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Total machine control systems.


Using an open-architecture approach, components of Modcell Advanced Systems are designed to be integrated with each other, as well as with other types of processing equipment. New Modcell Batchpac software provides users with a structured, step-by-step graphical approach for process-control implementation, which includes observing the process in real time, entering input values and commands, acknowledging alarms, and changing control variables. Software guides users through eight steps logically and intuitively to get systems up and running.


Offers a "single-window" extrusion process and product control system, with the flexibility of a field-proven distributed control system combined with AccuRay sensor technology. Through use of the Taylor MOD 300 system, all sensor and scanning functions required for product control are accomplished in one easy-to-configure system. Line-wide control, using AccuRay sensors and measurement technology, combined with Taylor advanced distributed-control expertise, provide an integrated system for extrusion. Coordination of line-wide processing functions, such as recipe management, resin handling, temperature control, motor-drive coordination, and product control, are all integrated into one expandable platform.


Provides a comprehensive injection molding control system combining process control, sequential control, and graphic operator interface. Two products make the system possible--the 1771-QDC plastic molding module and Pro-Set 600 injection molding software. Plastic molding module is an intelligent I/O module that performs open- or closed-loop injection process control and is used with company's standard programmable controllers. Adaptable to a wide range of applications, module enables users to configure an injection process-control system for a one- or two-valve system; proportional or servo valves; open- or closed-loop control for each cycle phase; injection/fill control-mode choices of velocity vs. position, pressure vs. position, and pressure vs. time; inject, pack and hold, and plastication phase profiles of ten steps each.

Pro-Set 600 injection molding software configures a standard Allen-Bradley PLC-5/40 controller and color CRT as an injection molding total machine control system. Process control, communication, and SQC data gathering are some features of the system. Pro-Set 600 software can save engineers development time by providing ladder-logic program for injection process control, clamp control, barrel-temperature control, and mold-temperature control, as well as alarming, SPC/SQC data collection, and other functions. It is designed specifically for company's Panel View color CRT and works as a system with PLC-5/40 programmable controllers and 1771-QDC plastic molding modules.


Offers multiple-loop control systems for thermoforming, extrusion, injection molding and other machines. Control-mixed inputs include temperature, pressure, flow, and drive speed. Controllers operate as standalone systems and include serial interface for computer supervision. IBM-PC high-level software is offered, which includes on-line data plot-ring, data acquisition, graphics, and some SPC functions. Systems are offered to end users and OEM machinery manufacturers. Controllers include:

* 12LS--1/8-DIN with 12 PID heat/cool loops.

* 8LS--1/4-DIN with 8 PID heat/cool and mixed process loops.

* System 32--Thirty-two PID loops and up to 96 data-acquisition inputs. Systems can include automatic heater checking, process and deviation alarms, and ramp-and-soak programming. Digital inputs and outputs provide control of other machine functions.


MACO 8000 provides total machine control for injection, extrusion, blow molding, or most any plastics or related process. Features include new Lumitech flatscreen, High-Tech Color-Touch or black and white touchscreen operator stations, Insta-Set solid-state cartridges for recipe storage and fast setup, MACO-Pac dedicated machine-function control modules and Auxiliary Equipment Integration Module (AEIM) for manufacturing-cell control. An SPC/SQC module gathers and reports production data, and provides CIM communications networking capabilities.

For supervisory CIM, multiple MACO 8000 systems can be linked to company's Cimac 8000 industrial-hardened computer for factory-floor use. Cimac 8000 is a supervisory network control system concept utilizing IBM-compatible computers and specialized data-gathering software for plastics applications.

Applications startup is provided to meet particular requirements of user. Software is user-configurable so that modifications to company's generated screens, or screen packages using color and mouse-driven graphics, can be made by the user.

MACO 4000 series control system for injection molding is less expensive and more compact than MACO 8000. Unit has a Lumitech flush-mountable, electro-luminescent operator station measuring 11 in. wide, 15.5 in. high and 3 in. deep. Circuit cards for all control functions fit in the sheet-metal enclosure. Six zones of full PID autotuning temperature control are standard. Process control includes ramping and closed-loop control of injection pressure or velocity, pack, hold, and backpressure, and cushion. Communication capabilities include RS485, RS432, printer port, and MACO-Net. An internal SPC package is also available. Operator-station display screens can be user modified, and new screens can be created with optional OptiGrafix software package designed for IBM and compatible PCs. New screens are downloaded from computer to MACO 4000.

