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Graham Packaging Co of York, PA, uses post-consumer reclaimed high polyester polyethylene materials for producing blow molded plastic bottles. The company is considered as the biggest vertically integrated, bottle-to-bottle recycler in the US. It also employs a well-engineered recycling assembly line that grinds, cleans and pelletizes dirty bottles effectively. This system does not only increases output but also reduces costs and improves quality.

Several new equipment were unveiled at the 1997 National Plastics Exposition. These include high-torque, low speed rotary grinders that use between 30 to 40 small cutters to carve bulky parts such a car instrument panels, BASF Corp and Philip Services Corp's 10-million lb/year glycolysis unit, United States Granulator Corp's line of large granulators and Hamos Elektronik GmbH's triboelectric separator.

Several machines with electro-mechanical servo-drive motors were unveiled during the 1997 National Plastics Exposition. These include Automa SpA's AE-30 all-electric accumulator-head model with 30-tin clamp, Ube Industries (America) Inc's blow-molded Class-A-surface spoiler, Nissei ASB Co's new high-output linear one-stage stretch-blow molding machine and Berkum America Corp's Model BM 704 DS double-shuttle station machine.

Packaging firms are showing increased interest in the in-line thermoforming of polypropylene. The trend is attributed to the development of new thermoforming machines that ensure high output and product quality. In-line thermoforming involves extruding plastics sheets directly into thermoforming machines instead of first extruding sheets and then winding these into rolls. Companies venturing into in-line thermoforming are described.

Ford Motor Co's 1.7 million-per-year blow molded gas tank capacity will be converted to six-layer coextrusion by Aug 1997. The figure will reach 2.7 million tanks by 1999. The automaker is also developing new blow molded bumper beams to replace 15 monolayer accumulator-head blow molding machines. In view of these, Ford is implementing manufacturing patterns with ergonomic flow-through for more manageable operations.

Lyondell Petrochemical Co. got a sheaf of major single-site patents when it bought the polyethylene production side of Occidental Petroleum in May 1995. The patents were applied for by Occidental Petroleum but was awarded to Lyondell Petrochemical after the sale. The patents included at least two new classes of single-site catalyst based on hetero-atom ligands. One is fully non-metallocene, based on bora-benzene rings, and used with zirconium and other metals. Other more novel hetero-atom ligands used materials previously unsuspected of having catalytic properties.

The advantages of using blow molding to produce complex and new double-wall designs, are lower costs and weight, greater durability and rigidity, and improved functionality. The processing of four double-wall blow-molded products such as a steeply contoured mail box, a phone booth the size of a bathtub, a car rear window shelf and a snap together office cart are presented.

Autofact '96, a Society of Manufacturing Engineers' exhibition held in Detroit, MI, in Nov. 1996, featured affordable CAD/CAM and rapid prototyping products. SolidWorks Corp. launched its Windows-based solid modeling and drafting software, SolidWorks '97, which was priced below $4,000 and without annual fees. AccelGraphics Inc. displayed its graphics accelerator boards, while 3D.Eye offered animation visualization software at $500.

Biodegradability is the ability of materials to completely disintegrate after microbes have eaten into them and had left only carbon dioxide and water. Although early biodegradable materials were found to be resistant to degradability in landfills, recent starch and starch-based polymers can boast of both degradability and water solubility. Combining material science, product design and new manufacturing methods, some new products are being tested for their potential degradability. These include the EarthShell package and dog chew toys from Doane Products Co.

There are about 100-150 domestic service bureaus in the country. Some used to be demonstration centers for newly invented rapid prototyping equipment while others started out of model or mold making shops, foundries or other tool makers. Some service bureaus are in-house design operations of big manufacturers. A list of 36 domestic hardware, software and other prototyping service bureaus is presented.

Nypro Pres. Gordon Lankton spearheaded the company's effort to improve its waste management and environmental practices in 1990. Lankton encouraged his employees to develop innovative approaches to reducing Nypro's waste production. The company established a waste-to-energy facility and replaced its aerosol mold cleaning equipment with pressurized tanks and pumps. Nypro also established an institute to train plastics professionals in the proper handling and disposal of wastes.

Catalyst combinations that would create bimodal resin possibilities with unusual property tailoring and enhanced processability are the research trend in resin companies. Mixing catalysts often resulted in non-distinct resin properties that looked like they resulted from only one catalyst. Quantum Chemical Co. and Montell Polyolefins produced a new form of bimodality by using a mixture of metallocene and Ziegler catalysts which resulted in high processability linear low-density polyethylene.

