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Xaloy Tech Tip - June 2010
06/24/2010
| | XALOY TECH TIP - June 2010 |
| General Extruder Inspection |
| From time to time it is necessary to perform a complete audit on the condition of an extruder to make sure that it is operating in top condition for maximum effectiveness and efficiency. Here, we offer some general information that should be considered to achieve a good extruder audit. |
General Inspection Information 1. Evaluate the condition of the gear box output shaft bearings with lift check: a) Check and record the front quill I.D. for wear and proper fit with the shank of the screw. b) Inspect and replace any shaft seals that may show leakage. c) Drain gear box lubricant; wash to remove any residue and metal shavings in the bottom of the gear box. d) Change lubricant oil filter. e) Check out the gear box cooling system, primarily the heat exchanger, if the extruder is fitted with one.
2. Check the front barrel support for proper thermal expansion; lubricate slide points with high temperature silicone grease.
3. Evaluate the effects of overhung loads which are caused by attaching screen changers, melt pumps and dies to the discharge end of the barrel.
4. Measure and record the feed throat bore dimensions and inspect for excessive wear or water leakage from the cooling cavity of the cast housing.
5. Measure the barrel and screw for wear (envelope or complete profile).
6. Check the extruder for base-to-floor stability.
7. Evaluate heating and cooling system, if required.
a) Flow test cooling tubes.
b) Using a clamp-type ammeter or a multi-meter test, check the resistance of the heaters. |
Components For Extrusion Download your free copy |
| We're always here to help!Submit an inquiry or call 1-888-XALOY-80 |
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| Xaloy serves the plastics industry by offering the highest quality process improvement products backed by superior customer care.  
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Engel all-electric injection press for closures at K 2010
06/05/2010
Engel to launch all-electric injection press for closures at K 2010 By David Vink | EUROPEAN PLASTICS NEWS Posted May 27, 2010 SCHWERTBERG, AUSTRIA (May 27, 10:55 a.m. ET) -- Injection machinery maker Engel Austria GmbH will launch a new all-electric molding machine designed specifically for production of plastics caps and closures at the K show in Düsseldorf, Germany. Speaking at a briefing at the company’s headquarters in Schwertberg, Vice President for R&D Georg Steinbichler said the e-Cap machine is the first all-electric type to be designed specifically for cap production. “No other machine in the market can produce caps and closures as economically as the e-Cap,” he said. A 380-metric-ton version of the e-Cap design has been running for some time in Engel’s development laboratory at Schwertberg. However, the company will show a larger 420-metric-ton version at K 2010, which it says is more typical of the type of machine required to handle the high production rates and the 96-cavity tooling typical in this sector. Key to the e-Cap’s high production efficiency is a newly designed injection unit with a special screw developed for high throughput plasticizing of packaging grade polymers, as well as an uprated ejector system, Steinbichler said. At the K show, the 420-ton machine will be fitted with a 96-cavity mold producing 26mm diameter “x-light” closures on a 2.6-second cycle time. According to Engel, the e-Cap has potential to bring faster cycle times and higher outputs to the plastics caps and closures market, which it estimates amounts to some 750 billion molded components a year worldwide. A major attraction of the machine will be low energy consumption of its electric drive technology. Steinbichler said energy typically accounts for 7.1 percent of overall cost of plastics caps and closure production, making it the second largest production cost after material (which accounts for a typical 67.5 percent of the total). Steinbichler said other significant costs include molds (6.4 percent), machinery (4.8 percent) and personnel and labor (3.5 percent). Caps and closures represent a very interesting and fast growing niche in the overall plastics packaging marketplace. According to Basingstoke, England-based beverage market and packaging analyst Canadean Ltd., global demand for caps and closures for beverage applications alone grew by an average rate of close to 4 percent a year since 2002; and even last year it posted an increase of 1.8 percent. Canadian estimates plastics account for more than 58 percent of global closure demand (excluding can ends).
