Adhesives & Sealants Industry April 2011

April 2011

• Volume 18, Issue 4

• www.adhesivesmag.com

Multi-Shaft MIXERS ❯ ASC Spring

Convention & Expo Preview

❯ Processing Equipment

A FREE virtual event covering trends in manufacturing from design to delivery. See page 23 for details!

18 below in Chicago. Super De-icer. Dreams take flight. NuSil Technology.

New ways to get from here to there. Silicone-coated aircraft wings that, one day, will enable planes to take off in extreme, icy conditions. Ultra-low-outgassing products that decrease volatility and increase longevity in outer space. Whatever your needs, the scientists at NuSil are dedicated to helping innovators innovate. As the leader in silicone solutions with nearly 30 years of aerospace experience, we can provide you with precise, custom formulations that make your ideas take off. What? When? Where? If it’s NuSil, it’s no problem.

©2010 NuSil Technology LLC. All rights reserved. ASI0410-A

What’s your challenge? www.nusil.com/asi USA +1-805-684-8780 Europe +33 (0) 4 92 96 93 31

796;,*;05..,50<: Connolly Bove attorneys understand your technology and how IP relates to your big picture needs.

It’s like we’re in your head. www.cblh.com

INNOVATION = VALUE COATINGS: Go ‘green’ with innovative binder and additive technologies.

ADHESIVES & SEALANTS:

Conserve energy in production and product use.

ELASTOMERS:

Formulate with alternative raw materials, and do it competitively.

YOUR CUSTOMERS DEMAND ENVIRONMENTALLY-FRIENDLY PRODUCTS. LET UNIVAR SHOW YOU HOW YOU CAN GO GREEN. Univar supplies the CASE industry with much more than a comprehensive line of sustainable ingredients — we can provide you with an innovative approach to your green formulation challenges, offering you technical expertise from concept to production. Consider Univar your partner in sustainable product development. We connect you to the latest materials and technologies, and help you bring environmentally-friendly products to market. Innovation, sustainability, expertise — it all adds up to value.

INNOVATION > TECHNICAL EXPERTISE > MARKETING > SALES > LOGISTICS > DISTRIBUTION

1.877.203.0045 | [email protected] www.univarcorp.com

IN THIS ISSUE ADHESIVES & SEALANTS INDUSTRY, VOLUME 18, NUMBER 4

12 14 20

28 34 36

42 43

DEPARTMENTS

Q&A ABOUT POLYURETHANE Scientists from the Business Development Group of Bayer MaterialScience LLC answer readers’ questions.

6

Editor’s Memo

BRINGING IT ALL BACK HOME

8

Company News

Reshoring Initiative aims to educate manufacturers about the true costs of outsourcing.

8

People

10

Calendar

46

What’s New

46

Product and Literature Showcase

47

Services Marketplace

49

Classifieds

50

Ask Dr. Dave

50

Ad Index

NETWORK AND LEARN Industry professionals are gearing up for the ASC’s 2011 Spring Convention & Expo, which will take place April 17-19 in Tampa, FL.

A CLOSER LOOK AT MULTI-SHAFT MIXERS

14

Multi-shaft mixers are often necessary when a product requires enhanced processing capabilities.

IMPROVE YOUR PROCESS Two pieces of process equipment are receiving attention in the industry.

HIGH-SPEED DISPERSION Dispersers are used to rapidly break apart lumps of powdery material, uniformly distributing and wetting them into a liquid.

BLADE BASICS

36

Dispersion blades are relatively inexpensive to replace and should be changed on a regular basis.

THE OPTIMUM TIME TO SELL YOUR COMPANY

April 2011

By the latter part of 2011, middle-market deal pricing is expected to increase to above normal levels.

• Volume 18, Issue 4

• www.adhesivesmag.com

Multi-Shaft MIXERS ❯ ASC Spring

Convention & Expo Preview

❯ Processing Equipment

A FREE virtual event covering trends in manufacturing from design to delivery. See page 23 for details!

43

Cover.indd 1

3/14/11 8:57 AM

ON THE COVER: Photo courtesy of Charles Ross & Son Company.

FOR SUBSCRIPTION INFORMATION OR QUESTIONS, CONTACT: Customer Service: (847) 763-9534 ADHESIVES & SEALANTS INDUSTRY (ISSN 1070-9592) is published 12 times annually, monthly, by BNP Media, 2401 W. Big Beaver Rd., Suite 700, Troy, MI 48084-3333. Telephone: (248) 362-3700, Fax: (248) 362-0317. No charge for subscriptions to qualified individuals. Annual rate for subscriptions to nonqualified individuals in the U.S.A.: $178.00 USD. Annual rate for subscriptions to nonqualified individuals in Canada: $216.00 USD (includes GST & postage); all other countries: $228.00 (Int’l mail) payable in U.S. funds. Printed in the U.S.A. Copyright 2011, by BNP Media. All rights reserved. The contents of this publication may not be reproduced in whole or in part without the consent of the publisher. The publisher is not responsible for product claims and representations. Periodicals Postage Paid at Troy, MI and at additional mailing offices. POSTMASTER: Send address changes to: ADHESIVES & SEALANTS INDUSTRY, P.O. Box 2148, Skokie, IL 60076. Canada Post: Publications Mail Agreement #40612608. GST account: 131263923. Send returns (Canada) to Pitney Bowes, P.O. Box 25542, London, ON, N6C 6B2. Change of address: Send old address label along with new address to ADHESIVES & SEALANTS INDUSTRY, P.O. Box 2148, Skokie, IL 60076. For single copies or back issues: contact Ann Kalb at (248) 244-6499 or [email protected].

April 2011

Adhesives & Sealants Industry

Audited by BPA Worldwide.

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®

EDITOR'S MEMO

TOO GOOD TO BE TRUE?

www.adhesivesmag.com 6075 B Glick Rd., Powell, OH 43065 • 614-789-1880

PUBLISHING STAFF John Schrei, Publishing Director — 248-786-1637, [email protected]

A representative from my cell phone company recently called and excitedly told me that I could upgrade my phone for FREE if I changed my plan and paid $20 more each month. I ran through a number of responses in my head, ranging from “You’ve got to be kidding,” and “Do you take me for a fool?” to “Please define free for me.” In the end, I decided it was one of those “if you don’t have anything nice to say, don’t say anything at all” kind of moments. I just laughed and said, “No, thank you.” On the surface, the concept of offshoring might seem like a great deal: moving operations overseas can enable manufacturers to dramatically slash costs and improve their profitability. But according to Harry Moser, founder of the Reshoring Initiative, when companies look deeper into the details of offshoring—particularly the logistics involved—additional costs become readily apparent. “According to a 2009 survey by Archstone Consulting, 60% of manufacturers use only rudimentary calculation methods to determine what it costs them to offshore,” he says. “On average, they miss about 20% of the total costs of offshoring.” Additional costs typically come in the form of travel, packaging, shipping and inventory, to name just a few. To help manufacturers calculate the true costs of offshoring, the Reshoring Initiative has developed a spreadsheet that includes a number of variables, both tangible and intangible. Moser will discuss these issues in detail when he delivers the keynote address at Tech ManufactureXPO, a live virtual event that will be held May 4. Co-sponsored by ASI, the free event will enable attendees to save on travel costs while gathering information and networking with peers—all from the comfort of their office. Learn more in “Bringing It All Back Home” on pp. 14-18 of this issue.

Tom Esposito, Senior Group Publisher — 610-436-4220, [email protected] Amy Vallance, Publisher — 281-550-5855, [email protected] Susan Sutton, Editor-in-Chief, Integrated Media — 330-336-4098, [email protected] Teresa McPherson, Managing Editor — 734-332-0541, [email protected] Kelsey Seidler, Associate Editor — 614-789-1881, [email protected] Lindsay Leusby, Art Director — 248-244-1735, [email protected] Karen Talan, Production Manager — 248-244-6246, [email protected]

SALES STAFF Amy Vallance, Sales Representative Midwest, West and Southwest U.S., and Western Canada 281-550-5855, [email protected] Brandon Miller, East Coast Sales Manager Eastern U.S. and Canada, Latin America 610-436-4220 x8513, [email protected] Patrick Connolly, Sales Representative, Europe Patco Media-London, 99 Kings Road, Westcliff on Sea, Essex SSO 8PH, England 44-1702-477341, FAX 44-1702-477559, [email protected] Peg Van Winkle, Inside Sales 614-760-4222, [email protected] Robert Liska, Postal List Rental Manager 800-223-2194 x726, [email protected] Shawn Kingston, E-mail List Rental Account Manager 800-409-4443 x828, [email protected]

CONTRIBUTING EDITORS Dave Dunn, bms North America Dan Murad, The ChemQuest Group Inc. David P. Nick, DPNA International Inc.

