While price still remains a critical purchase determinant, selecting the right equipment to realise enhanced productivity and efficiency has become the focal point for plastics processors.

While price still remains a critical purchase determinant, selecting the right equipment to realise enhanced productivity and efficiency has become the focal point for plastics processors. This priority is being reflected in the growing number of partnerships between plastics fabricators and machinery suppliers. 'Selecting the right plastics processing equipment is important and it is not always easy to choose correctly given the plethora of equipment suppliers by category, the increasing need for decreased energy consumption on top of equipment functionality and performance and the ever present capital investment quick payback requirement,' comments Research Analyst Donald V.

Rosato from Technical Insights, a business unit from Frost and Sullivan.

Collaborations between equipment suppliers and plastics fabricators need, therefore, to be flexible regardless of whether the plastics processing equipment is of a primary, auxiliary, software, or services variety.

For instance, an off-the-shelf robotic handling system cannot be standardised globally but needs to be adapted to suit regional requirements.

Worldwide, plastic manufacturers are aiming at boosting energy efficiency, upgrading standard equipment capability in terms of labour and material savings, adding cross-product differentiation features and speeding up marketing cycles.

'To develop these high velocity manufacturing systems, emerging cutting-edge plastic processing technologies are the foundation,' says Mr Rosato.

'True sustainable lean manufacturing excellence comes, however, with customising company needs to their given manufacturing environment.' The growing need to tailor equipment such as robots to accommodate the plastic fabricators' specific manufacturing environments is gaining particular significance in full manufacturing cells, which are defined by minimal production staff participation and designed for 'lights-out' manufacturing.

As plastics fabricators rationalise operations, primary and auxiliary equipment suppliers are being compelled to change accordingly.

For instance, auxiliary equipment supplier Wittmann is locating manufacturing plants in Hungary and China to supplement its Austrian base facility.

At the same time, the company has expanded from robot specialisation to become a full-service auxiliary equipment supplier.

Three way partnerships among globally leading plastics manufacturers and their primary/secondary equipment suppliers are becoming a common feature.

Many of these partnerships such as that between Nypro, Husky injection molding Systems and Hekuma in the area of high-tech state-of-the-art in-mould labelling have proved to be extremely productive and cost effective and have excelled at maintaining the proprietary nature of finished product development.

Whereas plastic fabricator manufacturers have concentrated on accelerated paybacks since they are always looking ahead to new orders, plastics processors have focused on emerging next-generation technologies.

Stellar technical progress has resulted in hybrid hydraulic and electric powered injection moulding machines that now deliver 15-30 per cent faster cycle times and in smart blown film software that has yielded the world's largest and most advanced 9-layer co-extrusion.

Embedded production and process monitoring system has been introduced in injection moulding equipment to create a 'boundaryless plant'.

An improved technology for hot runner moulding has also emerged, which displays breakthrough gating on angled surfaces.

Plastics Processing-Emerging Technologies and Trends Code: D287.

Background - Technical Insights is an international technology analysis business that produces a variety of technical news alerts, newsletters, and research services.

Frost and Sullivan, an international growth consultancy, has been supporting clients' expansion for more than four decades.

Our market expertise covers a broad spectrum of industries, while our portfolio of advisory competencies includes custom strategic consulting, market intelligence, and management training.

Our mission is to forge partnerships with our clients' management teams to deliver market insights and to create value and drive growth through innovative approaches.

Frost and Sullivan's network of consultants, industry experts, corporate trainers, and support staff spans the globe with offices in every major country.

Film Insert Moulding is gaining popularity as a method for decorating and manufacturing three dimensional plastic parts and a specialised website is on-line to support the technology.

Film insert moulding is gaining popularity as a method for decorating and manufacturing three dimensional plastic parts. Manufacturers across a variety of industries are recognising its potential and cost benefits, and are increasingly seeking information on the process and related products. With the launch of a new specialised independent website, there is now one portal to provide it.