News on Breeze IIc and MACO Compact Controls for All Plastic Processing
05/26/2010
| | | | | Replace those old
Hunkar & Moog Parison ControlsNo More Worries...No More Pegs!!! | The Breeze IIc stand-alone parison-only Blow Molding Machine Control replaces existing slide switch and pin only parison programmers on installed blow molding machinery. The control is packaged in an ce.net operator station configuration and a small card rack for easy installation. Breeze IIc utilizes the same internal cards, as the well-known MACO Compact Blow Molding total machine control system to provide users with highly precise parison control. And it is custom factory configured to the user's requirements based on the type of machine specified. It is shipped as a truly "out of the box" system. Anyone can connect it. Just a few, easy-to-reach external connections are all it takes.   (Switching languages is as easy as changing a setpoint) Breeze IIc is simple to set-up and operate. It minimizes the number of setpoints for your set up & operator personnel to enter. Rough profiles automatically become parts that meet spec with the absolute minimum material use part after part, day after day. But it's more than just a "breeze" to operate. It's a highly precise control that consistently and accurately achieves minimum wall thicknesses by micro-interpolating between set points. The result: consistently good parts with minimal material usage and scrap. And all at a price you can afford, $7,500. Why not order one now and see immediate results for a fast R.O.I. ! For more information on Breeze IIc, click this link... |
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| | | Let's Talk About Improving Production Capabilities on
Injection Molding, Blow Molding, and Extrusion Systems | Eurotherm has Control Retrofit Kits for nearly every make/model of injection molding, blow molding or extrusion machine ever built. For years, we have offered controls to help improve your processing needs in areas of temperature and pressure, parison only control and all the way up to full machine/line control systems. What type of control do you really need? Take a look at this list of the MACO Compact Controls that we're able to retrofit and if your equipment needs this type of mprovement, we'd love to talk today. - Injection Molding
- Blow Molding
- Extrusion
For more information on our complete line of plastic machine controls, click this link... |
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Adams/ENGEL Open House A Success!
05/21/2010
Adams/Engel Open House
May 18th, 2010 Adams Engineers hosted the ADAMS/ ENGEL Open House in Tyler, Texas on May 18th. 8 different companies attended to learn more about ENGEL and the auxiliary equipment represented by ADAMS Engineers and Equipment, Inc.    The ENGEL e-max was demonstrated utilizing a mold provided by STENCOR.    Energy Efficiency and Medical Molding presentations were given based on customer requests.   Texas Bar-B-Q was catered for lunch under a tent in a relaxed atmophere.   Joachim Kragl, ENGEL's Director Advanced Molding Systems & Processing, answered specific molding questions for the processors. Harald Wegerer, ENGEL's Director Customer Service, reinforced the ENGEL commitment to customer service in the region.
ADAMS / ENGEL Open House Reminder
04/26/2010
 
ADAMS/ENGEL Open House
ENGEL e-max Demonstration
Electric Injection Molding Technology
Joachim Kragl
ENGEL's Director Advanced Molding Systems & Processing
On Site to address your specific applications and questions The responses have been great!!
You don't want to miss this!
There's still time to RSVP-call or email. May 18th, 2010
10:00 AM to 3:00 PM
ADAMS Engineers & Equipment
Show Room
Tyler, Texas
903-561-8835
Lunch Served 11:30 to1:30
Flexible Format
RSVP
http://www.adamsengineers.com/request.php
Reference Open House in Info Block
Provide Contact Information
**Demonstration of ENGEL e-max on the hour
**Presentation of Advances in ENGEL all-Electric Technology & Industry Specific System Solutions on the half hour
Xaloy Tech Tip
04/21/2010
| | XALOY TECH TIP - April 2010 |
| Screw Speed vs. Recovery Time Look what happens when the optimum screw speed is used... |
| Many times we visit customers' facilities to help them with processing issues. In reviewing their set-up parameters, we often find that the screw speed is not set up to operate most effectively.
