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.

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.

Once more, the PHA component will drive your temperature strategy. To achieve a stable and workable parison, you must keep your heat near the low end of processing temperatures for PHA.

This process requires a specialized two-shot injection molding machine equipped with two separate sets of screws and barrels. This technology is capable of producing components with both aesthetic appeal and functional strength, finding widespread applications in the automotive, consumer electronics, and medical equipment industries.

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

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

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

At this point, the PHA is separated from the cellular components and processed, resulting in a light, white powder that can be combined with other materials like PLA to produce processable and usable bioplastic resins. These materials are typically compostable in home and industrial environments, and degradable in soil and marine environments.

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.

Two-shot molding, a sophisticated injection molding technique that simultaneously uses two different materials or colors in the same molding process, demands highly precise molds. Ensuring the success of this process involves strict control over several aspects.

This video shows the trial process of 2-shot molding. Because the product is small and has an undercut feature, it can’t be automatically removed from the mold. It might get stuck on the mold’s lifter, so it needs to be taken out manually.

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.

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

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 many cases, decreasing the discharge temperature will improve product quality and perhaps even boost rate. Here are ways to do it.

In the current legislative climate of bans on petroleum-based plastics and consumer requests for sustainable alternatives, bioplastics offer a unique opportunity. In prior decades, there has been significant resistance to bioplastics because of cost as well as unique, and often difficult, processing characteristics. Now, however, the development of many polyhydroxyalkanoate (PHA)-based resins — often combined with polylactic acid (PLA) — has resulted in bioplastic solutions that are well suited to current market needs.

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.

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

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.

This strategic collaboration will support long-term growth of bioplastics production requiring a blend of PHA and PLA inputs.

Currier Plastics had a major stake in small hotel amenity bottles until state legislators banned them. Here’s how Currier adapted to that challenge.

As noted, PHA is a hygroscopic polyester that will absorb environmental moisture. Having the material dry before processing will prevent degradation and melt thinning. A moisture content of less than 0.04% (400 ppm) is required. Recommended drying conditions are four hours at no greater than 170°F (80°C) with a desiccant dryer.

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

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.

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.

Choosing compatible materials is crucial for a successful bond. The substrate and overmolding materials must be compatible in their molten states without adverse chemical reactions. Material suppliers often provide guidance on which material pairings achieve the best adhesion.

When discussing two-shot molding technology, it’s common to compare it with overmolding. Though these two techniques seem similar in many aspects, involving multiple (two or more) injection molding processes, there are key differences between them.

First Injection: The process begins with the injection of the first material into one of the injection units of the molding machine, forming part of the product. Once this step is completed, the partially formed component remains fixed within the mold or is moved to another position through rotation or shifting of the mold.

This 1-day technical conference and exhibition showcases innovative developments in materials, processing and equipment for the additive manufacturing industry. This conference is specifically designed to inform, update and educate plastic processors about implementing new additive manufacturing technologies. Hear technical presentations on the newest advances in additive manufacturing related to: design, materials development, processing equipment and enabling technologies, new applications and more. See exhibits from engineering plastic suppliers, compounders, molders, design and engineering firms and machinery suppliers. Experts will show you how to apply the latest technologies to your next project or program. The conference includes a full day of technical presentations, plenary and keynote presentations on business trends; breakfast, lunch and breaks; exhibits of advanced technologies and an evening networking reception.   Note: Additive Manufacturing Media executive editor Stephanie Hendrixson will moderate the Supporting AM Adoption in Northeast Ohio panel at 11:20 a.m.

An overview on the use of chemical foaming agents (CFAs) to successfully foam single and multilayered rotational molding parts, this webinar will illustrate the multiple benefits rotational molders can achieve, including reducing resin consumption, decreasing part weight, enhancing wall thickness and improving structural rigidity. Agenda: Charging the mold Dosing ratios Venting Optimal decomposition temperatures, cycle times and drop times for drop box applications Cooling considerations

As cycle and crystallizing times decrease, the bottles will become softer and easier to damage. It may require some engineering and automation adjustments to enable some post-molding cure time before the parts are bulk packaged.

