The Manufacturer

Injection Molding

Injection Molding (or Moulding to use the UK spelling), along with extrusion ranks as one of the prime processes for producing plastics articles. It is a fast process and is used to produce large numbers of identical items from high precision engineering components to disposable consumer goods. 

 

Injection mouldings count for a significant proportion of all plastics products from micro parts to large components such as bumpers and wheelie bins.  Virtually all sectors of manufacturing use injection moulded parts - the flexibility in size and and shape possible through use of this process have consistently extended the boundaries of design in plastics and enabled significant replacement of traditional materials thanks to light weighting and design freedom.  The table below shows the type of products that can be injection moulded, but is by no means comprehensive.

Extruder Machine

An extruder machine can be used to produce a wide variety of products from an equally large range of raw materials. It is also an attractive alternative to other manufacturing processes as it allows for a larger selection of profiles and is suitable for use with brittle materials. In industrial applications, plastics are extruded to produce food packaging film, cladding sheets, insulation, automotive parts, and tubing products such as electrical conduit and plumbing pipes. Steel and alloys are extruded to form rods, pipes, and wires as well as steel conduits and construction members for light engineering. The food and pharmaceutical industries also make extensive use of extrusions in the production of products such as pasta, cereals, cookies, and several drug carriers.

In several extrusion applications, particularly those using plastics, the material to be extruded needs to be heated to melting point prior to being used. These applications typically use a screw feeder mechanism similar to those used in the injection molding process to heat and feed the material. Cold extrusion is also a common extrusion process and is normally limited to metals such as tin, lead, steel, aluminum, and copper. Cold extrusion has several benefits over the hot process such as a lack of oxidization, better surface finishes, and quicker extrusion times. A cold extrusion machine is used to produce items such as automotive pistons, steel cylinders, tubing, and gear blanks. 

What Is Pipe Extrusion?

Pipe extrusion is defined as a process of forcing the polymer melt through a shaping die (in this case: circular). The extrudate from the die is sized, cooled and the formed pipe is pulled to the winder or a cut off device with the aid of haul off device. Prior to this, the plastic material in the form of polymer granules is fed into the hopper, conveyed by a rotating screw through a long cylindrical barrel. This is subjected simultaneously to high temperature and pressure, forcing the melt through the die at a predetermined rate.

 

Plastic pipe is used in virtually every phase of North American industry due primarily to its chemical resistance. With the recognition of its other features, including ease of installation, durability and cost advantages, plastic piping has achieved significant use for water mains, gas distribution, storm and sanitary sewers, interior plumbing, electrical conduits, power and communications ducts, chilled water piping and well casing.

• Irrigation Drip, Sprinkler and Lift Irrigation
• Water transportation Potable water, drainage, sewage
• Industrial Chemicals, sandstowing, dewatering in mines, dredge pipelines, gas distribution and low voltage telecom/power cables 

 

5 Stages of the Plastic Recycling Process

Plastic recycling is the term given to the processing of waste plastic which turns old or scrap plastic in to a useable product which can then re-enter the manufacturing chain.
In order for the plastic to be in a suitable format for re use in manufacturing environments such as by injection moulding companies the waste or scrap plastic, needs to go through several recycling processes.

Stage One – Sorting the Plastic

Firstly the waste plastic needs to be collected by the recycling company, once the plastic arrives at the recycling plant the first stage is sort the plastic in to the specific types, plastic recycling is more complex than that of metal or glass recycling due to the many different types of plastic and more importantly mixed plastic cannot be used in manufacturing without delivering poor quality products, hence why plastic recycling companies need to be thorough when it comes to sorting the waste plastic in to the different forms prior to the next stage in the recycling process.

Stage Two - Washing Waste Plastic

Once the waste plastic has been identified and separated in to one of its many forms the cleaning process can begin, this usually starts with washing to remove paper labels, adhesives and other impurities, all the labels on your plastic containers, bottles and even your wheelie bin need to be completely removed as these will lower the quality of the finished recycled plastic.

Stage Three- Shredding the Plastic

The shredding stage is when the waste plastic is taken and loaded on to conveyor belts or directly in to huge hoppers that funnel the clean scrap towards rotating metal teeth that rip the plastic in to small pellets which are bagged up afterwards ready for testing.

Stage Four – Identify and Classify the Plastic

Once the shredded plastic has been bagged it is then chemically tested and labelled as to its exact specification, this rGrade plastic can be used as is by adding to a mix of virgin plastic in a manufacturing run, alternatively the rGrade plastic can be further recycled.

Stage Five - Extruding

This is the final stage in recycling plastic, this involves melting the clean shredded plastic and extruding in to the form of pellets which then go on to manufacture the next lot of plastic products.

Reasons to Recycle Plastic

Millions of tons of waste plastic end up in landfill when the vast majority of it can be recycled, it’s all too easy for us to throw away rubbish without a second thought but we need to take care of our planet and not just reduce the amount of rubbish we bury but also given that plastic is derived from oil a natural product with ever depleting resources it makes sense to recycling as much as possible. Recycled products are becoming more popular and are set to continue as oil exploration moves to ever more hostile and difficult to reach locations, which will of course result in prices of products made from oil will increase.

How Plastic Recycling Machine Works?

Plastic recycling machine is a well-established industry that globally processes and resells several million tons of used plastic material each year. Rather than operating merely out of environmental necessity, plastic material recovery services can be both cost-efficient and productive, saving resources for a range of different manufacturing applications. The recycling and reclamation field also encompasses the industrial processes by which plastic materials are separated into their base monomers and made available for further polymerization at secondary and tertiary levels.

