Photo courtesy of Kraiburg TPE
Photo courtesy of Eastman
Photo courtesy of Omegasonics
Photo courtesy of Milliken
Photo courtesy of DuPont
At Kraiburg TPE Corporation’s Duluth, Georgia, USA, facility, the product development department routinely evaluates material batches and new custom compounds for performance and customer specification viability. As an integral step in that process, its engineers utilize sophisticated co-rotating twin-screw extruder technology provided by KraussMaffei Berstorff.
Owing to the substantial varieties of color and durometer and the wide-ranging performance properties required at Kraiburg TPE, monitoring every aspect of machine performance is critical. This includes all temperatures, speeds, pressures, and torque on the extruder itself, plus an underwater pelletizer, gear pump, and multiple loss-of-weight feeders used on the line.
For the latest machine installed at the Kraiburg facility, as senior application engineer at KraussMaffei Bertstorff, David Frankenberg, explains, “The lab extrusion line is used for both process and product development assessment. A key requirement was the generation of all data in real time, as part of the management system to be used, as well as the condition-monitoring system needed for predictive maintenance strategies being employed.” In cooperation with the Kraiburg TPE team and after evaluating competitors for the control scheme, KraussMaffei turned to Siemens for assistance.
As Frankenberg and his electrical engineering associate Martin Gonzalez detailed, the Siemens EXT3370 application package represented a blending of a current PLC technology and drives platform with a human-machine interface (HMI) capable of providing all graphics and multiple data screens on a single display.
In addition, the system had the ability to feed the “big data” directly to the Kraiburg TPE process data archival
and analysis system, where it would reside for real-time and long-range performance evaluation by product development, quality, and process teams. All speeds, pressures, temperatures, and other parameters can be instantly assessed, using set-point and actual value data on the display, either at the machine HMI or a remote monitor within the Kraiburg network.
Allen Donn, product development engineer at Kraiburg TPE, along with his team of engineers and tech specialists, evaluated the installation and commissioning of the machine at the Duluth facility. “The data transfer from the PLC into the same process data archival and analysis system that we use for our other lines at Kraiburg TPE. A simple Excel file is generated with any parameters desired for analysis, plus we can easily exchange data between R&D and production here.
“The result is that our ability to utilize production machinery more efficiently has increased substantially with the use of the new KraussMaffei Bertstorff machine in our test department, as the control system gives us real-time hard data we can use to make adjustments on new recipes and entirely new materials.”
Eastman Chemical Company and Prestige Mold Incorporated have collaborated to create a first-of-its-kind multi-cavity hot-runner mold for producing intricate medical parts. The specialty chemical company and precision mold manufacturer proactively created the 32-cavity mold specifically for Eastman’s Tritan™ copolyester to address future customer needs for durable medical-device parts free of bisphenols A and S. Through the mold development, the companies also learned how to streamline future project startups and processes, while reducing project costs.
“Medical parts have to withstand the wear and tear that comes with ongoing exposure to aggressive disinfectants and harsh oncology drugs,” says Burt Capel, vice president and general manager, Specialty Plastics, Eastman. “We wanted to proactively address these concerns for manufacturers.”
The idea for the mold was prompted by customer needs for small medical device parts that are produced in a multi-cavity hot runner mold. Customers also required device parts that are free of bisphenols A and S and can withstand sterilization and harsh chemicals. Tritan copolyester reportedly is well-suited for the medical device market because it improves upon typical copolyesters that traditionally have good chemical resistance.
To develop the mold, the companies worked with Mold-Masters (owned by Milacron LLC), a supplier of hot-runner technology and systems, and Pres-Tek Plastics, Inc., a medical molding and technology center. Mold-Masters built the machinery, while Pres-Tek honed in on the molding process and validated the mold.
The biopolymer company MHG obtained the first “OK biodegradable MARINE” Certification from Vinçotte International. This verification distinguishes MHG’s marine bio- degradable product from unverified claims by competitors with similar products.
