NPE sneak previews & other news from Chicago Plastics Fair.

Last month's Chicago Plastics Fair held an abundance of new machinery introductions, many of which were upgrades of existing equipment. The spice of the show was all the talk of what will be introduced next year at NPE '94 in Chicago.

INJECTION MOLDING PRESSES

Newbury Industries Inc., Newbury, Ohio, is bringing out two new vertical presses. The company already has received bookings for its new 200-ton C-frame and 300-ton four-post vertical machines. Both machines utilize Barber-Colman MACO 4000 or 4100 programmable microprocessor-based controllers. The 200-ton C-frame, base priced at $130,000, can use both a horizontal shuttle table or a rotary table. The 300-ton machine is priced in the $180,000 range.

The most visible development for many injection presses at the Chicago show was new or upgraded computer controls. Boy Machines Inc., Exton, Pa., is introducing standard closed-loop controls for its 88- and 55-ton presses. Boy says the upgraded controls are now available at no additional cost. The units employ Mipronic-Plus microprocessor controller, which tracks SPC/SQC data and regulates speed, volume and injection pressures.

Updated controls also are featured on the JE-C5 line from JSW Plastics Machinery Inc., Santa Fe Springs, Calif. The |micro~PACS 5000 controller provides an integrated, single-screen display of all injection molding parameters. Processing setpoints previously had been available only on separate screen displays. The unit now also can print SPC data in English.

Niigata Engineering Co. (represented by Daiichi Jitsugyo America Inc., Elk Grove Village, Ill.) is offering its new A-4 Mitsubishi microprocessor controller on five models in its NE line (200 to 385 tons). The upgraded controls provide greater speed and reliability to hit processing setpoints. The A-4 serves as the central processing source, integrating various microprocessor "brains" that control individual molding parameters throughout the machine.

Two presses also have been upgraded by Niigata. The first, its "high-cycle" FS160S36ASE, features an upgraded pump and a new hydraulic circuit for clamp and nozzle pressures. Both upgrades are designed to shorten cycle times.

The second machine, model PS60E9ASE, features various safety improvements.

An upgraded control option also can be found on the full line of Vision 2000 vertical injection machines from PH Trueblood Corp., Columbus, Ohio. The Barber-Colman MACO 4000 controller is now available for molders seeking closed-loop and SPC capabilities. The standard control for the Vision line is the Allen-Bradley PLC 500.

An NPE preview was offered by Lucky-Goldstar International (America), Inc., Englewood Cliffs, N.J. The Korean-based firm plans to introduce a new H-Series 190-ton hydraulic press, a high-speed/high-precision unit with closed-loop computer controls. Goldstar also plans to bring out two new models in its EN standard precision-molding hydraulic series: a 390-ton press with closed-loop controls, and a 720-ton unit specifically designed for processing recycled resins.

Goldstar also recently introduced three large-tonnage hydraulic machines of 1100, 1450 and 2000 tons.

ROBOTS & HOT RUNNERS

A new three-axis, servo-drive robot, model TW 800 HM, was introduced by Star Automation Inc., Menomonee Falls, Wis. Designed to handle thin-walled parts from injection presses in the 150-220 ton range, it has a stationary ball screw that provides increased traversing speed for the robot carriage, Star says. The robot also features a new controller, known as the STEC-300M, which includes an integrated hand-held pendant.

Ventax Robot Inc., Ayr, Ont., rolled out its new VMR 3 series of two- and three-axis electric robots. The two models are designed for 100-400 ton injection machines. Linear bearings are standard for both models. The robots offer customized end-of-arm tooling for tasks such as trimming, fixturing, and degating. The robots are operated by a PLC, which can be linked to a PC and includes a hand-held pendant.

A recently introduced line of three-axis pneumatic robots was displayed by Ranger Automation Systems Inc., Shrewsbury, Mass. The pneumatic series complements Ranger's existing line of servo and electric robots. The RT pneumatic series is designed for injection presses from 50 to 4000 tons. The series has a modular design that facilitates upgrading, standard computer controls based on a commercially available microprocessor, and various end-of-arm tooling options.

