Manufacturing Matters: 5/11 Weekly Wrap Up

May 11, 2012 By Leave a Comment

The New York Times reports that manufacturing is “one of the few bright spot of the recovery, restoring 489,000 jobs since the beginning of 2010.” The article also describes geographic distinctions in growth, with half of the most manufacturing-specialized metropolitans now located in the Midwest.

Plastics News reports that in California a controversial pro-plastics lesson has been removed from a new statewide curriculum on the environment. After the EPA looked over the proposed curriculum, the section titled “Advantages of Plastic Shopping Bags” was replaced with recycling statistics in an 11th grade textbook.

image from flickr


ICIS News announces that researchers at technology company Siemens have developed an alternative to ABS plastic. The new material—made with 70% renewable content—is the result of a three-year project funded by the German Research Ministry and was successfully used to make a vacuum cleaner cover.

image from icis.com


GreenBiz examines the Sustainability Leadership List, which recognizes environmentally-conscious companies each year. But because some criticize the results, they also discuss plans for the Global Initiative for Sustainability Ratings that would develop a standardized method of measuring and ranking sustainability performance.

Plastics Today recognizes Dignity Health, the founding sponsor of the Healthier Hospitals Initiative, as one of the first hospital groups in the country to start using pigment-free patient plastics. This California-based healthcare organization is a leader in sustainability efforts to reduce hospitals’ impact on the environment by adopting innovative alternatives.

 

Filed Under: Manufacturing, Plastics Industry Tagged With: , , ,

Opportunities for Greater Efficiency in Custom Molding

May 7, 2012 By Leave a Comment

As more and more manufacturers see significant energy savings after insulating their machines, insulation jackets are becoming priority number one in many energy management strategies.

UniTherm has been supplying insulation jackets in the plastics industry for over 30 years, and with each new product and custom service, UniTherm strives to address a specific processing need. With this innovative mentality, UniTherm can provide opportunities for greater efficiency, as it has with its new product called QuickCool.

QuickCool is an insulation jacket with an additional feature—it is designed to open easily so that machines can quickly cool as they are prepared for different processes. QuickCool wraps completely around the barrel and insulates as well as UniTherm’s other jackets, but it has high-temperature straps on the inside to hold it in place while the top flap opens to release heat when necessary. Otherwise, the top flap velcros tightly to the rest of the jacket to keep machines working at high efficiency with minimal heat loss. This way, barrels and heater bands are always easily accessible without having to remove the entire jacket, and machines can reach and maintain different desired temperatures as needed.

QuickCool closed to insulate

QuickCool open to release heat

 

Barbara Arnold-Feret, custom molding expert and new addition to UniTherm’s sales team, calls QuickCool a “flexibility enhancer.” QuickCool, she explains, “offers all the advantages of insulation along with the ability to change temperatures quickly. It allows great flexibility for molders looking to cool their machines for whatever reason, including material changes.” No longer do custom molders need to worry about insulation encumbering their access to the machines or their ability to switch processes involving different materials. “It is especially convenient when working with polyolefins and perfect for molders that make a little of everything,” says Barbara.

In fact, a custom molder with 3,000 molds running short runs with PolyPro and ABS installed QuickCool blankets on its machines and found that the product allowed them to cool from 550˚F to 350˚F in the time it took to change the mold.

UniTherm has been supplying insulation for over 30 years, and the Research and Development team continues to explore new energy-efficient solutions. They are excited to offer a product that will not only save energy but also adapt to the alternating processes in custom molding.

Filed Under: Energy Efficiency, Plastics Industry Tagged With: , , , , ,

Manufacturing Matters: 5/4 Weekly Wrap Up

May 4, 2012 By Leave a Comment

Another great week ripe with industry news. Here are the highlights:

Plastics News reports that the shortage of nylon 12 has led the auto industry to seek alternatives resins to use in fuel lines, connectors, tubes, and other key components. Molders and resin makers have offered a variety of possible alternatives, and automakers have established a system to begin testing.

The Huffington Post addresses the current the job market as US Congressional Candidate Stacey Lawson proposes a plan for creating jobs and rebuilding our middle class. Lawson stresses that we can by reclaim the American dream by “restoring the high-wage jobs that are the foundation of a sustainable economic recovery,” and she lays out 7 priorities to help us get there.

Clean Technica overviews the Department of Energy’s voluntary energy savings specifications designed to help building owners, operators, and manufacturers develop minimum performance requirements. The DOE recently released new specifications for lighting troffers and parking lot lighting, which could reduce energy use by 40%.

fluorescent-lights

image from cleantechnica.com

Industry Intelligence announces a new compostable bioplastic film that extends the shelf life of fruits and vegetables by up to five days. The new film, developed by Sira-Flex Resolve, creates an ideal atmosphere to better preserve stored food.

fruits and vegetables in produce isle

image from flickr, courtesy of I-5 Design & Manufacture

And in a free webinar, Design World discusses how Design for Manufacturability (DDM) eliminates many restraints associated with conventional manufacturing. The webinar examines how DDM can create plastic parts, layer-by-layer without machining, molding, or casting.