Higher Mold Costs: The complex requirements for two-shot molds result in higher costs. Designing and manufacturing these molds demand extensive experience and precision, significantly increasing initial investments compared to traditional molding techniques.

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.

Enhanced Product Quality: Two-shot molding can produce more durable, structurally stable products. The integration of two materials can improve overall performance, such as impact resistance and sealing properties.

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.

Mold Rotation or Shifting: For some two-shot molding processes, the semi-finished product from the first injection needs to be transferred within the mold to a second injection position. This can be achieved by rotating or shifting the mold, depending on the design of the two-shot molding machine used.

To aid the crystallization rate, keeping the mold at 110-140°F (40-60°C) is recommended. The strategy is to get the mold warm enough to promote crystallization yet cool enough to enable part ejection and handling.

In some cases, the substrate’s surface may undergo special treatments such as sandblasting, chemical etching, or surface activation to increase its roughness and chemical reactivity, thereby enhancing the bond strength with the overmolding layer.

Private label manufacturer Eagle Beverage to use Danimer Scientific’s Nodax PHA for marine degradable straws and other product categories in the future.

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.

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

More than four years on, there are aspects of the COVID-19 pandemic that linger in their impacts to the plastics market and are made visible in our annual survey.

Here are processing guidelines aimed at both getting the PHA resin into the process without degrading it, and reducing residence time at melt temperatures.

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

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.

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

Recently, many processors have been experimenting with running PHA/PLA blends in their blow molding operations, with mixed success due to the blends’ unique characteristics. However, proper attention to the inherent characteristics of PHA/PLA materials when setting the processing parameters can lead to better and more consistent outcomes.

It would also be helpful to look at your extruder screw design and avoid screws with higher compression ratios or very short, aggressive compression sections.

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

The precision of mold alignment is crucial. Two-shot molding employs molds that include two sets of lower molds (moveable) and two sets of upper molds (stationary), which need to rotate or shift during the molding process to align interchangeably. It is essential to ensure that both sets of molds are completely consistent in terms of outer dimensions, internal cavities, and height.

Mold Opening and Ejection: After cooling and solidification, the mold is opened, and the finished two-color product is ejected.

At the interface of the two materials in their molten state, molecular diffusion occurs, meaning molecules from one material penetrate into the other. This helps form stronger chemical bonds and physical entanglements, enhancing the adhesion between the two materials

Mold design is also critical in ensuring a good combination of the two materials. The mold must precisely control the flow path of each material, ensuring that the second material forms a stable and uniform coverage over the first material’s surface.

In conclusion, while both two-shot molding and overmolding serve to create composite materials through multiple injection processes, they each offer unique benefits suited to different manufacturing needs.

AIM Processing has parlayed small part molding expertise and aggressive automation, even for short run production, into a highly successful custom molding business.

Plastics Technology Top Shops Benchmarking Survey provided both unanimous responses and divided results, but pervasive throughout is the sense of an industry still grappling with the aftermath of 2020’s global pandemic.

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.

You need to pay attention to the inherent characteristics of biopolymers PHA/PLA materials when setting process parameters to realize better and more consistent outcomes.

Second Injection: After the first part has solidified and been moved to the second position, the second material is injected into the mold through another injection unit, bonding with the first part to form the final product. This step requires precise control to ensure good adhesion between the two materials.

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.

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

In summary, two-shot molding is an advanced injection molding technique that efficiently combines two different materials or colors in a single cycle, offering significant advantages in terms of design flexibility, product quality, and production efficiency. Despite its higher initial investment in mold design and machinery, the technology presents a compelling case for applications requiring complex, multi-material components with high precision and strength.

