A 360-degree look at resin conveying systems: types, operation, economics, design, installation, components and controls.
This Knowledge Center provides an overview of resin moisture and the drying process, including information on the best drying practices for your manufacturing facility. Plastic Bottle Crushing Machine Price
Combat the skilled labor shortage using this comprehensive resource to train your own plastics processing experts.
Deep dive into the basics of blending versus dosing, controls, maintenance, process integration and more.
This Knowledge Center provides an overview of the considerations needed to understand the purchase, operation, and maintenance of a process cooling system.
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.
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.
While the major correction in PP prices was finally underway, generally stable pricing was anticipated for the other four commodity resins.
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.
First quarter was ending up with upward pricing, primarily due to higher feedstock costs and not supply/demand fundamentals.
Despite earlier anticipated rollover in prices for most of the volume commodity resins, prices were generally on the way up for all going into the third month of first quarter.
While price initiatives for PE and PVC were underway, resin prices had rollover potential for first two months of 2024, perhaps with the exception of PET.
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.
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 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.
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.
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.
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.
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.
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.
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.
Thousands of people visit our Supplier Guide every day to source equipment and materials. Get in front of them with a free company profile.
NPE2024: Lowering barriers to additive manufacturing adoption in toolmaking.
Allegheny Performance Plastics turned to 1factory's cloud-based manufacturing quality control software for streamlined, paperless quality systems.
To design the best mixers for single screws, you must completely understand how polymer moves through a mixer channel or groove.
NPE2024: Focus is on additives for plastics including PVC and WPC industries.
At NPE2024, Novatec moves to rewrite the rules for material conveying with patent-pending smart-pump technology.
While the major correction in PP prices was finally underway, generally stable pricing was anticipated for the other four commodity resins.
With no minimum order and an impeccable record of on-time delivery, Precision Color Compounds is becoming a force in the color masterbatch business.
Thermosets were the prevalent material in the early history of plastics, but were soon overtaken by thermoplastics in injection molding applications.
After a six-year hiatus, this year’s show was a resounding success, with meaningful technologies on display that will help processors run their businesses more efficiently.
Key factors for the progress are innovative materials, advanced automation and precision engineering.
Topping five other entries in voting by fellow molders, the Ultradent team talks about their Hot Shots sweep.
Serendipitous Learning Opportunities at PTXPO Underscore the Value of Being Present.
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.
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.
Shibaura discusses the upcoming Plastics Technology Expo (PTXPO) March 28-30
Line features a single touchscreen for easy setup and operation.
Oerlikon HRSflow’s T-Flow HRS control has launched with three models that are configurable to multiples of six zones.
NPE2024: Dukane’s new Ultrasonic Thin Wall welding system is well suited for welding applications of PP to PP TD25 painted parts.
Series offers higher output, lower melt temperatures and energy savings.
Noting that geopolitical changes require new corporate strategies, European plastics and rubber machinery trade groups announced that incoming orders fell 22% in 2023.
System tracks, controls and saves everything from material recipes to process parameters, operator activity from logging on to start, to emergency stops and more.
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.
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.
Multiple speakers at Molding 2023 will address the ways simulation can impact material substitution decisions, process profitability and simplification of mold design.
When, how, what and why to automate — leading robotics suppliers and forward-thinking moldmakers will share their insights on automating manufacturing at collocated event.
As self-imposed and government-issued sustainability mandates approach, injection molders reimagine their operations.
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.
Get your clicking finger in shape and sign up for all that we have in store for you in 2023.
Molding 2023 to take place Aug. 29-30 in Minnesota; Extrusion 2023 slated for Oct. 10-12 in Indiana.
Join this webinar to learn about Conair's patented Conveying with Optimizer system, which utilizes artificial intelligence (AI) to overcome resin conveying issues automatically. Conveying with Optimizer uses valves, remote sensors and AI to eliminate conveying challenges that operators face daily throughout the plant. With this new fully-retrofittable solution, interruptions like clogged filters, air leaks, changes in density or distance, moisture changes, and operators making manual adjustments can all be eliminated with Conair's Conveying with Optimizer. Agenda: What exactly is Conveying with Optimizer? What are the benefits of using Conveying with Optimizer? What problems does Conveying with Optimizer overcome? How to upgrade your system
Cooling time is typically the longest step of the molding process. How can you make it more productive? Learn how cooling time can be turned into production time by running two molding processes simultaneously on a single molding machine. For longer cycles, this can mean twice the productivity. In this webinar, you'll learn more about the Shuttle Mold System and how to calculate its potential productivity impacts for your application. Agenda: Learn how the Shuttle Mold System can deliver value to your business See the recent technical updates made to the system Calculate the potential impact on productivity
Discover possible applications in large format printing including layup tools, transport modules, film fixation devices, design components and enclosures. These are used in various industries such as automotive, aerospace, architecture and many others. Agenda: Possible applications in large format printing: layup tools, transport modules, film fixing devices, design components and enclosures. Process reliability and component quality in component production Pros and cons of the technology Sneak peek into current development projects—What will the large format printing of tomorrow look like?
