THIRD QUARTER 2012 N VOLUME 31 N NUMBER 3 Conference Edition

Home , Plastics Engineering, Rotational molding, Thermoforming

A JOURNAL OF THE THERMOFORMING DIVISION OF THE SOCIETY OF PLASTIC ENGINEERS THIRD QUARTER 2012 n VOLUME 31 n NUMBER 3 Conference Edition

Made IN MICHIGAN

Thermoformer of the Year page 7 INSIDE … Market Outlook page 10 Influencing Thermoforming Properties of PP Films with Additives page 14 Scholarship Winners page 24

Thermoforming QUARTERLY 1 WWW.THERMOFORMINGDIVISION.COM 2 Thermoforming quarterly Thermoforming THIRD QUARTER 2012 Thermoforming Quarterly® VOLUME 31 n NUMBER 3 Quarterly® A JOURNAL PUBLISHED EACH Contents CALENDAR QUARTER BY THE n Departments THERMOFORMING DIVISION OF THE SOCIETY OF Chairman’s Corner x 2 PLASTICS ENGINEERS Thermoforming in the News x 4-5 Editor University News x 24-25 Page 24 Conor Carlin (617) 771-3321 [email protected]

made in michigan Sponsorships Laura Pichon (847) 829-8124 Fax (815) 678-4248 [email protected]

Page 24 Front Cover Conference Coordinator n Features Gwen Mathis (706) 235-9298 Fax (706) 295-4276 The Business of Thermoforming x 10-13 Market Review and Outlook 2012 [email protected] Thermoforming Quarterly® is pub- ANTEC Paper x 14-18 lished four times annually as an infor- mational and educational bulletin to Influencing Thermoforming Properties of Polypropylene Films with the members of the Society of Plastics Additives Engineers, Thermoforming Division, and the thermoforming industry. The name, “Thermoforming Quarterly®” Industry Practie x 20-21 and its logotype, are registered trade- marks of the Thermoforming Division Pressure Forming and Special Effects – A Game Changer for Designers of the Society of Plastics Engineers, Inc. No part of this publication may be re- Page 7 produced in any form or by any means without prior written permission of the publisher, copyright holder. Opinions n of the authors are their own, and the In This Issue publishers cannot be held responsible for opinions or representations of any 2011 Thermoformer of the Year x 7 unsolicited material. Printed in the U.S.A. 2013 Conference x 29 Thermoforming Quarterly® is registered in the U.S. Patent and Trademark Sponsorships x 36 Office (Registration no. 2,229,747). x

Thermoforming QUARTERLY 1 Thermoforming Chairman’s Corner Quarterly® Inspiration, Ideas

Phil Barhouse and Innovation Several large processers, we will all be ready to raise a toolmakers and machinery glass to this ambitious program builders all call the Wolverine and to future of the industry. State home. Of course, no conversation about Michigan is With experts in thermoforming s a Board, one of our complete without talking about processes, materials and goalsA is to find better and more the profound impact that the sustainability, this year’s efficient ways of reaching out automotive industry continues technical program has something to the thermoforming industry. to exert in U.S. manufacturing. for everyone. Jim Throne will The flagship annual conference Thermoforming touches on be covering advanced topics is the most visible way that we multiple aspects of automotive while Eric Shiffer from Tech II accomplish this goal. supply, including innovative will explain how his company new developments in material When I started in this industry has brought the European in- science, exciting part design and mold labeling technology to the almost 20 years ago, we value-added service. communicated by telephone U.S. We will have our popular and by attending conferences. Grand Rapids offers us a unique thermoforming workshops, full Of course, today’s technology view into the heart of this days of technical presentations provides multiple ways of manufacturing mecca. While this and plant tours. Allen Extruders, gathering the information we region of the country still faces Formed Solutions and Fabri-Kal need, but I will argue that it is challenges, we can celebrate will be opening their doors for technical conferences that truly recent accomplishments such as you. provide the most effective means the $700,000 National Science of exchanging ideas for all of us Foundation grant awarded to As always, I would like to in the thermoforming industry. Mid Michigan Community hear your ideas, comments and No matter how advanced our College (see story on page 25). feedback. Together we will communication gets, I believe It is perhaps the most important continue to advance our industry that face-to-face discussions topic in our industry – workforce through inspiration, ideas and between suppliers, vendors, development – and we are consultants, customers and innovation. x delighted to celebrate this award students help keep our industry growing and competitive. with the recipients in their home state. Given that Grand Rapids Phil Barhouse Michigan is a state renowned was named “Beer City USA” for expertise in thermoforming. (well, tied with Asheville, NC),

2 Thermoforming quarterly Thermoforming New Members Quarterly®

Chris Allen Ron Eugene Hengst, Jr. Doug Ripley Mike Thornton Fabri-Kal Corp. MTS Medication Duo-Form Plastics Thermoforming Consulting LLC Duncan, SC Technologies Edwardsburg, MI Cadiz, KY St. Petersburg, FL Ian Ashton Marco Roche Riccardo Tresso Lake Forest, IL Joe Herres Plasticos Del Litoral S A Skydex Technologies Spartech PEP Guayaquil Centennial, CO Joseph L. Blass Newark, NJ Fabri-Kal Corp. Eduardo A. Rosales Kurt E. Valaskey Hazleton, PA Andrew Hinsley Dart Container Corp. University of Wisconsin-Platteville KYDEX, LLC Mason, MI Hazel Green, WI Randy Blin Barnsley, South Yorks Blin Management Co. Javier Alejandro Sabena Kjetil Vier Independence, IA Dan Kellenberger Cordoba Bryne Plast EGR USA Bryne, Rogaland Dave Bonadona Ontario, CA Dipak Sen Gupta ITW Deltar Ridat Co. Bart J. Wagner Frankfort, IL Mark Kishel London Computer Designs Inc. Arrowhead Plastic Whitehall, PA Ray Brooks Engineering Inc. Mohan Shanmugam Georg Utz Inc. Eaton, IN IAC Keith D. Ware Edinburgh, IN Rochester Hills, MI Designware Inc. Babu Kuruvilla Shelton, WA Steve Campbell Duni Corp. David A. Shipman Les Plastiques Qualiplast, Griffin, GA Hampel Corp. James Lynn Winters, Jr. Inc. Germantown, WI Commercial Vehicle Group Salaberry-de-Valleyfield, Gilles Le Du Tigard, OR QC Schneller Inc. Sev Sorensen Kent, OH Brentwood Industries Inc. Matt Wurz Simon Cheung Reading, PA Subzero Freezer Co. Summit Mfg. Pty. Ltd. Anthony Lewis Madison, WI Huntingwood, NSW CCMI Inc. John Thibado Geneva, NY Advanced Extrusion Inc. Sonia Villamizar Roger H. Dean Becker, MN Multipartes SA Prent Corp. Bryan Mace Cali Janesville, WI Solo Cup Co. Lake Forest, IL Blake Michael DuPont Willamette Plastics Inc. Tim Mallory Canby, OR Centennial, CO Why Join? Brian Paul Dupont Daniel Merritt Willamette Plastics Arrowhead Plastic Canby, OR Engineering Inc. Eaton, IN Hector L. Echaniz EasyPak LLC Steven Meyns Leominster, MA Vitalo Industries Meulebeke Tony Eigenmann Nursery Supplies Inc. Sylvia S. Moore Orange, CA Shintech Inc. Akron, OH Hemit D. Gandhi It has never been more important to be a member Mutual Industries Ltd. Matt O’Hagan Mumbai Maharashtra LyondellBasell Industries of your professional society than now, in the current W. Bloomfield, MI climate of change and volatility in the plastics industry. Gustavo Gomes De Amorim PLM Plastics SA Armando A. Petitjean Now, more than ever, the information you access and Curitiba Parana CEP AP4 Business LLC the personal networks you create can and will directly Miramar, FL Cory David Greene impact your future and your career. The Fabri-Form Co. Mario Perez New Concord, OH Creative Ideas S.A. Active membership in SPE – keeps you current, keeps Bogota Phillip Grim you informed, and keeps you connected. Robinson Industries, Inc. Gregory R. Pockat Coleman, MI Bemis The question really isn’t “why join?” Oshkosh, WI Daniel M. Hawkins, Sr. but … Spectre Industries Ralph Danny Quillen Chandler, AZ D&W Fine Pack Fort Wayne, IN Larry Hawkins Carlisle FoodServices Dan J. Renn Products CVG Why Not? Batavia, IL New Albany, OH

