P L A S T I C SHIPF TRAI NEES AT 5TH GPCA PLASTI CS EXCELLENCE AWARDS JANUARY, 2015.INJECTI ON MOLDI NG MACHI NE WI TH I NTEGRATED MOLD TEMPERATURE CONTROLLI NKYo u r L i n k t o t h e P l a s t i c sWo r l dDubai, UAE: HIPF congratulates the winners of 5th Plastics excellence awards which is an initiative of the Gulf Petrochemicals and Chemicals Association (GPCA).Thisawardrecognizetheoutstandinginitiativesinplasticsconversion,plasticsengineeringandproductdevelopmentbycompaniesand individuals from the Arabian Gulf region. HIPF trainees have competed in the final round with three projects under the category of Fikra : Rising stars of the plastics industry and secured the 1st and 2nd place in the competition. HIPF is proud of the achievement of the trainees and their mentors.Mold temperature control is a very important parameter for consistent quality of product. Normally a separate Mold temperature controller unit is used in other machines.ENGEL has developed mold temperature control system integrated with Injection Molding machine by providing a coolant flow monitoring and control system to keep the mold temperature constant during the production.There is a water manifold system which helps in process optimization and quality improvement. This is an ENGEL e-flomo series machine, which has electrical control valves to automatically control flow rate.As the flow is controlled automatically there is no fluctuation in volume of water needed for cooling which helps in process stability and thus reduction of scrap.Even if the water pressure varies or there is any choke in line, the system maintains constant flow rate of water for mold cooling throughout the production. This feature also takes care of the temperature control of water by sensing the temperature difference between input and output water of mold. It can work up to 120 degree Celsius. ENGEL e-flomo machine is better in terms of economy of the injection molding processbyfastmoldset-up,highermachineavailability,andscrapreduction.Allthesebenefitsareduetoincreasedprocess stability.SPECIAL POINTS OF INTEREST:IN THIS ISSUE: Recent Path Breaking Innovations in the field of Plastics. Selected International Plastics centered events and exhibitions. HIPF trainees at 5th GPCA plastics excellence awards Jan,2015..QUARTERLY ISSUED BY THE HIGHER INSTITUTE FOR PLASTICS FABRICATIONw w w . h i p f . e d u . s a01 Injection molding machine with integrated mold temperature control1 Automatic diameter change in pipe extrusion while running production line.2 Tips to increase the perform production.2 Systematic approach to diagnose mold filling and part quality variation for multi-cavity injection molding.3 PAF An Enhancer of durability for plastic materials.3 International Plastics Events.4 Contact Details.401n V O L U M E 0 7n I S S U E 0 1n A P R I L . 2 0 1 51stPlacewinners:Trainees:RayanZakariaMubarak Al-Ahmedi and Khaled Saleh Al-Mosalam, Mentors: Mr. M. A. Ghani and Mr. Ali Abdullah Al-Ramel.2nd Place winners: Trainees: Sultan Safar Al-Otaibi and Omar Al-Enazi, Mentors : Mr. Rolando M. Padua and Mr. Rameshwar S. Selukar.CourtCourtesyof industrynews specialchem/ ENGELnewsThe outer diameter of pipe can be altered without stopping extrusion line; it will save both material andtimeaswell.RecentlyInoexLLChasinnovatednewtechnologyinpipeextrusion,suitablefor polyolefins material. Usually, in regular extrusion process, the extrusion line has to pass through shut down and start up process for die changing which consumes a lot of time and generates scrap.The salient feature of calibration sleeve is, enabling multiple diameter ratio setting up to 1:1.8, for the maximum outer diameter 36inches, using same extruder and die.The designed pipe supports are high load bearing and flexible to the size changed. It can seal high vacuum and provide efficient cooling too. Here vacuum is generated by using frequency controlled vacuum pump. The extruder is equipped with human friendly terahertz frequency based, quantum non- destructive