In this webinar, Cold Jet will discuss some of the ways processors use dry ice such as in-machine mold cleaning at operating temperatures, de-flashing or de-burring parts, improving OEE scores, extending mold life, cleaning parts before painting, post-processing 3D printed parts, lowering GHG emissions, and monitoring and reporting the process. Agenda: Cold Jet Overview & Dry Ice 101 Understanding the Process and Fine-Tuning Techniques Case Studies: Applications in Plastics Monitoring the Process Exploring the Importance of Dry Ice Cleaning in an ESG Era
Finding it hard to get technical talent? Experiencing the pain of a knowledgeable, long-term employee's retirement? Learn how plastics processors are training generative AIs on their operations and unlocking the value from their tribal knowledge. Plastics processors are training generative AI models on their operations — from machine manuals to tools, polymers, procedures, maintenance records and engineering projects. Applying generative AI in the right ways can lower plastics processors' costs, improve overall equipment effectiveness (OEE) and upskill teams. In this webinar, you'll learn how to deploy AI technical assistants to your teams, what works and what doesn't, and how to use AI to build an organization that never loses tribal knowledge and fosters inter-team collaboration. Agenda: What is generative AI and how can its cognitive abilities be applied to plastics? Case study: how an injection molder trained a large language model on manuals and maintenance records to reduce downtime Case study: using generative AI in engineering teams to improve product development Live demonstration of a generative AI deep-trained on plastics knowledge Looking to the future: five predictions for an AI-augmented workforce in plastics
Turnaround time can be as low as 24 hours, although two or three days might be more typical. Rapid prototyping like this is especially useful to quickly identify critical end-use part geometries that will work in the molding process. Key components include material choice, 3D printing technology selected, use of adaptable mold bases for the mold inserts and implementation of appropriate injection molding process conditions. This presentation will review work conducted toward the assessment of a high-stiffness, high-temperature-resistant ceramic modified urethane acrylate for injection molding inserts. Agenda: Guide for 3D-printed injection mold inserts Optimization of digital light processing (DLP) printing Compatibility with various thermoplastics Real-world application success stories
Debuting in 2010, the Parts Cleaning Conference is the leading and most trusted manufacturing and industrial parts cleaning forum focused solely on delivering quality technical information in the specialized field of machined parts cleansing. Providing guidance and training to understand the recognized sets of standards for industrial cleaning, every year the Conference showcases industry experts who present educational sessions on the latest and most pressing topics affecting manufacturing facilities today. Discover all that the 2022 Parts Cleaning Conference has to offer!
Presented by Additive Manufacturing Media, Plastics Technology and MoldMaking Technology, the 3D Printing Workshop at IMTS 2024 is a chance for job shops to learn the emerging possibilities for part production via 3D printing and additive manufacturing. First introduced at IMTS 2014, this workshop has helped hundreds of manufacturing professionals expand their additive capabilities.
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).
Demand for building products is thriving, and profile extrusion houses are looking to expand capacity. The question they—and possibly you—face is to simply add more single-profile lines or “go dual.” Here’s what you need to consider.
While many industries have suffered during the coronavirus pandemic, some parts of the building-products industry have thrived. It’s clear that some consumers, stuck mostly at home, caught the DIY bug and took on “wish list” projects to help create more comfortable and enjoyable surroundings. One result has been increased demand for many types of profile extrusions, including everything from wood-plastic composite (WPC) decking and window profiles, to plastic lumber, PVC fencing products, siding, fascia and decorative trim items.
Upstream on the supply chain, plastic and WPC processors have welcomed the added demand for these extruded-profile building products. But for any extrusion processor, added demand raises questions about how to cost-effectively scale up production capacity. Recently, a number of extrusion processors have answered those questions by deciding to “go dual”—that is, to convert single-profile production lines into “dual-profile” lines to capture unused extruder capacity, or to scale up by installing new and larger, dual-profile lines instead of additional single lines.
Is that approach right for your operation? Start by asking yourself these questions:
1. Should I add new lines? If you are already running productive extrusion lines, the simplest way to dramatically expand production might be to add identical new lines. Depending on availability of space in your facility, you can simply install more of the same, based on exactly the same production model you currently use. So, there’s not much risk to making it work—you don’t have to push the edges of technology. What’s more, your personnel will already know exactly what to do. However, this approach is typically more expensive than the other alternatives.