Thermoforming QUARTERLY 3 Thermoforming in the News

Mid Michigan The college is also going to create The acquisition will allow CW to expand its customer base and offer Community College programs to teach skills in welding and computer numerical controlled Analytic’s products at a lower cost, he Starting Two-Year machining. said. Thermoforming A Mid-Michigan Plastics Industry Analytic vacuum forms parts, mainly Degree Alliance is forming to serve as an for commercial customers, in contrast advisory board. to CW who uses both vacuum and By Bill Bregar, Plastics News Staff pressure forming to make specialized Posted July 25, 2012 HARRISON, MI (12:55 p.m. ET) Govitz said community colleges can and technical parts, he said. play a key role in helping industry id Michigan Community compete. MMCC officials say CW also offers in-house tooling, MCollege is starting an Michigan has more than two thousand engineering and assembly. It largely associate’s degree program in skilled-trade job openings, the most of serves the transportation, aerospace, thermoforming plastics technology – any state. industrial and medial markets. the latest two-year plastics program CW is more focused on using the designed to teach job skills. “It’s a national issue and there’s this huge mismatch that’s occurring out in expansion to broaden its customer The National Science Foundation the world between people who are job- base rather than its product offerings, has awarded a $717,000 grant over and plans to “use our technologies to skill ready. And it’s at every level,” he three years to fund the program at get to a broader range of customers,” said. MMCC’s campus in Harrison, MI, x Brennan said. northwest of Midland. CW, a privately owned company, does “We’re looking primarily to serve Thermoformer not disclose financial information. It the local employment needs here, CW Thomas Buys currently has 45 employees. which are crying for people,” said Analytics reported sales of $1 million Scott Govitz, MMCC executive Local Rival Analytic in 2012, according to the most director of workforce and economic Plastics recent Plastics News survey of North development. By Jessica Holbrook, Plastics News Staff American thermoformers. x Students can begin taking some of Posted July 30, 2012 PHILADELPHIA, PA (3:55 p.m. ET) the classes this fall. The NSF grant will help the college buy equipment, W Thomas Inc., a thermoformer Faurecia Launches Govitz said. Cbased in Philadelphia, has acquired custom thermoformer 2nd Fraser Site “We’re advertising for a grant Analytic Plastics Inc. By Rhoda Miel, Plastics News Staff coordinator right now,” he said in Posted August 2, 2012 FRASER, MI (4:30 p.m. ET) mid-July. CW will move tools and some equipment from Analytic’s plant in uto supplier Faurecia SA has The associate’s degree will be nearby Bensalem, PA, to its own Alaunched production at its second transferrable to Ferris State 80,000-square-foot facility, and take plant in Fraser, and already has space University’s four-year bachelor’s over Analytic’s orders and inventory. set aside for future expansion. degree in plastics engineering technology. Govitz called it a The two plants are located about 10 Faurecia, with North American “laddered approach.” Ferris State miles apart. Three of Analytic’s six operations based in Auburn Hills, MI, began renovating an empty 160,000- is in Big Rapids, MI, about an hour employees will move to CW, said Bob square-foot building in January and is away from MMCC in Harrison. Brennan, vice president of operations. now producing key interior parts for Govitz said that part of Michigan has “It’s a very small company, but for us, General Motors Co.’s Cadillac ATS several thermoforming companies, it’s a nice little expansion,” he said by and Ford Motor Co.’s Focus. and they need employees with skills. phone. It has one injection molding machine MMCC students can get shorter Brennan would not disclose terms of in use now and space for up to 14, said certificate programs. the deal. plant manager Damien Duclair during

4 Thermoforming quarterly an interview at the plant’s August 2 opening ceremony. An overhead crane system covers the entire molding area, which is a key to the company’s rapid tooling changeover system, Single Minute Exchange of Dies, or SMED, practiced in Fraser and elsewhere globally. The name points to the company’s target, not its current tooling change pace, Duclair added. In addition to injection molding, the plant thermoforms thermoplastic olefin skins used on center consoles and doors and has in-house welding and assembly. It makes 10 different components for the Cadillac interiors, among them the glove box, knee bolster, defroster grille and front and rear door panels. The door panels use a natural fiber thermoplastic composite, which helps to reduce weight and resin content, Faurecia North America President Mike Heneka noted. It takes in parts from its sister plant on nearby 14 Mile Road in Fraser, another Faurecia site in Mexico and coordinates final assembly on some parts with sequencing specialists. The Masonic plant is working with recyclers who can separate multilayer scrap and allow the site to reuse the material, Duclair said. Faurecia entered the North American market less than 10 years ago and has been growing steadily since then. It is now the eighth largest auto supplier in North America, Heneka said. In addition to its interiors business, the company – with global headquarters in Nanterre, France – supplies seats, exterior systems including front-end modules and exhaust systems. Michigan Governor Rick Snyder joined a contingent of city, county and state officials to mark the opening ceremony, with Snyder noting Faurecia’s growing employment base in the state. x

Thermoforming QUARTERLY 5 See Excerpt on Pages 10-13

REDUCE! REUSE! RECYCLE!

6 Thermoforming quarterly 2011 Thermoformer of the Year

Randy A. Blin Executive Vice President Blin Management Co./Triangle Plastics Independence, IA

andy A. Blin has contributed dedicated accounting, manufacturing and administration Rservice over an extended period of covering a 20 year career at Triangle Plastics time to the Thermoforming Industry and to Randy was a dynamic leader. Triangle the SPE Thermoforming Division. Randy operated as a family owned thermoforming continues to carry that dedication and business and grew from a basement focused organizational structure in numerous operation in 1965 to the largest heavy gauge endeavors. It is clear from Randy’s career thermoforming company in North America that if you have a plan and the desire to do by 1998. Randy was closely involved in that whatever is necessary to act on that plan you growth, providing creativity and innovation will make a difference. with an emphasis on customer relationships, Randy Blin has a lifetime of making a process optimization, materials development difference. and strategic acquisition management. Those changes and that passion were Randy became an Eagle Scout at the age of Randy has a keen ability to analyze instrumental in developing the trade show 16. This is the same year he entered into the a situation and effectively formulate a environment of the conference model business world as a dishwasher at Kentucky successful action plan. He was a pioneer today. Randy clearly communicated that Fried Chicken. Within a year, as a high in the Thermoforming Industry leading the the conference is presented to provide school senior, he was the store manager and way in the transformation to CNC automated a service to the Thermoforming Industry he was just getting started. From that early trimming and cellular manufacturing. His with a mission to provide an educational introduction Randy has honed an extensive visions created the benchmark for the sheet event that broadens the exposure of and diversified business career built on hard fed Thermoforming industry to effectively form thermoforming technology. work and initiative. and finish parts with repeatable accuracy at With the vision of communicating the As the Executive Vice President of a very competitive price. At Triangle Plastics, value of the Thermoforming Industry as a Blin Management Co., Randy directs he led the acquisition team that successfully quality, engineering based process Randy the business activities of the Blin family integrated eight acquisitions in just eight years. provided the leadership to further change enterprises. BMC serves as the conduit for Randy became an SPE Thermoforming the Division newsletter from the traditional legal, accounting, and financial advising for Division Board member and made a to a high quality technical / industry managing the day to day activities of over difference. publication. 50 entities. These operations include; Blin After serving 2 years as treasurer he In 2004 Randy received the Farms Limited Partnership, Star Lake Cattle became the Thermoforming Division Chairman Thermoforming Division Lifetime Ranch, Independence BancShares, Inc., and serving a two year term, 1997 and 1998. Achievement Award in recognition Heartland Acres Agribition Center, as well as He continued as Past Chairman serving of his impact to the success of the numerous business consulting initiatives. on the Executive Committee in 1999 and SPE Thermoforming Division. The As for community activities Randy is 2000. As Chairman, Randy stayed focused advancements of the SPE Thermoforming making a difference. Randy has volunteered and committed to establishing a committee Division over the last 15 years, and with as a Founding Director and served as the format that improved the efficiency of Board many aspects of the thermoforming initial president of the Independence Area meetings. It was under Randy’s leadership industry, are the result of Randy’s take Dollars for Scholars. Every student that that the organization developed a structure for charge strength, contagious energy and applies is awarded at least one scholarship. continuity and sustainability within the SPE. inspiring leadership. Randy is active in the leadership at the Many of the changes that SPE has made over Experience and leadership in the First Presbyterian Church of Independence, the last decade to remain viable have can Thermoforming Industry as a business Iowa serving as an elder, president of the trace their beginnings to actions begun by owner and innovator, service to the congregation and chairman of the property the Thermoforming Division in this timeframe. professional society leading to the growth & finance committee. Randy also served on Randy’s leadership was paramount in of resources to further thermoforming the Board of the Hereford Youth Foundation developing much of the respect thermoforming education, continuing corporate success of America where they have worked to build has earned within the engineering and plastics with strategy development and dedicated a 2 million dollar endowment fund for youth processing community. community service, and his ability to be activities. In 1996, as Co-Chairman of the Conference there as a friend and confidant are the true Randy continued to make a difference. in Northern Kentucky, Randy’s passion for attributes of Randy Blin’s career. In the Thermoforming community, Randy success was contagious. Randy expanded There is little doubt that Randy Blin has really made a difference. As a manager the exhibit format and introduced a sponsor made and continues to make a difference. and corporate officer in the areas of sales, level for added value opportunity to exhibitors. x

Thermoforming QUARTERLY 7 Need help with your technical school or college expenses?

f you or someone you know is Iworking towards a career in the plastic industry, let the SPE Thermoforming Division help support those education goals. Within this past year alone, our organization has awarded multiple scholarships! Get involved and take advantage of available support from your plastic industry! Here is a partial list of schools and colleges whose students have benefited from theThermoforming Division Scholarship Program: • UMASS Lowell • San Jose State • Pittsburg State • Penn State Erie • University of Wisconsin • Michigan State REDUCE! REUSE! RECYCLE! • Ferris State • Madison Technical College • Clemson University • Illinois State • Penn College Start by completing the application forms at www.thermoformingdivision. com or at www.4spe.com. x

8 Thermoforming quarterly thermoforming

Achieve a sustainable balance of performance and cost.