Film Insert Moulding (FIM), a type of In Mould Decoration, is defined as '.

the application of pre printed film to a moulding as part of the plastics injection process.' It is beneficial in many applications: telecommunications and electronics, such as mobile phone fascias or touch sensitive keyboard pads; industrial moulded display panels; interior and exterior automotive parts and trims; and general consumer logos or badges.

Filminsertmoulding.com has been created to educate end users on the benefits of the process.

Endorsed by, and featuring products from, several key players in Film Insert Moulding such as Autotype International, Formech, Proell and Battenfeld, the website features knowledge and advice for those who wish to find out more about this versatile and cost effective process.

The site contains information on materials, a news section displaying up to date information and the latest technological development; and illustrations of the FIM process using Flash movies and comprehensive diagrams.

'Design Focus' looks at how FIM can enhance design productivity and 'Machine Focus' contains specifications of relevant industrial hardware.

Finally, the website also includes a list of suppliers of FIM products and services, from powerful industry leaders through to smaller specialist suppliers.

Manufacturers can research the FIM process and equipment, and select a supplier straight away.

This demonstrates how filminsertmoulding.com really does provide every necessity for understanding, researching and purchasing FIM, all at the click of a mouse.

A full line of carbon fiber reinforced compounds that are based on chopped carbon fiber, milled carbon fiber and carbon nanotubes provide more rigidity as well as electrical conductivity.

Premix Thermoplastics, announces the addition of a full line of carbon fiber reinforced compounds to the company's PRE-ELEC product portfolio. Based on chopped carbon fiber, milled carbon fiber and carbon nanotubes, the new compounds provide the increased rigidity of carbon fiber as well as the electrical conductivity. Premix carbon fiber compounds are available with as much as 60% carbon fiber in nylon 6 and 66 and PPS, and at least 40% in others, including PP, ABS, PC, POM and PSUL.

The addition of carbon fibers not only increases the flexural modulus (rigidity) of the compound, but also increases the tensile strength, lowers the shrinkage and increases the electrical conductivity.

Compounds that are based on milled carbon fiber are less prone to warpage while compounds that are based on carbon nanotubes can be electrically conductive with as little as 3% fiber reinforcement.

In addition, carbon nanotubes can also create thermally conductive polymer compounds when used at higher loadings.

Standard color is black.

Compounds that are 10% carbon fiber-based are available in a variety of colors that facilitate the color coding of molded parts.

Pre-Elec compounds include most of the commercially available thermoplastics combined with virtually all of the electrically conductive additives including: carbon black, carbon fiber, nickel coated carbon fiber, stainless steel fiber, graphite flake, nickel coated graphite flake, silver and silver coated additives, metal powders and flakes, inherently dissipative polymers (IDPs) and inherently conductive polymers (ICPs).

Premix Thermoplastics is a subsidiary of Premix Oy, a leading manufacturer of electrically conductive compounds in Europe.

It offers customers innovative, reliable and safe plastics raw material solutions in applications ranging from ESD proof packaging to EMI shielding.

Quadrant Plastic Composites (QPC) has been presented with the AVK-TV innovation award for work with GMT and lightweight composites.

Quadrant Plastic Composites (QPC), the world market leader in GMT and lightweight composites, has been presented with the innovation award of the Arbeitsgemeinschaft Verst„rkter Kunststoffe - Technische Vereinigung (AVK-TV: Reinforced Plastics Association - Technical Federation) in the Best Application of the Year category. QPC won this award for the underbody shields of the BMW 1 and 3 models, which are manufactured using the new Symalite technology. The AVK-TV Innovation Award is one of the most prestigious engineering awards in Europe in the reinforced plastics field.

Symalite, developed in-house by QPC, is an innovative, intelligent, lightweight reinforced thermoplastic composite material which is compression moulded under application of low moulding forces.