If you like the Weekly Wrap Up, follow our blog to receive more updates and industry news every Friday.

Filed Under: Manufacturing, Plastics Industry Tagged With: , , , , , , , ,

Manufacturing Matters: 4/23 Weekly Wrap Up

April 27, 2012 By Leave a Comment

It seems there is always so much exciting industry news, so we welcome you to our first of many weekly wrap ups.

The Economist says we have entered a third industrial revolution. With the advent of additive manufacturing and the refinement ofrobots, we can glimpse the future of factories. As manufacturing goes digital, we see new processes emerging that are vastly different from the 20thcentury assembly lines.

The third industrial revolution

image from economist.com


MIT discusses whether increasing complexity in engineered systems warrants a new approach to safety and testing. MIT professor Nancy Leveson claims that our modern, ever-evolving systems are more vulnerable to accidents, and she advocates a holistic, sum-of-its-parts approach over traditional safety engineering practices.

Engineering a Safer World

available at amazon.com


The Huffington Post poses the question, is Obama getting serious about manufacturing? Huff Post says that if the government acknowledges manufacturing as a stable and productive industry—a “uniquely important sector”—that support can benefit the broader economy and build a stronger country.

GE discusses the “robust renaissance” of manufacturing “fueled by new technologies, software, innovation, and lower energy costs” and posts a great infographic highlighting industry growth and the power of insourcing.

Envision Plastics announces the partnership between Alpha Packaging and Arla Foods, a partnership aiming to eliminate landfill waste with a zero-carbon facility. To launch the sustainability strategy, Alpha Packaging will produce milk bottles with 50% recycled material. Arla Foods recruited Alpha to mold and handle the bottles on site with two goals in mind: consuming the lowest amount of energy possible and creating the most environmentally advanced dairy in the world.

milk bottles

image from envisionplastics.com


Metal Architecture says that reducing factory footprints is not only environmentally friendly, but economically smart as well. Building owners who focus on decreasing carbon emissions and reaching LEED standards enjoy numerous benefits: improved image and marketability, greater employee engagement, higher renter rates, and more incentives.

We hope you enjoyed our first edition! Keep checking in for more industry updates from the top news sources.

Filed Under: Manufacturing, Plastics Industry Tagged With: , , , ,

Exciting Awards at NPE 2012

April 19, 2012 By Leave a Comment

Every three years, the world’s largest plastics expo, NPE, brings together the industry’s biggest names and brightest minds. This year’s  week-long event  featured 2,000 plastics suppliers on a one million square foot showroom floor and hosted design competitions, conferences, award ceremonies, and other exciting events.

A well-known organization for industry members, the Society of Plastics Engineers (SPE), gives annual mold maker awards to innovators who stand out in plastics processing, and this year’s honorees were announced at NPE 2012 during the exposition’s premier technical conference ANTEC.

UniTherm’s own Barbara Arnold-Feret of Fort Worth received the Mold Designer of the Year award, and Robert Novak of Milwaukee received the Mold Maker of the Year award.

image from moldmakingtechnology.com

 

Barbara’s award is especially noteworthy because she is the first honoree whose career did not focus entirely on injection molding. A lifelong veteran of the plastics industry, Barbara has worked extensively in the design and manufacture of rotational molds and related tooling, and she continues to consult with processors to help improve operations throughout the industry.

UniTherm brought Barbara on board earlier this year to cover its expanding sales territory and is proud to announce her award. Her extensive industry experience and widespread network enable UniTherm to better serve plastics processors with energy-saving solutions.

We’ll be looking forward to next year’s innovators. Until then, follow our blog for other exciting industry news.

Filed Under: Plastics Industry, UniTherm News Tagged With: , , , , , , ,

The New Heating System that will Radically Change the Way You Heat

April 17, 2012 By Leave a Comment

Imagine a world where heat is always consistent, quick, efficient, and safe. Imagine a heating system that is 70% more efficient than the way you heat now and still safe enough to touch with bare hands. Is this some distant dream, or have we truly arrived at the future of heat technology?

At NPE 2012, UniTherm International introduced its latest product—RapidTherm, an innovative heat solution designed for plastics machinery. UniTherm has been manufacturing insulation jackets for over 20 years, but this new jacket is truly the first of its kind.