The certification became available from Vinçotte in March of 2015. Since many plastic products and packaging have a high chance of ending up in the ocean or other waterways, this functionality adds great value to qualifying bioplastics. With Vinçotte’s recently added certification, products that are certified and do end up in marine water will completely biodegrade, instead of continually breaking down into smaller contaminants.
Vinçotte tested MHG’s PHA (polyhydroxyalkanoate) product according to international standards, and confirmed it would naturally break down completely in marine water.
“This additional certification provides even more support to the credibility and potential of Nodax™ PHA to have a significant impact on replacing [conventional] plastics,” remarks Paul Pereira, MHG’s CEO and executive chairman of the board of directors. The certification is the fifth one MHG has received from Vinçotte. It also holds certifications for biodegradability in soil, fresh water, and home and industrial composting.
Omegasonics, a manufacturer of ultrasonic cleaning systems, announced the introduction of the OMG4430, its largest standard unit, with a bath size of 40 x 30 x 30 in. (101 x 76 x 76 cm). This unit is designed to easily tackle the cleaning of injection molds and other parts that are large, oily, and/or dirty.
The OMG4430 utilizes precision ultrasonic technology to accurately and methodically remove all support material from large fused-deposition modeling 3-D printers and other oversized items. It effectively cleans ABS, polycarbonate, nylon 12, and PC-ABS parts, regardless of a part’s geometry and complexity.
“As companies have come to realize the benefits of ultrasonic cleaning, we have had more and more requests for equipment that will handle larger castings,” says Frank Pedeflous, president of Omegasonics.
“The OMG4430 meets that need and goes a step further. Its dual-cartridge filtration system traps contaminant particles that have been removed from the parts being cleaned. Filtering the cleaning fluid reduces the frequency with which the tank must be drained and the fluid replaced and reheated—a task that can take up to several hours.”
Fast and easy to use, the OMG4430 is designed with all solid state components and “plug & play” construction, and requires no regular maintenance. A stainless-steel parts basket ensures that parts are fully submerged in the ultrasonic bath for maximum cleaning throughout the entire cleaning cycle.
Polyolefin additives supplier Milliken is set to catch the eye of converters and brand owners at RosUpack 2015 (June 16-19 in Moscow, Russia) with the aesthetic appeal, application performance, and productivity improvements of “Ultra Clear” polypropylene at its booth. Visitors can experience the low-weight advantage and benefits of PP clarified with Milliken’s Millad® NX™ 8000 series for packaging. They can also look at opportunities to enhance PP with ClearTint® colorants offering deep, rich shades not yet available with traditional pigment colors, the company adds.
For thermoforming and sheet packaging, PP clarified with NX 8000 reportedly has “glass-clear” clarity. It gives PP a clarity boost that overcomes the traditional undesirable milky appearance to create highly attractive transparency similar to that of PET for applications such as meat trays, clamshell containers, and lids. The clarified PP also offers performance benefits such as mono-material packaging, easy sealing, chemical resistance, impact resistance, and heat resistance for microwaving and hot-filling.
The company says statistics support Ultra Clear PP’s productivity improvements, energy savings, low carbon footprint, and cost-efficiency, compared to alternative plastics. It offers a 17.8% weight savings compared to PET-based food trays, with possibilities to produce 70 trays from 1 kg of PP, compared with 57 trays from 1 kg of PET.
“Ultra Clear PP offers a host of value-adding benefits to the packaging industry, and we are looking forward to bringing these to the forefront at RosUpack 2015,” says Dariusz Lukaszewski, regional manager CEE, Milliken.
Dow Corning introduced the TC-4525 Thermally Conductive Gap Filler to meet fast-growing demand for improved processability and thermal management in automotive electronics applications. This high-performing new silicone technology delivers thermal conductivity of 2.5 W/m.K, greatly improved dispensability, significantly reduced abrasiveness, and stable performance for more reliable electronics in harsh automotive underhood environments.