MACO 4100 has the same control capability as MACO 4000 for injection molding. Unlike the Lumitech display on MACO 4000, MACO 4100 features a 320 x 200 pixel backlit LCD operator station with a 25-line by 40-character readout. With a 20% lower cost than MACO 4000, MACO 4100 is suitable where minimal operator/machine interface is needed or where cost is a main consideration.

MACO 5000 series is an extrusion control system patterned after MACO 4000. It features a control unit and Lumitech flat-panel operator station and is suitable for open- or closed-loop extruder total machine control applications, including drive, pressure, temperature and cascade control of downstream takeoff equipment. Automatic-tuning PID temperature control with ramping capability is standard on each control zone. Standard operator-station screen set is included for basic application and can be modified, or new screens created, with OptiGrafix screen-editor software package designed for IBM and compatible PCs. Optional SPC software, which includes trending, is available for use with MACO 5000 series.

MACO 6000 series, a high-performance blow molding machine control system targeted at process-critical blow molding applications, is patterned after MACO 4000 and 5000 series. The high-speed, multistepped parison control can be used for closed-loop control of up to eight heads on machine. Each of the loops is closed every 100 microseconds and may have its own unique 100-step profile. As many of the 100 steps as desired can be entered, then allowing the system to interpolate the remaining points either in a flat linear or hyperbolic fashion. A 16-slot control-card chassis is standard, and a multiple-chassis capability provides control for larger machines requiring additional temperature, inputs/outputs, timer counters, parison control, linear-positioning control, and pressure-flow control. A built-in math feature also available.


Supplies custom total machine control systems. Capabilities include cost-effective heat/cool autotune PID control, communications and user-alterable logic (sequence) control. Applications include presses, small injection machines, hot-stamp machines and special plastics processing machines. Non-Recurring Engineering (NRE) costs are minimized by an extensive library of existing functions.


Provides a family of microprocessor-based total machine controls for machinery applications, which include injection molding, RIM, extrusion blow molding, reheat blow molding, thermoforming, and extrusion.

Depending on application, features of controls include: electroluminescent or LCD operator displays, high-speed event detection for real-time response, high-density/high-power digital I/O, analog I/O, closed-loop control, alarm and fault detection and display, on-board diagnostics, Multibus or ISA bus architecture, 386 microprocessors, DOS platform, plotting and graphics, real-time clock, soft keys, printer output, and auxiliary-equipment interface. Controls are programmed with Mechanism Control Language (MCL), which offers complex logical and mathematical functions and English-language words and abbreviations. Ladder Diagram Programming (LDP) is also available.


Offers PLC-based EPIC II color touch-screen operator interface and supervisory control system. Features patented dual-thermocouple control, responsive closed-loop line control with a user-friendly graphical interface with pictorial control screens, historical trending, SPC/SQC and other capabilities.


Remanufactures and converts injection molding machinery and will retrofit machine control systems to upgrade both electrical and hydraulic systems to meet molding requirements for standardization of all makes and models of machinery. Offers E-1000 programmable control system, E-1000 system for machines to 1000 tons when closed-loop process control is required, and E-8000 for machines requiting unlimited I/Os for auxiliary-equipment integration, closed-loop process control, and other features.


EM-2 Extrusion Master complete extrusion control system is based on totally distributed architecture, which ensures minimum downtime. System integrates temperature control, melt-pressure control, melt-pump control, alarms and interlocks into a single package, which also can supervise other equipment such as gauges, feeders and drives. A variety of standard operator stations available for easy access to all process data, alarm information, diagnostics and recipes.

Integrated with EuroLink supervisory computer system, sophisticated trend analysis, recipe structures, as well as SPC and SQC process analysis, can be supplied.


Extrusion Quality Cell system, a pre-engineered measurement and control system for fiat die extrusion combines accurate on-line profile measurements, precise feedback control, and a tool set for meeting certification requirements. Extruder and melt-flow modeling, combined with automatic profile control for extrusion dies, provides fast startups and uniform steady-state profiles. DataCell interface toolkit allows Quality Cell to be easily integrated into linewide and plantwide control strategies using TCP/IP communications.