2. Can I get more production out of what I already have? Maybe. If you are running your extruders at less than full capacity, it may be possible to increase production by speeding up the line. If you turn up your extruder rpm and can manage the increased output without compromising profile quality, it may be possible to increase line output by 10 to 20%.
Pulling more out of an existing extrusion line can certainly be a cost-effective approach, but it requires a willingness to risk some level of process redefinition, redevelopment, and experimentation to get the added throughput you’re seeking. And it’s not a sure thing, because there are a lot of variables: Increasing extruder speed increases shear, which can introduce process instability, profile stress, or dimensional problems. While existing tooling may work, you may find that you’ll need to lengthen or modify dies and downstream tooling. And you’ll need to adjust speeds, cooling capacity, and other settings on your downstream equipment. So, while it’s sometimes possible to get more out of equipment you already have, the potential upside is limited to approximately 20%.
3. Can I convert single lines to dual-profile lines? Or build new dual lines from scratch? Yes to both. Converting a single-profile line to a dual-profile line can be a wise investment if you have a single-line extruder with unused capacity of at least 50%. If you can sell that much additional output in the foreseeable future, then the payback numbers for converting to dual-line downstream equipment should be favorable. Dual-line conversion becomes an even more favorable option if you want to utilize excess extruder capacity but have limited facility space, or if you’ve already tried to speed up a single extruder line but have been unable to stabilize the output at the higher production rate.
Consider this example: A processor has an extruder with a rated output of 1500 lb/hr, but has been unable to stabilize output at more than 1000 lb/hr on a single downstream line. In many cases, it is possible to successfully convert that extrusion line to dual-profile production, utilizing full extruder capacity to drive two profiles that run at about 75% of the original single-line speed, totaling a production boost of 50%. And, because the dual extrusions are running at slower line speeds than the original single extrusion, process stability issues are far less likely to occur.
Processors that require larger production increases should compare the benefits of adding multiple single-profile lines with those of adopting larger-capacity dual-profile lines. For example, with the soaring popularity of maintenance-free WPC decking, some decking manufacturers have shifted their primary production from single lines running about 1500 lb/hr—or 700+ ft of 5/4 × 6 in. decking/hr—to larger dual lines running 3000 to 3300 lb/hr—or nearly 1600 ft of decking/hr.
Processors that require larger production increases should compare the benefits of adding multiple single-profile lines with those of adopting larger-capacity dual-profile lines.
Of course, packing twice the production capacity into a limited amount of space takes a lot of planning. Upstream, there’s the need to increase capacity for material handling and preparation. If you are extruding WPC, there is also a need for increased drying and pelletizing capacity. Because of the high moisture content of wood flour, hot-air drying is typically used to dry the compounded pellet. And, in certain applications, a second dehumidifying drying step may be required prior to extrusion. Then there’s the need for a larger extruder. Downstream, there’s the need to duplicate everything—from tooling to cooling, measurement, haul-off, and cutting/material handling.
Committing to dual-profile lines represents a major commitment of skill and resources. Compared with the single lines you’re used to running, it does take greater patience and effort to get these larger, higher-capacity lines stabilized and running smoothly, because you’re pushing the boundaries of the technology harder. But from a numbers standpoint, dual-line production can be a very wise investment (see sidebar).
The key to success in switching from single-profile to dual-profile extrusion lines is to work from what you already know. Essentially, the idea is to create an identical second profile out of the extruder, and duplicate—as closely as possible—the tooling and process conditions already proven successful on the single-profile line.
The first challenge in successful dual-line production is in creating the dual melt stream at the extruder outlet. This involves development and installation of a “Y block,” a tool that splits the molten material into two equal streams. This output then flows through two identical die heads, providing two parallel profiles for downstream processing.
The second challenge is in stabilizing increased extruder output. Obviously, if you’re going to utilize excess capacity by extruding a second profile, the extruder is going to be running faster than it did before. And there will be a need to redefine and rework your process until extruder output is stabilized and dual profiles are successfully produced. Note that line speed, not extruder speed, is the key variable in profile quality. So long as the dual-profile output is running at or below 100% of the single-line speed, the profiles should be able to process through essentially the same downstream tooling and equipment with quality as good as the single-line profile product.
Downstream from the extrusion die, dual-profile equipment is essentially similar to single-line equipment, but duplicated and arranged in parallel. (For purposes of comparison, dual-profile equipment is typically of the same length and requires the same clearances as single-line equipment, but is about 50% wider.)