Economical composite moulds enable up to four components to be produced, die-cut and laminated directly with sensitive decorative material without using adhesives, in a single moulding stroke.

Symalite also enables components featuring different thicknesses to be produced: the degree of consolidation is smaller in the flat surface zones and greater in the edge zones and around attachment points, i.e where the greatest forces are at work.

Component manufacturer and systems supplier is Seeber AG and Co.

KG, Mannheim.

Advantages of Symalite: the underbody shields of the BMW 1 and 3 models are light in weight due to their reduced density; weight savings of some 30% were also achieved compared to conventional solutions as a result of using the new SymaLITE material concept, and the fully closed underfloor module makes the use of PVC for anti-corrosion protection unnecessary.

The high rigidity of the material combined with its low weight have enabled the aerodynamics to be improved significantly, thus reducing fuel consumption by 5%.

Acoustics have also been optimised by the semi-consolidated structure, which generates less noise in rain or from stone chips, and - in contrast to fully consolidated structures - absorbs noise.

'We are especially pleased to have won one of the most important European innovation awards with SymaLITE', commented Volker Fritz, CEO of Quadrant Plastic Composites.

'This award underlines the company's innovative thrust and the expertise of its personnel.

In recent years QPC has invested with the future in mind, and we are now earning the benefits.' The AVK-TV presents three innovation awards annually in the categories of: Promoting new industrial solutions; Achievements in environmental protection; Promoting university work in the field of composites and thermosetting moulding compounds.

The specification of requirements in the category 'Application of the Year 2004' was 'a new product ready for the market or a new, efficient manufacturing process.' The product or process advance, the improvement in the cost/benefit ratio and the development of new markets were rated in this context.

'The AVK is proud that Quadrant Plastic Composites from Switzerland has received the award for the best innovation this year, since this company has been an innovative manufacturer for many years and is very well known on the market', stated Dr U.

QPC already received the innovation award for the Most Innovative Use of Plastics presented by the Automotive Division of the Society of Plastics Engineers (SPE) in November 2003 for the underfloor modules of the BMW 5 and 6 models.

The Fassi Group, one of Europe's foremost manufacturers of hydraulic cranes, found its material solution in Nylatron 703 XL plate.

A crane's ability to efficiently and safely position its load requires a virtual absence of vibration during both fine and gross movements of the boom. Lubrication of moving parts helps to achieve this, but more and more, heavy equipment manufacturers are searching for lubrication-free materials that minimize or even eliminate stick-slip influences during operation. The Fassi Group, one of Europe's foremost manufacturers of hydraulic cranes, found its material solution in Nylatron 703 XL plate from Quadrant Engineering Plastic Products (QEPP).

QEPP's nylon material helped to endow Fassi's equipment with very accurate, smooth control over linear boom movements.

Further, it helped to eliminate chatter as sliding parts overcome inertia as they begin to move.

The material's static and dynamic coefficients of friction, which are consistent at virtually every point over its useful range, allowed Fassi's cranes an unprecedented degree of control.

QEPP developed Nylatron 703 XL nylon to meet the increasing demands for precise motion control, safety and elimination of lubrication in the construction industry.

In addition to its low coefficients of friction, the material offers a superb combination of high strength and stiffness as well as high wear-resistance.

Nylatron 703 XL's particular benefit to manufacturers of material handling equipment, however, is its ZERO 'stick-slip' during initial and continuous movements.

Comparative tests performed by an independent research institute established that Nylatron 703 XL has the lowest dynamic and static coefficient of friction of any commercial nylon tested against unpainted services.

Preliminary tests against painted surfaces show identical results.

Fassi's application represents the first commercial use of Nylatron 703 XL parts formed in customized low-pressure casts.

Low Pressure Casting (LPC) processes offer improved economies for plastic parts ranging from a few grams to several kilograms in weight, that carry no wall thickness limitations and that run in series from a few hundred to a several thousands parts per year.