UPES® resin is NOVA Chemicals’ proprietary additive resin. When used with polyolefins, this product enables significant source reduction while increasing performance at no additional cost.

Your Solution. Your uPES® rESin.

Sustainability • Up to 20% material source reduction • More efficient machine usage translates to energy savings • Recyclable Benefit • Improved crush strength - by up to 140% • 33% faster forming rates • Better part definition • Shorter start-ups and reduced scrap rates Efficiency • Downgauge • Easy processability at loadings up to 20% by weight • Runs on existing equipment • Blends well with polyolefins

www.upesresin.com • [email protected] • 1.724.770.6610

Thermoforming QUARTERLY 9 Thermoforming The Business of Thermoforming Quarterly® Thermoformers Market Review and Outlook 2012 Reprinted with permission, (Editor’s Note: Thermoforming Quarterly is pleased to provide our members with this exclusive Plastics News Reports excerpt from Plastics News’ recent publication, ”Thermoformers Market Review and Outlook 2012.” We invite our readers to visit www.plasticsnews.com for details on downloading the complete report. Thanks to Crain Communications for licensing rights.)

Thermoforming Market rule, thin-gauge material is used for sectors include medical; signage & & Process Overview packaging applications in a roll-fed displays; lawn & garden; electrical/ process and heavy-gauge is used for electronics; building and construction; s a process for forming plastics, industrial applications in a cut sheet swimming pools and spas; marine; Athermoforming represents one process. Companies covered here aerospace; agricultural; automotive/ of six categories. In those categories serve 22 separate end markets, 18 of transportation; appliances; and pallets. covered by Plastics News, $97.6 which fall into the industrial category. Smaller manufacturers will maintain billion were recorded in sales for their positions by creating niche companies ranked during 2011. The packaging industry is seeing markets. Thermoforming represented 9.7 substantial growth, especially for percent of the total market. Though sustainable packaging alternatives This report focuses on the North it’s a relatively smaller category in that will bolster recycling efforts American thermoforming market, plastics processing, thermoforming and cradle-to-cradle sustainability which has undergone significant is poised for growth. Advancements initiatives. Global packaging industry change over the past five years. revenues will increase to $530 billion in tooling, machinery and materials Thermoformers, material suppliers,and by 2014.1 That is an increase of make the process a viable choice equipment makers had a sizeable in many cases where it wouldn’t roughly 24 percent over 2009. Plastics presence during the International have been considered in the past. packaging will be the largest segment Plastics Exposition 2012, held April Essentially, the thermoforming of that. As a percentage of total sales, 1-5 in Orlando. Officials interviewed process can be broken down into the industrial sector decreased from there reported that both heavy-gauge two categories: pressure forming 18.4 percent of the total pie in 2007’s and thin-gauge sectors are growing and vacuum forming. During the ranking to 13.3 percent in 2012’s nicely, and companies across the thermoforming process, a heated ranking. That does not necessarily supply chain appeared busy at the start sheet of plastic is placed onto a mold mean that industrial has shrunk, of 2012. (male or female) where it is shaped however. Packaging has grown at a or formed. It is cooled, trimmed, very rapid pace. Industrial applications finished and fabricated into its final are finding their home in other Plastics News has been tracking part. markets like medical, for example, and ranking companies involved in where advances in equipment and thermoforming since the publication Thermoforming can be separated material have translated into advances of its first ranking in 1995. This into thin gauge (0.005" to 0.030") in aesthetic and physical properties. analysis is based on 227 companies and heavy gauge (0.031" to 0.310"), Thermoforming increasingly is with operations in the North American based on the thickness of the sheet taking market share in lower-quantity market for the 2011 business year. that is being formed. As a general applications, officials reported. Those

1 http://www.pikeresearch.com/newsroom/sustainable-packaging-market-to-reach-170-billion-worldwide-by-2014

10 Thermoforming quarterly Thermoformers Mergers Top 10 companies represented 55.8 & Acquisitions Analysis For an illustration of consolidation percent of the total market sales. It activity, one need only look at the increased slightly to 57.6 percent Consolidation is occurring through numbers represented in the Plastics in 2009’s ranking, then took a very all parts of the plastics supply chain, News North American Thermoformers minor dip in 2010, to 56.5 percent. including resin suppliers, machinery Special Report, which has full data Into 2012’s ranking, the Top 10 makers, mold makers and processors, online for 227 companies. That is a represented 63.7 percent of total sales and thermoforming is no exception. As decrease of roughly 4 percent from in the thermoforming market. globalization continues, it behooves one year earlier, when the number was companies to have scale, technological 236. That figure held steady in 2010’s Sonoco Plastics Thermoforming, leadership, marketing prowess and the ranking. But since 2007, the number ranked No. 6 with sales of $330 ability to provide multiple materials of companies reflected in the ranking million, has leaped its way into solutions to compete effectively. decreased nearly 19 percent, from 270 the Top 10. The firm snapped up Not surprisingly, more companies companies in 2007’s ranking to 227 in thermoformer Tegrant Alloyd Brands are moving toward varied models of the 2012 ranking. Inc., which it acquired as part of its vertical integration. In the world of $550 million purchase of Tegrant thermoforming, this can take shape in Interestingly, as the number of Corp. from private equity firm many ways. Companies can vertically companies decreases, the total sales Metalmark Capital LLC. According integrate in tool building and forming; increase. In 2007’s ranking, total to its website, the company partners companies can integrate in sheet sales were $8.2 billion for 270 total with the world’s largest food brands extrusion and forming. The models companies; in 2012, total sales reached in the consumer packaged goods that will take shape will depend on a $10.6 billion for 227 companies. But and food-service industries. It company’s market position and where what provides better support to the processes CPET and polypropylene. and how it makes the most sense to consolidation trend is the market share Its technologies include monolayer, take costs out of the business. of the Top 10. In 2008’s ranking, the coated and barrier and non-barrier laminated tubs, cups, spools, consumer and institutional trays.

Through 2011, smaller deals were happening, too. Spara LLC acquired the assets of TriEnda LLC. Spara bought TriEnda in a distressed situation, acquiring the assets from Fifth Third Bank in a foreclosure sale. Officials at that time acknowledged revenue problems at TriEnda.2

At the beginning of 2012, the activity didn’t seem to be slowing. In March, for example, No. 3 Dart Container Corp. ($480 million estimated thermoforming sales) announced it was buying No. 2 Solo This chart illustrates the continued impact of consolidation in the thermoforming market. Since 2008, the Top 10’s total share of the market increased from 55.8 percent to 63.7 percent in 2012. Cup Co. ($790 million estimated For 2012, the Top 10 companies are: Pactiv Foodservice; Solo Cup Co.; Dart Container Corp.; thermoforming sales). This was a $1 Genpak LLC; Berry Plastics Corp.; Sonoco Plastics Thermoforming; D&W Fine Pack LLC; Fabri-Kal billion transaction.3 Corp.; Anchor Packaging Inc.; and Tekni-Plex Inc.

2 http://www.plasticsnews.com/headlines2.html?id=11070400102&q=Spara+Logistics 3 www.plasticsnews.com: “Dart buying Solo Cup for $1 billion,” March 22, 2012. (continued on next page)

Thermoforming QUARTERLY 11 The M&A activity has been company in early 2010. Rohrer makes Because the definition of occurring from strategic and private thermoformed blister packaging as sustainability is so broad, these equity purchasers, and often, there well as paper cardstock for blisters initiatives vary in scope, size and can be a mix of both, for example, and folding paper cartons. ShoreView approach. with a strategic buyer that has private owns four other plastics-related equity backing. businesses. Dart Container Corp., for example, has an entire website dedicated to Smaller companies are gobbling Industry Mega Trend: “Environmental Information.”6 Dart up additional plants in bolt-on Sustainability is educating consumers through purchases. In January, Peninsula Major players across the plastics initiatives like, “Did you know …” Packaging Co. LLC (No. 12 in the industry have been increasing their where it lets views know that the ranking) of Exeter, Calif., purchased sustainability initiatives. In a review company’s sustainability efforts two thermoforming plants from by Plastics News of each website save enough energy each year to Berkley Operations LLC, which does of the Top 15 thermoforming heat nearly 105,000 homes. The business as Packaging Plus LLC.4 companies, each company had at company also lets site visitors know The company announced in March least one mention of “sustainability,” that it recovers waste heat from its that it would expand the acquired “environment,” or “recycling” or manufacturing processes and uses plant in Yakima, Wash., with a related language placed prominently it to heat buildings and boiler feed $20 million investment. In a deal on its home page or within one click water. between two thermoforming firms, once on its home page. Rohrer Corp. has purchased Buckell Sonoco markets itself as a leader Plastic Co. Inc. for an undisclosed Genpak LLC (No. 4 on the ranking) in recycling services and as one of price. Acquiring Lewistown, Pa.- has its sustainability initiatives the nation’s largest recyclers. The based Buckell will allow Rohrer to branded as “The Green Room” on its firm operates six material recovery strengthen its position in the visual home page. facilities, an increase from three that packaging market, officials said in it operated in 2010.7 a Jan. 4 news release. Buckell “is Berry Plastics (No. 5 in the ranking) a well-run company with products outlines its areas of focus. On its Spartech Packaging Technologies website, officials let viewers know that and customers that complement our of Portage, Wis., listed as No. 28 sustainability touches every aspect current book of business,” Rohrer on the ranking with $66 million of its business and the company has President and CEO Scot Adkins said in thermoforming sales, is part of prioritized its activities by focusing in the release. Buckell has annual Spartech Corp., which launched its on specific areas that have the greatest sales of about $3.5 million. Its first corporate sustainability report in impact. Its goal is to reduce overall 50,000-square-foot Lewistown plant resin usage by 5 percent, increase use March. Vicki Holt, Spartech Corp.’s – which makes custom thermoformed of recycled content in its products president and chief executive officer, packaging for medical, food, retail and continue to develop products that said corporate sustainability has and other markets – will join Rohrer incorporate bio-based materials.5 been part of Spartech for some time, plants in Wadsworth; Buford, Ga.; but the company has broadened its and Huntley, Ill. This marks the first This response has been due in part to communication efforts, increased deal for Wadsworth, Ohio-based mega-retailers like Wal-Mart Stores awareness, raised its standards and Rohrer since private equity firm Inc. mandating supplier changes started to monitor progress toward its ShoreView Industries of Minneapolis in its Sustainability Scorecard, and goals.8 bought controlling interest in the government mandates.

