Canadian Plastics April 2009

CanadianPlastics www.canplastics.com

MEDICAL MOLDING A STRONG PULSE

AN INSIDE LOOK AT SHOPS DOING IT RIGHT ALSO

The newest medical-grade resins

ROBOTS & AUTOMATION

The pros and cons of rebuilds and retrofits

DRYERS

Is yours running efficiently?

COLOUR MATCHING & TESTING EQUIPMENT The latest developments

APRIL 2009

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contents

Canadian Plastics APRIL 2009 VOLUME 67 NUMBER 3

LOOKING BACK...

In September 1980, Canadian Plastics reported that Springhill, N.S.-based Can-Am Containers — the largest manufacturer in Canada of fish handling boxes and trays at the time — was also manufacturing products for the agricultural and forestry sectors. Although CAC continued to supply plastic products for the east coast fishing industry, the company was also manufacturing molded PE field harvest boxes for the Canadian and U.S. blueberry industry, pails for shipping pickled beef and pork, hog feeders, a hog barn fresh air ventilating system and forest nursery trays.

page 21

Number of the month:

*48.6%

* Percentage of survey respondents that are manufacturing medical products or components in 2009. (See pg. 13)

4

Editorial: • Gone, but hopefully not forgotten

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Ideas & Innovations: • Solar powered thermoplastics hit the roof

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News: • CPIA taps Mark Badger • CAMM goes to House of Commons • Ralph Noble added to Hall of Fame • Special Report: PlastIndia 2009 • News Briefs and People

9

Executive’s Corner: • Surviving in trying times

23 Technology Showcase 26 Advertising Index 26 Plastics Data File 27 Classifieds 29 Design Ideas: • Sporty Applications 30 View from the Floor: • Spreading Out

page 10

page 18

cover story

10 MEDICAL PARTS MOLDING: A STRONG PULSE Industry analysts agree: there’s a growing demand for medical parts in North America, and this is good news for the plastics industry. But what kind of skill and equipment does it take to venture into the world of high performance medical molding? Inside, we check out some of the shops that are doing it right. Also, don’t miss our special look at some of the new medical-grade materials that are making it all possible. PLUS: The results are in on our newest Canadian medical molding survey! Find out who’s doing what, with what.

features

14 ROBOTS & AUTOMATION: THE PROS AND CONS OF REBUILDING AND RETROFITTING These days, most plastics processors are looking to avoid unnecessary machinery purchases. So when it comes to wanting to do more with their robots and automation equipment, it may seem like the perfect time to rebuild or retrofit. But, at the end of the day, is it really worth the time and trouble? Inside, we examine some of the advantages and disadvantages. 18 DRYERS: PREVENTATIVE MAINTENANCE In this downturn, manufacturers may mistakenly think that running leaner means having to cut corners. But when it comes to your plant's drying equipment, cutting corners on your maintenance budgets could affect your plant's efficiency. Use our maintenance tips and checklists to keep your dryers in tip top shape! 21 COLOUR MATCHING & TESTING EQUIPMENT: THE LATEST OFFERINGS Sure, injection molding machines are sexy, but don’t be fooled; in today’s business climate, getting the right colours and the right part specs is more important than ever — and for that you need cutting edge colour matching and testing and measuring equipment. Canadian Plastics gives you a look at some of the latest.

Visit us at www.canplastics.com www.canplastics.com April 2009 Canadian Plastics 3

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editor’s view

Gone, but hopefully not forgotten

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s Canadians suffer through a recession, at least one segment of the economy will see an increase in demand. Faced with layoffs and a dearth of new jobs, a greater number of people will be going back to school, hoping to boost their skills with a post-secondary education while riding out the recession. Unfortunately, though, these recruits won’t be working towards a new career in plastics. The Canadian Plastics Training Centre (CPTC), one of the last few remaining college-based training programs at Toronto’s Humber College Institute of Technology and Advanced Learning, recently announced that it was closing its doors. Although the program’s coordinator expressed sadness over the closure of the Humber program, he noted that it was the latest in a series of closures. The Northern Alberta Institute of Technology closed its Polymer Centre in 2004, and the British Columbia Institute of Technology closed its Plastics Engineering program recently. And this spring, Quebec’s A’Huntsic CEGEP will close its plastics program as well. It would be easy to blame colleges like Humber for closing these long-established programs, but bear in mind that colleges operate as businesses. They are governed by the same laws of supply and demand as any other corporation. When I met with Hamid Mohammadi, an instructor at the CPTC since 1996, for one last look at the now-defunct centre, he noted that there weren’t enough students enrolling in the program to make it profitable. Indeed, the centre had survived some pretty tough cuts, and it frankly seems like a miracle that it survived as long as it did. In the early aughts, the centre was relocated from a much larger facility to a small basement space at Humber’s North Campus. The plastics engineering program had been axed, and the CPTC had been downsized to focus just on the injection molding process. The final blow came

when the program couldn’t attract nearly enough students to fill a class of 20. How did we get here? Why can’t we find 20 people who would be interested in a career in injection molding? Some of the reasons are fairly obvious. For one, why would a student want to invest in a college certificate program given the relative lack of job security in the manufacturing sector? Mohammadi also noted that the return on investment on an education in plastics processing isn’t what it used to be. Prospective students are perhaps less inclined to enroll in plastics programs when they can only expect to earn an average wage of $12 an hour as an operator, he explained. These closures are setting us back many years, and the industry is concerned. They are eroding years of formalized training programs, and placing the onus of training costs back on the employer. Reflecting on the CPTC’s closure in our online poll, over 88 per cent of respondents said that they are concerned about finding trained and skilled employees in the future. Last year, after speaking with some of the talented people who had been put out to pasture after Progressive Molded Products went under, I used this space to predict that the continued cuts in the plastics industry were doing irreparable harm to the industry’s reputation, and would make it significantly harder for companies to attract top talent once they emerge from the shadows of this downturn. The CPTC closing its doors is just another step in that direction. At a time of turmoil and uncertainty, I’m sure that most businesses find it hard to even think about the future. But I feel that there is an important lesson to be learned here, and one that we mustn’t soon forget. The centre may be gone, and the modest basement room it occupied will probably be converted into a classroom to accommodate other, fuller programs. But the impact of what the CPTC’s closure means for the plastics industry will be felt for years to come. Umair Abdul, assistant editor uabdul@canplastics.com

Canadian Plastics magazine reports on and interprets developments in plastics markets and technologies worldwide for plastics processors, moldmakers and end-users based in Canada.

www.canplastics.com MANAGING EDITOR Mark Stephen 416-510-5110 Fax: 416-510-5134 E-mail: mstephen@canplastics.com TECHNICAL EDITOR Jim Anderton 416-751-5749 E-mail: jimeditorial@yahoo.ca ASSISTANT EDITOR Umair Abdul 416-510-5112 Fax: 416-510-5134 E-mail: uabdul@canplastics.com ART DIRECTOR Valerie Perrott PRODUCTION MANAGER Steve Hofmann 416-510-6757 E-mail: shofmann@bizinfogroup.ca PRINT PRODUCTION MANAGER Phyllis Wright PUBLISHER & EDITORIAL DIRECTOR Judith Nancekivell 416-510-5116 Fax: 416-510-5134 E-mail: jnancekivell@canplastics.com ADVERTISING SALES REPRESENTATIVE Brayden Ford 416-510-5124 Fax: 416-510-5134 E-mail: bford@canplastics.com CIRCULATION MANAGER Diane Rakoff 416-510 5216 Fax: 416-510-6875 E-mail: drakoff@bizinfogroup.ca HEAD OFFICE 12 Concorde Place, Suite 800, Toronto ON M3C 4J2. 416-442-5600, Fax: 416-510-5134 CANADIAN PLASTICS is published 10 times a year by the Business Information Group, a division of BIG Magazines LP., a leading Canadian information company with interests in daily and community newspapers and business-to-business information services. 2009 SUBSCRIPTION RATES, 1 YEAR 9 ISSUES CANADIAN PLASTICS, PLUS DEC. 2009 BUYER’S GUIDE: CANADA: $68.95 plus applicable taxes. USA: US$76.95; FOREIGN: US$120.95 DEC. 2009 BUYERS’ GUIDE ONLY: CANADA: $103.00 plus applicable taxes and $5.00 shipping USA & FOREIGN: US$88.50 plus $5.00 shipping. From time to time we make our subscription list available to select companies and organizations whose product or service may interest you. If you do not wish your contact information to be made available, please contact us via one of the following methods: phone 800-668-2374; fax 416-442-2191; e-mail: privacyofficer@businessinformationgroup.ca; mail: Privacy Officer, Business Information Group, 12 Concorde Place, Suite 800, Toronto, ON M3C 4J2. The contents of this magazine are protected by copyright and may be used only for your personal non-commercial purposes. All other rights are reserved and commercial use is prohibited. To make use of any of this material you must first obtain the permission of the owner of the copyright. For further information please contact Judith Nancekivell, 416-510-5116. For Reprints call RSiCopyright, Michelle Hegland, msh@rsicopyright.com USPS 745-670. U.S. Office of Publication, 2424 Niagara Falls Blvd., Niagara Falls, NY. 14304-0357. Periodical Postage paid at Niagara Falls NY USA. Postmaster: Send address changes to Canadian Plastics, PO Box 1118, Niagara Falls NY 14304-0357. PAP Registration No. 11035 CANADA POST – Publications Mail Agreement No. 40069240. Return undeliverable Canadian addresses to: Circulation Dept. – Canadian Plastics, 12 Concorde Place, Suite 800, Toronto, ON M3C 4J2. RETURN POSTAGE GUARANTEED INDEXED BY CBPI ISSN 0008-4778 MEMBER: Canadian Business Press, Canadian Plastics Industry Association. EDITORIAL ADVISORY BOARD: Brian Read, president, Horizon Plastics Company Ltd. Tom Meisels, president, F.G.L. Precision Works Ltd. Mark Lichtblau, vice-president, Haremar Plastic Manufacturing Ltd. We acknowledge the financial support of the Government of Canada through the Publications Assistance Program towards our mailing costs

4 Canadian Plastics April 2009 www.canplastics.com

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ideas and innovations

Solar powered thermoplastics hit the roof

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By Mark Stephen, managing editor

hen it comes to shingles, there are some types you million, 1,350-ton tandem clamp injection molding machine nickwant and some you don’t. named “The Beast” that produces the solar cell-imbedded shingles. From a medical perspective, few of us are inter- The project also involves construction of a state-of-the-art market ested in getting the contagious rash known as shingles. development plant and R&D facility at Dow’s corporate headquarAs far as shingles as a rooftop covering, however, our feelings ters in Midland, Mich., move that will create 22 new jobs. are probably a little warmer — particularly if a new project to “The average cost of electricity purchased from a utility is about manufacture power-generating roof shingles made from plastics eight cents per kWh, and at present, solar energy costs three times proves a success. more,” Cleereman of 1the SAI, Dow and its team SPE/AB/CPL 3/18/09 said. 3:00 “As PM part Page For the past year, The Dow Chemical Co. has been at work on members plan to bring solar-generated electricity costs below 10 a US$50 million project called Dow Solar Solutions, designed cents per kWh by 2015.” to develop thermoplastic roof shingles for the North Ameri- Dow Chemical Company (Midland, Mich.); can market that incorporate solar energy generation materials www.dow.com; 989-636-1000 directly into the shingle design. Dow is collaborating with Global Solar Energy Inc., an Arizona-based maker of flexible materials, and hopes to start selling the power-generating roof shingles by 2011. The project, funded from the Solar America Initiative (SAI) Technology Pathway Partnerships program through the U.S. Department of Energy, aims to provide an alternative to traditional solar-powered panels. Consisting of silicon-based solar cells packaged within heavy glass, these panels are expensive Thurs. May 14, 2009 and difficult to install, and, while they produce electricity, the Delta Toronto Airport West Hotel cost is many times higher than conventionally generated elec5444 Dixie Road, Mississauga, ON L4W 2L2 tricity sold by utility companies. “Dow’s innovative technology is based on a much more costA one-day seminar relating to extrusion theory, effective photovoltaic material, called CIGS, and these cells are operating principles and practices. Topics will include: packaged within the roofing product to create a solar shingle,” • Single and twin screw extrusion technologies said Bob Cleereman, Dow’s senior technical director of building • Die and downstream system advances integrated photovoltaic technology. “This approach enables lower • Screw design and troubleshooting techniques fabrication and installation costs, because both the conventional • Auxiliary equipment design and application and solar roofing shingles are installed at the same time.” The • Developments in compounding, film/sheet, and profile extrusion result for the home or building owner, Cleereman continued, is This is an excellent opportunity to brush up on the latest extrusion that solar-generated electricity costs no more than power genertechnology and to make new contacts with industry experts and ated by burning green house gas-creating fossil fuels. peers. So mark your calendar now and plan to attend. “CIGS has proven to be the most efficient, cost-effective thinJointly sponsored by the film technology for integrated photovoltaic applications, and by SPE Ontario Section and SPE Extrusion Division. teaming up with Global Solar we are working with an industry Cost: Until May 6: $150; After May 6: $200 leader,” Cleereman said. “Global Solar is the only company in A limited number of sponsorship opportunities and full-scale production of CIGS cells on flexible substrates, and tabletop exhibit space for $250 is also available has achieved a record-setting average 10 per cent solar cell effiContact: ciency, meeting SAI’s requirements.” At the centre of the Dow Solar Solutions project is a US$2.5 Andrew Marshall at 416-781-5286 X2250, amarshall@ontor.com