pipemeasurementsystem.Itcanmeasurewallthicknessofsmoothpipeaswellasfoamedand corrugate pipes accurately.w w w . h i p f . e d u . s aAUTOMATIC DIAMETER CHANGE IN PIPE EXTRUSION WHILE RUNNING PRODUCTION LINEClarified PP has high gloss and low haze.TIPS TO INCREASE PET PREFORM PRODUCTIONIn the PET perform molding, there are a many ways themolderscanoptimizeandreducethecycle times up to level of 6 seconds which result in higher productivity.Fewimportantparameterswhicheffectthecycle time of perform molding are Injection time;Hold time and Cooling time..Injectiontime:Moldersshouldachievethenormal fillrateof8to12g/sec/cavityforthepreformsup toabout4-mmwallthickness.However,thicker preformscanbefilledmuchfasterasitiseasierfor the resin to flow fast through the feed channels. For example, a 525 g preform with a wall thickness of 8.5 mm can be filled at 27 sec, giving fill speed of 19.4 g/sec/cavity.HoldTime:Thepurposeofholdtimeistoapply pressure on the melt after filling the cavity avoid the voids in preforms as they shrink from a melt density of1.15g/cm3tothesoliddensityof1.33g/cm3. This difference is about 13% due to which the void is inevitable but by proper hold on pressure and time, this can be avoided. Considering this, the switchover or transition point setting is an important parameter. Thetransitionpointshouldbebeforethemeltfully cool down. The transition point is to be set between 6% to 8% of the total stroke to have switch over from injectiontoholdonattherightpositionwhenthe cavity is actually filled.Coolingduringholdtimeisveryeffectivebecause themeltispushedagainstbothcoreandcavity. Times are dependent on wall thickness.Cooling time: Cooling time should be a minimum of 1.5 sec but can be as high as 20 sec for very thick preforms. It should be optimized to get the desired demolding temperature.Courtesy of InoexThepurposeofthebalancefillanalysisistoevaluatethethermaland flow balance of the plastic distribution system in the mold. The variation in the plastics flow from cavity to cavity will lead to quality problems. It is important to have the flow balanced to each cavity to get consistent qualityproducts,achievinghighCpk(processcapabilityindex)and producing identical parts. Procedure to estimate Cavity Balance1.Fillthe90to95%ofthemoldwithoutgivingholding/packing pressure. The part should not be completely filled. 2.Setyourmelttemperatureasrecommendedbythematerial manufacturer. 3.Set the holding pressure and time to zero. 4.Usescrewtransferpositionforswitchoverpressure.(i.e.)from injection phase to holding phase. 5.Thedelaytimeforscrewchargingsetlonger.(closetoestimated holding time)6.Set the adequate cooling time so that your product can eject without problem.7.SetyourinjectionspeedtothevalueobtainedfromtheViscosity Curve study.8.Start to molding. 9.Only by adjusting the transfer position, mold parts that are just short. Ifthereisavisiblecavityimbalance,thenthe biggestpartshouldbe just short. 10.Make 3 to 5 such shots and take the average weight of each cavity and plot a excel sheet as like below. How to use this information: Checkthe%variationbetweenthemaximumandtheminimumfill cavities. Ifyourproductsarehavingverytighttolerance(e.g.Electronic, automobile etc) then your variation should not exceed to 5%. Ifthevariationismorethan5%itmeansthemoldcavitiesarenot balanced and needs correction. The following should be considered: a.Amorphousmaterialscantoleratemoreimbalancethancrystalline materials. b. Make sure that the air venting is the same for all cavities.Steps you could take if there is high variation in filling:1. Ensure correct hot tip operation, read power usage and temperature setting/variation on display unit.2. Check the gate area for any interruption. 