Measuring Dew Point in Drying Resins with MoistureMaster Technology

March 14th, 2013

When drying resin, if dew point is not properly maintained, resin and regrind material run the risk of being under or over dried.  If this occurs it can yield an end product that is brittle, discolored, splayed, bubbled, streaked and will overall sacrifice quality.

What is Dew Point?

Simply, dew point is the measurement of humidity in the air – but that doesn’t mean it’s simple to keep constant. Most resin drying systems produce very dry air at a dew point of -40 ° F at high temperatures. This air is then circulated in the drying hopper that contains the resin pellets for a determined period of time, depending on the type of resin being used. The issue here is that resin moisture content isn’t constant and can start at different levels regardless of resin type depending on where it was stored and humidity levels in the surrounding ambient air. Knowing the moisture content of the resin as it exists the hopper and before it enters the process machine permits drying times to be adjusted to facilitate proper levels of moisture content for processing. But how can this be done?

How Can Moisture Content of Resins Be Effectively Measured?

MoistureMaster™ sensing technology uses an AC current to take approximately 500 samples per minute and measure moisture content. Gaining data about the dielectric constant of a resin allows readings to be compared to the known capacitance constant of water. With this information, PLC controls built into MoistureMaster™ dryers calculate the actual moisture content of the pellets themselves as they move through the sensor!

With a MoistureMaster™ controller, pellet moisture can be monitored. Offline Moisture Analyzers, which consume extra time and have a marginal amount of room for human error, are less efficient and may yield faulty resin products. Using MoistureMaster translates to saved money, time and a quality end product. What could be better?

To learn more, please visit www.moisturemaster.com today!  Plus, you can follow us on FacebookTwitter, and Google+!

How to Measure Moisture Content of Resin Efficiently and Effectively

March 1st, 2013

From food containers to car parts, plastic exists to make our lives more convenient – but preparing resin for plastic production can be anything but convenient. Traditionally, processors have relied on the circulation of hot, -40° dew point air to dry material. The problem with this approach is that the dryness of process air does not measure the dryness of the material itself, thereby creating an increased probability of producing resin that has been either over or under dried, both of which ultimately yields defective parts. There’s no way around the fact that defective parts leads to lost profits, as man hours are wasted sorting out bad parts, and some wind up getting thrown out entirely.

Most plastics processors perform moisture analysis in order to minimize production waste. Taking moisture samples manually is a tricky process subject to human error, involving high investment in labor and precise record keeping. With several different people conducting the same task and ten steps required to measure moisture in each sample, it’s not uncommon for the tests to come out inaccurately. And even if they were guaranteed to be error proof, it can take an hour to see the results of the moisture test, by which time, it may already be too late: the product could be in the box, ready to ship.

That’s where the MoistureMaster™ On-line, Real Time Moisture Sensing Technology comes into play. By measuring the moisture content in the resin itself, rather than the air around it, MoistureMaster™ provides accurate readings that can truly eliminate waste caused by improperly dried materials. Taking the dielectric constant of a given resin and/or additive, the sensors then map those readings against the known capacitance constant of water to determine the moisture of the materials. An upfront investment in this advanced technology can save time, manpower, and of course, money for plastics processors.  To learn more, please visit our website here today.

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Current Status On Use of Plastics in Automobiles

February 15th, 2013

Recyclable Plastics:

The use of engineering resins in the automotive industry is expected to kick into high gear in the New Year. High-end auto producers are seeking to meet consumer demand for recyclable materials by incorporating more plastics into vehicles that can ultimately be broken down and reused in other applications when a car is no longer in commission.

Increased Auto Sales and Mileage Requirements Bode Well For Injection Molders

As auto sales increase – so do the sales of the plastics manufacturers who supply the industry. In addition, the mileage requirements the automotive industry agreed to last year mean that auto manufacturers will be moving towards more CNG and electric cars. And that means they will also be looking for even more ways to incorporate lightweight plastic parts into new models to ensure that these high-mileage vehicles can maintain a performance level that pleases buyers.

Injection molded engineering resins used in the process of automobile manufacturing include nylons, PET, PPO, polycarbonates, and more.

Let’s face it, we are surrounded by plastics in our homes, offices and automobiles – but the search goes on for more and more applications and molders are pressed to increase productivity and efficiency while maintaining quality.

