NPE Technology Preview

It’s almost here—the event some of you have been waiting for since you walked out the doors at McCormick Place three years ago. Here’s a snack to whet your appetite for the feast of technology this year’s NPE will offer.

If you still haven’t bought your plane ticket and booked a hotel room, you may be packing up the Buick and staying with Aunt Mildred in Evanston if you want to attend this country’s largest plastics industry trade show.

It’s like a toy store, really, and the new gadgets you bring back to your plant have the added benefit of making you more successful at what you do. So waste no time in finalizing your plans.

As usual, IMM wants to make it easy for you to navigate the show and enjoy Chicago, too. Here’s what we have in this issue to help you find the molding-specific companies at NPE:

McCormick Place hall map. You never take a trip without the right guide, and our complete listing of exhibitors and how to find them is attached to p. 19. Tuck this lightweight, fold-out map into your pocket or briefcase and hit the halls.

Show Planner. On the facing page you’ll find a booklet containing a tool to aid in locating IM-related companies by category. It’s designed for quick reference when searching for a company that makes a specific product you need.

Technology highlights. If you aren’t already excited about what you’ll see at the show, the following pages should get the blood pumping. Materials, injection molding machines, robots, and other items being introduced at the show are here for your advanced perusal. Be sure to bring this issue on the plane to get you ready to explore. Enjoy the show!

Materials, colorants, and additives

Advanced Polymer Alloys will display its lines of Alcryn melt-processible rubber (MPR) and DuraGrip TPE, as well as its custom compounding capabilities. Both material types offer unique soft-touch characteristics without compromising performance.

AGC Chemicals Americas, the joint venture between Asahi Glass Fluoropolymers and AGA Chemicals, will feature its Fluon PTFE fluropolymer resins and fluoroelastomer compounds, melt-processible compounds, and PTFE micropowders.

BASF will showcase its PlasticsPlus specialty portfolio: Luran S ASA, Ecoflex and Ecovio 100% biodegradable aliphatic-aromatic copolyesters, Styroflex SBS block copolymer, Terblend N (PA/ABS) for automotive interior applications, Terlux MABS for medical equipment and consumer products, and Styrolux SBC clear styrene-butadiene copolymers. Urethane offerings will include new grades of soft-touch Elastollan TPU for automotive interiors, aliphatic TPUs for automotive instrument panel skins, and higher-temperature-resistant, hard-phase-modified TPUs with improved compression set targeted for higher-performance applications.

Bayer MaterialScience plans to dazzle attendees with the Rinspeed zaZen concept car on display in its stand. The car features a teardrop-shaped PC roof and Swarovski crystal coating. In addition, the company’s VisionWorks-themed booth will showcase Aura color infusion, which allows users to custom color already molded parts; holography for optical data storage, security, imaging, optics, and displays; nanoscale additives that eliminate property trade-offs; polycarbonate glazing for automotive applications; transparent conductive polymers (Baytron); electroluminescent 3D parts; and multiwalled carbon nanotubes (Baytubes).

According to Bob Kumpf, VP of future business, Bayer uses an open innovation model to bring new technologies to market. “In the past, we did all of the invention ourselves. Now, we are partnering with small businesses, universities, and equity firms during the ‘greenhouse’ or project development phase.” Kumpf says that Bayer is now able to produce Baytubes, the multiwall carbon nanotubes, in sample quantities for initial testing, thanks to the open innovation model.

But don’t expect new polymer molecules or backbones to be cropping up anytime soon. “We focus on new materials, not new polymers, because the benefits to our customers come from modifying existing materials,” he says. He sees a strong future for polycarbonate glazing in automotive applications such as roofs, fixed side windows, backlites, even movable side windows. “Our Makrolon material represents a value proposition for replacing glass. It takes weight out and improves styling,” he adds. When used as a roof material, PC lowers the car’s center of gravity, Kumpf explains, making it safer. Another product launching in Makrolon is optical disks for storing high-definition video, both HD-DVDs and Blu-ray Discs.

