/ŶŶŽǀĂƟŽŶƐĨŽƌƉƌŽĐĞƐƐŝŶŐĂŶĚƚŽŽůŝŶŐƚĞĐŚŶŽůŽŐLJ Magazine ƉůĂƐƟĐƐŵĂĐŚŝŶĞƌLJŵĂŐĂnjŝŶĞ͘ĐŽŵ ƵŐƵƐƚϮϬϭϵ Problem Solved HEATERS WARM THE MELT, NOT OPERATORS

Problem: Band heaters on injection presses were slow to heat up, wasting money and creating an uncomfortable work environment. Solution: ‹‰ŠǦ‡ˆϔ‹ ‹‡ ›”ƒ†‹ƒ–„ƒ””‡Ž heaters dramatically reduced machine start-up times, saving money and keeping employees cool. By Bruce Adams PAYBACK PERIODS on industrial equipment investments are usually „‡‡ϐ‹–•Ǥ

–ǯ•‘–‘ˆ–‡–Šƒ–ƒ plant will see a complete return calculated in years based on expected on its investment ‹Ž‡•• –Šƒƒ›‡ƒ”ǡ „—––Šƒ–ǯ•™Šƒ–

‡Ž‹ ƒ”‘†— – ‹•‡š’‡ –‹‰ –‘ƒ Š‹‡˜‡ƒ–‹–•

‘””ƒ ‡ǡƒŽ‹ˆǤǡ ‹Œ‡ –‹‘‘Ž†‹‰’Žƒ–Ǥ s ‡Ž‹ ƒ‹•–ƒŽŽ‡†‡šƒ–‡”‹ƒŽ•ǯŠ‡”ƒŽ

‘–”‘Ž‘Ž—–‹‘ȋȌ„ƒ””‡ŽŠ‡ƒ–‡”•ǡ™Š‹ Š—•‡

”ƒ†‹ƒ–Š‡ƒ–ƒ†‹•—Žƒ–‹‘–‘†‹”‡ ––Š‡Š‡ƒ–‹–‘ –Š‡‡Ž–ǤŠ‡ ‘’ƒ›”‡’Žƒ ‡†–”ƒ†‹–‹‘ƒŽ„ƒ†Š‡ ƒ–‡”•‘ͳͲ‹Œ‡ –‹‘‘Ž ‹‰ƒ Š‹‡•–Šƒ–™‡”‡ Rex Materials Inc. photos ”‡Ž‡ƒ•‹‰–‘‘— ŠŠ‡ƒ–‹–‘–Š‡‡˜‹”‘‡ Above, Pelican Products’ Gabe Guerra touches a TCS d radiant heater to illustrate its safety. Doing this on a ™Š‹ Š ™ƒ•–‡†‡‡”‰›ƒ†”‡•—Ž–‡†‹Ž‘‰ t, ƚƌĂĚŝƟŽŶĂůŚĞĂƚĞƌďĂŶĚǁŽƵůĚĐĂƵƐĞĂƐĞǀĞƌĞďƵƌŶ͘ Inset: Rex Materials’ TCS barrel heaters start-up Š‡ ‘’ƒ›‹˜‡•–‡†ƒ’’”‘š‹ƒ–‡Ž› times. ̈́ͻͷǡͲͲͲǡ‹ Ž—†‹‰̈́ͳͲǡͲͲͲ‹‹•–ƒŽŽƒ–‹‘ ‘•–•ǡ–‘ our savings and the larger th ‘—–ϐ‹––Š‡ƒ Š‹‡•ǡ™Š‹ ŠŠƒ˜‡ Žƒ’‹‰ˆ‘” ‡• – ƒ†‡ƒŽ‘–‘ˆ•‡•‡ ‘’ƒ’‡”ǡ ‘™™‡ ‡ˆ‘” ‡‡–ǡϐ‹”‡ •ƒˆ‡–›ƒ†‡–‡”–ƒ‹‡– e incentive," Guerra ”ƒ‰‹‰ˆ”‘͸ͲͲ–‘•–‘ͳǡͺͲͲ–‘•ǡƒ ‘”†‹‰–‘ Œ—•–‡‡†–‘ ‘ϐ‹”–Šƒ–™‡ƒ”‡‰‡––‹‰–Š‡ •‡ –‘”•Ǥ‡Ž‹ ƒŠƒ••‹šƒ—ˆƒ –—”‹‰Ž‘ ƒ–‹‘• said. " ƒ„‡ —‡””ƒǡ†‹”‡ –‘”‘ˆƒ—ˆƒ –—”‹‰‘’‡”ƒ–‹‘  •ƒ˜‹‰•–Šƒ–™‡‡š’‡ –Ǥdz ‹‘”–Š‡”‹ ƒǡ—”‘’‡ƒ†—•–”ƒŽ‹ƒǢ –Š”‡‡ ‘ˆ