EDITORIAL ADVISORY BOARD Susan Sutton is Editor-in-Chief, Integrated Media for Adhesives & Sealants Industry and Ceramic Industry magazines. If you wish to send a letter to the editor, please e-mail [email protected]. Letters must include the sender’s address, phone number and e-mail address, when possible. Letters may be edited for space and clarity.

THIS MONTH ON www.adhesivesmag.com... Online Exclusive: Network and Learn— ASC Spring Convention & Expo Preview The Adhesive and Sealant Council’s (ASC) 2011 Spring Convention & Expo will take place April 17-19 in Tampa, FL. The online version of this preview article will also include a schedule of events. Online Exclusive: Laser Cutting Technology State-of-the-art laser cutting systems can consistently cut more intricate designs with tighter tolerances than ever before. Online Exclusive: Acquisitions Stay up to date on the industry’s latest buying/ selling activities with this listing of recent acquisitions. Digital Edition ASI’s digital editions are easy to read, search and download. This month’s digital edition is sponsored by Emerald Performance Materials.

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Steven Gailbreath, Arizona Chemical Richard P. Muny, Chemsultants International Network Larry Owen, Franklin International Lex Reynolds, Reynolds Glue Deborah Chrzanowski, Intertape Polymer Group and PSTC Technical Steering Committee Chair

AUDIENCE DEVELOPMENT Jill Buchowski, Audience Development Manager Kelly Carlson, Multimedia Specialist Carolyn M. Alexander, Audience Audit Coordinator For subscription information or service, please contact Customer Service at: Tel. (847) 763-9534 or Fax (847) 763-9538 or e-mail [email protected]

CORPORATE DIRECTORS Publishing: Timothy A. Fausch

Creative: Michael T. Powell

Publishing: John R. Schrei

Directories: Nikki Smith

Corporate Strategy: Rita M. Foumia

Human Resources: Marlene J. Witthoft

Marketing: Ariane Claire

Conferences & Events: Emily Patten

Production: Vincent M. Miconi

Clear Seas Research: Beth A. Surowiec

Finance: Lisa L. Paulus

BNP Media Helps People Succeed in Business with Superior Information

April 2011

Semco® Packaging & Application Systems solves another packaging puzzle for the solder paste industry! Introducing the Semco® Solder Paste Jar s Ergonomically compliant threaded cap s Complies with industry requirements for viscometers and mixing equipment s Contoured to minimize waste s Cost-effective

COMPANY NEWS ATLAS MATERIAL TESTING TECHNOLOGY has announced its 2011 Client Education Calendar of events, with workshops and seminars scheduled throughout the U.S. and Europe. The hands-on training workshops cover Ci Series Weather-Ometers, as well as the SUNTEST ® and Xenotest ® instruments. In addition, Atlas offers basic and advanced Fundamentals of Weathering seminars to educate attendees on the essential elements of weathering testing. For additional details, visit the website at www.atlas-mts.com. BASF recently announced it has appointed RIBELIN SALES INC. as a southeast and Gulf Coast U.S. distributor for polyurethane chemicals to the CASE (coatings, adhesives and binders, sealants and elastomers) market. For more information, visit www.basf.us or www.ribelin.com.

A new distribution facility in Jakarta has been built to meet BRENNTAG’S growing market demand. The facility will provide a bigger storage capacity than the cur-

rent warehouse in Jakarta, and allow the company to improve and expand valueadded customer support throughout the supply chain. The new facility adds to the company’s seven existing warehouses in Indonesia and Brenntag’s growing distribution network in the Asia Pacific region, which also includes more than 40 distribution centers. For additional details, visit www.brenntag.com. CELANESE CORP. has announced that it will expand capacity at its Edmonton, Canada, manufacturing facility due to strong growth in strategic, high-value segments. Global EVA production increases are fueled by growth in the photovoltaic cell industry in China and strong demand for EVA in other parts of Asia. The company expects to increase capacity by up to 15% for higher vinyl acetate content EVA grades at the Edmonton facility in the second half of 2011. For additional details, visit www.celanese.com. C O AT E X a n d A R K E M A E M U L S I O N SYSTEMS have announced the opening

Max Flow Meters

If you measure very little, you need us a lot Tiny flow rates and small dosages FDQEH measureG Don't change your process, change your meter.

Max Machinery Inc.

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ELLSWORTH ADHESIVES announced it has moved to a larger facility in Madrid, Spain. The expansion to a larger office in Madrid reportedly reflects the company’s global commitment to expand its presence in Europe. Ellsworth Adhesives Ibérica provides local support to Spanish and Portuguese customers with technical support, local stocking, and more delivery options. For additional details, visit www. ellsworth.com. MICHELMAN has formally organized its growing chemical sales into the fibers and composites markets under a business unit umbrella. The new Fibers and Composites Global Business Unit offers manufacturing capabilities in North America, Europe and Asia; worldwide distribution; dedicated business development personnel around the world; and technical and sales support staff. The new business unit will be led by Yves De Smet, Ph.D., and Andy Brink, Ph.D. De Smet will be responsible for the commercial aspects of the business, including sales and marketing, while Brink will be responsible for technology and business development. For additional details, visit www.michelman.com. NORDSON CORP. has opened a new 28,000-sq-ft global headquarters facility in Westlake, Ohio, that incorporates leading green building technologies and is expected to earn a Leadership in Energy & Environmental Design (LEED) certification later this year. Nordson’s corporate staff of 51 moved into the new building at the end of 2010. For additional details, visit www.nordsonefd.com.

Flow measurement you can count on

an ISO9001:2008 certified company

of a new Asia Pacific coatings application laboratory in Changshu, China. This new facility will provide technical support to coatings customers in the region. Both businesses are part of the Arkema group; Arkema Emulsion Systems focuses on latex binders, while Coatex is dedicated to water-based rheology additives. They share a common vision of the business based on sustainable growth, innovation and responsiveness to customer needs. For more information, visit www.arkema emulsionsystems.com or www.coatex.com.

PEOPLE maxmachinery.com T 707.433.2662

Royal Adhesives and Sealants LLC has named GREG FONZI and WILLIAM WHITE April 2011

to its Floor Covering Distribution Sales Team. Fonzi will cover a territory in New England and will be located in the greater Boston area, while White will cover the West, with an office located in Portland, OR. MACtac® Specialty Products has appointed TRAVIS FRANCY sales representative for the northeastern and southeastern U.S. territories, as well as parts of the Midwest (Minnesota, Wisconsin, Iowa, Illinois and Missouri).

How to strengthen your assets with every adhesive delivery system.

Plasticolors Inc. recently appointed LARRY HAINES to the position of strategic development manager, responsible for identifying and successfully entering new markets and applications with an emphasis on gaining greater access to global markets. Huntsman Corp. has announced the appointment of ANTHONY P. HANKINS, president of the company’s Polyurethanes division, to the new role of chief executive officer, Asia Pacific. Hankins, who will be based in new regional headquarters in Hong Kong, will facilitate the corporate and cross-divisional activities required to deliver growth. Hankins will continue as president of the Polyurethanes division, which will relocate its global headquarters from The Woodlands, Texas, to Hong Kong this year.

Call today for a Free sample using your supplied material. You’ve invested heavily in time and expense to develop your market. You need the reassurance that how your delivery system is packaged will enhance its performance. Now is the time to make the most of your investment with APS as your solution provider of custom packaging of both single & multi-component materials. For over 25 years, we have understood the importance of providing the highest quality world wide, cost effectively, with delivery schedules that remain unsurpassed in the industry.

Arkema Emulsion Systems has announced the addition of JOHN HIEL as its new North American Marketing manager. Hiel will be responsible for program management, strategy and tactics across the region for all of the company’s emulsion product lines. He has 20 years’ experience in the industry, previously serving as industry manager for performance chemicals in the Coatings division at BASF and working at LORD Corp.