And for hot-runner molding, Nissui Corp., East Lansing, Mich., showed a new line of nozzle-blockage detectors for the first time in the U.S. The system is based on Airtect Leak Monitors made by K-Tron International Ltd. in Dublin, Ireland. These use electro-pneumatic pressure sensors to detect nozzle blockage and sound an alarm. Airtect Single, for one nozzle runner, costs $595; Airtect Multiple, with eight sensor points for multiples of eight nozzles, costs 81800.

NEWS IN BLOW MOLDING

Cincinnati Milacron Plastics Machinery Systems, Cincinnati, released specification sheets on the first of its "T" series of accumulator-head blow molders. Milacron has talked about these machines for a year. They will be displayed publicly for the first time at NPE '94.

The first six models--T1100, T1100W, T2000, T2000W, T3000 and T3000W--have modular, flexible layouts. "W" signifies a wide configuration with platens rotated 90 |degrees~ from vertical to horizontal position to provide room for more cavities. All T-series machines use Milacron's Apex brushless d-c driven extruders, and Cyclone accumulator heads. The latter come in sizes of 3, 5, 6, 9, 15, 20 and 30 liters, with 60 liters still to come. The machines have Milacron BEL electroluminescent controls for parison programming and machine sequencing.

Machine designations indicate the metric damp tonnage: T1100, 110 metric tons (125 U.S. tons); T2000, 200 metric tons (220 U.S.); and T3000, 300 metric (330 U.S.) tons. Both T1100 models have 71 in. of mold daylight, 40-in. platen stroke, and 50 x 62 in. platens. The wide platen has 30-in. center distance to accommodate dual 9-liter heads. The vertical platen handles a single 30-liter head.

T2000 models have 82.5 in. of daylight; 51-in. platen stroke; and 60 x 82.5 in. platens. Wide platens fit dual 15-liter heads, vertical platens a single 60-liter head. T3000 models have 82.5 in. of daylight; 51-in. platen stroke and 72 x 82.5 in. platens. Wide platens have 40-in. center distance for up to dual 20-liter heads. Vertical platens will handle a single 60-liter head. Model T1100W is expected to cost about $550,000 with two 9-liter heads.

THERMOFORMING TRIMMER 

Thermwood Corp., Dale, Ind., showed a dramatically streamlined and inexpensive new five-axis trimmer/router. Model 67, with a double-ended head, is the same size and performs virtually the same functions (including 360 |degrees~ trimming) as Thermwood's previous Model 75. It is a top-to-bottom re-engineering of the earlier model, replacing many previously outsourced parts with less expensive designs produced by Thermwood including a redesigned overhead powertrack. Model 67 costs $114,000 vs. 8150,000 for the Model 75.

NEWS IN EXTRUSION

HPM Corp., Mount Gilead, Ohio, revived the venerable Prodex name for a new line of single-screw extruders. Five models of 2, 2 1/2, 3 1/2, 4 1/2, and 6 in. are designed especially for profiles, as well as pipe and tubing. Features include brushless d-c motors, bimetallic barrels, modular control cabinets, and 24:1 standard L/D, with 30:1 also available in the two largest models. Machines are prewired for additional options, such as extra die zones, digital melt pressure, and remote motor-speed control.

Conair Gatto, Bay City, Mich., div. of the Conair Group, showed the first example of a patent-pending, "high-tech" vacuum tank for special small-diameter tubing--e.g., medical and shrink tubing, fiber-optic jacketing and reinforced pressure hose. Model HT104-9.5-4 is an upgraded and redesigned 9.5-ft long vacuum cooling tank. Specially designed for sticky resins, it draws profiles over self-lubricating sizing rolls made of glass-filled fluoropolymer. More precise positioning of the tank is said to be possible with a refined gear-and-piston movement. The tanks cost about 822,000 depending on options.

Conair also showed a new line of digital d-c driven takeoffs. Series 2000 Cat-a-Pullers with keypad speed controls and LED readout come in a range of capacities.