Plastics plants are investing on new plastic removal techniques to clean molds and tools. Burn-off ovens decompose plastic thermally into vapor by using extremely high temperature. The pyrolytic ovens work in the same principle as burn-off ovens but they pull a vacuum over parts to remove combustible air. Hot aerated sand uses a fluid bed of quartz crystal with a temperature of 800 degrees Fahrenheit to remove plastic from internal holes and assembled parts. The other alternatives are hot salt, carbon dioxide blasting and ultrasonics.

Dry paint is a multi-layer film which comes in rolls and replaces conventional paint. It has been used on exterior car parts and on flat metal parts and extrusions. There are five dry paint suppliers working with auto makers to develop dry-painted bumpers. However, tests still reveal some problems on the material. Among its advantages, though, is that it does not use volatile organic compounds, thinners and solvents. This gives manufacturers big savings on operating costs in their paint lines. Dry paint is also recyclable when ground and pelletized.

The first commercial application of foam for blow molding has yet to be determined. Possible applications include tortilla warmers, shipping boxes and shampoo bottles. Foaming saves about 25-30% on resin. This is significant in Europe where lighter weight containers conform to environmental regulations. It gives soft feel and brighter colors for toys and gives stiffness and strength for industrial parts. However, the delay in foaming has been due to the difficulty in getting even distribution of bubbles in bottle walls.

The FDA has allowed several food container manufacturers to use recycled polyethylene theeaphthalate (PET) for their products. The FDA approved manufacturers who used depolymerization and multilayer preform technology for making products that would eventually come in direct contact with food items. PET is made by degrading the plastic polymers and repolymerizing them to remove volatile materials. However, manufacturers have found greater demand for PET-derived packaging outside the US.

Merchant recycling is again being affected by price instabilities of high- density polyethylene (HDPE) bottles as a recent decrease in prices resulted in bankruptcies and closures. Despite the downward trend, many still predict that 1996 will generally be a better year for high density recycling. HDPE milk and detergent bottles are cheaper and more useful for recyclers than polyethylene terephthalate ones. Meanwhile, Consource Plastic Recycling is bent on bringing in all Duales System Deutschland recycled plastic into the US, despite the difficulties that might be posed by too much supply.

Krupp Kautex Maschinenbau GmbH in Germany has been developing the patented coextruded foam blow molding since the mid-1980s. Foam blow molding reduces part density from five to 50%, saving material and adding strength. The process produces parts using two or three layers of foam and skin, using roughly the same number of extruders. The technology is marketed as a package, including product design assistance, machinery, mold supply, resin compounded with foaming agent, process know-how and training.

Rubbermaid Inc. of Wooster, OH, has been quite successful with its blow-molded furnitures. Heavy investments in machinery and personnel training as well as its Total Cycle Time Management contributed to the success of its blow molding operation. Rubbermaid has also embarked on a waste reduction and injury reduction program in its plants.

Several plastics manufacturers are coming up with structural commingled glass/polymer fibers for use in their products. These companies include BASF AG, Hoechst Celanese, AlliedSignal Plastics, Vetrotex, DuPont's Advanced Fiber Composite Div., Owens-Corning, Zoltek Carbon Fibers Div. and J.M. Huber's Calcium Carbonate Div.

Impact modifiers are designed to improve the characteristics of polymers and upgrade less expensive resins for use in other applications. Several companies, including Dow Chemical Co., DuPont Dow Elastomer, Synthetic Rubber Technologies and Amoco Chemical Co. are developing new impact modifiers for polypropylene and other plastic materials.

ABC group has grown to become North America's largest automotive industrial blow molder. It attributes its success to its emphasis on in-house inventiveness, having already obtained more than 70 patents and registrations globally for process, machine, material and mold developments. The company boasts of two million sq. ft. of manufacturing space and sales of almost $300 million as of FY 1994.

Norwalk, CT-based Continental Plastic Containers Inc.'s financial position took a turn for the better when it was purchased by former company Pres. Donald Bainton. The company's machinery, which were operating at only 60% of their capacity before Bainton's return, were overhauled as Continental embarked on its first capital spending program since the 1970s. Better management practices also led to significant improvements in the company's products, increasing the company's competitiveness.

The plastic industry has put pressure on manufacturers of flame retardant plastic additives to make retardants that do not contain polybrominated diphenyl oxides. These bromine-based materials reportedly release carcinogenic dioxins and dibenzo furans when burned. However, retardant manufacturers refuse to reveal the contents of their other materials, and merely assure plastic firms that they are not bromine-based.

Plastics manufacturers have developed new polyolefins with unique properties through the use of new metallocene catalysts. These products open new opportunities for manufacturers within the plastics industry. However, the continued development of new metallocene-catalyzed products could be hindered by brewing patent disputes. Many of the innovators in metallocene catalytic processes do not want their competitors to use the same materials.