Chemtura, formed last year by Crompton and Great Lakes Chemical, will highlight its portfolio of 4000-plus additive products from flame retardants and antioxidants to lubricants and UV stabilizers. The world’s largest plastics additive company will also feature Polybond coupling agents for wood plastic composites.

DuPont Engineering Polymers debuts four new materials for wear and friction applications. Two are acetal (Delrin) and two are PPA-based nylon (Zytel HTN). Delrin 100TL with Teflon PTFE micropowder features impact strength and elongation with very low wear and friction. Delrin 500MP economically produces parts needing low wear, friction, and squeak; it contains a lubricant package based on Teflon micropowder and a proprietary ingredient. For higher-temperature applications, Zytel HTNWRF51MP20 combines low friction with good wear resistance, while Kevlar-reinforced Zytel HTNWRF51K20 offers exceptional abrasive wear resistance.

DuPont’s booth will also feature an innovative noise-eliminating propeller hub for Mercury Marine, formed by overmolding Delrin 150 onto titanium rods.

GLS will introduce a new line of water-clear TPEs with excellent overmold bond strength to polar substrates such as PC, ABS, and others. Versaflex OM 3000 overcomes former challenges to obtaining clarity and adhesion in the same material, and provides a silky feel that enhances perceived quality. In addition, the company is set to unveil its second generation of nylon-compatible TPEs, the Versaflex OM6200 Series, which minimizes the antiadhesion effects of nylon-type variations (PA6, PA6/6, PA6/12) and modifiers such as colorants, lubricants, glass, and others. The new grades also do not require drying for either the TPE or the nylon substrate prior to molding.

Merquinsa, a supplier dedicated solely to TPUs, plans to introduce a pair of fast-cycling materials for the automotive industry, Pearlthane D11T85UV and D11T93. Target applications include overmolded interior parts such as armrests and gearshifts, where the materials can be used to provide abrasion resistance, tactile qualities, and a leather look. Adhesion with any polar substrate, including ABS and PC/ABS, is excellent, according to Dennis Lauzon, North American business manager.

Noveon’s line of Estane TPU elastomeric materials bridges the gap between flexible rubber and rigid plastics, providing toughness and durability in a flexible elastomeric system. Noveon offers high-performance polyester and polyether-based resins and compounds in a broad range of hardnesses along with Tecoflex, a family of medical-grade TPUs used in devices that contact either tissue or blood. These aliphatic TPUs are formulated for biocompatibility, flexural endurance, high strength, and processing versatility.

Teknor Color brings 14 new earth, wood, and stone hues to NPE 2006 in concentrate and dry-color formulations for five commonly used construction polymers, with each customizable for specific product requirements. Called Tekpro Construction colors, they are based on light-stable pigments, contain UV stabilizers, and are available in standard pellet and bead forms as well as Color Sphere mini-beads. Compatible polymers include HDPE, PP, mineral-filled PP, rigid PVC, and flexible vinyl.—MM

New machines

NPE will be the North American debut of Arburg’s economical new Golden Edition Series molding machines, built to celebrate the company’s 50-year anniversary (see May 2006 IMM, immnet.com/product_news/2006/May/1995). Five models, ranging from 44-220 tons, will be available here after the show.

Battenfeld of America will introduce us to its fully re-engineered HM series of variable-volume, full-hydraulic, two-platen presses with retractable tiebars. Company sources say that although, ton-for-ton, its closed-loop Unilog B4-controlled HM Series machines are the shortest full hydraulics on the market, they pack a generous amount of tiebar spacing into their compact footprint. They’re fast, too, thanks to quick-stroke, externally mounted clamp cylinders. A 400-ton Model HM 400/2250 Unilog B4, equipped with Battenfeld’s own Unirob R10 S robot, will manufacture boxes at the show in 30-second cycles.

A sixth-generation version of Cincinnati Milacron’s venerable line of Magna hydraulic toggles debuts at NPE 2006. Dubbed the MTg, the affordable, new, made-in-the-USA models reportedly combine a compact footprint with a fast-lock-over clamp, easily serviceable hydraulics, excellent repeatability, and a brand-new injection unit with Milacron’s new Mosaic control.