“While dense, high-functioning electronic assemblies deliver greater value to automotive safety, reliability, performance, and comfort, they are also generating higher temperatures that can reduce device performance and reliability over time,” says Brice Le Gouic, global market manager for Transportation Electronics, Dow Corning.
“Building on our six-plus decades of expertise in the automotive industry, Dow Corning formulated [the TC-4525 Gap Filler] as a competitively priced alternative that combined higher processability with enhanced thermal conductivity. More specifically, our goal was to enable customers to cost-effectively manage the rising heat in their next-generation electronics designs.”
The TC-4525 product is a soft, compressible, two-part silicone that can be dispensed directly from its original packaging with minimal to no additional process preparation. It’s said to be well-suited for automated dispensing, using standard meter mix equipment. The material’s thixotropic properties enable it to dispense easily, avoid slumping on vertical surfaces
during assembly, and—after curing—maintain its vertical stability, even after long use, the company adds.
DuPont Protection Technologies and Reebok International announced the signing of a multi-year trademark license agreement for the use of the DuPont™ Kevlar® and Dare Bigger™ trademarks. The new spring-summer 2015 Reebok CrossFit® collection incorporates the DuPont advanced material and features the DuPont trademarks.
Kevlar fiber is known for its extreme strength and durability. Best known for its use in ballistic and stab-resistant body armor, Kevlar has helped to save the lives of thousands of people around the world. The Kevlar brand and science also are used in many consumer products such as mobile phones, tires, work-wear, and high-performance sporting apparel, shoes, and equipment. This year, DuPont is celebrating the 50th anniversary of the discoveries that led to Kevlar, and this new line of Reebok CrossFit apparel and footwear is an example of advancing it forward.
“My CrossFit training regimen is constantly testing my limits. I work out multiple times a day, so I need consistent, durable gear that withstands the toughest workout,” says Camille Leblanc-Bazinet, professional athlete and female winner of the 2014 Reebok CrossFit Games. The “apparel and footwear made with DuPont Kevlar are an ideal combination, resulting in high-performance gear that allows me to do even more than I think is possible.”
“Reebok has strategically engineered Kevlar into key abrasion zones within its apparel and footwear so they are durable enough to withstand even the toughest workouts,” says Corinna Werkle, senior vice president, Training, at Reebok. “We value our relationship with DuPont for the science behind these world-class products and for the power of the DuPont Kevlar brand.”
eFACTOR3, LLC announced the addition of Pallmann Industries, Inc. and Pla.to Technology to its select group of partners. “These are exciting partnerships with strong, complimentary lines that build on the high-quality equipment already available through eFACTOR3,” says company president, Hartmut Bendfeldt.
Pallmann Industries, Inc. is a major machine manufacturer with worldwide capacities, specializing in size reduction and preparation techniques. The company offers solutions in granulation, pulverizing, agglomeration, and recycling. It boasts over 100,000 installations worldwide and more than 1,000 machine types in what is the world’s largest range of size-reduction equipment for all materials: from soft to medium-hard, brittle to tough, and fibrous products, for industries including blow molding, extrusion, film, and rubber.
A globally active machine manufacturer and plant engineering company, Pla.to Technology specializes in manufacturing and engineering high-quality washing and drying lines. The company is described as the market leader in systems for long-lasting recycling equipment, thanks to the wear-resistant steel materials used in its machines. Equipment is built to the latest standards, with great attention to detail, providing cost-efficient, environmentally friendly recycling of plastics.
Crizaf, a leader in conveying systems, parts separators, filling and storage systems, and weighing and counting systems, announced it has opened a new manufacturing location in Durham, North Carolina, USA, to serve the USA, Canada, and Mexico.
Over the past 60 years, the company has become a multinational organization with production sites in Italy, the USA, Brazil, and India. Crizaf has developed a diverse and agile sales network with distribution in more than 50 countries around the world. Crizaf’s products are used in a wide range of industries including plastics, food, pharmaceuticals, cosmetics, and automotive. Products include a broad line of conveyors with fabric and plastic belting, plus filling and storage systems, parts separators, and indexers.