APS...We package more strength into your adhesive delivery systems.

DAILY UPDATES For all of the latest industry news and information, visit us online at www. adhesivesmag.com.

April 2011

ISO 9001: 2000 CERTIFIED © Adhesive Packaging Specialties, 2006

103 Foster St., Peabody, MA 01960 (800) 222-1117 T (978) 531-3300 F (978) 532-8901 [email protected] www.adhesivepackaging.com Adhesives & Sealants Industry

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COMPANY NEWS CALENDAR APRIL 17-19 ASC Spring Convention and Expo; Tampa, FL; www.ascouncil.org

9-11 Construction, Corrosion & Infrastructure Conference; Las Vegas, NV; http://www.goeshow. com/acma/CCI/ereg497293.cfm?clear

MAY

9-13 PSTC Week of Learning; Hyatt Regency Grand Cypress; Orlando, FL; www.pstc.org

3-5

Chemspec USA 2011; Pennsylvania Convention Center; Philadelphia; www.chemspecevents.com/usa/

4

Tech ManufactureXPO virtual trade show, www.techmanufacturexpo.com

23-25 2011 Binding Industries Association Conference; ChampionsGate, FL; www.printing.org/ biaconference

A word from our customers:

30-6/1 13th European PLACE Conference; Festpielhaus on Lake Constance; Bregenz, Austria; www.tappi.org

JUNE 7-9

Green Manufacturing Expo; New York City; www.canontradeshows.com/expo/gmx11/ ana_event.html

7-9

Green Manufacturing Expo; Toronto, Ont.; www.canontradeshows.com/expo/gmx11/ ana_event.html

19-21 Forest Products Society’s 65th International Convention; Portland, OR; www.forestprod.org/ ic65/overview.html

JULY

"Merlin's flexibility is remarkable. They stock our material and can turn on a dime when our requirements change. They always ship quickly, and more than once have responded to emergencies with next-day delivery. Nice people that are easy to work with. Overall, Merlin is an excellent supplier." B. S. Specialty polymer supplier Merlin customer for 9 years

"Merlin is extremely qualityconscious, with fast delivery and excellent attention to detail. They've given us the opportunity to be competitive on smaller orders by downpacking drums into custom cartridges. Our sales have grown steadily, thanks in no small part to Merlin Packaging." Eric Watson Purchasing Supervisor Rudolph Brothers & Co. Merlin customer for 10 years Merlin provides accurate filling of dual cartridges, syringes, pouches, mixed frozen, and many other packaging options. For fast delivery of big or small orders of quality custom packaging, call Merlin Packaging Technologies today.

15-15 COMPOSITES CHINA; Shanghai, China; chris. [email protected] 26-27 ASC Sustainability Summit; Rosemont, IL; www.ascouncil.org

SEPTEMBER 13-14 Nanopolymers 2011; Dusseldorf, Germany; http:// ismithers.net/venue-details/XNAN11 15-16 FEICA Conference; Valencia, Spain; www.feica.eu 20-22 Green Manufacturing Expo; Rosemont (Chicago), IL; www.canontradeshows.com/expo/gmx11/ ana_event.html 20-22 Assembly and Automation Technology Expo; Rosemont (Chicago), IL; www.aatexpo.com 26-28 CPP Expo; Las Vegas Convention Center: Las Vegas; www.cppexpo.com/

OCTOBER 6-8

TURKCOAT COATINGS SHOW; Istanbul Expo Center; Istanbul, Turkey; www.turkcoat.com

16-18 ASC 2011 Fall Convention; Indianapolis, IN; www.ascouncil.org

NOVEMBER 1-3

2011 CHEM SHOW; Jacob K. Javits Convention Center; www.chemshow.com

9-10 The Composites Engineering Show; Birmingham, UK; www.compositesexhibition.com 21-23 Abrafati 2011; Sao Paolo, Brazil; www.abrafati2011.com.br/index_engl.html

861 Taylor Road, Suite E

Gahanna, OH 43230 Toll-free: 888-648-7878 [email protected] www.merlinpackaging.com

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MAY 2012 7-10 American Coatings Show 2012; Indianapolis, IN; www.american-coatings-show.com/en/default.ashx For a more detailed listing, visit www.adhesivesmag.com.

April 2011

WHAT

COULD YOU DO WITH AN

ADHESIVE

THIS GOOD? Adhesives are critical elements to successful manufacturing. Regardless of the surface, when designing a bonding solution for metal, wood or plastic, Kraton Polymers' premium elastomers deliver a broad array of customized options. Whether you are targeting increased processing speed or alternative functionality, Kraton® polymers can give you optimal versatility with world-class quality. Kraton products enable you to deliver proven cost savings and enhanced performance in diverse film, label and personal care applications. With these capabilities, you can understand what makes Kraton Polymers a global leader in the industry. For all your adhesive and sealant needs, Kraton Polymers is your single source for highly innovative solutions, service and support.

Please visit us at ASC Spring Conference April 17 - 19 Booth #115

Delivering solutions to your toughest challenges is what we do best.

For more information, call 1-800-4-KRATON or visit our website at www.kraton.com

QA &

About Polyurethane

QA

A PARTICULAR APPLICATION WILL REQUIRE ME TO BOND A VARIETY OF OPTICALLY CLEAR POLYMERS & EACH OTHER AND TO GLASS. WHAT ADHESIVE TO OPTIONS ARE AVAILABLE? A variety of polymeric film adhesives are on the market that may work for your application. The main types are optical aliphatic polyurethanes (OATPUs), plasticized polyvinyl butyral (PVB), and reactive adhesives that cure by heat or light. In protective glazing structures, the adhesive layer is the key factor in creating a robust, successful design. OATPU films or sheets are used as adhesive inter-layers between layers of glass, polycarbonate or acrylics. They are currently one of the materials of choice for adhesive films because of their ability to bond to a variety of substrates and their optimal performance over an extended time period. OATPU adhesive inter-layers are inherently soft due to their molecular block structure. They are synthesized using an aliphatic diisocyanate, macrodiol (polyol) and short chain diol (extender). These urethanes maintain their physical properties over a wide temperature range and therefore exhibit excellent impact resistance and anti-spalling properties of the laminated structure. The inherent soft elastic properties of OATPU prevent delamination by allowing rigid glass and polycarbonate substrates to expand and contract over a range of temperatures. Since they are based on aliphatic isocyanates, these TPU films exhibit long-term color stability, which eliminates yellowing problems associated with exposure to ultraviolet light. They also show long-term optical clarity and low light distortion. Typical applications include bonding glass/glass and glass/polycarbonate for a variety of security and military applications, such as forced entry protection and ballistic and explosive attacks. PVB provides good bonding ability at low cost and offers some level of protection against spalling, but it has a major disadvantage in that its plasticizer content is not compatible with polycarbonate. Also, the PVB laminating temperature is in excess of 260°F; this high temperature level causes stress cracks in a polycarbonate coating. Liquid resin adhesives are cast or poured into voids between the glass, polycarbonate or acrylic substrates and cured by ultraviolet light or heat. These

resin systems are used in special design applications such as curved laminates and laminates containing inserts.

QA

I AM FAMILIAR WITH THE USE OF WATERBORNE POLYMERS FOR TEXTILE BONDING APPLICATIONS, BUT & I AM INTERESTED IN A 100% SOLIDS SYSTEM. WHAT OPTIONS EXIST FOR THE USE OF POLYURETHANE POLYMERS?

Thermoplastic polyurethane films are used in textile applications to serve as an adhesive or barrier layer. A typical adhesive application is in the manufacture and application of emblems. The emblems are a multi-layer construction typically made from polyester and nonwoven or woven fabrics. TPU films are used to bond these layers of fabric together and serve as the adhesive backing on the emblem, which is then hot-pressed onto articles of clothing. The TPU adhesive films are based on polyester polyols and aromatic isocyanates. These ester-based films are preferred over ether-based films because they are inherently tackier when molten and generate better bond strength at the film/fabric interface. A temperature of 300°F is used to laminate fabric layers together or adhere the emblem to clothing. Emblems constructed with ester-based TPU adhesive films are able to withstand laundering and dry cleaning cycles. TPU films function both as an adhesive and a barrier layer in automotive applications, where foam-in-place manufacturing techniques are used for the production of arm and head rests and seats. For these applications, either an aromatic ether-based or an ester-based TPU film can be used. Typically, a tri-laminate of fabric or vinyl/soft porous PU foam/TPU film is made by a flame lamination process, in which the soft porous foam is sandwiched between the fabric and the TPU film. This three-layer structure is then cut and sewn to form the cover of the part. The sewn assembly is placed into a mold with the outer fabric layer contacting the mold surface. The reactive components used to make the structural PU foam are then poured into the mold, and the foam expands to form the part. The TPU film acts as a barrier that prevents the reacting foam from bleeding through the layer of soft porous foam. An unwanted bleed-through could cause the part to be rejected for a dimpled appearance or a rigid feel in the outer surface of the assembly.