4 www.plasticsnews.com: “Peninsula buys two thermoforming plants,” January 9, 2012. 5 www.berryplastics.com 6 http://www.dart.biz/web/environ.nsf/pages/menu 7 Sonoco 2011 annual report, pg. 10. 8 Spartech Corp. Press Release, March 28, 2012

12 Thermoforming quarterly The company illustrates its Manufacturer’s Zero-Waste-to- this more apparent than NPE2012: manufacturing sustainability Landfill Workshop in Raleigh, N.C., The International Plastics efforts through technologies such in late 2011. Showcase. GN Thermoforming, for as EnviroAir. This is a foaming example, showcased its plug-assist technology that allowed Spartech to In early 2012, the Society of the thermoforming machinery and reduce the amount of plastic used Plastics Industry Inc. and the tooling technology. The cut-in-place in a Danone yogurt cup by up to 20 National Association for PET machine is targeted for medium-to- percent. The materials require less Container Resources (NAPCOR) low-volume runs. Officials touted energy to thermoform, are lighter in announced that three United States its energy efficiency and minimal weight than solid sheet and provide recycling operators were selected to waste production. improved thermal insulation.9 receive grants toward establishing model programs for collection and Conclusion The efforts are not restricted to intermediate processing of PET Processors will continue dealing packaging applications. Spartech thermoformed packaging. with the volatility in resin pricing released its Reinforce product and must maintain a cautious line of compounds, which allows Resin Pricing Impact outlook for a moderately improving the company to produce thinner Companies have been struggling U.S. economy. At the writing of wall designs that meet structural with raw material price increases, this report, the U.S. economy was requirements for industrial in addition to increases in prices experiencing moderate growth. The applications. for energy and freight costs. The Federal Open Market Committee most dominant resins used in on April 25 released its decision Even among smaller firms, the thermoforming process are to keep the federal funds rate at sustainability and recycling initiatives polyethylene, polypropylene, 0 to 0.25 percent at least through have become a way of doing polystyrene and PET. 11 2014. Global financial markets are business. Shepherd Thermoforming & experiencing their own problems, Packaging Inc. of Brampton, Ontario, HDPE (extrusion sheet), has which can have significant impact promotes the use of materials that experienced a 13 percent increase on the performance of the U.S. come from recycled plastics wherever in per-pound pricing since January economy. possible, according to its company 2011 and an increase of 6.5 percent website. In 2011, the company since January 2012. PP (extrusion Although the labor market has processed close to 2 million pounds sheet) has experienced a 21 percent improved, unemployment does of RPET, letting its customers know increase since January 2011, and a remain high in the U.S. Effective that activity is equivalent to diverting 20 percent increase since January companies must consider all macro- roughly 36 million water bottles from 2012. PS (high-impact, extrusion) is economic factors when choosing the landfill.10 up 25 percent on per-pound pricing how to deploy resources, especially since January 2012, and 13 percent in a sector such as thermoforming. | At Dordan Manufacturing Co. Inc. since January 2012. All the data is for of Woodstock, Ill., officials have a large-volume purchases of more than “Recycling in America” blog. The 20 million pounds per year. company offers a bioresin show and tell; Wal-Mart Scorecard Packaging Machinery makers serving this sector Modeling; and a Four-Step Design have been making adjustments in for Sustainability Process. The their equipment as well. Nowhere was company also presented at the Green

9 Sustainability Report 10 www.shepherdthermoforming.com/materials-recycling.html 11 Plastics News’ Thermoforming & Packaging Special Report, March 5, 2012

Thermoforming QUARTERLY 13 Thermoforming ANTEC Paper Quarterly®

InfluencingINFLUENCING THERMOFORMING Thermoforming PROPERTIES OF POLYPROPYLENE Properties FILMS of WITH ADDITIVES Polypropylene Films with Additives Prof. Dr.-Ing. Ch. Hopmann, Prof. Dr.-Ing. Dr.-Ing. E. h. W. Michaeli, Dipl.-Ing. M. Begemann By Prof. Dr.-Ing. Ch. Hopmann, Prof.Institute Dr.-Ing. ofDr. Ing.Plastics E. h. W. ProcessingMichaeli, Dipl.-Ing. at M. RWTH Begemann, Aachen Institute ofUniversity Plastics Processing (IKV), at RWTH Germany Aachen University (IKV), Germany

AbstractAbstract Raw Thermo- Extrusion Film Part material forming The processing and product characteristics of thermoformed polypropylene can be influenced by the Polymer Process Product Process Product amorphous temperature crystallinity absorption wall thickness additives added during the extrusion process. The Institute partially pressure colour heating time top load of Plastics Processing (IKV) at RWTH Aachen crystalline throughput gloss temperature barrier cooling transparency pressure surface University, Germany, is conducting extensive tests with homopolymer additives thickness stretching ratio sealability the different additives in extrusion and consecutive copolymer fillers COF cooling printability thermoforming. This paper deals with the influence of slip, antiblocking and antistatic agents on the Integrated examination of the process chain thermoforming behavior of polypropylene. FigureFig 1. 1. Effects Effects on on properties properties of ofthermoformed thermoformed parts. parts.

Introduction Introduction Many raw material producers have cut down their product portfolio. Therefore especially smaller film Thermoforming is the process of choice for producers cannot get hands on customized materials for manufacturing thin-gauge or large-area parts for their applications anymore. Thereby, the addition of packaging or technical applications [1]. The process additives is increasingly relocated to the processors. The allows low-weight parts to be produced very rapidly and multiplicity of additives and the interaction among each economically. other often do not allow an a priori assessment of the effectiveness. Many film producers tend to overdose the The wall thickness distribution is an essential and additives to achieve the required effect definitely. The often critical characteristic of thermoformed parts [2]. It precise composition of the raw materials and possible influences the necessary part weight among other additives are often unknown. On that account it is hardly important properties. Beside mechanical properties like possible to create a specific additive range for a certain strength and rigidity the wall thickness distribution affects application. e.g. the permeation behavior. This criteria describes the sturdiness of the packaging and the shelf life of the A well-directed matching of the additives to the packed victuals. thermoforming application can avoid overdosing or the addition of unneeded additives. The saving of expensive The semi-finished product is decisive for the quality additives and the optimization of the heating behavior can of the thermoformed part. Thermoforming uses (co-) positively influence the productivity and the energy extruded films from amorphous and semi-crystalline consumption. This paper shows the characteristics of thermoplastics. With the choice of the polymer the basic polypropylene with additives. properties of the posterior part are fixed. Therefore many raw material producers offer optimized materials for the AdditivesAdditives for thermoformingThermoforming applicationsApplications thermoforming process. The film production for thermoforming application Beside the choice of the raw material the extrusion uses a huge variety of additives: parameters widely influence the thermoforming behavior and the properties of the thermoformed part. For example nucleating agents (metal oxides, talc, …) a very fast cooling of the melt of semi-crystalline thermoplastics leads to a fine spherulite structure. The fillers (talc, chalk, …) same effect can be achieved by the use of nucleating colorants (TiO2, carbon black, pigments, …) agents or colored pigments which act as initial nucleus. antistatic agents (fatty acid esters, …) To validate the influence of additives on the product antiblocking agents (polydimethyl siloxane, …) properties of thermoformed parts, it is necessary to slip agents (internal & external) examine and to analyze the entire process chain (Fig 1). There are processing aids that influence for example the flow characteristics of the melt or the surface friction of the film and additives that directly affect the

14 Thermoforming quarterly mechanical and thermal properties of the film. If the compatibility to the polymer [8]. The amid molecules fraction is less than 5 % it is named ‘additive’. When it is orient on the surface in a way, that the polar amide groups between 10 and 70 % is usually called ‘filler’ [3]. The (-CONH2) are in contact with polymer and themselves. additives are typically added as masterbatch to the The hydrocarbon chains are projected outwards and avoid extrusion process. In the following the additives used in contact with other surfaces. this paper are described.