‡Ž‹ ƒ‡š’‡ –•–‘ƒ Š‹‡˜‡ƒ—ƒŽ•ƒ˜‹‰•‘ˆ ‡šƒ–‡”‹ƒŽ•‹•–ƒŽŽ‡†–Š‡Š‡ƒ–‡”•‘‘‡ –Š‘•‡ ƒ”‡‹–Š‡ǤǤ –‘’‡”ƒ–‡•‹ ʹ͸ ‘—–”‹‡• ns. ̈́ͺͲǡʹͶͲ„›—•‹‰ͶͳʹǡͲͳ͵ˆ‡™‡”‹Ž‘™ƒ––Š‘—”•–‘ ƒ Š‹‡’‡”™‡‡ˆ‘”ͳͲ™‡‡•†—”‹‰ ’Žƒ‡† ™‹–ŠʹͶ‹–‡”ƒ–‹‘ƒŽ•ƒŽ‡•‘ˆϐ‹ ‡•Ǥ

Š‡ƒ––Š‘•‡ͳͲ ƒ Š‹‡•ǤŠ‡ ‘’ƒ›ƒŽ•‘‹• ™‡‡‡†•Š—–†‘™•ǡ•‘’”‘†— –‹‘™ƒ•‘– ”‘†— –‹‘”‡•—Ž–•ƒ†‹‹–‹ƒŽ‡‡”‰›•ƒ˜‹‰•

‡Ž‹‰‹„Ž‡–‘”‡ ‡‹˜‡̈́ͶͶǡͳͳʹ‹‹ ‡–‹˜‡•ˆ”‘ ƒˆˆ‡ –‡†Ǥ ƒ”‡•‘‡ ‘—”ƒ‰‹‰–Šƒ– —‡””ƒ‹–‡†•–‘‹•–ƒŽŽ m ‘—–Š‡”ƒŽ‹ˆ‘”‹ƒ†‹•‘ǡ‹–•—–‹Ž‹–› ‘’ƒ›ǡˆ‘” DzŠ‡‹•–ƒŽŽƒ–‹‘™ƒ••‘‘–Šǡƒ†‹–™ƒ•ƒ –Š‡”ƒ†‹ƒ–Š‡ƒ–‡”•‘ˆ‘—”‘”‡’”‡••‡•

‹˜‡•–‹‰‹‡‡”‰›•ƒ˜‹‰•ǡŠ‡•ƒ‹†ǤŠƒ–‡“—ƒ–‡•–‘ •‡ƒŽ‡••–”ƒ•‹–‹‘ǡdz —‡””ƒ•ƒ‹†ǤDzŽŽ–Š‡‡™ ‡š–