ABOUT THE AUTHOR Patrick Stennett is a member of the Functional Films group at Bayer MaterialScience LLC, with responsibility for Technical Service. For additional information on the topics addressed or to ask another question, e-mail [email protected] with the subject line “Polyurethane Q&A.” Any views or opinions expressed in this column are those of the author and do not represent those of Adhesives & Sealants Industry, its staff, Editorial Advisory Board or BNP Media.

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April 2011

CREATING TOMORROW’S SOLUTIONS

YOU KNOW US. YOU JUST DIDN’T KNOW IT.

Quality. Reliability. Global knowledge. Technical expertise. WACKER silicone-based materials are so versatile and adaptable, they have virtually unlimited applications just about anywhere imaginable, making WACKER an integral part of our daily lives. Engineered to deliver consistent and dependable performance, WACKER materials are known the world over for helping create new business opportunities through innovation. Ask our technical experts how we can help you meet the competitive challenges of a global economy. Get to know us even better. Visit www.wacker.com/knows-solutions Wacker Chemical Corporation, 3301 Sutton Road, Adrian, MI 49221, USA TEL: +1 888 922 5374, FAX: +1 517 264 4068, [email protected]

Bringing It All Back Home Reshoring Initiative aims to educate manufacturers about the true costs of outsourcing. By John Sprovieri, Editor, ASSEMBLY Magazine

arry Moser might be the only person ever elected to a Hall of Fame based not on what he’s done, but on what he’s going to do. This past November, Moser was named one of the 2010 inductees into Industry Week magazine’s Manufacturing Hall of Fame, an institution that includes Michael Dell, founder and CEO of Dell Inc.; Jack Welch, former CEO of General Electric; and James Womack, lean guru and author of The Machine That Changed the World. Although Moser has spent more than 40 years in American manufacturing—the last 22 as president of Swiss machine tool supplier GF Agie Chamilles—he became a “Hall of Famer” for founding the Reshoring Initiative, a nonprofit organization dedicated to persuading manufacturers to bring work back to the U.S. from overseas. His passion has led him to travel the

H

According to a 2009 survey by Archstone Consulting, 60% of manufacturers use only rudimentary calculation methods to determine what it costs them to offshore. (Photo courtesy of Hella.) 14

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country, work with policymakers, and offer manufacturers a total-cost-of-ownership formula that helps them calculate the real impact of offshoring on their balance sheets. “For decades, I promised America’s youth and their parents that if they went into the skilled manufacturing trades...there would be jobs for them,” says Moser. “Then, all the jobs started to go away. I had to redeem by promise. I had to do my best to bring jobs back.” Moser will share his vision for achieving that goal May 4 during a keynote address to start Tech ManufactureXPO, a virtual trade show sponsored by ASSEMBLY, Quality, CircuiTree, ASI and World Trade. (See sidebar on page 16.)

THE RESHORING INITIATIVE Moser’s roots are firmly planted in manufacturing. Both his father and grandfather worked at Singer Corp.’s massive sewing machine factory in Elizabeth, NJ. Moser himself worked there summers during high school and college. “Once the envy of the world, the Singer plant is now long gone, and I don’t want to see more U.S. manufacturing disappear,” he says. After meeting Moser at his home in Kildeer, IL, northwest of Chicago, it’s clear he’s no stuffed shirt. He’s optimistic, quick to laugh and passionate about manufacturing. “Most people don’t understand reshoring—they think it has something to do with Lake Michigan,” he quips. “When they realize I’m trying to bring manufacturing jobs back to the U.S., everyone agrees that it’s about the most important thing anyone in the country can do....They think I’m a hero just for trying.” Moser is also a man of considerable energy. Since he launched the Reshoring Initiative last year, he’s been quoted in The Wall Street Journal and USA Today, and he’s appeared on CBS News and CNBC. Moser has also met with myriad local and national organizations, including the AFL-CIO, the Society of Manufacturing Engineers, the Institute of Supply Management, the Council on Competitiveness, the Manufacturing Extension Partnership, and the Association for Manufacturing Excellence. In each case, he urges OEMs to look beyond just the unit price of a part when deciding whether to produce it domestically or offshore. April 2011

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See us at ASC booth 205.

BRINGING IT ALL BACK HOME Tech ManufactureXPO A virtual trade show, Tech ManufactureXPO will be held May 4 from 8:30 a.m. to 3:30 p.m. EDT. It’s the online equivalent of a traditional trade show, featuring webinars, podcasts and “virtual booths.” Participants can browse exhibitor booths, chat with booth representatives, and collect information, such as brochures, data sheets, and white papers. Nearly 30 suppliers are exhibiting at the event (see list below). In addition to live webinars, the event will also include 15-minute how-to podcasts from Automated Precision Inc., InterTech

Tech ManufactureXPO Exhibitors to Date Automation Tool Co.—Custom automated assembly and test systems. Automated Industrial Systems Inc.—Pad printers and highspeed installation equipment for O-rings, seals, backup rings and retaining rings. Automated Precision Inc.—Advanced metrology equipment. ATI Industrial Automation—Robotic accessories and tooling, including automatic tool changers, collision sensors and compliance devices. Avdel USA—Rivets, inserts, and threaded fasteners, and tools for installing them. Balluff—Innovative sensors for a range of applications and industries. Baltec Corp.—Radial and orbital riveting equipment and assembly presses. Bosch Rexroth Corp.—Hydraulics, pneumatics, electric drives, motors and control systems, conveyors, and linear motion and assembly systems. COX North America Inc.—Manual, pneumatic and batterypowered caulk guns and epoxy applicators. CyberMetrics—Affordable, scalable software solutions for calibration management, preventative maintenance and supplier QA. Delta Regis Tools, Inc.—Assembly tools and torque measurement systems. Design Tool Inc.—Automatic screw feeding and driving systems. Emhart Teknologies—Rivets, inserts, and threaded fasteners, and tools for installing them. FARO Technologies Inc.—Computer-aided coordinate measurement machines and software. “According to a 2009 survey by Archstone Consulting, 60% of manufacturers use only rudimentary calculation methods to determine what it costs them to offshore,” he explains. “On average, they miss about 20% of the total costs of offshoring.” These additional, hidden expenses include higher costs for travel, packaging, shipping and inventory. For example, overseas suppliers typically deliver parts in larger shipments than domestic suppliers. Delivery times will also be longer. As a result, OEMs must keep a large supply of parts at a local warehouse, which necessitates additional costs for storage and retrieval. 16

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Development Co., Sealant Equipment & Engineering Inc., and Bosch Rexroth. A “lunch-and-learn” session on trends in green manufacturing will be held from 12:30-1:00 p.m. In this interactive chat-room session, which will be led by the editors of the five sponsoring magazines, manufacturing professionals will learn about the latest ideas in environmentally friendly materials, landfill-free manufacturing, supply chain management and more. For more information, see pp. 23-27 in this issue or visit www.tech manufacturexpo.com. Intelex Technologies Inc.—Software that captures, tracks and reports on essential corporate data. InterTech Development Co.—Leak testing equipment, functional testing equipment, and automated assembly and test systems. Item International America—Modular building kits, including aluminum framing, fasteners, linear guides, tubing and workbench systems. Logistick, Inc.—One-way, disposable freight securing devices. Mahr Federal Inc.—Dimensional metrology equipment, from handheld gauges to advanced measurement systems for form, contour, surface finish and length. Motoman Robotics—Robotic automation solutions for virtually every industry and application. Origin Technologies Corp.—Laser-based dimensional measurement and surface contour inspection systems. Promess Inc.—Highly adaptive monitoring and motion control systems to assemble and test products. Schunk Inc.—Grippers, rotary actuators, linear slides, robotic accessories, and pick-and-place equipment. Sealant Equipment & Engineering Inc.—Dispensing systems for bonding, sealing, potting, encapsulating, casting, gasketing and lubricating. SINTECO Robotics—Robotic systems and custom automated assembly, handling, machining, and testing systems for smalland medium-sized products. Sprinter Marking—Automatic ink code marking machinery for date, product, lot and spot ink marking impressions. Weiss North America Inc.—Rotary indexing tables, palletized conveyors, motor-driven pick-and-place units, camand servo-driven assembly chassis, indexing rings, machine bases, and tool plates.