SPE EXTRUSION MINITEC

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news

CPIA taps Mark Badger Mark Badger has been appointed as the new executive director of the Canadian Plastics Industry Association (CPIA), effective March 9, 2009. Badger replaces outgoing president Serge Lavoie. “I think that Mark is an excellent choice for the organization because he brings a really strong depth of knowledge of the industry,” said Lavoie. Badger was a vice president of pipe and profile extruder Royal Group from 1995 through 2008, where he was in charge of corporate communications, marketing and corporate development. Subsequent to Georgia Gulf’s acquisition of Royal Group in 2006, he also led Georgia Gulf’s investor relations activities. “I can’t think of a job that is closer to the job of a CEO of an association than investor relations,” noted Lavoie. “You have all these different publics that you are trying to balance your interests with.” Badger graduated with an Honours Degree in Business Administration from the University of Western Ontario in 1980. He received a Queen’s Jubilee Medal from the Governor General of Canada in 2002, in recognition of his leadership roles with charitable organizations.

CAMM goes to the House of Commons

The House of Commons Industry Committee recently set up a subcommittee to analyze the automotive industry, and conducted hearings about the crisis that is affecting the sector. Angelo Carnevale, vice president of the Canadian Association of Moldmakers, spoke at the March 9 session, voicing the concerns of mold, tool and die makers serving the automotive market. “To state the obvious, our toolmaking industry is in crisis,” Carnevale told the committee. Carnevale said that the root of the industry’s problems is the inequitable payment terms from the the Detroit Three, or PPAP payment terms. He noted that the delay in getting payment for tooling — a process that can take anywhere from 18 to 48 months — placed a financial burden on moldmakers. Carnevale said that the payment model was “broken,” and called on the government to give a portion of any loans to tooling companies. “This payment strategy must be stopped for the future health of the small to medium sized businesses which cannot afford to finance the Detroit 3,” he said. Carnevale also noted that the mold, tool and die industry should be viewed as an independent sector, and could be a robust business if companies were paid for their work and could reinvest in new technologies. He noted that many tool shops are owed money by the Detroit 3, and that banks lump tool shops in with automotive supplier.

“Mark is exactly the person we need at this point in CPIA’s development,” said Dave Birkby, chair of the board of the CPIA. “He has Mark Badger Serge Lavoie a long history in the plastics industry in Canada and he has first hand understanding of the value this trade association brings to its members.” Badger arrives at the CPIA after a major restructuring of the organization. According to Lavoie, Badger is inheriting a much smaller organization than he did six years ago, and Badger’s role will be to rebuild the association. “During my recent conversations with members, I have also been reminded of the difficult economic environment, as well as the commercial challenges facing our industry,” said Badger in a note to association members. Badger noted that the CPIA was a much leaner organization than in past years, and that he couldn’t promise that the association would fulfill every industry need. “[But] we can promise you that we are excited about serving CPIA’s members and determined to help the industry reach its full potential,” said Badger. Carnevale asked the committee to earmark a portion of any funds to pay off “critical” suppliers, with toolmakers designated as critical suppliers. He also called for the discontinuation of the PPAP system, and an increase in credit coverage for the Detroit 3 from EDC. “We are not before you requesting any loans, only timely payment for services already rendered to the OEMs, and a return to fair practice payment terms so that we can move forward to invest our money in our own futures,” he said.

Ralph Noble added to Hall of Fame

A Canadian plastics pioneer is one of nine business leaders who will be inducted into the Plastics Hall of Fame in June at the NPE2009 trade show. Ralph Noble, co-founder of Mississauga, Ont.-based Carley Chemicals (which became Synergistics Industries Ltd.), will be added to the hall of fame. During his tenure at the Canadian compounder, Noble was a pioneer in plasticizers in flexible compounds, and supported research at Canada’s major research facilities. Noble was also the first non-American to hold the position of president at the Society of Plastics Engineers (SPE), and was an active member of the Canadian plastics industry. He is now a member of the regional Plastics Pioneers group. The Plastics Hall of Fame banquet will take place on June 22 at NPE, with a keynote speech by football hall of famer Mike Ditka. Tickets are available on the show’s website, at www.npe.org.

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news

SPECIAL REPORT: PLASTINDIA 2009

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lastIndia 2009 was described as a “thumping success” by PlastIndia Foundation president Arvind Mehta. And Canadian exhibitors couldn’t agree more. The show — held from February 4 to 9 in New Delhi, India — featured 1,517 exhibitors and drew more than 130,000 business visitors, almost double the 2006 show figure of 80,000. The event featured 20 country pavilions and four theme pavilions, including Plastics in Agriculture, Recycling, Energy Conservation and an End User Pavilion. With India being one of the few countries to forecast a growth in GDP for 2009, there was a good deal of industry buzz centred around the show — and neither exhibitors nor attendees seemed disappointed with the end result, according to Tom Sockett, head of trade and shows at the Canadian Plastics Industry Association (CPIA). “The show was incredibly busy,” said Sockett, who attended as part of the CPIA/Canada mini-pavilion. One of the CPIA’s missions at PlastIndia, Sockett said, was “to beat the drum for Canada’s plastics industry,” and to reinforce the fact that Canadian businesses are interested in making connections with Indian firms. “Attendees expressed considerable interest and curiosity about Canada from several perspectives: business, educational, and job opportunities,” Sockett said. “A lot of this interest stems from the fact that there are substantial populations of people from India in both B.C. and Ontario.” The CPIA/Canada mini-pavilion hosted moldmakerProsin Molds of Mississauga, Ont., and equipment supplier Corma Inc., of Concord, Ont. According to John Hynds, Prosin Molds’ vice president of sales and business development, he fielded a large number of business inquiries during the six days of the show. “This was our company’s first appearance at a PlastIndia show, and the number of contacts we made definitely met our expectations,” he said. “Like a lot of mold shops, we see doing business in India as a long term strategy, and going to the show was an important step in this process.” According to Tom Sockett, the CPIA/Canada mini-pavilion also served as a home base for Export Development Canada (EDC). “This enabled EDC regional manager Vibhav Agarwal to contact Canadian exhibitor’s participating independently at the show,” he said. Canadian companies exhibiting independently at PlastIndia 2009 included Alpha Marathon Film Extrusion Technologies Inc., Husky Injection Molding Systems, Macro Engineering & Technology Inc., and Mold-Masters Technologies Ltd. The next PlastIndia show will take place in February 2012.

The CPIA’s Tom Sockett and friends.

Prosin Molds’ John Hynds (right) making contacts.

The CPIA/Canada mini-pavilion.

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news

Milacron files for Chapter 11, agrees to sell assets to its major investors

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quipment supplier Milacron Inc. has voluntarily filed for Chapter 11 bankruptcy protection from creditors, and has reached an agreement with its two major investors for a financial restructuring. According to a company press release, Batavia, Ohiobased Milacron remains committed to continuing its operations. The company blamed “severely reduced sales and orders in recent months — precipitated by the ongoing credit crisis and deteriorating global economic conditions.” Under the terms, Avenue Capital and DDJ Capital Management LLC — which hold 78 per cent of Milacron’s senior

NEWS BRIEFS Abu Dhabi’s state oil company International Petroleum Investment Company (IPIC) has announced plans to buy Nova Chemicals, a Canadian polyethylene supplier and cracker operator, for $2.3 billion. The purchase is subject to regulatory approvals. Under the agreement, Nova will continue to operate as a stand-alone company to invest substantially in its operations in Alberta and Ontario. Controls and instrumentation supplier Carlo Gavazzi, of Mississauga, Ont. has named Winnipeg-based Hi-Tech Sales Ltd. as its manufacturer’s representative responsible for Saskatchewan, Manitoba and northwestern Ontario.

notes — will provide the company with US$80 million in debtor-in-possession financing, and will purchase substantially all of the company’s assets. “Pursuit of these transactions is a positive step that is in the best interests of the company, our employees, customers, suppliers and other constituents,” said Dave Lawrence, Milacron’s president and chief executive officer. “Avenue Capital and DDJ’s continued support is indicative of their faith in Milacron’s brands, products and people, each helping to create value in the marketplace. This process will allow the business to withstand current economic conditions as part of a new enterprise with a healthy balance sheet.”

Injection molding machine supplier Engel Canada Inc. has named MarieFrance Sosa as regional account manager for Quebec and Eastern Canada. PCS Company, a Fraser, Mich.-based supMarie France Sosa plier of mold bases, pins and components, hot runner systems and special made components, has named Brian Campbell as its sales manager for Canada. Campbell is based in Windsor, Ont.

ting and Leone will all serve as officers of the company. Clariant Masterbatches Canada has appointed two new sales reps. Grant Erikson will serve as a new sales rep for colour and additive masterbatches, covering Western Canada; and Allison Reed has been named sales rep for colour and additive masterbatches in the U.S. Pacific Northwest region. Wayne Voorhees has been named director of sales, pipes, for pipe and siding extruder American Maplan Corporation, of McPherson, Kansas. Wayne Voorhees

Materials supplier Lanxess Corporation has sold its Ficel blowing agent product line in Canada and the U.S. to Hughes Polymer Additives Corporation. Hughes Polymer is located in Acworth, Ga., with manufacturing sites in various locations throughout the U.S.

PEOPLE Flexible packaging supplier Plastic Technologies, Inc., of Holland, Ohio, has named Craig S. Barrow as its new president.

Vince Leone

Dave Huntting

Jeff Colman

Hot runner temperature control system supplier Gammaflux L.P., of Sterling, Va., has named Jeff Colman to the position of president and CEO. He replaces David Huntting, who has been named chairman of the company. The company also announced that Vince Leone has been promoted to vice president. Colman, Hunt-

Colour concentrate supplier Chroma Corporation, of McHenry, Ill., has named Mir Ali as its new director of technology. Heat transfer fluids manMir Ali ufacturer Paratherm Corporation, of West Conshohocken, Pa., has appointed Rich Clements as its new COO and vice-president of operations.

8 Canadian Plastics April 2009 www.canplastics.com

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executive’s corner

Surviving in trying times

In an uncertain economy, concentrate on the things you can control

By Edmée Métivier, Business Development Bank of Canada

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hese days, the business world is awash in red ink, and some of the most trusted financial institutions in the world have been strongly shaken. This is the environment in which Canada’s small business owners must operate. Indications are that Canada’s economy is more resilient than many national economies around the world, and should recover more quickly. Nevertheless, the slowdown in U.S. consumer and business spending will have an impact on many Canadian SMEs — especially those who depend on revenues from exports to the U.S.