LPC's lower processing temperatures and injection pressures also enable the use of aluminium tools rather than hardened tool steel, further benefiting small volume series and parts produced for evaluation purposes.

An attractive colour finish with a decorative sparkle can be produced from an aluminium impregnation of plastic materials - even in small batches.

An attractive colour finish with a decorative sparkle can be produced from an aluminium impregnation of plastic materials which adds to the presentation of any container for the 'cosmetics' market. Designed and manufactured by Toolcraft Plastics of Swindon in tough PPR, (random co-polypropylene), the thread can be pre-formed into stopper and body, making the complete product 'ready for market' without additional operations. Toolcraft Plastics of Swindon specialise in tooling and manufacture of plastic parts with particular finishes and colours, even in small batches.

Special pre-moulding and mixing techniques guarantee parts with clean finishes and colours with good dispersion.

With experience in plastics of all colours, transparent, opaques, luminescent, even metallics Toolcraft can colour match to existing parts or customer choice, or create a special finish to enhance the product or presentation.

A 12-month research project undertaken by Pera Innovation has shown that recycled plastic can be successfully used as a reinforcement medium for high pressure engineering applications.

A 12-month research project undertaken by Pera Innovation has shown that recycled plastic can be successfully used as a reinforcement medium for high pressure engineering applications. Pera Innovation, a unique independent research and development organisation, won a grant of GBP 152,420 from The Onyx Environmental Trust through the Landfill Tax Credit Scheme to carry out this innovative research project. Researchers wanted to demonstrate that Polyethylene Terephthalate (PET) fibres and tapes derived from plastic squash bottles and food trays could be treated and reused to manufacture high value reinforced thermoplastic pipes.

The products were also assessed in terms of life cycle analysis to further determine their commercial viability.

A number of prototypes were developed, together with a mechanism for joining the pipes to.

When tested, the prototypes were successful in achieving proof of concept for putting recycled PET from the plastic bottle waste stream into a high added value pipe application, achieving burst pressure exceeding 100bar.

Andy Huang, Researcher for Pera Innovation said: 'Preliminary cost assessments suggest that this pipe will cost less than a third compared with products currently on the market with the same pressure rating.

'Such reinforced thermoplastic pipes could play a major role in the GBP 900m European market for transmission lines used in the oil and gas industries.

By creating this new high value market for low value PET waste, the team has provided a great incentive to recycle and re-use the material.' Margaret Cobbold, General Manager of The Onyx Environmental Trust, said: 'The Trust is delighted to see such encouraging results from this research project.

Pera's innovative approach to identifying commercial opportunities by recycling materials demonstrates environmentally responsible alternatives available to the engineering industry.' Now that the proof of concept has been established, Pera is seeking further industrial sponsorship to develop and demonstrate a full-scale continuous manufacturing facility that will help ensure the technology is adopted and exploited by industry.

With further research, the same technology could be utilised in many other products and market sectors.

Materials driers offers plastics processing customers a significant key benefi, that of energy saving and fully automatic operation for medium to large throughputs.

Sandretto UK's latest range of materials driers offers plastics processing customers a significant key benefit: energy saving with a market leading performance. Sandretto UK offers two ranges in this area. For small material throughputs a single desiccant system and for medium to large material throughputs two desiccant systems are used.

The DDT model offers: a.High saving of energy.

b.High linear dew-point (up to - 50).

c.Fully automatic operation.

d.Operation without refrigerated water.

e.Operation without compressed air.

In terms of energy saving, the return air from both the process and regeneration is intercepted and recycled, hence reducing the amount of wasted energy.

In more traditional driers the return air is cooled using water and is then reheated again, making for increased running costs.

Any cooling that is required before the air reaches the blower is achieved by a small electric fan.

This procedure eliminates the need for water cooling and gives the DDT dryers a high saving of energy, typically up to 30 - 40% compared with traditional dryers.