Designed with custom, medical, and precision molders in mind, other standard features include Milacron’s Meltstar screw, twin-cylinder injection with twin pull-in cylinders, and three clamp closing speeds with mold protection configurable in three setpoints. With proportional hydraulics, positioning accuracy to ±.0014 inch, and closed-loop process control, MTg machines will be available in four sizes from 170-450 tons.

Also, the new Milacron Fanuc Roboshot S2000i-B series of all-electrics will make its NAFTA debut at NPE. Key features include Fanuc’s new, even more artificially intelligent machine control with a 62.5-ms scan time; its latest servo technology; new injection pressure load cell technology; a new moving platen design; wider tiebar spacing; and a zero-to-300-mm/sec injection acceleration in less than 30 msec. Not fast enough for your thin-wall parts? Well, a new, optional shooter accelerates at 500 mm/sec in less than 30 msec at 2.02G. The Roboshot comes in five sizes from 55-330 tons.

At NPE 2006 Negri-Bossi will debut a 1500-ton/340-oz model in its new Bi-Power series of really big twin-platen hybrids with really compact footprints. They range from 1100-6000 tons/80-1600-plus oz and feature all-electric injection units, plus NB’s signature CANbus control technology.

Two traversing cylinders on the moving platen quickly open and close the clamp with symmetrical and uniform force. And the clamps feature a patented locking mechanism. Other features include simultaneous cycle-phase overlapping; digital, wireless communications; and an overall low-profile design for easier integration of automation and more convenient clamp access.

Speaking of new hybrids, Nissei America will introduce us to its brand-new FNX140 at McCormick. It features Nissei’s new, silent-running X Pump, which combines a servomotor with a conventional hydraulic pump. Its X Pump uses 55% less oil and reportedly reduces energy consumption 40% vs. more conventional hydraulic pumps. The X Pump also makes cooling water virtually unnecessary, according to the company.

Nissei’s FNX machines are engineered to provide excellent resolution and reproducibility in the low-velocity/low-pressure range, and to cost less than all-electrics.

New machine models

Wilmington Machinery will display its latest Lumina LP structural plastics press, with platen sizes up to 110 by 200 inches and shot sizes up to 300 lb. Luminas now feature the new Versafil independent nozzle control, designed to easily configure the press for sequential filling of large parts to increase strength, reduce weight, or to facilitate the running of multiple molds to reduce part costs. An improved five-cylinder clamping system allows the Lumina LP to convert easily from structural foam to gas-assist processing and its redesigned nozzles and access area reduces setup time for mold changes.

Wilmington also will give showgoers a sneak peek at its NextGen series of twin-platen hybrids, which can be equipped with single or dual shooters and FIFO two-stage injection. The NextGens are designed for molding large solid and foam parts up to 150 lb.

IML machines

Inmold labeled (IML) drinking glasses will run on a 99-ton Boy 90 A from Boy Machines. The press features increased platen space and the company’s Procan CT control. Demag will produce IML’ed containers and lids in a 165-ton El-Exis running Swiss-built family tooling. You’ll see a special-purpose robot simultaneously removing the finished containers and lids, and inserting the labels.

Husky hinted at showing an IML system at NPE 2006 in its preshow releases. If it’s anything like the system the company displayed at a recent European trade show, we’re all in for a treat. In a radically uncomplicated IML system, Husky’s 120-ton Hylectric H120 hybrid ran containers in a Husky valve-gated, two-cavity mold at that show every 2.3 seconds. Labels were delivered from an easily refillable, machine-mounted magazine rack. A cam-operated swing-chute unit inserted the labels into the mold, removed the finished parts, and transferred them to a stacking/counting unit. The automation was developed by Husky and SysTec Komplettsysteme GmbH (Bad Urach, Germany). And that cell can scale up to handle four-, six-, or eight-cavity molds.

