FAQs of Injection Molding Additives
Even under optimal conditions, most injection molders face pain points at some point in the process. Check out a few of our frequently asked questions and how Amcor provides cost effective solutions.
Can the right additive reduce cycle times?
Many customers have been able to reduce cycle times by up to 25% by using our internal mold release Amease-FP. AmEase-FP improves resin flow and dispersion and promotes fast mold release, thereby reducing cycle times. For every 100 parts produced, you can produce an additional 25 parts, preventing a purchase of an additional machine and/or reducing the amount of labor hours required. In a case study of Amease-FP, one molder running a 750 ton press an average of 7200 hours annually, saved $72,000 and gained 74,000 extra shots per year.
Is it really possible to reduce the amount of resin without sacrificing the integrity of the design?
YES! This may be done through foaming, reducing wall thickness or reducing part weight. Resin/weight reduction comes with other added benefits that can be marketed to your customers. Think about products that are heavy and need to be moved around. You could see a 20% weight reduction by adding a just small percentage of the chemical blowing agent Amcell MZ20. Weight reduction could allow you to gain that competitive edge in the market you’ve been reaching for.
What about using more cost-effective resins?
In a volatile resin market, it can be quite a challenge to control costs, often leaving little room for additives in the budget. One molder wanted to move away from expensive polypropylene (PP) and use high density polyethylene (HDPE) instead. Unfortunately, the HDPE caused the part to stick in the mold. Amcor was able to relieve this issue by providing the processing aid Ampro-C73. It is designed to increase production speeds by decreasing polymer cooling rates. Ampro-C73 also helps reduce sink marks, improve product surface finish, and allows for easier part release.
Is it possible to combat brittleness?
Brittleness is commonly caused by weather exposure, the type of resin being used, or the processing temperatures. Amstar-41 is a proprietary additive that is designed as an elastomeric modifier for thermoplastic resins. It is used to enhance adhesion, elasticity and toughness, and impact strength, as well as in the compatibilization of styrenic/olefin blends.
What about colors?
Colors fade when exposed to the elements. Products such as garbage cans, play equipment, and garden planters are all examples of what can happen when left outdoors for a long period of time. Amshield-A25 stabilizes the color by protecting it from the degradation caused by UV rays. With suggested load levels starting at just 0.5% for every year of protection desired, Amshield-A25 keeps those colors lasting long into another season.
From the start we have been guided by a simple yet powerful philosophy: To solve customers’ problems and challenges. Amcor has grown from a single product line to hundreds of products and five product divisions. Each product we develop is the solution to a problem a customer has experienced or an opportunity for a customer to be different in the market. This “problem/opportunity/solution” approach has given us access to new segments to which we can apply our expertise and know how.
Our philosophy continues to energize and guide all of Amcor’s efforts today. We increasingly solve new and more challenging problems in current and new markets, while also internationalizing our offerings and presence around the world.
How do antistatic additives work?
Antistatic agents are used to manage static charges during various stages of processing and to provide long-term static protection based on end-use applications.
Static electricity can occur during an imbalance of positive and negative charges in an object. When enough electrical charges accumulate on the surface, a discharge occurs. The negative impacts of an electric discharge (e.g. life expectancy, sterility, speed of manufacturing), can affect the product, the packaging, the end user, and even the manufacturing personnel. By using the appropriate antistatic additives, static electricity can be diminished or entirely eliminated. Antistatic agents can be divided according to their application in two groups: external and internal antistatic agents.
External antistatic agents are temporary and can be applied on the surface of the finished product by dipping, wiping or spraying. On the contrary, internal antistatic agents are long-lasting and blended into the plastic when its being processed at the extrusion level. This application attracts water molecules onto the surface and charges dissipate rapidly. Other benefits of an antistat incorporated into a polymer include: internal and external lubrication, improved processability and mold release.