Sandretto UK's latest range of drier can link a number of materials hoppers to a single dehumidifier generator unit.

The dehumidifier supplies the air unheated to the hoppers hence eliminating the need to lag pipes.

Each hopper has its own heater and booster blower attached that controls the flow of air through the hopper.

If the hopper is turned off for material change a valve automatically closes off the dehumidified air supply to that hopper.

Chris Whitlam, National Manager for Sandretto Ancillaries and Automation reports that 'our ancillary sales have this year exceeded budget and expectation.

Not only do moulders prefer one-stop-shopping with their injection moulding machinery supplier, they are also ever more cost conscious.

This is good news for our energy saving driers and bodes well for their success into next year.'

Series of materials dryers for the plastics processing sector has been expanded in order to include the option of two drying hoppers, each with independent temperature control.

Wittmann UK has expanded its Drymax C30 Series of materials dryers for the plastics processing sector in order to include the option of two drying hoppers, each with independent temperature control. Besides the currently available configurations of the Drymax C30 with one drying hopper, either as a hopper mounted unit or beside-the-press unit, and as a compact dryer mounted on a frame and attached to the drying hopper, the Drymax C30 can now be supplied with two hoppers mounted on a frame with casters. In this configuration the Drymax C30 is available in several combinations of hopper sizes of 20, 30, 50 and 70 litres.

The Drymax C30 dryer generates a dry air capacity of 30m3/h and guarantees throughputs up to 20kg/h depending on the material to be dried.

The dual hopper version of the Drymax C30 offers all the features of the single hopper unit with the added flexibility to dry two materials independently using a single dryer.

The Drymax dryer uses the principals of adsorption and is equipped with two independent desiccant beds for a constant dry air supply.

By means of reverse flow direction between process and regeneration air, the dryer is able to achieve a constant process air temperature and dew point of - 60 deg C, independent of the ambient air condition.

The Drymax microprocessor control has been developed and optimized by Wittmann for drying applications and performs extensive monitoring and temperature control tasks in addition to the automatic and independent adjustment of airflow through the two drying hoppers.

The integrated SmartFlow function controls two motorized flappers to divert the airflow based on the material throughput of each drying hopper.

In conjunction with the embedded material saver function, the set point of the process heaters are lowered as soon as a press stoppage is detected in order to avoid over-drying and thermal degradation of the material residing in the drying hopper.

Should an increase of the material consumption be indicated via a rising temperature differential in the hopper, the microprocessor automatically raises the drying temperature to the original set point and the SmartFlow motor valve increases the air flow according to the material throughput.

By using electrically driven switch-over valves in the dryer and SmartFlow valves no compressed air supply is required for the operation of the Drymax C30 dryer.

Technical brief provides plastics processors vital insights toward meeting goals for Increased purity and productivity and helps identify practical and effective purging technology.

Novachem, a leading provider of safe and effective purging solutions for thermoplastics processors, has announced the availability of a free industry White Paper that tackles head-on various purging issues and dilemmas facing todays plastics processing managers. The 12-page technical brief, entitled 'Toward a Systematic Approach to Evaluation and Resolution of Purging Issues in Thermoplastics Processing', includes an abstract overview and a four-page appendix of useful tools, such as a data collection sheet, a factors checklist, and a cost comparison matrix. Written by Novachem General Manager and industry specialist Frank Van Haste, the document offers approaches to contemporary purging issues, including reducing product contamination and increasing the efficiency of color and/or resin changes.

The report also discusses the impact of these challenges on overall productivity, and provides solutions for increased efficiency.

'An informed and systematic technical approach - the antithesis of the typical - episodic or ad hoc approach - is now required to truly minimize the effects of contamination while maximizing productivity', adds Van Haste.

'As an industry leader, Novachem has made it a priority to provide meaningful resources and unbiased solutions for its many constituents in plastics processing', comments Frank Winner, V.P.

Marketing and Sales, 'and this White Paper is just one of many steps we are actively taking'.

