Presentation given at SPE section meeting held at Hennepin Technical College March 29, 2016. Covers why injection molding training is so important, best practices for injection molding training and case studies from Paulson injection molding customers and scientific molding training

1. Society of Plastics Engineers
(SPE) - Hennepin Technical
College - March 29, 2016
“Training Today’s Personnel in
the Science of Plastics
Processing”

2. Paulson
Training
Programs
▪ Lead Provider of Scientific
Plastic Processing Training
▪ Established in 1977
▪ Over 50,000 Trained by PTP
During the Past 38 Years
▪ 3,000+ Companies Use
Paulson Training
▪ Products & Services
Developed in Cooperation
with Industry Experts and
Product Advisory Boards

3. Q: Why Start Training?
A: Secret: You’ve already started
▪ Lost production efficiencies (cycle
time, reject rate, downtime)
▪ Broken, damaged equipment
▪ Wasted resin
▪ Excessive time to 1st in-spec part
▪ Efficiency differences between shifts
▪ Cost of finding/replacing workers
▪ Unmotivated employees
Why Train?

4. Efficiency of a Molding Plant
Is measured by:
Quality of Data-driven decisions:
▪ Cycle time
▪ Scrap
▪ Uptime/Downtime
▪ Labor costs
Overall throughput
Conversion of raw materials into
sell-able finished goods.

5. A sample of the
practical tools
▪ Short shot analysis
▪ Balance of fill analysis
▪ Gate freeze study – used for
cold gate molds mostly though
some application to hot gates
as well
▪ Vent viability test – This test is
standard to determine if the
vents are adequate.
▪ Hot spot analysis – Steel
temps taken on various parts of
the mold to determine balance
of BTU extraction.
▪ Optimal fill rate analysis-
Rheology curves etc.

6. The Economics
of Injection Molding
What is Effective Throughput?
▪ Is it Cycle time?
▪ Low scrap rate?
▪ First time quality?
▪ Full Cavitation?
▪ Low labor content?
▪ Utilization?
▪ Efficiency?
▪
YES!
It’s all of these!

7. What do you sell?
▪ Plastic parts?...........NO- What was ordered
▪ Finished goods?......NO- What you produced
▪ Labor?.....................NO- Cost
▪ Service?..................NO- Expected
▪ Efficiency?...............NO- Cost driver
▪ Quality?...................NO-Expected
▪ Skill/Talent?.............YES - Without it you lose
▪ Time?......................YES!

8. Teaching Plastics
Processing from the
“Plastic’s Point of View”
Physics doesn’t change. Plastic reacts to
just four basic variables*: Heat, Flow,
Pressure, and Cooling. This is the
foundation for all injection molding
training.
*As discovered by plastic engineer and educator Donald C. Paulson.

9. The Four Primary Plastic Conditions

10. Plastic Melt Temperature
▪ Frequently is not the same as the
barrel temperature settings (common
misconception)
▪ Must be measured to actually know
what effect the screw speed and
back pressure are having on true
melt temperature.
▪ 30/30 method with Pyrometer and
melt probe

11. A Pyrometer is a MUST have.

12. Plastic Flow Rate
▪ The next variable we MUST control
▪ Plastic is a Non-Newtonian visco-
elastic material
▪ Faster flow rates result in lower
viscosity

13. Plastic Flow Rate
▪ Fill time is directly related to cycle time
▪ Less pressure equals less stress
• Non-Newtonian characteristics of plastics
▪ Fill rate control allows the machine to
adapt to inherent viscosity shifts in the
resin while maintaining CONTROL of
the process

14. Plastic Pressure
▪ Hold/Pack pressure is how we determine
structural integrity and final dimensions of
the part.
• Some folks think cooling time
establishes dimensions
▪ Hold pressure should not be confused
with Hold time
▪ Sometimes we need to profile pack and
hold pressure

15. Relationship of Fill Rate
to Pack/Hold Pressure
 Fill rate control helps us adapt to intrinsic
viscosity shifts in the raw material.
 Pack/hold time establishes the final
dimensions of the part and it’s structural
integrity.
 Hold time is about gate freeze. If the gate
doesn’t freeze we are not in control of our
process. Many times hold time can be
traded for cooling time.