RapidTherm is unique in that it combines heating elements and insulation in one easy to use, easy to service unit. The 1-piece, removable insulation jacket includes a built-in thermal vein powerful enough to heat an entire machine. Not only is the thermal vein a more efficient heat source than traditional heater bands, but because it’s encased in high temperature insulation, it saves energy by eliminating excess heat loss.

In tests, the RapidTherm jacket heated barrels twice as fast (cutting start up time in half) and dramatically decreased energy usage. On production equipment, the new heating system

  • Decreased start-up time by 50%,
  • Cut energy usage by 70%
  • Kept the outer surface cool enough to comply with OSHA hot surface standards
  • Increased worker safety
  • Cut maintenance time and costs
  • Eliminated hot spots on the barrel heating profile
  • Eliminated the need for a barrel shroud

RapidTherm has proven itself as an efficient heating system and promises to liberate processors from the hassle of heater bands. “For years, we’ve known there has to be a better, more efficient way to heat machines,” explains UniTherm president Dan Sherrill. However, previous alternatives to heater bands have been plagued with problems. NPE 2012 was the perfect opportunity to unveil the new heating system, and RapidTherm sparked interest among processors looking to save time and money at their machines. It seems RapidTherm will be the solution that finally puts the heater band headache to rest.

It’s certainly an exciting time for new technology in engineering and manufacturing. Subscribe to our blog for more innovative ideas and industry updates.

Filed Under: Energy Efficiency, Plastics Industry, UniTherm News Tagged With: , , , , , , , , , , , ,

Less is More and Lean is Better: Managing Inventory in Manufacturing

March 20, 2012 By Leave a Comment

The concept of lean manufacturing is simple. Much like a diet for your facility, the goal is to reduce your waste (like you would your waist) for healthier operations. It’s not about starving your business because, let’s face it, you can’t run a marathon or outlast competitors without proper sustenance. Lean strategies are about taking in only what you need and making the most of it—kind of like politely pushing away a plate of food when you’re full rather than stockpiling calories for a later date.

Now I know by March many of our weight loss resolutions have run their short-lived and often unfulfilled courses, but it’s always a good time of year to take on a new style of inventory management.

How manufacturers manage inventory
Many manufacturers produce products in large runs, even when the demand for that product is low. Products are stored or kept in inventory until they are eventually sold, which often leads the manufacturer to overspend on storage. When production runs are too large, manufacturers run the risk of filling inventory with products that might become outdated and remain unsold.

Why lean strategies are more efficient
A crucial component of lean manufacturing involves controlling inventory by reducing excess production. This means implementing a system for monitoring inventory and producing products in smaller runs rather than keeping excess inventory in storage.

Wait, it takes time and money to modify the way you manage inventory and thin out the production line. But just like dropping a few pounds, the payoff doesn’t occur overnight. Soon enough, the savings from storage costs and unnecessary waste will find their way to the bottom line. It’s well worth the change—just ask Toyota, Boeing, Caterpillar, and Xerox.

Not only will lean strategies lower your overhead costs, but they will also challenge your employees to think critically to improve existing procedures. No reason to keep things the way they are just because—hopefully your facility is always on the look out for more efficient ways to operate. Plus, you won’t have to feel that little pang of guilt as you throw away perfectly good products because of bad timing.

Filed Under: Manufacturing, Plastics Industry Tagged With: , , , , , , , ,

See it to Believe it: The Benefits of Thermal Imaging

March 13, 2012 By Leave a Comment

When thinking about energy output in a manufacturing plant, it’s natural to go to the lights and the HVAC. This makes sense since these are typically the top energy expenditures, but it’s a plant’s machines that devour more energy than all other utilities combined. That’s right, machines consume about 60% of total energy costs. How do we know this? Well, government agencies and other entities provide plenty of studies and statistics for us to read over, but why not see the energy output for yourself?

Thermography is more than fancy spy gear for secret agents to expose hidden enemies—it has a wide range of commercial and industrial applications for those of us in the real world as well. For manufacturers, thermal imaging allows you to visually track the amount and consistency of heat emitted by your equipment. With a thermal camera, you can compare the output of the different heat sources (even those not-so-easy-to-access heat sources) in your facility from a comfortable distance. This way you can find defects in shafts and pipes and locate deteriorating components before they fail.

Equipped with a thermal picture (a thermogram, in case you want to sound technical), you can easily spot the energy hogs highlighted in yellow, orange, and red—so you know exactly what areas to target as you take steps to reduce your energy costs.

Thermal Imaging

 

Immediately you’ll see your machines light up hot—as they should, that’s how they work. But most likely they don’t need to be operating that hot or emitting as much heat as they do.