FINANCING IS AVAILABLE Almost any entrepreneur will say that access to financing is the biggest challenge to achieving growth objectives. Clearly, that access to financing is becoming even more difficult today. While Canada’s private sector banks have not stopped lending to smaller businesses, they have adopted a more cautious approach. At the same time, U.S. lenders in the Canadian market have slowed down their activities considerably, resulting in a reduction in the number of sources of financing available to Canadian businesses. Fortunately, alternative sources of financing are available in Canada. In times like these, it’s not unusual for financial institutions from the public and private sector to work in partnership to offer financing to entrepreneurs. While not a replacement for private sector banking, public institutions such as the Business Development Bank of Canada, Export Development Canada, the Community Futures Development Corporations and Business Development Centers are well positioned to offer stability and support during economic downturns.

don their projects while waiting for better times. SMEs exporting to the U.S., as well as those focused on the local market, must attempt to enlarge their markets. In an environment of uncertainty, there are many things entrepreneurs cannot control. Rather than worry about things they can’t change, entrepreneurs should focus on the things that are within their ability to manage. What are they?

1. Taking a long-term view. This can be difficult when the daily media barrage is overwhelmingly negative, but Canada’s smaller businesses need to innovate, improve productivity and export to new markets to be competitive in a global economy. Canada’s entrepreneurs must continue to plan and prepare for development opportunities. 2. Free up working capital through aggressive cost reduction. During an economic slowdown, managing working capital is crucial and requires the constant attention of business leaders.Rigorous cost management led by improved business processes, eliminating services purchases and other expenses that do not add significant value to the operation are simple ways to free up working capital. Note that it is important to analyze where value lies before the cutting begins. 3. Work on the organization. When an enterprise is busy and overstretched, its management team often does not have the time to focus on its efficiency. A slowdown may be the ideal time to think about the effectiveness of a healthy work organization. 4. Cement relationships with customers and suppliers. When projects slow down,

WHAT YOU CAN CONTROL the time is right to look more closely at While today’s economic climate is not ideal for startups, new projects or business growth, entrepreneurs cannot simply aban-

your day-to-day business. Meeting customers face-to-face is always a good idea. It helps to solidify relationships and can

provide first-hand insights into customer service needs.

5. Look for ways to innovate and improve productivity. Many productivity gains are possible through information technology, logistics, process improvement, and other related concepts. When asked, employees can often suggest ways to do their work better and faster. Focusing on innovation can lead to the development of new or improved products and services.

TAKE ADVANTAGE OF THE SITUATION By concentrating on the things they can control, Canada’s SMEs can set the stage for an economic rebound. Numerous recent surveys have found that, in spite of increasing worries related to access to financing and the economic slowdown, the majority of entrepreneurs are optimistic about the long-term outlook. An Ipsos Reid survey concluded that more than half are cutting back on unnecessary expenses; almost half are working to provide extra value to customers, while others are finding ways to reduce energy and fuel consumption and increase marketing efforts. These days, economic conditions can make business more challenging than ever. By taking measures to survive the economic downturn and stay strong, SMEs can position themselves to take advantage of opportunities, become more competitive, and ensure their long-term success. Edmée Métivier is executive vice president, Finance and Consulting, for Business Development Bank of Canada (BDC). BDC is a financial institution wholly owned by the Government of Canada that actively supports the development and growth of Canadian small and medium-size businesses through its complementary financing, investment, and consulting solutions. For more information, visit www.bdc.ca. www.canplastics.com April 2009 Canadian Plastics 9

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medical manufacturing

COLUMBIA PLASTICS

AT THE HEAD OF THE PACK By Mark Stephen, managing editor

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e all know the adage about the difficulties of teaching an old dog new tricks. For those wondering if a well-established manufacturer can learn new ways of staying competitive, look no further than Columbia Plastics Ltd. The 65-year old Surrey, B.C.-based plastics processing company made a recent move into the world of medical parts molding, and hasn’t looked back since. Founded in 1945, and maintained as a family-held corporation since 1961, Columbia Plastics weathered numerous recessions and industry changes over the decades, acquiring a great deal of experience manufacturing small, high tolerance parts along the way. Some five years ago, though, the company’s management sensed the approach of something that threatened to alter the fundamental shape of the business landscape. “We came to realize how serious the threat from offshore competition was becoming, and began looking for types of molding that offshore companies wouldn’t be very strong in,” said Greg Howard, Columbia Plastics’ president. “Given our long history of working with small, high tolerance parts, we decided that medicaldevice molding would be a good fit.”

GOING CLEAN An early step in this new direction was the installation of a permanent Class 10,000 cleanroom, a particularly high certification standard that provides an environment with between 50 to 100 times fewer particles per cubic foot of air than is found in a typical office building. The cleanroom allows Columbia Plastics to mold particularly critical medical parts, such as components used in invasive surgical

A cleanroom molded part by Columbia Plastics.

Health care product manufactured by Columbia Plastics with in-molded pin connectors.

procedures. “We decided at the outset that we weren’t going to approach medical molding halfheartedly, and that having this cleanroom was crucial to opening up new possibilities,” Howard explained. “At present, we’re still one of only three Canadian molders to have a permanent Class 10,000 cleanroom.” Armed with a cleanroom, the company’s next step involved building a client base one customer at a time, usually by attending and making contacts at medical industry trade shows. After that, the molding itself presented only limited challenges. “From the time of our first contracts, the main adjustment we had to make didn’t relate to the technical aspects of medical molding, but rather to the fact that everything is driven by procedure,” Howard said. “But since we’d been ISO-certified for over 10 years by that point, we were able to adjust to this fairly quickly.” At present, Columbia Plastics carries out a mixture of both cleanroom molding and molding that meets the lesser standard of so-called clean manufacturing environment. “The surgical and diagnostic parts that we make require Class 10,000 cleanroom molding, assembly, and packaging,”

Howard said. “Our health care parts require only a clean manufacturing environment.”

GROWING OPPORTUNITIES Perhaps ironically, having the cleanroom opened up possibilities in other types of injection molding at the company’s 50,000 square foot, 28 injection molding machine-strong facility. “We also use our cleanroom for sterile non-medical molding, such as electronic parts, that need either cleanroom molding or cleanroom assembly,” Howard said. “On some electronic parts, the wafers or RFID tags, for example, need to be packaged in a cleanroom environment.” Medical parts molding, for both domestic and foreign customers, currently accounts for approximately 10 per cent of Columbia Plastics’ business, Howard said, although this figure is growing. The competition for medical molding contracts is growing too, but Howard takes this in stride. “When it comes to medical molding, we’ve shown our customers that we’re early adopters,” he said. “We’re happy to be at the head of the pack.” Columbia Plastics Ltd. (Surrey, B.C.); www.columbiaplastics.com; 604-530-9990

10 Canadian Plastics April 2009 www.canplastics.com

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medical manufacturing

CHINA ARRAY PLASTICS

EXPERIENCE COUNTS By Mark Stephen, managing editor

T

here’s no shortage of plastics processors looking to break into the medical parts market nowadays. Not many of these shops, however, engineer their products in the U.S., manufacture them in China, and then sell them into Canada. And even fewer have prolonged experience working with the type of high performance materials required in most medical parts. China Array Plastics fits the bill on all counts. Founded in 1980, the custom injection molding company has sales and engineering offices in Pittsfield, Mass., an injection molding facility in Wuhan, China, and customers that include awardwinning medical parts supplier Canica Design, of Altamonte, Ont. A longtime molder of complex electronic and aerospace components, China Array began manufacturing medicaldevice parts in 2008. According to Carl Olson, vice president of sales and marketing, the company was able to adjust to the demands of medical suppliers relatively easily, due to its history of molding high performance materials. “Our company was set up specifically for molding high performance plastics in China,” he said. “This gives us the experience to work with polysulfone (PSU), polyetherimide (PEI), polyetheretherketone (PEEK), all of which are commonly used in medicaldevice parts.” Branching off into the medical molding industry was a welcome development for the company, Olson said. “Compared to other injection molding markets, the traditional markets for high performance parts are limited, because the materials are very expensive and the volumes fairly small,”

Molding parts at China Array’s Wuhan, China Facility.

he explained. “The medical parts market, by contrast, is growing rapidly, even through the present economic slowdown. Medical OEMs are seeing the advantages that high-end thermoplastics have over metals, glass and lower-performing plastics, offering a tremendous opportunity not only to China Array, but to the plastics industry as a whole.”

THE BEST OF BOTH WORLDS Olson points to the mix of Asian and North American elements as one reason for China Array’s success in the medicaldevices market. “We’re able to combine the low manufacturing costs associated with molding in China with the expertise of our U.S. technical staff; too many mold shops have a limited number of technical people that they can call on when doing high performance molding of medical parts,” Olson said. Medical manufacturing currently makes up approximately 25 per cent of the company’s business, Olson said, a number that is expected to grow. He also

noted that, at present, the company is not molding any implantable medical devices. “Our products are used either in general surgery or analysis,” he said. “They have to be clean, of course, but we don’t have to guarantee sterility.” China Array uses portable, softwall cleanrooms, but is planning a dedicated cleanroom for an expansion project set for the end of 2009, allowing the company to compete for an even wider range of contracts. The company is also planning to mold medical parts for the Chinese consumer market. “This is a huge growth market, given the growth of a middle class that is now expecting and demanding health care,” Olson said. Although the core of China Array’s business is high performance materials for high performance applications, the company will also take on less stringent jobs. “We’re quite happy to do low volume production runs to accommodate our customers, and then work to get larger orders of high performance parts,” Olson said. “It’s a necessary step nowadays in setting yourself apart from the competition.” The company also assembles many of the parts that it molds. “Our interest in doing assembly is that it allows us to control the tolerances,” Olson said. “I’ve seen mold shops that were quite proficient at certain types of molding but didn’t have the experience of controlling quality or controlling other features,” Olson said. “We feel the advantages we have are a good working knowledge of the medical industry, and an even better working knowledge of what it takes to do high performance parts.” China Array Plastics (Pittsfield, Mass.); www.chinaarray.com; 413-499-9890 www.canplastics.com April 2009 Canadian Plastics 11

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medical manufacturing

MEDICAL PLASTICS —

THE LATEST DEVELOPMENTS

D

As the medical-device industry continues to grow, spurred by an aging population and changing trends in health care, so to do the amounts of plastics required to meet these needs. Canadian Plastics presents a sampling of just a few of the many new materials designed for use in medical devices, medical packaging, and patient-care supplies.

emand for medical plastics in North America is forecast to expand 2.6 per cent annually to five billion pounds in 2012, valued at US$6.55 billion, according to a recent study by Chicago-based market research firm The Freedonia Group. With plastics processors finding more and more opportunities for manufacturing for the medical-device market, resin suppliers are stepping up production of higher performing materials suitable for a wide range of challenging health care applications.

TPEs GLS Corporation is launching a portfolio of specialty Versaflex TPEs, engineered for dynamic-seal gaskets and static-seal stoppers for the health care industry. The GLS materials support regulatory and eco-initiatives by avoiding halogens, polynuclear aromatics (PNAs), nitrosamines, 2-MBT, and other controversial additives. For gasketing applications such as drug storage seals, the new grades are said to provide good coefficient of friction. Both dynamic sealing grades are available in black. For stoppers, the new Versaflex grades for static sealing avoid the issue of coring - bits of material breaking off during needle insertion - that is typical of thermoset rubber. According to GLS, it has successfully tested the resealing performance of its Versaflex HC 2110-43N grade with needles as large as 16 gauge. Both static sealing grades are autoclavable and are available in natural colour. Applications include blood collection and pharmaceutical containers. Versaflex HC 2110-43N is said to offer good reseal performance and good compression set for stoppers for fluid delivery devices such as IV bottles and medical vials. Teknor Apex Company is introducing a new

medical-grade TPE guide called Medalist, containing extensive data on each of 33 Medalist highpurity elastomer compounds for health care applications. According to the company, information includes a grade selector plus data on toxicology, sterilization, chemical resistance, physical properties, processing parameters, process guidelines, and design considerations. Complete information in all of these categories is available for each of the 33 Medalist elastomer grades currently available. This initial range of 33 Medalist compounds includes grades with Shore A hardness from 5 to 87. Clear, translucent, and opaque formulations are available. New from Saint-Gobain Performance Plastics, Tygon S-95-E is a clear, non-DEHP medical-grade TPE designed to provide good peristalic pump life and flexibility. According to Saint-Gobain, the material meets USP Class VI and FDA standards, and is able to withstand both EtO and gamma sterilization. Tygon is offered in a range of tubing formulations and sizes. Non-DEHP PVC formulations are also available.