Cimline is a real-time process management system for sheet, film, and roll. Provides accurate on-line measurements, advanced control strategies, and true single-window operation of the entire process area. Available measurements include thickness, weight, moisture, and discrete coextrusion layers. Also pre-engineered supervisory interface packages for PLC, temperature, and drive controls. Industry-standard X Window System graphics provide fully interactive real-time display access from networked PCs and workstations, allowing line conditions to be monitored from remote locations.


Dataline 2000 microprocessor extrusion line control system has all preprogrammed software, hard-disk drive and memory, and capacity to control 52 zones designated as heat/cool or heat only. Up to 500 recipes and/or profiles can be stored and recalled at will. Particularly useful for blown film coextrusion applications are CRT monitoring of die-zone heating with setpoint, actual and deviation display, melt temperature, melt pressure, extruder screw rpm, extruder motor amperage, main line speed, as well as die-zone amperage and a high-and low-pressure alarm. System has large expansion potential.


For extrusion control Fisher-Rosemount offers its RTM/1 Real-Time Process Management Solutions hardware/software, which include:

* Continuous control of temperatures, pressures and speeds.

* Batch control for batch blending and processing of resins.

* Sequential control for routines such as automatic startups and product changeover.

Discrete control for resin handling, motor start/stop, and solenoid valves.

* Process optimization.


GE Alphix plastic process-control system offers an improved level of integrated control for injection molding machines, extrusion lines, blow molding, and compounding. Hosted on a high-speed programmable-controller (PLC)-based platform with dedicated microprocessor-controlled function modules, Alphix integrates sophisticated closed-loop process-control capabilities with machine sequencing and a color operator interface. This provides advantages normally associated with a PLC-based system: flexibility, broad selection of I/O, industrialized hardware, maintenance-friendly software; and the sophistication of special-function modules designed specifically for plastic and rubber process control. High-efficiency structured hardware and software modules are used throughout the system.

Alphix offers a choice of two color operator interface systems: the 12-in. Basic Alphix operator terminal with soft function-key control; and the 14- or 19-in. Advanced Alphix workstation, a multi-tasking microcomputer system, which brings a significant level of data storage/display/analysis, SQC/SPC, and diagnostic capabilities.

Alphix systems are available for both new machines and as fully installed retrofits, and offer both the OEM/retrofitter and the end user better control of machine and process.


Distributed Control system for extrusion. Microprocessor-based Digipanel controller is mounted on extruder and provides total control of line, including temperature, using company's three-mode Duosense control loops and Digisynch digital control and synchronization of rpm. Tube-Trol, Sheetrol, or Pipe-Trol systems provide closed-loop control of melt pressure and melt temperature, monitoring and alarm of differential pressure across the screen, and closed-loop control of product dimensions. A Central Control and Manage ment Console oversees all implant activity. It has total SQC and "Time Machine" capability, which allows reconstruction of any parameter on any line for the previous week.


New and aftermarket electronic control systems are capable of data collection, SPC, SQC, trending, and other applications. Company can tailor systems for any type of extrusion and other plastic processing lines, and continues to expand its offering of electrical retrofit packages.

HES temperature controller utilizes a patented dual-thermocouple design to maintain precise temperature control in critical production processes. System that uses two thermocouples in each barrel zone: With one thermocouple located in the heater/cooler and the other at the deepest point of the barrel, corrective heating or cooling action can be taken to bring the inner barrel surface temperature to stability quickly, and is done automatically with no adjustments required. In addition, its recipe feature reduces the amount of scrap manufactured during startup and grade-change operations.

HES Epic I graphical touchscreen supervisory-control system has the ability to collect data from each manufacturing run for analysis and review. Operator has access to almost all process data on a line, which can be monitored and trended on unit's CRT, making it possible to efficiently fine-tune the entire process from the workstation. Epic enables troubleshooting of alarm conditions, capturing data related to all process conditions. Controls have touchscreen simplicity and "at-a-glance" feedback on all process functions. Statistical Process Control (SPC) charts (X,R) of process data are displayed and documented for statistical quality control.


Offers a control system for injection molding based on IBM's OS/2 software.


