Archive for July, 2009

EDI develops advanced layer multiplier

Thursday, July 30th, 2009

Completely the Product of EDI Engineering, New Layer Multiplier Is Supplied without Royalty and Installs in Existing Production Lines with Minimal Modification

CHIPPEWA FALLS, WI, U.S.A., July 29, 2009: A completely new layer multiplier enables producers of cast film and sheet to obtain the substantial property enhancements of microlayer structures yet is easier to deploy, more compact, more accurate, and far more versatile than any other layer multiplier system, including one previously offered by EDI, the company announced today.

The advanced layer multiplier was developed by EDI engineers and is available to purchasers without licensing or royalties. Tooling based on the new design can be supplied for applications over a large range of widths and has been used successfully for a 171-in. (4.3 m) product, according to Gary D. Oliver, vice president of technology. The system can be engineered to multiply materials from three, five, seven, nine, or more melt streams.

As an example of the compactness and productivity of the system, Oliver cited the case of a layer multiplier for a product with a total of 84 microlayers. The tool consists of a series of four components: a five-layer coextrusion feedblock, two multiplier modules, and another five-layer feedblock. The length of the tool is only 24 in. (609 mm), representing the total distance from the inlet of the polymer streams into the tool to the exit of the multiplied structure. The tool is being used at a typical line speed of 1,000 lb. (454 kg).

“This compactness of EDI’s new layer multiplier is absolutely critical for maintaining streamlined flow, developing layer uniformity, and adapting to normal variations in material viscosity or extrusion rate,” said Oliver. “Some competing layer multipliers involve massive tools with long flow paths that compromise layer uniformity, limit adaptability, and multiply materials from a limited number of melt streams.”

One factor in the compactness of the new EDI system is the development of a new version of the company’s Ultraflow® IV feedblock. A five-layer feedblock of this type is now only 6 in. (152 mm) long, one-third the size of the earlier version.

The new layer-multiplier tooling can be installed in an existing extrusion line with only minor modifications, Oliver noted. The downtime required for cleaning out the system can be as little as four hours, as compared with a much longer period—as much as a week—with other systems.

How the Layer Multiplier Works

As in standard coextrusion, multiple streams of molten polymer enter the layer multiplier system by going through a feedblock, which produces a conventionally sized (4 by ¾ in., or 102 by 19 mm) “sandwich” of three, five, or seven layers. The materials in this structure are subsequently multiplied in EDI’s proprietary layer multiplier modules. Finally, the resulting microlayer product enters a second feedblock, which produces another conventionally sized sandwich that passes into the manifold of a flat die, where the structure is expanded to the target product width. The finished product has a standard thickness, yet its internal structure can consist of many—even hundreds—of microlayers.

EDI’s system can be used to multiply selected melt streams or all of the streams entering the system.

While layer-multiplied film and sheet are no thicker than their conventional counterparts, the multiplicity of microlayers in their internal structure generates synergistic effects that result in improved mechanical and barrier properties.

Binks & DeVilbiss: Unbeatable in ceramics & sanitary ware

Thursday, July 23rd, 2009

Spray guns for glazing: From 2001V to Viper

Bangkok, Thailand, July 22 2009 - In the year 1892 Joseph Binks built the first cold water paint spray machine to whitewash the companies large sub-basements. And only one year later this invention rescued the opening of the 1893 Columbian Exposition in a spectacular action: Painters for the 1893 Chicago Columbian Exposition could not keep pace to finish the construction and used the Binks paint spraying machine to whitewash everything on time.

Over the last decades Binks, represented in Thailand by B.S.C. Teknik, introduced several ground-breaking manual and automatic spray guns: In the year 1934 Binks introduced its popular Model 7 spray gun which has been used in every conceivable application since then. The legendary conventional spray guns Model 630, 2001V, 95A, AGN are still very popular today and still widely used for spray glazing of sanitary ware and ceramic products, even in industrial-scale production. One of the reasons: Most needles and nozzles are also available in tungsten carbide which can much better withstand the abrasiveness of the glaze material.

The tough environment of spray glazing

The high-humidity spray environment is corrosive and the abrasiveness of glaze can accelerate equipment wear. Ceramic glazes are inorganic coatings which also consists of silicate particles (hydrated magnesium silicate) and flint, a very hard sedimentary rock composed mainly of silica. Flint is such a hard material that prehistoric people made tools and weapons out of it. The silicate and silica materials are highly abrasive and can cause excessive wear on normal stainless steel needles and nozzles.

