owner.

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.

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.

Typically, 70% or more of a polymer’s global warming potential (GWP) is derived from its monomers. “Hytrel HTR9223LCF is manufactured utilizing monomers with significantly lower GWP,” explained Petros Dafniotis, global Hytrel T&I leader for automotive boots and bellows. A life-cycle assessment indicates that Hytrel HTR9223LCF can reduce GWP by 30% or more per part versus standard Hytrel commercial grades for constant velocity joint (CVJ) boots.

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.

To prove out this new design, I am seeking four or five shops to trial this new screw. I am offering to pay $1000 to the screw supplier who developed it toward the purchase of this new screw design, providing the accepting molder agrees to share production data before and after testing the new design (within 6 months of receipt of the screw). The participating molders will also need to agree to use a specific common nozzle tip, costing $20. Plastics Technology and I will then review this data and write a follow-up article showing results. In short, technology changes and there is good chance that new screw technology will make your life easier and save you some money to boot.

About the author: John Bozzelli is the founder of Injection Molding Solutions/Scientific Molding in Midland, Michigan, a provider of training and consulting services to injection molders, including LIMS and other specialties. Contact john@scientificmolding.com.

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.

“The automotive industry needs to become more sustainable. We are pleased to be one of the first companies to test and certify the performance of Hytrel HTR9223LCF and look forward to press blow molding the material to help our customers reduce their environmental footprint,” added Galgani.

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.

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.

Back in the early 1990s, I was fortunate enough to have worked on a research program to solve problems of mixing color concentrates into natural resins. After about a year and a half and more than $250,000 spent on several barrier-type screws, we did not have an answer. One screw supplier had a “melt uniformity screw.” This melt uniformity screw passed rigorous requirements for color distribution and uniformity. We trialed it further in seven production machines making complex parts for six months. The results were impressive (see accompanying table).

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

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.

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

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.

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.

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

Like pieces in a puzzle, these components interact with each other. Each has a staggering number of details that interrelate. So where to begin? First is to build a team — not one or two people — that encompasses these five components. It would be nice if the team members were all within your company, but that is not what I suggest. Build your team, but realize the best of us make mistakes. So double check the first three key components with known experts before the tool is built. Yes — the time and expense are worth it.

In September 2022, Galgani and his leadership team were invited to attend a customer event at the Meyrin, Switzerland, facility of Celanese. There, Galgani and his colleagues learned about a new thermoplastic copolyester (TPC) elastomer, Hytrel HTR8745LV, that enables injection molding of diaphragm boots in multi-cavity molds. For manufacturers, injection molding offers the chance to increase productivity compared with blow molding and to save material by designing more compact bellows.

The data speaks for itself. General-purpose screws are costing you money. Melt uniformity screws, not barrier designs, will save time, make your life easier on the shop floor and make you significantly more money with less hassle. Check out what Mike Sepe had to say about his trials with the screw design.

“My team is very strong, but we also seek partnerships that bring us even further. The collaboration with Celanese has done exactly that, and helped my company win new business in an exciting and expanding part of the automotive industry,” Galgani commented.

There are solutions, but be careful who you talk to. When anyone asks for better melt quality, most machine and screw manufactures provide the knee jerk response: “Try our barrier screw.” I say, do not waste your time! Why not? Figure 5 shows a typical barrier type screw after it was purged. Note the green polymer is still in the barrier flights.

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.

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.

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

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

I’m looking for a few good molders to help trial a new screw design, and share data and results for a future article to prove the benefits of a melt uniformity screw.

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

The team at Insit was very interested and asked the processing and advanced CAE experts at Celanese for support during trials of the material at a new Insit facility in Italy. The trials went so well that Insit introduced the parts to its Tier 1 customer, which also quickly recognized the value of the new material and the positive aspects of injection molded boots and bellows.

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.

Figure 3 presents actual samples showing solids bed breakup and poor melt uniformity. Figure 4 shows the typical degradation of the polymer often seen when a screw is pulled for cleaning or repair. My guess is that roughly 80% of all machines running today exhibit these problems. This is a global problem in the molding industry. How much does this cost you in degraded resin, wasted machine time and color changes? Big bucks!

Why is it so important? You would be hard pressed to name a single, common molding/part problem that melt non-uniformity does not cause or exacerbate. To name a few:

Further, validation testing at a Tier 1 parts supplier proved performance of the parts for rear half-shaft drive trains in electric vehicles (EVs), and this Tier 1 has asked Insit to begin commercial supply of the injection molded bellows for new EV models being launched in Europe, with start of production in 2023 and 2024.

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

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

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

Time passes and with the help of a new screw manufacturer and two years of research/trials, we have an updated version. After a year of testing, it has passed my tests for melt uniformity and provides rapid color/material change, in addition to being easier to clean. Figure 6 provides an example of a resin change in less than eight shots without purging.

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.

Under the leadership of owner/president Luigi Galgani, automotive parts manufacturer Insit (Montà, Italy) has long been willing to experiment with new materials and processes. The results have been positive, as the company has expanded its manufacturing network beyond Italy to encompass Brazil and India, thereby supporting its global customer base. The majority of Insit’s business is generated by press blow molding of boots and bellows for the automotive industry. This is complemented by production of injection molded components, which are always processed using materials supplied by Celanese.

Material savings realized by injection molding of compact boots is one way to improve the sustainability of vehicles. Insit, however, has gone one step further as one of the first manufacturers to have tested and validated the performance of another recent Celanese innovation, Hytrel HTR9223LCF thermoplastic elastomer with a lower carbon footprint.

FIG 4 Degraded polymer shown at junction of flight and root diameter of a general purpose screw (dead space). Photo: J. Bozzelli

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.

Editor’s Note: This article updates a column originally published in the January 2021 issue. At that time, the author was struggling to find a manufacturing partner for the new screw design. He has since found a manufacturer for the screw and, with a year of testing data in hand, he’s ready to issue a challenge to our molding readers.

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

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

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.

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

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 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.

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 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

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.

Big money can be saved and higher production rates can be realized by obtaining melt uniformity. So, what does it take to get that melt uniformity? Let’s start with the melt model of a GP screw shown in Figure 1, which shows a typical design with a 20:1 Length/Diameter (L/D) geometry. Figure 2 attempts to show the non-uniformity of melt developed during typical processing with this 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

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.

What is required for an injection molding company to make plastic parts profitably with a sustainable future internationally? The number of variables involved is staggering. So where do you start? There are five key components of making acceptable parts profitably … long term:

By switching from press blow molding to injection molding automotive boots and bellows and using a newly developed elastomer, Insit increased productivity and reduced material usage.

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.

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

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

Renowned screw designer Robert F. Dray wrote to me recently, lamenting that injection molding screw design has not received the kind of attention that the extrusion industry has paid to perfecting this fundamental processing component.

This screw dominates the market, yet it is well established that it does not provide melt uniformity. I think it was Bob Dray who labeled these as “No-Purpose” screws. That is, GP screws fall far short in providing melt consistency or uniform temperature. But both are critically important for production.

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.