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®Thermoforming®QuarterlyA JOURNAL OF THE THERMOFORMING DIVISION OF THE SOCIETY OF PLASTIC ENGINEERS FOURTH QUARTER 2012 n VOLUME 31 n NUMBER 4Post Conference EditionWrapping Up 2012 in StyleINSIDE …The Business of Thermoforming: Industrial Investments pages 10-13ANTEC Paper: Liquid Crystal Polymer pages 14-182012 Conference Review page 20WWW.THERMOFORMINGDIVISION.COMThermoforming QUARTERLY 1

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Are Youhttp://www.linked.com/groups?gid=3992496&trk=mygugrp ovrGroup Name:Thermoforming Division,a subgroup of SPEModerator:Mark StrachanTrending Topics(as of November 28, 2012)1. Material selection: PP vsHIPS for yogurt cups2. Machinery options forproducing cups and lidsWith over 380 membersand growing, theThermoforming Division isusing Linkedin to expandthe conversation. Meetfellow professionals,ask tough technicalquestions, explorerelated groups.Join us today!Thermoforming QUARTERLY 3

ThermoformingQuarterly ®New MembersPierre AlbertynPolytechCape TownTawnya Suzanne ClarkGE AppliancesLouisville, KYDaniel C. RobinsonPLI Inc.Suwanee, GATom Van NortwickInnovative Plastech, Inc.Batavia, ILEd AndersonDistinctive MoldsHenderson, COMatt ConwayACI PlasticsKansas City, MOYugi RyoshoMytex PolymersJeffersonville, INAnne WalkerNova ChemicalsMonaca, PAJohn AnthonyAndexEscanaba, MIErasmo AvilaImpersealco S.A. de C.V.Tultitlan, Estado de MéxicoHermes AzzoMidwest Exchange Inc.Gurnee, ILTroy BeemanACI PlasticsKansas City, MOBeverly BejaminBenjamin Mfg.Bellflower, CARay BergBushwacker, Inc.Portland, ORKristen BoardGE AppliancesLouisville, KYDavid A. BranscombJohn Deere TechnologyCenterDubuque, IALeBron BrightVeluxGreenwood, SCC. Matthew BrownPoly Flex Products, Inc.Farmington Hills, MIRich CamachoAmerichem, Inc.Elgin, ILMichael CameronKlockner PentaplastSylvania, OHTony D. CentrittoCraft Originators, Inc.Hamilton, OntarioShawn Andrew ChisholmNeocon InternationalDartmouth, Nova ScotiaAnne-Marie ChronasNu-B Inc.St. Laurent, QCJay CoventryBoltaronDover, OHSam CultronaPlastics Machinery GroupSolon, OHCaroline D’AllardStyl’MondePont D’AinNatalie DeGraceuVu TechnologiesBoca Raton, FLWesley J. DistefanoCreative FoamFenton, MIMedhi M. EmadArkema Inc.King of Prussia, PATim FeltonPlastic IngenuityMaumelle, ARKate M. QuigleyState GardenChelsea, MAZvi RapaportBushwacherPortland, ORJohn RhoadesPlaconFitchburg, WIRick RialPlas-Tech ThermoformingLtd.Brandesburton, East YorksKevin Andrew RichardsonDeltaformBridgewater, SomersetBen RidleyFormit ServicesFountaindale, NSWBob RindoHampel Corp.Germantown, WIDeepa SamkuttyArlington, TXBill SchneiderMonark-EquipmentAuburn, MISteven SchulzeIndustrial RecyclersSidney, OHLeon E. SheridanCrown PlasticFestus, MOCraig SmithCPS Resources Inc.Indian Trail, NCMatt StadtmuellerBemisNeenah, WIMichael StaelgraeveDandy Pkg. Inc.Monroe, MIRonald StaubSay Plastics Inc.McSherrystown, PAJack L. SubelThe Fabri-Form Co.New Concord, OHJohn SugdenThe Dow Chemical Co.Midland, MINik TaritasKydex LLCBartlett, ILBarry TaylorConcote Corp.Coppell, TXNick ThonDart ContainerLansing, MIThomas TodebushBrueckner Group USAWarren, MICarol Trier-BlackSC JohnsonBay City, MIKatie M. WaznySC JohnsonBay City, MIRick ForbisBattenfeld CincinnatiMint Hill, NCJason Froesethink4DAltona, MBDiego GaravitoCarvajal EmpaquesCali, ValleFarzad GhodsCarburesGreenville, SCEric GivensHampel Corp.Germantown, WITim GoinsAmerican AirlinesTulsa, OKMartijn HaexBosch Sprang BVSprang-CapelleTimothy J. HagueProcter and GambleCincinnati, OHJack HamerAcrofab, Inc.Zeeland, MIAllan HarrisDraderEdmonton, ABHeather HawkMAAC MachineryCarol Stream, ILMichael HaynieVeluxGreenwood, SCBrent Allen Hedding3M Co.St. Paul, MNAllen HendrixHeritage PlasticsFairmount, GA4 thermoforming quarterly

ThermoformingQuarterly ®New Members (continued)Paul D. HickeyAuburn Vacuum FormingCo.Auburn, NYAmr HosnyBariQ-A Raya HoldingSubsidiaryGizaAndrew HuntPlastic IngenuityMaumelle, ARJay KumarUniversal PlasticsHolyoke, MARhys Lewis-SmithFormit ServicesBellevue Hill, NSWTony Y-Tsen LoWestern MichiganUniversityPortage, MIJason NewmanBrown MachineBeaverton, MIScott W. NiedzwieckiSonoco ProtectivePackagingDekalb, ILTed OwenMSA Components, Inc.Cincinnati, OHWhyJoin?Michael W. IrvinSchutt Sports Mfg. Co.Salem, ILJared LorensonDisplay PackGrand Rapids, MIJeremy PhillipsMinimizerBlooming Prairie, MNRocky JacobsConcote Corp.Tyler, TXMichael MacDonaldODC Tooling and MoldsWaterloo, OntarioMichael John PolanskyInnovative Plastech Inc.Batavia, ILMichael David JoudreyGN ThermoformingEquipmentChester, Nova ScotiaJaime Arturo JuliaoPropilcoBogota, CundinamarcaMartin MaillouxPlastique ArtSte-Claire, QuebecLuke McCarronGN ThermoformingEquipmentChester, NSAndrew WebbInsul-Fab, Div. of ConcoteCorp.Coppell, TXJoe WeberHampelGermantown, WIIt has never been moreimportant to be a member ofyour professional society thannow, in the current climate ofchange and volatility in theJames KarnesCrown PlasticsFestus, MOSteve KastnerVelux GreenwoodGreenwood, SCNancy KiefferPlastics Unlimited Inc.Preston, IAChris KirbyCreative Foam Corp.Granger, INAndrew K. KitsonGDC, Inc.Goshen, INRex KnechtlyMcClarin Plastics, Inc.Hanover, PAJared KorrecktWNAChattanooga, TNSteve KoskiDraderEdmonton, ABDan KosterCreative PlasticsGrand Haven, MIDale Edward McCarthyYescoLas Vegas, NVMichael McConnaghyOMV-USAElkhorn, WIBrian McFadyenCraft Originators Inc.Hamilton, OntarioRobert McNealNcNeal EnterprisesSan Jose, CANick MellentuinPlastic IngenityMaumelle, ARAdam MelvilleFormit ServicesFountaindale, NSWMichael MillerBellingham, WAKen MinerACI PlasticsKansas City, MONatalie MoormanCarol Stream, ILMarjorie WeinerSociety of PlasticsEngineersBrooklyn, CTAndrew WiessVantage PlasticsStandish, MIDan WilliamsPlacon Corp.Madison, WIMark WilsonPlas-Tech ThermoformingLtd.Brandesburton, EastYorkshireKyle Thomas WrightClifton Park, NYWes YandtMultifab Inc.Spokane Vly, WARobert W. ZachrichThe Fabri-Form Co.New Concord, OHLincoln ZevallosPlastic Package Inc.Sacramento, CAplastics industry. Now, morethan ever, the informationyou access and the personalnetworks you create can andwill directly impact your futureand your career.Active membership in SPE– keeps you current, keepsyou informed, and keeps youconnected.The question reallyisn’t “why join?”but …WhyNot?Thermoforming QUARTERLY 5