16. Plastic Cooling Rate
▪ Injection molding inputs heat energy
(BTU’s) into the plastic, allowing
plastic to flow and pack the cavity to
achieve structural integrity. Cooling
removes the heat energy thus
converting the plastic to a net shape.
▪ The mold is a very expensive cooling
fixture

17. Mold Temperature Control
< 5°∆T

18. What really matters...
▪ Product efficiency should be
monitored daily
▪ Low product efficiency is an
operational concern
▪ Is it cycle time?
▪ Cavitation?
▪ Machine stoppages?
▪ Conduct a Root cause analysis
followed by a Corrective action plan

19. Root Cause analysis (link)

20. What you need to know
▪ Annual/Monthly
requirements
▪ Material
▪ Material cost
▪ Part weight
▪ Cycle time
▪ Number of cavities
▪ Projected area
▪ Packaging
▪ Machine rate
▪ Labor requirement
▪ Special Quality criteria
▪ Probable efficiency
(likely scrap rate)
▪ Set-ups per year

21. The Four M’s
Causes of variation in injection molded
plastic product production
▪ Mold
▪ Machine
▪ Material
▪ Man

22. Industry Observations
Problem statements:
There is a shortage of skilled process
technicians in the industry today.
▪ Evidence of this can be found on almost
every job posting site.
▪ Dozens of ads for Process techs and/or
Process engineers for Injection Molding.

23. Benefits of
Training
▪ Profitability
• Reduced waste, improved cycle times, fewer
mistakes and other training benefits all add
up in your bottom line.
▪ Productivity
• Trained employees solve problems quickly
and fewer problems occur.
• Trained employees make better decisions on
the production floor.
▪ Knowledge
• Training develops a technically competent
workforce.
• Training explains the “why”, not just the
“how”.
▪ Consistency
• Training develops consistency of techniques -
employee to employee, shift to shift, plant to
plant.“The Paulson products
are EXCELLENT!”
Jim Proffitt, Rubbermaid

24. Why Train
with Paulson?
$26,000 Reduced Cycle Times Savings
$15,000 Reduce Reject Savings
$ 6,000 Reduced Credits Savings
$47,000 Monthly Additional Profits
$564,000 Annual Additional Profits
➢ Dramatically Improved Efficiency
➢ Return On Investment
➢ Increased Profits
▪ Downtime Reduced by 32%
▪ Mold Change Time is 10%
Lower
▪ Revenue/Machine Hour
Improved 35%
▪ Scrap Parts Down 8% and
Production Up 15%

25. SkillBuilder™
World’s leading
injection molding
machine simulator

26. SkillBuilder Benefits
▪ Employees practice molding in
a safe environment and are not
tying up valuable machine time,
materials and resources.
▪ Uses interactive training
platform to improve processing
knowledge - quickly. One hour
of simulation practice is equal to
5 actual machine hours!
▪ “Free Mold” for learning
problems solving techniques
and optimizing cycle times.

27. More SkillBuilder Benefits
▪ Provides structured tutorial to see
the effects of each machine control
on melt temperature and part
dimensions.
▪ Develops understanding of plastic
behavior under processing
conditions.
▪ Reinforces the information
presented in training modules.
▪ Turns theory of processing into
reality.
▪ Turns knowledge into skill.
▪ Automatic record keeping of all
training activities

28. SkillBuilder Connects the Classroom
with the Production Floor

29. What You Can Do With SkillBuilder
MORE Interactive Lab Lessons
Optimizing Machine Control
Settings with SkillBuilder
Injection Molded Part Problems
and Solutions with SkillBuilder
1. Optimizing the Melt Temperature
with an Amorphous Plastic
2. Optimizing the Melt Temperature
with a Crystalline Plastic
3. Finding the Minimum Fill Time
Required
4. Optimizing Part Dimensions
5. Optimizing Part Weight
6. Achieving the most efficient Cycle
Time
1. Getting Rid of Burnmarks
2. Molding to Precise
Dimensional Tolerances
3. Controlling Flash on a
Molded Part
4. Solving Sinkmark Problems
5. Identifying and Solving
Voids in Molded Parts
6. Weldline Formation and
Possible Solutions

30. Paulson
Products and
Services
“Great products, easy to use and dynamic 3-D graphics!”
Ken Lewis, S&L Plastics
▪ Injection Molding Process
Training
▪ Injection Molding Simulation
▪ Thin Sheet Thermoforming
▪ Twin Screw Compounding
▪ Sheet Extrusion Technology
▪ Extrusion Blow Molding
▪ Products in Multiple Languages

31. Injection
Molding
▪ Basic Molding Machine Operations
▪ Practical Injection Molding
▪ Optimizing Machine Control Settings
▪ Injection Molded Part Problems &
Solutions
▪ Hot Runner Molding Solutions
▪ Implementing DECOUPLED MOLDING
▪ Design of Experiments
▪ SPC for Injection Molding
▪ Efficient Mold Setting
▪ Understanding Materials for Profitable
Molding
▪ Plastics Drying Technology
“BESPAK has had a very positive experience using Paulson Interactive Training Programs. Not
only all of our molding personnel, but many of our office & support staff have completed the
training, which has given them greater insight into our primary manufacturing process of
injection molding.” David Hepbrun, BESPAK
SM

32. Extruder Operation
and Control Single Screw
1. The Single Screw Extruder: Parts and Operation
2. The Structure of Plastic Raw Materials
3. The Characteristics of Plastics for Extrusion
4. Effects of Pressure, Temperature and Flow
5. Optimizing Extruder Controls – Part 1
6. Optimizing Extruder Controls – Part 2
7. Safety, Pre-Start and Start-Up Procedures
8. Steady-State Operation, Shutdown and
Maintenance Procedures
9. Single Screw Extruder Troubleshooting