 

While the plastic recycle industry was originally focused on recovering manufacturing scraps and byproducts left over from initial plastic fabrication, present-day recycling services are capable of reclaiming heterogeneous post-consumer goods as well. The methods employed by material recovery systems tend to vary according to the type of plastic being processed, but there are some essential practices common to most recycling services. Stages such as sorting, cleaning, size reduction, separation, and pelletizing can be found in most plastic recycling operations. Likewise, the machinery used to achieve these processes generally falls into a handful of equipment categories.

Polymer Insulator Resists Thousands of Volts

Polymer insulators are made from resins, a relatively uncommon material for insulator compared with porcelain. With high electrical resistance, it can moderate the voltage for stable operation. Polymer insulator being a common product applied in electronic device, it can moderate the voltage for stable operation with high electrical resistance.

 

An electrical insulator is a material whose internal electric charges do not flow freely, and which therefore does not conduct an electric current, under the influence of an electric field. A perfect insulator does not exist, but some materials such as glass, paper and Teflon, which have high resistivity, are very good electrical insulators. A much larger class of materials, even though they may have lower bulk resistivity, are still good enough to insulate electrical wiring and cables. Examples include rubber-like polymers and most plastics. Such materials can serve as practical and safe insulators for low to moderate voltages (hundreds, or even thousands, of volts).

The Process and Function about Ultrasonic Welding Machine

       For joining complex injection molded thermoplastic parts, ultrasonic welding machine can be easily customized to fit the exact specifications of the parts being welded. The parts are sandwiched between a fixed shaped nest and a sonotrode (horn) connected to a transducer, and a ~20 kHz low-amplitude acoustic vibration is emitted.. When welding plastics, the interface of the two parts is specially designed to concentrate the melting process. One of the materials usually has a spiked energy director which contacts the second plastic part. The ultrasonic energy melts the point contact between the parts, creating a joint. This process is a good automated alternative to glue, screws or snap-fit designs. It is typically used with small parts such as cell phones, consumer electronics, disposable medical tools, toys, etc., but it can be used on parts as large as a small automotive instrument cluster.

       Ultrasonic welding can be used for both hard and soft plastics, such as semicrystalline plastics, and metals. Ultrasonic welding machine also has much more power now. The understanding of ultrasonic welding has increased with research and testing. The invention of more sophisticated and inexpensive equipment and increased demand for plastic and electronic components has led to a growing knowledge of the fundamental process. Scientists from the Institute of Materials Science and Engineering (WKK) of University of Kaiserslautern, with the support from the German Research Foundation, have succeeded in proving that using ultrasonic welding processes can lead to highly durable bonds between light metals and Carbon-fiber-reinforced polymer (CFRP) sheets.

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How to Use Ultrasonic Welder to Assemble Thermoplastics?

       Ultrasonic plastic welding is the joining or reforming of thermoplastics through the use of heat generated from high-frequency mechanical motion. It is accomplished by converting high-frequency electrical energy into high-frequency mechanical motion. That mechanical motion, along with applied force, creates frictional heat at the plastic components' mating surfaces (joint area) so the plastic material will melt and form a molecular bond between the parts. Plastics assembly is a fast, clean, efficient, and repeatable process that consumes very little energy. No solvents, adhesives, mechanical fasteners, or other consumables are required, and finished assemblies are strong and clean.

       Using ultrasonic welder has many advantages over traditional methods. For one, welding occurs at low temperatures relative to other methods. So, the manufacturer does not need to expend vast amounts of fuel or other energy to reach high temperatures. This makes the process cheaper. It's also faster and safer. The process occurs in fractions of a second to seconds. So, it can be done more quickly than other methods. Ultrasonic welding does not require flammable fuels and open flames, so compared to other welding methods, it's a safer process. Workers are not exposed to flammable gases or noxious solvents. Finally, ultrasonic welds are as strong and durable as conventional welds of the same materials. Ultrasonic welding can be used to bond the metal in less time and at lower temperatures than traditional welding.

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How to get your ideal molded plastic design?

Plastic injection molding is a process that involving the use of plastic.  With the granular polymer which is fed into a heated barrel, the rotation process of a screw type plunger is therefore generated by the friction between polymer granules while the screw is rotating.  Nowadays, one of the most popular techniques on plastic injection is called double injection.  This common technique contains several of factors to influence the quality of the molded plastic product.  In this way, the selection of a plastic injection manufacturer for your molded design is crucial. 

Start with material melting process, the melted plastic is forced into a mold cavity with the required shape through a nozzle.  The action is finished by the screw rotation action, and then the mold is waited to be cold, sometimes you will need cooling channels to run through it.  After the cooling, the molten plastic will be solidified while the mold cavity is filled.  The whole double injection process is simple, and with the fact that the plastic is not expensive, it can be manipulated into any shape.  So you can prepare more extra shape in hand to handle any failure during the manufacturing.  

Cosmetic Airless Bottles, the Most Suitable Cosmetic Bottles for Your Cosmetics

       For women, cosmetic products are very important. They can give women glamorous and beautiful appearances. What’s more, women will become more confident by using cosmetics. In the process of becoming pretty by cosmetic, firstly, women need to choose the quality cosmetics. Then, they have to know how to apply cosmetic wisely to fit for their skin condition and shape.

       For the first step, the key factors to determine whether the cosmetic products are with high quality not only lie on the quality of cosmetic ingredients, but count on the cosmetic bottles as well. Nowadays, airless packaging continues to show up in all areas of skin care, including natural and organic products, mass-market and prestige facial products, and even body care products. It is said to be the most sanitary way to reserve cosmetics.

       Among the various cosmetic and skin care products, airless packages are especially well suited to highly viscous skin care products for the body, such as body butters. The airless cosmetic bottles may also help maintain decorative product fills. One popular fill design is a swirl. Airless technology can help a product’s swirl design maintain its form as product is being dispensed.