Thermoforming in the NewsPlasticIngenuityBuys Vitalo deMexico AssetsBy Jessica Holbrook, Plastics News StaffPosted October 17, 2012MONTERREY, MEXICO (4:35 p.m. ET)Plastic Ingenuity de Mexico,an affiliate of PlasticIngenuity Inc., has purchasedthe assets of thermoformedpackaging producer Vitalo deMexico.The acquisition allows PlasticIngenuity to boost capacity andcapabilities, as well as expandoperations – the company willnow operate two plants inMonterrey, Mexico, along withVitalo de Mexico’s facilities inGuadalupe, Nuevo León.It also allows the companyto “capitalize on the returnof manufacturing business toNorth America from Asia,”said Tom Kuehn, president ofPlastic Ingenuity, in a newsrelease.Vitalo de Mexico is a branch ofBelgium thermoforming giantthe Vitalo Group.Terms of the deal were notdisclosed.Plastic Ingenuity de Mexicowas formed in 2006 through ajoint venture between PlasticIngenuity and Converforma6 thermoforming quarterlyof Monterrey. Prior to theacquisition, the companyoperated eight vacuum forminglines at its Monterrey plant.Based in Cross Plains,Wisconsin, Plastic Ingenuitymakes custom thermoformedpackaging for a variety ofmarkets including food, medical,electronics and retail. Thecompany has approximately500 employees, and operates11 extrusion lines and 46thermoforming lines across itsfour U.S. locations.Plastic Ingenuity had salesof $80 million in 2012 andwas No. 24 in the most recentPlastics News ranking of NorthAmerican thermoformers. xFaerchPlast TestsRecyclableBlack CPETBy Charlotte Eyre, European Plastics News StaffPosted October 30, 2012HOLSTEBRO, DENMARK (1:45 p.m. ET)Danish thermoformer FaerchPlast A/S is developinga type of crystalline PET thatcan be detected by infra redtechnology in recycling streams,meaning the material can beseparated from mixed plasticswaste.“When recycling plastics,companies have infra redcameras to identify what theplastics are,” spokesman JoeIannidinardo told EuropeanPlastics News. “But when theplastic is black light can’t shinethrough it, meaning it can’t bedetected by the cameras.”Faerch Plast has reformulated itsCPET material with a differentpigment arrangement. Thisallows some of the infra redlight to reflect back into thecameras, meaning the materialcan be recycled in mixed wastestreams.The company developed thematerial at its R&D centerin Denmark but is currentlytesting using the material tomanufacture trays for readymeals in the UK, which is themain market for these products.The firm is now carryingout tests with stakeholders,including WRAP and varioussupermarkets.“We’re excited about the projectbecause it brings the idea ofa closed loop system closerand closer,” said Iannidinardo,adding: “The aim is to have thetrays come back to use as flakes,perhaps even three or fourtimes.”Iannidinardo did not go intodetail about how Faerch Plastplans to manufacture thematerial but says the companyaims to make the process “costneutral” compared to othermaterials on the market. x

2013EDITORIALCALENDARQuarterly Deadlines forCopy and SponsorshipsALL FINAL COPY FOREDITORIAL APPROVAL15-FEB Spring31-JUL FallConference Edition30-APR Summer15-NOV WinterPost-Conference EditionAll artwork to be sent in .epsor .jpg format with minimum300dpi resolution.Gwen Mathis Named Emeritus DirectorIn recognition of her years of dedicated service to the SPEThermoforming Division and the industry at large, GwenMathis was named Emeritus Director, Board of Directors,Thermoforming Division.Emeritus Director status replaces current board memberstatus and has a term of three years. Emeritus Directors canbe involved in all board activities including conference preparation andinvolvement with technical committees. Emeritus Directors continue to receivequarterly newsletters and all other Board of Director announcements andemails. They are not required to attend board meetings and do not have votingresponsibilities. Emeritus members are encouraged to be members of theSociety of Plastics Engineers (SPE). Qualified candidates are recommendedthrough the Membership Committee and brought to the attention of theExecutive Committee for consideration and approval. xBecome aThermoformingQuarterly Sponsorin 2013!Additional sponsorshipopportunities will include4-color, full page, and1/2 page.RESERVE YOUR PRIMESPONSORSHIPSPACE TODAY.Questions? Call or emailLaura PichonEx-Tech Plastics847-829-8124Lpichon@extechplastics.comBOOK SPACEIN 2013!Thermoforming QUARTERLY 7

thermoformingAchieve a sustainable balance of performance and cost.UPES ® resin is NOVA Chemicals’ proprietary additive resin.When used with polyolefins, this product enables significant sourcereduction while increasing performance at no additional cost.xYOUR SOLUTION. YOUR UPES ® RESIN.Sustainability• Up to 20% material source reduction• More efficient machine usage translates to energy savings• RecyclableBenefit• Improved crush strength - by up to 140%• 33% faster forming rates• Better part definition• Shorter start-ups and reduced scrap ratesEfficiency• Downgauge• Easy processability at loadings up to 20% by weight• Runs on existing equipment• Blends well with polyolefinswww.upesresin.com • upes@novachem.com • 1.724.770.66108 thermoforming quarterly

ThermoformingQuarterly ®10 thermoforming quarterlyThe Business of ThermoformingUnderstanding Industrial InvestmentDecision-MakingBy Christopher Russell and Rachel Young,American Council for an Energy Efficient EconomyExecutive SummaryAfter a prolonged recession,the U.S. economy is poised forrecovery. Economic reboundimplies growth and renewalto accompany the ongoingevolution of energy markets,regulations, and technologies.And because manufacturing isby nature a capital-intensiveactivity, we anticipate that thesector’s economic renewal ispartially dependent on capitalinvestment in new and efficienttechnologies. Industrial energyefficiency opportunities coincidewith economic recovery and thegrowth and modernization ofdomestic production capacity.Economic recovery prospectsacross the manufacturingsector are stronger for someindustries than for others. As themanufacturing sector changes,so should the nature of energyefficiency programs. Industry’smotivation for achieving energyimprovements still lags its truepotential, as the propensityto adopt energy managementprinciples remains irregular,even across facilities of theEditor’s Note: The following excerpts are reprinted with permission from the AmericanCouncil for an Energy Efficient Economy (ACEEE). We offer this synopsis to our readersbecause the report has broad implications for thermoforming OEMs, processors, suppliersand toolmakers surrounding capital and operational investments. The complete reportincludes in-depth survey results from NAICS-coded industrial sectors, including plastics(326). Please visit www.aceee.org for more details.same company. As facilitiescontinues to capture many ofthe low- and no-cost energyimprovement opportunities,future improvements will beincreasingly linked to industry’scapital investment activity.Industrial energy programadministrators will need abetter understanding of capitalinvestment processes as thesevary throughout industry. Byinfluencing capital investmentdecisions, the next generation ofenergy efficiency programs caninfluence the profile of industrialenergy use for years to come.Despite a decade of sluggisheconomic growth (2000-2009),output and productivity data from1998-2009 reveal an industrialsector with elements of growth,recuperation, and surprisinglylittle retrenchment. Productivitygains achieved by manyindustries during this decadedespite their low growth ofoutput are evidence of the muscleneeded for an economic rebound,while capacity utilizationand investment rates point toopportunities for industrialexpansion.IntroductionIn 2012, the U.S. economyis poised for recovery from aprolonged recession. Aiding therecovery is the trend of re-shoringof industrial production facilitiesfrom overseas locations (MAPI2012, BCG 2012). Recoverywill in part reflect capitalinvestment in new and moreefficient manufacturing facilitieson U.S. soil. At the core of thisactivity is capital investment inindustrial assets. Investment indurable facility and productionassets will shape industrialenergy intensity for years tocome. This is an opportunity toevolve and intensify industrialenergy efficiency programs tosupport the implementation ofefficient technologies. Successfulindustrial energy programswill increasingly depend onknowledge of industry’s capitalinvestment decision-makingprocess. This report examines

industrial capital investmentexperience, using macroeconomicdata as well as a survey ofindustrial energy users andrelated market and programfacilitators. 1 The findings suggestan evolution of energy programdesign and conduct.Trends in manufacturing outputhave direct implications forthe national economy on threebroad dimensions. First, whileU.S. manufacturing output isdecreasing as a proportion oftotal GDP, the absolute volumeof manufacturing output is stillincreasing. This simply meansthat manufacturing as a wholeis not growing as quickly assome other sectors (Pollack2012). Still, each dollar ofmanufacturing output alsogenerates an additional $1.40worth of non-manufacturingservices throughout the domesticeconomy (NAM 2009). Second,the industrial sector represents31 percent of all domestic energyconsumption (EIA 2010). Thesector is therefore an inescapablecomponent of ongoing energypolicy and program development.Finally, prospects for the nationaleconomy and its energy resourcesare inextricably linked by capitalinvestment in more efficientproductive assets.Because energy is a universalingredient in all manufacturing,improved energy technologiesprovide potential benefits toall industries, regardless oftheir product mix or facilitysize. Similarly, the sheermagnitude of manufacturingenergy consumption makes it anunavoidable focus for achievingthe state and regional energysupply balances sought byregulators of energy distributionutilities.At first glance, the growth ofU.S. manufacturing outputduring the first decade of the21st century appeared to bestagnant. Observers have raiseda variety of concerns about thisperformance, debating the needfor a national manufacturingpolicy (Romer 2012, Sperling2012). But in 2012, after adecade capped off by a prolongedrecession, manufacturers havean unprecedented opportunityfor contributing to economicrecovery. Several facts point tothis opportunity. First, publicallytradedU.S. corporations aresitting on a lot of cash. Theirbalance sheets have cash balancesof over $2.2 trillion, up from$1.5 trillion at the end of 2007(Fortune 2012). The samedecade was characterized by theoff-shoring of some industrialproduction capacity combinedwith reluctance to reinvestin domestic capacity due toeconomic uncertainty. As notedin an earlier study, by 2008 theU.S. manufacturing sector wasnot only reaching full capacity,it was also beginning to reversethe trend of production offshoring,thanks to the costs anddifficulties of global supplychains (Elliott et al. 2008).Additionally, the manufacturingsector reflects pent-up demandfor new capacity after a decadeof tepid capital investment(Kaushal et al. 2011). Together,these facts suggest thatdomestic manufacturers havean opportunity to not only buildnew capacity, but to obtainthe competitive edge thatnew technology will provide.Reinvestment in domesticmanufacturing should directlycontribute to U.S. economicrecovery. New macroeconomicdata, not yet available at thetime of this report, may verifythe recovery’s relationship tocapital investment.Recently, an unprecedentedvolume of public and utilityratepayer funds have beenpoured into energy incentiveand assistance programs forthe manufacturing sector(Chittum and Nowak 2012).While assistance programsfrequently reveal improvementopportunities of all kinds andmagnitudes, many facilitiestend to favor solutions thatinvolve low- and no-costimprovements to existingassets. Meanwhile, a sluggisheconomic recovery combinedwith uncertain future tax andregulatory consequences havediscouraged many companies1See Acknowledgements, p. iv, for a definition of survey respondent types.(continued on next page)Thermoforming QUARTERLY 11

