Archive for March, 2009

EDI: New flat die system to multiply key functional layers in cast film and sheet

Saturday, March 28th, 2009

An innovation in flat extrusion die systems makes it possible to multiply key functional layers in cast film and sheet, substantially improving properties without increasing either overall thickness or raw material content, it was announced today by Extrusion Dies Industries, LLC (EDI), which will introduce the technology at NPE2009 (Booth 85007).

The new “microlayer” technology enables extrusion processors and converters to achieve increases in impact strength, elongation, oxygen and moisture barrier, and other properties, according to EDI. Potential applications range widely, from industrial wraps to rigid and flexible barrier packaging.

The key to the improvements is special tooling developed by EDI to implement a coextrusion process designed and patented by The Dow Chemical Company. Called a “layer multiplier,” the flat die system transforms a typical sandwich structure from a standard coextrusion feedblock into a structure in which one or more of the layers has been subdivided into multiple microlayers. The overall thickness of the resulting coextrusion is no greater than if the original sandwich structure had been transferred directly from the feedblock to the extrusion die, without the intervention of the layer multiplier.

“Drawing on work that EDI carried out under a U.S. Department of Defense contract for developing long-shelf-life containers for military food supplies, we have further adapted our layer multiplier system to selectively multiply only the functionally critical layer materials in a coextrusion sandwich, such as the barrier layers,” said Gary D. Oliver, vice president of technology. “Without adding even a tiny increment in the amount of barrier resin used for a given volume of product, this proliferation of layers creates synergistic effects that reduce oxygen ingress from 3 to 5 times in comparison with a conventional barrier coextrusion.”

As an example, Oliver cited the case of a standard rigid barrier packaging container. While a conventional structure for this application has a single barrier layer, a structure produced with the EDI’s layer-multiplier system has four micro barrier layers (see cross sectional photos). The amount of barrier material is the same in both structures, but the oxygen transmission rate for the A and B sides of the one-barrier layer structure is substantially greater than for those of the four-barrier layer structure.

In stretch film, similarly, EDI has demonstrated improvements in tensile properties by alternating multiple layers of “performance” materials with commodity resins. In one series of tests, EDI compared 1) a standard five-layer polyethylene structure having outer “cling” layers and a core consisting of three linear low-density polyethylene (LLDPE) layers with hexene, butene, and hexene co-monomer side chains, respectively; 2) a 14-layer structure, with the core multiplied four times; and a 50-layer structure with the core multiplied 16 times. Layer multiplication substantially increased strength properties and the key “stretch” property of elongation.

Harvel Introduces Industry’s First UV Resistant Clear PVC Piping

Tuesday, March 24th, 2009

from Omnexus

Harvel® Plastics, Inc., announces the launch of EnviroKingUV™, a clear PVC piping that is suitable for exposure to sunlight. Unique UV blocking technology reduces harmful ultraviolet light wavelengths from penetrating the plastic while allowing beneficial wavelengths through….

NewAge® Industries Launches an E-Newsletter Focusing on Plastic & Rubber Tubing & Hose

Tuesday, March 24th, 2009

from NewAge® Industries

extrusions is the new e-newsletter from plastic tubing manufacturer NewAge Industries, Inc. Introduced in mid-January, extrusions is a communication tool developed to inform, educate, and advise users of plastic and rubber tubing and hose, fittings and clamps, hose assemblies, and custom extrusions.

Lauren Manufacturing Introduces New Low Density EPDM Sponge

Tuesday, March 24th, 2009

from (press release), NY

New Philadelphia, OH, March 22, 2009 -( Lauren Manufacturing has developed a new low density EPDM sponge product for continuously extruded profiles. The compound is capable of maintaining a 6-8 pound per cubic foot density on closed cell

Optical reader converts analog gauges and transducers to wireless

Friday, March 20th, 2009

from Control Engineering, IL

More solidly on the sustainable engineering front—due to its energy saving potential—is Cypress’ Wireless Steam Trap Monitor. Again, like the gauge and transducer readers, no breaking of seals or running new wires is required.

Dynisco Instruments OPT.TROL modular extrusion control system for plastics extruders

Thursday, March 19th, 2009
Dynisco Instruments have released the OPT.TROL polymer control system for complete control of extrusion lines. This system is designed for small to medium sized extrusion lines and can either be equipped

LyondellBasell first achieves PP 125 classification for polypropylene used in pipe

Tuesday, March 17th, 2009

from LyondellBasell

ROTTERDAM, Netherlands, March 16, 2009 LyondellBasell Industries has become the first polyolefins supplier to receive the ISO PP 125 classification for polypropylene resins used in water pipe applications. According to ISO 12162, pipe produced using the resins have successfully resisted internal…

ENER-Plast: EU-funded project promoting the benefits of energy efficiency in the mould & tool industry

Monday, March 16th, 2009

The European mould and tool industry is quickly losing ground in the manufacturing sector and companies are facing major challenges. Increased tool making capacity in the Far East has led to overcapacity and increased market pressure to cut prices.