AntistaticAntistatic agents Agents

Plastics are electrical insulators and can build up high electrical charges. This can lead to handling problems during transportation, storage and packing [4]. Electrostatic charges e.g. can hinder the separation of packing units. In food packaging hygienic aspects like freedom of dust between thermoforming and filling are essential. Antistatic agents help to reduce the electrical surface resistance so far, that dust attraction and potential Figure 2. Migration behavior of fatty acid amines Fig. 2. Migration behavior of fatty acid amines process disturbances through electrostatic charges are (according to [9]. minimized [5]. Those charges also lead to dust enclosure (according to [9]). and lacerated edges of printed images [6]. AntiblockingAntiblocking agentsAgents Internal antiblocking agents are added during film extrusion to influence the electrical surface resistance. Antiblocking agents inhibit the adhesive sticking of This can be fatty acid ester or amide, ethoxylated amine, adjacent layers of film. This sticking, also called blocking, alkyl sulphonate and cyanophthalocyanine which are often occurs in tightly wound rolls and when sheets are incorporated into the base material. Those agents are stacked under pressure and heat [7]. The action incompatible to the base material and migrate to the mechanism of antiblocking agents differs from slip surface. The resulting hydrophilic layer attracts water agents. The antiblocking agent obtrudes to the surface due from the surrounding which leads to conductivity [3]. The to shrinkage of the film thickness during solidification. effect of antistatic agents is depending on the ambient This creates a surface roughness that helps to minimize conditions during storage as well as from the time film-to-film contact and hence reduces blocking. Typical between production and further processing. substances used are inorganic and synthetic silicates and talc. SlipSlip Agents agents MachineryMachinery The friction properties of films are very important during film extrusion and the subsequent thermoforming. For the film extrusion the IKV is equipped with an Films with high COF tend to wrinkle during winding. extrusion line with 60 mm-extruder (L/D=27), gear pump Sleek films with a low COF lead to shifting of the inner and a slit die with an adjustable lip. Due to the local layers of the reel, the so called telescoping [7]. The adjustability of the melt flow at the outlet of the die, a friction behavior is greatly affected by the surface homogeneous distribution of the melt can be warranted. properties, which can be adjusted by the use of slip and antiblocking agents. The thermoforming tests are conducted on a single station thermoforming machine type LDFG 23 (Illig Slip agents are widely used in films for packaging Maschinenbau GmbH & Co. KG, Heilbronn/ Germany). applications. The literature differs between internal slip This machine is equipped with a both-sided quartz IR- agents, which reduce the melt viscosity, and external slip heating. The parts are formed with negative plug-assist agents, which act as lubricants between melt and metal thermoforming into a cup-shape with an opening diameter cladding [3]. The last one should be finely dispersed in the of 60 mm and a drawing depth of 40 mm. melt and be incompatible with the polymer. During cooling the slip agent migrates to the surface. After a The wall thickness distribution of the formed cups is certain time there will be an equilibrium state between the determined nondestructive using a MagnaMike 8000 from slip agent remaining in the film and on the film surface. Panametrics GmbH, Hofheim/ Germany. The measured COF stabilizes to a constant value [7].

Polyolefines mostly use fatty acid amides. The slip agent molecules migrate to the surface due to their weak

(continued on next page)

Thermoforming QUARTERLY 15 MaterialsMaterials antistatics: 1.0/ 1.5/ 2.0 weight-% For the tests a polypropylene (PP) HP400H of Basell slip agents: 1.0/ 1.5/ 2.0 weight-% Polyolefine GmbH, Wesseling/Germany, was used. This antiblocking: 2.0/ 2.5/ 3.0 weight-% homopolymer is featured with a basic stabilization but no further additives or fillers. It is widely used for To solely examine the additive influence, the thermoformed cups and trays, blister packs and flower thermoforming parameters are kept constant throughout pots. the experiments.

The additives were provided as masterbatches by heating power: 500 W A. Schulman GmbH, Kerpen/Germany and Clariant forming temperature: 163 °C Masterbatches (Deutschland) GmbH, Ahrensburg/ plug displacement: 95 % Germany. Table 1 provides an overview of the deployed forming pressure: 4 bar additive masterbatches. GM2 is based on polyethylene, all other masterbatches are based on polypropylene. The Results main active ingredient of the antistatic agents is

ethoxylated amine. The slip agents are based on erucic After film extrusion the analysis of the film, acid amide and the antiblocking agents use synthetic thermoforming and part properties is performed. The silica. reference film without additives and the corresponding properties are indicated in the following with “Ref”. Table 1. Additives Additives used.used.

additive abbr. name supplier The results of the DSC show no definite dependency antistatic AS1 ASB 20 G A. Schulman of the degree of crystallization on the additive dosage. agent AS2 ASPA 2446 A. Schulman The addition of the antistatic and slip agents result in a slip agent GM1 SPER 6 A. Schulman slightly lower degree of crystallization (Fig. 3). With (external) GM1 CESA-slip PEA Clariant exception of the antistatic AS1 the degree of 0025148 crystallization increases slightly with increasing dosage of antiblocking AB1 ABPP 05 A. Schulman additive. This indicates a nucleating effect of the agent AB2 CESA-block Clariant additives. Micrographs show a finer spherulite structure 1102 with increasing additive dosage. Evidently the additives act as additional crystal nucleus and lead to a finer

DOE crystalline structure. DOE 52 All parameters concerning the extruder are kept 50 constant during film extrusion with different additives. This is necessary to differ between the influence of the 48 extrusion parameters and the additives. Particularly the 46 film thickness is kept constant to keep the films 44 comparable. 42

degree crystallinityofdegree [%] 40 cylinder: 210/ 230 / 240/ 250/ 250 °C Ref die: 250 °C AB1_1% AB1_2% AB2_1% AB2_2% AS1_2% AS1_3% AS2_2% AS2_3% chill roll: 20 °C GM1_1% GM1_2% GM2_1% GM2_2% speed melt pump: 20 min-1 FigureFig. 3. 3. Degree Degree ofof crystallizationcrystallization dependingdepending on on additive feed pressure pump: 70 bar additive type.type film thickness: 1.2 mm The use of additives influences the surface properties The additive masterbatches are added individually of the films. The coefficients of friction (COF) are with different dosages to characterize the influence on the measured using a self-construction. A test sled with a thermoforming properties separately. The research contact area of syntactic foam is pulled with a defined concerning the combined adding of additives are not part speed over the tempered film surface. The required force of this paper. To depict possible saving potential the is measured and the COF is calculated. manufacturer recommendation is chosen as maximum dosage. The following dosages are chosen for the different Fig. 4 shows the average over the results of all additive masterbatches: dosages of one additive. The low standard deviations proves the assumption, that the influence of the dosage is

16 Thermoforming quarterly very low. The exception is the slip agent GM1. The COF distributions of the cups with antistatic agent films are decreases from 0,189 at 1 % masterbatch to 0,108 at shown in Fig. 6. The kind of additive influences the wall 1,5 % masterbatch. At high dosages it does not decrease thickness distribution. The lower the COF of the film, the further. Adding antistatic and slip agents leads to a less the wall thickness at the bottom of the cup. reduction of the COF compared to the reference in the 1,0 range of 33-73 %. Adding any antiblocking agent bottom side increases the COF around 22 %. 0,8 0,5 0,6

0,4 0,4 0,2 wall [mm] wall thickness

0,3 0,0 0 10 20 30 40 50 60

COF [-] 0,2 measuring position [mm]

Ref AS1 AS2 0,1 FigureFig. 6. 6. Influence Influence of of antistatic antistatic agents agents on on wall wall thickness 0,0 thicknessdistribution distribution. Ref AS1 AS2 GM1 GM2 AB1 AB2

FigureFig. 4. 4. InfluenceInfluence ofof additives additives on onCOF COF at room at room The last examination presented in this paper is the top temperature.temperature load behavior. The cups are pressed in a tensile testing machine. The force at failure (Fmax) and the compression During thermoforming the heating times are at failure (smax) are recorded. Fig. 7 shows the results as an measured. The influence of the additives on the heating average over all dosages again. The additives mainly time is already achieved by the lowest dosage used in this influence the force which the cups can withstand before DOE. An increased dosage does not lead to a further failure. The corresponding compression alternates only influence on the heating time. This is proved again by the 5 % around the value of the reference. The antistatic standard deviation in Fig. 5, which is formed over all agents lead in both cases to a reduction of the maximum three dosages of the same additive. force. The effect of slip and antiblocking agents depend on the exact type of additive and again cannot be Both antistatics lead to reduction of heating time of generalized. about 12 % compared to the reference. The slip agent GM1 leads to a reduction of 18 %, whereas GM2 leads to 250 10 s an increasing of the heating time of 5 %. The same FmaxFmax x atmax Fmax 9 inconsistent scheme is observed for the antiblocking 200 8 agent. AB1 increases the heating time by 17 %, AB2 does 7 not influence the heating time. The conclusion from the 150 6 5 examined additives is, that any antistatic reduces heating 100 4

times. The effect of slip and antiblocking agent depend on force at failure [N] 3 the exact type of additive and cannot be generalized. 50 2

1 [mm] atcompression failure 30 0 0 Ref AS1 AS2 GM1 GM2 AB1 AB2 25 Figure 7. Influence of additives on product behavior. 20 Fig. 7. Influence of additives on product behavior

15 ConclusionConclusion andand perspectivePerspective heating[s] time 10 The quality of thermoformed parts is decisively 5 influenced by the semi-finished product. With the choice of the polymer the basic properties of the posterior part 0 Ref AS1 AS2 GM1 GM2 AB1 AB2 are fixed. Beside the choice of the raw material the additives added during film extrusion widely influence the FigureFig. 5. 5. InfluenceInfluence of of additivesadditives onon heatingheating time time during during thermoforming behavior and the properties of the thermoforming thermoforming. thermoformed part.

