In what may appear to be a contradiction, thermoplastic resin distributor General Polymers is teaching plastic processors how to use less - rather than more - material. ``We explain scientific molding strategies that have the potential to increase processors' profits by 10-50 percent,'' John Bozzelli, senior technical consultant, explained. ``Profit-killers are poor cost estimation, long cycle times, rejected parts or scrap and excessive downtime.''
The company welcomed about 140 customers to a daylong, Sept. 12 course on systematic molding at a City of Industry, Calif., hotel. A July 24-25 course in Charlotte, N.C., attracted more than 200.
During the California session, General Polymers made parts on a 55-ton Toyo injection molding machine with a Dartnet process monitoring system. Hydraulic-component-specialist RJG Technologies in Traverse City, Mich., makes the Dartnet system. The operation ran for 71/2 hours in the hotel's main ballroom.
Bozzelli explained the importance of controlling plastic flow rate through technical demonstrations and flow curves.
``It is tricky to understand, is often misunderstood, may not be logical and applies to every shot,'' Bozzelli said. ``Is every shot the same?''
The Dartnet system monitors actual pressure of the injection ram and cavity pressure at gate and end-of-fill in the mold.
General Polymers offered to provide attendees with a polymer-processing evaluation and monitoring service. The company owns five Dartnet systems and has held in-plant sessions with more than 25 large customers with processing operations in the Southeast and Midwest.
``We do an in-house seminar and set up a Dartnet system in their shop,'' said Mark Schnurr, district manager in Santa Ana, Calif. ``We work with processors on their efficiency and report on how to optimize cycle times.''
General Polymers provides the service on a value-added basis without a charge.
``The service is most applicable for injection, extrusion and blow molding customers using multiple types of thermoplastics on a variety of molding machines,'' Schnurr said.
General Polymers has 20 North American sales offices and distribution locations. Competitors include General Electric Co.'s Polymerland Inc. unit in Parkersburg, W.Va., M.A. Hanna Co. of Cleveland and A. Schulman Inc. of Akron, Ohio. General Polymers is a division of Ashland Chemical Co., a unit of energy and chemical firm Ashland Inc. of Russell, Ky.