There have been times, for example, when a customer was processing Xenoy®, and complaining that the screw was degrading the resin. The screw was turning at a fairly moderate speed, recovering in 5 seconds, then sitting in the back position before injecting for an additional 8 seconds. Then, during the injection stroke, degassing and smoke were evident at the nozzle.
After witnessing several cycles of operation in the above manner, we suggested reducing the screw rotation to the point where the screw got back just in time so that a count of "3" could be obtained. Then the screw was stroked forward to fill the mold. The screw speed was practically reduced by half, and within about three shots, the degraded material was flushed out of the barrel and the smoking stopped.
This simple change in the processing parameter reduced the shear on the resin and improved the process. Not only was the degradation eliminated, but most of all, the overall melt temperature was reduced. This, in turn, reduced the cooling time and therefore reduced the overall cycle time.
 Click here to make an inquiry |
| We're ready to meet your needs! Contact us at 1-888-XALOY-80 to discuss our recommended screw design for your specific application. |
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| | Xaloy serves the plastics industry by offering the highest quality process improvement products backed by superior customer service. XENOY® is a registered trademark of SABIC Innovative Plastics |
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ADAMS / ENGEL Open House
04/21/2010
ADAMS / ENGEL Open House
ENGEL e-max Demonstration
Electric Injection Molding Technology
Medical/Packaging/Technical
Turnkey System Solutions
Presentations May 18th, 2010
10:00 AM to 3:00 PM
ADAMS Engineers & Equipment
Show Room
Tyler, Texas Lunch Served 11:30 to 1:30
Flexible Format **Demonstration of ENGEL e-max on the hour **Presentation of Advances in ENGEL all-Electric Technology & Industry Specific System Solutions on the half hour
Dynamic Conveyor - New: Rapid Part Cooling
04/21/2010
| | April 20, 2010 | | 
| | News from Dynamic Conveyor Corporation |
| NEW: Rapid Part Cooling
If air cooling (either natural or by moving ambient air with fans) proves to be too slow and you want to speed the production of your products, Dynamic Conveyor has the solution.
A chilled air cooling unit can be added to your new or existing DynaCon conveyor system for rapid part cooling. The portable spot air cooling unit provides instant cool air in the hottest environments such as injection molding, production lines and manufacturing processes. - Instant cool air up to 25 degrees below room temperature
- Up to 60,000 BTU/hour
- Costs as little as $0.10 per hour to operate
- Requires little installation and is simple to use
- Offers up to 94.7 percent reduction in product cool down time
Click to learn more about our new products >>>
Request a quote for a rapid part cooling system >>>
Improved Cross Bar We redesigned our cross bar! It is now simpler to install, remove, use and makes the conveyor more rigid. The new cross bar can be installed BEFORE or AFTER the conveyor is attached to the leg supports. Feel free to give us your feedback on this new design.
