3.PEC (Pan European Conference), Rome, Italy
21-24 March 2004
Attendees: 380+ (plus 75 spouses)
Countries Represented: 35+
Diverse and inquisitive; the group of
attendees proved just as interesting as the show itself. AISR (Italy), ARMCE
(Central Europe), IRMA (Ireland),
BPF (UK), ARM International (USA) and AFR (France) coordinated an interesting and worthwhile event
that covered the major technology and trends of the rotomolding world. Most of
the associations were strongly represented by their membership with a lot of
molders attending from Asia as well. The presentations were once again given
in their language of choice by the presenters and simultaneously
translated into four languages.
Technical Exhibits:
A technical exhibit was held with 32 suppliers on display
showing a wide array of material, mold and machinery choices for molders - a
bigger room might have allowed more suppliers to exhibit but it was an
interesting display nonetheless.
Presentations:
Keynote Address: 'Vision for the Future', Prof. Roy Crawford, The
Queen's University of Belfast
Roy presented a look at the future of rotational molding,
analyzing the strengths, weaknesses, threats and opportunities for the
process. Opportunities for improvement lie in process control, with
temperature and pressure controls, reducing cycle times to a quarter of their
current values and improving the palette of materials available for molders.
An excellent presentation as always with ideas for everyone to work on. I
agree that temperature controls and improvements to molds will help all
molders but I'm not sure that I agree that all materials can be rotomolded (the rheology
of many materials will not allow them to form acceptable parts in the low shear
environment of a rotational mold) nor that pressure measurement is meaningful
for most molders.
'Rotational Moulding Around the World', Paul Nugent
A copy of this presentation can be seen at Rotomo(u)lding
Around the World
'Special Resins for Rotomoulding', Eric Maziers, Atofina
Chemicals
Atofina have produced nylon and PVDF materials for rotomolding
for a number of years but this is their first introduction of polyolefin
materials. Eric described how their new single site catalyst materials (mPE)
have finer crystal structures and better warpage control that some of the
earlier generation single site materials. The materials exhibit fast
processing times with low bubble content. He also presented some ideas on
combining polyamide materials and polyolefins for possible use in fuel tank
applications for example.
'New Crosslink Material', Walter Bonazzi, Aeroplastik SpA
Walter represents A. Schulman in Europe offering 'Schulink'
crosslink materials and their polypropylene material, PD2000. He also
offers the K-Pak process control system.
'Is Rotomoulding Really Stress Free?', John Steele, ICO
Polymers, Ltd.
This was one of those 'hidden gem' papers that I hope leads to
more understanding of some of the basic phenomena in rotomolding. John
presented a series of data for shrinkage of materials in a test tool to
examine the effects of residual stress on impact and tensile strength.
Surprisingly, the data showed that even when parts are heavily restricted in
shrink during cooling, no appreciable effect on impact strength or tensile
behavior could be seen. The material appears to absorb the effect in some form
of 'relaxation' or the process is localized. I look forward to the next
installment.
'Improved Resins for Rotomoulding', Peter Schindler, DOW
Chemicals
Peter gave a review of the DOW family of materials. They have
some very interesting flexible materials with very low densities.
'Twin Wall Tanks', Manuel Terzi, Cremar Metallurgia / Zweva
Cremar and Zweva combined to present information on Zweva
patented twin-walled underground storage tank system. To the disappointment of
the audience, however, they did not go into details...
'New Millennium Graphics', Tom Innis, Mold-in-Graphics Systems, Inc.
Interesting developments from Mold-in-Graphics as always, the
Millennium graphics are a practical step forward for graphics, primarily for
their robust backing material, better handling characteristics and, of course,
improved temperature rating (three times a charm Tom?).
'Machine Comparisons', Carlos Garcia, Rotoline, Inc.
Reduction Engineering has expanded it's line of equipment with
new shuttle machines under the Rotoline brand. Carlos presented a review of
the efficiency of two double shuttle machines vs. a four arm carousel. The
results were interesting and as a flexible molding system, is certainly worth
considering when assessing machinery requirements for a given production
setup.