Provides a complete on-machine control system for injection molding. DAC-III system includes machine-mounted terminals, sensors, and appropriate valves. Process-control programs with equipment include injector-control, pressure-control, shot-control, diagnostic, and process-monitor programs.

Injection-control program is a self-adaptive, closed-loop position control of the injection ram, which ensures precise shot and decompression control. Injection velocity profile is adaptively distributed over the shot in direct relationship to cavity filling.

Pressure-control program is a self-adaptive, closed-loop pressure control, which ensures precise repeatability over a range of oil temperatures and load vibrations. Provides faster startups and repeatability of subsequent setups.

Shot-control program is an intelligent three-mode boost-cutoff program, which ensures that boost is properly terminated even if melt conditions or mold temperatures change. Program automatically selects the proper mode for boost-cutoff and shot correction.

DAC-III diagnostic program provides maintenance personnel with a sophisticated, easy-to-use instrument to visualize correct functioning of the system to machine interface, as well as correct calibration of all sensors and servo valve connected to machine.


Offers the Smarthopper system for gravimetric extruder output control. System provides screw-speed control for extruders and additive feeders, as well as pullet speed for total yield control. Multiple-feeder systems and multiple-extruder systems are controlled through a special communication link. For a single-ingredient system a master/slave relationship is established to control a line to the common recipe. These communication and control features are offered as options.

There are three keyboard selectable-control variations to choose from, each maintaining an extruder's output weight to within [+ or -]5%--lb/hr via screw speed control, lb/ft via screw speed control, and lb/ft via line speed control. Process information, such as total pounds used and total feet produced are available on controller display, or can be printed. Smarthoppers range in output from under 2 lb/hr for feeders to over 12,000 lb/hr for extruders. System meets SPI protocol specifications for communication with a host control system.


Profitmaster line of extrusion process-control systems includes measurement and feedback control of thickness or basis weight, or moisture for web processing lines such as extruders, coaters, calenders, nonwoven, or composite. Primary sensors include radiation type, infrared, microwave and caliper. On-line control systems can link to temperature controllers and PLCs and other systems. SPC is available and IBM-compatible PC captures MIS data and links to plantwide network systems of all types.


Offers complete line of extrusion process-control systems for small lines to multiline applications, providing closed-loop control of all process and product parameters.

Sentry Pro 1000 provides complete control and monitoring for small lines. Suitable for pipe, profile, tubing and single extruders, system features operator interface with menu-driven touchscreen and optional real-time trending, along with melt-pump control interface.

Larger lines can be controlled and monitored by Command Sentry 1500, which offers a high-resolution, menu-driven color touchscreen featuring four-quadrant display that provides information at a touch. Housed in a free-standing NEMA-12 enclosure, system provides real-time trending as standard. Options include real-time SQC charting, melt-pump interface, and sheet/film gauge inspection capabilities.

Sentry 2000 process-control system provides complete control and monitoring of multiple extruders, multiple lines and large process applications from silo to wind-up. It features operator interface with touchscreen for menu-driven command input and separate screen for data and graphics, allowing user to view real-time trending and SQC charting.

Sentry Master 3000 Extrusion Host system works with firm's other control systems, providing off-line automated data capture and historical analysis of all process and product parameters with multiline and networking capabilities.

All control systems come standard with full closed-loop, digital speed control; temperature control; and total line process control, including product-code recipe subsystem, security codes, strategy-loop system, cold-start protection, alarm functions, PID loop control, and failed or broken thermocouple override.


MXOpen Measurement and Control System (MCS) provides a fully integrated solution for control of fines producing sheet, film, and coated and laminated products. System encompasses temperature controls, drive-system supervision, thickness profile, other scanning measurements, and automatic startup and shutdown of line material handling. The operator console accesses all information and necessary control, and provides a single interface for information such as scanning measurement, process data, trending and current process values, and complete SPC/SQC charting, recipe storage and editing for product and process.

MXOpen MCS is compatible with most programmable controls, drives, etc., and includes communication links to programmable controllers, temperature controllers, PCs, drive systems, individual transactional computers and industry-standard networks.

Inspection of 100% of the web for visual defects is offered by the Roibox product line. The extension of MXOpen capability into web inspection offers a solution for quality optimization.


