Case Study: Geon Vinyl - Aquarium Pump - PolyOne

Case Study
Geon Performance Materials
Geon Vinyl Outperforms
ASA in Aquarium Pump
Aquarium equipment manufacturer reduced operating costs and
improved part quality with Geon Vinyl Solution.
Situation
A leading global manufacturer of aquarium equipment, based in
Shenzhen, China, produces a variety of components including water
pumps, air pumps, fi lters, chillers, and heaters. One of its water pump
lines incorporated an acrylonitrile-styrene-acrylate (ASA) housing sourced
from North America. Because the aquarium equipment industry is
extremely competitive and, therefore, cost sensitive, the manufacturer
decided to investigate local sourcing as a way to reduce the total cost
associated with manufacturing this pump.
The manufacturer’s product development group selected
a local grade of ASA that contained recycled material.
While this selection reduced raw material costs and
improved logistics, it created quality problems and
increased scrap rates. At that point, the manufacturer
turned to PolyOne in Dongguan, China for help.
The PolyOne Difference
A PolyOne sales and technical service team met with the
manufacturer’s product development group to gain an
understanding of current challenges with the water pump
housing and performance requirements.
The water pump is often used in outdoor aquariums and
as a result, any material used in the housing must meet
water immersion requirements and have a UL f1 rating,
indicating it is suitable for outdoor use with respect to
exposure to ultraviolet light and water. The housing must
resist the elements without signifi cant color change or loss
in physical properties. The pump housing must also have
good impact performance to endure overseas shipping and
assembly. Finally, the material used for the housing needs
to be RoHS compliant because the end markets for the
pumps are Europe and North America.
The PolyOne team also observed that the molding process
suffered from poor quality parts and high scrap rates using
the locally sourced ASA. Because rejected parts contained
degraded material, using them as regrind would signifi cantly
reduce the impact strength of the parts. As a result, the
manufacturer couldn’t use any scrap parts for regrind,
further increasing costs.

Based on these insights, the PolyOne team recommended Geon M5240 for its performance and economic
potential. Geon M5240 is a RoHS-compliant formulation offering outdoor weatherability, a UL f1 rating, high impact
resistance, and excellent resistance to water. Before trialing Geon Vinyl, the PolyOne team completed an economic
analysis based on the specifi cs of the application to estimate the value that PolyOne’s solution could offer over the
partially recycled ASA material. This analysis showed the potential for a clear economic advantage, which convinced
the manufacturer that a trial should be scheduled as soon as possible.
Transitioning from one polymer to another requires careful planning and a methodical approach. PolyOne analyzed
the tool and determined that Geon Vinyl could be run in the original ASA tool without modifi cation. The manufacturer
was new to molding rigid vinyl but the PolyOne technical service worked side-by-side with them to recommend
optimal equipment and processing conditions needed to make excellent quality pump housings with Geon Vinyl.
Delivering a Value-Added Solution
By switching to PolyOne’s Geon solution, the manufacturer was able to retain local supply and save an estimated
$100,000 in molding-related costs, including cycle time and scrap rate reductions, while gaining the ability to use
regrind. PolyOne’s solution improved part quality and reduced molding scrap rates by over 60%. When needed,
the manufacturer can also incorporate up to 20% regrind without sacrifi cing part quality – something that was not
feasible with the ASA material.
With its fl ame, chemical, and UV resistance, Geon Vinyl is an exceptional choice for applications requiring
performance and quality. PolyOne not only added value with a material solution, but provided industry-leading
service to facilitate a smooth transition from ASA to Geon Vinyl. This combination of material and service illustrates
PolyOne’s commitment to collaborating with its customers to drive innovation and help make them more profi table.
PolyOne offers specialized solutions, such as Geon Vinyl, that are targeted at helping customers meet performance
goals, improve manufacturing effi ciency, and maximize value in every way possible.
Product choices often vary by region due to differences in regulatory and agency requirements,
availability and other key factors. Please contact your nearest sales office for assistance in
choosing the right solution for your locale.
CONTACT INFORMATION
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Copyright © 2012, PolyOne Corporation. PolyOne makes no representations, guarantees, or warranties of any kind with respect to the Information contained in this document about its accuracy, suitability for particular
applications, or the results obtained or obtainable using the information. Some of the Information arises from laboratory work with small-scale equipment which may not provide a reliable indication of performance or
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