Click to learn more >>> Email your thoughts on the new cross bar >>>
Conveyor Planning DynaCon modules for designing your next DynaCon conveyor are now available on our website. Use our AutoCAD ready planning kit along with your quotation request before making your next conveyor purchase. Click to get started today >>>
Follow Dynamic Conveyor
| HighlightsNEW PRODUCT:
Rapid Part CoolingMaximize your production time by cooling your parts faster Improved Cross BarWe are making our conveyors more "user-friendly" Conveyor Layout PlanningDesigning your own conveyors is now possible Become a Follower For the latest news, follow us on LinkedIn and Facebook | |
 
Xaloy & Compulast Seminar - Polymer Extrusion: Melt Delivery Systems
03/24/2010
XALOY & Compuplast Seminar
Polymer Extrusion: Melt Delivery Systems
April 12-14, 2010 Limited Seating Available -- Register Now! |
| | | TRAINING CENTER 1399 Countyline Road
New Castle, PA 16101 1-800-XALOY-80 |
| Over 90% of past attendees have reported that they would recommend Compuplast seminars to their associates. "This course was so useful for my job. These are the types of courses we need more of. This was money well spent." |
| | | COURSE OVERVIEW This popular, international short course has been developed to help train extrusion process personnel and equipment designers on the intricacies of polymer flow within extrusion equipment. The emphasis is on understanding polymer flow behavior (rheology) and how it relates to the extrusion process. The concepts are presented in a very practical manner and re-enforced through many "case study" style examples. The short course also includes a lab portion where the concepts presented will be re-enforced on physical equipment and with state-of-the-art simulation. Upon completing this seminar, the attendees will have a good understanding of practical polymer rheology and how to apply CAE methods towards the analysis, design or troubleshooting of any extrusion process. |
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| WHO SHOULD ATTEND This course is intended for anyone who is currently (or training to become) responsible for the design or performance of an extrusion process. Extrusion process engineers, technical service personnel, screw and die designers, research and development personnel and particularly, those responsible for troubleshooting extrusion processes will obtain the most benefit from the information presented. |
| REGISTER TODAY! Click here to register online Participants must register by Monday, March 29. Course participation is US$900 per person. There is a 25% discount for 4 or more people from the same company. The price includes all course materials, lunch, refreshment breaks and a welcome reception on the evening before the seminar. The registration fee also includes a special 1-year trial license of the COMPUPLAST Extrusion Calculator so that attendees can apply their knowledge to their work immediately upon completing this course. This is a $1000 value. |
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Xaloy: Meeting Your Screw and Barrel Needs
03/16/2010
| | | | Xaloy's extensive database gives us the ability to data mine historical product specifications. | We have what it takes to get that replacement screw or barrel for your machine... old or new...injection or extrusion!  Xaloy has been designing and manufacturing barrels for decades. Ask about our recommendation for your specific application. |
| | | From general purpose to high-performance mixing screws, XALOY has the data that will deliver exactly what your processing requires. | | | Looking for a replacement screw or barrel? Just give us a call -- we'll get you exactly what you need! |
1-888-XALOY-80 |
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Engel Medical Conference
02/24/2010
 
Med.con The ENGEL medical conference Welcome to med.con 2010, the ENGEL medical conference. ENGEL will present today's latest trends in medical technology on March 17th & 18th, 2010 in Schwertberg Austria. The Engel Medical Conference Invitation
Eurotherm's Maco Compact HT Series
02/10/2010
Case Study Metro Custom Plastics 10/9/09 Metro Custom Plastics (Arlington, TX) MACO Compact Controller injects greater productivity into custom mold shop. Started in 1974 as a tool shop, Metro Custom Plastics has found a niche developing a product line of plastic thread protectors used in oil and gas fields, an industry that today accounts for about 20 percent of the firm’s sales. Since current President Mike Havel joined the company in 1982, Metro Custom has diversified into multiple other markets and currently processes many different types of plastic including ABS, ACETYL, PE, PP, Styrene, nylon, and polyester. The company has invested in maintaining a modern and well-equipped facility to provide both an edge in productivity as well as product quality. They operate custom plastic injection molding machines ranging in size from 165 ton (6 oz) to 450 ton (60 oz). Key