from making strategic capitalinvestment in energy-intensivesystems. In sum, great potentialremains for industrial energyimprovement. However, variousindustries experience cycles ofcapital infrastructure renewalover intervals of five, ten, ormore years (Elliott et al. 2008).This means that recently-gainedawareness of potential energyimprovements should lead toimplementation of efficiencymeasures throughout the comingdecade.Various manufacturingcorporations respond differentlyto energy program incentives.Each company demonstratesa unique combination ofmotivations and investmentdecision-making processes.This is an ongoing challengefor energy efficiency programadministrators. To improvetheir future effectiveness,program administrators willneed a better understanding ofthe industrial sector’s prospectsfor investment, as well as thenature of the corporate decisionprocess. While previous studiesof industrial output and energyconsumption typically examineenergy intensity (e.g., Kolwey2005), there is a need to studycapital investment dynamicsas these may shape the designand conduct of future energyefficiency programs.CompetingConsiderationsBroadly speaking, industrialasset management is a trade-offbetween two choices: squeezingincremental value from existingfacilities and equipment – doingthings right – versus updatingfacilities to obtain a strategiccompetitive advantage – doingthe right thing. The trade-offreflects management strategy, andhas direct implications for capitalinvestment. By choosing to dothings right, a company implicitlycommits to refining its currentproducts, markets, and processes.By contrast, a company wishingto do the right thing is thinkingbeyond today in anticipation oftomorrow’s opportunities forinnovation, relocation, expansion,and growth. This choicedetermines whether businessreturns are maximized for theshort run or for the long term.These strategy differences explainwhy two manufacturing facilities,similar in every physical aspect,can demonstrate vastly differentappetites for investment in energyefficiency.At least seven respondentsindicate that business growthis the primary goal of capitalinvestment. Aside frommeeting business growthneeds, many manufacturersare compelled by statutorysafety and environmentalcompliance needs to investin existing facilities. Add tothis the capital requirementsto simply repair and maintaincurrent facilities. Accordingto most respondents, energyimprovement proposals competewith (rather than contributeto) these primary investmentgoals. While “efficiency” isnot entirely dismissed, it isusually a secondary priority. Onerespondent states that the primarygoal for energy management isto ensure that energy supplies aredistributed adequately throughouta facility in a timely fashion – atask that is sometimes at oddswith efficiency rather thanbecause of it.Unless it is to replace a failedasset, an energy efficiencyimprovement is more difficultto justify than a growthorientedinvestment. At leastfive respondents indicate thatenergy improvements aremore easily addressed in newconstruction than in the retrofitof existing facilities. Abouthalf the respondents indicatethat capital allocations favorproposals that promise growth,address mandatory safety orenvironmental compliance,or both. A similar number ofrespondents (not always thesame counted for the last point)say that energy impacts are atleast one of many factors to beconsidered when evaluatinga capital investment. Sixrespondents (four of them largecompanies) indicate that energyimprovements compete with allother capital funding requests.However, three respondents (allwere large companies) indicatethat their organization maintainsa capital budget track for energyseparate from all other investmentpurposes. A dedicated energy12 thermoforming quarterly

fund ensures that at least somecapital is available each yearfor energy improvements. Ofnote is the claim by at least fiverespondents that energy projectsare often the kind of items paidfor from either non-capital fundsor from any budget remaindersat the end of the fiscal year. Tothe extent that this is true, itsuggests that industrial energyimprovements happen more bychance than by deliberate effort.It is not accurate to conclude thatenergy improvements always“compete” with all other capitalinvestment opportunities. Asone large company respondentpoints out, energy improvementsare sometimes the consequenceof modernization or automationefforts. Documenting theseimpacts will help whenassembling justifications forfuture improvements.Impacts of EnergyImprovementsDespite the many difficulties,many energy managers canand do overcome barriers. TwoSME respondents note thattheir organizations originallyavoided energy improvementsin favor of other investments.But once some initial energyproject results were available,managers were convinced andwanted more! Four respondentsreiterate that project success isoften predicated on non-energybenefits. Specifically: 90 percentof energy projects also have aproductivity impact (one largecompany, one facilitator); energyimprovements provide a four-foldreturn in the form of productionimprovements (one largecompany); and two other largecompanies claim that non-energybenefits “dominate” the returnsfrom energy projects. There’s stillroom for improvement: at leastone large company respondentsays the company experiences animplementation success rate forenergy proposals of 30 percentor less. A facilitator claims an 80percent implementation rate.At least one respondent notes thatenergy improvements are harderto justify with today’s relativelylow gas prices. Upon reflection,this may reveal a strategicopportunity. As discussed in Part1 of this report, the industrialsector is experiencing a reshoringof production facilitieson domestic soil. This is due inpart to lower gas prices. But doesthis not underscore the need toinvest in new facilities? If so,this investment is an opportunityto implement advanced, energysavingtechnologies that willhedge these new facilities againstfuture energy price increases.Conclusions forFuture ProgramDesign and ConductThe U.S. manufacturing sectorreveals varying readiness foreconomic recovery after adecade of capacity destructionand overall stagnant growth.Segmentation of the sectorper trends in output andproductivity reveal that mostof the manufacturing sector (94percent of value produced) infact increased its productivitybetween 1998 and 2009.Considering also the sector’spotential for increased capitalinvestment in modernizedfacilities, the muscle foreconomic recovery seems tobe in place. The industrialsegmentation described in thisreport suggests where futureenergy program outreach shouldbe focused.OverallConclusions andRecommendationsOpportunities for manufacturingsector expansion are emergingafter a decade of economicturmoil. With this expansioncomes the opportunityto modernize industrialinfrastructure, which canhave direct, positive impactsfor energy efficiency as wellas industry competitivenessand overall economic growth.Manufacturing assets areemployed for years or evendecades at a time. Shouldcompanies fail to implementefficient technologies from theonset of facility construction,the cost liabilities will be longlasting.xThermoforming QUARTERLY 13