G.F. Goodman & Son Inc., Warminster, Pa., unveiled its upgraded, redesigned MED/1000S medical tubing cutter designed for small-diameter (0.015-0.25 in.), flexible and semirigid PVC, PE, urethane, silicone, or fluoropolymer tubing. It has a redesigned, shorter belt for more accurate feeding. The compact design minimizes material drag, deflection and jams. The machine is designed to be compatible with clean-room medical environments, line speeds up to 300 ft/min, and cycle rates up to 1000 cuts/min.

Another redesigned unit from Goodman is the Model 2BXT medical bump/bubble tubing puller. A newly designed "Synchro-Pull" double-side timing-belt drive train helps eliminate backlash, improve accuracy and increase line speed. An improved touch screen controller reportedly offers simplified commands and easy transition from continuous to bump-tube operation.

Killion Extruders Inc., Cedar Grove, N.J., introduced a new die head for multilayer profiles. So new it hasn't a name yet, this die design is unusual for having a removable core cylinder, which allows conversion from three layers (ABA) to two or one layer. Although removable core cylinders are common on small dies used for laboratory or small-scale production work, Killion believes it has built the first larger size--for a 2 1/2-in. extruder.

NEWS IN RECYCLING

Processing Technologies Inc., Addison, Ill., displayed for the first time a Trident Series Model 4500 extrusion pelletizing system for reprocessing film, foam or rigid plastics. (The show model was sold to reprocess PS foam.) The system costs about $200,000.

PTI is also installing a new patent-pending, 5000-lb/hr (30-million-lb/yr) turnkey film recycling line for Carlisle Plastics Inc., Minneapolis, scheduled to start up this month. That line has conveyors, hydraulic shredder, ferrous and nonferrous metal detection, 8-in. extruder with pneumatic stuffer ram, back-flushing screenchanger, and water-ring pelletizer.

Modern Machinery of Beaverton Inc., Beaverton, Mich., showed photos of its smallest cryogenic recycling line, a Cryoclean 1000 for 1500 lb/hr. The machine, which Modern Machinery ran in-house for over a year, was just installed at Cyber Plastics Industries Ltd. in Beaverton. Modern Machinery has previously sold 2000-lb/hr Cryo-Clean 2000 models.

Kice Industries Inc., Wichita, Kans., is field-testing a new model of its heavy, multi-duty aspirator/deduster, which will for the first time have static eliminators on the air-intake slots. De-ionized air streams pass through plastic flakes or pellets to remove dust and fines, which cling with any static charge. The new version will be shown for the first time at NPE '94.

CIM ALLIANCE

IQ Management Systems Inc., Ontario, Calif., and RJG Technologies Inc., Traverse City, Mich., have married their respective software and hardware products into a new CIM offering. The two companies collaborated on a joint installation of RJG machine data-collection units and IQ/Genesis software at an injection molding company last July, and decided to offer their products together as an integrated system. RJG's DART (Data Acquisition Retrieval for Transducers) units gather machine data on each cycle, then pass it on to the PC-based IQ/Genesis Plant Management System, where job scheduling, production statistics, SPC data, and other process and production data are graphically displayed with colored screens. (The full IQ/Genesis package includes MRP, quoting, inventory, order entry, payroll, and accounting functions.) Trade name and pricing of the new CIM product are being worked out, but the cost should be less than buying the two products separately.

Barco NV of Belgium (represented by Barco Automation Inc., Charlotte, N.C.) showed a new, less expensive version of its Dextralog machine monitor. The new Graphics Data unit still displays production cycles and lets operators enter scrap and downtime data. Functionality is virtually the same as Dextralog's original, but it costs only $3000 vs. $4500 for its predecessor.

LOTS OF NEWS IN AUXILIARY EQUIPMENT

Nippondenso of Los Angeles Inc. in Long Beach, Calif., brought its MovinCool portable air conditioners to their first plastics show. The space coolers blast cold air through large hoses to cool parts, molds or operators. Part cooling can prevent warpage, while blanketing mold areas of presses with cold, dry air prevents condensation. Space coolers come in six sizes from 10,000 to 60,000 Btu/hr. All are UL-rated. Industrial model 15SFU, with 1.5-hp compressor, runs in ambient temperatures up to 104 F. Model 20HFU, with a 2-hp compressor, works at up to 113 F ambient. Model 15SFU costs $3200; 20HFU costs $3900.