advantages for Metro Custom Plastics include a documented ability to meet specifications within tight tolerances, fast turnaround, and a strong commitment to on-time delivery. Among the challenges they face are a need to control costs by reducing scrap and maintaining a 500+ mold inventory that requires frequent and quick changeovers. As the original controller on some of their Van Dorn HT machines became unreliable, Havel, Maintenance Manager Ellis Thomas, and Plant Manager Fred Guardiola began looking at options for a controller that would provide a demonstrable improvement over the OEM equipment. "We run about 50 percent reprocessed plastic in many of our parts," said Havel. "We needed a controller with the ability to help us in processing this material better than ever. Because of the inherent problems associated with the inconsistency of such material, processing control features were very important for us in making a decision." The goals of the retrofit were to promote efficiency and ultimately extend the lifecycle of the molds and machinery. Reliability and ease of operation were also considerations as was a strong ROI. Eurotherm’s MACO Compact HT Series controller, designed exclusively for Van Dorn HT injection molding machines, provided a reliable solution to help Metro Custom Plastics engineers reach those goals. "User friendliness, reliability, overall component design, and a package that would meet the needs of production and operators were what we were looking for," said Thomas. From a mess of wires to a streamlined process Although the team said that the presentation of benefits was compelling and the Eurotherm technical team was well prepared for the installation, Guardiola admitted some reservations as the set up commenced. Worrying is part of a plant manager’s job description. "At first, when they began to tear into the cabinet and wires were hanging out all over the place I was a bit skeptical; however, in the end, I was amazed that it went so smoothly," said Guardiola. "The installation crew was very professional and completed the installation on time. But in the end, it wasn’t how good it looked but how well it worked. And it worked great." Thomas describes the installation as quick, professional, and efficient which was important because of Metro Custom Plastic’s production schedule. Many of Metro’s customers use JIT practices and delays could have been costly. "Startup went very well, and with just a few adjustments, we were ready to go," said Thomas. "Downtime had to be carefully planned as quick turnaround response to customer needs has always been a top priority for Metro Custom Plastics. We couldn’t afford to have the timing of this project overrun." ROI: The value Eurotherm brought to Metro Custom Plastics. Eurotherm’s MACO compact controller has delivered multifaceted benefits for the Arlington, Texas based manufacturer. "Improvement in low mold close/mold protection was dramatic over the original control resulting in a reduction in mold damage problems and the cost associated in fixing them," Guardiola said. Production Benefits - - Actual downtime has been reduced by double digit percentages
- - Improved production of up to 1 hour per day because of less downtime
- - Total machine productivity improvement is approximately five percent
- - On one part alone, cycle time went from 42 to 40 seconds, a 4-5 percent improvement
According to Thomas, "The ability to show problems through the control diagnostics is extremely helpful. It allows us to address problems quickly and get back in production." Additionally, the company has been able to reduce scrap by approximately 3.5 percent and significantly reduced the need for major maintenance due to better control reliability. Quality Benefits - - Consistent pressure, temperature, and positions over the production cycle provides uniformity in part quality, supporting Metro Custom Plastic customer’s expectations
- - Impact II process control on the MACO was a major improvement over the original OEM offering
Safety improvements - - Temp Control (high/low) prevents damage to the machine and components
- - Mold protection
"Improving performance and reducing downtime extends the useful life of a good existing machine and makes the ROI entire package well worth the investment," said Havel. He also added, "In these tough economic times, carefully choosing what and when to invest allows us to not only maintain our customer base but also to increase it with new business as it develops. Right now there an estimated 200,000 molds looking for a new home. We have the machines, people and process ready to take in a lot of new business. " Havel adds, "Since we are debt free and plan to remain debt free, we must continue to invest wisely to be a survivor. Customers will not sacrifice quality just because the economy is down. When potential customers visit our facility, presentation of the machines with these new upgrades shows our commitment to continuous improvement."