“The problem is, the typical accounting system isn’t designed to aggregate that data,” says Moser. “It simply calculates the cost of goods sold and therefore misses out on these other variables.” To give OEMs a better idea of these hidden costs, Moser developed a spreadsheet that compares the total cost of ownership for domestic and offshored parts (see sidebar on p. 18). The spreadsheet covers “hard” costs, such as packaging, shipping, duties and brokerage fees. But it also includes less tangible variables, such as missed opportunities due to long delivery times, product warranty and liability costs, and intellectual property losses.

Each input includes a brief explanation for how to assign a value for it. If OEMs don’t trust the “softer” variables, they can be excluded from the analysis or considered separately. If the parts will be supplied for a number of years, OEMs can enter estimates for wage inflation and currency appreciation to see how that affects the bottom line over the long term. Once all the variables have been entered, the spreadsheet outputs tables and graphs comparing the total cost of ownership of the domestic part vs. the offshored part over the life of the contract. “Let’s say a part made in the U.S. costs $100 and the same part made in China April 2011

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BRINGING IT ALL BACK HOME The Total Costs of Offshoring Inputs

U.S.

China

Unit price

$100

$70

Common to Both

Units per year

12,000

Part category

Part

Unit weight

2 lbs

Unit weight, packaging

0.1 lb

0.2 lb

52

6

100%

90%

Shipments per year Percent of shipment planned for surface freight Product life Supplier relationship life Packaging, percent of price Lag from shipment date to actual payment date Shipment time

Explanation

Part category determines duty percentage.

Offshored parts typically weigh more, because packaging for export is more complex.

The remaining percentage is airfreighted. 5 years

Time until product is obsolete or revised.

5 years

5 years

Estimated time from first purchase until last.

1%

2%

Packaging for offshored parts typically costs more.

2 months

0

Asian suppliers are often paid prior to shipment.

0.04 month

1 month

Annual carrying cost, in transit, percent of price

8%

Probably cost of capital.

Annual carrying cost, in warehouse, percent of price

22%

Most articles suggest 25%.

Percent of shipments that can be delivered just in time

100%

Cost to store and retrieve parts from warehouse, percent of price

0

Offshored shipments are typically larger and must be locally warehoused. 2%

Locally warehoused parts must be stored and retrieved before delivery to the factory.

This excerpt from the Reshoring Initiative’s Total Cost of Ownership spreadsheet shows some of the variables to consider when deciding whether to source parts domestically or offshore. (The figures are examples.) Other variables included in the spreadsheet include expedited freight costs, liability costs, intellectual property risk and travel costs. (Source: The Reshoring Initiative)

costs $70, a difference of $30,” says Moser. “When you look at the total cost of ownership, the price is $108 for the U.S. part and $97 for the Chinese part. Now the difference is $11, and at that point, a supply chain manager may think outsourcing the part isn’t worth the trouble. However, if you look forward at the projected price increases over time, the price of the U.S. part barely changes, while the price of the Chinese part increases. In five years, the price of the Chinese part is actually $10 higher than the U.S. part.”

THE NEXT STEP After spending more than a year preach18

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ing the gospel of reshoring, the next step for Moser is to set up regional reshoring events that bring OEMs and domestic contract manufacturers together to consummate business relationships. Moser has already begun the process in Illinois. Working with industry associations and local government agencies, Moser is organizing a series of conferences dubbed the Illinois Reshoring Initiative. The first conference, aimed at OEMs, was held March 16 at Harper College in Palatine, IL. The goal of the conference was to educate OEMs about the true costs of offshoring and the advantages of working with domestic suppli-

ers. The second conference, aimed at suppliers, will be held in July. The goal of that meeting is to teach suppliers how best to meet the needs of OEMs. Finally, in September, the Initiative will hold a purchasing fair that enables OEMs to meet and evaluate numerous local suppliers in one day. “Our hope is that these reshoring events will result in a measurable number of jobs being brought back,” says Moser. For more information on the Reshoring Initiative or to download a free copy of the total cost of ownership spreadsheet, e-mail [email protected] or visit www.reshorenow.org.

April 2011

A permanent affair. Visit our new website www.evonik.com/adhesives-sealants our booth Visit us at C 2011 at the AS nvention Spring Co and EXPO

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Evonik Industries is one of the major suppliers to the adhesives industry. Based on various chemical platforms we offer products which enable adhesive manufacturers to enhance

For further information please visit our website or send an e-mail to: [email protected] www.evonik.com/adhesives-sealants

Industry professionals are gearing up for the ASC’s 2011 Spring Convention & Expo, which will take place April 17-19 in Tampa, FL.

ndustry professionals are gearing up for the Adhesive and Sealant Council’s (ASC) 2011 Spring Convention & Expo, which will take place April 17-19 at the Tampa Marriott Waterside Hotel and Marina in Tampa, FL. More than 450 visitors from a variety of sectors are expected to attend, and this year’s program has several exciting events in store.

I

HEAR FROM THE EXPERTS Three designated keynote speakers make up a major highlight of the program schedule. Each speaker will bring a valuable perspective to the overall conversation about hot topics and trends for the adhesives and sealants industry. During the opening general session breakfast on Monday, April 18, Clearview Economics President Ken Mayland will present an overview of the predicted economic recovery in 2011. In addition, CocaCola will be represented at the ASC Conference for the first time by Maury Zimring, Corporate Responsibility and Sustainability manager. Coca-Cola’s 20

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agenda for sustainable packaging will be the discussion topic for the general session breakfast on Tuesday. Finally, David Crowe, Ph.D., chief economist and senior vice president of the National Association of Home Builders (NAHB), will discuss the economic forecast for the housing industry—one of the major market sectors for any manufacturer or supplier of adhesives and sealants. “Connecting industry professionals with experts who can shed light on the economic conditions and leading market segment indicators is essential,” says Glenn Frommer, ASC chairman and president of ADCO Products Inc.

DISCOVER THE LATEST NEWS AND TECHNOLOGY Another notable aspect of the ASC Spring Convention will be the industrycentered educational sessions. “For the spring convention, the ASC Program Committee wanted to build on the success of a revamped educational program that was introduced last fall,” explains Matt Croson, ASC’s president. “Many

of the educational sessions have a customer-centric focus to incorporate the entire supply chain.” Meaningful and informative sessions—45 in all—will be split into morning and afternoon segments. These segments will be further divided into three topical education tracks: Business Development, Te c h n i c a l a n d G o v e r n m e n t Regulations, and New Technology and Application. “Responding to industry needs, a large focus on raw materials will be offered,” says Croson. “ASC is bringing in raw materials experts to analyze and report on trends since raw materials, availability, pricing, etc. are hot topics for ASC members and the industry at large these days.” Specific topics covered during the educational sessions will include formulation, safety, research, wind energy, building and construction, small business, international markets, and more. The Hot Melts Short Course will be offered as part of the educational program again this year. Chemists, engineers, and marketing and sales professionals will all benefit from this two-day course, which will focus on hot-melt adhesive development, handling, and performance. Attendees will learn how to devise a suitable hot-melt formula to meet specific customer needs, and the course will be taught by experts in a range of relevant market sectors, including electronics, packaging, and automotive. April 2011

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Extensive selection of standard and specialty MDI Isocyanates Globally available product line with a local focus Formulation and technical assistance Ability to provide a custom product Quick access to material samples

So if you are working on the next industry-changing product or are just looking to set yourself apart, make sure you call Huntsman today.