Sterling Inc., Milwaukee, introduced its newly redesigned Sterlco high-temperature, hot-oil mold-temperature controller. The unit has a choice of digital solid-state or microprocessor controller, simplified piping design, two-pass oil tank, optional drop-in heat exchanger with replaceable bundles, positive-displacement mechanical-seal pump, and a variety of ergonomic improvements.

Simco Co. Inc., Hatfield, Pa. introduced a new ionizing air blower. Aero-stat Sentry ion emitter covers a 3 x 6 ft area and can be bench or pedestal mounted to treat sheet, profiles or 3-D parts on a conveyor. It costs $695. Simco also showed a hand-held anti-static gun. The Cobra Static Neutralizing Blow-Off Gun ($495) is a heavy-duty portable ionizer to blow dust and dirt off molded parts.

Nissui introduced a new double version of its Scutter granulator to grind larger parts. Like the original Scutter for sprues and runners, the Double-Scutter has large "S"-shaped cutters that break up parts into chunks that smaller teeth can then bite into uniform size without screening (photo, p. 19). Cutting chamber and cutters are imported from Nissui Ltd. in Japan, while motor, hopper, bases and electricals are built here.

A new line of mid-size granulators for injection and blow molding was introduced by Rapid Granulator, Inc., Rockford, Ill. The SR Series has a staggered rotor design with cassette knives that require no adjustment or resharpening. Low rotor speed (190 rpm) and insulated sound enclosure help minimize noise. Units come with 6 x 6, 6 x 9, and 6 x 11 in. feed openings, tangentially fed cutting chambers, and Allen-Bradley starters.

Cumberland Engineering div. of John Brown Plastics Machinery, South Attleboro, Mass., introduced a new intermediate-size granulator with a wide-throat configuration, targeting bulky injection molded parts and scrap. The new 18 x 24 model in the A series offers an 18 x 24 in. feed throat with flexibility for either hand or conveyor feeding and 30-50 hp motors. It costs $24,800.

Dynamic Conveyor Corp., Muskegon, Mich., showed a new wet-table conveyor suitable for water-bath applications or for easy washing down. The new option mounts all electricals outside the conveyor trough on an external plate for easy disconnecting. The wet conveyor option costs about 8300 more than corresponding dry conveyors.

Colourmate Inc., Woodbridge, Ont., showed a filterless, screenless hopper loader. Instead of having in-hop-per filters that plug up or need cleaning with color changes, the new FL-110 loader uses a bell-shaped cyclone in the hopper and a remote power unit with its own dual-cyclone separation and motor protection filter. Thus, the only filter maintenance required is on a more easily accessible component. The loader costs $1450.

Whitlock/AEC Inc., Wood Dale, Ill., showed a new microprocessor-based control system for vacuum conveying to as many as eight hoppers with one pump. The new VacTrac & Station Smart Control can program each station individually based on either filling time or volume. VacTrac 8 controls cost about $1100.

HydReclaim Corp., Fenton, Mich., introduced a new soundproof (78-80 dbA) central vacuum system. Whisper-Vac VP-5 has a soundproof vacuum motor (3-30 hp standard), microprocessor control, RS485 remote-control panel and sound enclosure. It costs about $6500.

Whitlock/AEC also introduced a machine-mounted SBB Small Batch Blender for up to 500 lb/hr of as many as four components. It's said to be unaffected by varying bulk densities, with total accuracy of 0.25% or better. It can handle proportions of individual components as small as 0.1%.

A new batch blender from Mould-Tek Industries Inc., Scarborough, Ontario, Canada, the GXB-4, features capacity of up to 4000 lb with as many as eight material bins. New microprocessor-based controls offer SPC capabilities as well as an RS232 port linking it with a PC.