Offers system controls and control panels for manufacturing polyurethane products. Equipment includes vertical or slope-faced control panels, which include a programmable logic controller and microprocessor. Panels include all controls for foam metering equipment and can include controls for auxiliary equipment such as turntables or fixtures. Additional controls and functions may be added, including support programs to aid operating personnel.


Offers total machine control systems for injection molding and extrusion blow molding. Systems handle any machine configuration and are easy to set up and operate. Features include simple sequence-logic programming that reduces required engineering to apply a new control system, simple screen layout that saves operator training and set-up time, and one-screen programming that allows for fast changes without paging through many screens.

Mopac 22 injection control system provides closed-loop control of fill speed, packing, holding, backpressures, and shot volume. As a microprocessor-based control, Mopac 22 allows for precise setpoint entry, storage of setups for fast and easy starraps, monitoring and display of important process variables, part sorting, reporting of production and rejects, communications for networking, and optional temperature control.

All Mopac 22s can be connected to company's MopacNet to provide a complete shop-floor monitoring network.

Moog-Buhl Gravimacs system enables continuous measurement and control of extruder feed. System is based on gravimetric loss-in-weight principle, and extruder speed can be automatically adjusted for desired weight/hr (or weight/length) as set in the controller. Gravimacs reportedly offers rapid, automatic response to process variations that saves wasted material and setup time while improving product quality and consistency.

Moog-Buhl PPC Ultrasonic Measurement & Control System provides a continuous, 360[degrees] thickness profile display that provides ready reference for die-centering setup, typically on wire or pipe extruder lines. Alarms signal changes in the process that affect material thickness and prevent accumulation of bad product. System provides improved product quality, materials savings, reduced scrap and SQC quality documentation, according to company.


Offers the 2010 computer control system for blow molding and most other processes. System comes custom-packaged and programmed and includes panel design, control programming and documentation. System can control up to eight axes of closed-loop servo motion and all necessary digital and analog I/O requirements. Electroluminescent screen, remote control-panel capability, membrane,switch full-function keypad, and status and error messages ease in machine control and troubleshooting.


Now McNeil & NRM Inc.


CIM strategy covers process knowledge in plastics extrusion, PLC programming expertise, PC network expertise, touchscreen graphics, color-graphics monitoring, recipe management, inventory control, major/minor ingredient blending for liquids and solids, historical trending, SPC/SQC data requisition, diagnostics, engineering/design of software packages, field installation crews, complete startup assistance, training, comprehensive and straightforward documentation, and operator and trouble-shooting manuals.

Control system incorporates integration and visibility through multi-windowing user-interface software. Multi-windowing operations on multitasking processors allow users to perform more than one activity at a time by viewing entirely different areas of the same manufacturing line.


Gravitrol gravimetric extrusion control system is designed to control output of any extrusion line by weight. Gravitrol systems are used on coextrusion processes such as blown film, cast film, sheet, tube, pipe, profile, and wire and cable coating. Layer percentages of [+ or -]0.25% by weight can be achieved and maintained on any extrusion line.

Custom-designed computer board on each weight hopper (mounted on the throat of extruder) calculates extruder mass throughput and sends information over a high-speed serial network to the central computer.

Central computer and user interface controls the extrusion process. Operator keys in layer percentages, total extruder throughput and weight per running length. Computer monitors mass throughput for each extruder and compares it to set rates. Any deviation is accounted for by adjusting rpm of screw.

Drive module for each extruder, designed to be mounted in an existing drive-controller cabinet, takes speed set-points from the central computer and provides analog output (0-10 v or 4-20 mA) necessary to drive extruder screw. Module also can monitor other analog signals such as melt temperature or pressure for recording or alarm purposes.

Line-speed monitor/control module can control line output (in fpm) to maintain constant weight per running length. High-speed pulse generator is used to provide the control computer with accurate measure of line speed.

Components are designed for maximum flexibility to control lines of one to eight extruders. Throughput rates of 5 to 10,000 lb/hr can be handled with accuracy of [+ or -]0.25%. Systems can be purchased with new lines, or retrofitted to existing lines.

Gravitrol also available as part of an integrated resin blending system.


Line of modular process control systems for plastic pipe production includes ultrasonic 360 [degrees] wall-thickness measurement, pullet control, cutter control, die-centering temperature control, extruder-output control, fully automatic extruder control, gravimetric feeding, automatic calibration, production scheduling, overweight and scrap registration, pipe OD measurement and control, vacuum control, SPC functions, and data storage and retrieval.