Viper automatic spray gun: Dismantlement without tools

DeVilbiss introduced a completely new design of spray gun, purpose made for the tough working conditions in the glaze & ceramics industries, i.e. very suitable for sanitaryware, tableware, ceramic floor and wall tiles, ceramic cookware and applying vitreous enamel to many household electrical appliances like washers, dryers, stove tops and hot water heaters.

The patented “Quick’Up” system (instant ¼ turn air cap and fluid tip removal) allows easy and fast disassembly of the air cap and fluid tip which significantly reduces production downtime. Moreover, all working parts of the gun can be completely disassembled in seconds without the use of tools.

The new so-called “Bellow” system, also patented, protects the needle and needle packing which extends the operating life cycle of the spray gun. Spray performance and fluid flow can be controlled by means of a fluid adjusting knob with 18 indexing positions.

And like a must for all “glazing spray guns” of DeVilbiss (and Binks), fluid tips and needles made from tungsten carbide are also available.

About us:
B.S.C. Teknik supplies and services the whole range of ITW DeVilbiss and Binks spray coating equipment, from the newest Viper gun to spare parts for spray gun classics. The website contains online information about maintenance, troubleshooting and painting techniques. More information:
[email protected] | www.bsc-teknik.com

Energy Efficiency: Moulds & Tools

Friday, July 10th, 2009
European project to address energy anxieties in the polymer supply chain

ENER-Plast is a 3-year EU-funded project to help the European polymer industry and its supply chains increase their energy efficiency and reduce their environmental impact.  The web-based tools and resources include:
  • Industry specific Carbon Impact Calculator
  • Best Practice Guides for Energy Efficiency
  • Directory of Energy Efficient Equipment & Products
  • European Energy and Environmental Legislation Guide

BUT … in order for us to produce all the exciting and innovative resources we want to, we need your help!!

ENER-Plast is looking for companies to complete a quick and simple questionnaire on purchasing decisions, especially in relation to moulds, tools and dies.

To complete the questionnaire, go to http://www.Swiftpage7.com/survey/Enerplast
All respondents will recieve a copy of the final report and the resulting publication ‘Energy Efficiency and the Mould & Tool Industry’.

To start benefiting from the ENER-Plast project register your details at www.enerplast.eu.

TOV viscometer for continuous measurement in polymer processes (resin, fiber, filament)

Wednesday, July 8th, 2009

Mansco Products Inc., the manufacturer of the TOV viscometer for continuous measurement in polymer processes (resin, fiber, filament), has achieved the milestone of shipping its 200th TOV sensor to be installed in China.

Originally, the TOV was sold under agreement only to Dupont and Dupont Engineered plants. In 1999, a new license agreement was signed and Mansco entered the general marketplace.  Since this time, Mansco Products has established itself in the China polymer market through direct sales and several OEM machinery or engineering companies, achieving a very high market share through successful installations in a very short time.   --- Mangle, Mansco Product’s Vice President commented: “The TOV’s design using a torsional measurement principle allows the sensor to have unmatched sensitivity and reliability in a polymer installation. Since the TOV’s sensor can be installed directly in the main process (at the exit of the reactor or extruder), most of our customers have immediately seen the advantages over other methods they previously used such as monitoring the pressure differential over a capillary side stream. The TOV’s design gives us the capability to give much quicker response, measure with high accuracy, eliminate temperature differences by measuring in the main process, and provide an effective measurement that is often used in feedback control such as DCS vacuum control.” He added, “We were able to establish a local presence cooperating with several engineering companies with great success and this has also led to a very high number of repeat orders with the larger companies and through the engineering companies themselves. We also are able to offer excellent local service and installation services using our technical staff based in China, which was also an important factor in our growth.” Most recently, several orders have been booked for recent new large projects announced in China. The TOV has been installed in several recent projects in India as well.

Viscosity uniformity is one of the most critical properties affecting the quality and downstream performance of the product. The TOV has emerged as playing a key role for many companies in China producing Polyester resins and continuous fiber or filament.  Additionally, the TOV has also been successfully utilized in other areas such as extrusion applications (film, fiber, recycling, etc) and also higher technological and higher value specialty products.