'Improvement Factors', Paolo Legnani, Caccia SpA
Caccia offered some new concepts and ideas for improving the
efficiency of a molding cycle including: arm movement between stations, shape
of the oven, door open and close speeds, computer controls and reduced gas
consumption.
'Range of Products & Services', Ryan Keates, Resin Express,
Ltd.
Ryan presented an overview of Ravago and Resin Express along
with their offerings in terms of materials, color compounding and technical
service for the European market.
'Leonardo', Andrea Rottigni, Persico, SpA
Persico continue to push the boundaries of what is possible in
rotomolding. The Leonardo machine offers the possibility of fully automated
processing for rotational molding including automated insert location,
automated venting, material delivery and preheating, part handling and
built-in cooling systems.
'Concept Parts Calculation', Christophe Guillerme, Metroplast
Christophe described a project for the design, modeling and
production of a tool box for an automotive application. Good solid project
management process.
'Sewage-Manhole', Miki Burmil, Polivinil, SpA
Miki described a joint design project involving Polivinil
molding equipment for the production of sewage manhole products.
'Reduction of Cycle Times', Mark Kearns, The Queen's University
of Belfast
Mark showed data from tests using a direct electrical heating
method developed by PPA Teo in Ireland. This uses electrical elements bonded
to the surface of standard molds combined with a variety of different cooling
systems. The relative performance of the molds for different thicknesses were
compared favorably with a standard rotational molding machine. Deep parts with
complex surfaces should benefit from using this type of approach due to the
ability to supply and control heat at the same level as the rest of the rest
of a part.
'Strategic Marketing Campaign', Allan Joyce, Balmoral Tanks, Ltd.
Allan left us with some thought provoking observations and
truisms including; "Yesterday companies competed on price, today it is on quality -
in the future it will be design" and "Most change is forced and it is often the result of complacency".
'493K - KPaq', Gareth McDowell, 493K, Ltd.
Permanent data acquisition on the arms of the machine is
always a good idea. However, I felt as though I was watching a rerun of a
Rotolog presentation during this one. The graphs presented looked dangerously
close to measuring the internal air temperature for parts and those that were
monitoring mold temperature looked exactly like those that are gathered using
IRT non-contact systems. Interesting development in low maintenance slip rings
for the hot joint on the machine.
'PUR and Rotomolding', Peter Orywol, Bayer Polymers
Peter presented an overview of Bayer's two phase liquid
urethane systems for molding hard or soft parts in a reactive process. The
materials are dispensed into a mold and react at room temperature (or slightly
above due to an exotherm) to form a part without the need for an oven or
cooling station.
'Micro-pellets & Benefits', Michael Eloo, Gala
Underwater pelletizing can produce very small pellets with
particle size distributions approaching those of powder which have been
ground. These may offer advantages for certain types of parts in terms of flow
and filling behavior but still may have challenges in terms of material
distribution due to their fast flow behavior. Michael showed how they have
been successfully used in small to large parts as well as in parts that were
difficult to make using powders. Interesting stuff.
'Black Maus Coating (BMC)', John Barker, Maus, GmbH
The new coating system from Maus is a very interesting
development that could benefit a lot of molders. The characteristics of the
surface of this coating appear to fall somewhere between TeflonTM
and standard release agents in terms of grip and therefore part shape control.
It also appears to help with heat transfer and filling of difficult details
such as threads. John offers this service in the UK and Norstar offer it in
the US as well as Maus from their main facility in Germany.
'Equipment', Eugene Reinhardt, Reinhardt, GmbH
Eugene reviewed some of the latest machinery styles offered by
Reinhardt including their new linear style shuttle machine which allows molds
to bypass each other by using a suspended oven and cooling station design.
'Empirical Models in Moulding', Nick Henwood, Matrix Polymers,
Ltd.