See us at ASC booth 412. Tel: (800) 553-8624 x 7431, (248) 322-7431, E-mail: [email protected]

www.huntsman.com/pu/ace

NETWORK AND LEARN NETWORK WITH OTHER PROFESSIONALS The ASC Expo will provide an outstanding networking opportunity from 4-7 p.m. on Monday, April 18. Definitive “expo-only” hours will increase traffic and allow attendees a better chance of interaction. “The ASC Expo has already sold out, which is an extremely positive economic indicator,” says Croson. “Exhibitors are excited to showcase their latest products and innovations.” Some of the premier suppliers, distributors and manufacturers in the industry will be present for the event. An Exhibitor Appreciation Reception will be held during the Expo hours, and attendees will have a chance to win prizes; PoGo printer bundles, digital cameras, Apple iPods and Amazon Kindles will all be raffled off. Additional networking opportunities during ASC’s Spring Convention & Expo will include the opening and closing receptions, as well as a handful of special interest and committee meetings. The spring golf outing, which will be open to a limited number of registrants, will take place at Innisbrook Resort on Sunday, April 17. For additional details, visit www.ascouncil.org.

GPM Mercaptan Hardeners UÊ-«icialtyÊCustomÊ li˜ds UÊCuriÊTimisÊfromÊ{0Ê-ico˜dsÊtœÊ30ÊMi˜utis UÊowÊ œœÀÊEÊ"`œr UÊ/…iÊ"Àˆ}ˆ˜>Ê-œÕÀViʜvÊiÀV>«Ì>˜Ê>À`i˜iÀà UʏoL>ÊAvailability Contact us for more information, a product sample, or the name of your U.S. and global distributor/agent.

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22ASI04114Gabriel.indd | www.adhesivesmag.com 1

April 2011

3/14/11 10:11 AM

We dne sd a y, Ma y 4 8:30am – 3:30pm EDT

! E E R F Event Sponsors:

An educational virtual event covering trends in manufacturing from design to delivery.

SHOW DIRECTORY R E G I ST E R f or F REE T OD AY: www.TechManufactureXPO.com Questions? [email protected] • FAQs www.bnpevents.com/vts.htm Are you limited by time and budget constraints but hungry to hear from industry experts, view product demonstrations, take home whitepapers and case studies, network with peers and visit multiple suppliers all in one trip? We have the solution! On May 4, right from the comfort of your desk, you’ll be able do all this and more at Tech ManufactureXPO, THE virtual event for the manufacturing industry, bringing you trends in manufacturing from design to delivery. The team has been working hard and is pleased to announce that all educational sessions will be FREE to registrants.

What is a virtual event? A virtual event is a gathering of people sharing a common environment online to create an interactive experience similar to a conventional trade show. As an attendee, you can interact with booth personnel, network with peers, watch equipment video demonstrations and webinars and download product catalogs or other technical documents into your virtual trade show bag, just as you would at a conventional trade show. Since virtual trade shows can be attended by your entire team and be viewed from a single computer screen, cost of travel, lodging and time away from the office issues are essentially eliminated.

Media Sponsors:

LIVE webinars will be taking place all day in the Auditorium. After each webinar, you’ll be able to participate in an Ask the Expert chat with the presenter/s. A special Lunch-n-Learn session on Trends in Green Manufacturing will take place from 12:30-1pm ET in the Networking Lounge. All sessions are included with your FREE registration. 9:00- 9:45am ET Keynote Reshoring: A key to lower costs, more sales and a stronger economy Harry Moser, Founder and President of The Reshoring Initiative The Reshoring Initiative helps quantify the benefits of sourcing in the United States instead of offshore. To help companies make better sourcing decisions the Initiative, www.reshorenow.org, provides: software to calculate the real impact of offshoring on a manufacturer’s P&L, linked NTMA/PMA Purchasing Fairs to help companies find competitive U.S. sources, publicity to drive the reshoring trend, an online Library of 98 articles about successful reshorings and a 5-step process for focused regional reshoring programs. Benefits of attending include: 1. Free Total Cost of Ownership (TCO) software 2. Customers: learn how and why to calculate TCO 3. Suppliers: learn how to sell the benefits of local sourcing. SPONSORED BY

9:45-10:00am ET Ask the Expert: Harry Moser 10:00- 10:45am ET Automation: It’s not just for high volumes anymore Kurt Greissinger, Industry Manager- Assembly & Handling Kurt Greissinger, Industry Manager for Assembly Products at Bosch Rexroth, takes on some common myths about automation and lean, and uses a variety of examples drawn from real-world applications to prove that automation makes a vital contribution to lean manufacturing solutions. At a time when companies are tearing out conveyor systems in the name of lean, he will describe the roles automation can play and the benefits it offers across multiple applications. Through this webinar, engineers and systems designers will gain new insight into the nuances of human interaction with automation and key ergonomic considerations in automated and semi-automated processes. • The Role of Automation in a Lean Manufacturing Environment • Humans vs. Robots • Ergonomic Considerations for Assembly • Considerations for Manual vs. Automated Tasks

10:45-11:00am ET Ask the Expert: Kurt Greissinger 11:15- 12:00pm ET TBA Educational Topic 12:00-12:15pm ET Ask the Expert 12:30- 1:00pm ET Lunch-n-Learn: Trends in Green Manufacturing Manufacturers are increasingly looking at their operations with an eye toward sustainability. In this interactive session, manufacturing professionals can chat live with the editors of ASSEMBLY, Quality, Adhesives & Sealants Industry, CircuiTree and World Trade 100 about the latest trends in green manufacturing. Manufacturing professionals will learn about the latest ideas in environmentally friendly materials, design for the environment, landfill-free manufacturing, supply chain management and other topics. It’s also an opportunity for you to share what your company is doing to become more sustainable. No matter what your industry or company size, you won’t want to miss this session. 1:15- 2:00pm ET Lowering the Total Installed Cost of Assemblies in Today’s Manufacturing Environment Michael Poth, Director of Global Marketing, Stanley Assembly Technologies Emhart Teknologies delivers engineered fasteners and systems that provide solutions to an array of extremely complex fastening challenges customers face today. Through optimal engineering and design the webinar will show you how the Emhart Family of companies use varied techniques to lower the total installed costs of assemblies. 2:00- 2:15pm ET Ask the Expert: Michael Poth 2:30- 3:15pm ET Reverse Engineering Featuring Paul Jr. Designs Julius Ndulue, Applications Engineer, FARO Paul Jr. & Vinnie – Paul Jr. Designs The purpose of this webinar is to demonstrate how to use a portable coordinate measuring machine (CMM) for the reverse engineering of parts. Paul Jr. and Vinnie of Paul Jr. Designs will be sharing their experiences using a CMM and how it has improved their reverse engineering processes. 3:15- 3:30pm ET Ask the Expert: Julius Ndulue, Paul Jr. & Vinnie

Register For Free Today!

podcasts Listen to these 15-minute How-To Podcasts On-Demand all day!

Lean in Assembly Operations Lean expert Dan Fleming is Continuous Improvement Manager with the Greater Boston Manufacturing Partnership, a non-profit consultancy that helps businesses become more productive and competitive through lean practices. In this podcast, part of the popular Bosch Rexroth Lean Manufacturing Series, he discusses how, contrary to popular perception, automation technology and lean practices actually work well together in assembly operations. Dan explains that any assembly operation -- manual, semi-automated or fully automated -- can be wasteful and inefficient if poorly designed. He shows how lean can be designed into automation systems, to make them effective components of a fully lean manufacturing operation.

Selecting the Right Meter-Mix Dispensing Equipment Many factors need to be considered before the right meter-mix dispensing system can be selected for your adheisve or selant dispensing application. Sealant Equipment ensures the right machine is assembled by offering all eight (8) metering principles and selects the right model to match the process and application of material. We work with the customer and their suppliers to ensure the right components are selected for precision performance, quality products and lowest return on investment for the life of the system.

Testing Advances for 2011 This podcast will focus on applications in the medical device and automotive industries. They will demonstrate how state of the art technology in leak testing and functional testing help global manucturers improve quality and reduce costs to exceed customer expectations.

Measure Your Entire Process

Measurement, inspection and verifying that both parts and machine tools meet spec is critical to delivering product quality. Performing such tasks over long distances and with large parts is the done most effectively and accurately with a laser tracker and a variety of targets that expand a laser tracker’s capability. Measuring the machine tools that manufacture those parts is a critical aspect of ensuring part quality too, and not every technology supplier takes you through the whole process. Automated Precision Inc. will address the fundamentals of sound measurement and inspection, from the time you install your machine tool to before you cut the first part until you complete final assembly; and how laser-based, noncontact, optical inspection makes it all possible.

www.TechManufactureXPO.com

Product Reviews Get a sneak peek at products featured in the show!