ƒϐ‹”•–Ǧ›‡ƒ”•ƒ˜‹‰•‘ˆ‘”‡–Šƒ̈́ͳʹͶǡͲͲͲ‘ƒ Š‡ƒ–‡”„ƒ†•™‡”‡‹•–ƒŽŽ‡†„›’”‹ŽʹͲͳͻǡƒ† year. "We plan on doing this whether we get ̈́ͻͷǡͲͲͲ‹˜‡•–‡–Ǥ we already are noticing substantial savings on the incentives or not," he said. Dz‡ ‘—Ž†Šƒ˜‡•–ƒ”–‡†„›‹•–ƒŽŽ‹‰–Š‡ our ‡‡”‰›„‹ŽŽ•Ǥdz Ken Van Nimwegen, global Sales manager at ‘‘Ž›‘‡ƒ Š‹‡ƒ†”‡ ‡‹˜‡†ƒ— Š Rex Materials, said that injection molding •ƒŽŽ‡”‹ ‡–‹˜‡ǡ„—–™‡”‡ ‘‰‹œ‡† The company manufactures protective machines with clamping forces of 300 tons or that the larger cases, temperature-controlled packaging and larger are ideal for the company's TCS radiant weather-resistant flashlights used by several heaters. 18 Plastics Machinery Magazine August 2019 industries, including the military, law Problem Solved DzŠ‡•ƒŽŽ‡”ƒ Š‹‡•†‘ǯ–—•‡ƒ•— Š DzŠ‡”‡‹•ƒ•ƒˆ‡–›ˆƒ –‘”ǡ™Š‡”‡‹ˆ•‘‡„‘†› ‡‡”‰›ǡ„—––Š‡”‡ƒ”‡‘–Š‡”ˆƒ –‘”•–‘ ‘•‹†‡”ǡdz Dz‡™‘—Ž†Ž‘•‡ƒ›™Š‡”‡ˆ”‘ͳͲ–‘ʹͷ ’—–•–Š‡‹”Šƒ†‘ƒ–”ƒ†‹–‹‘ƒŽŠ‡ƒ–‡”„ƒ†ǡ‹–

ƒ‹™‡‰‡•ƒ‹†ǤDz ˆ ‘’ƒ‹‡•”—ƒŠ‹‰Š ‹—–‡•‡˜‡”›–‹‡ƒƒ Š‹‡™‡–†‘™Ǥ‹–Štemperature. Then you can restart production. ‹•ͷͲͲ†‡‰”‡‡•ƒ†›‘—™‹ŽŽ‰‡–„—”‡†ǡdz —‡””ƒ

ϐŽ‘™”ƒ–‡™‹–Š“—‹  › Ž‡–‹‡•ǡ–Š‡›ƒ”‡ –Š‡”ƒ†‹ƒ–Š‡ƒ–‡”•ǡ‡˜‡”›–Š‹‰‹•‹•—Žƒ–‡†ǡ •ƒ‹†ǤDz‡•Š‹‡Ž†‘’‡”ƒ–‘”•ˆ”‘–Šƒ–„› ‘˜‡”‹‰