ThermoformingQuarterly ®ANTEC PaperTThermoformable H E R M O F O R M A B L E L I QLiquid UID UID C R YST YSTA LCrystal PO POL Y M E R (L (LCP)PolymerBing Bing Lu, Lu, Achim Achim Hofmann, Hofmann, Paul Paul Yung YungTicona Engineering (LCP) Polymers, Florence, KYTicona Engineering Polymers, Florence, KYBy Bing Lu, Achim Hofmann, Paul Yung, Ticona Engineering Polymers, Florence, KentuckyAbstractAbstractAbstractThermoforming is an economical process for formingThermoforming is an economical process for forminglarge shape products. High performance liquid crystallarge shape products. High performance liquid crystalpolymer (LCP) has high thermal stability, excellentpolymer (LCP) has high thermal stability, excellentdimensional stability and high chemical resistance, whichdimensional stability and high chemical resistance, whichoffers new application opportunities in demandingoffers new application opportunities in demandingapplications. In this paper, a new thermoformable LCPapplications. In this paper, new thermoformable LCPresin is compared with injection molding LCP onresin is compared with injection molding LCP onmechanical, thermal and rheological properties. Sheetmechanical, thermal and rheological properties. Sheetextrusion and thermoforming process conditions areextrusion and thermoforming process conditions arediscussed.discussed.MaterialsMaterialsThermoformable VectraThermoformable Vectra ® ® T.rexT.rex 541 LCP resin541 LCP resinmanufactured by Ticona Engineering Polymers is a highmanufactured by Ticona Engineering Polymers is highmelt viscosity LCP resin with >30wt% mineral fillers. Themelt viscosity LCP resin with >30wt% mineral fillers. Theresin was converted into sheets on a laboratory scale usingresin was converted into sheets on laboratory scale usingdie and commercially on die and commercially on (~457mm) die. LCP sheets were tested for(~457mm) die. LCP sheets were tested forthermoformability using a lab Technoformthermoformability using lab Technoform ® ® tester andtester andalso formed into parts on a commercial thermoformingalso formed into parts on commercial thermoformingline.line.Results Results and DiscussionIntroductionIntroductionThermoforming is a method widely used forThermoforming is method widely used forprocessing of polymers into desired shapes from extrudedprocessing of polymers into desired shapes from extrudedsheets. It is a process typically suited for low volume largesheets. It is process typically suited for low volume largeparts where injection molding is non-ideal due to its highparts where injection molding is non-ideal due to its highfixed costs. Liquid crystal polymer (LCP) is a highfixed costs. Liquid crystal polymer (LCP) is highperformance polymer with high thermal stability, high heatperformance polymer with high thermal stability, high heatdefection temperatures (HDT), excellent chemicaldefection temperatures (HDT), excellent chemicalresistance and high dimensional stability.resistance and high dimensional stability. [1-4] [1-4] Ticona hasTicona hasintroduced the first commercially available extrudable andintroduced the first commercially available extrudable andthermoformable LCP resin Vectrathermoformable LCP resin Vectra ® ® T.rexT.rex 541. This541. Thisnovel LCP resin formulation permits the fabrication ofnovel LCP resin formulation permits the fabrication ofextrusion sheets with high thermal stability forextrusion sheets with high thermal stability forthermoforming parts in applications such as industrialthermoforming parts in applications such as industrialbaking trays and high performance heat shields. Forbaking trays and high performance heat shields. Forexample, in industrial baking trays, LCP provides valuesexample, in industrial baking trays, LCP provides valuesof energy saving and maintenance cost reductionof energy saving and maintenance cost reductioncompared to traditional PTFE-coated steel trays orcompared to traditional PTFE-coated steel trays orstainless steel trays because of its fast heating, lightweightstainless steel trays because of its fast heating, lightweightand long operating life. LCP properties also inherently addand long operating life. LCP properties also inherently addnon-stick and microwave-ability to these applications.non-stick and microwave-ability to these applications.Unlike most semi-crystalline resins, the rigid, rod-likeUnlike most semi-crystalline resins, the rigid, rod-likemolecular structure of LCP resins imparts a unique meltmolecular structure of LCP resins imparts unique meltbehavior (nematic transition). This property requiresbehavior (nematic transition). This property requiresspecial resin selection and processing consideration tospecial resin selection and processing consideration tomeet the requirements in both sheet extrusion and in themeet the requirements in both sheet extrusion and in thethermoforming process. In this paper, we review thethermoforming process. In this paper, we review theproperties of T.rexproperties of T.rex thermoformable LCP, and itsthermoformable LCP, and itsprocessing conditions for sheet extrusion andprocessing conditions for sheet extrusion andthermoforming. Thermformability is also discussed.thermoforming. Thermformability is also discussed.14 thermoforming quarterlyProperty OverviewTable 1 lists an overall comparison of T.rexTable lists an overall comparison of T.rex thermoformable LCP resin and an injection molding LCPthermoformable LCP resin and an injection molding LCPresin on mechanical, thermal, physical and rheologicalresin on mechanical, thermal, physical and rheologicalproperties. Both resins are based on the same polymerproperties. Both resins are based on the same polymercomposition and filler package.composition and filler package.Table 1. Comparison of Properties of InjectionTable 1. Comparison of Properties of InjectionMolding L CP and Thermoformable L CPMolding CP and Thermoformable CPProperties Injection Molding LCP Thermoformable LCPProperties Injection Molding LCP Thermoformable LCPPhysicalPhysicalDensity (g/cm 3Density (g/cm 3 ) 1.74 1.74) 1.74 1.74Melt Viscosity at 400 s -1Melt Viscosity at 400 s -1 (Pa.s) 56 180(Pa.s) 56 180Melt Viscosity at 1000 s -1Melt Viscosity at 1000 s -1 (Pa.s) 37 114(Pa.s) 37 114MechanicalMechanicalTensile Modulus (G Pa) 8.5 10.8Tensile Modulus (G Pa) 8.5 10.8Tensile Strength (M Pa) 96 118Tensile Strength (M Pa) 96 118Break Strain (%) 2.7 3.6Break Strain (%) 2.7 3.6Flexural Modulus (G Pa) 9.1 11.6Flexural Modulus (G Pa) 9.1 11.6Flexural Strength (M Pa) 119 128Flexural Strength (M Pa) 119 128Notched Izod Impact (KJ/m 2Notched Izod Impact (KJ/m 2 ) 5 7.4) 7.4ThermalThermalMelting Point ( oMelting Point ( o C) 357 357C) 357 357DTUL @1.8 M Pa ( oDTUL @1.8 Pa ( o C) 240 245C) 240 245As indicated from melt viscosity, thermoformableAs indicated from melt viscosity, thermoformableLCP (TF-LCP) has much higher molecular weight thanLCP (TF-LCP) has much higher molecular weight thaninjection molding LCP (IM-LCP), which enhances HDTinjection molding LCP (IM-LCP), which enhances HDTand mechanical properties, including modulus, strength,and mechanical properties, including modulus, strength,elongation and impact strength of TF-LCP.elongation and impact strength of TF-LCP.Figure 1compares the capillary melt viscosity of TF-Figure 1compares the capillary melt viscosity of TF-LCP and IM-LCP. The much higher melt shear viscosityLCP and IM-LCP. The much higher melt shear viscosity

of TF-LCP improves its melt strength, a key property forextrusion and thermoforming. The slope ofviscosity/shear-rate of both LCP types are very similar,indicating similar shear thinning behavior contributedfrom similar molecular structure rigid rods. The slope ishigher than that of typical semi-crystalline polymers.Additional studies were conducted on both resins witha dynamic rotational rheometer. Figure 2 comparescomplex melt viscosity of both LCPs with frequencysweep at 360 o C. It clearly shows much higher zero meltviscosity of TF-LCP compared with IM-LCP. There is nosignificant viscosity plateau near zero to low shear rateregion as normally observed in typical semi-crystallinepolymers. This phenomenon is attributed to both the LCPrigid rod molecular structure and the filler effect.was observed around 290-300 oC, which can beTo further demonstrate the target formingtemperature, dynamic mechanical analysis (DMA) wasperformed from -50 o C to 300 o C. As shown in Figure 4, at280 o C there is a peak of loss modulus, which reflects the-transition observed in DSC. Both storage and lossmodulus decreased rapidly around 300 o C, which can beused as an initial target forming temperature. Thisproperty is common between IM-LCP and TF-LCPgrades.Figure 3. DSC of thermoformable L CP1000Figure 1. Capillary Melt Viscosity at 370 o CCapillary Melt Viscosity at 370 o CThermoformable LCPApparent Melt Viscosity (Pa.s)100Injection Molding LCPFigure 4. D M A curves of injection molding L CP (A)and thermoformable L CP (B)1050 500 5000Shear Rate (1/s)Figure 2. Dynamic Melt Viscosity at 360 o CA!"""""">/92#,.(=?&26(+,-."-,*/(2*(@AB " !!"#$%&'()&%*(+,-."-,*/(0123-4!"""""!""""!"""!""#$%&'()(&'*+,%-./0123%456(2-7(,8629-./0B!"" ! !" !""56&78&9./(0:2;