I-360™ 2011

The Avinut™ Insert from Avdel®

Automated Precision Inc. now brings industry the I-360™ 2011 model. The newest iteration of both the wireless and the probe/scanning versions of the I-360™ have all the great features you need, while implementing a sleeker, more user-friendly design. The streamlined silhouette is easy to use, and more comfortable to hold. In addition, the new red color helps operators easily locate their I-360™ 2011 whether using it on the shop floor or in the field.

The Avinut™ Insert from Avdel® is a rapidly installed threadless insert utilising Speed Fastening® technology that mates with thread forming screws providing robust, reliable joints. Avinut™ is ideal for applications prone to screw cross-threading or painted assemblies because threads are formed by the screw, eliminating the need for costly secondary operations like thread masking for excess paint.

Automated Precision Inc. 15000 Johns Hopkins Drive Rockville, MD 20850 (240) 268-0400, [email protected] www.apisensor.com

Contact: Infastech™ Marketing Tel: 704 888 7039 E-mail: [email protected]

EcoShape: The Next Dimension in Tubular Framing

FARO Edge

Get the new shape of lean with Rexroth EcoShape Tubular Framing. Simple, versatile and efficient, EcoShape framing makes it easy to build custom workstations, material shuttles or flow racks. Create new solutions or extend existing ones using EcoShape’s advanced connection technology and full range of connectors.

As the industry leader, FARO once again raises the bar in portable measurement with the revolutionary FARO Edge – the most advanced state-of-the-art FaroArm® ever introduced.

www.boschrexroth-us.com/lean

The FARO Edge’s industry-leading features make it the ideal tool for companies constrained by the limitations of fixed CMMs and lesser portable measurement arms. www.faro.com

Promess PRO Monitoring The Promess Mini-PRO Monitoring System is a stand alone process monitoring and test device. It is powerful yet simple to use making it perfect for monitoring assembly applications. The Mini-PRO system allows for the connection of a large range of sensors to monitor a variety of processes some of which include force, distance, torque, current, pressure, flow, etc. Promess Inc www.promessinc.com 810-229-9334

New Pneumatic Nutsetters offer improved Accuracy and Ergonomics The new AA series nutsetters from Stanley offer increased productivity in a new ergonomic and modular package. With a new clutch shut-off system, the AA series offers improved tightening accuracy from 4.5 to 118 Nm in multiple configurations while sharing heads and gearing with the QPM line of DC tooling. Schedule a demo today. For more Information call (877) 709-8007 or e-mail [email protected]

Exhibitor Directory

Chat with reps and experts LIVE during the show on May 4 from 8:30-3:30 p.m. EDT in the Exhibit Hall.

Custom Automated Test & Assembly Equipment www.automationtool.com Experience innovative measurement solutions from API with products such as laser trackers and accessories, measurement arms, and machine tool calibration products. www.apisensor.com O-ring, Seal, and Retaining Ring Installation Machines / Pad Printing Equipment www.asporing.com, www.padmark.com Visit our virtual booth to see all of our latest Robotic End-Effector products and developments. www.ati-ia.com www.infastech.com One of the world’s leading sensor manufacturers, providing innovative and practical sensing solutions for a wide range of applications and industries. www.balluff.com Radial riveting, Orbital riveting, press assembly equipment. Single station, semi-automated and automated workcells. www.baltecorporation.com The Drive and Control Company. World-class drive, motion and control technologies to power today’s most advanced manufacturing systems. www.boschrexroth-us.com Customized Automated Assembly and In-line Testing Machines for High-Volume Production www.bucci-industries.us COX is the leading manufacturer of quality caulk guns and epoxy applicators offering manual, pneumatic and battery powered variants. Made in the USA & UK! www.cox-applicators.com Affordable, scalable software solutions for calibration management, preventative maintenance and supplier QA. www.cybermetrics.com DELTA REGIS Tools Inc.

Delta Regis Tools, Inc. has been steadily growing for the last 15 years with a focus on Customer Service, Quality and Value. www.deltaregis.com Automatic Screw Feeding and Driving Systems www.designtoolinc.com FARO develops portable computer-aided coordinate measurement and imaging devices and software. www.faro.com Software that Enables Effortless Quality Management www.intelex.com World Leader in Test Technology www.intertechdevelopment.com New product presentation and introduction of the USA item distributors www.item24.com/en Logistick provides a variety of one-way, disposable freight securing devices for use in the transportation industry. www.logistick.com The Application Experts www.mahr.com www.motoman.com Origin/laser gauge logo LaserGauge: flexible, handheld laser-profiling system used for dimensional measurements and inspections. www.origintech.com A leading U.S. manufacturer of highly adaptive monitoring and motion control systems used around the world to assemble and test products. www.promessinc.com Your partner for Toolholding, Workholding and Automation Components www.us.schunk.com Dispensing Systems for Bonding, Sealing, Potting, Encapsulation, Casting, Gasketing, Lubrication and more. www.sealantequipment.com Automatic Ink Code-Marking Machinery for date, product, lot and spot ink marking impressions on a wide variety of surfaces. www.sprintermarking.com Complete product selection guides, information and specifications. www.emhartamericas.com A worldwide leader developing Inspiring Automation. www.weissna.com

w w w.Te c h M a n u f a c t u r e X P O . c o m

Dual-shaft mixer with three-wing anchor and rotor/stator.

A Closer Look at Multi-Shaft Mixers Multi-shaft mixers are often necessary when a product requires enhanced processing capabilities. By Christine Banaszek, Application Engineer, Charles Ross & Son Company any

enerally speaking, the bonding agent of an adhesive comprises the bulk of its solid portion, while the solvent is only a carrier that provides an easy method of application. Therefore, formulations with a higher solids percentage typically contain more usable adhesive per gallon of finished product. Many adhesive slurries, cements and pastes are high-solid, viscous formulations that cannot be processed using propellers, turbines, saw-tooth-type dispersers or rotor/stator mixers by themselves. These single-shaft devices face a comdev mon limitation— viscosity. When batch vi viscosity rises, localvi ized heating can occur in the area suro rounding the blade ro as product turnover starts start to slow down. Meanwhile, materials close to the vessel walls wall become stagnant and do not benefit from the agitation in the vesag sel. Eventually, losses from fro inefficiency, prolonged batch times or lon poor poo product quality become too significant to ignore. If any of these mixa ing problems occur i in i your process, it is Dual-shaft mixer time to t consider upgradwith three-wing anchor and ing to a multi-shaft mixer. multiple saw-tooth disperser blades.

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MULTI-SHAFT MIXERS Multi-shaft mixers rs comprise two or more inde independently driven agitators working in tandem. A low-speed anchor complements one or two high-shear devices. On its own, a saw-tooth disperser blade will produce acceptable flow patterns for products up to around 50,000 centipoise (cP); a rotor/stator’s recommended viscosity limit is even lower, around 10,000-20,000 cP. Thus, there is a need for a supplementary agitator to improve bulk flow and deliver viscous product to the high-shear devices. The addition of an anchor agitator allows a multi-shaft mixer to process formulations that are several hundred thousand centipoise. The most common low-speed anchor designs have two or three wings. For added efficiency—especially in terms of axial flow—the anchor can be modified to feature helical flights in between adjacent wings, or the vertical wings can be entirely replaced with helical ribbons supported from the top and bottom. The anchor provides a means for agitating product near the vessel surface. The horizontal and vertical wings are designed to run at close proximity to the vessel walls. This, in itself, helps to constantly remove product from the sidewalls and bottom so that fresh material can fill those areas. However, as shown in Figure 1 (p. 30), the use of scrapers, which actually contact the vessel surfaces, significantly increases heat transfer efficiency (especially in cooling operations). Aside from the improved capability of multi-shaft mixers over single-shaft devices from a viscosity and heat transfer standpoint, another design advantage is that they are closed systems and can offer benefits in vacuum mixing. When processed under vacuum, certain adhesives and sealants develop higher densities and achieve better tensile properties as a result of improved shearing and contact of the different components. With other adhesive formulations, vacuum mixing keeps entrapped oxygen to a minimum, which ensures longer shelflife and improved stability. April 2011

Agitation system of a multi-shaft mixer featuring a three-wing anchor with helical flights and Teflon scrapers, as well as a saw-tooth disperser with slinger to prevent batch material from climbing up the highspeed shaft.