Many building-product extrusions—WPC decking, WPC or PVC window profiles, PVC fencing and the like—emerge from the extruder and are drawn “dry” through a series of sizing dies on a calibration table. The dies are equipped with internal water cooling so that they maintain an even temperature relative to the hot profiles, and may trickle drips of water to gently lubricate the profiles as they slide through. To help thin or complex profiles retain their shapes, some of these dies may draw a vacuum.
The profiles next enter a dual spray-cooling tank. Compared with immersion-style cooling, spray cooling is significantly more efficient. While immersion cooling tanks can allow for the development of an insulating “strata” of warmed water around a hot profile, spray tanks utilize more-efficient evaporative cooling to dissipate more heat more quickly. Spray cooling is a must for WPC extrusions like decking, since the heat index for their wood-flour component is much higher than that of typical polymer components in the composite mix. Tanks must also supply a much higher flow of cooling water for WPC profiles—up to three times more than is needed by ordinary plastic profiles. Spray cooling is also typical for large or complex vinyl extrusions used in window frames and fencing.
Extrusion processors considering production expansions owe it to themselves to consider a variety of alternatives.
The overall speed of the process is fine-tuned using a dual-line cleated puller, with speeds slaved to the master extrusion control. Though both of the cleated puller lines share a common equipment housing, the speed of each is controlled independently. So, each can fine-tune or “trim” process speeds by small increments based on the line speed and continuous feedback from the extrusion process controller. This is important because although dual extrusion lines are designed to perform identically, small variations in flow through the y-block and the extruder head are common, necessitating these fine adjustments. (Speed adjustments greater than 10% must be handled by adjusting the extruder rpm.)
Following the puller, the profiles next proceed to a dual-line saw table. Once again, the speed of each line—and the length of each profile—is managed by dual, independent measurement systems that drive dual saws. Profiles are cut to finished lengths and then pushed onto a dual dump table, which accumulates and then unloads cut lengths into stacks for pickup and packaging.
Extrusion processors considering production expansions owe it to themselves to consider a variety of alternatives. While installing new single production lines of capacity identical to existing lines is often simplest in terms of effort, it is typically the most costly in terms of capital and facility space costs. Adopting, or converting to, dual-profile production lines requires significant upfront planning and additional startup and process-development time, but can be significantly less costly in terms of capital and facility space, while scaling up the overall production capacity of your business.
ABOUT THE AUTHOR: Ernie Preiato is v.p., extrusion, for the Conair Group. Preiato joined Conair in 1988 and has focused on developing downstream solutions for processors of pipe, profile and tubing. Contact: 724-584-5423; epreiato@conairgroup.com; conairgroup.com
Processors requiring additional extrusion production capacity face difficult choices about how best to expand. Below are “rules of thumb” for two common expansion scenarios and a visual comparison.
• Example 1: Installation of two new single-profile lines vs. one dual-profile line of the same throughput.
This example assumes a dual line with twice the extruder capacity and throughput, with dual profiles running through two sets of tooling, followed by a dual-line spray tank, measurement system, puller/haul-off, and unloading system. Dual-line equipment is assumed to be identical to single-line equipment in length and clearances, but wider. For simplicity, access aisles are each assumed to be 8 ft. wide.
• Example 2: Converting a single-line with 50% unused extruder capacity to dual-profile output.
• Example 3: Production space requirements for single-profile and dual-profile production
The accompanying illustration compares floorspace requirements for installation of four single coextrusion lines (top) vs. two dual coextrusion lines. Lines are typical of those used to make fence and deck profiles that are capped with PVC or color-stabilized WPC materials. Each line includes:
• Coextruder and die heads
• Calibration table with tooling
• Cooling tanks
• Haul-off/puller
• Cutoff saw
• Drop-off table
The four single lines and access aisles require 9252 ft2/line, while the two dual lines require 5334 ft2/line for twice the profile output.
You can better visualize the melting process by “flipping” the observation point so that the barrel appears to be turning clockwise around a stationary screw.
It’s one of the biggest quandaries in extrusion, as there is little or nothing published to give operators some guidance. So let’s try to shed some light on this trial-and-error process.
Barrel temperature may impact melting in the case of very small extruders running very slowly. Otherwise, melting is mainly the result of shear heating of the polymer.
Understanding how polymer melts in a single-screw extruder could help you optimize your screw design to eliminate defect-causing solid polymer fragments.
Doing it right is critical to maintaining profile dimensions.
Steady growth in product demand and a full manufacturing floor required profile extruder Intralox to get creative when it needed to upgrade its equipment.
"Extruder Pelletizer " 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