New laws in California, Florida and Oregon requiring higher postconsumer content in packaging materials have spurred the demand for recycled material. However, manufacturers are complaining that there is a severe shortage of recycled materials. Analysts believe that the combination of increased domestic demand, production problems and rising export demand for commodity plastics is to blame for the situation. The shortage is so acute that recyclers' profitability has been limited to 23 cents per pound.

The automotive industry's use of recycled plastics is proving to be quite profitable for the companies that have taken the time to discover how postconsumer plastics can be used. Ford Motor Co., for example, now saves over a million dollars annually by using recycled plastics for its interior trim. Chrysler, on the other hand, has cut costs by using post-use recycled plastic to make parts such as the panel tops of its Minivans. General Motors, meanwhile, is experimenting with recycled battery cases and instrument panel ducts.

The 1994 National Plastics Exposition featured new products in blow molding from hitherto unknown firms. Many of the products were aimed at small and flexible production plants in such markets as Latin America. Other products showcased were a new biodegradable bottle and a bottle blowing method that used amorphous PET. A prototype of a two-stage injection stretch-blow molding machine was also presented.

Janesville, WI-based Prent Corp. was the first North American thermoforming processor to receive ISO 9000 registration. The certification aims to set minimum quality standards for manufacturers. Rexham Container's Union, MO, facility received ISO 9002 two months after Prent was certified. Several US thermoforming processors are determined to institute total quality management and gain ISO 9000 registration. Some of these companies preparing for ISO 9000 are C.W. Thomas Inc., Penda Corp. and Kintz Plastics.

The 1994 National Plastics Exposition scheduled to be held in June in Chicago, IL, will prove to be significant for recyclers in the plastics industry. Many surprises are in store for recyclers, such as the first displays of automatic visual-sorting of flake and cryogenic grinding. A unique method of recycling fiber-entangled plant scrap and new higher-efficiency extrusion recycling lines for film will also be featured.

Many firsts in the area of thermoforming will be seen in the 1994 National Plastics Exposition scheduled to be held in June in Chicago, IL. These firsts in thermoformers will include the first live demonstrations of catalytic ovens, new machine introductions, new temperature controls and software. Among new thermoforming machines to be introduced during the show are a roll-fed inline thermoformer for high-speed, deep draw polypropylene deli containers as well as trim-in-place machines.

More machines and processors are expected to be put on display by blow molding machine manufacturers at the National Plastics Exposition to be held in Chicago, IL, in Jun. 1994. Featured will be new generations of machine controls and process monitoring, and new downstream machines for automation and quality inspection. While several had already been exhibited at Kunststoff '92 and other major shows, some had never been displayed.

Higher-heat catalytic ovens offer many advantages over gas-fired ovens such as high energy savings and better temperature control. Realizing such advantages, many thermoformers and local utilities are offering rebates and other benefits to encourage old-oven users to convert such equipment to new catalytic panels. A discussion is presented on how catalytic heaters work.

Blow molders are becoming increasingly interested in the use of computer integrated manufacturing (CIM) to boost production management. A study on the use of CIM by Clearplass Containers Inc. is presented. Clearplass availed of $1.5 million worth of computer equipment to set up a Novell Network file server that runs six personal computers (PC) and a series of PC monitors for use by managers. Through CIM, Clearplass was able to streamline and speed up its Q-C data base and record-keeping systems.

A survey of blow molding hourly rates conducted by Plastics World magazine revealed that 75% of respondents have suffered flat rates in 1996. About 22.9% blow molders claim a 7.7% increase in hourly rates, while 2.1% of respondents admit a 7% drop in rates. In the toy and dairy container sectors, molders reported flat hourly rates as 16.7% of their automotive industry counterparts posted a 5% hourly rate increase.

The first thermoformed male condom in the world has been developed that may allow for up to a 20:1 draw ratio and has wall thicknesses of 0.005-0.25 mm. Although condoms have been made of latex since the 1940s, the thermoformed-polyesterurethane (TPE) condoms will be the first non-latex condoms to be commercially viable and produced at high speed. While latex condoms have the strength of 24 mpa, TPE condoms are doubly strong, giving them better reliability against viral transmission.

Johnson Controls Inc. has been hogging the market with its Uniloy models of milk jug blow molding machines. However, changes in the industry are impacting milk jugs as the molders which can make them thinner and faster will certainly lord it over the market. Thus, attempts from new suppliers of high density polyethylene to lodge Phillips Chemical Co., Solvay Polymers Inc. and Paxon Polymer Co. out of the market are on the rise. A guideline on how to address the mechanical problems of blow molding machines is provided.

Many bottle manufacturers prefer to use polyethylene terephthalate (PET) because of its clarity, orientation strength, barrier properties, recyclability and moldability. The most common processes for blowing PET bottles are the two-step reheat-stretch-blow method, the one-step injection-stretch-blow method, injection and extrusion blow molding. The most important factor influencing the strength and quality of blown bottles is the dryness of the raw PET. Ideally, crystallized PET pellets or flakes need to be dried for four hours at an air temperature of 350 degrees fahrenheit and at a maximum dew point of -20 degrees fahrenheit.