Krauss-Maffei’s IML demo will be built around one of its high-speed C3 Sprinters—a 380-ton Model KM 380-2700-CE-AP, to be more precise. It will run 22-oz stadium cups decorated with 3D hologram labels in an eight-cavity mold. A high-performance robot will insert the labels, remove the decorated cups, and stack them for packaging.

The undisputed market leader in the IML world, Netstal, will run IML’ed 32-oz stadium cups in a fully automated cell built around its SynErgy 5000-5500E. The labels reportedly will have “animated” graphics, so you’d better leave some room for them in your show-goodies bag.

Multimolding machines

All-electric multimolding with LSR will be in the spotlight at Engel’s booth. A 110-ton Engel E-motion Combi US with a floor-space-saving LSR injection unit riding on top of a shooter running PBT will be shown.

Engel also will demonstrate its Glazemelt technology for the first time stateside on its two-platen Engel Duo 1650 Combi M U.S. press. The machine features an injection unit configuration designed to accommodate a multicomponent stack mold with or without a rotary unit. Two-color automotive sunroof panels will be molded on the Engel Duo at the show. If a rotary unit is used on a Duo, the second shooter is mounted behind the moving mold-mounting platen, and material is delivered from below, through the center stack.

More multimolding machines

Nissei’s multimolding model at NPE will be a 154-ton all-electric designated Elject DCE 140. Featuring Nissei’s new “double-flat” clamping mechanism, which is engineered to uniformly transmit clamping force to both mold faces, this press also is equipped with a high-torque mold rotation servomotor for faster cycling—the mold can open while it’s rotating, for instance.

A two-machine overmolding cell will be running at Toshiba Machine’s booth. Machine #1 will mold TP parts, which will be transferred by a high-precision Toshiba Scara robot to the second machine, where they will be overmolded with LSR. Both machines will be Toshiba’s new EC-NII Series all-electrics. They feature newly developed low-inertia injectors with high-performance/low-inertia servomotors designed for quick responsiveness and enhanced holding pressure performance regardless of sharp load fluctuations.

The cell also will feature Toshiba’s brand-new V30 control, with extended onboard mold setup memory, USB porting, and integrated remote control of auxiliaries.

High-speed machines

You’ll see high-precision medical parts running in 16-cavity tooling on Boy Machines’ 60.5-ton Boy 55 A, equipped with the company’s Procan CT control, a servoelectric screw drive, and eject-on-the-fly capabilities.

Engel will introduce us to 200- and 300-ton models in its new 1000-mm/sec Speed line of hydraulic toggles, which are capable of 1.1- to 2.2-second dry cycle times. Available from around 150-715 tons with or without electric screw drives, Speed machines are equipped with special frame-mounted guides that extend beyond the platen for handling big, heavy molds, with no direct play in the guiding from the tiebars. Also, their inline injection units are designed to reduce mass acceleration during injection, even if they do make the machines a little longer.

Netstal Machinery will display what company sources say is the “world’s largest PET system ever at a trade show.” Its 660-ton PET-Line 6000 press will run a 192-cavity preform mold capable of producing more than 90,000 high-quality preforms/hr.

Micromolding machines

Boy plans to micromold gears weighing just .0009g each in a two-cavity mold on its Boy 12A, a press equipped with a 12-mm-diameter screw unit—that’s right, 12 mm. Its design reportedly reduces dwell time 50% when compared to “larger” 14-mm plasticating units. A pneumatic parts handling system will transfer the gears into small glass containers mounted under the safety gate.

More must-see machines

Battenfeld will mold 2-cm-diameter POM double cogwheels in a four-cavity mold at 8-second cycles on a 25-ton Model HM 25/130. Boy Machines promises to introduce us to a new degree of insert molding versatility in the form of a 60-ton, all-vertical Boy 55 VV press equipped with a multiaxis robot directly mounted on its base. This self-contained cell, small enough to fit inline in a production line, will produce four different-sized encapsulated hex keys.