COLOURS Clariant Masterbatches is offering new colour concentrates specifically formulated for use with Purell medical-grade polyolefins from LyondellBassell. According to Clariant, Purell PE and PP resins were developed to deliver high performance, flexibility, and stability in applications in the cosmetic, pharmaceutical, medical device, laboratory, syringe, and diagnostics industries. The standard Purell-based Remafin MD masterbatches include a wide range of solid, opaque colours, as well as translucent and transparent tints. Class-VI-compliant custom colours are also available. The company has also made available colour concentrates

12 Canadian Plastics April 2009 www.canplastics.com

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medical manufacturing for PEBA and nylon 12 resins in medical applications. Renol MD masterbatches, in both standard and custom colours, are formulated to maintain the critical performance properties of virtually any of the tough-to-colour engineering resins. RTP Company recently introduced UniColor universal masterbatch and precoloured resins, designed for use in medical devices, medical packaging, disposable medical products, and pharmaceutical applications that meet ISO 10993-1 standards for biocompatibility. The company has entered into an agreement with Solvay Advanced Polymers to compound and market precoloured Radel polyphenylsulfone (PPSU) and Udel polysulfone (PSU) resins. According to RTP Company, the Radel materials are well suited to medical and healthcare applications, especially in orthopedics.

POLYMERS Nova Chemicals is making available a new generation of clear, impact-modified acrylic copolymers for injection molded medical devices and components. Zylar 631 is designed to provide good performance while being easy to process and decorate. According to Nova Chemicals,

recent applications include surgical suction wands, medical brush handles, bloodfiltration canisters, chest evacuators, and IV components. Bayer MaterialScience is expanding its offering of Bayblend PC/ABS blend resins with DP M850 and DP M850XF, the company’s first medical-grade PC/ABS blends. The new grades are said to offer a good combination of impact resistance, rigidity, dimensional stability, and colour stability, and meet the requirements of the FDA-modified ISO 10933, Part 1 tests, for biocompatibility. Solvay Advanced Polymers recently introduced a new polyamide for medicaldevice applications. Gamma radiationstabilized Ixef is available in eight stock colours, and is designed to replace metal in such products as foreceps, hemostats, and other reusable instruments. According to Solvay, the high-performance Ixef material provides a surface finish comparable to painted metal, as well as good stiffness, strength, and chemical-resistance. The new Terlux 2812 HD from BASF represents an addition to the company’s existing range of medical-grade polymers. Compared to the already introduced Ter-

lux 2802 HD, the transparent MABS Terlux 2812 HD offers a higher melt index, and can easily be injection molded in multi-cavity molds for economical production of especially complex transparent components. “This makes the material an interesting alternative to polycarbonate, since better processability translates into improved functional integration such as that needed for lab-on-a-chip applications,” BASF said. CPL Resource List BASF Canada (Toronto); www.plasticsportal.com; 1-800-267-2955 Bayer Inc. - Bayer MaterialScience LLP (Toronto); www.bayer.ca; 866-770-1102 Clariant Masterbatches Division (Toronto); www.clariant.masterbatches.com; 800-265-3773 GLS Corporation (McHenry, Ill.); www.glscorp.com; 815-385-8500 Nova Chemicals Inc. (Moon Township, Pa.); www.zylar.com; 866-890-6354 RTP Company (Winona, Minn.); www.rtpcompany.com; 1-800-433-4787 Saint-Gobain Performance Plastics (Valley Forge, Pa.); www.saint-gobain.com; 610-341-7000 Solvay Advanced Polymers, LLC (Alpharetta, Ga.); www.solvay.com; 770-772-8200 Teknor Apex Company (Pawtucket, R.I.); www.teknorapex.com; 866-438-8737

SURVEY SAYS...

Last year, in order to gauge how interested Canadian processors were in the growing medical products market, Canadian Plastics sent out a medical manufacturing survey to molders and extruders. We have conducted a second medical manufacturing survey this year, and the results are quite revealing. Over 70% of this year’s respondents were injection molders, but we also heard from several pipe (8.8%), profile (23.5%) and tubing (14.7%) extruders. When asked if they manufacture devices or components for the medical sector, nearly half of the manufacturers surveyed responded in the affirmative. This is a significant increase when compared to last year’s survey, where only 36.4% of respondents were manufacturing medical products. Additionally, manufacturers also seem to be more interested in entering the medical market. Out of the respondents that don’t currently serve the medical industries, 48.1% said they hope to manufacture products for the sector in the next two years, compared to 36.4% in 2008. Increases in the number of companies serving or looking to serve the medical field shows that manufacturers are looking at the emerging market in the face of weakening traditional business segments. Canadian manufacturers also continue to invest in technologies that support medical manufacturing. Fifty per cent of this year’s respondents have cleanrooms and controlled environments at their plants, and processors are also investing in micro molding machinery and equipment (23.5%), other machinery or equipment related to medical applications (20.6%), and special certification or compliance with industry standards (23.5%).

DO YOU MANUFACTURE MEDICAL DO YOU PLAN ON MANUFACTURING PRODUCTS/COMPONENTS? MEDICAL PARTS IN THE NEXT 2 YEARS? 80

80

70

2008

60 50

63.6%

50

36.4%

40

70

48.6%

48.6%

40

30

30

20

20

10

48.6%

10

YES 0

2008

60

51.4%

48.6%

48.6%

YES 2009

2009

YES

NO

NO

YES

YES

NO

NO

0

WHAT INVESTMENTS HAVE YOU MADE? Cleanrooms and/or controlled environments - 40.7% Micro molding machinery and equipment - 14.8% Other machinery or equipment for medical applications - 48.1% Special certification or compliance with standards - 14.8% www.canplastics.com April 2009 Canadian Plastics 13

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YES

robots and automation

REBUILDING AND RETROFITTING ROBOTS

YEA OR NAY? By Mark Stephen, managing editor

With most plastics processors looking to avoid unnecessary machinery purchases, this may seem like the perfect time to rebuild or retrofit your older robots and automation equipment to do more. But, at the end of the day, is it really worth the time and trouble? Canadian Plastics looks at some of the advantages and disadvantages.

S

hakespeare’s Hamlet famously wondered whether it was better to be or not to be. When it comes to robots and automation, the question facing many of today’s plastics processors looking to do more with their machinery is whether it’s better to rebuild or not to rebuild. And while they’re pondering that question, here’s another, closely related: when does it make sense to retrofit older robots and automation with new controls? For many plastics manufacturers, the rebuilding and /or retrofitting options have probably never seemed more plausible than right now. With large numbers of relatively inexpensive used robotic and automation equipment available at auction, the temptation to purchase a unit that’s almost-but-not-quiteright, with the idea that it can be tweaked to perfection, is strong.

“Upgrading or retrofitting applications has become an option that a lot of our customers are requesting, as they try to avoid investing in new capital equipment,” said Brad Lemieux, sales manager with Yushin Automation representative En-Plas Inc. “Typically, they buy the standard offthe-shelf robotics not knowing what the future is going to bring, then upgrade as necessary.”

THE DOWNSIDE There’s no mystery, of course, as to what processors want to accomplish. “Most customers want their robots to offer higher speeds and acceleration rates, better accuracy and repeatability, as well as capable of handling more payload,” said Bill Egert, vice president, engineering for Logic One Robots, a supplier of new and rebuilt robots. “For controls, they tend to want more user-friendly operator interface.” But are rebuilding and retrofitting the right strategies to achieve these ends? Most importantly, when all the factors are considered, will the cost of rebuilding or retrofitting the equipment amount to the same — or more — than the price of a new unit? According to robot and automation suppliers, the first question for processors considering a retrofit or rebuild to answer is whether the equipment is, from a mechanical point of view, even worth the effort. A good history of preventative maintenance for a robot or automation equipment doesn’t guarantee that a rebuild

14 Canadian Plastics April 2009 www.canplastics.com

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robots and automation

can be done, but it helps. “In theory, a robot can be 20 years old and still be cost-effective to rebuild if the mechanics are solid,” said Bill Egert. A poor maintenance record, especially on an older machine, is usually the deciding factor in stopping a rebuild or retrofit project cold. “If the machine is in poor shape, usually because proper maintenance procedures haven’t been followed, we will advise a customer against trying to rebuild for that reason alone,” said Jim Healy, vice president of sales and marketing with automation manufacturer Sepro America Inc. An obvious point, but often overlooked by processors, is that determining if a robot should be rebuilt is easier if the unit is actually operational. “It’s always simpler to evaluate the robot if it’s running, as opposed to sitting on a skid,” Healy continued. If a robot or piece of automation equipment is in good working condition, other questions follow. “The company performing the rebuild or retrofit will want to know what the make and model are, what size press it’s on, and then application questions about what the customer wants the unit to do after it’s been rebuilt,” said Bill Egert. According to Egert, a rebuilder might shy away from working on an unfamiliar make of machinery. “We don’t always know enough about the more obscure robot brands to proceed with a rebuild,” he said.

THE DOWNSIDE (CONTINUED) Another hurdle involves the age of the machine. Indeed, age can be the decisive hurdle - at least from the rebuilder’s point of view, regardless of maintenance history. “If a robot was not built with at least a ten-year lifetime on the mechanics, it’s probably not worth rebuilding,” Egert said. Key problems in rebuilding older equipment are the availability and cost of spare parts. “Most robot and automation manufacturers maintain an inventory of spare parts for older models and, once depleted, can be expensive to have custom manufactured,” said Christian Weiss, technical sales, robots and automation at equipment manufacturer Wittmann Canada Inc. “On the controls side, for example, it’s not always possible to make a new controller work on an older system because older systems are not always backwards-compatible.” Assuming spare parts are available and not prohibitively expensive, the focus may shift to whether the rebuild or retrofit is cost-effective in the larger sense. According to Bill Egert, a full rebuild of an older robot with new motors and servo drives can cost up to US$35,000, a total that approaches the cost of some new units. “Because newer robots have decreased greatly in price, and the technology in the drives and controls has improved substantially, there may actually be no cost benefit to retrofitting or rebuilding as opposed to simply buying new equipment,” said Christian Weiss. Indeed, according to some automation providers, substantial

rebuilds of older machines are invariably too expensive. “If a robot requires a significant rebuild, it’s almost never a good idea,” said Joe Corturillo, engineering manager at Wittmann Canada. “If a processor is trying to increase the robot’s vertical stroke, for example, they’re probably looking at an investment almost equal to the cost of a new robot.” Rebuilds, in particular, often have hidden costs and inconveniences, as well. “If the decision is made to go ahead with a rebuild, the robot usually has to be taken off the press and shipped to the rebuilder’s facility,” said Jim Healy. “This translates into cost of freight back and forth, as well as a good deal of machine downtime.”

