Advanced Methods in Plastic Manufacturing

Colour Process Automation Technology:

Plastics manufacturing is a complex, multi-step process that moves at rapid speeds to create high product yields. Maintaining colour quality and consistency throughout the manufacturing processes can be difficult, but advancements in colour process automation technology offer continual monitoring for real-time identification of colour changes. Continual monitoring, from pellet colours and extruded plastics to pre-formed products, allows for automatic adjustments to be set, creating a more efficient and cost-effective process stream. New technology provides affordable options for colour process measurement using smaller self-contained instrumentation that can easily adapt to any production line.

colour Process Automation Technology (cPAT) with ACLCC by Plastore and  Hunter Lab for plastics manufacturing is a fully integrated, online color measurement and color control solution tailored to meet the needs of plastics manufacturers. From plastic sheet manufacturing, to window profile, vinyl siding, custom profile and compounding, cPAT offers best practices and automated solution tools to improve manufacturing efficiencies, ensure product quality, and reduce overall costs.

Today’s plastic extrusion color control process relies a bit on ‘black magic’ to be successful. Time-interval based color monitoring is insufficient in providing information on baseline, variation or improvement opportunities. The process is not very controllable, predictable or often times even understandable. cPAT eliminates the ‘black magic’, making the process something that operators can control, predict and troubleshoot.

Improving costs and efficiency

Today’s colour process measurement systems are fully integrated, allowing for precise workflow monitoring and improved quality control (QC). The ability to provide real-time, quantifiable results allows manufacturers to set defined parameters and predict potential variations and changes in final color outcomes. According to the online article “Best Practices and Solution Tools to Automate Colour Quality Control in Plastic Extrusion Processing”, “Colour Process Automation Technology (cPAT) introduces best practices and solution tools to help plastics manufacturers achieve greater performance by moving from a philosophy of time-interval based colour QC to a more dynamic approach to continuous monitoring, closed-loop colour control, and automated defect containment. Colour process automation technology allows organizations to measure, analyze, control and document the colour of extruded plastic in real-time through the measurement of Critical Colour Process Parameters (CCPP) which affect Critical Colour Quality Attributes (CCQA).”

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Idea about Plastic Recycling

What is Plastic Recycling?

Plastic recycling is the process of recovering different types of plastic material in order to reprocess them into varied other products, unlike their original form. An item made out of plastic is recycled into a different product, which usually cannot be recycled again.

Process of Plastic Recycling

The following is a step by step process of plastic recycling:

1. Collection

Plastics are available in a number of forms for example plastic containers, jars, bottles, plastic bags, packaging plastic, big industrial plastics just to mention but a few. Due to their nature and availability, there are plastic collection centres and some business people have ventured into plastic collecting business as a source of income. Tons and tons of scrap plastic are collected and sent to a collecting yard where they are then packed and transported to plastic processing plants. Unfortunately, not all countries have the capacity to recycle plastic. Very few developing countries can actually recycle plastic. This means that plastic waste is still a major problem in some countries in the world.

2. Sorting

The actual plastic recycling process starts with the sorting of the different plastic items by their resin content and colour. This process is also done to ensure all contaminants are eliminated. There are specially designed machines that help in the sorting of the plastics according to their resin content. Then the recycling mill sorts the scrap plastic by symbols at the bottom of the plastics.

3. Shredding

After sorting the plastics, the next step is to cut the plastics into tiny chunks or pieces. The plastic bottles and containers are then ground and cut into tiny pieces or flakes. The heavier and lighter plastic flakes are separated using a specially designed machine. The separation process helps in ensuring that the different plastics are not put together or mixed up in the final product. Remember that different plastics are used to make different items.

4. Cleaning

After a complete separation, the flakes or chunks are then washed with detergents to remove the remaining contamination. Once the cleaning process is complete, the clean flakes are passed through specialized equipment that further separates the plastic resin types. The plastic flakes are then subjected to moderate heat to dry.

5. Melting

The dry flakes are melted down. They can be melted down and moulded into a new shape or they are melted down and processed into granules. The melting process is done under-regulated temperatures. There is specialized equipment designed to melt down plastic without destroying them.

6. Making of pellets

After the melting process, the plastic pieces are then compressed into tiny pellets known as nurdles. In this state, the plastic pellets are ready for reuse or are redesigned into new plastic products. It is important to point out that recycled plastic is hardly used to make the identical plastic item or its previous form. It is in this pellet form that plastics are transported to plastic manufacturing companies to be redesigned and be used in making other useful plastic products.

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Plastics for Food Packaging

Use of plastics for food packaging applications is increasing both in quantum as well as in variety. Plastics are available in various forms such as monofilms, co-extruded films, laminates, sachets, jars, bottles, jerry cans, trays, cups and containers of all shapes and sizes. Realising the versatility of plastic packaging which has prompted its wide usage in food packaging in the country, it was considered expedient by the BIS to formulate standard on this subject – IS: 10171-1982, Guide on Suitability of Plastics for Food Packaging.

