March 12, 2008
Check Out These Important Trends in Processing Control...A Two Part Article
Improvements in molding technology are in demand now more than ever due to the highly competitive business of producing plastic parts worldwide and the high cost of material. This two part article gives you two options for process control: Parison Control (for blow molding applications) and Melt Pressure Control (for injection molding applications).
(Part 1) Injection Molding Melt Pressure Control Systems
iPact Working With Intellimold
A slightly different approach to standard process control is Melt Pressure Control. Eurotherm’s iPact feature utilizes Intellimold™, a complete real-time closed loop system that controls molding processes based on recommended processing conditions for the material. The novelty is that for the first time the non-linear behavior of the molten plastic is electrically "toggled" with the non- linear behavior of the machine through screw velocity adjustments in real time. This is CRITICAL in order to achieve and maintain melt pressures specified by the material suppliers for optimum composition and morphology, which maximizes the materials properties used in part performance specifications.
Controlling to these conditions reduces material degradation and deformation, which correlates to better parts. The processing conditions are:
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Injection pressure (dynamic fill, and pack & hold)
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Melt temperature
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Injection time
With some materials the key to good molding is to control the internal melt pressure in real time in order to give the material optimal molding conditions to solidify in a state of designed morphology. Internal melt pressure is the result of four dynamic components. These components are shrinkage forces, resistance of the mold, resistance of the air trapped in the tool, and partial solidification of the melt. Since these forces vary throughout the cycle, so does the internal melt pressure.
Advantages of molding with melt pressure control are: fast start-up; reduced cycle time, real time  control, less scrap, improved surface quality, consistent part density, and improved repeatability. This method of process control is available in a total machine control systems or as a stand-alone package from Eurotherm.
More on iPact...
More on Intellimold...
(Part 2) Blow Molding Parison Control Systems
In-machine controller or used as a stand alone system
Parison-only control systems bring parison-only wall thickness control capability to the average operator, as well as added productivity and profit to blow molders. It can be specified on new machines or added as a retrofit to a wide variety of machines to provide consistent wall thickness for improved product quality, less material consumption and reduced scrap.
 A pre-engineered system is factory configured for most blow molding applications. The user needs only needs to specify the type of machine and the unit will be factory programmed and wired for that type of machine. Once the unit is installed, calibrate the tool/accumulator and enter the desired parison profile.
A popular parison system on the market today includes such feature as:
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pre-configured for common machines (time or position),
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100 point parison profile,
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100 point velocity push out control,
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graphically enter and display the parison profile,
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actual tooling performance versus entered profile displayed,
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separate weight & die gap settings,
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very high speed loop closure - 0.1ms, multiple security levels,
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large color touch screen,
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store parison setups to internal memory or USB sticks.
A well designed parison control system can be cost effectively programmed to meet specific requirements for the most demanding blow molding applications or customer needs, and provides the foundation for future expansion to total machine control in which the full capability and advantages of a new control system can be realized. One such system on the market today is Breeze II from Eurotherm.
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US Government Announces Tax Relief On Capital Equipment Purchases
Looking for purchasing help / justification reasons to buy equipment this year?
Check out the full information on “The Recovery Rebates and Economic Stimulus for the American People Act of 2008” by clicking this link.
Here are a few details for you to consider:
*50% bonus depreciation for new capital equipment expenditures ordered and placed into service during 2008. Simply, the old law would allow a 14% depreciation of costs over the first year (IE: $14,000 on a $100,000 purchase.) The new law allows for 50% depreciation for the first year, plus the 14% regular depreciation on the remaining amount. (IE: $100,000 purchase – $50,000 first year depreciation – {14% depreciation over the remaining balance: $50,000 – 14% = $7,000}. This results in a $57,000 depreciation (2008 rules) versus a $14,000 depreciation (old rules) over the first year, resulting in a 43% greater tax deduction for your next equipment purchase.
*Increases in how much smaller businesses can write off for new equipment purchases in 2008. The increased Section 179 Expensing for Small Business more than doubles the amount that small businesses can write off for new equipment purchased during 2008…from $128,000 to $250,000. Additionally, the new law significantly increased the amount that can be purchased during the year and still receive the full benefits of the Section 179 expensing option – from the previous cap of $510,000 to $800,000.
So take advantage of these tax benefits by buying new Eurotherm control equipment--just click here. And feel free to give us a call at 703-443-0000.
To view a press release from The Association for Manufacturing Technology (AMT) explaining it all, click here.
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UPCOMING PLASTICS EVENTS
KOPLAS (19th Korea International Plastics & Rubber Show) March 27-30, 2008 Goyang, Korea
CHINAPLAS 2008 April 17-20, 2008 Pudong, Shanghai, PR China, Booth E2-NO5, Hall E-2
NPE 2009 (SPI) June 22-26, 2009 Chicago, IL (McCormick Place), booth 69039-North Hall
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