The mold design and review process must be highly meticulous. Given the high cost of two-shot molds, any flaws in the design could lead to modifications in both sets of molds, thereby incurring additional costs. Therefore, the design stage of the molds must carefully consider various elements, including the design of gates and runners, the arrangement of sliders, and the layout of the cooling system. These aspects require thorough verification and validation to ensure no oversight.

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.

Typically, a CMM (Coordinate Measuring Machine, a three-dimensional measuring equipment) is used in production to check the precision of the molds, preventing injection molding defects such as flash due to misalignment.

The low melt temperature aims to achieve a parison with enough melt strength to hold together. You will find that PHA/PLA blends are sensitive to the smallest temperature changes, and viscosity will drop rapidly as melt temperature increases. We typically advise processors new to PHA/PLA blends to think of adjusting temperatures by two or three degrees at a time, not the usual five-degree changes.

Because PHA can degrade quickly under heat and shear, it is recommended that you purge fresh material forward anytime the machine is idled for more than five minutes before starting up again. It is not only the temperature of the melt that matters but also the residence time. High residence times will cause the material viscosity to decrease and can cause problems with machine startup.

Design Flexibility: It allows designers to combine different colors or types of plastics in one component, offering unique visual and tactile qualities.

It is recommended to purge the machine completely with LDPE to remove the previous resin and, after cooling the extruder to the process set points referenced below, introduce the PHA/PLA blend. This procedure should get you into the production material without degrading the resin. PHA/PLA blends have an upper temperature limit of around 400°F and will rapidly degrade around this temperature.

Another reason to keep the tool warm is that most blow-molded PHA/PLA blends will stick to a cold mold surface, making it difficult to eject them.

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.

Through the methods and mechanisms described above, two-shot molding can achieve a tight bond between the substrate and the overmolding layer, producing composite material products that are both aesthetically pleasing and high-performing. This technology is widely applied in various fields such as electronic devices, automotive parts, and medical instruments, offering more possibilities for product design and functionality.

What are the basic building blocks of plastics and how do they affect the processing of that material and its potential applications in the real world? Meet the repeat unit.

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

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.

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

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

In two-shot molding, the bonding between the substrate and the overmolding layer is achieved through chemical and physical processes, involving material selection, mold design, and processing conditions. This bonding process ensures that two different materials tightly integrate in the final product, forming a structurally intact and functionally robust composite. Here are several key factors in this bonding process:

At the end of production, the machine should again be purged clear of the PHA/PLA blend — using LDPE at process temperatures — before increasing temperatures to go to the next resin.

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).

This detailed process showcases the technical complexity and precision required in two-shot molding, allowing for the production of high-quality, multifunctional components used across various industries.

This area requires particular attention. The PHA component of the PHA/PLA blend requires a warm tool to promote timely crystallization. If you process into a cold tool at 40-60°F, the parts will come out soft and pliable and then, over the next 60-90 sec, become firm. What is happening is the part is crystallizing in your hand. The cold temperature is retarding the crystallization rate. When working with PHA/PLA blends, crystallizing and cooling are different. Parts can be cold and not crystallized.

Hopefully, this outline will provide some basis for developing a process for your parts. If you go at it slowly and methodically, you should be able to create a stable process and then improve from there. Remember that PHA/PLA blends are relatively new and different materials that require some new and different processing techniques.

One of the opportunities to use PHA and its compostable characteristics is in blow-molded articles. The positive end-of-life scenarios offer one possible solution to the overabundance of plastic in the market. PHA can be blow molded into various shapes, sizes and designs for many applications, from personal use to food and drink storage.

At Danimer Scientific, most of our research effort has been with extrusion blow molding (EBM), which is the process covered here.

Environmental Concerns: Utilizing two distinct materials complicates recycling efforts, as effectively separating these materials can be challenging. The complexity of recycling and the inability to reuse production rejects pose significant challenges for two-shot molding.

This CW Tech Days virtual event will explore the technologies, materials and strategies used by composites manufacturers working in the evolving space market. Presentations from industry experts will emphasize the use of composite materials in applications requiring the weight savings, structural benefits and ability to withstand extreme temperatures that only composites can provide.

