ARM International 29th Annual Fall Conference 

Cleveland, Ohio, 2nd-5th October 2004

Attendees:  400+ (with spouses)

Countries Represented: 24+

Molder Companies / Attendees: 80 / 170

Supplier Companies / Attendees: 75 / 230

Booths: 64

Presentations

A well attended meeting in downtown Cleveland. The technical papers were informative and there were some new items of interest to be found in the exhibits. While the hotel could have been better, the entertainment was great and it was, as always, a terrific opportunity for networking. 

The recent surge in interest in the fuel tank market generated by the CARB regulations proposed in California has produced a welcome flood of interest from suppliers offering potential solutions to the problem - Day 1 was close to being a fuel-tank convention! Can we generate some new regulations for POP or the food service industry to continue the interest from other suppliers? 

Here's a brief summary of the papers that I was able to attend. Contact ARM International for copies of the hand-outs and more details if you need them (www.rotomolding.org):

Our Next Step - Michael Paloian, Integrated Design Systems, Inc.

The keynote address was given by Mike Paloian of IDS. Always informative, Mike is one of a relatively small (but hopefully growing) group of designers that use rotomolding on a regular basis. I echo his calls for more material choices and improved productivity - as designers and end-markets push the requirements of the current process, we should see benefits extend to other areas. Interesting projection on future gas pricing...

Pulverizing Systems & Services - Jim Hummel, Powder King

Jim gave an overview of the products that he now offers including lab, single and dual mill systems. His new disposable disk concept includes air cooling technology for improved performance. He now also offers Kelly Duplex mixers and MedKeff-Nye lab-scale equipment.

Mity Lite Turns to Roto - Phil Swindler, Mity Lite

Mity Lite of Utah have produced an outstanding product which incorporates a foamed core and steel runners within a narrow table cross-section to provide excellent load bearing characteristics within tight flatness tolerances. They swept the board for prizes in the parts competition (see below).

Cyclic Engineering Thermoplastic - Jim Mihalich, Cyclics Corp.

This is a fascinating material that starts as a powder made up of small ring-shaped molecules that melts and becomes liquid during molding and then reacts to form long chain molecules. The analogy of going from spaghetti 'O's to spaghetti fits well. The final properties of the material have potential in a number of applications including fuel tanks (in a dual layer configuration) and may offer the promise of a scratch resistant material that is relatively easy to mold for aesthetic applications. Material supplies are limited and expensive at present but a new facility which comes on stream in February 05 will reduce costs and provide plenty of material. Watch this space.

How To:

    Understand Shrinkage and Warpage, Paul Nugent

A 45-minute marathon of words covering the basic elements of shrinkage and warpage, the key factors that affect them and how to deal with shrinkage and warpage before, during and after molding. This workshop was #7 in my new series of training CDs to be released soon. The only problem giving workshops is that you don't have a chance to see the other ones....

    Rotationally Mold CBT (Cyclic Engineering Material)

       Sorry, didn't see this one.

    Design Parting Lines for Max. Efficiency and Mold Life

       Sorry, didn't see this one

    Pick the Right Resin

       Sorry didn't see this one.

Permeation Sub-Committee Update - George Kraemer, Kracor, Inc.

ARM International has convened a Permeation Committee to address the fuel tank regulations being proposed in California. The committee consists of a number of material suppliers and those primary molders who are affected by the changes. George updated the group on the progress of the committee.

Rotational Molding with Acetal Copolymer - Alan Dubin, Ticona

Ticona has a very broad range of engineering and high performance materials in it's portfolio. Fuel tanks have again generated a welcome development program using their permeation-resistant Acetal material. They displayed samples of fuel tanks with dual layers of PE and Acetal Copolymer for permeation resistance and are continuing to work on impact performance and multi-layer systems.

New Rotomolding Products & Processes for Lower Permeation Fuel Tanks - Gregory O'Brien, Atofina

Gregory discussed the molding characteristics of their nylon / polyethylene Petro-Seal system for fuel tanks and how their combination of materials allows for good bonds between the layers in a multi-layer tank. He presented some good examples of processing guidelines and conditions. 

Advances in Plastic Fuel Tanks - Bernard Bauman, Fluoro-Seal

Fluoro-Seal's approach to permeation resistance involves a coating system that is applied to the exterior of a tank. This is done by treating the surface of the tank to prepare it for coating and then applying an epoxy coating that has high-barrier properties. 