This standard is expected to provide general guidance to the food packer in selecting the specific thermoplastic material or its combination to design an acceptable food packaging system. The standard, however, does not provide guidance on the actual design of the food packaging system or cover the shelf-life requirements for various food products. The standard also states that the plastics used shall be of food grade material and should be safe for food contact and conform to the relevant Indian Standards and used in conjunction with the following series of standards on food contact plastics of which it forms a part.

Standards and Specifications of Plastic Recycling

The Indian plastic industry has helped formulate standards and specifications for plastics recycling in the country. There are two BIS standards introducing the coding system recycling practices and standards for the manufacture & usage of recycled plastics.

• Recycled Plastics for Manufacturing of Products Designation IS: 14535

Scope:

1. This standard is intended to be used for the identification of the recycled plastic material on the basis of its basic properties and applications.

2. This standard applies to recycled plastics material ready for normal use without any further modifications.

3. Though some modification and test methods have been provided in the standard, any specific modification and the relevant test method, which may be necessary for some specific applications, shall have to be agreed between the purchaser and the supplier.

4. Though this designation system is only indicative of a broad classification of the recycled material, the absolute value of the low results may be provided which shall be agreed to, between the purchaser and the supplier.

• Guidelines for Recycling of Plastics

This standard prescribes guidelines to the manufacturers of plastic products with regard to the marking to be used on the finished product in order to facilitate identification of the basic raw material. It will also help in identifying whether the material used on the end product is recyclate or a blend of virgin and recyclate.

Terminology:

1. End Products: Products made out of the virgin, recycled/reprocessed plastics. Typical suggested end products along with the use of appropriate types of plastic waste/scrap are given. A process by which plastic waste is collected, segregated, processed and returned for use.

2. Classification of Recycling: Plastics recycling technologies have been historically divided into four general types – primary, secondary, tertiary and quaternary

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The World of Plastic

It's hard to imagine a day without plastics nowadays. Almost every industry requires it. Plastic is a man made synthetic or semi synthetic moldable material.  The use of plastic all over the world has great impact on the development of our economy. By the definition, a plastic is any material that can be shaped or molded into any shapes.Its versatility and unique adaptable  properties allow it to be used in everything like bottles, shoes to car parts and banners.

Many industries strongly prefer to use plastics as this helps them to save a large amount of money. They are able to save a big amount of money because plastics decreases energy consumption and it is durable. Construction industries and automotive industries are major users of plastics. To them, plastics are durable, it doesn't easily wear out, is resistant to corrosion, and gives them an easy way to add colors and simple auto finishing.

The main ingredient in plastic is oil. Plastic materials contain a large amount of carbon-containing compounds due to oil being a carbon-rich material. Plastic items contain large molecules called polymers. These polymers consist of repeating units of shorter carbon-containing compounds which are called monomers. One of the important benefits of plastic is that it can virtually be molded into an endless variety of different shapes.

The benefits of using plastics

Plastic is easy to clean,lightweight, cheap. It has the ability to be molded into complex shapes. Plastic is thermally insulating and can cut heat or cold loss in buildings by up to 70%. Plastic retains is sturdy and retains its molded quality forever. It can be easily shipped, waterproof, and safe. Its lightweight quality keeps our home electronic items lighter on weight and also lighter on our pockets!

Plastics are widely used, for so many products, it is impossible to list them all! plastic machine shops and Manufacturers create large number of plastic products, using Teflon machining and vespal machining. The most Common uses for plastic include plastic drink bottles, carrier bags, packaging, food containers and wrappers, furniture, fixtures and fittings, clothing such as protective rain wear, and polyester fabrics, outdoor tents, boats, bicycle parts, car parts, and flooring.

Smart packaging one of the best plastic manufacturers, suppliers and exporters in India. We go through several processes to ensure that the plastics produced are of high quality. Plastic injection molding machine is the machine used in the process of making plastics. Smart Packaging has producing a large category of plastic containers for all kinds of purposes. They are producing plastic bottles in an advanced state of art technology with innovative structural design. Smart packaging is best  as  a PET bottle manufacture in Kerala, Tamil Nadu, Karnataka and  Andhra Pradesh.

How Plastic Recycling Saves Energy?

Plastic Recycling Saves Energy by reducing the energy consumption in recycling the plastic packaging materials. Recycling only take very less energy to produce brand new recycled item. This helps in reducing the pollution caused by the this plastic packaging materials. 

Manufacturing brand new plastic packaging materials will consume a lot of energy than recycling and producing brand new recycled items. Glass is also another kind of material which can be recycled. 

Plastic Bottle Manufacturers