Sheet ExtrusionThe quality of extrusion sheets is a key factor forthermoforming process and final part quality. A labfilm/sheet extrusion line was first used to make a 50-80micron film to identify process conditions. (~100mm) (~38mm) single screw extruder, L/D=20; coat-hanger die,up to 100mmX100micron opening; no-rip roller, twinstacked 100mm diameterX152mm width polished chromeroller to a varied speed powered take-up roller. The rollertemperature was set to 120 o C for good surface filmquality. The LCP resins were dried at 150 o C for 6 hoursbefore extrusion. It is important to note that the dryingprocess is critical. Residual moisture has been observed tolead to polymer degradation and blister formation on thesheet surface.Table 2 lists the processing conditions andobservations of film extrusion of TF-LCP and IM-LCP.This analysis demonstrated conclusively that TF-LCPproduced films with significantly higher quality than IM-LCP. It is believed that the high melt strength is thenecessary feature for film/sheet extrusion. From Table 2,the optimal extrusion melt temperature range wasdetermined to be between 345-360 o C. (This relativelynarrow processing temperature range of LCP compared totraditional semi-crystalline resins is due predominantly toits narrow nematic melt transition behavior.)Table 2. Film extrusion result comparisonRoller Speed Melt Temp Die TempResin Test No. (inch/sec) ( o C) ( o C)Observation1 1.3 330 332Holes in film, difficult to roll,uneven widthInjection Molding 2 1.35 342 340Few holes, still difficult to roll,unven widthLCP3 0.95 331 335Few holes, still difficult to roll,unven width4 0.95 327 330Mlet freezing in the die, fewholes, cracking on edgeThermoformableLCP1 1.3 347 3452 1.3 347 3453 1.45 357 3554 1.45 370 3655 1.5 375 375Very smooth surface, no flowmark/gel/holesIncreased width, very smoothsurface, nogel/holes, very fewflow marksIncreased width, very smoothsurface, nogel/holes, very fewflow marksSurface became rough, edgestarting to crackRough surface, edgecrackingTo translate this technology to a commercial scale,TF-LCP was extruded into sheets on a commercial sheetextrusion line with an (~457mm) die at melttemperature around 355 o C and roller temperatures around120 o C. The sheets had the thickness about 0.80-0.90 mm.The sheets had excellent surface quality with nohole/gel/flow mark.Tensile-bar samples were cut from the sheets, andtensile properties were measured. Table 3 shows thetensile properties of the sheet in flow and transversedirection.Table 3. Tensile Properties of T F-L CP SheetsProperty Flow TranseverseModulus (G Pa) 11.2 5.8Tensile Strength (M Pa) 84 42Break Strain (%) 1.3 1.8As shown in Table 3, the TF-LCP sheets exhibitedanisotropic mechanical properties. On flow direction, therig rod-like molecules aligned together to enhancemodulus and strength. In the sheet extrusion, it ispreferable not to stretch the sheet much so that the sheetcan have reduced anisotropic effect. Furthermore, inthermoforming part design, anisotropic factor needs to beconsidered to provide the best mechanical strengthrequirement. Figure 5 shows a typical LCP rod structureand skin-core layer structure scheme.Figure 5. L CP rod and skin-core layer structureschemeThermoforming TestThermoforming ability was tested on TF-LCP sheets (~457mm) extrusion sheet line usingTechnoform ® Tester by Transmit Technology Group.127mmX127mm samples cut from extrusion sheetswere held firmly between two aluminum plates (sampletray) having 57mm diameter opening. A 32mm diameter100mm long polished aluminum plug tool was used forforming. Plug was heated to 150 o C. Samples were heated16 thermoforming quarterly

y two independently controlled and movable ceramic IRheaters. The top heater position was varied from 38 to76mm and bottom heater was kept at 76mm from thesample surface. Both heaters were maintained at 830 o C.After samples reached the set temperatures, they weremoved to be formed with the plug. Test temperatures werevaried. Figure 5 shows the plug and sample tray, andFigure 6 shows the Technoform ® tester.Figure 6. Test Plug and Sample T raythermoformable LCP sheet samples with set temperatures.Below 330 o t show any sag. There was arapid increase of sag distance around 340 o C, and then aplateau around 350-370 o C, and then a sharp increaseabove 380 o C. Sag was uniform in these temperatureranges, and the indicating adequate melt strength of TF-LCP resin. Figure9 shows a sag sample and a formed sample.Figure 9. Pictures of a sag sample (at 400 o C)and a formed sample (350 o C/plug speed60mm/sec)Formedsample!">=,-*29.&(0##4(D-3(E&#$&62*86&(0 " !4"?"" ?;" ?"

esseltnt.toersanichlyereereer-heat but a amorphous materials. Generally, amorphous polymershave a wider forming process temperature range thancrystalline polymers. LCP has small heat transition, whichmeans it is heated fast in heating stage and cooled rapidlymelt during strength forming can stage. be formed but will exhibit thicknessvariation and wall thinning. Crystalline materials lose meltstrength As and shown melt in elasticity Table 4, above good their uniform peak melting shapes point. wereCrystalline formed Run materials 1, 3 and also 4. require For Run a lot 2, higher some holes energy were toheat formed but around a thin neck, which indicated that an overdrawingratio materials. caused breakages. Generally, This amorphous breakage may polymers relateamorphoushave to two a factors: wider forming one is fast process decrease temperature of form temperature, range thancrystalline another is strain polymers. hardening. LCP has Overall, small heat forming transition, temperatures whichmeans around it 320-340 is heated o C fast offer in a heating good forming stage and window. cooled rapidlyduring forming stage.To further verify the melt elasticity, vacuum formingwithout As a shown plug on in pre-heated Table 4, samples good uniform was tested. shapes Vacuum wereformed forming in is Run a very 1, 3 and rapid 4. process. For Run Figure 2, some 10 holes shows were aformed vacuum around formed thin sample. neck, It has which good, indicated even thickness that an in overdrawingbulb and ratio there caused is no breakages. hole/breakage, This which breakage indicates may relate thattheto the two TF-LCP factors: has one excellent is fast melt decrease elasticity. of form temperature,another is strain hardening. Overall, forming temperaturesaround 320-340 Figure o C offer 10. Vacuum a good forming window. sampleTo further verify the melt elasticity, vacuum formingwithout a plug on pre-heated samples was tested. Vacuumforming is a very rapid process. Figure 10 shows avacuum formed sample. It has good, even thickness in thebulb and there is no hole/breakage, which indicates thatthe TF-LCP has excellent melt elasticity.Figure 10. Vacuum forming sampleThermoformable LCP sheets were also formed atcommercial thermoforming units. Figure 11 shows anexample of a heart shape tray, and Figure 12 shows anexample of a baking tray.Figure 11. Chocolate heart shape form tray bythermoformable L CPThermoformable LCP sheets were also formed atcommercial thermoforming units. Figure 11 shows anexample of a heart shape tray, and Figure 12 shows anexample of a baking tray.Figure 11. Chocolate heart shape form tray bythermoformable L CPFigure 12. Baking tray by thermoformable L CP18 thermoforming quarterlyFigure 12. Baking tray by thermoformable L CPFigure 12. Baking tray by thermoformable L CPConclusions30 mmThermoformable LCP shows very high melt viscosityand high heat deflection temperature. It can be extrudedinto sheets for thermoforming. Due to its unique melttransition, compared with semi-crystalline or amorphouspolymers, thermoformable LCP resin needs 30 special mmprocessing conditions for extruding quality sheets andforming good parts. For TF-LCP discussed in this paper,the sheet extrusion melt Conclusions temperature is about 345-360 o Cand the forming temperature range is about 320-340 o C.The Thermoformable TF-LCP has good LCP melt shows strength very and high elasticity melt viscosity basedand on thermoformability high heat deflection tests. temperature. Due to its It rapid can be heating extruded andinto cooling sheets characteristics, for thermoforming. special means Due for to its heat unique retention melt istransition, needed during compared forming. with Vacuum semi-crystalline forming or is amorphous preferredpolymers, because of fast thermoformable forming cycle and LCP minimum resin needs heat loss. specialxprocessing conditions for extruding quality sheets andforming good parts. For ReferencesTF-LCP discussed in this paper,the sheet extrusion melt temperature is about 345-360 o Cand 1. the forming temperature range is about 320-340 o C.The 01)TF-LCP has good melt strength and elasticity basedon 2. thermoformability tests. Due to its rapid heating th Ed., andcooling Hanser characteristics, Gardner (2001 special means for heat retention isneeded 3. during forming. Vacuum forming is preferredbecause Hanser of fast Verlag forming (1996) cycle and minimum heat loss.4. M. Mogilevsky, Polymer Engineering and Science,Vol. 38, 322-329 (1998) References1. 01)2. Key Words th Ed.,Hanser Gardner (2001ANTEC, 3. thermoforming, sheet, extrusion, process,liquid Hanser crystal Verlag polymer (1996) (LCP), thermoformability,performance4. M. Mogilevsky, Polymer Engineering and Science,Vol. 38, 322-329 (1998)

Thermoforming QUARTERLY 19

ThermoformingQuarterly ®Industry PracticeSPE Thermoforming Division’s21st Annual Conference ReportBy Lesley Kyle, OpenMindWorks, Inc.The Thermoforming Division hosted its21st Annual Conference in Grand Rapids,Michigan, September 23-25. Over 730 industryprofessionals representing 16 countries attendedthe Conference to learn about trends and newdevelopments in technology, machinery andmaterials. The City of Grand Rapids rolled out thered carpet for the Thermoforming Division andConference attendees who had the opportunity topartake in Art Prize – a huge, citywide indoor andoutdoor art exhibition – when they weren’t busyattending sessions or walking the show floor.Conference attendees had their choice of two fulldayworkshops, led by McConnell & Companyand Mark Strachan. The workshops, attendedby nearly 200 industry professionals, addressedfundamental principles and troubleshooting forboth roll fed and sheet fed thermoforming. Atthe conclusion of the Conference, more than 150attendees participated in the plant tours hosted byAllen Extruders, Formed Solutions, and Fabri-Kal.Approximately 85 companies exhibited at theConference with over 10 new exhibiting companiesin attendance. Nearly 30 presentations on technicaland business-related topics were delivered duringtwo days of conference sessions. Wim DeVos,CEO of the Society of Plastics Engineers,delivered a keynote presentation on plastics inthe OEM industries. Todd Shepherd, President ofShepherd Thermoforming, headlined the secondday of sessions with his keynote presentation,“Re-Shoring to North America.”One of the highlights of the Conference was theThermoformer of the Year and Parts CompetitionAwards Dinner. Randy Blin of Blin ManagementCompany was honored as the 2012 Thermoformerof the Year. Mr. Blin, a part of the second father-sonwinning duo in the history of the award, acceptedhearty applause in front of his family, friends, priorwinners and several hundred conference attendees.A variety of awards in different categories were alsopresented to winners of the Parts Competition. Seepagse 28-29 for full details on and photos of theParts Competition winners. A special presentationhighlighting the professional accomplishmentsof Gwen Mathis, Conference Coordinator, wasdelivered by Jim Armor of the ThermoformingDivision Board of Directors. Ms. Mathis is retiringfrom her position as Conference Coordinator at theend of this year.Planning is already underway for the SPE 2013Thermoforming Conference ® ! Please join usin Atlanta, Georgia, for the 22nd Annual SPEThermoforming Conference: September 9-12.The conference dates will shift from the weekendto a weekday pattern in 2013. For the most upto-dateinformation, visit the website at www.thermoformingdivision.com or contact Lesley Kyleat thermoformingdivision@gmail.com. x20 thermoforming quarterly