THE UPSIDE Given these factors, is a rebuild or a retrofit ever a good idea? Under certain conditions, suppliers say, the answer is yes. “Rebuilds can be cost-effective on larger tonnage machines performing pick and place operations, where cycle times are not as critical, and we’ve performed these rebuilds successfully in the past,” said Jim Healy. “Generally speaking, the larger the robot is, the more costeffective it can be to rebuild.” On the retrofit side, most robots that are less than five years old still have functional controls, and thus can be retrofitted to perform some additional operations without too much trouble or expense, according to Joe Corturillo. Within these parameters, there are real benefits to be gained by rebuilding or retrofitting robots and automation units. “Many processors have modified their robots to have more vacuum systems and gripper circuits, allowing them to pick and place multiple products and package or separate cavities in quality control situations,” said Brad Lemieux. Also, rebuilding robots or retro fitting with servo motors can increase speed by 100 per cent or more while improving repeatability from 2-3 mm to 0.25 mm, according to Bill Egert. “Servo controls can also increase payload capacity, and improve low-speed jogging and motion with smoother, more repeatable www.canplastics.com April 2009 Canadian Plastics 15

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robots and automation

stepping,” he said. “New servo controls offer many special features that allow for better in-mold and post-mold operations, increasing the number of jobs that can run on a press.” When retrofitting controls, Egert advised, processors should be wary of using displays that overload the system with information, display excessive messaging, and have a tendency to lock up. In the end, if the decision is made to rebuild or retrofit either a robot or piece of automation equipment, equipment suppli-

ers stress the importance of involving them in the process. “The danger in trying to rebuild robots without professional help is that robotics gives you the perfect chance to fail, because it combines mechanics, electronics, and software, and also interfaces with the injection molding machine, mold, downstream equipment, production workers, and setup and maintenance technicians,” said Bill Egert. “Unlike a passive machine that sits in a corner performing a simple function, an automation system basically takes the place of a person on

the production floor for up to 24 hours a day.” CPL RESOURCE LIST En-Plas Inc. (Toronto); www.en-plasinc.com; 416-286-3030 Logic One Robots (Addison, Ill.); www.logicone-robots.com; Sepro America (Pittsburgh, Pa.); www.seproamerica.com; 412-459-0450 Shadow Automation Inc. (Uxbridge, Ont.); 905-649-2652 Wittmann Canada Inc. (Richmond Hill, Ont.); www.wittmann-canada.com; 888-466-8266 Anplast Inc. (Anjou, Que.); 1-800-387-4590

Pros and cons of rebuilding gantry robots By Bill Egert, Logic One Robots

•

•

• •

•

What’s good

Capital savings. A rebuilt robot can provide the same advanced controls and software for about half the cost of a new robot. Partial rebuilds (refurbishing) cost 20-30% of new robots. Some buyers may be concerned about older controls, but a completely remanufactured robot using state-of-the-art controls is very similar to a new robot; the only difference is that large structural components (e.g., steel beams and channels and aluminum frames and tubes) are reused. Improved performance. Rebuilding older pneumatic or electric robots and converting them with servo motors increases robot speed by 150-300%, improves reliability, reduces mold changeover time, improves machine uptime, and increases positioning accuracy while extending the robot’s life up to 10 years. Reduced need to purchase spare parts. Existing spare parts can be used. Less training. Robots rebuilt with similar controls allow technicians to use familiar control hardware with minimal software training. Plus, up-to-date software and interfaces can reduce error recovery and product changeover time. Warranties intact. Unlike used robots purchased at auction, a fully rebuilt robot comes with a one- to two-year full warranty.

•

•

• •

What’s not

Downtime during rebuilding. It takes longer to bring a remanufactured robot up to speed than to set up a new robot. But this delay can be reduced using a spare robot, and swapping robots as each rebuild is completed. In addition, retrofitting or partially rebuilding a robot must be carefully considered to ensure the robot can perform to expectations, and is not slowed by older, limited parts. Downtime during component reengineering. Rebuilding robots may involve redesigning components not intended for higher speed and accuracy. Such added engineering will increase time and cost of delivery. Fewer choices. Rebuilding robots is limited to your current stock of old robots, or whatever quantity you are buying from auction or equipment broker. Limited part availability. Refurbishing or rebuilding foreigndesigned or -assembled robots can be difficult, especially if critical parts are not available domestically. If foreign-sourced parts are not stocked locally, or are made per-order overseas, you may wait three to four months for a replacement part. Also, if a part design is changed by the foreign robot manufacturer, you may not easily get spare parts if the original part vendor does not have a sales office in North America.

16 Canadian Plastics April 2009 www.canplastics.com

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New Facility, New Products for AceTronic

New

AceTronic supplies ALL you need in automation, control and electrical/electronic services, and now we can do this even better. We’ve moved to a new facility that gives us more warehouse space, so we can keep even more stock on hand for quick delivery. Plus, our increased production area means we can better serve custom orders. We know that a quick turnaround is important to many of our customers and we do our utmost to meet your needs. For example, we recently built and shipped 36 mold cables within 24 hours of receiving the order. In addition to the new facility, we’ve expanded our product line. We are pleased to announce that Slide Products has appointed us as distributor of their line of mold release agents, purging compounds, rust inhibitors, mold cleaners and lubricants. Also, we’ve recently signed on with Wika as their exclusive distributor of thermocouples and gauges to the plastics industry in Canada. Other suppliers that we represent are: RKC Instruments (temperature and process controllers); GP:50 (transducers); and Dalton (split sheath cartridge heaters). AceTronic builds our own line of hot runner temperature controls and cables, water temperature control units, and custom electrical control panels. Our services include repair, calibration and troubleshooting by our highly qualified technicians. AcetronicsQtr Ad/AB/CPL 3/12/09 5:12 PM Page 1 Our new facility is conveniently located at the 410 and 401 crossroads: 7015 Ordan Drive, Units 6 and 7, Mississauga, ON L5T 1Y2 800-803-8871, www.acetronic.com

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High operating temperature range – up to 650F˚ Will not freeze, melt or gum up

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• Fuzzy Logic Phase and Burst Control • Amperage and Voltage Measurement Display • Real-Time Fault Detection • Type J and K Thermocouple • Automatic Bumpless Control for Thermocouple Break • 2 Years Limited Warranty

AceTRONIC Industrial Controls Inc. Mississauga, Ontario 905-564-7227 or 1-800-803-8871 An ISO 9001:2000 registered company

p 17 acetronic.indd 17

www.acetronic.com

®2009 Slide Products, Inc.

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www.slideproducts.com Ask questions, get samples & buy on-line Mold releases, purging compounds, rust preventives, cleaners and more.

3/23/09 1:48:24 PM

dryers

DRY BUT IMPORTANT

Umair Abdul, assistant editor

Preventative maintenance isn’t exactly the most exciting topic, but a few cautionary tips and tricks could help you reduce downtime and run your dryer more efficiently. Check the integrity of the hoses in a dryer to ensure that adequate air volume and temperature are maintained. PHOTO CREDIT:The Conair Group

I

n dire economic times like these, an inefficient operation is every processor’s worst nightmare. Unfortunately, however, many companies are also finding their budgets constrained in leaner times, and many have had to cut back on the amount they spend to maintain their plant’s equipment. There was a time, and it’s still true today, where everybody had their own maintenance crews who would maintain their equipment,” noted technical support manager Bill Collis of Universal Dynamics Inc. “I think gradually we have been seeing a trend where people are getting rid of their maintenance crews.” When it comes to dryers, suppliers note that downtime or inefficient drying often boils down to poor or improper maintenance. A few

quick and easy preventative maintenance steps can help ensure that your drying system is running optimally, or help identify inefficiencies in your drying process. “Typically, processors don’t even touch the dryer until they have a problem with a part, and then they start to investigate,” explained Joe Corturillo, engineering manager for Wittmann Canada. Here are a few pointers to stay ahead of the curve, and avoid any unpleasant surprises when it comes to your dryers. Check and replace your filters. Most suppliers identify poorly maintained filters as the number one culprit for drying inefficiencies. “This is often the primary cause of poor dry-

BUYER BEWARE: AUCTIONS

With the recent wave of consolidation in the industry, there has been a glut of used equipment in the market, with new auctions taking place on an almost weekly basis. But according to major suppliers, buying a dryer off the auction block may be more trouble than it’s worth. Buying a dryer on auction is not the same as buying a second-hand dryer, because you can’t test auctioned equipment before buying it. “At an auction, you can’t plug the dryer in,” noted Brian Davis at Maguire Canada. “Also, you don’t know how well it’s been maintained.” Davis points to one major processor that went under last year and had its capital equipment auctioned off. He notes, however, that the company had had to cut its entire maintenance budgets eight months before it went under. When a processor purchases a piece of used equipment from a supplier or distributor, the “buyer beware” is often taken out of the equation. “We completely check over every used piece of equipment we sell and either completely refurbish the unit so it runs and looks like new or at the very minimum give the customer a checklist of potential concerns,” noted Brad Lemieux at En-Plas Inc. If purchasing drying equipment at an auction, customers should try to check seals, filters and hoses to get a sense of the dryer’s maintenance record. Additionally, make sure that the cabinet control wiring is intact, and look for warning signs like rusted out boxes. “The very least a person can do at an auction is check the quality of the steel,” said Davis. “That way, you will at least get a good shell.” Suppliers also advise potential buyers to do their research before going to the auction, noting that dryers are often sized and engineered for a very specific application. Once the equipment has been purchased, you want to clean up the dryer, including the hopper, and replace the filters and the desiccant. “With the seals, go through and check if they are pliable and soft because you don’t want to start with air leaks,” said Corturillo. Additionally, manufacturers also warn that equipment on the auction block can often be older, and savings on the sticker price may be lost when running the equipment at your plant. “When you are buying an older product, you know it’s not the newest technology,” said Corturillo. “So odds are it’s not as efficient as the technology available today.” 18 Canadian Plastics April 2009 www.canplastics.com

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dryers

MAINTENANCE SCHEDULE CHECKLIST

Desiccant Bead Dryers ing,” said Charles Sears, president of Dri-Air Industries, Inc. “Not only does it affect the dryer performance, but without adequate air flow, the material will not heat up to the proper drying temperature.” Equipment manufacturers advise that you regularly inspect the process and regeneration filters, and clean or replace them if necessary. Suppliers note that some processors don’t even use regeneration filters on their machines. “Some people think regeneration filters are not important, but in many of these plants you have dryers and grinders next to the machine, and sometimes these grinders generate a lot of dust,” said engineering manager Kalhan Tavakoli of Universal Dynamics. “When the plastic dust gets pulled into the regeneration system, the plastic dust melts and fuses itself to the desiccant.” Maguire Canada’s Brian Davis explains that the regeneration filters on Novatech dryers are exposed to avoid this “out of sight, out of mind” mentality. How often should you check your filters? It depends on who you ask, but it can also depend on the material you are running through the machine. “If the material is dusty, has an additive in it, or has a plasticizer in it, you may have to clean the filter every shift,” said Dri-Air’s Sears. Check your dew point. If your machine is not already equipped with a dew point meter, portable ones can be purchased for periodic checks of dew point levels. One supplier compared being without a dew point meter to operating an automobile without a speedometer. “If you’ve got a bad dew point, your first line of defense is to check the desiccant,” said Maguire Canada’s Davis. Davis also recommends that processors check their desiccant once a month, which is relatively easy to do with a beaker test. Check for ambient air leaks. Suppliers also recommend that plant managers check their equipment for any leaks that may let ambient into the process, affecting the air flow and pressure in the system. “It’s supposed to be a closed system, and if you’re bringing ambient air into it, you are reducing the efficiency,” said Maguire’s Davis. Wipers and seals should be checked and not allowed to degrade. Brad Lemieux, sales manager at En-Plas Inc., also recommends that processors check for leaks at the hopper - most commonly the lid or access door of the hopper - or for leaks inside the dryer (bed seals, hoses and heater boxes) if the machine isn’t maintaining dew point. Additionally, Jamie Jamison, product manager for dryers at The Conair Group, recommends that operators check all the hosing to ensure that there are no cracks or holes letting air into the process. “Collapsed air hoses will reduce air flow and compromise

Every Month n A. Inspect air filters. Clean or replace as required. n B. Check system for air leaks and correct as required. Every 3 Months n A. U nits equipped with sleeve bearing motors should be lubricated with SAE 20 oil. n B. Units equipped with ball bearing motors are factory greased and should be re-lubricated with high-grade ball bearing grease. WHEN ADDING LUBRICANT n 1. Remove filters plugs at the bearings and install grease fittings suitable to your grease guns. Also, remove the drain plugs at the bearings. n 2. Add ball bearing grease until all of the old grease is expelled through the drain hole. n 3. Run motor with drain plug removed to eliminate excess grease. n 4. Clean and replace drain plug. n C. Check heater amperage n D. Check Motor(s) amperage NOTE: Most units are equipped with permanently lubricated bearings and no lubrication is required. All motors should be examined on an individual basis. Once Every Year n A. Check dehumidifier valve linkage and operation of valve. n B. Check ëwiper bladesí for wear and replace, if necessary ñ In general this requires that the valve be disassembled for maintenance Every 2 Years or as Needed Remove top covers of towers and replace desiccant. Use high temperature silicon tore-seal the covers.

Desiccant Wheel Dryer Every Month n A. Inspect and clean process and regeneration filters n B. Check system for air leaks and correct as required. n C. If a belt is used to drive the desiccant wheel ñ check for wear/stretching and replace as necessary Every 6 Months If a chain is used to drive the desiccant wheel, lubricate the chain Once Each Year n A. R otor Seals should initially be inspected after 1 week and 3 months for damage ñ after that, check yearly. They are designed to last for several years n B. Desiccant rotors should last several years if properly used ñ some are guaranteed for 5-years

Membrane/Compressed Air Dryers Every Month n A. Inspect and clean process air filter n B. Check system for air leaks and correct as required. Every 6 -12 Months (Depending on model and manufacturer) n A. R eplace 2 coalescing filter elements NOTE: Some brands of Membrane/Compressed Air dryers use 2-3 times as much energy as other brands. Compare before you buy.