MoistureMaster™, from NOVATEC, ensures improves part quality by measuring the moisture content of resin in real time and eliminating the need to test and take samples of the materials. Just one more way that molders can achieve the increased productivity, efficiency and quality level required to remain competitive.  To learn more, please visit our website here today.

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Plastic Distribution Continues to See Growth in 2013

February 1st, 2013

In 2012, the plastics industry took off, with more jobs opening up in the field than had been available in decades and shipments of the polymers increasing considerably. The projection for the new year is looking to be just as strong; distribution officials have already begun weighing in with their predictions for continued success in plastic sales in 2013.

The first nine months of 2012 alone showed a positive development for distributors. PolyOne Distribution, deemed “North America’s Premier Resin Distributor,” garnered $788 million in sales during this period, with an operating income of nearly $50 million. From the first nine months of the year prior, this represented a growth of 3% in sales and close to 13% in operating income. Overall, the company saw a 3-4% rise in volume and revenue in 2012; in 2013, the same is expected, with an outlook of mid-to-high single digit rates for the year.

According to the President of PolyOne Distribution, Kurt Schuering, transportation and appliance of resins are expected to do well in 2013, in large part due to initiatives, which seek to create additional manufacturing jobs in the United States. With this movement, Original Equipment Manufacturers, or OEMs, are spearheading an effort to return manufacturing to the United States to improve both the value chain and quality. Last year also saw improved relations between resin producers and distributors to facilitate GDP-plus growth rates.

But what types of plastics in particular show strong growth rates?  Polypropylene will see continued use in consumer goods and housewares. The automotive market has also proven to be an area of increased development, with a high demand for recyclable materials, like engineering resins, to be used in high-end auto applications.

NOVATEC has revolutionized plastics processing with groundbreaking MoistureMaster™ sensor technology.  MoistureMaster  accurately measures resin moisture content of plastic pellets, flake, or regrind  in-line in real time. No more hourly sample taking and testing.  This enhances the quality of parts produced, while reducing faulty parts to an absolute minimum. MoistureMaster™ allows plastic manufacturers to carefully monitor the drying of plastic materials and modify the process to ensure efficient and accurate processing. We look forward to the plastic industry’s continued growth in 2013.

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Sources:

Distributors soaring into new year

Plastics Production Proliferated in 2012, but the Forecast is Uncertain for the New Year

January 25th, 2013

Plastic: whether used to make the furniture we sit on or the dishes we eat from, the synthetic material is used to manufacture a wide array of products. Given the proliferation of plastic-based packaging and goods, it should be no surprise that the U.S. plastics industry recently increased its jobs total by a large number for the first time since the late 1990s. In 2012, the plastics sector in the States employed 885,000 workers, which demonstrated an increase of 1% – or 9,000 individuals – since 2010. The areas with the highest rate of plastics jobs include California, ranked highest with 75,000 positions; Ohio, Texas, Michigan, and Illinois follow. Though produced in this country, many of the plastics products get exported, with Venezuela, Singapore, Nigeria, Russia, and Vietnam comprising America’s biggest partners.

During 2011, plastic-related shipments were shown to have increased by 11%, totaling to over $380 billion. And for 2012? More expansion: the first nine months of the year alone saw the value of exported molds rise by nearly 18%, and the value of exported machinery by almost 8%. The Society of the Plastics Industry (SPI) has confirmed that this growth indicates the sector’s strength over and above other manufacturing industries. But not all is steady and stable: SPI also concluded that even though their jobs, molds, and machinery were all up, total U.S. plastic exports increased by only a fraction of a percent, largely due to uncertainty over how the fiscal cliff would impact the industry.

Regardless, the visible growth in plastics production is apparent, making the need for efficient and accurate processing even more pressing. That’s where MoistureMaster™ comes into play: the state-of-the-art drying sensors allow plastic manufacturers to carefully monitor the drying of plastic materials by measuring and adjusting the moisture content of plastic pellets, flake, and regrind. To learn more, please visit our website here today.