This paper did show the characteristics of After thermoforming the wall thickness distribution polypropylene with slip, antiblocking and antistatic of the cups is measured. Exemplarily the wall thickness

(continued on next page)

Thermoforming QUARTERLY 17 agents. The additives have no distinctive influence on the 8. Allan, A.: Surface properties of PE: Effect of an degree of crystallization. A higher dosage of additive amphatic additiv. Journal of Colloid Science 14 leads to a finer crystalline structure. (1959) 2, S. 206-221 9. Maltby, A.; Marquis, R.E.: Slip Additives for Film Both antistatic and slip agents lead to a reduction of Extrusion. Journal of Plastic Film and Sheeting 14 the COF. Antiblocking agents increase the COF. The COF (1998) 4, S. 111-120 directly influences the wall thickness distribution of thermoformed cups. A low COF leads to a low wall thickness at the bottom of the cup. The heating time during thermoforming can be reduced by the use of antistatic agents. But coincidental antistatic agents reduce the force the thermoformed part can withstand.

It was shown, that the lowest dosages used for the experiments are already sufficient to achieve the desired effects. These dosages were chosen lower than the manufacturers recommendation. The thoughtful use of additives has a huge economic potential. The heating time reduction attained by the use of antistatic agents allows possible energy savings in thermoforming production. x

AcknowledgementsAcknowledgements

The research project 16106 N of the Forschungs- vereinigung Kunststoffverarbeitung has been sponsored as part of the "Industrielle Gemeinschaftsforschung und -entwicklung (IGF)" by the German Bundesministerium für Wirtschaft und Technologie (BMWi) due to an enactment of the German Bundestag through the AiF.

Furthermore we would like to thank the companies A. Schulman GmbH, Kerpen/Germany, Basell Polyolefine GmbH, Wesseling/Germany and Clariant Masterbatches (Deutschland) GmbH, Ahrensburg/ Germany, for supplying materials for the experiments.

ReferencesReferences

1. Michaeli, W.: Einführung in die Kunststoffverarbeitung. Munich, Vienna: Hanser, 2010 2. Throne, J.; Beine, J.: Technology of thermoforming. Munich, Vienna, New York: Hanser, 1996 3. Brinkmann, S.; Oberbach, K.; Baur, E.; Schmachtenberg, E.; Osswald, T.A.: International Plastics Handbook: The Resource for Plastics Engineering. Munich: Hanser, 2006 4. N.N.: Atmer anti-static. Croda Europe Ltd., Cowick Hall, East Yorkshire/ Great Britain, 2007 5. Schwarzmann, P.: Thermoforming: a practical guide. Munich: Hanser, 2001 6. N.N.: Tampondruck - Theorie und Praxis. Pröll KG, T Weißenburg/ Germany, 2002 7. Rohse, N.; de Wael, P.; van der Meeren, I.: Gleitverhalten von Folien. In: Wertschöpfung bei der Folienextrusion. Düsseldorf: VDI-Verlag, 1999 Q

18 Thermoforming quarterly T Q

Thermoforming QUARTERLY 19 Thermoforming Industry Practice Quarterly® Pressure Forming and Special Effects – A Game Changer for Designers By Ronn Cort, President at KYDEX, LLC Conversely, pressure forming – a process that integrates design and forming – can deliver low- n recent years, new advances and continuous cost, highly aesthetic parts that rival the process of Iinnovation in the thermoforming industry injection molding. The combination of air pressure have changed the playing field for designers. and vacuum, as well as more sophisticated Previously considered much later in the process, process controls that better monitor tool and sheet thermoplastics were selected on the basis of temperatures, enable the delivery of consistent price, quantity and compliance. Today, designers parts, precise detail and intricate undercuts. are considering thermoplastics at the beginning With air pressure forcing the material into the of the design process, which is paving the way minute crevices of a mold, features like small, for new design capabilities in industries like tight corners, molded-in vents and ribs, and logo aviation, mass transit and medical devices. More silhouettes can be formed more accurately. accurate color matching, special effects and the ability to produce more acute details deliver Pressure forming gives processors the ability to stronger brand recognition and enhance customer selectively texture various surfaces on a single experience. formed component. Instead of embossing a texture into the extruded sheet, thermoformers Advances in thermoplastic materials are now applying the texture directly to the mold development are providing designers with andeliminating the risks of inconsistencies caused capabilities that were previously not widely by stretched or distorted materials. available. Thermoforming processes, like pressure forming, and changes in how the One airline took advantage of new design industry uses molds also contribute to design capabilities inherent in pressure forming when innovations. it created new cup holders for its business class seats. The designer wanted a cup holder that was Pressure Forming selectively textured, with texture on the exterior of the cup holder and a smooth surface on the As pressure forming continues to deliver value- interior. Because pressure forming can create tight added components throughout modern industry, corners that more accurately fit together, the cup thermoformers are improving quality by holder was created in two pieces that were snapped delivering more detailed parts that have greater together, eliminating the need for an additional consistency across the batch. With traditional step of applying adhesive. forming, wall thinning can be a challenge, caused by deviations in how the material is stretched Changes in how thermoformers are using molds over the tool. Furthermore, detail like reverse also deliver a higher quality product. Although angles and undercuts cannot be achieved by temperature-controlled molds have been around traditional forming alone. for decades, in recent years we’ve seen more

20 Thermoforming quarterly widespread adoption of them. Evenly cooling the interiors in Europe and in Asia tend to be more formed part delivers a more stable product, aiding design-forward than in North America, we’re consistency and enhancing quality. starting to see color and translucents play a more prominent role across the industry. One airline, Special Effects based in Eastern Asia, is taking advantage of new thermoplastic design offerings. The airline is evaluating the use of a fountain in its premier class While advances in the process of thermoforming cabin using a colored translucent thermoplastic to deliver more dynamic parts and new capabilities highlight the waterfall through backlighting. for designers, innovations impacting materials like thermoplastics also contribute to new design Designers in the mass transit industry are also functionality. In the past, designers were limited starting to look at new capabilities and how they by the availability of color in compliant materials. might enhance the customer experience. While Special effects – like color and texture – were European mass transit is a true leader in this area, typically only used for high-end products due to American designers are beginning to evaluate new cost. Now, some manufacturers can offer custom possibilities. Thermoplastics manufacturers are color matching capabilities and materials that are working to proactively develop new palettes and fully compliant with highly regulated industries, capabilities to help guide design-forward progress like aviation. For example, a designer that wants for mass transit in the U.S. red for a retail fixture is no longer limited by the cherry red offered by a given thermoplastics The medical device industry is also experiencing manufacturer. Custom color matching enables the changes based on new device and component designer to choose from variations in red such as capabilities presented through advances in burgundy, crimson, brick red, or virtually any red thermoforming. The level of detail achieved in between. through pressure forming allows for more articulately formed recesses, pulls and depressions Beyond color, thermoplastic manufacturers where labels can be applied. While whites and are pushing the boundaries in special effects blues have been the industry standard for medical capabilities. Metallic or pearlescent sheet, equipment, designers are beginning to deviate previously achieved through the application of from traditional colors. New thermoplastic special a special metallic cap, can be created without effects, like metallic finishes, are starting to be additional processing. The use of monolithic sheet applied to give equipment a more “high end” creates consistency of color or of effect through appearance. the entire sheet. For example, if the sheet becomes scratched or damaged in use, the color won’t As designers start to turn to thermoformers earlier, scratch off, increasing part longevity. they’re becoming aware of new capabilities that can transform the design process. As these Translucent thermoplastics are another game- partnerships continue to evolve, thermoformers changer for designers. Now offered in color, and need to think proactively and understand the fully compliant within verticals like mass transit nuances of the industries they serve in order to and aviation, translucents create a new aesthetic continue delivering innovative solutions and high for cabin and rail interiors. Today, translucent quality products. thermoplastics are being used for partitions x between cabin classes, or decoratively for fixtures like lighting or even fountains. While aviation

Thermoforming QUARTERLY 21 22 Thermoforming quarterly Control Your Destiny BROWN IS INNOVATION

Control over product. What gives the Quad greater control over your finished product? Combining high-tonnage stamping (coining) force with high-tonnage holding force, and without platen deflection. This powerful combination produces consistent material distribution, ensuring better part consistency at higher speeds. It all adds up to producing quality parts faster, with less scrap.

The Brown Quad Series high-tonnage Control over process power and user-friendly operation All machine control functions and diagnostics are easily managed at the HMI provides process engineers greater level. An Allen-Bradley open and integrated control over the thermoforming architecture control system with user-friendly process and their finished products HMI and Logix 5000 single program solution. more than ever before. This solution optimizes and synchronizes the functions of logic, motion, and oven control. The system is fully supported worldwide by both Brown and Allen Bradley.

Find out more at: www.brown-machine.com Global Leader in Thermoforming Solutions or call 989.435.7741

Thermoforming QUARTERLY 23 University News

2012 Thermoforming Scholarship Recipients

SHARNA-KAY DOBNEY HARRY KOSHULSKY The Segen Griep Memorial Scholarship - $5,000 The Thermoforming Division Memorial Scholarship Kettering University - $2,000 Sharna-Kay Dobney is an international student from Pennsylvania College of Technology Jamaica pursuing a Bachelor’s degree in Chemical Harry Koshulsky is a senior at the Pennsylvania College Engineering at Kettering University. She is a senior and is of Technology in Williamsport, Pennsylvania. Harry will looking forward to graduating in Spring 2013. In her spare graduate in May 2013 with a Bachelor of Science degree in time, she reads novels, travels, and enjoys swimming and Plastics and Polymer Engineering Technology. He started socializing. She currently holds the position of vice president studying plastics as a junior in high school by taking Dual for Kettering University’s SPE student chapter. She helped Enrollment College Courses in Thermoforming, Injection revitalize the chapter, which had been dormant for the past Molding, Extrusion Blow Molding, Rotational Molding and 5 years. The chapter currently has 13 national members, Basic Machining through the Pennsylvania College of and is actively recruiting for the upcoming Fall 2012 term. Technology Now Program. During his senior year in high Sharna-Kay is a co-op student at Inteva Products, a major school, Harry received an Advanced on the NOCTI (National producer of automotive interior systems, where she has Occupational Competency Testing Institute) for the end of been working with some of the leading advanced materials program assessment in the Computer Aided Drafting and in the automotive industry including thermoplastic olefins Design Program in which he received the Pennsylvania Skills (TPO). At Inteva Products, she has become familiar with Certificate from the Pennsylvania Department of Education. numerous plastic processes, including injection molding, Upon college graduation, Harry will be the first student to thermoforming and compression molding. It is Sharna- complete the Workforce Leadership Dual Enrollment 2+2+2 Kay's dream to make a difference in the plastic industry in the Plastics and Polymers Technology Program. During by contributing to the development of more eco-friendly his summer break, Harry works at TE Connectivity, formerly plastic components. She is honored to be a recipient of the Tyco Electronics, in the Injection Molding Department. His Segen Griep Memorial Scholarship, and is very thankful job responsibilities range from the basic operation of three for SPE’s generosity in providing her with this scholarship. molding presses, inspecting parts for quality assurance, to “It well definitely propel me a step further in pursuing my pulling and setting molds. Since his freshman year, Harry dream,” she stated. x has been a member of the Society of Plastics Engineers Student Chapter at the Pennsylvania College of Technology and a member of the Society of Plastics Engineers National Chapter since his sophomore year. In his junior year, Harry was voted as the Fundraising Chairman of the Society of Plastics Engineers Student Chapter and Fundraising Co- Chairman for his senior year. x

24 Thermoforming quarterly MMCC Receives Grant to Offer Training in Plastics Technology

id Michigan Community College (MMCC) has months, MMCC will work closely with other local Mreceived a three-year grant through the National manufacturing employers to identify their training Science Foundation (NSF) for over $700,000 to and staffing needs and to build short-term training support the creation of a Plastics Technology program programs that specifically meet those needs. on its Harrison Campus. “The plastics industry is stable and growing, and our The new grant will provide for training in the plastics local manufacturers are key to economic vitality in industry through a laddered approach. College this region,” notes Scott Govitz, Executive Director students will be able to pursue non-credit training, of Workforce and Economic Development. “This academic certificates, or an associate’s degree that will grant is aimed at supporting these manufacturers and seamlessly integrate with Ferris State University’s putting people to work in the plastics sector. We’re bachelor’s in Plastics Engineering Technology very excited about the possibilities it holds.” program. The grant serves as a powerful example of the In order to educate K-12 students about high-tech and importance of proactive and collaborative efforts in-demand careers, manufacturing career awareness to provide local opportunities that make significant opportunities will be provided through classroom local impacts. MMCC is enthusiastic about working instruction, field work and apprenticeships. with FSU and the CGRESD to increase the impact of the plastics program in both scope and reach. The plastics program at MMCC represents a collaborative partnership between the college, the MMCC’s technical offerings are undergoing Clare-Gladwin Regional Educational Service District a number of changes. Over the last few years, (CGRESD), and Ferris State University (FSU). technical facilities and programs have been upgraded Funding through the grant will support the creation of and modernized. Included in these changes are program curriculum, the purchase of new equipment roughly $2,000,000 in upgrades to both the MMCC for hands-on training prep, as well as a program welding lab and the Heating/Refrigeration/Air director. Conditioning facility, which included the addition of working geothermal fields for student study and Building from the existing trade and technical classes research. that MMCC offers, a new level of classes that focus specifically on the plastics technology arena will be “MMCC has always remained flexible and adaptable developed over the next two years. The grant also so that it could meet the needs of area industry and provides possibilities and opportunities for area employers,” Govitz said. “Our new structure brings manufacturers who seek qualified training in this all of the college’s technical offerings under one emerging field. umbrella that offers students and employers one place to get the training they need.” x Direct assessments of area employment opportunities in the plastics field prompted the college to procure To learn more about the the NSF grant and develop a plastics program. This Technology Center at MMCC or the initiative represents a deepening of the college’s technical and trade offerings, partnership with area manufacturers. Over the coming visit midmich.edu.

Thermoforming QUARTERLY 25 26 Thermoforming quarterly From the Editor

f you are an educator, student or advisor in a college or university Iwith a plastics program, we want to hear from you! The SPE Thermoforming Division has a long and rich tradition of working with academic partners. From scholarships and grants to workforce development programs, the division seeks to promote a stronger bond between industry and academia.

Thermoforming Quarterly is proud to publish news and stories related to the science and business of thermoforming: ISO 9001:2000 • New materials development Juliet Oehler Goff, President/CEO, Kal Plastics • New applications

• Innovative technologies

• Industry partnerships

• New or expanding laboratory facilities

• Endowments REDUCE! REUSE! We are also interested in hearing from our members and colleagues RECYCLE! around the world. If your school or institution has an international partner, please invite them to submit relevant content. We publish press releases, student essays, photos and technical papers. If you would like to arrange an interview, please contact Brian Winton, Academic Programs, at: REDUCE! REUSE! [email protected] or 989.435.7718, ext. 32 RECYCLE!

Thermoforming QUARTERLY 27 Have an Idea for an Article for TQ? Submission Guidelines

• We are a technical journal. We strive for objective, technical articles that help advance our readers’ understanding of thermoforming (process, tooling, machinery, ancillary services); in other words, no commercials.

• Article length: 1,000 - 2,000 words. Look to past articles for guidance.

• Format: .doc or .docx

Artwork: hi-res images are encouraged (300 dpi) with appropriate credits.

Send all submissions to Conor Carlin, Editor

[email protected]

28 Thermoforming quarterly MARK YOUR CALENDAR! September 9 – 12, 2013 22nd Annual Thermoforming Conference Atlanta, Georgia

Co-Chair Bret Joslyn Joslyn Manufacturing 9400 Valley View Road Macedonia, OH 44056 330.467.8111 [email protected]

Co-Chair Eric Short Premier Material Concepts (PMC) 2040 Industrial Drive Findlay, OH 45840 248.705.2830 [email protected]

Cut Sheet Technical Chair Roger Jean Premier Material Concepts (PMC) 2040 Industrial Drive Findlay, OH 45840 567.208.9758 [email protected]

RENAISSANCE WAVERLY HOTEL Roll Fed Technical Chair Mark Strachan & COBB GALLERIA UVU Technologies 6600 E. Rogers Circle Boca Raton, FL 33487 754.224.7513 [email protected]

Parts Competition Jim Arnet Kydex Company 3604 Welborne Lane Flower Mound, TX 75022 For Reservations: 972.213.6499 1-888-391-8724 [email protected] Request SPE Room Rate of $169.00 SAVE THE DATE!! www.thermoformingdivision.com

Thermoforming QUARTERLY 29 Meet the Two Fastest in the World.

Peregrine MR-J3 Servo Falcon 2100 Hz 202 MPH Speed Frequency Response Time

Blazing fast response time means one thing: maximum Maximize your solution with throughput. This is paramount to achieving the lowest total of cost ownership (TCO) with your investment. our Servos and Motion Controls. But there’s much more. An auto-tuning function saving hours of set-up and tuning time. A patented design for MT Works2 Motion Software the most compact and efficient motors in the industry. Bus speeds of 50 Mbps when you combine our servos and motion products. And the widest range of motors Single-Axis available from 50 watt up to 220 kW. All this adds up Stand-Alone to why Mitsubishi is ranked #1 in the servo and motion business worldwide. Get with the best to be the best and watch your competitors take a swan dive.

Motors up to 6000 RPM Multi-Axis for iQ Series

www.meau.com

30 Thermoforming quarterly Are You

Our mission is to facilitate the http://www.linked.com/ advancement of thermoforming groups?gid=3992496&trk=myg ugrp ovr technologies through education, application, promotion and Group Name: research. Thermoforming Division, a subgroup of SPE SPE National Moderator: Executive Director Mark Strachan Willem de Vos 13 Church Hill Road Newtown, CT 06470 USA Trending Topics Phone: +1 203-775-0471 (as of September 6th, 2012) Fax: +1 203-775-8490

1. How to start a thermoforming plant Conference Coordinator 2. Applications for high dies and steel rule Gwen Mathis dies in PET 6 S. Second Street, SE Lindale, Georgia 30147 706/235-9298 With over 380 members and growing, the Fax: 706/295-4276 Thermoforming Division is using Linkedin email: [email protected] to expand the conversation. Meet fellow professionals, ask tough technical questions, Visit Our Website at: explore related groups. www. thermoformingdivision. Join us today! com

Thermoforming QUARTERLY 31 32 Thermoforming quarterly 2012 REDUCE! REUSE! RECYCLE! EDITORIAL CALENDAR Quarterly Deadlines for Copy and Sponsorships ALL FINAL COPY FOR EDITORIAL APPROVAL

15-FEB Spring 30-APR Summer

31-JUL Fall 15-NOV Winter Conference Edition Post-Conference Edition All artwork to be sent in .eps REDUCE! REUSE! RECYCLE! or .jpg format with minimum 300dpi resolution.

Become a Thermoforming Quarterly Sponsor in 2013!

Additional sponsorship opportunities will include 4-color, full page, and 1/2 page.

RESERVE YOUR PRIME SPONSORSHIP SPACE TODAY. Questions? Call or email Laura Pichon Ex-Tech Plastics 847-829-8124 [email protected]

BOOK SPACE IN 2013!

Thermoforming QUARTERLY 33 Executive 2012 - 2014 THERMOFORMING DIVISION ORGANIZATIONAL CHART Chair Committee Phil Barhouse

Chair Elect Secretary Treasurer Councilor Prior Chair 2012 - 2014 Mark Strachan Bret Joslyn James Alongi Roger Kipp Ken Griep CHAIR 2012 Conference Phil Barhouse Finance Nominating AARC Grand Rapids, MI Membership Spartech Packaging Technologies Bob Porsche Tim Hamilton Rich Freeman Haydn Forward & Haydn Forward Lola Carere 100 Creative Way, PO Box 128

Ripon, WI 54971 Publications / Antec 2013 Conference Communications Technical Committees Advertising (920) 748-1119 Brian Winton Atlanta, GA Clarissa Schroeder Fax (920) 748-9466 Laura Pichon Bret Joslyn [email protected] Newsletter / Technical Conference Processing Student Programs Recognition Editor Coordinator Haydn Forward Brian Winton Juliet Goff CHAIR ELECT Conor Carlin Consultant Gwen Mathis Mark Strachan Global Thermoforming Materials OPCOM Technologies Roger Jean Mark Strachan 1550 SW 24th Avenue Ft. Lauderdale, FL 33312 Machinery (754) 224-7513 Don Kruschke [email protected]

TREASURER James Alongi MAAC Machinery 590 Tower Blvd. Carol Stream, IL 60188 (630) 665-1700 Fax (630) 665-7799 [email protected] SECRETARY Bret Joslyn Joslyn Manufacturing 9400 Valley View Road Macedonia, OH 44056 (330) 467-8111 Fax (330) 467-6574 [email protected] COUNCILOR WITH TERM ENDING 2015 Roger Kipp McClarin Plastics P. O. Box 486, 15 Industrial Drive Hanover, PA 17331 (717) 637-2241 x4003 Fax (717) 637-4811 [email protected] PRIOR CHAIR Ken Griep Portage Casting & Mold 2901 Portage Road Portage, WI 53901 (608) 742-7137 Fax (608) 742-2199 [email protected]

34 Thermoforming quarterly Board of Directors

MACHINERY COMMITTEE MATERIALS COMMITTEE Robert G. Porsche Stephen Murrill General Plastics Profile Plastics James Alongi Jim Armor 2609 West Mill Road 65 S. Waukegan MAAC Machinery Armor & Associates Milwaukee, WI 53209 Lake Bluff, IL 60044 590 Tower Blvd. 16181 Santa Barbara Lane T: 414-351-1000 T: 847.604.5100 x29 Carol Stream, IL 60188 Huntington Beach, CA 92649 F: 414-351-1284 F: 847.604.8030 T: 630.665.1700 T: 714.846.7000 [email protected] [email protected] F: 630.665.7799 F: 714.846.7001 [email protected] [email protected] Clarissa Schroeder Mark Strachan Auriga Polymers Global Thermoforming Roger Fox Jim Arnet 1551 Dewberry Road Technologies The Foxmor Group Kydex LLC Spartanburg, SC 29307 1550 SW 24th Avenue 1119 Wheaton Oaks Court 3604 Welbourne Lane T: 864.579.5047 Ft. Lauderdale, FL 33312 Wheaton, IL 60187 Flower Mount, TX 75022 F: 864.579.5288 T: 754.224.7513 T: 630.653.2200 T: 972.724.2628 [email protected] [email protected] F: 630.653.1474 [email protected] [email protected] Eric Short Jay Waddell Phil Barhouse Premier Material Concepts Plastics Concepts & Innovations Don Kruschke (Chair) Spartech Packaging 11165 Horton Road 1127 Queensborough Road Plastics Machinery Group Technologies Holly, Michigan 48442 Suite 102 31005 Bainbridge Rd. #6 100 Creative Way T: 248.705.2830 Mt. Pleasant, SC 29464 Solon, OH 44739 PO Box 128 [email protected] T: 843.971.7833 T: 440.498.4000 Ripon, WI 54971 F: 843.216.6151 F: 440.498.4001 T: 920.748.1119 [email protected] [email protected] F: 920.748.9466 PROCESSING COMMITTEE [email protected] Director Emeritus Mike Sirotnak Haydn Forward (Chair) Art Buckel Solar Products Lola Carere Specialty Manufacturing Co. McConnell Company 228 Wanaque Avenue C and K Plastics, Inc. 6790 Nancy Ridge Road 3452 Bayonne Drive Pompton Lakes, NJ 07442 512 Fox Creek Crossing San Diego, CA 92121 San Diego, CA 92109 T: 973.248.9370 Woodstock, GA 30188 T: 858.450.1591 T: 858.273.9620 F: 973.835.7856 T: 732.841.0376 F: 858.450.0400 [email protected] [email protected] [email protected] [email protected]

Brian Ray Tim Hamilton Ken Griep Ray Products Spartech Corporation Portage Casting & Mold 1700 Chablis Drive 11650 Lakeside Crossing Court 2901 Portage Road Ontario, CA 91761 Maryland Heights, MO 63146 Portage, WI 53901 T: 909.390.9906 T: 314.569.7407 T: 608.742.7137 F: 909.390.9984 [email protected] F: 608.742.2199 [email protected] [email protected] Donald Hylton Brian Winton McConnell Company Steve Hasselbach Lyle Industries, Inc. 646 Holyfield Highway CMI Plastics 4144 W. Lyle Road Fairburn, GA 30213 222 Pepsi Way Beaverton, MI 48612 T: 678.772.5008 Ayden, NC 28416 T: 989-435-7714 x 32 [email protected] T: 252.746.2171 F: 989-435-7250 F: 252.746.2172 [email protected] Roger P. Jean (Chair) [email protected] Rowmark/PMC PO Box 1605 Roger Kipp 2040 Industrial Drive McClarin Plastics Findlay, OH 45840 15 Industrial Drive T: 567.208.9758 PO Box 486 [email protected] Hanover, PA 17331 T: 717.637.2241 Laura Pichon F: 717.637.2091 Ex-Tech Plastics [email protected] PO Box 576 11413 Burlington Road Bret Joslyn Richmond, IL 60071 Joslyn Manufacturing T: 847.829.8124 9400 Valley View Road F: 815.678.4248 Macedonia, OH 44056 [email protected] T: 330.467.8111 F: 330.467.6574 [email protected]

Thermoforming QUARTERLY 35 Thermoforming THIRD QUARTER 2012 Quarterly® VOLUME 31 n NUMBER 3

Sponsor Index These sponsors enable us to publish Thermoforming Quarterly n Allen...... 27 n Brown Machine...... 23 n CMT Materials...... 5 n GN Plastics...... 28 n GPEC 2013...... 32 n Kiefel...... 27 n KMT...... 33 n Kydex...... Back Cover n MAAC Machinery...... 33 n McClarin Plastics...... 28 n Mitsubishi Electric...... 30 n Nova Chemicals...... 9 n PCI...... 34 n Plastics Machinery Group...... 34 n Plastics News Reports...... 6 n Plastics Technology...... 22 n PMC...... Inside Front Cover n Portage Casting & Mold...... 28 n Primex Plastics...... 5 n Productive Plastics...... 27 n Profile Plastics Corp...... 27 n PTi...... Inside Back Cover n Ray Products...... 27 n Solar Products...... 28 n Spartech...... 8 n Tempco...... 36 n TPS...... 8 n TSL...... 19 n Weco Int’l. Inc...... 5 n Yushin ...... 26 n Zed Industries...... 27 Thermoforming Division Membership Benefits n Access to industry knowledge from one central location: www.thermoformingdivision.com. n Subscription to Thermoforming Quarterly, voted “Publication of the Year” by SPE National. n Exposure to new ideas and trends from across the globe n New and innovative part design at the Parts Competition. n Open dialogue with the entire industry at the annual conference. n Discounts, discounts, discounts on books, seminars and conferences. n For managers: workshops and presentations tailored specifically to the needs of your operators. n For operators: workshops and presentations that will send you home with new tools to improve your performance, make your job easier and help the company’s bottom line. Join D25 today!

36 Thermoforming quarterly Thermoforming QUARTERLY 37 38 Thermoforming quarterly