Sunday, January 26, 2014

Productivity and IE in Plastics Material and Resin Manufacturing

Polymer Pumps for Resin Plants & for Plastic Processing - Productivity Improvements

Energy Consumption by Chemical Industries

Opportunities for Energy Efficiency in Hydrocarbon Resin Manufacturing Facilities

This paper summarizes the results of a plant-wide assessment of Neville Chemical
plants in Anaheim, CA and Pittsburgh, PA. US DOE cosponsored the assessments (Ganji, et
al. 2002).

Detailed plant-wide assessment of two hydrocarbon resin manufacturing facilities of
Neville Chemical revealed significant opportunities for energy efficiency, and consequently
air emissions and green house gas reduction in such facilities. The energy efficiency
opportunities (EEOs) in the Anaheim plant, the smaller of the two facilities, could save 27%
of the facility’s annual electrical energy usage, and 36% of its annual natural gas energy
usage. The cost savings is estimated at about 20% of this facility’s annual energy costs, with
an overall simple payback of 1.6 years. The EEOs identified in the Pittsburgh plant, a much
larger facility, could save 9% of the facility’s annual electrical energy usage, and 54% of its
annual natural gas usage. The total annual energy cost savings would represent about 30% of
the facility’s annual energy costs with an overall payback of 0.9 year. Significant non-energy
benefits including waste reduction and productivity improvement measures were also

Vacuum Forming

Vacuum thermoforming is a plastic manufacturing process in which a 2 dimensional thermoplastic sheet is heated to a forming optimal temperature and, using vacuum and pressure, is formed into a 3 dimensional part.

Materials Commonly Used in Vacuum Forming
ABS - Broad spectrum of resins used across a number of applications. Can be formulated to meet UL flammability standards.
PC/ABS - Alloy delivers UL approval in addition to high impact performance.
HDPE - Cost effective material for industrial applications requiring high impact strength.
TPO - High impact material delivering performance in cold and high heat applications.
HIPS - Low cost resin used in many POP applications requiring excellent forming characteristics.
PVC/Acrylic - Widely used resin in micro-processor based equipment housings. Meets most stringent UL standards for flammability and can be made in wide range of colors and textures.

Plastics Manufacturing Systems Engineering
David O. Kazmer
Hanser, 2009 - Kunststoffverarbeitung - 502 pages

"Plastics manufacturing is a highly interdisciplinary endeavor requiring knowledge related to materials science, physics, engineering, and management. This book was written to educate and support plastics processing engineers, but is also highly useful to others involved with plastics manufacturing who are performing process development, research, and even machinery design"--Provided by publisher.

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