A.L.P. adds press to silicone operation

Niles, Ill. — Four is better than three when it comes to large injection molding presses. That's the case for Niles-based A.L.P. Lighting Components, which recently added a 240-ton injection molding press for optical silicone applications.

Better known as a thermoplastic company with experience in compression molding, A.L.P. also manufactures optical silicone components, an option that offers valuable properties for lighting, automotive and other demanding applications. The new 240-ton press is specifically used for liquid silicone rubber molding.

Optical silicone parts are impact-and heat-resistant while being less susceptible to degradation from UV rays. Silicone also is known for its refraction reflection, and diffusion properties, along with self-mounting and self-gasket features.

It's been a challenge for A.L.P. to keep up with increasing demand given the popularity of LED lighting in multiple industries and for many different applications. Optical silicone components help to minimize the adverse impact that high temperature levels can help on thermoplastics used in LED lighting, said Tom Barnes, A.L.P. vice president and business unit manager. This is particularly important because many clients are using LED lights for outside usage in warm temperatures.

Meanwhile, available supply of raw materials used in the process of creating optical silicone parts has been difficult to attain. A.L.P.'s lone supplier was limiting component availability for nearly two years while outreach to other suppliers for additional resources proved fruitless.

A.L.P. was finally able to secure a second supplier, which made the addition of the new 240-ton injection molding press a viable investment. As a result, A.L.P. has replenished its silicone resin inventory, recovering from recent supply chain issues felt throughout the injection molding industry.

"We struggled with the same shortages that everyone else did," Tim DeYoung, A.L.P. LexaLite's director of operations, said in a statement. "Fortunately, we now have a good inventory of raw materials, and we are ready to take on new business."

The new 240-ton press augments A.L.P.'s existing capacity of 180-, 240- and 660-ton presses, all of which can run moldable optical silicone. The new press features a shot size up to nine ounces, mold bases up to 24 x 24 inches, and can produce parts up to 20 x 20 inches. The 600-ton press was modified last year from an old thermoplastic machine and includes a retrofitted silicone unit on the front.

"We have waited for a while but it's gotten to the point where supply finally seems to be catching up with demand," Barnes said. "I don't have firsthand knowledge if this is accurate, but what we've heard is that feedstock limitations are behind the shortage of raw materials."

A.L.P. began LSR molding in-house in 2014 with its 180-ton press before later adding a 240-ton press, Barnes said. Over this time, the company hired several new employees based on growth in silicone operations. All operators are eventually cross-trained for both silicone and thermoplastic processing. A.L.P.'s employee base has grown by 15 percent during the last five years, and optical silicone has become one of its fastest growing segments.

"We are running 24 hours a day, five days a week and weekends as needed," he said. "We have in the range of 30-40 percent capacity available. Based on what we've heard, we are now molding the largest optical silicone parts anywhere."

While Barnes would not confirm the investment made in the new press, internet searches for new and used 240-ton presses with similar characteristics generally start at more than $100,000.

LSR started to become an option in the late 1970s and early 1980s. Its distinctive qualities of liquid silicone rubber injection molding make it different from molding conventional high-consistency silicone and other thermoplastic injection molding processes and ideal for certain applications.

Despite the added growth that the fourth machine will allow, optical silicone still represents a small part of A.L.P.'s overall business. It employs more than 160 professionals at two sites. Barnes sees additional opportunities for expanding its business with light fixtures and high-impact LED lighting. A.L.P. has a long history as a premier supplier of custom injection molded components for lighting, automotive, medical, marine, point-of-purchase and other industries. Examples of marine applications include buoys and beacons. Lighting visible to airplanes in and around airports is another common need.

The company sells primarily to customers in North America, with about 5 percent of its sales coming from overseas customers, Barnes said. It will continue to promote its optical silicone molding capacity through its international rep program, and the company continues to evolve as a leader in the design, manufacturing and distribution of lighting components and components for other technical industries. All of A.L.P.'s LSR parts are custom molded.