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Sources:

US plastics industry shows gains, but uncertainty clouds 2013 outlook

How to Maintain -40° dew point in a Dual Bed Desiccant Dryer

January 4th, 2013

Plastics processing: it can be as finicky as a toddler, requiring many conditions to be in place to ensure the proper drying of regrind and pellets used to create plastic products. If you work in the industry, you know that one of the magic numbers in this process is -40° — that is, a dew point of -40°. This is the accepted ideal dew point for the heated process air to produce resin that is adequately dried for processing. If your dual bed desiccant dryer isn’t efficiently reaching or maintaining a -40° dew point, there are several aspects of your machine to check in order to make sure everything is functioning as it should. Read our guide below and follow these simple steps to help you get to the bottom of your dual bed desiccant dryer’s dew point problems:

  • Check all hoses, gaskets, and clamps to make sure there are no air leaks in the closed loop air system. Make sure no air is coming through the vacuum loader, either, by being careful to avoid letting the bulk bin get empty, which can suck air into the vacuum loader. Also be sure to consistently keep the wand in your material when filling the hopper.
  • On microprocessor-controlled dryers, it’s important to keep regeneration temperatures set properly according to what your model dryer specifies. Alternatively, if a cam timer controls your dryer, make sure the cam lobes are correctly set, allowing an output to the regeneration heaters.
  • Check your regeneration heater for bad elements with an ammeter.
  • For small dual bed dryers that can process up to 50 lb./hr., look to be sure the valve assembly doesn’t have broken cotter pins, broken springs, bad solenoid, or bad gaskets.
  • For larger dual bed dryers, that process over 100 lb./hr., ensure that the lower valve seal isn’t leaking. If it is, it might be the result of a weakened seal on the valve. You can see if this is the case by checking that the regeneration blower turns backwards when the dryer is in static cooling.
  • Look for clogs in the air lines to the sensor, and ensure air does not blow towards the sensor.
  • Check the dew point circuit in the CPU of a microprocessor-controlled dryer by unplugging the dew point sensor. Verify that the temperature on the sensor within the expected range.

What else goes into maintaining that magic -40° dew point? Proper airflow. Check to be sure your dryer’s airflow isn’t at all constrained by doing the following:

  • Cleaning filters or replacing damaged ones.
  • Tightening hose connections to avoid leaks.
  • Removing any obstacles in the air hoses and checking to make sure linings haven’t collapsed.
  • Replacing any hoses that might have gotten bent.

Just like your car, your dual bed desiccant dryer needs a mechanical check-up from time to time to make sure all parts are running properly – proper dew point is a big part of efficient dryer operation.

If you have any questions about achieving a -40° dew point on your dual bed desiccant dryer, call 1-800-237-8379 or click here today. Remember the MoistureMaster™ On-line, Real Time Moisture Sensing Technology can also facilitate better drying processes with its state-of-the-art ability to measure resin moisture and ensure properly dried product.

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Sources:

Dryer Maintenance

Variable-Frequency Drives: Saving Energy in Plastics Processing

January 4th, 2013

Plastics processors spend thousands of dollars each month on utility bills to power the equipment used to turn resin pellets into plastic parts. With the rising cost of electricity, cutting energy is essential to the efficient operating functions of processors. Variable-frequency drives, which are adjustable speed drives that control motor speed , are one way of eliminating excessive energy expenditures.

Reducing heat losses by controlling air flow is one of the most effective means of saving energy in the drying of plastic resins. A variable-frequency drive, or VFD, is an operative way to do this because it changes the air flow to suit the need, thereby reducing the energy compared to a static drive..

In a dryer without a variable-frequency drive, as material rate is reduced, temperature increases. Utilizing a VFD controlled system, however, produces a steady state operation.

VFD controls process blower speed and thus the air flow, creating a uniform hopper air return temperature in spite of the change in the material rate. A good control system ensures that the temperature leaving the hopper is only a little bit higher than the temperature of the resin being introduced. This produces the effect of maintaining the heat introduced in the resin, which allows for optimal process stability and heat conservation.

Temperature setback is sometimes attributed as a successful means of energy savings, but it is far less effective than using a variable-frequency drive to reduce energy usage. Here’s why: when the return air from the hopper starts rising, the inlet temperature drops to feed to the resin. Therefore, the resin temperature entering the extruder is lower.  As the extruder goes to melt the resin in the screw, the energy used, either by the additional shear required or the band heaters must increase.  This negates much uf the energy savings of temperature setback.