A free, downloadable PDF version is available online at the companys website.

*Title: 'Toward a Systematic Approach to Evaluation and Resolution of Purging Issues in Thermoplastics Processing'.

* Author: Frank Van Haste.

* Abstract - purging issues (which encompass changes in color and/or resin type and the removal of contamination from equipment) historically have received little attention from engineering and production managements.

The pressures to optimize productivity that prevail in the modern industrial environment make this kind of inattention unacceptable.

The present paper describes an unbiased, systematic approach to the evaluation and resolution of these issues that is commensurate with the importance of their impact on productivity and gives examples of the benefits that are derived when such an approach is adopted.

The approach must be planned and implemented in an orderly way, consistent with good manufacturing engineering practices.

* Relevance - it has long been a fact of life in the thermoplastics processing industry that color changes, material changes and the presence of contamination in process equipment - collectively, purging issues - would negatively affect productivity.

This has been accepted in the industry for two reasons: (1) because every facility faced the same problems, there was no differential effect on competitiveness; and (2) in the hierarchy of problems to be solved ranked by expected benefit, these issues were not at or near the top of the list.

Heretofore a variety of ad hoc approaches have been employed to address purging issues on an episodic basis: * Running large amounts of resin, preferably of a low melt-flow character; * Partial or complete disassembly and mechanical cleaning; * Symptomatic application of one or more formulated purging products.

However, this episodic approach neglects underlying causes and fails to address whether the result actually represents a significant improvement.

Therefore, an informed and systematic technical approach is required to truly minimize the negative productivity impact of purging issues.

Four major German automotive companies agreed to back the Industrial Ethernet standard Profnet which has been developed by Profibus International, the organization responsible for the PROFIBUS.

German automotive OEMs choose common Ethernet platform In an announcement made at the SPS/IPC/Drives Fair in Nuremberg on November 24th, four major German automotive companies agreed to back the Industrial Ethernet standard profinet which has been developed by PROFIBUS International, the organization responsible for the PROFIBUS and PROFINET automation technologies. Speaking jointly at a PROFIBUS International press conference, representatives of Audi, BMW, DaimlerChrysler and Volkswagen said that the announcement is intended to encourage supplier companies to introduce PROFINET-based systems quickly so that the requirements of next generation automation systems in automotive manufacturing can be met. The target is to achieve a fixed, uniform protocol that is neutral with regard to manufacturers and users and which has an integrated safety technology.

Standardization of the engineering tools for the communications bus is also required.

The four companies make up AIDA, the Automation Initiative of German Domestic Automobile manufacturers, which took as its starting point the fact that today's automation systems are heterogeneous and are compatible to a restricted extent only.

Also, fieldbus systems tend to have relatively limited bandwidth and can restrict the distribution of automation components.

Today, this requires additional resources and integration and results in increased costs.

AIDA believes that a common Industrial Ethernet platform is the way to overcome these challenges in future automation systems and has selected PROFIBUS International's PROFINET for the task.

Edgar Kuester, Chairman of PROFIBUS International, said: 'This announcement will not only influence the automotive industry in Germany but the rest of the world too.

I also believe that the leadership of the automotive industry will have a significant influence on most other branches of industry.

This exciting moment in the history of automation offers us all the chance to focus on real end user benefits using a vendor-neutral communications solution.

One of the unique advantages of PROFINET is that it enables legacy fieldbus systems like PROFIBUS and INTERBUS to be integrated easily, thus protecting existing automation investments.

Everybody looks to be a winner in this new automation world and I invite once again other major fieldbus organizations to join our mission.' Mike Bryant, Deputy Chairman of PROFIBUS International and Executive Director of the PROFIBUS Trade Organization in North America added: 'This decision by key players in the European automotive market sends out a powerful signal globally.