The application of additives to modify post-consumer recycled (PCR) plastics prior to or during processing can yield numerous benefits. These include substantial improvements in u.v. stability, strength, consistency, stiffness and processability. Additives also help PCRs compensate for damage sustained in the past or during recycling and help neutralize harmful substances and impurities.

More resins producers plan to purchase grinders or tandem shredder grinders as a result of surging resin prices. Choosing the best equipment depends on factors such as plastic volume and size, material handling efficiency and capital cost. Among the significant considerations raised by granulator and shredder manufacturers are energy costs, regrind use and the nature of feedstock.

Improvements in computer numerical control (CNC) trimming may make thermoformed housings more competitive with their injection-molded counterparts. Several five-axis CNC trimmers were previously needed to match the output of a single thermoforming machine. Innovations such as automatic tool changing, laser thermoforming and water-jet trimming have significantly boosted efficiency.

The Autofact show held in Detroit, MI, in Nov. 1994 featured the latest developments in rapid prototyping equipment and CAD CAM software. The latest CAD CAM software packages are more flexible and cheaper, with several advances in mold-filling analysis. Several rapid prototyping equipment manufacturers, meanwhile, are working on their first ceramic models and employing methods such as inkjet printing, photocuring and sheet lamination.

Graham Engineering Corp. is scheduled to launch an industrial blow machine called the GEC-10D in Dec. 1994. The dual-10-pound-head model features a unique head design that allows the machine to be disassembled and reassembled easily, without falling apart. The GEC 10D has a 3.5-inch grooved extruder that speeds cycles up by up to 10% depending on the material used. It is the first machine in a new line of blow machines that shall feature models with single and dual 1-, 3-, 6-, 8-, 10-, 15- and 20- heads.

NPE '97 was a venue for innovations in thermoforming, with the general focus on increased efficiency, repeatability and flexibility. These were achieved by increasing the use of servo-drives which improved process controls, and cycle-time and position controls. ZED Industries Inc.of Vandalia, OH, introduced a modification of its 'SC Series,' a thermoforming machine with the capability of forming Kapton polyimide films at extremely high temperatures, high clamp pressures and high steel-rule-die trimming pressures.

DuPont Co. has developed a commercial, roll-fed thermoforming machine for thermosets to form a polyimide film, trademarked Kapton. Polyimide film is a super-high-heat resistant, heat forming, thermoset material originally produced with the use of a complicated matched metal molding process. Among the five available Kapton grades, the JP grade is more thermoformable, has a lower glass transition temperature, and reaches deeper draws without losing its other physical properties.

Exxon Chemical Co unveiled its experimental bimodal polypropylenes at the Polyolefins X conference in Houston, TX, in Feb 1997. The isotactic polypropylene homopolymers and copolymers feature tacticity distribution control to address narrow melt temperature ranges and processing limitations. The polypropylenes were made in a single reactor with single support dual metallocene catalysts. Albemarle Corp, Fina and Montell Polyolefins are also developing polypropylenes.

Mercury Plastics Inc. of Middlefield, OH, recently introduced the first irradiation cross-linked polyethylene (PEX) pipe after gaining approval from the Plastic Pipe Institute and NSF International. The PEX pipe which is used for pressurized hot water was developed after Shell Chemical Co. took its polybutylene (PB) pipe off the market in 1995 due to a class-action suit against the use of PB.

Nova Chemicals Ltd. and Dow Chemical Co. have developed new polyethylene (PE) processes. Nova boasts of its bimodal performance PE systems developed with the latest Ziegler-Natta catalyst in solution reactor series. The company has vowed to create octene-copolymer linear low density PE that could perform better than metallocenes over 0.905 density. Dow will start to commercially produce six grades of enhanced metallocene PE with above 0.905 density.

Roll-fed thermoforming machines require certain applications to keep them functional. Regardless of the differences of these machines, the use and timing of plug assists and/or ring assists must be correct for uniform material distribution and easily-removable parts from the mold. Parts trimming, counting and stacking methods and equipment are also vital to the proper operation of the system. However, oven temperatures must be maintained for proper part quality and line speed and to lessen unidirectional orientation.

Two start-ups have discovered that their respective polystyrene (PS) recycling systems can be combined for more cost-effective recycling. Resource Recovery Technologies (RRT) and International Foam Solutions Inc. (IFS) have patents on the use of commercially available solvents to reduce the density of foamed food service and packaging PS by making it into a viscous gel that allows for more economical transportation and delivery. While IFS is currently working to recycle the gel into usable PS, RRT has a downstream solvent technology which needs PS sources of collection.