3. Measure gate size/shape (i.e. circularity) in cavity.4. Consult with mold makers. Poly Aromatic Framework is a new material developed by the scientists intherecentpast.Thismaterialhasbeenfoundtoblendwiththe porous polymer materials easily and also improves the durability of the porous polymer products like linings, filters etc.PAFhasprovedtobeabetteradditivetoimprovetheperformance ofthesuperglassypolymermaterials,whichareinitiallyporousand permeableandsoonlosessomeofitsproperties.Thisadditivewhen blended with polymer materials is, capable of retaining the porosity by absorbingsomeofthepolymerchainswithinitsporesandmaintains them intact.Plasticsliningwithholesofdiameteraboutonenanometerarewidely usedinpowergenerators.Frommanydecades,scientistshavebeen involvedindevelopingstableplasticswithlargerholes,inorder toreducecostandincreaseefficiencysavingsbutincontrarythe available plastics material with larger holes collapses quickly. Therefore PAFaddedplasticslininghascomeouttobeaviableoptionforthe innovators and offered a big reduction in cost and increased efficiency savings.Thetechniquesusedtoseparategases,liquidsandsolidsconsume enormous amount of energy but by using PAF in the polymer material there is a great increase in the rate of separation process and could also be used for separating fuel from the pollutants efficiently. P L A S T I C SLI NKw w w . h i p f . e d u . s aTIPS TO INCREASE PET PREFORM PRODUCTIONPAF AN ENHANCER OF DURABILITY FOR PLASTIC MATERIALS.SYSTEMATIC APPROACH TO DIAGNOSE MOLD FILLING AND PART QUALITY VARIATION FORMULTI-CAVITY INJECTION MOLDING Note the table above is for 8 cavity mold, Courtesy of faculty.ferris.eduCourtesy of joloosanitary.com01Shot1 Shot2 Shot3 Shot4 Shot5 AverageCavity 1Cavity 2Cavity 3Cavity 4Cavity 5Cavity 6Cavity 7Cavity 8Higher Institute For Plastics FabricationP L A S T I C SLI NK7798 AlKharj Road, New City Industry, Unit #1, Riyadh 14331 - 3244Facebook: HIPF2010Twitter: HIPF2012Contact Details:Tel.: +966 11 498 9600, +966 11 498 9678Fax: +966 11 498 9650e-mail: info@hipf.edu.sawww.hipf.edu.saPLASTICS LINKYour Link to the World of PlasticsThe establishment of HIPF aims to prepare Saudi youth to participate as skilled technicians in the booming plastics industry of the Kingdom and to develop the technical knowledge and skills of Saudi workforce towards localization of plastics fabrication technology.TheEditorialboardoftheNewsletterwouldliketoremindthereader thatthearticlesinthisnewsletterarecollatedfromthevarioussources ofinformation.HIPFdoesitsbesttoverifythesourcesandconfirm theauthenticityofthearticlespublishedinthenewsletter.TheHIPF willnotassumeanylegalliabilityforthecontent,quality,accuracyor completenessofsaidinformationandmaterials.Thesourcesofthe articlesandthetermsandconditionsofthenewsletterPlasticLinkare available with the board of Editors and are available on request.s www.hipf.edu.sa2015I N T E R N AT I O N A L PL A S T I C S E V E N T S01FRONTIERS IN POLYMER SCIENCE 20154th International symposium focusing on polymer science, Polymer synthesis and Polymer chemistry.CHINAPLAS 201529th International exhibition on Plastics and Rubbers.APCE 2015 Plastics in MotionAutomotive Plastics conference and exhibition. GRC 2015Gordon Research Conference focusing on fundamental synthesis and macromolecules. EPF 2015European Polymer Congress 2015.ICSP & AM 4 4Th International Caucasian symposium of polymers and advance materials.ISBPPBInternational Society for Biomedical Polymers and Polymeric Biomaterials 2nd Annual Conference and Exposition.APS Australasian Polymer symposium.IUPAC 4th International Union for Pure and Applied Chemistry world chemistry congress.BPS 2015Bayreuth Polymer Symposium 2015.APME 2015International conference on advanced polymers via Macromolecular engineering. Polymer Club 2014 Fall symposiumA symposium on applied chemistry, plastics, paints and synthetic materials.Rive del LGarda (on lake Garda), Italy.Guangzhou, PR China.Adoba Hotel, U.S.A.South Hadley, U.K.Dresden, Germany.Batumi, Georgia.Orlando, U.S.A. Gold coast, AustraliaBussan, South Korea.Bayreuth, Germany.Yokohama, Japan.Warwick, U.K.May 20-22, 2015.May 23, 2015.May 3 1- Jun 04, 2015.Jun 14-19, 2015. Jun 21 - 26, 2015.July 01 - 04, 2015.July 08 10, 2015.July 12 - 15, 2015. Aug 09 14, 2015.Sep 20 22, 2015Oct 18- 22, 2015. Dec 17, 2015.CURRE NT &UPCOMI NGT RADE S HOWS ANDT RADE E VE NTS F ORPL AS T I CS &PL AS T I CPRODUC TS