Using less space and 70% less energy, a single 550-ton Cincinnati Milacron Powerline NT550 all-electric press will manufacture assembled flowerpots with RFID labeling in an unattended cell—products that normally run on two hydraulic machines and are manually assembled. The Powerline will be equipped with a new 54-oz, direct-drive, reciprocating-screw injection unit designed to reduce noise and inertia. The new direct-drive shooter is equipped with a nozzle shutoff valve and an 80-mm/24:1 L/D ServTek feedscrew.

Finally, Rep Corp. will show you all an all-vertical reciprocating-screw press designed specifically to run TPV, TPR, and TPU. Backpressure control accuracies reportedly obviate the need for a shutoff nozzle.—CK

Automation

At NPE, the newest version of Automated Assemblies’ Raptor Vision Software adds simultaneous access of up to four cameras and displays current inspection and four failed inspections. Automated’s new Raptor 3000-HP high-performance, top-entry robot offers single and double vertical arm configurations for three-plate and stack molds. Dynamic Conveyor has a slew of new modules, features, and enhancements for its DynaCon modular conveyor system. A split belt simplifies viewing, labeling, printing, or bar code reading. And the Work Zone Module, built for the real world, uses 10-gauge stainless panels that can support a couple of techs and their tools.

The new PIAB Duraflex vacuum cups that EMI-EOAT added to its large line of cups, nippers, and grippers use a combo of stiff and flexible PUR so your EOAT can get a firm grip on curved or textured parts and keep them on as the robot moves.

Fanuc Robotics’ new industrial robot is made for efficient integration into painting systems. It features a hollow wrist and options for two motors on the outer arm for gear pumps. The Fanuc R-J3iC Robot control in the booth includes an integrated vision function.

Harvard Factory Automation (HFA) is showing its new U-slide, an under-press product chute to eliminate the traditional but aesthetically challenged cardboard-and-duct-tape solutions. It’s made to match the style and size of the molding machine.

The new fourth-generation Top IV Series sprue and parts picker from Hyrobotics has an improved control, CE certification. .7-second takeout cycle, and higher speed. Ask about the NPE free delivery offer in the United States.

Kuka Robotics will show you its new injection molding function package that will reduce engineering and install time when integrating an industrial robot into any IM from 100-6000 tons. It works with any Kuka robot used for part removal and is optimized for its KS shelf-mounted IM robots, which will also be at NPE.

Mac Automation’s new tray-filling and stacking system offers tray indexing as fast as 3 seconds and vertical stacking that saves floor space. Mac’s Airveyor System uses air to move parts, which Mac says is a comparatively low-cost solution.

Robotic Production Technology (RPT) has a brand-new, pre-engineered, plastics-specific router-trimming/knife-deflashing system. The RoboTrim RT-500 handles taller parts for added flexibility. The NPE system includes RPT’s new AccuTrim R-110 robot with a 6-second auto tool change option.

Sailor Automation is showing its newly developed Vibration Suppression Control technology that keeps even heavy payloads from shaking, especially in the unloading position. The air line connection of the new GEP end-ported gripper arm at SAS Automation is directly in line with the vacuum cup mounting, so it works with minimal clearance around the target area. Mounting can be clampable or by threaded shaft.

Amidst the broad line of Stäubli Robotics, take a peek at the compact TX 60 six-axis robot in a production cell insert molding Allen Keys. An identical system is running at Boy Machines, the two companies partnering on this one. Robot repeatability: .02 mm.

Wittmann’s new remedy for molders with the low-ceiling blues, the W 723 CS3 Series servo robots combine a telescopic-stroke vertical arm with fast part removal motions. Built for presses to 275 tons, they handle an 11-lb payload and need no external control cabinet. The control system can add internal I/Os for complex gripping or insertion.

Yushin America’s new SVR-B50 two-axis robot made for vertical machines to 150 tons will also do inserting for IMs to 50 tons. The traverse axis uses a two-stage slide mechanism that reduces the arm size and makes the robot compact overall. For you big kids, Yushin’s SXA-800III fast side-entry robot works with 450-850 tonners.—RN

Material handling

Acrison Inc.’s new 170 Series feeders are said to offer rapid total cleanout for fast changeover. And catch the global launch of the 407 Series weight-loss feeders that save space but can handle a broad range of difficult solids.