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.

Increased Production Hourly Rates: Specialized two-shot molding machines are more expensive than standard injection molding machines. Additionally, operating these machines requires specialized skills, contributing to higher hourly rates.

There are five specific areas that designers and manufacturers need to consider to realize the potential of these unique materials.

Two-shot injection molding, also known as dual-shot or double injection molding, is an efficient injection molding technology that creates composite components made of two different colors or types of plastic materials within a single molding cycle.

When combining PHA with PLA, you will find that the processing requirements for the PHA will drive most of your processing strategies. PHA is hygroscopic and needs to be dry. It is sensitive to residence time and requires a warm (120-130°F) mold to crystallize.

To successfully extrusion blow mold PHA/PLA bottles you need to take heed of the unique processing charactertics of the material. Photos: Danimer Scientific

Uniloy is revising its machinery lines across the board and strengthening after-sales services in tooling maintenance, spare parts and tech service.

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

Two-shot molding necessitates the use of a specialized two-shot injection molding machine and precisely designed molds. The design of the mold must take into account the flow, cooling, and solidification characteristics of both materials to ensure they combine correctly within the mold. The steps are as follows:

You may also have to explore some forms of ejection and part holding as the mold opens to keep the bottles releasing consistently due to some variability in whether the bottles will stick to one side or the other or release cleanly.

About the Authors: Russell Mullins is Danimer Scientific’s special operations technical advisor and has more than 45 years of experience in plastics injection molding and product design. Dr. Karson Durie is associate director of Danimer’s facility in Athens, Georgia, and earned a Ph.D. in chemistry from the University of Georgia. Contact: 229-243-7075; russellmullins@danimer.com; danimerscientific.com.

The parameters during the injection molding process, such as temperature, pressure, and cooling time, need careful adjustment to suit the characteristics of both materials. Proper temperature and pressure can promote good material bonding, while the right cooling time ensures that the materials solidify without internal stress, affecting the bond strength.

An important part of any blow-molding process is how you handle the parts once molded. The handling of parts made from PHA/PLA blends will become more difficult as production speeds increase.

Cooling and Solidification: Following the injection of the second material, the entire component cools and solidifies within the mold. This stage is critical for the quality of the product, necessitating precise control over cooling speed and time.

Reduced Production Steps and Costs: This method consolidates the injection of multiple materials into one cycle, eliminating subsequent processes and lowering both production costs and time.

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.

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.

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.

Considering the emphasis on production efficiency in two-shot molding, mold designs should aim for automatic degating whenever possible. This means that at the end of the injection molding process, excess material from the injection ports can be automatically removed from the product without manual intervention. This reduces labor costs and enhances production efficiency.

Two-shot molding has the distinct advantage of producing complex, high-quality products with diverse appearances in a single molding cycle. It can reduce post-processing steps, enhance production efficiency, and lower costs. However, this technology demands high requirements for mold design and manufacturing, leading to relatively high initial investments.

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

When evaluating ERP solutions, consider the power of interactive production scheduling to effectively plan and allocate primary and secondary equipment, materials and resources on the overall production capacity of the business and conclude that this is a key area that cannot be overlooked.   __PRESENT

While extruder speed is directly related to cycle time, it should be noted that PHA is a shear heating material similar to PVC (polyvinyl chloride). As production rates and extruder speeds increase, you will see temperature override in your extruder zones. If your machine has heat cool bands, you can employ those to keep temperatures inline or you can try to introduce some heat earlier in the extruder to reduce friction and shear heating.

PHAs are a naturally occurring biodegradable material produced via bacterial fermentation, similar to brewing alcohol. During fermentation, when nutrients and food sources are optimized, the bacterial strains start making and storing PHA as a food source, eventually producing a peak amount of PHA.

The process of two-shot molding is outlined as follows, highlighting the intricate steps involved in creating a composite component within a single molding cycle: