TECHNOLOGY TO BECOME A BETTER ROTOMOLDER. Michel Truax STP Rotomachinery Inc. - Canada

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1 TECHNOLOGY TO BECOME A BETTER ROTOMOLDER. Michel Truax STP Rotomachinery Inc. - Canada

2 TECHNOLOGY TO BECOME A BETTER ROTOMOLDER. Rotational molders in the U.S. have been reluctant to change their old routines and adapt to new technologies. Paul Nugent Source: Plastics News November 11, 2008

3 TECHNOLOGY TO BECOME A BETTER ROTOMOLDER. This statement got me thinking

4 TECHNOLOGY TO BECOME A BETTER ROTOMOLDER. Many rotomoulders think they are magicians

5 TECHNOLOGY TO BECOME A BETTER ROTOMOLDER. or worst, mad scientists

6 TECHNOLOGY TO BECOME A BETTER ROTOMOLDER....and things get out of hand so they start acting like madmen

7 HOW TO BECOME A BETTER ROTOMOULDER My scrap rate is out of control!

8 TECHNOLOGY TO BECOME A BETTER ROTOMOULDER. Fortunately, there are solutions for rotomoulders that are seaking results

9 TECHNOLOGY TO BECOME A BETTER ROTOMOULDER. When rotomoulding needs to «BORROW» technology from other processes.

10 TECHNOLOGY TO BECOME A BETTER ROTOMOLDER. Source: Electrolux

11 TECHNOLOGY TO BECOME A BETTER ROTOMOLDER. CAN YOU SEE A PARALLEL WITH ROTOMOLDING?

12 HOW TO BECOME A BETTER ROTOMOLDER From the PERFECT TURKEY BUTTON to PERFECT MOLDING BUTTON.

13 TECHNOLOGY TO BECOME A BETTER ROTOMOLDER. THE PERFECT MOLDING BUTTON DOES EXIST. FUNDAMENTAL CONCEPT True process control: real-time temperature monitoring. Measuring the temperature of the air inside the mould is easier. Temperature of air inside the mould closely tracks temperature of material and identifies all the key events during a cycle (eg melting, correct cure, release of material during cooling).

14 TECHNOLOGY TO BECOME A BETTER ROTOMOLDER. THE PERFECT MOLDING BUTTON DOES EXIST. FUNDAMENTAL CONCEPT Products such as the K-Paq wireless device overcomes practical difficulties in measuring temperature during rotomoulding (biaxial rotation), using an insulated and cooled canister to contain sensitive electronics. Temperature data is collected and transmitted to receiver every 2 seconds. Up to 4 thermocouple inputs can be used to measure a choice of parameters, including air temperature inside mould, mould wall temperature and ambient air temperature adjacent to mould.

15 TECHNOLOGY TO BECOME A BETTER ROTOMOLDER. THE PERFECT MOLDING BUTTON DOES EXIST. FUNDAMENTAL CONCEPT Information is relayed to PLC of machine for total process control via a closed-loop system.

16 TECHNOLOGY TO BECOME A BETTER ROTOMOLDER. HARDWARE OVERVIEW RADIO RECEIVER RADIO TRANSMITTER (K-PAQ) SERIAL-USB LINK PLC

17 TECHNOLOGY TO BECOME A BETTER ROTOMOLDER. FUNDAMENTAL CONCEPT No more need to enter cook time or cooling time enter a set point for each stage.

18 TECHNOLOGY TO BECOME A BETTER ROTOMOLDER. FUNDAMENTAL CONCEPT For the cooking step, the set point is reached when the actual temperature inside the mould exceeds the entered set point for more than 10 seconds; This will trigger the need to go to the next step end cook cycle!

19 TECHNOLOGY TO BECOME A BETTER ROTOMOLDER. FUNDAMENTAL CONCEPT For a cooling step, the set point is reached when the temperature inside the mould goes under the entered set point for more than 10 seconds. This will also trigger the need to go to the next step end cooling cycle!

moulding cycle: Densification Peak Internal Air Temperature Material begins to solidify (crystallisation) Material is completely melted and

20 THEORY: A TYPICAL TEMPERATURE CURVE OF THE MOULDING PROCESS. It may be useful remember the most significant points of the curve describing the air temperature progress inside the mould during a typical moulding cycle: Densification Peak Internal Air Temperature Material begins to solidify (crystallisation) Material is completely melted and adheres to the mold wall (sintering/coalescence) Material is fully solidified Material comes off the mold wall Material begins to melt and adheres to the mold wall (melting temperature) HEATING COOLING Extraction of the molded item

PRM-3000-3C MACHINE FEATURES Burner Capacity: 500,000 kcal/h (2,035,000 BTU/h) Cooking Chamber fan capacity: 35,000 m³/h (20,600 CFM) Cooling blowing fan capacity : 2 x 22,000 m³/h (13,000 CFM)

21 PRM C MACHINE FEATURES Burner Capacity: 500,000 kcal/h (2,035,000 BTU/h) Cooking Chamber fan capacity: 35,000 m³/h (20,600 CFM) Cooling blowing fan capacity : 2 x 22,000 m³/h (13,000 CFM) Cooling extraction fan capacity : 28,000 m³/h (15,300 CFM) Performed Tests USED MATERIAL: medium density linear PE MFI: 4,5 g/10min Density: 938 g/m 3 Melting Point: 127 C (260 F) Product data: SQUAIR POLIVINIL ROTOMACHINERY S.p.A. ARMCHAIR 12 kg (double layer obtained with DROP-BOX Kg 7 green - Kg 5 yellow) When changing some of the variables as the mold enters the oven, let s see how the system reacts.

10 kg (22 lbs) MOULDING TEMPERATURE SET: 250 C (482 F) OVEN TEMP.

22 LATEST TECHNOLOGICAL INNOVATIONS TEST N 1 STANDARD RECIPE ONLY EXTERNAL LAYER red line: temperature of the oven black line: temperature of the polymer green line: temperature of the air inside the mold MATERIAL: PE, 10 kg (22 lbs) MOULDING TEMPERATURE SET: 250 C (482 F) OVEN TEMP. AT MOULD ENTRY: 250 C (482 F) COOKING TIME: AIR TEMP. INSIDE MOLD, COOKING END: 158 C (316 F) COOLING TIME: 33 MATERIAL TEMP. AT COOLING END: 110 C (230 F)

LATEST TECHNOLOGICAL INNOVATIONS TEST N 2 - CHANGING PROCESS CONDITION COLD OVEN AT MOLD ENTRY: 150 C (300 F) INSTEAD OF 250 C (482 F) ONLY EXTERNAL LAYER red line: temperature of the oven black

23 LATEST TECHNOLOGICAL INNOVATIONS TEST N 2 - CHANGING PROCESS CONDITION COLD OVEN AT MOLD ENTRY: 150 C (300 F) INSTEAD OF 250 C (482 F) ONLY EXTERNAL LAYER red line: temperature of the oven black line: temperature of the polymer green line: temperature of the air inside the mold MATERIAL: PE, 10 kg (22 lbs) MOLDING TEMPERATURE SET: 250 C (482 F) OVEN TEMP. AT MOLD ENTRY: 150 C (302 F) 100 C or 212 F COOKING TIME: (plus 4 ) AIR TEMP. INSIDE MOLD AT COOKING END : 158 C (316 F) COOLING TIME: 31 (minus 2 ) MATERIAL TEMP. AT COOLING END: 110 C (230 F)

MOULDING TEMPERATURE SET: 250 C (482 F) OVEN TEMP. AT MOULD ENTRY: 250 C (482 F) COOKING TIME: 21 30 AIR TEMP.

24 LATEST TECHNOLOGICAL INNOVATIONS TEST N 3 - STANDARD CHECK BUT WATER AT COOLING END ONLY EXTERNAL LAYER red line: temperature of the oven black line: temperature of the polymer green line: temperature of the air inside the mold MATERIAL: PE, 10 kg (22 lbs) MOULDING TEMPERATURE SET: 250 C (482 F) OVEN TEMP. AT MOULD ENTRY: 250 C (482 F) COOKING TIME: AIR TEMP. INSIDE MOULD AT COOKING END : 158 C (316 F) COOLING TIME: 30 (minus 3 ) MATERIAL TEMP. AT COOLING END: 110 C (212 F) WATER AT MATERIAL TEMP.:120 C (248 F)

4 lbs) MOULDING TEMPERATURE SET: 250 C (482 F) OVEN TEMP. AT MOULD ENTRY: 250 C (482 F) DROP BOX OPENING DELAY: 18 30 AIR TEMP.

25 LATEST TECHNOLOGICAL INNOVATIONS TEST N 4 STANDARD WITH DROP-BOX FINAL PRODUCT: DOUBLE LAYER red line: temperature of the oven blue line: temperature of the polymer green line: temperature of the air inside the mold MATERIAL: PE, INSIDE 5Kg (11 lbs) - OUTSIDE 7Kg (15.4 lbs) MOULDING TEMPERATURE SET: 250 C (482 F) OVEN TEMP. AT MOULD ENTRY: 250 C (482 F) DROP BOX OPENING DELAY: AIR TEMP. INSIDE THE MOULD AT DROP BOX OPENING: 125 C (257 F) COOKING TIME: 27 AIR TEMP. INSIDE MOULD AT COOKING END : 158 C (316 F) COOLING TIME: 35 MATERIAL TEMP. AT COOLING END: 110 C (230 F)

LATEST TECHNOLOGICAL INNOVATIONS TEST N 5: CHANGING PROCESS CONDITION MOLDING TEMPERATURE 270 C INSTEAD OF 250 C FINAL PRODUCT: DOUBLE LAYER red line: temperature

6 lbs) - INSIDE 5 kg (11 lbs) MOULDING TEMPERATURE SET: 270 C (518 F) OVEN TEMP. AT MOULD ENTRY: 270 C (518 F) DROP BOX OPENING DELAY: 16 48 (minus 1 42 ) AIR TEMP.

26 LATEST TECHNOLOGICAL INNOVATIONS TEST N 5: CHANGING PROCESS CONDITION MOLDING TEMPERATURE 270 C INSTEAD OF 250 C FINAL PRODUCT: DOUBLE LAYER red line: temperature of the oven black line: temperature of the polymer green line: temperature of the air inside the mold MATERIAL: PE, OUTSIDE 8 Kg (17.6 lbs) - INSIDE 5 kg (11 lbs) MOULDING TEMPERATURE SET: 270 C (518 F) OVEN TEMP. AT MOULD ENTRY: 270 C (518 F) DROP BOX OPENING DELAY: (minus 1 42 ) AIR TEMP. INSIDE THE MOULD AT DROP BOX OPENING:125 C (257 F) COOKING TIME: 24 (minus 3 ) AIR TEMP. INSIDE MOULD AT COOKING END : 158 C (316 F) COOLING TIME: 33 (minus 2 ) MATERIAL TEMP. AT COOLING END: 110

27 The ROTOMACHINERY GROUP: 360 ROTOMOULDING Michel Truax STP Rotomachinery Inc. - Canada

28 WHO ARE WE? WORLDWIDE ROTOMOULDING EQUIPMENT SUPPLIER SINCE 1979; 2 PLANTS: CANADA AND ITALY (TOTAL 20,000 SQUARE METERS); 150 EMPLOYEES AND DIRECT SUB-CONTRACTORS; 100% ROTOMOULDING: ENGINEERING, DESIGN, FABRICATION, TEST AND INSTALLATION OF MACHINERY, ACCESSORIES, MOULDS AND MATERIAL PREPARATION / HANDLING SYSTEM; MORE THAN 500 MACHINES OPERATING IN 6 CONTINENTS; EXCELLENT REPUTATION IN THE MARKET FOR SUPPLY OF STATE-OF- THE-ART MACHINERY APPRECIATED FOR RELIABILITY, LOW ENERGY CONSUMPTION, COST-EFFECTIVE MANAGEMENT; PATENTS FOR ROTOMOULDING MACHINERY AND PROCESS CONTROL.

29 OUR MISSION? - Our mission is to offer and produce a complete line of robust, reliable and productive rotomolding equipment for the rotomoulding industry.

30 INDEPENDENT ARM SHUTTLES ROCKING OVENS TURRETS BOX-OVENS 360 PRODUCT LINE MOLDS LAB MACHINE PULVERIZERS DOSING SWING ARM

quality or workmanship; Reliable and efficient; New

31 CRM SERIES: INDEPENDENT-ARM MACHINE Main features: 6 independent stations: up to 4 arms; No compromise on quality or workmanship; Reliable and efficient; New design for hot air flow; New design for door mechanism.

32 SRM SERIES: SHUTTLE MACHINES The most economical way of exploiting all the advantages offered by this technology. 2 or 3 stations: 1 oven and 1 or 2 cooling - load/unload stations; Open cooling or enclosed cooling stations; High load bearing capacity; Indexing both axes on arms: encoders on gear-motors; Direct rotation movements using robust gear mechanisms; End panels mounted on carts: no doors to maintain.

33 SRM SERIES: SHUTTLE MACHINES The brand new 3-sided shuttle machine! much more flexibility than any other shuttle or any other machine for that matter; offered with either 2 or 3 carts; if only 2 carts, can also go in a corner ( L shaped); Indexing both axes on arms: encoders on gear-motors; End panels mounted on carts: no doors to maintain.

34 HRM SERIES: R&R shuttle The only shuttle with a rocking oven on the market! Main features: Ideal for long narrow parts. The only R&R with 3 stations: keep floor space to a minimum; Two independent carts alternating in cooking and cooling stages; oven with 3,4 or 5 independent cooking zones; Floor level machine no pit!

35 TRM SERIES: SWING-ARM MACHINES Total independence of each arm. Main features: Ideal for parts that require very long cooling cycles or unload times in relation to the cook times; Central oven and 4 arms passing from cooking to cooling independently; Machine can be operated even if some arms are down for maintenance or mold changes; Each arm has its own cooling station: total freedom; Oven doors swing in and out of the oven.

Via Crosa, 53 120 rue des PME 28065 Cerano

tel: +39 0321 772021 tel: +1 819 846 2787 fax:

36 THANKS FOR YOUR ATTENTION Polivinil Rotomachinery S.P.A. S.T.P. Rotomachinery Inc. Via Crosa, rue des PME Cerano (NO) Italy Sherbrooke (Quebec) Canada J1C 0R2 tel: tel: fax: fax:

BEHIND THE LINES. Guarding & Machine Safety. Ian Hansen RotoConsult ARM Annual Meeting ARM Annual Meeting

BEHIND THE LINES. Guarding & Machine Safety. Ian Hansen RotoConsult ARM Annual Meeting ARM Annual Meeting BEHIND THE LINES Guarding & Machine Safety Ian Hansen RotoConsult www.ianhansenconsult.com Summary of presentation Industry Association resources Machine Safe Guarding Risk Assessment vs Risk Reduction