The new VacTrac Series 24/128 control at the AEC stand makes it easy to manage up to 24 vacuum conveying pumps, 128 loading stations, and 128 purge valves in a materials system joined by a DeviceNet distributed I/O network.

The new Autoload On-Spec OS-1 augurless feeder uses a stepper motor with a feed cylinder to ensure reliable, consistent material delivery to the machine at up to 55 lb/hr. Autoload’s new OS-B Gravimetric Feeder is said to cut waste and raise quality at a fraction the price of other loss-in-weight feeders.

Its new Color Xpert Color Feeder, says Comet Automation Systems, is the first entirely in stainless steel, including the easy-change screw and sleeve, and thus faster to clean. Comet will show its redesigned FCD Honeycomb dryer, smaller overall, including the control system.

Want ideas? Conair is showing products embodying ideas that solve problems. The new rotating desiccant wheel in Carousel Plus Dryers makes them 45% more energy efficient, more precise, and easier to maintain. The big idea in TrueBlend blenders could be higher throughputs, higher accuracy, or the simplified, more versatile control, but you may be happiest that they don’t leak pellets onto the floor.

The K-Tron Control Module (KCM) at the heart of the new generation of Smart Connex Feeder Controls integrates control and motor drive modules directly on the feeder, bringing the functionality of the two previous generations of controls into one compact housing that improves both flexibility and performance. K-Tron’s enhanced KT12 Micro Feeder is for rates down to 20 g/hr.

Maguire Products said it would significantly raise the throughput max of its weigh scale blender, and at NPE you will find MaxiBatch HT, which doses palletized materials at rates up to 10,000 lb/hr. That’s double Maguire’s next-largest Maxi-Batch. Hello high-throughput molders.

The focal point of Motan Inc.’s booth is ControlNet, an integrated suite of Ethernet-based controls that networks Motan’s LuxorNet (drying), GraviNet (blending), and MetroNet stand-alone control systems into a seamless unit. Motan says ControlNet already has momentum in North America.

Novatec has considerably upgraded its NovaDrier compressed air/membrane system. Filter elements now last a year, slashing maintenance and element replacement costs. And check the new Novatec Infra-Red Rotary Dryer/Crystallizer: Novatec says it uses less energy than desiccant PET systems.

Pelletron downsized its dedusting hardware but bumped up the performance. The new version is 50% shorter than its predecessor but has 100% more cleaning area than previously. Energy and air consumption are down, too.

Plastore’s new single gravimetric feeder, the Plasticolor GR System, uses a special algorithm to filter out vibrations and clamp movement so it can accurately feed free-flowing color and additives at the barrel throat. High-resolution speed control—.3-225 rpm—comes via a stepper motor.

Premier Pneumatics wants to help you with material separation when handling PVC fine powder, as well as with regrind, granulates, and even pellets. Its Series3 2400 PVC Receiver is its solution, a low-height unit pairing a cyclonic primary separator and an internal cartridge secondary separator with automatic air pulse cleaning.

Process Control Corp.’s new PF Series gravimetric powder blenders accurately meter and blend nonflowable with free-flowing powder, pellets, and/or regrind at rates from .2-3000 lb/hr. A round-to-trough area in the stainless feeder element promotes consistent mass flow.

The new Vortex HDP Slide Gate valve from Salina Vortex is designed for bin/silo discharge gates with high aeration and other tough applications. It isolates pressure to 5 bar, and won’t leak to the atmosphere or across the valve.

Sterling’s SDAP Series portable drying and conveying systems feature an integrated drying/conveying control interface, plus simple startup, shutdown, and parameter changes. The new smallest model in the SGBD gravimetric blender series features a stainless hopper, mixer bowl, and a safety system that shuts off air and power if the mixer door opens.

Thoreson McCosh centralized material drying systems now have preheaters on hopper air inlets so different resins can dry at different temps, plus Delta Temperature monitors on the air inlets that switch temperatu