ThermoformingQuarterly ®Industry PracticeThermoforming Continues toCreate Job OpportunitiesBy Zach Ernest, KLA Industries, Inc.Thermoforming continues to be a job-creatingsegment of the plastics industry. In thickgaugeforming, this can be attributed to increasingapplications in the rebounding auto industryand to major manufacturers who are re-shoringtheir thermoforming operations. In thin-gaugethermoforming, the growth and increased competitionin the food and medical packaging markets are drivingmaterial and product innovation.Increased competition and rising material pricescontinue to constrict margins for plastic thermoformers.As a result, companies are looking for areas that theycan control in order to maintain and, where possible,increase profitability. Many organizations havefocused their efforts on process improvement withformal training in LEAN manufacturing principles inorder to reduce scrap and maximize production rates.One of the primary metrics that thermoformers aretargeting for improvement is their Overall EquipmentEffectiveness (OEE). To ensure profitability in whatcan be a high volume, low margin industry, one mustminimize downtime for extrusion and thermoforminglines.The implementation and execution of a strongPreventative Maintenance Program is paramount forsustained performance, especially in order to optimizeequipment efficiency and increase the life of expensiveassets and machinery. This need for an organizedmaintenance system is creating opportunities forengineers with strong preventative and predictivemaintenance and Reliability backgrounds.Steady M&A activity in the industry has caused someheadcount reduction due to synergies created whencompanies merge. However, the competition for toptalent remains fierce due to demographic changes inthe industry and the first wave of retirement for thebaby boomer generation. In fact, last year the oldestmembers of this generation turned 65. Every day forthe next 19 years, about 10,000 more will cross thatthreshold. Companies need to plan for this shift andensure that they are prepared for the replacement ofretiring employees as they will be losing their mostexperienced people.To attract top talent, companies must positionthemselves as innovators who are capable offostering the career of potential candidates,whether they are hiring new college graduates ortrying to lure away engineers or technicians fromcompetitors. Employers are combing resumes forskills including, SPC, Lean, Six Sigma and TPM.Candidates need to make sure that they have bothformal training and a wide breadth of skills in orderto differentiate themselves.The future is bright for this growing industry andschools like Mid Michigan Community Collegeand Penn College are taking notice by addingthermoforming programs to their curriculum.Whether you are a degreed engineer or a highlyskilled maintenance or production worker, onething is certain: opportunities to advance yourselfprofessionally are all around you. xZach Ernest, CPC is VP of Thermoforming forKLA Industries, Inc., an Executive Search Firmspecializing in the Polymer and Plastics Industry.www.klaindustries.com zach@klaindustries.comThermoforming QUARTERLY 21

Meet the Two Fastest in the World.PeregrineFalcon202 MPHMR-J3 Servo2100 HzSpeedFrequencyResponseTimeMaximize your solution withour Servos and Motion Controls.MT Works2 Motion SoftwareSingle-AxisStand-AloneBlazing fast response time means one thing: maximumthroughput. This is paramount to achieving the lowesttotal of cost ownership (TCO) with your investment.But there’s much more. An auto-tuning function savinghours of set-up and tuning time. A patented design forthe most compact and efficient motors in the industry.Bus speeds of 50 Mbps when you combine our servosand motion products. And the widest range of motorsavailable from 50 watt up to 220 kW. All this adds upto why Mitsubishi is ranked #1 in the servo and motionbusiness worldwide. Get with the best to be the bestand watch your competitors take a swan dive.Motors up to6000 RPMMulti-Axis for iQ Serieswww.meau.com22 thermoforming quarterly

Control Your DestinyBROWN IS INNOVATIONControl over product.What gives the Quad greater control over your finished product?Combining high-tonnage stamping (coining) force with high-tonnageholding force, and without platen deflection. This powerful combinationproduces consistent material distribution, ensuring better partconsistency at higher speeds. It all adds up to producing quality partsfaster, with less scrap.The Brown Quad Series high-tonnagepower and user-friendly operationprovides process engineers greatercontrol over the thermoformingprocess and their finished productsmore than ever before.Global Leader in Thermoforming SolutionsControl over processAll machine control functions anddiagnostics are easily managed at the HMIlevel. An Allen-Bradley open and integratedarchitecture control system with user-friendlyHMI and Logix 5000 single program solution.This solution optimizes and synchronizes thefunctions of logic, motion, and oven control.The system is fully supported worldwide byboth Brown and Allen Bradley.Find out more at:www.brown-machine.comor call 989.435.7741Thermoforming QUARTERLY 23

2012 Conference - Grand Rapids, MIPhotos courtesy of Dallager Photography24 thermoforming quarterly

From the EditorIf you are an educator, student or advisor in a college or universitywith a plastics program, we want to hear from you! The SPEThermoforming Division has a long and rich tradition of workingwith academic partners. From scholarships and grants to workforcedevelopment programs, the division seeks to promote a strongerbond between industry and academia.Thermoforming Quarterly is proud to publish news and storiesrelated to the science and business of thermoforming:ISO 9001:2000• New materials developmentJuliet Oehler Goff, President/CEO, Kal Plastics• New applications• Innovative technologies• Industry partnerships• New or expanding laboratory facilities• EndowmentsWe are also interested in hearing from our members and colleaguesaround the world. If your school or institution has an internationalpartner, please invite them to submit relevant content. We publishpress releases, student essays, photos and technical papers. If youwould like to arrange an interview, please contact Brian Winton,Academic Programs, at:bwinton@lyleindustries.com or 989.435.7718, ext. 32REDUCE! REUSE!RECYCLE!REDUCE! REUSE!RECYCLE!Thermoforming QUARTERLY 25

In MemoriamWilliam Harold “Bill” BenjaminOur mission is to facilitate theadvancement of thermoformingtechnologies through education,application, promotion andresearch.SPE NationalExecutive DirectorWillem de Vos13 Church Hill RoadNewtown, CT 06470 USAPhone: +1 203-775-0471Fax: +1 203-775-8490Conference CoordinatorLesley Kyle56 Glenvue DriveCarmel, NY 10512914/671-9524email: lesley@openmindworks.comVisit Our Website at:www.thermoformingdivision.comWilliam Harold “Bill” Benjamin, 73, of Bellflower, CA,passed away on October 27, 2012 in Bellflower, CA. Billwas born July 19, 1939 in Youngstown, Ohio to Harold andMary Benjamin. Bill was preceded in death by his parentsHarold and Mary Benjamin, and his in-laws, George andEleanor Grandy.Bill passed away peacefully at his home surroundedby his wife of 54 years, Beverly “Weiser” Benjamin, andfamily.Bill Benjamin was President of Benjamin Mfg. Co.,Inc. which he and his wife Beverly started in 1961. Hissons, Jeff and Rick, will continue his legacy at BenjaminMfg. Co., Inc. in Paramount, CA and Lithia Springs, GA.In 1967, he started Benjamin Mfg. Co. in Downey, CA.Bill began thermoforming parts on machinery he designedand built himself since the type of machinery that heenvisioned was not available for purchase. Bill continuedto design and build several of these machines which arestill in use at his plants in California and Georgia. Bill alsodesigned and built a two-station biforcator thermoformer.Bill has six patented products and three trademarks.His first registered trademark was for his “Lustre-Lav”which was made from the forerunner of DR Acrylic ABSmaterial. This material remains a big part of the spa andplumbing industries today. In 1980, a second plant wasopened in Lithia Springs, GA. In 2003, Bill was awardedThermoformer of the Year by the SPE ThermoformingDivision where he also served several terms as a memberof that group’s Board of Directors.Bill is survived by three children: Jeff and ToddyBenjamin of Rossmoor, CA; Laurie “Benjamin” andMike Pike of Palm Desert, CA; Rick and Lisa Benjaminof Bellflower, CA; six grandchildren: Aubrey “Luas”(John) Weston and Amber Luas (Laurie Pike), Whitney“Benjamin” (Chad) Wilkinson, Kayla Benjamin, andPatrick Benjamin (Rick Benjamin), and Farren Benjamin(Jeff Benjamin); brother, Robert Benjamin of Chandler,AZ, sister, Cindy Benjamin of Bellflower, CA, and sisterin-lawand her husband, Carol “Grandy” and RobbieBertocchi, of Douglasville, GA.In lieu of flowers, the family requests donations be madeto: Bill Benjamin Memorial Scholarship Fund, (checksmade out to: SPE TF Division, P.O. Box 471, Lindale, GA30147. xThermoforming QUARTERLY 27