My assessment at this point in time, based on our experience of the PROFIBUS market 10 years ago and because PROFINET offers a number of key Industrial Ethernet advantages, is that AIDA's lead will be followed by automotive manufacturers worldwide, including I believe in North America.' PROFINET has been developed by PROFIBUS International for distributed automation and component-based automation applications.

PROFINET is also supported by the INTERBUS Club whose members are now developing PROFINET-compatible products.

Together, PROFIBUS and INTERBUS have nearly 20 million fieldbus devices installed, roughly 75% of the world fieldbus market.

At SPS/IPC/Drives PROFIBUS International announced that more than 70 PROFINET products and services are now available from 20+ major vendors in North America, Europe and Japan.

PROFIBUS International believes the number of PROFINET products will rise significantly by hannover fair in April 2005.

PROFINET can simultaneously meet the needs of three automation domains with a single-cable Industrial Ethernet solution.

These are: IT integration, realtime automation and isochronous realtime motion control.

The PROFINET solution is fully compatible with IEEE802.3 standards.

In motion control applications PROFINET can control up to 150 axes in 1mS using the isochronous realtime (IRT) mode while other automation or IT functions are running.

More than 140 engineers are working today in 11 international Working Groups on the development, enhancement and standardization of PROFINET, including key features such as data security and the integration of PROFINET into MES systems.

A machine and personnel safety profile based on the proven PROFIsafe fieldbus solution is under development.

In response to increasing market demand for products that enable and enhance colour identity, a range of colours for extruded Acetal stockshapes is available.

Quadrant Engineering Plastics (EPP) has introduced a range of standard colours for extruded Acetal stockshapes. The company launched the selection in response to increasing market demand for products that enable and enhance colour identity. The products deliver all the familiar performance qualities of Quadrant EPP's range of Acetal materials, including an excellent ratio of weight/strength performance, a low coefficient of friction and good abrasion resistance.

The Ertacetal product line is also known for its excellent machinability.

But Quadrant's new line delivers several additional benefits related specifically to colour.

For example: * Companies wish to distinguish themselves and their products from the competition, and colour offers a simple visual approach to brand recognition.

* Standard colours can quickly determine whether a faulty part originated at a company's factories or those of a competitor.

* Ordering materials and parts in standard colours simplifies many customer designs and processes by removing guesswork about colour consistency and accuracy during later product development stages.

* Pre-coloured materials and parts simplify design of colour-coded systems that require multiple parts to be accurately changed out or replaced.

* Colour-coding parts not only helps customers avoid accidental mistakes in assembly processes, it can also improve safety, facilitate product inspections, and save time.

Quadrant now offers customers with a broad selection of Acetal stock shapes in a range of seven standard colours beyond the black and white.

The new colours include red, blue, yellow, green, orange, brown and grey.

Customers can select from these standard colours instead of formulating their own custom colours.

Independent research report highlights the continuing evolution of fluorosilicone rubber (FSR) technology, and compares new materials with conventional FKM compounds.

Dow Corning has published independent research entitled 'FSRs in Extreme Applications', which highlights the continuing evolution of fluorosilicone rubber (FSR) technology, describing laboratory results comparing the performance of Silastic brand LS 5-2060 and LS-2860 FSR from Dow Corning against conventional FKM compounds. In addition, the research outlines the opportunities these FSR materials represent for more cost-effective, high-performance elastomer applications that require superior chemical, fuel, and oil resistance; good abrasion resistance; and excellent performance at extreme temperatures. FSRs in Extreme Applications alerts designers and OEM engineers of new chemical and compounding advances for fluorosilicone materials that could help usher in higher performance and more cost-effective solutions.

The published research summarizes conclusions derived from laboratory tests sponsored by Dow Corning and conducted in 2003 by Rapra Technology, an independent plastics and rubber testing company located in Shawbury, United Kingdom (www.rapra.net).

'The results of these tests could augur a paradigm shift for FSRs, demonstrating enhanced performance and lower price points,' said Martin Rowlands, Engineered Elastomer Industry, Science and Technology Global Director, Dow Corning.