The good news? Machines represent your greatest opportunity to conserve energy. Instead of idling, consider powering down equipment during non-peak hours, make sure motors are working as efficiently as possible, and insulate, insulate, insulate. The ROI is remarkable—insulation saves an average of $164 per machine per month. See what thermal imaging reveals so you can start saving.

Filed Under: Energy Efficiency, Manufacturing, Plastics Industry Tagged With: , , , , , , , , , , , , , , , ,

Why Induction Heat is Super Efficient

February 28, 2012 By Leave a Comment

Faster than a speeding bullet! More powerful than a locomotive! It’s not up in the sky, it’s…unbelievably efficient induction heat technology!

Ok, maybe I sound a little fanatical, but if you’ve never seen induction heaters in action, I seriously recommended you watch some induction heating demos. These videos will blow your mind.  You’ll see metal wires melt, aluminum cans explode, and ice cubes set ablaze—before they even have a chance to melt!

What is induction heat?
Induction is a heating method, but unlike conduction or convection heating methods, it doesn’t require a transfer medium. The inductor itself can be a simple-looking strip of coiled metal (precisely designed to optimize the magnetic field and alternating currents), and the magic is, the inductor never touches what it’s heating, and it never gets too hot to handle with bare hands. I won’t get into the physics of it all, but if you’re interested in how induction heating works, see inductionatmostpheres.com. Basically, induction heat uses radio frequencies, and that’s how it can work sans transfer medium—heat is “induced” by the circulating electrical currents.

The shift toward lean manufacturing and the emphasis on better quality control have led to the rebirth of induction technology and the development of precisely controlled, solid-state induction power supplies.

How can induction heat benefit manufacturers?
For most industrial applications, induction heating offers significant advantages over traditional heating methods—the fast, accurate, and consistent heat transfer reduces energy consumption and creates a safer working environment.

Companies like Ford, John Deere, GM, Cat, Volkswagen, and BMW have already implemented induction heat into their manufacturing processes. Most manufacturers that switch over to induction technology report a decrease in their utility bills. Why is this? Because induction is a highly efficient means of heating that requires less energy to do the same job as, say, a heater band, which is constantly losing energy and reheating.

In fact, uninsulated heater bands are only 30-70% efficient and have a limited lifespan because they must stay hot to operate. Induction heaters, on the other hand, are typically 95% efficient and don’t emit excess energy. Even better, insulated induction heaters can reduce ambient energy loss by 98%.

How can you use induction heat to make your manufacturing process more efficient? If you haven’t already, start thinking about this innovative heating method, and stay tuned for the latest in energy efficient technology.

Filed Under: Energy Efficiency, Manufacturing, Plastics Industry Tagged With: , , , , , , , , , , , , , , , ,

The Best Ways for Manufacturers to Save Energy: Surveying the Site

February 21, 2012 By Leave a Comment

Who doesn’t want to save energy? Now more than ever, we are all looking for ways to cut back—we turn down the lights and turn off the thermostat, we run the dishwasher less and take shorter showers—hoping to save some money on the monthly energy bill.

But when you run a large manufacturing plant, the task of saving energy may be a bit more daunting. Before you can start conserving energy, you have to know where the most energy is being consumed and what the best opportunities are for reducing high-energy output.

Knowledge is power, so we’ve put together a simple site survey checklist to help managers get well acquainted with their plant’s energy output. According to the Energy in Plastics Good Practice Guide, you should carry out an initial survey immediately because “if energy is being wasted, it is costing money.” A 20% cut in energy costs can equal the same bottom line benefit as a 5% increase in sales.

It’s also a good idea to take an unannounced walk around the site at about mid-shift to see how things are running during normal working hours.

What to look for during an initial walk through
Keep a close eye on the machines. Machines consume about 60% of energy costs. Yikes. But think of it this way—here lies your greatest opportunity for energy savings.

As you survey the site, keep these questions in mind:

  • Which areas have the largest energy load? Look for the largest machines; they will have the largest motors and consume the most energy.
  • Which motors are running? Would smaller motors be more efficient? Could they be turned off during non-peak hours?
  • Are machines well insulated? Is the insulation in good condition?
  • Are hot and cold pipes insulated? Is the insulation in good condition?
  • Which cooling water pumps and vacuum pumps are running?
  • Does compressed air pressure need to be so high, or the vacuum so low? Can you hear steam and compressed air leaks?
  • Are lights and machine heaters left on? What is running during lunch breaks and and after working hours?

With a better understanding of where unnecessary energy output occurs, you can now take productive steps to decrease it. Don’t wait—conduct your site survey today to start saving energy and increase that bottom line!

*Statistics from European Best Practice Guide.

Filed Under: Energy Efficiency, Manufacturing, Plastics Industry Tagged With: , , , , , , , , , , , , , , , ,
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