Vacuum Dryers Every Week n A. Drain and purge compressed air filter/regulator Every Month n A. Inspect and clean process air filter n B. Check system for air leaks and correct as required. Every 6 Months n A. Inspect canister seals. These are designed to last several years. Source: Maguire Canada

www.canplastics.com April 2009 Canadian Plastics 19

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dryers dryer performance,” said Jamison. “Frayed or damaged hoses may draw wet ambient air into the closed-loop drying circuit, causing premature desiccant loading and resulting in high dew points.” With larger dryers, Universal Dynamics also suggests that customers ensure they are using proper ducting made for the pressure the system will be under. “Seamless ducting is important in large dryers for maintaining pressure,” said Collis “We find that people think that normal house ducting will be sufficient, but it doesn’t get you there.”

CPL

Check your air temperature. If you’ve made sure your filters and hoses are clean and in good shape, but notice that material is still not drying properly, check your drying air temperature. The drying air temperature should be monitored and controlled at the inlet of the hopper rather than at the dryer outlet, and the sensor should be positioned in the center of the air duct to prevent false readings. “A low drying temperature at the hopper inlet may be caused by something as Digital Adas1\2 3/12/09 adjusted 3:39 PM Page simple an improperly control-

ler, or something a little more sinister like failure of heater elements, heater contractor, thermocouple or controller,” said Conair’s Jamison. Check your heaters. “When you check heaters, you are checking for continuity, to make sure you don’t have any breaks in the heating element,” said Wittmann’s Corturillo. “As long as the heater is producing the air temperature that is required for regeneration, you are usually fine.” According to Sears at Dri-Air, heaters can fail at any time and greatly affect the operation of the dryer. “Also, fuses and relays to control the heaters can fail, making the dryer ineffective,” said Sears. “It is easy to spot a failed process heater but the failure of regeneration heaters are not apparent until the dew point is affected and defective parts are molded.” Sears adds that some newer dryer models include circuitry to check the status of the heaters, but circuitry is not easy to add to an existing dryer. Although these steps seem simple 1enough, they will go a long way in helping

you ensure that your dryer runs efficiently and provide early warning signs if problems do arise. You should also follow your manufacturer’s specifications, contact a representative and use the maintenance schedule checklist on pg. 10. CPL RESOURCE LIST Conair (Cranberry Township, Penn.); www.conairnet.com; 800-654-6661 Hamilton Avtec Inc.(Mississauga, Ont.); www.hamiltonavtec.com; 905-568-1133 Dri-Air Industries, Inc. (Windsor, Conn.); www.dri-air.com; 860-627-5110 Plastics Machinery Inc. (Newmarket, Ont.); www.pmiplastics.com; 905-895-5054 Maguire Canada Inc. (Vaughan, Ont.); www.maguirecanada.com; 866-441-8409 Motan Inc. (Plainwell, Mich.); www.motan.com; 269-685-1050 Dier International Plastics Inc. (Unionville, Ont.); www.dierinternational.com; 905-474-9874 Thoreson-McCosh Inc. (Troy, Mich.); www.thoresonmccosh.com; 248-362-0960 Universal Dynamics, Inc. (Woodbridge, Va.); www.unadyn.com; 703-490-7000 Resource Polytec Inc. (Vancouver, B.C.); www.resourcepolytec.com; 604-454-1295 Wittmann Canada Inc. (Richmond Hill, Ont.); www.wittmann-canada.com; 888-466-8266 Anplast Inc. (Anjou, Que.); 1-800-387-4590

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digital.canplastics.com 3/23/09 11:41:23 AM

colour matching

NEW PRODUCT REPORT: Colour matching equipment By Mark Stephen, managing editor PRODUCT: BYK-Gardner’s BYK-mac colour measurement INFO:The new BYK-mac system from BYK-Gardner is designed to objectively characterize the total colour impression of special effect coatings in automotive and other applications. In contrast to conventional solid colours, special effect or metallic finishes change their appearance with viewing angles and lighting conditions, and cannot be described sufficiently with traditional multi-angle colour measurement. The BYK-mac is said to be unique in that it objectively measures two parameters in one portable device: flake characterization, by measuring with a camera the visual impression of sparkling and graininess, simulating effect changes under direct and diffuse lighting conditions; and multi-angle colour measurement, to give more information about the colour travel of special effect finishes. “We’ve taken traditional multi-angle colour measurement and added a camera to measure and evaluate the effect we see when we look at special effects coatings,” said Greg Shrider, vice president, sales. “The key advancement is that, in addition to colour illumination, we use different angles to illuminate and measure the sparkle, including both direct and diffuse illumination, which is akin to measuring how something looks on a sunny day and then on a cloudy day.” For further analysis and professional documentation of measurement results, the BYK-mac comes with the software autochart: measured data is saved in an Access database and directly transferred to standardized reports in Excel. CONTACT: BYK-Gardner USA (Columbia, Md.); www.byk.com/instruments; 800-343-7721 REP: Folio Instruments Inc. (Kitchener, Ont.); 800-683-6546

PRODUCT: X-Rite’s Version 6.0 Color iQC colour measurement system INFO: According to X-Rite, its new Version 6.0 adds many new features and significantly improves X-Rite’s ability to support and expand the digitization of workflows in measuring colour formulation and quality control. Color iQC is designed meet the many different methodologies in use throughout the retail colour supply chain — a single system that is capable of handling QC, recipe formulation, communication, and tracking colour approval status. The new features in Version 6.0 support management of the colour supply chain workflow to make the submission process smoother and easier for specifiers and suppliers. Version 6.0 is capable of receiving data from competitive systems and permits the specifier to maximize the benefits of control and communication with internal and external supply chain partners. Key benefits of Version 6.0 are said to include the ability to distribute responsibility and approval points throughout the supply chain; communicate colour information globally to all participants; monitor the steps in the colour approval process, including the ability to grade the performance of vendors and suppliers; the ability to integrate colour data into other parallel business systems; a workflow solution that is seamless, has an open architecture and is easy to use that provides distributed approval points, multiple submission points, multiple response points, and flexible user roles; and a new database reporting and retrieval feature that allows users to easily organize, recall, and manage their data. CONTACT: X-Rite Inc. (Grand Rapids, Mich.); www.xrite.com; 800-248-9748 REP: Manutrol (Montreal); Metch-Rite (Mississauga, Ont.)

PRODUCT: Konica Minolta’ CM-660d and CM-700d spectrophotometers INFO: Konica Minolta Sensing Americas, Inc. (KMSA) has introduced its Spectrophotometer CM-600d and CM-700d, two compact, lightweight, portable vertical-format spectrophotometers that offer such advanced features as Bluetooth wireless communication and a colour LCD screen. According to KMSA, the two models are approximately 25 per cent smaller in volume than previous models, as well as approximately 20 per cent lighter. “The CM-600d and CM-700d are equipped with colour TFT LCDs that enable colour patches to be shown for each measurement to allow immediate, intuitive operation,” said Kaoru Morishita, president, KMSA. “The measurement tips of the spectrophotometers are narrow, so there are fewer limitations on what can be measured, including flat areas, protruding areas and sunken areas.” Colour patches for both target and sample are shown in the display, he continued, so that the difference that was previously shown as only numerical values can be visually experienced, making the degree of colour difference easily understood. Additionally, various optional accessories are also available, such as a target mask with glass over the measurement aperture, a granular materials attachment, and a dust cover to enable measurement of a wide variety of subjects including pastes, powders, and wet surfaces. CONTACT: Konica Minolta Sensing Americas, Inc. (Ramsey, N.J.); www.konicaminolta.us; REP: Folio Instruments Inc. (Kitchener, Ont.); 800-683-6546 www.canplastics.com April 2009 Canadian Plastics 21

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testing & measuring

NEW PRODUCT REPORT: Testing & measuring equipment By Mark Stephen, managing editor PRODUCT: Mitutoyo’s Quick Vision measurement system INFO: Mitutoyo Canada Inc. is reporting new advancements in its line of Quick Vision measurement systems. The system now has higher measuring accuracy, achieved by improving the algorithms for collecting data acquisition points. Also, higher drive speed has been attained through controller enhancements, and improved optical lens performance, via more LED light sources. In addition, the ability of the new Mitutoyo QVPak 7.4 software platform has a built-in ‘Auto Tool Recovery’ when executing a CNC program. This is an auto correction tool used when edges or features cannot be detected due to issues related to surface conditions, or edge detail. According to Mitutoyo Canada, the machine will automatically search for the edges or features within the video window and correct itself without pausing the program. CONTACT: Mitutoyo Canada Inc. (Mississauga, Ont.); www.mitutoyo.ca; 905-821-1261 PRODUCT: Qualitest’s CR-6000 high pressure capillary rheometers INFO: Qualitest has released a new line of high pressure capillary rheometers specially designed to determine the flow behavior and viscosity of high polymers, polymers, thermoplastics and elastomers. The CR-6000 offers ergonomic design, advanced features, high accuracy and a newly developed software with unparalleled ease of operation and control of the test cycle. The unit is equipped with advanced high temperature and pressure transducers coupled with a highend servo motor and state-of the-art operating software. According to Qualitest, the key features of the CR-6000 capillary rheometer are all digital calibration, up to 50 shear stress or shear rate data points per test, data collection through CPU, 25 piston speeds or melt pressures can be preset in either the constant speed or constant pressure mode. CONTACT: Qualitest International Inc. (Richmond Hill, Ont.); www.qualitest-inc.com; 905-944-9825

PRODUCT: Cognex Corp.’s DataMan 100V fixed mount verifier INFO: The DataMan 100V fixed-mount verifiers are said to ensure code quality and uniformity in all parts entering the manufacturing and supply chains, making them well-suited for precision parts manufactured for the automotive, aerospace, packaging, electronics, and medical-devices industries. Designed for ease of use, the 100V Series comes standard with an automatic report generation service, and measures label and direct part mark quality to all industry standards. According to Cognex, the DataMan 100V verifiers are available for easy integration into marking, labeling, and other types of equipment, or as a complete turnkey solution for contract compliance applications. CONTACT: Cognex Corporation (Natick, Mass.); www.cognex.com; 877-264-6391 REP: Shelley Industrial Automation (Toronto); 416-447-6471 Rotalec Group (St-Laurent, Que.); 514-341-3685 PRODUCT: Dynisco’s SPXD digital display system INFO: The new SPDX from Dynisco is described as an intrinsicallysafe, loop-powered digital display system, that takes a 4-20mA signal from a pressure sensor or any 4-20mA transmitter and displays the value on a large one inch LCD. Weighing 1.8 lb., the SPDX includes a highly visible five-digit LCD display that’s backlit for easy viewing in dark areas. The display also includes a bar graph that shows the measured value in 10 per cent increments of full scale. According to Dynisco, power for the entire unit is supplied by the loop. Range setting, decimal placement, offset, and other parameters are said to be easily configurable via a front panel push button. The entire package is rated NEMA 4X (IP66) for rugged process application, and can be mounted directly to the wall. An optional wall/pipe mounting kit is also available. CONTACT: Dynisco (Franklin, Mass.); www.dynisco.com; 508-541-9400 REP: Process Heaters Inc. (Toronto); 416-747-8250 Auxiplast Inc. (Ste. Julie, Que.); 450-922-0282

22 Canadian Plastics April 2009 www.canplastics.com

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technology showcase

CASE STUDY

FULLY AUTOMATED CO-EXTRUDER WITH MODERN CONTROLS

THE CUSTOMER

Newly opened Plastics Process Technology Group (PPTG), of Brampton, Ont., services the plastics industry by building new machinery with modern controls — and the company is turning to Omron Canada Inc. to provide innovative control platforms.