'These new materials could potentially begin to supplant hydrogenated nitrile rubber (HNBR), carboxylated nitrile rubber (XNBR), urethane, acrylic rubber (ACM), ethylene acrylic rubber (AEM), and FKM materials in extreme applications.' As proof of this new paradigm, Dow Corning's research results details the comparative performance of two FSR compounds tested against three FKM-based compounds.

Some examples of what Rapra Technology's tests demonstrated include: * The tear strength at 200 deg C (392 deg F) of the two FSR compounds tested was significantly higher than the FKM compounds; * The elongation at break for the FSR compounds at 200 deg C was significantly better than any of the FKM compounds evaluated; * The two FSR compounds exhibited tensile strength values at 200 deg C, similar to those of FKM compounds; * FSR compounds generally had a wider operating temperature range compared to FKM compounds, due to their lower glass transition temperatures; and * With better tear strength performance and with similar tensile strength values, FSR elastomers compared favorably with FKM materials for high-temperature applications (up to 200 deg C).

For more than 40 years, FSRs have delivered excellent fuel resistance and performance in both low- and high-temperature conditions.

Dow Corning developed an advanced compounding expertise that offers a new family of high-value, specific compounds.

This innovation has improved FSRs' historically excellent balance of fuel and oil resistance and good mechanical properties over a wide range of temperatures.

Dow Corning's publication also summarizes the company's unique range of services in base formulation technology and compounding expertise.

These value-added services enable Dow Corning to meet specific customer needs while delivering the exact properties their design needs to be competitive.

FSRs in Extreme Applications points out, for example, that formulations based on Silastic LS 5-2040 FSR exhibit good resistance to lubricating oils, while the more consistent properties of the company's Silastic LS 4-9062 fluorosilicone rubber product stem from the fact that it is a blend of FSR and VMQ elastomers.

When a major manufacturer of camping and outdoor recreation equipment, decided to switch to thermoplastic parts it found a heat-resistant product that did the job.

When the Coleman Company, of Wichita, Kansas, USA, a major manufacturer of camping and outdoor recreation equipment, decided to switch from metal to thermoplastic parts in order to increase performance and reduce the size and weight of their products, they chose Victrex PEEK for the heat-resistant swivel ring on their F1 Power Stove. The F1 Power Stove is a butane/propane cartridge-type portable stove used in camping or mountain climbing. With a high-power burner producing 3,700kcal/h, the highest heating power of all the companys products, it is capable of boiling 1 liter of water in 2 minutes and 30 seconds.

The swivel ring is built into the fitting base of the stoves pan support and is located directly under the burner which produces a 1500 deg C (2732 deg F) to 1600 deg C (2912 deg F) flame.

The part, therefore, needs to withstand temperatures exceeding 200 deg C (392 deg F) that result through heat transfer.

'Prior to switching to Victrex PEEK, Coleman used brass or plated iron to provide the necessary strength and heat resistance,' says Andrew Ragan, Victrex Global Leader—Industrial, 'They switched to Victrex PEEK because it delivers the high-temperature resistance [320 deg C (608 deg F)] and high strength required by the swivel ring.

It also enabled them to limit the main units weight to 146g (5.1oz), achieving a 10% weight reduction over the unit with the previously used brass part.' The lubricity provided by Victrex PEEK is another important factor.

According to Ragan, 'The F1 Power Stove uses a rotating/retractable pan support, which requires that the swivel ring be able to slide, and since Victrex PEEK also exhibits excellent lubricity, it is ideal for the application.' In addition, says Ragan, 'Since the swivel ring has a complex shape, switching from the machining of a metal part to the injection molding of a thermoplastic part has also contributed to reduced manufacturing costs.' Victrex USA, a division of Victrex, is the sole manufacturer and supplier of PEEK polymer worldwide.