33. Thin Sheet Thermoforming
▪ Optimizing operating controls
▪ Safety around the thermoforming
machinery
▪ Thermoforming for maximum
efficiency and profit.
 Operation of the machinery
used in thermoforming
 The function of each
component of thermoforming
line
 Plastic behavior during the
thermoforming process
 Sheet extrusion fundamentals,

34. Extrusion Blow Molding
Technology
 Recognize processing
conditions that affect quality
 Analyze and solve practical
blow molding problems
 Develop a working knowledge of
blow molding machinery
 Evaluate and improve operating
procedures

35. Compounding with the
Twin Screw Extruder
 Detailed video explanation of what is going
on inside the extruder, and how control
setting adjustments affect the plastic and
output.
 Describes optimal machine-running
procedures with proven employee-learning
models for more thorough, better-retained
learning
 Teaches in-depth operating skills for
increased efficiency and productivity
 Develops insight for quicker, more accurate
troubleshooting and problem resolution
 Strengthens process control skills for
greater productivity and less waste

36. Sheet Extrusion Technology
▪ The Sheet Extrusion Line:
Parts and Operation
▪ Sheet Extrusion Dies
▪ Controlling Plastic Flow in the Die
▪ Plastic Behavior in the
Sheet Extrusion Line
▪ Pre-Start, Start-up, and Steady-State
Operating Procedures
▪ Safety and Shutdown Procedures
▪ Troubleshooting the Sheet Extrusion Line

37. The Paulson
Difference
“We’re pleased to add Paulson Training Programs to our group of affiliate
partners. They have a well-established reputation due to top quality products
and through years of providing advances in training such as their injection
molding simulator, SimTech.” Bill Gruber, Concentric Custom Services
▪ 24/7 Cross platform deliverability.
Phone, tablet, computer. Anytime,
anywhere
▪ Innovative injection molding simulation
teaching tools
▪ Paulson Plastics Academy Tech Center
▪ Seminars at your plant in Injection
Molding, Thermoforming,
Extrusion Blow Molding

38. Paulson Plastics
Academy
Seminars from the
Paulson Plastics
Academy teach the
fundamentals of plastics
engineering and scientific
molding. All classes are
led by expert instructors
who bring to life the
basics and advanced
topics of injection
molding.

39. Paulson Plastics
Academy Seminar Titles
 ProMolder 1
 ProMolder 2
 Data-Driven Molding
 Module 1 Set-Up
 Module 2 Process
 Module 3 Certification
 Mold Design Fundamentals
 Managing a Molding Plant
 ProEx 1
 ProEx Blow Molding

40. Paulson Plastics Academy
Technical Center
Offering a whole new learning experience
Located in sunny Florida, the Tech Center offers:
 A dedicated, 9,000 sq. ft. injection molding
training facility
 Expert injection molding instructors
 Four injection molding machines for hands-
on machine time
 Multiple Classrooms
 Six-station computer lab, loaded with
Paulson courseware & simulator
 QC Lab

41. All-in-One Training Solution
Online
• ONLINE-TRAINING
Anytime, anywhere
• REAL-TIME
INTERACTIVE
Molding simulation
OnSite
• CUSTOM ONSITE
Customized training at
your facility
HandsOn
• MULTI-CITY SEMINAR
TRAINING
Hands-on and in person
• DEDICATED TRAINING
CENTER
Classrooms & Machines

42. Skilled People Come From Paulson
▪New Hires
▪Machine Operators
▪Process Engineers
▪Supervisors
▪Part Handlers
▪Technicians
▪Production Management
▪CEOs

43. Partial List of our 3,000+ Clients

44. Winners
Powered
by
Paulson
2005 - U.S. Farathane Corp.
2004 - Miniature Precision
Components Inc.
2002 - (Tie) Tech Group Inc. &
Precise Technology Inc.
2001 - Cascade Engineering Inc.
2000 - Tessy Plastics Corp.
1997 - Nypro Inc.
2015 – Evco Plastics
2014 - Stihl Inc.
2013 - Tech Molded Plastics Inc.
2012 - Hoffer Plastics Corp.
2011 - Steinwall Inc.
2010 - Plastikos Inc.
2009 - GW Plastics Inc.
2008 - Plastic Components Inc.
2007 - Innovative Injection
Technologies Inc.
2006 - Mack Molding Co.
Plastics News – Processor of the
Year

45. Industry
Alliances
and
Partners

46. THANK YOU
Society of Plastics Engineers, SPE
Hennepin Technical College
and all attendees for your time today!

47. www.PaulsonTraining.com
Ted Chryzanowski
800-826-1901
tedc@paulsontraining.com
Powerful Training. Proven Results.