Nick discussed the results of an extensive set of tests
evaluating the stiffness of parts vs. their density concluding that the
empirical data supported the cubic function of the standard beam bending
theory.
'Mechanism of Polyethylene Foaming', Abbas Tcharkhtchi, ENSAM
Paris
Abbas presented data on a series of laboratory experiments
examining the mechanisms behind foam formation during the rotomolding process.
His paper examines the various stages involved in the growth of a bubble and
the factors that affect their size and development.
'Inserts', Ian Butland, Anchor Inserts, Ltd.
Anchor provide a wide range of inserts for rotomolding
including designs that improve torque resistance to prevent pullout during
assembly. Ian reviewed their offerings and company policies for delivery and
service.
'Engineering Plastic Powder', Herbert Trier, Pallman, GmbH
Pallman makes sturdy grinding equipment that can be used not
only for polyethylene but also for polypropylene, polycarbonate and other
materials at room temperature. Herbert reviewed some of the basic quality
control parameters that molders should check before using powders for molding.
'Lean Management', Paul Nugent
A copy of this presentation can be seen at Lean
Manufacturing
'SAT Compant Profile', Walter Jaconelli, SAT S.A.
SAT are a specialist company making furnaces for a wide range
of industries. They have a specialized range of rotomolding and slush molding
machines that are used for many applications including automotive parts.
Walter showed video segments of a two station shuttle machine (moving oven), a
single station smaller machine and a larger multi-arm independent style
machine.
'Opportunities by Effect and Service Concepts', Andreas Thurmer,
CIBA Specialty Chemicals
Ciba always offer a comprehensive package of information. In
this case, Andreas showed data gathered for a new additive system that helped
improve the moldability and impact performance of a base resin while at the
same time reduce its yellowness. He also discussed pigment dispersion and
weatherability as well as reviewing the expert services that they offer the
industry.
'Automatic Powder Transport & Dosage', Filippo Randazzo, Planitec,
SpA
Planitec offer systems for handling powders all the way
through from color addition to dispensing in the mold. Filippo showed how his
vacuum dispensing system worked.
'Hydrogen Storage, All Composite Tank', Phillipe Mazabraud, CEA
Now this was hi-tech stuff. A fuel tank for storing hydrogen
for cars driven using a fuel cell concept. Phillipe's presentation covered the
development and testing of a multi-layered rotomolded tank that formed the
inner liner of a composite winding for strength. The test results were quite
impressive but I think I will wait until several thousand of these have been
thoroughly tested before I sit in the car!
Round Table Discussion - Susan Gibson, Rotation Magazine
Susan gathered a dozen panelists for a discussion on issues
surrounding rotomolding. It was fun participating - it will be interesting to
hear what the audience thought.
Toga Party:
The Sheraton hotel put on a great toga party and show for
everyone at the conference. It wasn't quite Caligulan but the outfits were
generally becoming and the atmosphere was good. My camera was straining in the
dark but I am sure that Rotation Magazine will have some good shots and there
will probably be more over at the ARM International website. Anyway, here's a
few snaps of the evening's entertainment....
Italian Association President, Francesco Mondini proving that
the Romans really weren't as tough as the Scots after all! Another little known
fact was that the Romans obviously had eye-glasses in a variety of prescription
strengths and fashionable styles thousands of years ago.
Yes, they really did have a grand chariot entrance complete
with horses, fire breathers and flaming dishes.
Emperor Boersch with Cleopatra Busceme.
The crowds bayed for blood during the gladiator fighting
(actually I think they just kept drinking the wine).
ARM International CEO, Jeff Arnold and Alan Joyce from the BPF
keeping transatlantic relations cordial while enjoying traditional Roman
delicacies such as boiled partridge tongues, roasted bats ears and deep fried
badger noses.
What do you call a group of goddesses? Harem, huddle, wump or
gaggle?
Speaking of goddesses, the Gibson girls always add to the
glamour of any evening.
This is when my camera started to overheat...
and, finally, how often do you have a chance to see Terry
Gillian and Harry Covington in a dress?