Temperature setback is an appropriate drying approach when it is used to help resolve resin degradation caused by excessive heating and over-drying when the resin is likely to spend too much time drying in the hopper.   The use of temperature setback is best applied as a material saver – it’s not an energy saving technique.

With a VFD, air flow is controlled, making extruder energy and performance constant and stable – this truly saves energy.  The temperature of the resin entering the extruder is held constant and no additional energy is used by the extruder.  It truly is an energy saving technique and not an energy transfer mechanism.

MoistureMaster™ dryers feature patented variable frequency drive technology that dries resin faster and reduces energy costs.

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Sources:

VFD’s & Temperature Setback Effect on Process Energy

 

Plastics in Medical Implants on the Rise: News from Plastics Processors

December 21st, 2012

Hospitals and medical centers are beginning to rely as much on plastic as they do the doctors, nurses, and health care workers that treat patients. Think about it: disposable syringes, bed pans, heart valves, IV bags, and more are all made of plastic. Dominating medical implant technology in particular, plastic manufacturers are making strides to develop synthetic materials that are safe for long-term insertion in the human body.

Twenty-plus years ago, plastic implants were more experimental than an accepted application and practice. But chemical companies that broke into the field early have been innovating products that have now become standard in medical use. The FDA has been providing 510(k) clearances of PEEK related devices, which are semi-crystalline engineering thermoplastics .These clearances help monitor new medical devices developed for human use, identifying their role in the marketplace as well as their safeness and effectiveness. In the past decade, there’s been a significant increase in the number of plastics products for medical use that have received FDA 510(k) approval. In 2001, only one implantable device that contained PEEK garnered a 510(k) clearance, whereas in 2011, that number rose to 17. This year alone, there were 6 FDA 510(k) clearances for PEEK products in the first quarter.

Regardless of the clearances plastic implants are receiving, currently, high prices of PEEK materials found in implants are limiting their widespread use in practical applications. PEEK is considered desirable because of its properties, but high manufacturing costs caused by abundant testing procedures, set in place to reduce risks and liabilities, means that price points for these synthetic materials are steep.

About MoistureMaster:

Groundbreaking MoistureMaster™ sensors measure and adjust the moisture content of plastic pellets, flake, or regrind. This state-of-the-art technology allows plastic manufacturers to carefully monitor the drying of plastic materials and modify the process to ensure efficient and accurate processing. This is particularly important when it comes to any plastic part used for medical purposes.

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Sources:

Use of plastics in medical implants is soaring

A Consumer Guide to Recycling Plastics: Plastics Processing

December 14th, 2012

Look around you: there’s plastic everywhere. From the obvious forms of it like disposable water bottles and utensils to the less commonly thought of manifestations – your PC keyboard, car parts, and product packaging – the American marketplace has developed a strong reliance on the synthetic material. Though recycling continues to catch on as an important part of plastic consumption, many Americans are still either unsure or uniformed about all the different varieties of plastic that exist and the rules surrounding their reuse. We’re here to break down plastic types and recyclability with this step-by-step guide.

Number 1 Plastics

These are your soft drink bottles, vegetable oil containers, medicine cases, and other prevalent consumer product packaging. Number 1 plastics are generally made from PET or PETE (polyethylene terephthalate) and used for single-use goods because it is economical to produce and relatively easy to recycle. In spite of its reusability, the recycling rate for number 1 plastics is still low at about 20% , indicating a real gap in consumer education and follow through when it comes to its recycling. Manufacturers continue to push for the use of number 1 plastics as cost-effective options for packaging that yields minimally negative environmental impact when recycled properly.

Number 2 Plastics

A higher density, more durable polyethylene plastic is used for thicker containers – like the ones that hold laundry detergent and shampoo. Another easily recycled plastic, number 2 products often get remade into toys, floor tile, pens, and more, and are touted for their low risk of leaching breakdown products.

Number 3 Plastics

Made of polyvinyl chloride (PVC), this tough form of plastic withstands weather and is therefore often use in building materials like piping and siding. Most recycling centers don’t accept number 3 plastic, even though many people mistakenly believe it can be recycled. Certain plastic lumber makers may take number 3 products, however, and process them for reuse in decks, paneling, gutters, flooring, and so forth.

