Case Study


Elastomeric Modifier Benefits

Greater yield allows users to create more while maximizing machine and operator time. Down gauged benefits are generally one for one with material reduction. Reduced material thickness means less material to heat or cool resulting in reduced cycle times and less waste in the environment. When it comes to advances in materials, product performance, process efficiencies and reduction in waste, Amcor, Inc. has been successful in delivering more performance and profit with less material and waste.

In the expanding industry of plastic manufacturing, the evolution of industry specific additives creates numerous opportunities for increasing profits, boosting green credentials and improving efficiency, a “win-win” scenario for everyone.

One of these concepts is down gauging, creating a thinner product with all the salient physical properties of the original thickness. While the idea is simple, the actual process can be challenging. Amcor draws on its extensive experience and cutting edge technologies to provide the customer with specific solutions for down gauging. By combining these factors, our customers can manufacture products that offer the performance of conventional products but from material that is 10% to 25% lighter.

Financial Case Study

The customer was evaluating the use of filler for cost reduction. Amcor, Inc. suggested down gauging with Amstar-41 as an alternative that would maintain performance, but still reduce cost. Parts produced with the filler did lower cost by $100,000.00 per year. However, part weight increased, efficiency declined and the rate of failure on tear strength proved unacceptable.

The introduction of Amstar-41 at a low loading of 4-6% allowed for a 10% reduction in sheet thickness. Parts produced were 10% lighter with a reduction in yield loss, improved efficiency and the tear strength increased.

The trial with Amstar-41 resulted in a part that exceeded current performance and achieved an annual reduction in material costs of $300,000, yield loss improvement of $86,000 and an efficiency gain of $12,000. The net savings and yields for this customer totaled $398,000 annually.