ENER-Plast, the European project to help the European polymer and its supply chain industries reduce their carbon footprint and environmental impact, is looking for companies to complete a short survey about purchasing decisions when buying moulds and tools. Is cost the major influencer or do any other factors, such as energy efficiency, quality, and locality of supplier have an impact?

Using the results of the survey, ENER-Plast aims to help the European industry increase their competitiveness by publishing ‘Energy Efficiency and the Mould & Tool Industry’. The Guide will cover new production and process techniques, technologies and methodologies and research (National, European or International). All companies that complete the survey will be sent a copy of the final report and publication.

The survey is one of several actions within a European-funded programme specifically intended to help the industry efficiently manage their energy consumption and reduce their carbon and environmental impact. The information we collect will influence future actions under this programme, as well as providing important benchmarking data. We will not disclose any data about individual companies within the survey results. To complete the survey, visit

There are many benefits to being a part of ENER-Plast, including an industry specific Carbon Impact Calculator, Best Practice Guides for Energy Efficiency, Directory of Energy Efficient Equipment and Products and a European Energy and Environmental Legislation Guide for the European Polymer Industry.

Register your details at or email [email protected] to access the tools and resources and for further information.

Zumbach: Measurement solutions at NPE 2009

Sunday, March 15th, 2009

An extensive range of measurement solutions and the latest technological advancements will be  demonstrated: ODAC® laser diameter scanners; WALLMASTER® ultrasonic wall thickness  measurement and control system; PROFILEMASTER® non-contact laser/camera profile measurement systems; KW Flaw Detection Systems; SIMAC Vision-Based Surface Inspection Systems; GagePro Off-Line Dimensional Measurement Systems and more.
The Zumbach product line provides tremendous opportunity for plastic extrusion manufacturers to improve product quality, reduce scrap and material waste, and save raw overall & raw material usage. The application range includes precision medical tubing; consumer, industrial, automotive and irrigation hose and tubing; small diameter to large diameter pipe and profiles of all shapes and sizes. The equipment has been proven in thousands of applications for over 50 years; Manufacturing a broad range of measurement, control, and data acquisition systems for extruded tube, pipe and profile.

Macro Line Makes Prestretched Film Rolls in Single Process

Tuesday, March 10th, 2009

Macro Engineering & Technology Inc., a global supplier of film and sheet extrusion systems, announced a new series of blown film lines, the BPS Series, designed to produce soft, prestretched film rolls in a single process.

Films created with the blown process exhibit better puncture and tear resistance than cast produced films; however, stretch films produced using blown systems require significantly more energy (or strength) to prestretch during end use applications – a limitation steering many end users away from blown stretch films. Macro’s BPS line eliminates this limitation by prestretching the film, creating a film with the superior mechanical properties of a blown process without the high-energy prestretch requirements of regular blown stretch films.
Macro’s BPS line creates soft, lightweight prestretched rolls that are easy to unwind and suitable for machine and hand wrapping applications. The bubble is intentionally blocked to create a 2-ply film structure that provides an extra layer of strength. The film is very thin (6-7 microns); however, the edges can be made 40-80% thicker to provide additional strength and minimize the possibility of tearing when wrapping. The film is immediately tacky without the need for additional conditioning or special storage.
Macro’s patented process is based on an uncomplicated single-layer blown film method using a mixture of butene-based LLDPE and LDPE with an appropriate amount of PIB or tackifier additive; resins that are much less expensive than the octene-based resins used in traditional prestretch film production. The stretching unit provides precise control of the prestretch, minimizing the possibility of the film tearing during application. The line’s tower height is very low; only 5.5 m, no trims are taken and no scrap is created in the process.
“The combination of very thin film created with inexpensive resins, and no trim or scrap generates significant savings to the processor,” said Mirek Planeta, Macro’s President. “Not only does the processor use less resin, which is also less expensive, there is also no need for costly reclaim and conveying systems to collect trims.”
The film is wound on a fully automatic turret winder, which is specially designed for winding soft rolls at a production speed of 500 m/min. “Soft rolls provide the advantage of being more resilient than hard rolls,” added Planeta. “The edges will not damage if the roll is dropped, also the rolls are lightweight and require less force to unwind.”
The first line was installed in March 2009 in North America. Macro has been awarded two US patents for this technology.