Polyaxis PR-1000 - A New Compound for Reduction - Greg Le Fevre, A. Schulman

Schulman's approach involves a drop-in replacement single layer polyethylene material that has been modified for permeation resistance. Data was presented that showed performance characteristics well within the CARB regulations and able to meet the marine regulations.

Globalization: A Brave New World for Rotomolders - Peter Mooney, Plastics Custom Research Services

I always enjoy listening to the Irish lilt of Dr Mooney. And to-boot he actually makes sense when he talks. Globalization is with us whether we like it or not. It is not new and it is not the end of the world. The outcry over outsourcing is overplayed and is not properly balanced by the level of 'insourcing' that we all benefit from in any country nor does it recognize that all companies need to buy from the most cost-effective source. Many rotomolding markets are protected to a large degree by the size of the parts that they make - in those size ranges that can be shipped cost-effectively from overseas, however, molders need to invest in new systems for improved productivity. And to counteract the threat of seeing products going elsewhere, Peter encourages molders to look beyond their own borders and broaden their horizons to other markets.

Microface 1^®: Permanent Silver Ion-Based Antimicrobial for Molded Polyolefin Plastics - Jason Brownell, Mold In Graphic Systems

Neat product presented well by Jason. Concise, on-time and informative. Interesting resource for molders to have in their tool box.

New Product Innovations for Maximizing Machine Production / Efficiency & JIT Material Handling - Dirk Yerian, reSource, Inc.

Dirk has some great ideas for pre-heating of powder as it is being pumped into a mold and also for coloring materials on-demand as they are being dispensed. Tested in the demanding toy industry, the move into general custom molding facilities will be another interesting challenge.

Cycle Time Reduction Project Report - Debes Bhattacharayya, University of Auckland, New Zealand

Debes gave an excellent presentation on the work conducted at the University of Auckland on the Cycle Time Reduction project for ARM International. The experimental test data was developed to support the work and came together nicely to show that potential improvements can be made by modifying the surface of the molds, molding at elevated temperatures (380ºC -716ºF(?)), applying internal cooling and applying internal pressure. 

My biggest question, however, is on the guidance given by ARM to Auckland on the project - the baseline cycle numbers presented that were used to determine some of the % cycle savings were twice as long as those that I commonly see in industry (48+ minute heating and cooling cycles for a 3mm (1/8" part)?). The techniques used can provide savings but they were not as large as the 60-70% savings shown. More industry input / Committee review on projects please.

Rotomolding in China - Dr. Linda Xu, LiDa Corp.

Linda gave an overview of the growth of the Chinese rotomolding market. In it's formative stages, the association in China reports 180 molders with possibly up to 500 active in the country. While much of the activity is in tanks, toys and containers, there is some work being done in automotive. Much of the equipment used is homemade just as it is in many other countries but continues to develop.  

Lean Clamping Methods for the Rotational Molding Industry - Ray Pachuta - De-Sta-Co Industries, Inc.

Ray described some changes based on molder feedback that De-Sta-Co have made to their basic clamps to make them more user friendly and 'lean'. He also showed their high-temperature pneumatic clamps that can survive repeated oven cycles.

Untapped Markets for Rotomolding - A Designer's Perspective - Warren Ginn, Integrated Design Systems, Inc.

Sorry - I didn't see this one but I know that Warren always does an excellent job!

The Safe Application of Internal Mould Pressure - Dr. Gareth McDowell, 493K, Ltd.

Gareth reviewed a pulse pressurization approach to safety for pressurizing molds. This was fascinating and may actually have benefits beyond what may be considered safety issues. Can the pulsing affect the way in which materials fill complex shapes or ribs, for example? Bob Fried's Unifuse system uses vibration to good effect and this may have similar benefits.

Surpass Resins^TM: Breaking Paradigms and Bringing Value to the Rotational Molding Market - Rod Gonzales & Mark Weber, NOVA Chemicals

Slick presentation on the two new octene based grades that use their single-site catalyst technology. Aimed at high-performance applications, the two grades reportedly offer ease of processing with good stiffness while maintaining toughness.

Rotomolding at the Molecular Scale - Dr. Nick Henwood, Matrix Polymers, Ltd.

Nick presented data on how degradation in parts can be detected using an infrared spectrometer that identifies the presence of carbonyl groups as oxygen attacks the material. Interestingly he observed that some carbonyl presence could be detected at the outer surface of very thick parts.