–Š‡„ƒ””‡Ž•‘–Šƒ–†‘‡•ǯ–Šƒ’’‡Ǥ‹–Šǡ  ƒ ‡Ž–‹‰‘”‡’Žƒ•–‹ ƒ†–Š‡›‡‡†‘”‡ ƒ† ›‘—ƒ”‡‘–Ž‘•‹‰ — ŠŠ‡ƒ–Ǥ‘™ ™‡‘Ž› ’Žƒ ‡›Šƒ†‘–Š‡Š‡ƒ–‡”™Š‹Ž‡–Š‡ƒ Š‹‡ ‡‡”‰›Ǥ –ǯ•‘”‡ƒ„‘—– Ž‘•‡ƒ ‹—–‡‘”–™‘ƒ†–Š‡Š‡ƒ– ‹•„ƒ  —’–‘ ‹•”—‹‰ƒ†‹–‹•‘Ž›ƒ„‘—–ͺͲ‘”ͻͲ†‡‰”‡‡•Ǥ  ™Š‡”‡‹–™ƒ•™Š‡ ™‡•Š—––Š‡ƒ Š‹‡ †‘™Ǥ the energy used for ‘— ‘—Ž†‡˜‡”†‘–Šƒ–™‹–Š–Š‡‘Ž†Š‡ƒ–‡” ˆ›‘—•Š—– ‹–†‘™ˆ‘”ˆ‘—”Š‘—”•‘”‘˜‡”‹‰Š–ǡ heating than the tonnage of press." „ƒ†•Ǥdz ›‘—™‹ŽŽŠƒ˜‡ –‘™ƒ‹–Ž‘‰‡”ˆ‘”‹––‘ Š‡ƒ– –’”‡••–‹‡ǡ‡Ž‹ ƒŠƒ†‘–›‡–—•‡†–Š‡ In addition, available space on and „ƒ —’ǡ „—–‘–ƒ•Ž‘‰ƒ•‹ˆ™‡Šƒ†–‘™ƒ‹–ˆ‘” ”ƒ†‹ƒ–Š‡ƒ–‡”•†—”‹‰•—‡”‘–Š•ǡ around an injection molding machine can be a –Š‡„ƒ†Š‡ƒ–‡”•ǤŠ‡ ‘ˆˆ‡”•ƒ ’”‘†— –‹‘ „—– —‡””ƒŠƒ•‰”‡ƒ–‡š’‡ –ƒ–‹‘•ƒ„‘—––Š‡‹” limiting factor. ‡ˆϐ‹ ‹‡ ›‰ƒ‹Ǥdz ’‡”ˆ‘”ƒ ‡Ǥ "The bigger machines have a lot more space ƒ‹™‡‰‡•ƒ‹†‡šƒ–‡”‹ƒŽ• DzŠ‡”‡‹•ƒŽ‘–‘ˆ”ƒ†‹ƒ–Š‡ƒ––Šƒ– ‘‡•‘ˆˆ to work on," Van Nimwegen said. "We need 3.25 ‘†— –‡† ƒ ‘–”‘ŽŽ‡†•–—†›–‘ †‡–‡”‹‡ –Š‡–”ƒ†‹–‹‘ƒŽŠ‡ƒ–‡”„ƒ†•ǡdzŠ‡•ƒ‹†ǤDzŠ‡‹– inches around the entire circumference of the –Š‡‘”‡–‹ ƒŽŠ‡ƒ– ϐŽ‘™–‘–Š‡‡Ž–ƒ†–‘–Š‡ ‹•ͻͲ†‡‰”‡‡•‘—–•‹†‡ǡ‹–‹•ͳͲͲ‹•‹†‡™‹–ŠƒŽŽ–Š‡ barrel to install the TCS. Smaller machines have •—””‘—†‹‰ƒ”‡ƒˆ‘” –”ƒ†‹–‹‘ƒŽŠ‡ƒ–‡”„ƒ†• Š‡ƒ–‡”„ƒ†••‡†‹‰‘ˆˆƒ„‹‡–Š‡ƒ–ǤŠ‡ more interference, like the nozzle shut-off valve. ƒ†ˆ‘”„ƒ””‡ŽŠ‡ƒ–‡”•ǤŠ‡•–—†›ˆ‘—†–Šƒ– •—‡” ‘‡•ǡ™‡™‘ǯ–ˆ‡‡Ž–Šƒ–ƒ††‹–‹‘ƒŽŠ‡ƒ– It is a combination of needing extra space for ʹͷ’‡” ‡–‘ˆ–Š‡‡‡”‰›„‡‹‰ ’”‘†— ‡†„› –Šƒ–™‡ǯ˜‡ˆ‡Ž–‹–Š‡’ƒ•–„‡ ƒ—•‡ ‘–ƒ‹•–Š‡ installation and the energy consumption that Š‡ƒ–‡”„ƒ†•‰‘‡•‹–‘–Š‡‡Ž– ƒ†͹ͷ’‡” ‡– Š‡ƒ–Ǥdz makes machines above 300 tons the better ‰‘‡•‹–‘–Š‡‡˜‹”‘‡–Ǥ ‘” „ƒ””‡Ž Bruce Adams, senior staff reporter range." Š‡ƒ–‡”•ǡ–Š‡•–—†›•Š‘™‡†–Šƒ–ͺͲ’‡” ‡– [email protected] The biggest benefit of the TCS is its ability to retain heat on the injection molding of For more information machines, which improve machine productivity, the energy being produced goes into the melt Pelican Products Inc., according to Guerra. while 20 percent goes into the environment. Torrance, Calif., 310-326-4700, "When a machine goes down for a color TCS also improves safety because www.pelican.com change, a mold change, maintenance or for operators are less likely to be burned if they Rex Materials Inc., whatever reason, you have to cut the power and accidentally touch the unit. Traditional heater Howell, Mich., 404-558-1653, you start losing heat," Guerra said. "When you bands allow more heat to escape, creating touch www.rexmaterials.com start the machine back up, you have to wait for hazards and hot working conditions. the band heater to come back up to

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