2012 PartsV WinnThis year’s Parts Competition saw entries from as far away as Ecuador and as close as the Conference host-city, Grand Rapids,Michigan. From what this year lacked in quantity, it certainly made up for in quality of submissions. With a balance of small,design-challenging thin-gauge applications and large, complex assembled heavy-gauge parts, the Competition judges had noeasy task in selecting the winners. The similarities ended there as thin-gauge winners were picked for efficiency of material usewith Industrial increased functionality. Roll-Fed CategoryBigger was certainly better as all the heavy-gauge winners consisted of large-panel forming withintegrated assembly techniques. I am proud to have been a part of this year’s Parts Competition and look forward to seeing whatnew Gold and innovative Winner submissions will be made in next year’s Conference in Atlanta, Georgia.Plasticos Ecuatorianos S.A. Silver Winner— Eric Short, Chair, Parts CompetitionGuayaquil, Ecuador Placon CorporationVertically-Ribbed Cup Madison, WisconsinBronze WinnerEvolutions Deli ContainerAmros Industries, Inc.Industrial Roll-FedCleveland, OhioCenterpiece Ice Sculpture Drip PanBronze WinnerCenterpiece Ice Sculpture Drip Pan was designed for a world known ice sculpting artist whalso a distributor of many unique tools and accessories made specifically for the ice sculptindustry.Amros Industries, Inc.The main objective of this custom design was to create and build an attractive container wwill be able to hold a centerpiece ice sculpture with an average weight of 200 lbs, collect 2Critical Elements Silver of Design Winner gallons of water from Cleveland, the melting ice be presentable Ohioenough to be the centerpiece ofparty table.Gold Winner • Designed for leak resistancePlacon Corporation Our two-piece part Centerpiecedesign incorporates strategically placed top and bottom reinforcing ribProduct: Cup, vertically ribbed o Perimeter inside seal is the is capable primary of supporting seal up to and 250 lbs of fully weight. engages with a tightPlasticos EcuatorianosCenterpiece Ice Sculpture Drip Pan is made out of .040” rigid PVC and runs on the inlineCapacidad: 6oz.Madison, o In addition Wisconsin to tight fitting thermoformer. lid, corner Ice snap Sculptureallows container to stay closeColor: Natural S.A.impacts and drops (company internalEvolutionsDriptesting/findings).PanWeight: Guayaquil, 1.7g• Designed for tamper-evidence and resistanceEcuador Deli o Corner Containersnap developed to securely hold the two flanges together.• Vertically-RibbedProduct descriptiono Tight lid fit combined with a small lid flange that is turned downward aA product designedCupfor the consumer sector, below disposable, a small less base weight perimeter and greater rib makes strength access in difficult.their wallso Lid flange is disguised by visually blending with other perimeter “light cedges”.• Designed • for Critical easy-opening elements by of the design customerCongratulationsotoOnce Asallseparated, has been2012considered the corner flange criticalWinners!!!and elements lid snap of geometry can be graspeopening. design the structured form of the container• Designed for walls, strength which act as reinforcement.o Base bottom corners are multi-radius fillets which add structural strengsimple chamfers.•28 thermoforming quarterly o Design contains no fragile perforations or • slit features found on compeproducts.•

Competitioners VHeavy Gauge - VacuumGold WinnerAMD PlasticsEuclid, OhioAgricultural Equipment HoodHeavy-GaugeVacuumHeavy-GaugePressurePhotos courtesy of Dallager PhotographyJudges’ AwardGold WinnerIntended Use• OEM, four piece hood assembly for newly designed Apache SprayerCritical elements of Design• Large parts – final hood measuring 93.25 inches x 49.5 inches x 56.13 inches• Temperature controlled toolingAMD Plastics• Deep and shallow draws. Side panels require large area of sheet and “bag” into aparticularly small draw on the toolEuclid, OhioMaterial Used• Allen ALEXTRA-MV, a coextruded Polycarbonate copolymer capped, PC/ABSInnovative Aspects• Reduction in previous metal and fiberglass hood weight by 140 lbs.• Utilization of anAgriculturalin-molded color-highly weatherable copolymer, with high heatresistance and durability allowed transformation from FRP and metal.Silver WinnerEquipment HoodHampelCorporationGermantown, WisconsinDairy Calf HouseGold WinnerSMISan Diego, CaliforniaMedical DeviceEnclosureMolded Plastic Industries, Inc.Silver WinnerHolt, MichiganPressure Formed CNG Tank CoverCraft Originators, Inc./Tasus GroupHamilton, Ontario,CanadaFiat 500 Dr DreSpeakersPeople’s ChoiceAwardSilver WinnerIntended UseIn 1981 this thermoforming company first introduced a proprietary product line consisting ofthermoformed plastic housing used principally for raising calves in the dairy industry. Today,with an installed base of over 400,000 units world-wide, these dairy housing units areresponsible for providing an optimal environment for accelerated growth to nearly 2,000,000Hampel Corporationcalves annually.Germantown, WisconsinInnovationsPart Size and Depth of DrawThe single most innovative aspect of this product is its 67” depth of draw. The part measures98.5” long x 60.5” wide x 57” tall and is formed from a single sheet of high molecular weightpolyethyleneDairy(HMWPE). The raw sheetCalfis .375” thickHousingand the finished material thickness rangingfrom.10” - .200” thick.TheSilvercritical elements of design were achievingWinnera styled design with molded-in features whichwould protect the Compressed Natural Gas tank from the daily abuse of the panels theirservice life. Alternate designs of fiberglass and metal we considered. However neither materialoffered the flexibility of design to achieve styling offered utilizing the pressure forming process.The lead design team of Murray Design, LLC (MurrayDesign@ymail.com) developed theconceptual designs to meet the customer’s initial styling requirement with the modularity forfuture variant applications – such as tool boxes and larger CNG tanks. Molded Plastic providedthe design assistanceMoldednecessary to achieve the customersPlasticstyling requirements, panelperformance, while maintaining manufacturability and serviceability.Industries, Inc.Holt, MichiganPressure FormedCNG Tank CoverMolded Plastic chose CASTEK Aluminum, Incorporated of Elyria, Ohio to build the forming toolsas the lead-time for the three (3) tools was less than eight (8) weeks. The tool design teamconsisted of Tom Petek of CASTEK, Ed Bearse of Advance Plastic Consultants, LLC and FrankPhillips, Jr. of Molded Plastic. Frequent meetings face to face or by WEB EX assured the toolswere delivered on time.SMI - San Diego, CAMedical DeviceEnclosureThermoforming QUARTERLY 29

Have an Ideafor an Articlefor TQ?Submission Guidelines• We are a technicaljournal. We strive forobjective, technicalarticles that help advanceour readers’ understandingof thermoforming (process,tooling, machinery, ancillaryservices); in other words,no commercials.• Article length: 1,000 -2,000 words. Look to pastarticles for guidance.• Format: .doc or .docxArtwork: hi-res images areencouraged (300 dpi) withappropriate credits.Send all submissions toConor Carlin, Editorcpcarlin@gmail.com30 thermoforming quarterly

MARK YOUR CALENDAR!September 9 – 12, 201322nd Annual Thermoforming ConferenceAtlanta, GeorgiaCo-ChairBret JoslynJoslyn Manufacturing9400 Valley View RoadMacedonia, OH 44056330.467.8111bret@joslyn-mfg.comCo-ChairEric ShortPremier Material Concepts (PMC)2040 Industrial DriveFindlay, OH 45840248.705.2830eshort@buypmc.comRENAISSANCE WAVERLY HOTEL& COBB GALLERIACut Sheet Technical ChairRoger JeanPremier Material Concepts (PMC)2040 Industrial DriveFindlay, OH 45840567.208.9758rjean@buypmc.comRoll Fed Technical ChairMark StrachanUVU Technologies6600 E. Rogers CircleBoca Raton, FL 33487754.224.7513mark@uvutech.comFor Reservations:1-888-391-8724Request SPE Room Rate of $169.00Parts CompetitionJim ArnetKydex Company3604 Welborne LaneFlower Mound, TX 75022972.213.6499arnetj@kydex.comSAVE THE DATE!!www.thermoformingdivision.comThermoforming QUARTERLY 31

