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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.

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Caveat Emptor: Selling Older Machines…

I was recently working with a company who had an interesting tale regarding the sale of one of their larger, older, hydraulic molding machines with a very large cylinder clamping unit and corresponding hydraulic reservoir…

Engineer
When we were trying to sell one of these pieces of junk, my recommendation was to drain the oil and sell it for scrap metal or parts. Purchasing then told me they had agreed to sell the machine for a few thousand dollars, hydraulic fluid and all.
note: After a quick calculation, he explained to them that they had just lost money since the value of the hydraulic fluid currently in the machine is worth almost twice the amount they are getting for the machine.
My Thoughts
Although complicated to quantify, most of these older machines are a real drag on the company and their resources. In this case, oil in the machine was more valuable than the machine itself. The machine was being sold because it was slow, unreliable, and wasting resources. It will provide the same drain of resources on the next molder who tries to operate it. Especially when your incorporate the expense of relocating, configuring, and hooking up the machine. In this case, I believe the engineer is right… the fluid should have been reclaimed and  the machine should have been either scrapped or sold for parts rather than be brought back into service.
-Andy

Training as a Resource…

Recently I was at a customer site and they had many older training materials sitting the the training room unused…

HR
We plan on keeping all these materials here as before so they can be used as a resource while people use your training.
My Response
Training materials are only useful when they are incorporated into the overall training plan. As a rule, employees will not open a book or take training unless they are directed to do so. They are typically too busy to just sit down and read books or take training unless it is requested of them. Believe it or not, if the training is captivating, relevant, and self paced, employees will be very interested in taking training when asked to do so.
Additional Thoughts
It is better to fill your training room with instructional aids such as part prints, sample defects, and work instructions.
-Andy

Guarding Older Machines…

I was recently at a company with many older (30+ years) home-made molding machines. Although the machines have a large number of moving components and cams, the molder did a great job of adding full guarding around the entire machine. This guarding was not particularly complex, or expensive, but it is a great way to ensure your employees stay safe.

Additional Comments
Make sure all your older machines are well guarded to protect your employees and your company from liability. Even though your machine was legal the day it was purchased does not mean it is not a liability today.
-Andy

Measuring Mold Temperature…

I received this question last week…

JIM
Do you have any recommendations on how to capture actual steel temps other than installing thermocouples?  We currently use a surface probe which is time consuming and often difficult to capture the true operating temperature.
My Response
Thermal imaging cameras tend to be inaccurate for mold steel due to the reflectance of the steel. The best bet would be to measure the water temperature going in and out of the tool… since the temperatures along with the difference can give you a good idea of the consistency and adequacy of the cooling. This can be done by surface measurement of the water fittings or in-line sensors.
Additional Thoughts
R is a great technology, but it is most effective at non-reflective textured surfaces. Many times people think they are measuring the temperature of a part or tool, but they are really measuring a nearby wall due to a reflective surface.
-Andy

Processing PVC and Acetal

This question just came
in from a medical molder…

 

KH

We are extruding
flexible PVC and started injection molding Acetal in the same facility. On the
PVC die heads and downstream auxiliary equipment there is a white layer of
powdery build up on the metal. What is the cause of this?

 

My Response

The white layer of
buildup on the machines is most likely a result of a chemical reaction between
the formaldehyde gas and hydrochloric gas byproducts of your two processes. The
hydrocholoric gases that result from PVC processing will also attacking any
non-treated steal. When processing these two materials in the same facility
proper safety measures must be put in place to separate the two materials. To
help prevent the white buildup a larger ventilation system with separate exhausts
for each process could be put in place.

 

Additional Thoughts

It is dangerous to
process PVC and Acetal in the same facility and extreme care should be taken to
separate the two materials at all times. A high concentration of formaldehyde
and hydrochloric gas may be enough to cause an explosion in the facility. If
the PVC or Acetal were accidentally mislabeled, mishandled, and processed
together, it would cause an explosion!  

 

-Andy

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