Specializes in total machine control for injection molding. Product line includes both stand-alone models and those that include manual controls and are mounted directly on machine. Products range from systems for small machines with limited control ability, to systems for very large machines with sequence and process control. Options enable communication with CIM networks, intelligent production-cell equipment, remote processing systems, printers, CRT terminals, plotters, etc. Job setups can be stored internally or in a data cartridge for quicker job change-over and startup. In addition, they may be stored in software library of a PC and downloaded to the control system. Up-grades are available. Company will develop control systems for custom applications.


New Farex-SR Mini general purpose controller system consists of small compact DIN Rail-mounted temperature-control modules mounted inside the panel. Single- or two-zone modules accept thermocouple, RTD or continuous voltage and current inputs, as well as switch relays, S S Rs, or current output devices. Optional heat/cool modules, loop break, and heater break alarms available.

Control modules are connected to either a man machine interface (MMI) or a host computer via digital communications. System uses a "mother block" connection structure. A maximum of 10 modules can be connected in a single system, and a maximum of 16 systems connected to a single host computer/MMI. Optional expansion functions allow up to 40 digital outputs. System can be retrofitted to existing equipment or used as original equipment for extrusion, injection molding, blow molding, and thermoforming.

Farex Mighty M5E process controller for extruders reduces difficult problems often encountered in linking extrusion lines to a host computer. Acting as an interface between extrusion line and computer system, Farex M5E provides an abundance of inputs and outputs and ROM-based control software. Accurate and stable PID control prevents variation of product quality due to unstable temperature. while melt-pressure control provides precision dimensional control. Thickness, OD, width and output control can be fed back to system for better control results.

A single Farex M5E can handle plural extrusion lines with up to 104 channels, 12 motor drives, and 36 analog inputs; or it can control a multilayer sheet extrusion line. Farex M5E also incorporates a maximum of 144 digital inputs and outputs for alarms or other system safety equipment; an autotuning function, which computes and sets optimum PID constants automatically; a job-file function or optional memory card, which requires no re-entry of set data when product item is changed; and ability to monitor, print, or send production-management data to a supervisory computer.

System can be configured to user needs and offers an optional RS422A interface. Compact housing requires less panel space than conventional panels. Easy-to-view screen offers both digital and graphic displays of operations, temperature status, analog input status, motor status, job files, and trend graphs. Utility screens are used for setting various functions.


Offers line of special modules in series of programmable controllers for injection molding machine control. Special modules are part of TurboMold family. TurboPlastic module, for example, controls closed-loop injection, pack, hold and plasticate cycles, as well as closed-loop control of the clamp end. Additional modules can be used to control pick-and-place robots, conveyors, bar-code readers and other functions. Operator interface software and cell-level controls with SPC/SQC functions available specifically for plastics.


Develops and manufactures wide range of sensors, computers, and software for monitoring and control of calender and extruder lines. Company has background in on-line, noncontact, non-destructive testing of materials for quality standards. Expertise includes ultrasonic detection of delamination and poor bonding, and optical precision-size profiling of sheet and contoured products. Software monitoring and control include high-speed, real-time optimization of process variables. Factory services include product testing, sensor and software demonstrations, recommendations for system specifications and configuration, and economic feasibility assistance.


Offers microprocessor controls for injection molding machines and sheet molding compound presses.

System 230 is a 16-bit, modular-concept microprocessor for new and retrofit injection molding applications. It offers precise open- and closed-loop control of all machine functions, including molding sequence, temperature, proportional devices, and process parameters. It also provides faster setup, startup, cycle times, consistent parts reproducibility, and reduced downtime due to a clear-text color CRT display of malfunctions and process variables.

System 235 provides many of the same features for SMC press applications, in addition to reducing average cycle times from 4 min to less than 1 min. It offers improved part surface finish and dimensional accuracy, and reduced scrap. Parallelism and in-mold coating control included.
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Title Annotation:Manufacturing Handbook & Buyers' Guide 1994/95; includes data sheets
Publication:Plastics Technology
Article Type:Directory
Date:Jul 15, 1994
Previous Article:Process and production monitoring systems.
Next Article:Heaters and heating elements.

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