Need helpwith yourtechnical schoolor collegeexpenses?If you or someone you know isworking towards a career inthe plastic industry, let the SPEThermoforming Division help supportthose education goals.Within this past year alone, ourorganization has awarded multiplescholarships! Get involved and takeadvantage of available support fromyour plastic industry!Here is a partial list of schoolsand colleges whose students havebenefited from the ThermoformingDivision Scholarship Program:• UMASS Lowell• San Jose State• Pittsburg State• Penn State Erie• University of Wisconsin• Michigan State• Ferris State• Madison Technical College• Clemson University• Illinois State• Penn CollegeStart by completing the applicationforms at www.thermoformingdivision.com or at www.4spe.com. xREDUCE! REUSE! RECYCLE!32 thermoforming quarterly

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ExecutiveCommittee2012 - 2014CHAIRPhil BarhouseSpartech Packaging Technologies100 Creative Way, PO Box 128Ripon, WI 54971(920) 748-1119Fax (920) 748-9466phil.barhouse@spartech.comCHAIR ELECTMark StrachanGlobal ThermoformingTechnologies1550 SW 24th AvenueFt. Lauderdale, FL 33312(754) 224-7513mark@global-tti.com2012 - 2014 THERMOFORMING DIVISION ORGANIZATIONAL CHARTChair ElectMark StrachanFinanceBob PorscheTechnical CommitteesProcessingHaydn ForwardMaterialsRoger JeanMachineryDon KruschkeSecretaryBret JoslynNominatingTim HamiltonChairPhil BarhouseNewsletter / TechnicalEditorConor CarlinOPCOMMark StrachanTreasurerJames AlongiAARCBrian RayAntecBrian WintonStudent ProgramsBrian WintonCouncilorRoger Kipp2012 ConferenceGrand Rapids, MIHaydn ForwardLola Carere2013 ConferenceAtlanta, GABret JoslynConferenceCoordinatorLesley KylePrior ChairKen GriepCommunicationsClarissa SchroederMembershipHaydn ForwardPublications /AdvertisingLaura PichonRecognitionJuliet GoffTREASURERJames AlongiMAAC Machinery590 Tower Blvd.Carol Stream, IL 60188(630) 665-1700Fax (630) 665-7799jalongi@maacmachinery.comSECRETARYBret JoslynJoslyn Manufacturing9400 Valley View RoadMacedonia, OH 44056(330) 467-8111Fax (330) 467-6574bret@joslyn-mfg.comCOUNCILOR WITH TERMENDING 2015Roger KippMcClarin PlasticsP. O. Box 486, 15 Industrial DriveHanover, PA 17331(717) 637-2241 x4003Fax (717) 637-4811rkipp@mcclarinplastics.comPRIOR CHAIRKen GriepPortage Casting & Mold2901 Portage RoadPortage, WI 53901(608) 742-7137Fax (608) 742-2199ken@pcmwi.com34 thermoforming quarterly

Board of DirectorsMACHINERY COMMITTEEJames AlongiMAAC Machinery590 Tower Blvd.Carol Stream, IL 60188T: 630.665.1700F: 630.665.7799jalongi@maacmachinery.comRoger FoxThe Foxmor Group1119 Wheaton Oaks CourtWheaton, IL 60187T: 630.653.2200F: 630.653.1474rfox@foxmor.comDon Kruschke (Chair)Plastics Machinery Group31005 Bainbridge Rd. #6Solon, OH 44739T: 440.498.4000F: 440.498.4001donk@plasticsmg.comMike SirotnakSolar Products228 Wanaque AvenuePompton Lakes, NJ 07442T: 973.248.9370F: 973.835.7856msirotnak@solarproducts.comBrian RayRay Products1700 Chablis DriveOntario, CA 91761T: 909.390.9906F: 909.390.9984brianr@rayplastics.comBrian WintonLyle Industries, Inc.4144 W. Lyle RoadBeaverton, MI 48612T: 989-435-7714 x 32F: 989-435-7250bwinton@lyleindustries.comMATERIALS COMMITTEEJim ArmorArmor & Associates16181 Santa Barbara LaneHuntington Beach, CA 92649T: 714.846.7000F: 714.846.7001jimarmor@aol.comJim ArnetKydex LLC3604 Welbourne LaneFlower Mount, TX 75022T: 972.724.2628arnetj@kydex.comPhil BarhouseSpartech PackagingTechnologies100 Creative WayPO Box 128Ripon, WI 54971T: 920.748.1119F: 920.748.9466phil.barhouse@spartech.comLola CarereC and K Plastics, Inc.512 Fox Creek CrossingWoodstock, GA 30188T: 732.841.0376lcarere@candkplastics.comJuliet GoffKal Plastics2050 East 48th StreetVernon, CA 90058-2022T: 323.581.6194juliet@kal-plastics.comTim HamiltonSpartech Corporation11650 Lakeside Crossing CourtMaryland Heights, MO 63146T: 314.569.7407tim.hamilton@spartech.comDonald HyltonMcConnell Company646 Holyfield HighwayFairburn, GA 30213T: 678.772.5008don@thermoformingmc.comRoger P. Jean (Chair)Rowmark/PMCPO Box 16052040 Industrial DriveFindlay, OH 45840T: 567.208.9758rjean@rowmark.comLaura PichonEx-Tech PlasticsPO Box 57611413 Burlington RoadRichmond, IL 60071T: 847.829.8124F: 815.678.4248lpichon@extechplastics.comRobert G. PorscheGeneral Plastics2609 West Mill RoadMilwaukee, WI 53209T: 414-351-1000F: 414-351-1284bob@genplas.comClarissa SchroederAuriga Polymers1551 Dewberry RoadSpartanburg, SC 29307T: 864.579.5047F: 864.579.5288clarissa.schroeder@us.indorama.netEric ShortPremier Material Concepts11165 Horton RoadHolly, Michigan 48442T: 248.705.2830eshort@rowmark.comPROCESSING COMMITTEEHaydn Forward (Chair)Specialty Manufacturing Co.6790 Nancy Ridge RoadSan Diego, CA 92121T: 858.450.1591F: 858.450.0400hforward@smi-mfg.comKen GriepPortage Casting & Mold2901 Portage RoadPortage, WI 53901T: 608.742.7137F: 608.742.2199ken@pcmwi.comSteve HasselbachCMI Plastics222 Pepsi WayAyden, NC 28416T: 252.746.2171F: 252.746.2172steve@cmiplastics.comRoger KippMcClarin Plastics15 Industrial DrivePO Box 486Hanover, PA 17331T: 717.637.2241F: 717.637.2091rkipp@mcclarinplastics.comBret JoslynJoslyn Manufacturing9400 Valley View RoadMacedonia, OH 44056T: 330.467.8111F: 330.467.6574bret@joslyn-mfg.comStephen MurrillProfile Plastics65 S. WaukeganLake Bluff, IL 60044T: 847.604.5100 x29F: 847.604.8030smurrill@thermoform.comMark StrachanGlobal ThermoformingTechnologies1550 SW 24th AvenueFt. Lauderdale, FL 33312T: 754.224.7513globalmarks@hotmail.comJay WaddellPlastics Concepts & Innovations1127 Queensborough RoadSuite 102Mt. Pleasant, SC 29464T: 843.971.7833F: 843.216.6151jwaddell@plasticoncepts.comDirector EmeritusArt BuckelMcConnell Company3452 Bayonne DriveSan Diego, CA 92109T: 858.273.9620artbuckel@thermoformingmc.comDirector EmeritusGwen MathisPO Box 471Lindale, GA 30147-0471T: 706.235.9298F: 706.295.4276gmathis224@aol.comThermoforming QUARTERLY 35

ThermoformingQuarterly ® FOURTH QUARTER 2012VOLUME 31 n NUMBER 4Sponsor Index These sponsors enable us to publish Thermoforming Quarterly• Allen..................................25• Brown Machine...................23• CMT Materials.......................3• GN Plastics.........................30• GPEC 2013.........................33• Kiefel.................................25• KMT....................................7• Kydex.......... Inside Back Cover• MAAC Machinery...................7• McClarin Plastics.................30• Mitsubishi Electric................22• Nova Chemicals....................8• PCI....................................34• Plastics Machinery Group......34• PMC............ Inside Back Cover• Portage Casting & Mold........30• Primex Plastics......................3• Productive Plastics...............25• Profile Plastics Corp. ...........25• PTi..............Inside Front Cover• Ray Products......................25• Solar Products....................30• Spartech............................32• Tempco..............................36• TPS...................................32• TSL...................................19• Weco Int’l. Inc. ....................3• Zed Industries....................25Thermoforming Division Membership BenefitsnnnnnnnnAccess to industry knowledge from one central location: www.thermoformingdivision.com.Subscription to Thermoforming Quarterly, voted “Publication of the Year” by SPE National.Exposure to new ideas and trends from across the globeNew and innovative part design at the Parts Competition.Open dialogue with the entire industry at the annual conference.Discounts, discounts, discounts on books, seminars and conferences.For managers: workshops and presentations tailored specifically to the needs of your operators.For operators: workshops and presentations that will send you home with new tools to improve your performance, make your job easier and help thecompany’s bottom line.Join D25 today!36 thermoforming quarterly

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