Tradeshow Exhibits:

'How many times have I told you not to interrupt me when I'm selling machines!'  Ann Rowland of Ferry Industries puts me in my place.

Dennis Anderson of Rivers Metal Products displays samples of their new mold coating system that produces a textured (shot peen effect) surface on steel molds. It also has benefits in terms of incorporating a release agent/system directly onto the mold.

The Boys from Rotoline giving some attitude on their cool stand....

...and the Boys from Wheeler Boyce trying to do the same (you look much too happy though Clark).

Neat spring arrangement (red plate) for locating core pins, etc. on mold frames at the Wheeler booth.

Past President George Kraemer of Kracor talking tech with Ted Eveleth of Cyclics Corp.

Joel Martin has promised that he will to find a bigger sign for The Jerico Group for the next show - I need to see headlines in these photos. Roy Crawford agrees.

Come on Larry do I even need to mention the sign? E.L. Stone, always there, always willing to help.

The dynamic and attractive Chevron Phillips team - four new materials and a lot of energy for rotomolding.

Mario with Orenda's grinding equipment and automation services. 

Ron Partridge (left) is almost a neighbor of mine in Pennsylvania but Riku Kumpu from Finncont Oy lives a little further away in Finland. Atofina supplies nylon and PVDF materials for rotomolding in North America and also supplies a new range of single site catalyst polyethylenes in Europe. 

North and South American relations continue to be good. Moldmaker Randy Johnson of JohnDel, Inc. chatting with molder Hugo Bisanti of Chemical Containers Andina from Venezuela.

Canada represented well by Michel Truax of STP Machinery with their signature shuttle machine line and Derek Nielsen of Zeebest Plastics of Canada. 

Alan Dubin of Ticona showing their new acetal materials for rotational molding along with some samples. Customer restrictions prevented them from showing the fully developed multi-layered system for fuel tanks that they have been working on with their customers but he assures me that they have achieved full bonding and even distribution. The stand-alone parts looked well-molded and attractive. 

Gareth McDowell of 493K discussing his new permanently attached control system for rotational mo(u)lding with Bill Spencely of Flexahopper and Einar Voldner of Synergy Polymers.

The boys from Brunk.

Teknor have some interesting grades for kayaks and high-performance products. The charming Gretchen Leighliter explains the benefits of their Tektuff materials. Did you know that Harry Howard is retiring at the end of this year? All the best Harry - try to keep in touch.

First Rotomolders Suppliers provide materials from Polimers Mexicanos here in the US. From left, Warren Bowman, Courtney Harris, Ana Paula Garcia and Jose Antonio Chacon. Polimers Mexicanos are preparing for their Mexican molding congress to be held in Acapulco in November. Hope to see you there!

Parts Competition

There were not as many parts on display this year but that did not take away from the winning entries.

The Terrible Twins of the Laws clan from Mity Lite proudly displaying their triple award winning table.  

This was a conversion category part which replaced a water massage machine tank. Complex arrangement of inserts and fittings. 

This large part is a 'bridgeshark' which is a spinning system designed to keep waterways clear.

Student Design Competition

Ana Paula Garcia y Colome Gongora of the National University in Mexico City, Mexico attended the meeting to collect her prize in the student design competition. Well done Ana, there were some excellent designs on display here.

Awards

The gala dinner is always a great opportunity to recognize individuals who have contributed to the rotational molding industry and Cleveland was no exception. 

Glenn Beall received the Charles D. Frederick Distinguished Service Award for exceptional work promoting the process...

...as did Ravi Mehra for his work.

Mark Kearns accepted the Organizational Service Award on behalf of Queen's University, Belfast.

The top honor from the Association was awarded to Bob Dunne and Bud Boyce. Induction into the Rotational Molding Hall of Fame was well deserved for these two pioneers of the industry who both started well before ARM even existed.

Congratulations everyone!

Entertainment

The ARM Band was back in great style for some great entertainment to round off the night. Tom Innis did an outstanding job again in putting together his own band with the usual cast of characters from the floor. Clark 'Bad Boy' Boyce knows how to get things going....

...while Jennifer 'Texas Rose' Gibson has the voice of an angel and mesmerized the crowd with her singing.

The Rockettes were back in their new slimmed down format. What a backing group.

And the crowd cried out for more. Celal Beysel, Susan Gibson, Jim Leitz and Mike Paloian enjoying the show.

See you in Florida!

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