INTRODUCTIONS IN PRINTING & DECORATING

Markem Corp., Keene, N.H., showed two all-electronic pad printers for the first time. Models 590 and GTS 1500 (Gantry Transfer System) both offer closed-cup inking and keyboard setup. The small 590 machine has a 2 x 4 in. touchscreen display and can change jobs in seconds by recalling setups from memory. It costs under $12,000. The large GTS 1500 has six ink reservoirs and four rotating, x-y print heads, each with eight faces--accommodating a total of 32 images in six colors. An integrated gantry robot operates the rotary tool holding the pads, providing capability for multicolor, multi-legend and multi-plane printing. Parts can be fixtured either in-line or on a rotary table. Computer controls operate the system and store job routines. GTS 1500 costs $100,000-250,000 depending on complexity and parts-handling options.

Reisch & Associates, Westmont, Ill., showed a new small pad printer with semi-enclosed ink tray, which is roughly two-thirds the price of its previous smallest model. The electro-pneumatic model is operated by foot pedal. It has a 3 x 3 in. print area and costs $3900.

United Silicone Inc., Lancaster, N.Y., displayed its new Model 2000 MkII hot-stamp/label press. United Silicone is the North American representative for Newfoil Machines Ltd. in England. Model 2000 performs overlaminating, die cutting and rewinding all on one pass. Another new machine, the Model 5000, with two stamp heads and one die cutter, will be introduced in the U.S. early next year.

ADVANCED WELDING CONTROL

A new controller offering advanced in-process amplitude profiling capabilities was brought out by Branson Ultrasonics Corp., Danbury, Conn. The WPC-1 weld profile controller works in conjunction with the company's recently introduced Model 920MA power supply to provide closed-loop amplitude control. The controller reacts to feedback during different phases of the weld cycle and changes amplitude instantaneously to minimize flash and enhance weld quality.

The WPC-1 can also be programmed to switch between two levels of amplitude "on the fly" during a cycle, triggered by a specified time, power, or energy level. For example, reducing amplitude toward the end of a weld may reduce flash, prevent ruptures or "diaphragmming" in delicate applications that involve fine membranes, and eliminate "ring-down" or residual horn vibration after weld time is completed. The WPC-1 controller also monitors the process and displays real-time information on amplitude, operating frequency, and setpoint frequency, which can be useful for diagnostic purposes.

Branson also introduced the ergonomically designed "Ergo Base" for a wide range of welding models, which features side-mounted palm buttons with lower activation force.

New software for ultrasonic welding controls was highlighted by Dukane Corp., St. Charles, Ill. The company announced the release of Version 3.0 software for its Ultra-Com process controller, which provides enhanced capability for setup sequencing, process-data outputs for SPC, and pressure regulation. A new continuous welding mode enables the Ultra-Com to monitor continuous and scan welding applications. The software enables users to download welding programs from a PC.

NON-SOLVENT MOLD SPRAYS

Zip-Chem Products, San Jose, Calif., showed a new line of aerosol mold releases, cleaners, and corrosion inhibitors that have been reformulated without solvents like methylene chloride or ozone-depleting chemicals like HCFC-22. Now, the company uses EPA-sanctioned chemicals, including orange-peel-based cleaners. (Molders take note: After the 11th of this month, companies using any CFCs or HCFCs in their processes will have to print warning labels either on their products or shipping containers, depending on the type of ozone depleter.)

Zip-Chem's new NS (non solvent) corrosion inhibitors and mold releases are said to behave just like the old CFC and HCFC formulations But NS spray cleaners (formerly based on methylene chloride) require different procedures. "You have to spray, wait 30 seconds, maybe spray once more, then wipe," Zip-Chem says. Zip-Chem's NS cleaners cost about 30% more than the solvent formulations.

Percy Harms Corp., Wheeling, Ill., another maker of aerosol chemical sprays, has converted some products to non-ozone-depleting formulations, including new Quick II silicone, paintable, and lecithin-type mold releases. Quick II silicone spray costs $57.07/case vs. $34.23 for the HCFC-141B formulation.

Another new product from Percy Harms is "Improve," a hand-touch-up spray to hide blemishes like shiny streaks on matte-finish styrenic parts by slightly etching their surfaces. Improve aerosols cost $35/case.