Mansco Products specialists can support customizing a TOV installation specification for almost any polymer application for an existing plant process or in any new plant design.

Further information is also available on Mansco’s website www.manscoproducts.com.

Reduce, Reuse, Recycle

Tuesday, July 7th, 2009

ATLANTA, JULY 2, 2009/ POST - NPE 2009 – Unique Reprocessing Technology on show at NPE 2009 / Following on from a hugely successful show at NPE 2009 TSM Control Systems is now offering plastics producers the answer to their reprocessing problems. As demonstrated at NPE 2009 TSM’s innovative new blending solutions are directly combating many of the processing difficulties being experienced by plastics processors around the world from Chicago to to China.

Many plastics processors took the opportunity at NPE 09 to outline difficulties that they are having in processing regrind materials. The common complaints centered on being unable to process higher percentages of regrind materials due to the constraints of their existing mixing equipment. In particular, their inabilities to get these higher percentages of regrind material through the throat of their processing equipment. It seems this demand for processing more regrind materials corresponds to a consistent drop in virgin resin usage by processors relating to market demands to reduce final product costs.

With the exception of LLDPHE resin every type of resin production usage is down at least 10% in the first quarter of 2009 compared with the same figure in 2008 (American Chemistry Council, 2009). This figure illustrates that production may still be slowing but we also believe that it is also due to many processors substituting less expensive regrind materials for virgin resins in their production processes.”

TSM’s mixing solution directly overcomes this processing difficulty by cramming material through the throat of the processing machine using their patented reverse flight auger mixing technique. This unique mixing technique allows processing of up to 100% low bulk density flake regrind directly in TSM’s new OPTI-MIXTM range of gravimetric blenders. TSM maintain that their mixing technique allows processors to reuse more regrind materials without re-pelletizing costs, while using more recycled materials reduces material usage of expensive virgin materials and reducing material wastage.

We have the technology that allows plastics processors to increase their recipe percentages of regrind materials without diminishing their product output quality as would have usually been the case using other blender suppliers. We believe our patented mixing technique, which allows higher percentage regrind processing, will also facilitating the markets’ demand to move towards reusing scrap materials, reducing waste materials and recycling existing materials which are currently being sent to landfill.”

Much of TSM’s product development in recent times has also been focused on reducing production costs for processors with fully automatic self-cleaning blenders; which eliminate health and safety risks, greater accuracy in material usage and production optimization software. Now that the market is aligning with the same objective – processing cost reduction – TSM seem set to change how plastics processors do business.

TSM Control Systems, www.tsmcontrols.com.

New Coating for Flat Dies withstands Hydrochloric Acid Attack from PVC

Thursday, July 2nd, 2009

CHICAGO, June 22, 2009: A new surface coating now available on flat dies from Extrusion Dies Industries, LLC (EDI) withstands most attacks from the corrosive hydrochloric acid (HCl) generated in the course of extruding PVC, the company announced at NPE2009 (Booth N85007).

Called DuraCoat™, the coating is inert when exposed to harsh chemicals, according to Gary D. Oliver, vice president of technology. While EDI is exploring possible uses with a range of other corrosive plastics, it is recommending DuraCoat for dies used to produce PVC foam, film, and sheet. The thermal degradation of PVC caused by heat and shear during extrusion generates HCl byproduct that can inflict extensive damage to dies with conventional surfaces.

“This new coating forms an extremely thin film on the steel surface of the die that has no effect on even the most intricate features machined into flow surfaces,” said Oliver. “The low friction coefficient of the coating provides improved slip release in comparison with that of standard chrome plating.”

DuraCoat exhibits exceptional hardness, very high melting and oxidation temperatures, and insolubility in most acids and bases, Oliver added.

The coating has been successfully applied to tooling in the injection molding industry and has already been used by EDI customers producing vinyl residential siding (post-formed from sheet) and foams, according to Oliver. “On two occasions, one customer mistakenly processed the PVC at a very slow rate, and the extended residence time for the polymer caused enough burn and HCl out-gassing to ruin standard chrome plating and make it necessary to rework the die,” he said. “But the die in this case was DuraCoat-coated and withstood both burn-outs without damage.”