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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.

Costs of Hands-On Training…

I recently heard this statement…

Potential Customer
We save money by just using shadowing to train our employees.

My Response
Personally, I believe that shadowing alone has shown to be the most costly for any company to rely on for many reasons. First, the best you can hope for is that the employee learns the minimal information necessary to perform their job. Second, any success relies on the knowledge of the guiding person and their ability to convey this information properly. Third, constant retraining and reminding is always needed since the minimal information is conveyed to begin with. Forth, this process requires the labor of two employees, the training cots add up quickly.
Additional Thoughts
Since people only learn the ‘how’ of a process, they lack the full understanding as to why an action, procedure, or step is required. As a result, the employees seldom put little emphasis on adherence to procedures in such scenarios. The result is generally a higher level of csrap and damage than that of a well-trained workplace.
-Andy

Follow-Up on Safety Glasses…

A blog reader posted a response to a post on safety glasses, and I believe it deserves a little more attention…

TJ
I think safety glasses should be used in tool room and maintenance area as Personal Protection Equipment, there is no need in quality lab and warehouse.

My Response
I agree with the Tool Room and Maintenance… As for the lab and warehouse, many eye related accidents actually occur in these areas.
In the lab, many companies do dangerous activities such as perform mechanical testing, use chemical agents, cut samples, and even perform rheological tests. Many of the activities in a quality lab can be dangerous and each company should take a look at this before making a judgement.
As for the warehouse, many eye injuries occur when someone is looking up while something is falling down. It is very common for dust, debris, and pellets to accumulate on the top of boxes, molds, and containers stored within a warehouse. When these are pulled from the upper storage racks the employee is looking up while all this dust and debris is falling down.
Additional Thoughts
In many situations, safety glasses are not required in the lab or warehouse, but your company should truly assess the risks before making a decision.
-Andy

Mold Bolt Specifications From Supplier…

I received this question from a recent customer…

Jim
{Our supplier} cannot supply specification documentation that the mold clamp bolts they supply are Grade 8. This is one of the reasons why we are looking at other suppliers.
note: Jim included the name of the supplier, but it was omitted for the purpose of our blog.
My Response
Since these bolts are being used to hold down the mold, the bolt class specifications are not as critical as you might think. When used for mounting injection molds, the bolts are torqued to values siginifcantly lower than their maximum. Since the company you are purchasing from is reputable, you should be fine.
Additional Thoughts
The more important factor is to use a toque wrench to secure the bolts while minimizing any excessive loads. Using the appropriate torque values will be most important in manitaining the long term integrity of the bolts, nuts, and t-slots.
For more on torque values, please feel free to read:
-Andy

Understanding Hydrolysis…

I was discussing material dying with a technician and was asked this question…

Bob
What is Hydrolysis? I looked it up online, but I don’t understand the technical jargon.

My Response
Basically, water molecules are formed with two hydrogen atoms and one oxygen atom (H2O). This is a relatively stable relationship under room conditions. When heated during processing, one of the hydrogen atoms can become easily dislodged from the molecule creating a positively charged hydrogen atom H+. This will also leave a negatively charged alcohol molecule OH-.
Additional Thoughts
What is important about this process is that many polymers are attacked by the results of the hydrolyzed water molecule causing polymer chain degradation. This is why properly drying hygroscopic materials is so important.
-Andy

Compressed-Air Drying Trends…

I had a discussion with another consultant recently and thought it may be helpful to convey some thoughts about the growing use of compressed air material dryers…

Compressed Air Dryers
The compressed air dryer uses air that is provided from an existing air compressor. The air passes through a heater before reaching the pellets. At the compressor, the air loses moisture and the dewpoint typically drops 25 degrees Celsius or 45 degrees Fahrenheit below the dewpoint of the ambient air within the room. Since the dewpoint is not as low that of a desiccant dryer, they are not commonly used for highly hygroscopic materials such as nylon and acrylic.
Growing Trends
These dryers are growing in popularity with respect to two purposes:1) Small Batch Drying – although these dryers are not the most effective method of drying, they can be used to dry virtually all materials, but they often take as much as 50% more time to accomplish the task. 2) Supplemental Drying – although many molders are trending towards large centralized material delivery systems, the material resides at the hopper for a period of time. Small capacity, compressed air dryers are a helpful method of maintaining a dry material at the hopper, especially during a process interruption.
-Andy