Amstat internal antistatic agents are designed to be incorporated into the compound or masterbatch. After processing, the additive migrates to the surface to prevent the buildup of static charge. All of our Amstat products were developed to meet the static decay and surface resistivity requirements of the United States Military Specification MIL-PRF-81705-D in LDPE and LLDPE films.
- Amstat-H15: is highly concentrated and able to resist high temperatures. As a general rule, 3% addition level is a good starting point.
- Amstat-F18: is a highly concentrated amide based antistat. Suggested starting addition level is 4%-6%.
- Amstat-AGF: is long lasting and is used as a substitute for a gas diffusing agents. The recommended addition level for foam is 10% and 6% for film applications.
Amcor's Amstat additives have many applications, including PE foam, blown and cast film. Contact Amcor, Inc. today for more information on our Amstat line of proven products.
Additives for Foam Extrusion
When choosing a supplier, it is important to know that the materials you purchase for your operation are of the highest quality and are supported by industry leading technical experts with decades of experience in polymer science. Amcor, Inc. has become the go-to source for foamers when looking to create new products, solve manufacturing challenges, and enhance material properties.
Corrugation is one such challenge that many extruders face. Amcor’s corrugation reduction additives include a line of proprietary elastomeric and rheology modifiers that enhance flatness, improve surface quality, and increase lamination speeds. These low-cost additives can mitigate the need for expensive equipment modifications and allow you to extrude consistently high-quality foam.
Ampro N2 by Amcor, Inc. is a process aid designed to improve surface quality (skin) on polyethylene foam. This process aid significantly increases foam compression strength. Ampro-N2 prevents delayed collapse in large profile foam extrusion and is ideally suited for the production of high-quality foam plank, exercise rollers, and floor underlayment. Ampro-N2 melts without imparting shear heat and in most cases, can be added to the extruder without any process condition adjustments.
Amblend-RV is a proprietary high melt strength copolymer with rheological properties specifically designed to enhance foam resilience and resist set. It is beneficial where softness, resiliency, and flexibility is desired. It can be foamed with physical blowing agents to 1.0 lb/ft3.
Due to our in-depth knowledge of plastic foam, we understand how different physical blowing agents impact the foaming and aging processes. For over 20 years, Amcor, Inc. has supplied the PE/PP/PS foaming industry with high purity, high quality gases and gas blends. Our gas customers have access to our technical staff’s vast knowledge of foamable resins and additives, the manufacturing processes, and equipment unique to the foam industry. Amcor’s investment in technology and service enables remote tank monitoring. This allows for just-in-time delivery of your blowing agent.
Regardless of what you foam, Amcor, Inc. is a valuable resource by your side.
Slips and Mold Releases
Slip additives not only improve the manufacturing of films, but also the plastic molding/extrusion process and the end use properties. Slip additives work by migrating to the surface and improving coefficient of friction (COF).
Are you a film manufacturer looking for a workhorse?
Amslip SCFB-is a slip powerhouse designed with ultra-high clarity film in mind. Compounded with LDPE, this slip is formulated to be twice as effective as a standard fast slip. Producers can achieve the target CoF by using less than one half as much slip, ie: 0.75% vs. 1.5% addition level.
Amslip F5- is a concentrated additive that allows the slip to bloom to the surface very quickly. It is typical that the slip will start blooming to the surface during film production with the majority of the slip migrating to the surface within 24 to 48 hrs. Bloom will continue to improve over the next 7-10 days. This product is ideal for air bubble film and bubble-out bags.
Amslip S5-is a high purity slow slip where a delay in slip bloom is necessary. Slip properties will not start to reach the surface of the film until 14 days after manufacturing. Use of this product enhances roll conformance and on-line corona treatment.
I'm an injection molder. Why do I need slip?
Amease FP Internal Mold Release-Effective at low levels (0.5%-1%), this product provides a cost-effective replacement for external, sprayed mold release agents. Proven benefits include: resin flow and dispersion improvement, faster mold release, and cycle time reduction.
Amcor, Inc. offers a broad variety of slips and mold releases that can be customized to your process, converting, product end use and product life.