Number 4 Plastics

Chances are you have a storage closet or drawer somewhere in your house stuffed with plastic shopping bags made of low density polyethylene (LDPE). Why the frequent build-up of disposable bags? Most curbside recycling services do not accept them, and many shoppers haven’t yet completely converted to the reusable bag system. Other forms of number 4 plastics include bread bags, frozen food packaging, carpet, and squeeze bottles.

Number 5 Plastic

With a high melting point, polypropylene (PP) is often used for containers meant for holding hot liquids and is accepted by some curbside programs. Straws, syrup bottles, yogurt containers, and the like are often manufactured from number 5 plastic.

Number 6 Plastics

When you grab takeout or a box for leftovers, it’s probably made of polystyrene (PS), which are moderately recyclable and often turned into things like insulation, egg cartons, foam packaging, and of course – more food packaging.

Number 7 Plastics

These are the miscellaneous plastics – ones made of various different types of numbers 1-6 or with formulations that are not widely utilized. Sometimes branded with a number 7 and other times not at all, these plastics are the most difficult to recycle – sunglasses, iPod cases, nylon, and more. Conscious consumers can return products made of these materials to the manufacturer to let them handle the recycling of these difficult-to-breakdown synthetics.

NOVATEC has helped transform the way plastics are processed by producing resin dryers with groundbreaking MoistureMaster™ sensors that measure and adjust the moisture content of plastic pellets, flake, or regrind –  greatly improving the quality of parts produced, reducing faulty parts to an absolute  minimum. This innovative technology allows plastic manufacturers to carefully monitor the drying of plastic materials and modify the process to ensure efficient and accurate processing. We are committed to reducing the overuse of non-renewable resources used to make plastics through our drying systems that make the recycling of plastics possible.

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Sources:

What Do Recycling Symbols on Plastics Mean?

What are 5 Commonly used Plastics?

 

How Resin Dryers for Plastic Recycling Can Benefit the Auto Industry

December 7th, 2012

With finite natural resources and the rising costs of fuel, the auto industry has spearheaded an effort to manufacture cars that rely less on gasoline and more on power sources like electricity and hydrogen. But there is a Catch 22…in order to produce lightweight vehicles that run efficiently, automakers utilize a higher quantity of plastic components and, on average, 100 gallons of oil is required to manufacture those parts. This move towards efficient cars has placed increasing pressure on the plastics industry to process  plastics more efficiently and make plastics more recyclable.

Earlier automobiles were considered to be gas-guzzlers and were mostly made of heavier metal parts. Contemporary cars have countless plastic components in efforts to push for better fuel efficiency.  Seat frames , dashboards, bumpers, engine components, exterior panels and the like add up to over 260 pounds of plastic per vehicle but greatly reduces the auto weights from years gone by.

Though there are different varieties of plastic requiring different manufacturing techniques, on average, it takes about 0.4 gallons of crude oil to make a pound of plastic. That means that about 8% of the world’s oil production is used to make a myriad of plastic products. How much of that plastic finds its way into automobiles? In the 27-year period from 1977-2004, the use of plastics in U.S. automobiles has increased from 4.6% to 7%.

In order to minimize the effect that all these plastic auto components have on the world’s oil consumption, industry experts are proposing possible solutions to improving plastics’ impact on the environment, including making them biodegradable, producing them from renewable resources like corn and sugarcane, transforming the way in which they are recycled and improving the ways they are processed.

NOVATEC has contributed to the reinvention of the way plastics are processed by producing resin dryers that utilize the groundbreaking MoistureMaster™ sensors that measure and adjust the moisture content of plastic pellets, flake, or regrind –  greatly improving the quality of parts produced, reducing faulty parts to an absolute n minimum. This state-of-the-art technology allows plastic manufacturers to carefully monitor the drying of plastic materials and modify the process to ensure efficient and accurate processing. As the auto industry creates more and more vehicles with even more plastic components, it is becoming imperative that auto manufacturers use every pound of plastic (and every .4 gallons of oil) in the most efficient way possible.  Follow us on Facebook, Twitter, and Google+ today!

Sources:

The Chemistry of Life: The Plastic in Cars