At Plastribution we are focused on providing cost effective thermoplastic raw material solutions, and one of our objectives is to utilize our technical expertise to assist customers to enhance their own profitability. After some basic research we discovered that thermoplastic raw materials expenses often represented the majority of the production cost of an injection moulded plastic component:
This information was used to come up with a 3-point plan , which could be employed to establish if raw material costs could be reduced, or if productivity could be increased.
Some plastics are basically transparent (or appear translucent or opaque). If a moulding is transparent it is most likely to be one of the following:
Answer the following three questions:
1. Is specification preventing you from buying more cost effectively?
2. Is the application over-engineered?
3. Does material selection impact on process optimization?
Let's take each one of these in turn:
Many people are familiar with the situation where a particular grade from a particular manufacturer is specified for a component. In our experience at Plastribution, it is almost always the case that where materials are specified a premium is charged to you, the customer. Without validating a suitable alternative material there is little chance of reducing the premium.
Whilst not all applications are suitable, in many cases Plastribution can propose excellent alternatives that could generate cost savings in the range of 5 - 25%,
without any compromise in terms of product quality or performance.
Gaining approvals can be a complex process, however through our technical team we can assist in the following areas:-
1) Evaluation of suitability for re-specification
2) Sample production / moulding trials
3) Third party testing
4) Certification
5) End-user support.
In some cases we may also be able to help in funding testing by third party assessors, or through the resources of our world-class suppliers (many of which operate some of the most advanced technical resources currently available).
It's simple. Through this initiative Plastribution wants to grow its business, and in order to achieve this objective, we believe that we must do as much as we can to ensure that our customers are successful and competitive within their own market. If we ignore this principle our customers stand the risk of losing work, becoming less profitable, and less willing to invest in the future of the industry.
Over-engineering describes a situation where either through component geometry or materials selection, the finished component has properties which exceed the design/ application requirements. The situation of over-engineering through material selection can result from a number of causes, including:
1) Caution on the part of the product designer
2) Incomplete survey of suitable materials
3) More suitable polymers / formulations have been developed since initial material selection
4) Technological improvements, which enable process or material modification.
i) Injection moulded car number plates
In this example APET has successfully been substituted for impact modified PMMA. The high impact and good weathering characteristics of PET has enabled it to become a lower cost alternative.
ii) Metallic Finishes
Recent developments in metal effect finishes by Addiplast have led to the elimination of costly secondary paint spray finishing of plastic components, with the added benefit that the effect cannot be scratched or chipped off. This progress in metallic finishes incorporated into polymers has been significant. It is now possible to simulate effects such as aluminium in automotive applications, such as cosmetic engine covers.
Naturally there are some (very few) applications, which are not suitable, and there is still the need to carefully consider gate design and location in order to eliminate/reduce flow lines.
In the case of process optimization, the objective is to evaluate if, through the use of alternative grades/formulations, it is possible to enhance productivity. Again, here Plastribution is adopting customer focus, going beyond the raw material and looking at the total cost of production. Typical examples of process optimization include:
Thin Wall Trays
Selection of high flow PPCP improved productivity through reduced cycle time, and reduced scrap rates through better pigment dispersion! The improved impact performance of more recent high flow PPCP grades ensured that suitable mechanical impact performance could be achieved.
Pipe Production
Recent work on material selection has enabled a producer of large diameter low-pressure pipe to reduce scrap rates to below one fifth of the industry average.
Plastribution is here to help you to achieve the best out of your business. Our objective is to provide cost effective solutions to your plastic raw material requirements. We want to be your business partner and to achieve this we will apply technology, imagination, flexibility and resources. Just call any member of our team and we will be pleased to help.