THE TECHNOLOGY One of the key innovations in retrofitting any piece of processing machinery is to have a controller that encompasses all of the machine operations in a central control panel, and for this PPTG chose Omron’s CP1H micro PLC. In order for the operator to “see” all of the machine dynamics, a touch screen is used as a “window” into the PLC memory map. The PLC memory contains all of the I/O status as well as data communicated from VFDs, thermocouples, pressure sensors and encoders. The touch screen is able to represent the data graphically so that it is not overly complicated for the operator. One of the benefits of communicating all of the peripheral parts of the machine to the PLC is the recipe function. With recipes the operator makes one selection from a spread sheet object that automatically downloads set points, timer values, production targets and on/off selections used for various parts being manufactured. PPTG was able to deliver a fully automated co-extruder to the market by offering the features contained in the new Omron control products, and by demonstrating the paybacks to their end customers. This particular co-extruder uses an Omron 3G3 high performance micro inverter to turn the screw. The 3G3 offers DeviceNet communications to the PLC, which provides vital information. The current that runs in the motor is monitored in real time and gives detailed information of the health of the machine (too much current at a set speed may mean a blown phase, improper plastic viscosity, etc.). The 3G3 also comes

PPTG’s Alex Chermaz (left) and Omron’s Steve Wyatt with co-extruder.

One of the benefits of communicating all of the peripheral parts of the machine to the PLC is the recipe function.

of the temperature data to the PLC without programming. The touch screen is thus able to report any alarms, heater burnouts instantly in addition to the recipe setting of set points and alarm set points. The cutter/puller section of the extrusion line uses the micro PLC from Omron, CP1H. This is a low cost PLC with built in analog I/O for speed control of the puller, and a built in high-speed counter used from product measurement in the cut to length section.

THE END RESULT standard with an interlock device, preventing the 3G3 drive from rotating the screw until all of the temperature zones are at a minimum level. PPTG also selected Omron’s E5ZN din rail temperature control unit, mounted to save panel space and labour. It has an advanced PID algorithm that supports auto tune and heat/cool loops. Finally, the unit offers a single DeviceNet adapter module for up to 32 zones that communicates all

The Omron team worked together to provide PPTG with the modern control system needed to automate the co-extruder, and to allow PPTG to differentiate themselves in a tough market. As a result, PPTG has gained new business at a Woodbridge, Ont. extrusion shop, outfitting all 44 lines with cutter/puller machines, and most with co-extruders. Omron Canada Inc. (Toronto); www.omron.ca; 416-286-6465 www.canplastics.com April 2009 Canadian Plastics 23

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technology showcase

AUXILIARY EQUIPMENT TCU provides consistent temperatures for critical processes

Sterling’s 2012 Series temperature control units feature a high-tech design, and simplified internal cast or nonferrous circuit with 40 per cent fewer connections and 80 per cent fewer mechanical parts. The 2012 units also feature a higher-efficiency pump for higher flow rates at lower pressure, resulting in enhanced water flow for superior temperature control. The units are available with a cast-andflange design to reduce connection points, half- and full-heat capacity, and forward facing liquid-filled To and From Process pressure gauges. Sterling (New Berlin, Wis.); www.sterlco.com; 262-641-8610 CN Smith Plastics Machinery Sales (Georgetown, Ont.); 416-917-3737 Equipment Resources Northwest (Eugene, Ore.); 503-281-3612

whereby low operation with low levels of both noise and dust is ensured. A safety coupling between the direct drive and the rotor of the 35 tons heavy machine prevents disturbance in the event of unintended feeding of a large amount of contaminating material. Weima America Inc. (Fort Mill, S.C.); www.weimaamerica.com; 888-440-7170 Crowther Machinery Ltd. (Longueuil, Que.); 514-636-1166 Ry-Coll Industries Inc. (Langley, B.C.); 604-530-0636

INJECTION MOLDING

Energy-saving small tonnage machines

Direct-drive shredder The PowerLine 3000 shredder from Weima features a working width of 3,000 mm, together with rotor diameter of 800 mm. Reversible knives in a special throughtempered tool-quality steel, and edge lengths of 80mm x 80mm, are fitted around the full extent of the rotor, enabling extremely long lifetime of 250-300 hours before reversal or a replacement of the blade is required. Exchangeable armouring of the rotor guarantees a high degree of protection and enables lifetime of several tens of thousands of hours. The shredder is equipped with direct drive of power rating of 350 kW. The speed is controlled continuously up to approx. 170 rpm via a frequency converter,

Boy Machines’ new BOY 55 E and BOY 90 E injection molding machines are designed to save energy with each cycle. Compared to current technology, the “E” series machines reduce energy consumption by more than 50 per cent, savings enabled by a servomotor pump drive. The speed of the motor is only as high as the respective cycle phase requires. At all times, the motor is performing in an optimum, energy-efficient way. Further advantages of the new drive technology are a 20 per cent reduction of the noise level, as well as improvements in precision and dynamics. Extensive repeatability measurements

showed a maximum deviation in weight of only 0.115 per cent from the average value. Due to the short response and low inertia properties of the servomotor pump drive, the operation of the BOY injection molding machines is more dynamic and agile. By using this new drive technology, it’s possible to surpass the positive technical features of electro-mechanical machines without acquiring their disadvantages such as investment cost, spare parts cost, wear, and high connected load. Boy Machines Inc. (Exton, Penn.); www.boymachines.com; 610-363-9121 Barway Plastic Equipment Inc. (Vaudreuil-Dorion, Que.); 450-455-1396 Plascom Plastic Machinery Inc. (Toronto); 416-491-8450

EXTRUSION

Screw design simplifies CPVC pipe extrusion Processing chlorinated polyvinyl chloride (CPVC) compounds can present various issues because of their thermal instability characteristics. American Maplan has now made available a new screw design that provides a typical reduction of melt temperature of up to 15-20°F, while providing superior plastification, for CPVC pipe extrusion.

A reduction of melt temperature extends the reaction or decomposition time significantly. Typically, reductions of melt temperature of 15-20°F can double the decomposition time of CPVC compounds. In addition, the use of this screw geometry typically doubles the time between purging and shut downs for cleaning. American Maplan Corporation (McPherson, Kan.); www.maplan.com; 620-241-6843

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technology showcase

ROBOTS & AUTOMATION

“SmartRemoval” cuts automation cycle times

Wittmann is introducing the SmartRemoval function on the new upcoming R8 control, designed to optimize part takeout time. SmartRemoval monitors all the timerelevant processes in parallel, regardless of whether they are connected to the robot or the machine. In collaboration with the machine controller, the software then optimizes the takeout path for the robot to streamline the takeout path and eliminates wasted time and movement. The program calculates when the mold will open, allowing the Y-axis to begin moving from the waiting position just before the mold has fully opened.

The Food Series option includes a robot arm IP-65 protection rating, food grade oil in the robot reducers, USDA certifiable white robot coating selected to withstand common industry sanitizers, and a stainless steel robot control cabinet. Kuka Robotics Corporation USA (Clinton Township, Mich.); www.kukarobotics.com; 866-873-5852

CONTROLS

Thermal imaging on production lines Macro Engineering’s Supercom Supervisory and Control System for blown and cast film lines has recently been upgraded to include an optional thermal imaging system that allows processors to monitor bubble temperatures from anywhere an internet connection is available.

Savings of up to 0.5 seconds per cycle can be achieved, corresponding to timesavings of about 10 per cent on a total cycle time of five seconds. Wittmann Canada Inc. (Richmond Hill, Ont.); www.wittmann-canada.com; 888-466-8266 Anplast Inc. (Anjou, Que.); 1-800-387-4590

New food series robots Designed to meet the requirements of the food industry, the new Food Series Option from Kuka Robotics is available on a variety of robots designed for packaging and palletizing application, including KR 40 PA, KR 50 PA, KR 100-2 PA, KR 180-2, PA & KR 150. These units offer robotic solutions from 2-axis packaging, 4-axis palletizing, and 6-axis palletizing and handling.

The system consists of one more infrared camera that targets specific points on the bubble to monitor temperatures. The data is displayed in real-time on the Supercom HMI and stored by the supervisory system for future analyses. The system can also be used to monitor a configurable zone to provide a broader range of observation. Alarms are easily programmed to bring attention to any temperatures that fall out of the desired maximum and minimum thresholds. In addition to on-site alarm signals, an email is automatically

generated with a snapshot of the screen and sent to offsite personnel for immediate notification of temperature-related problems. The cameras can also be directed at specific line equipment, such as the die or extruders, to monitor preheating during early morning or overnight startups when supervision may be limited. If equipment temperatures reach unsafe levels, the system will automatically shut down heating to avoid damage to the line. The upgraded software allows the user to run analysis tools, set up alarms and scheduled data collection events, and adjusts the camera settings. Macro Engineering & Technology Inc. (Mississauga, Ont.); www.macroeng.com; 905-507-9000

Easy to use, softwarebased controller Setting the outputs of the new ATC880 pressure/temperature controller from Dynisco Instruments is now quicker and easier than ever, so proper installation is virtually assured. Software-based configuration, using touch buttons on the face of the unit, gives users almost unlimited design options in a very cost-effective device. The user can choose from simple range and alarm settings to complex security codes and update speeds depending on the sensitive nature of the application. The new ATC880 is also remotely configurable via an optional Modbus or PC link. This discrete, self-tuning controller is well suited for managing critical process parameters such as polymer melt pressure or temperature. Dynisco Instruments (Franklin, Mass.); www.dynisco.com; 800-396-4726 Auxiplast Inc. (Sainte-Julie, Que.); 450-922-0282 Precision Mold Supplies Ltd. (Delta, B.C.); 604-943-7702 Process Heaters Inc. (Toronto); 877-747-8250 www.canplastics.com April 2009 Canadian Plastics 25

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technology showcase

FILTRATION SYSTEMS

Energy efficient filtration system The new generation RSFgenius filtration system from Gneuss is characterized by a newly developed insulation of the screen changer which has resulted in a reduction of the energy necessary for heating the unit by approximately 40 per cent compared to conventional continuous screen changers. This further reduces the operating costs for this screen changer. The RSFgenius operates with minimal running costs, energy consumption and waste. In addition, with the new insulation the RSFgenius now fulfills the requirements of DIN EN 563:2000 when processing most materials. All surface temperatures have to be below 140°F (60°C), so there is no risk of burns during short contacts. The RSFgenius can be used for all types of polymers, offers minimal melt residence time, an active filtration area up to 800 square inches (5.100 cm), and does not impact the process during filter changes. Gneuss, Inc. (Matthews, N.C.); www.gneuss.com; 704-841-7251

HOT RUNNERS

Enhanced hot runner system D-M-E Company has launched an inclusive upgrade to the popular Stellar 4000 micromolding product line. The 5000 Series now offers customers enhancements to the standard format for commodity material applications, and a high performance format for engineering and filled material applications. The Standard 5000 Series feature a solid titanium point gate retainer for improved heat isolation, and a shielded mini-coil heater that quickens heat transfer for commodity grade materials. For harder-to-process applications and materials, the High-Performance 5000 Series includes an embedded brass heater for optimized heat transfer with engineering grade materials, and a thru-hole tip sub-assembly that offers superior wear resistance. D-M-E of Canada Ltd. (Mississauga, Ont.); www.dme.net; 800-387-6600

MATERIALS

Forecast brochure highlights future hot colours

The ColorForward 2010 colour forecasting guide from Clariant Masterbatches is intended to help designers and brand managers seeking a competitive edge to make successful colour choices today for products and packaging that will be marketed a year or more in the future. The latest edition of the annual color trend analysis and design tool, ColorForward 2010 is the work of an international group of Clariant colour specialists, including members of every influential colour analysis organization in the world. After determining which cultural and lifestyle trends will have true global relevance, they identify colours that convey the same ideas and emotions. An eight-page brochure captures all the ColorForward 2010 social trend themes and colour directions in dozens of photographs and illustrations, while a boxed set of 20 colour chips provides a more hands-on experience. Clariant Masterbatches Division (Toronto); www.clariantmasterbatches.com; 800-265-3773

plastics data file CNC robots

Wittmann high performance CNC servo robots offer high speed operation and simple graphical programming — all at an affordable price! Choose from a wide variety of models and features to ensure optimum performance for your specific application. Wittmann Canada Inc. 35 Leek Crescent Richmond Hill, ON L4B 4C2 Tel: 1-888-466-8266 Fax: 905-887-1162 www.wittmann-canada.com

advertising index Advertiser Acetronic Canadian Plastics Digital Editions Canadian Plastics Resin Outlook Conference Canadian Plastics Sector Council NPE2009 SPE Ontario Minitec Wittmann Canada Inc.