About Eurotherm Eurotherm is a leading global supplier of control, measurement and data recording solutions and services to industrial and process customers. The company’s international reputation as a provider of innovative solutions across a broad spectrum of vertical markets is supported by engineering services designed to realize greater benefits to customers’ plant-wide assets. Eurotherm's product range includes distributed process automation systems and machine control incorporating single and multi-loop control, operator displays, data management and graphic recorders, power control and signal conditioning. Eurotherm, Inc. is an ISO9000 approved company, and operates TickIT protocols for software management. Eurotherm is a key business within Invensys, the global automation, controls and process solutions group. Invensys products, service expertise and ongoing support enable intelligent systems to monitor and control processes in many different environments. Leading companies in a wide range of industries rely on Invensys to help them perform with greater efficiency, safety and cost-effectiveness. Headquartered in London and listed on the London Stock Exchange, the Invensys Group is made up of four businesses: Process Systems, Eurotherm, Rail Systems and Controls. Invensys, Eurotherm, MACO, IMPACT, OPtima, Continental, Chessell, and Action Instruments are trademarks of Invensys plc, its subsidiaries or affiliates. Barber-Colman is a trademark of TAC and used under license to Eurotherm. About Metro Custom Plastics Metro Custom Plastics is an ISO 9001/2000 molding facility strategically located in the North Texas DFW area serving customers nationwide. If you need custom plastic injection molding, warehousing, engineering, and distribution services, contact Mike Havel at: Metro Custom Plastics Inc 615 109th Street Arlington, Texas 76011 817-640.5646 sales@metrocustomplastics.com www.metrocustomplastics.com Turning Your Ideas Into Plastic!
ENGEL Representation
01/19/2010
ENGEL Names Adams Engineers
To Represent Southwestern U.S. Region YORK, Pa. – Jan. 11, 2010 – Adams Engineers & Equipment, Inc., distributor of a full range of plastic processing equipment, has become the newest representative of ENGEL North America products. The company will work with ENGEL customers in the Southwestern U.S. and northern Mexico. ENGEL, a world leader in the design and manufacture of injection molding machines and part-handling automation systems, has added Adams Engineers & Equipment, Inc., Tyler, Texas, to its representative group team. Adams Engineers will handle sales to ENGEL customers in Texas, Oklahoma, Arkansas and Louisiana in the U.S., and in the northern Mexican state of Tamaulipas.Established in 1991, Adams Engineers is a technology-driven organization that provides a range of engineering services and plastic processing equipment used in injection molding, extrusion, blow molding, thermoforming and decorating of plastic products. The company assists manufacturers with economic justification, process improvement, plant layout, project management, equipment installation supervision and asset management. “Our company is on the same page philosophically as ENGEL,” explained Cliff Adams, president of Adams Engineers. “We are dedicated to providing our customers the additional services they need to incorporate equipment and technology into their operations. ENGEL has the machine technology, as well as application and market specific system solutions that are so necessary today.” -more-“We are excited about the appointment of Adams Engineers because of their technical focus and competencies,” said Steve Braig, president and CEO of ENGEL North America. “Adams Engineers will aid our customers in choosing the most effective injection molding equipment solution from ENGEL’s technologically-advanced product portfolio.” ENGEL North America From facilities in the United States and Mexico, ENGEL North America provides its customers a single source for design and manufacture of injection molding machines for thermoplastics and elastomers, a full range of plastics processing technology modules and a full scope of automation solutions. With eight production plants in Europe, North America and Asia (China, Korea), subsidiaries in 17 countries and representatives in over 70 countries, ENGEL provides its customers the global support they need to compete and succeed with new technologies and leading-edge production systems. For more information, visit www.engelglobal.com/na. Contacts:Kleta Childs, Sales Support Manager, ENGEL North America3740 Board Rd., York, Pa., 17402, Tel.: 717.764.6818 ext. 4250
fax: 717.764.8093 Email: Kleta.childs@engelglobal.com Gerd Liebig, Group Marketing Director, ENGEL AUSTRIA GmbHLudwig-Engel-Strasse 1, A-4311 Schwertberg/Austria, Tel.: 011 43 50 6200,
Fax: 011 43 50 620 3009 Email: gerd.liebig@engel.at Julie Pompa, APR, The Lauerer Markin Group
1700 Woodlands Dr., Maumee, Ohio 43537 USA Tel.: 1.419.887.6827, Fax: 1.419.893.1050
Email: juliep@LMGnet.com
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