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This informative blog allows plastics professionals to discuss plastics training and technology. Brought to you by Routsis Training: the plastic industry's premiere training provider.

High Temp Machinery…

Just because a machine is capable of processing at high temperatures, does not mean it is optimized for use at these temperatures. A machine which spends most of it’s time at high temperatures should be purchased and designed for that intent. A failure to do so will result in potential inefficiencies and premature equipment failure.

Situation: Recently I was working with a company who processes a large number of high-temperature materials. The manufacturer states the machine can operate at high temperatures without significant modifications, but it is not operating optimally. The melt temperature is consistently 30-50 degrees C below set point and the locking check ring is expanding more than the barrel causing a squealing to occur.
My Recommendations: If you occasionally run high temp materials, then a stock machine may be OK. If you are intending to process mostly high temp materials, especially at high speeds, you should consider a machine deigned for that application. Any thermal expansion differentials should be considered with respect to the materials & tolerances used for the screw, check ring, and barrel. The machine should also be fitted with heater bands designed for high temperature use to heat the material quickly and efficiently. There are many other considerations such as proper heat shield design, adequate nozzle heaters, and a pre-heating capable hopper which can improve the overall efficiency of the machine.
-Andy

FREE Plastics Training Webinar

You are all invited to join a webinar being presented this Wednesday entitled:
“Making Permanent Sustainable Change Through Training… A Better Way to Develop Talented Techs”
All participants will receive 10-day access to four of our most popular training courses as well as the highly popular Injection Molding Reference Guide & a Scientific Molding Process spreadsheet.
This free webinar being this Wednesday, October 2nd @ 2PM Eastern Time.
-Andy

Scientific Molding & Valve Gates…

The basic principles apply whether you are using valve gates or not. In theory, you try to use one flow rate through the gates whenever possible to fill the mold because it reduces variation in the process due to a consistent shear on the material.

Question:One of your recommendations on scientific processing is to avoid profiling and perform mold filling in 1st stage.
How this more relevant in today’s scenario as many molders are molding the molds having Hot runner systems with sequence in gating?
My Response: The recommendation of using one injection speed when possible is based on the goal of maintaining one shear rate (flow rate) through the gate as the material fills the mold.  Not every mold make a good part with one flow rate, but you always strive for this since it simplifies the process and reduces variability. The approach to sequential valve gating is based on the gating layout and purpose. I will lay out 2 common scenarios and how this can be dealt with the same theoretical approach.
Scenario 1 – Gates opens after melt front has passed: In this case, the flow front begins when the first gate in the cavity opens and then more gates open sequentially only after the melt front has passed. In this situation, you should maintain the same injection speed when possible. This is because the material flow front will maintain the same flow rate and will result in a more consistent shear rate across the entire part.
Scenario 2 – Gates open at different locations starting new flow fronts: In this case, the first gate in the cavity opens, possibly to fill a larger area, and then a second gate opens in a different location and begins a new flow front. These flow fronts will eventually meet as the cavity fills. Assuming the gates are of similar size, you would want to double the injection speed as the gate opens since you doubled the number of flow fronts being serviced. This will cause the flow rate though each gate to remain the same resulting in an even shear rate across the part.
-Andy

Making Change Stick…

Implementing change takes time. Change is a critical aspect of business today, but you cannot just say ‘Do This’ and expect everyone to jump on board immediately.

Issue: Every time we implement something new, our people go back to the old ways in just a couple weeks.
My Response: It takes 3-6 months to replace an old learned behavior with a new behavior. For this reason you need to view change with an on-going approach. You cannot just tell someone that a different way is better, and expect them to change. This is especially true if they are experienced and have invested many years into doing things a different way. You have to remember that they have been succeeding for years with the old way, so they need to understand the ‘Why’ as well as the ‘How’. Furthermore, you have to reinforce the new behavior for months to prevent them from going back to comfortable.
-Andy

The Need for Technicians…

The lack of good technical employees to hire is a global issue and must be addressed in-house. You cannot rely on poaching talent from others to fill all your technician needs.

Question: You don’t understand how hard it is to hire technicians in our area. Where is the best place to look for technicians?
My Response: There is no place on the planet where plastics technicians grow on trees. Every company has their own equipment, procedures, parts, customers, paperwork, molds, plastics, etc. For this reason, even if you can hire a technician you hope knows how to process, they still need to learn everything else about your company. This takes time to make a poached technician effective in your company and typically result in a technician which can barely get the job done. Your best bet is to determine the skills and knowledge necessary to develop a good technician and have a plan to teach your employees this information so they can advance from within.
-Andy