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Telephone

E-mail

Website

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800-803-8871

sales@acetronic.com

416-510-5116 613-231-4470

jnancekivell@canplastics.com info@cpsc-ccsp.ca

www.acetronic.com digital.canplastics.com www.canplastics.com www.cpsc-ccsp.ca www.npe.org

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classified ads MATERIALS • 60 MT PRIME VIR NAT DUPONT LASER +C (US) CZ-302 (CHINA) PET BOTTLE RESIN -Orig Super Sacs • TL HDPE WATER BOTTLE CAPS size: 26.67 & 28.0 MM- no inserts white, black, blue, green, nat. Never used. Orig unopened cartons. • 2000 MODEL LT-7500 STERLING FULL TANDEM STR. TRUCK CAT 3126B ENG 275 HP 28’ extended box easily handle 16 plastic gylds air DOWNSIZING brakes/air cond. • 1989 MODEL FGC-15 MITSUBISHI PROPANE FORK LIFTAuto3,000lb cpy. extended forks, 3 stage mast/power brakes/side shifter • MODEL G1424-M 50 HP NELMOR GRANULATOR complete w/6 hp blower & cyclone, steel stand & railings. Xtra blades. • MODEL PH 1418-C 25 HP ROTOGRAN GRANULATOR complete ON ALL OR PART OF; w/ 6 hp blower and cyclone, steel stand & railings. Xtra blades. • MODEL BU801 CAST IRON BANDSAW 6.5 hp extra 19’ blades • GRADUATED ELECTRONIC SCALE- 0-10 mplus

DUE TO A RECENT

WE ARE ACCEPTING BIDS

Great opportunity to get into the challenging and exciting world of plastics. RAM RESINS INC. Tel: 705-719-2587

38 Irene Drive, Barrie, ON L4N 0Y8

Fax: 705-719-2590 E-mail: ramresins@sympatico.ca

MACHINERY & EQUIPMENT

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20 ton to 1000 ton machines. Concept to finished part approach. ISO9001/2000 Certified. Short runs accepted. Contact: craig@penplast.com 905-871-4766 ext #222 www.penplast.com 1" booth ad 08.pdf

Domino Plastics

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SCRAP BUYERS 25 YEAR VETERAN Email: domino@domplas.com • Fx 631-642-1771 631-642-1995 Website: www.domplas.com domino@domplas.com Phone: (631) 751-1995 Fax: (631) 751-9396 www.domplas.com

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SALES AGENTS WANTED

1:41:23 PM

SERVICES

Asico International We buy and sell all kinds of plastic scrap, regrind & pellets.

Ph: 416-291-0077 sales@asicotrade.com

INTEGRITY TESTING LABORATORY (ITL) INC.

20 years in service of major plastics, packaging & recycling industries iso 9001:2000 and cgp registered

Comprehensive analysis, testing, R&D of plastics and polymers. Q.A./Q.C. - troubleshooting, customer returns; failure analysis; manufacturing process control, reverse engineering, case studies. RoHS, environmental, physical, chemical, mechanical testing. All major test procedures: glass transition, degree of curing, OIT, viscosity, surface/roughness analysis, microhardness, Vicat, etc.. DSC/TGA/TMA, SEM/ EDS, ICP, FTIR, XRF, UV-VIS,QUV, X-ray imaging analysis, Auger, optical interferometry (WYCO system), most ASTM standard tests, etc.. 80 Esna Park Drive, #7-9, Markham, Ontario, L3R 2R7, Canada tel: (905) 415-2207; fax: (905) 415-3633; website: www.itlinc.com; e-mail: info@itlinc.com.

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09 RESIN CONF AD

3/19/09

11:21 AM

Page 1

HOW MUCH WILL YOU BE PAYING FOR RESINS IN 2010? Find out at the 14th Annual Canadian Plastics Resin Outlook Conference Wednesday, October 7, 2009 NEW VENUE: Toronto International Centre 6900 Airport Rd. Mississauga, ON

Hear forecasts from experts on supply, demand and pricing for the major commodity and engineering resins. Investment per person: Early Bird Registration – register and pay in full by Aug. 28 $395 plus g.s.t. Regular Registration – after Aug. 29 $495 plus g.s.t. Group Registration – 50% discount for second and subsequent attendees from the same company Organized by Canadian Plastics magazine. Endorsed by the Canadian Plastics Industry Association. Conference details are on the Canadian Plastics website at www.canplastics.com/Conference/conference.asp

Here’s what delegates at last year’s conference said they liked about last year’s conference: • Provided us with lots of info in a short period of time • Broad range of topics covered the majority of resins purchased by my company, with potential for new materials for new products. • Always a great conference, with key attendees present. • Good cross section of speakers. • Insights into various resins and the variables that control the pricing of these commodities • Gained knowledge and confidence • Networking opportunities.

For more information, contact: Judith Nancekivell, Tel: 416-510-5116, Email: jnancekivell@canplastics.com SPONSORS TO DATE:

“Earning your trust one stripe at a Cantec time.” Polymers INC.

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design ideas • sporty applications

Bringing a little bit of “green” to skiing

Putting target practice indoors Seasonal golf tournaments will soon be upon us, and golfers looking to sharpen their skills need to look no further than the Putt 2 from 2Targets. The practice device is receiving plenty of attention from collegiate teams that need indoor putting practice. The putting target owes its weighty feel, resiliency, bright white colour, and smooth, printable surface to KRATON G7720-1 thermoplastic elastomer (TPE). “The two keys to the Putt 2’s success are design and material,” said 2Targets founder and CEO Donnie Price. “The bell-shaped target has to be molded of a material offering heft for stability, resiliency to repel the ball, a smooth surface finish for printing, and resistance to degradation from UV light.” KRATON G7720-1 grade is an easyprocessing, general-purpose material with 60 Shore A hardness. According to Prince, the Putt 2 has been a hole in one for the company, with a positive response from coaches and collegiate golfers. “It’s a small, portable target you can put in a golf bag and use in the office, the gym, or at home to improve your putting skills and it’s also an attractive, useful promotional item any golfer would enjoy,” said Prince. GLS Corp. (McHenry, Ill.); www. glscorp.com; 1-800-457-8777

What do ski hills and cornfields have in common? If your answer was “ski boot,” you’re not wrong. The collar of the Salomon ‘Ghost’ freerider alpine ski-boot is one of the first applications with Dupont’s Hytrel RS (renewably-sourced) thermoplastic elastomer. The TPE provides all the performance characteristics necessary for a winter sports application, but the grade used to mold the collar contains 27 wt per cent renewably-sourced polyol derived from corn or other natural resources. Ski-boot collars help provide a secure fit of the boot to the skier and protect the lower require. Additionally, they need to be flexible enough to ensure a good and reliable transfer of movement from the leg to the ski. The Hytrel RS material provides excellent flex fatigue and flexibility at temperatures as low as –4°F/ 20°C and high impact resistance. The collar is injection molded as a single piece and coloured white using masterbatch. The Salomon ‘Ghost’ motif is added to the collar using pad printing. E.I. du Pont Canada Company (Mississauga, Ont.); www.dupont.com; 1-800-387-2122

Innovative scuba flip fins The Amphibian flip fins by Omega Aquatics, designed by Designcraft, allow scuba divers to switch from walking with the fin blade up to swimming with the blade extended without using their hands. The fins pair the disparate materials of a stiff, shiny, yellow polypropylene (PP) and a soft, flexible, matte-black thermoplastic elastomer (TPE). The unique, convertible design relies on overmolding DYNAFLEX thermoplastic elastomers from GLS onto a polypropylene base, so that divers enjoy a soft, comfortable feel and enhanced buoyancy and agility underwater. “This was a complex design due to the contrasting requirements of walking with the fin blade up and swimming with the blade extended,” said designer and project manager Casey Stahl. “When the blade is resting against the chin, it’s important to have a flexible, soft material for comfort. The footpiece also requires a comfortable fit, but must be durable for walking on the ground.” Stahl noted that the application required a combination of stiffness and flexibility for propulsion and turning, and light weight materials for near neutral buoyancy. GLS Corp. (McHenry, Ill.); www.glscorp.com; 1-800-457-8777

www.canplastics.com April 2009 Canadian Plastics 29

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view from the floor

Spreading Out By Jim Anderton, technical editor

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ot everything we do in this industry involves turning pellets of resin into polymer parts. In many cases, the processor has to do something post-mold that is often decorative. While the ability to mold or extrude parts with the colour “built in” has been an important advantage of thermoplastics technology for about 70 years, I think that coatings (“paint”) don’t get the credit they’re due in our industry. I was around when the future in automotive bodies was predicted to be plastic, with exotic technologies like “sheet molding compound” and vehicles like the Pontiac Fiero — few survive today, technologically speaking. Why? The main reason, at least as OEM types tell me, is the inability to obtain a Class A finish on resin body panels in a cost effective way. Of course, the other reason is that the steel industry counterattacked with low-cost, easy to paint solutions like high strength low alloy sheet, making car bodies cheaper and lighter. Plastics will be back in automotive bodies, but in the meantime, a lot of research into coating plastics has led to “paint” becoming a viable option for many parts, especially consumer durables and novelties. Anyone who’s ever paid to have a resin bumper repainted, however, knows it’s surprisingly expensive — and when pressed, the body shop service writer inevitably explains that it’s because of the high level of preparation required to get the expensive paint to stick.

Why? The answer, like so much of plastics technology, isn’t simple, but here’s an “executive summary” of what’s in play when you’re looking at top coating a resin part. If we ignore the coating method at this point, the paint problem distills down to two related problems: wetting and adhesion. Put simply, how do you get the coating to flow over the surface evenly and completely, and then how do you get it to stick? The first problem, wetting, is intuitively simple, but there’s a little physics involved. Materials, all materials, from a PE pipe to a cheese sandwich, have an intrinsic energy associated with them. The energy comes from the individual energies of the atoms and molecules that are bonded together to form the material. At the surface of a material, the attractive forces between the atoms and molecules are greater than the attraction between the molecules and the surrounding air, which is why it’s a solid and not a gas or vapour. That’s fine for the solids vs. air comparison, but what about liquids? Water has intermolecular bonds strong enough to keep it from instantly flashing into vapour at normal temperatures and pressures. In space or in free fall (rain) it forms spherical droplets. This is because the lowest energy state for a drop of water is the one with the smallest exposed surface area for a given volume, and that’s always a sphere. Throw that droplet against a waxed fender and it also tries to form a sphere, or bead as the droplet moves to its lowest energy configuration. We commonly call the

phenomenon “surface tension,” and the point is that getting the droplet to turn into a thin covering film means making the energy available on the part surface large enough to overcome the surface tension, so the thinly coated surface is the lowest energy configuration. Car wax makers want to go one way, plastics processors the other. Unfortunately for us, neat commodity resins have few “polar groups” (molecules with energy available as electrostatic charge “built in”) compared to highly polar liquids like water, so the tendency is to bead and resist wetting. If the coating you or your customer needs has relatively high surface tension, you need to provide it with a part surface with enough surface energy to encourage that coating to wet spontaneously. Of course Murphy’s Law rears its head: commodity resins like polyethylene and polypropylene are two of the lowest surface energy materials around, so some surface modification is a certainty to get most coatings to wet the part. Getting that surface energy up usually involves the same technique that water uses, namely adding an atom to the molecule that makes it polar. Oxygen is good choice, since it’s really cheap and doesn’t have to be shipped, mainly because it’s in the air we breathe. Hoe do you get that oxygen to bond to the resin’s weakly polar hydrocarbon molecules? Of course, energy. Plasma, UV radiation, corona discharge, and flame treatment are good, fast techniques. It’s possible to use reactive chemicals like acids where it’s difficult to get at the surface with flame or radiation. No matter how you do it though, wetting is only half the battle. Getting the coating to stick is can be a lot more difficult. I’ll look at adhesion next issue. CPL

30 Canadian Plastics April 2009 www.canplastics.com

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