A 600-gal Ross Multi-Shaft VersaMix/Reactor used for the production of polyurethane thermoset resins. This reactor is equipped with PLC-based automated controls and recipe system.

Mixing under vacuum also eliminates unwanted air voids that can be produced through agitation under atmospheric conditions. Pulling vacuum during mixing eliminates costly downstream de-aeration steps and shaves overall processing time. It is fairly common for multi-shaft mixers to function as specialized reactors. In many cases, the efficiency of mechanical mixing has a decided influence on percent yield and end product properties. Multi-shaft mixers are effective in this aspect because the reactants are constantly kept homogenous, and the reaction environment can be carefully controlled for temperature, level, pressure, etc. To illustrate, let’s look at a case of a one-part urethane sealant formulation that begins with isocyanates and polyether polyols. A company developing such a product used a laboratory reactor to produce the prepolymer for the sealant and used a separate bench-top mixer to prepare the final product. When the time came to scale up for commercial batches, the company’s engineers began looking into glass and steel production reactors. While comparing costs and performance, it occurred to them that a reactor (whether it is a tank, tube or kettle) does not perform any function other than containing the reaction. Using a 300-gal Ross VersaMix Multi-Shaft Mixer that they already had on site, the company prepared a prepolymer in fewer than two hours. The necessary fillers, plasticizers, thixotropes and adhesion promoters were then added and mixed under deep vacuum. Samples of the sealant tested well, and a production routine was established. The current total cycle time is under four hours, half of which is allocated to polymer preparation and the other half to mixing. One shift is capable of producing 900 gal of sealant. To confirm whether a multi-shaft mixer suits your application, it would be worth taking a close look at the following key design elements. April 2011

MIXER CONFIGURATION Since multi-shaft mixers can comprise two or more independently driven agitators, one of the first things to determine is the configuration that will serve your process the best. Below are some common combinations and sample applications. Dual-Shaft Mixer Equipped with Two-Wing Anchor and Saw-Tooth Disperser Dual-shaft mixers are typically used for straightforward dispersion requirements. It is the most economical multi-shaft mixer configuration. The saw-tooth disperser blade enables fast powder wet-out and dispersion, while the two-wing anchor supplies a steady exchange of materials from different parts of the vessel, essentially “feeding” the high-speed blade. Sample applications include glue stick hot melts, pressure-sensitive adhesives, RTV silicon compounds and woodworking adhesives. Dual-Shaft Mixer Equipped with Three-Wing Anchor and Saw-Tooth Disperser This configuration is typically more customizable. For instance, provisions can be made for the future addition of a third agitator. The three-wing anchor is also better able to accommodate helical flights than a two-wing anchor. Dual- or Triple-Shaft Mixer Equipped with Three-Wing Anchor and Multiple Saw-Tooth Disperser Blades In this configuration, the disperser shaft is equipped with two blades: the bottom blade is fixed at the lowest point of the shaft, and the other blade (of equal or smaller diameter) is usually adjustable along the length of the shaft. This supplementary upper blade helps create a more powerful vortex to quickly draw large amounts of solid ingredients into the liquid phase. It is typically positioned one blade diameter below the liquid surface. Adhesives & Sealants Industry

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Series 540 Sealant Tester

A CLOSER LOOK

Computer Controlled Test Frame

• Designed to perform reliable cyclic testing of sealants, adhesives, and coating to various specifications. • Ask about the optional heat/cool chamber with control system! • PC with Windows ™ based software.

Figure 1. Comparison of Heating and Cooling Times screen shot of software

Applied Testing Systems, Inc. has been supplying quality test equipment for the industry for more than 40 years. Call one of our sales engineers today to set up your custom model or to request a catalog.

(724) 283-1212 www.atspa.com [email protected]

Series 510 and 520 horizontal sealant testers also available!

ASI12064Applied.indd 1

10/24/06 9:52:42 AM Figure

2. Improved Dispersion and Color Development in a TripleShaft Mixer with Three-Wing Anchor, Saw-Tooth Disperser and Rotor/Stator (right), vs. in a Dual-Shaft Mixer with Two-Wing Anchor and Saw-Tooth Disperser (left)

For a more demanding process, a second disperser shaft may be added; thus, the mixer can use a total of four disperser blades. Typical applications include highly filled formulations such as soy-based adhesives, cement pastes, urethane sealants and other caulking compounds. Triple-Shaft Mixer Equipped with Three-Wing Anchor, Saw-Tooth Disperser and Rotor/Stator This configuration is popular in the processing of adhesive and sealant formulations when droplet size or particle size distribution is critical. Using a high-speed, saw-tooth blade to incorporate powders into liquid results in acceptable levels of dispersion, but applying a more shear-intensive device such as a rotor/stator mixer typically promotes a finer and more uniform particle size distribution (see Figure 2). The same holds true for formulations involving two or more immiscible liquids; a high-shear rotor/stator achieves a more stable emulsion due to the formation of smaller droplets. Sample applications include polybutene/water emulsions and pigmented epoxies, as well as rubber cements in which the rotor/stator mixer quickly reduces the size of rubber particles (which in turn accelerates the dissolution process). Dual-Shaft Mixer Equipped with Three-Wing Anchor and Rotor/Stator Emulsion adhesives, polyvinyl alcohol solutions and other intermediates with low solids content are commonly batched using this dual30

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shaft mixer configuration. A candidate formulation may be one that could be processed using a stand-alone rotor/stator but would benefit from improved temperature control or processing under vacuum. The impact could be as dramatic as cutting processing time in half, especially if a cooling cycle is involved.

SEAL ARRANGEMENTS Unlike mixers with bottom-entering agitators, multi-shaft mixers have no bearings or agitator shaft seals submerged in the product zone, which inherently protects against contamination. A variety of shaft seal designs are available, from cost-effective lip seals to cartridge-type mechanical seals. Lip seals are simple, durable and sufficient for many moderate-duty industrial mixing applications. Mechanical seals utilize specially designed precision sealing faces that run against each other to maintain a seal. They typically provide a longer service life than lip seals and do not wear against the surface of the agitator shaft itself. The agitator shafts of vacuum-capable mixers are often sealed at the cover with single mechanical seals. These seals and the shaft bearings are to be lubricated with a low-viscosity, low-density lubricating fluid. When processing solvent-based adhesives and sealants, it is important to check that the lubricant and elastomers on the seals are compatible with all the solvents present in the formulations. Hightemperature applications such as those requiring prolonged heating of the mixer to 300°F or higher benefit from double mechanical seals, which offer better temperature control and lubrication than single mechanical seals. Sensitive formulations like medical-grade adhesives require enhanced protection against contamination, which could be caused by leakage of the seal lubricant. Dry-running, gas-purged

double mechanical seals may be chosen for these applications. Typical barrier fluids used in gas seals include clean air, nitrogen and other inert gases.

CHANGE-CAN VS. FIXED-TANK DESIGN A change-can design allows semi-continuous operation through the use of multiple interchangeable vessels. The process can be broken down into mixing, discharging, cleaning and preparation. Thus, multiple vessels can be used to extend the production capacity of a single mixer. One vessel would be under the mixer while another would be in the discharge or clean-up stage, and still another would be the loading area being charged with raw materials for the next run. The fixed-tank design is more common on production multi-shaft mixers in the range of 500 gal or larger. The primary disadvantage to a change-can design on a very large mixer is that agitator lift mechanisms of this size add significantly to the mixer cost. Fixed-tank mixers feature hinged covers or large enough access ports to allow for maintenance or cleaning when required.

DISCHARGE MECHANISM After mixing, product can be discharged from a multi-shaft mixer is a variety of ways. The simplest method is to allow the product to flow by gravity through a discharge valve. When scrapers are included, the anchor agitator is typically run at low speeds to assist the flow and wipe product off the sidewalls. A flat-bottomed vessel will naturally retain a layer of material. When a more complete discharge is required, one can opt for a dished or conical bottom vessel. The anchor agitator in this case would be contoured to match the shape of the vessel.

Sine pumps - the ideal choice for high viscosity • Flow rates up to 400 gpm • Handles adhesives, sealants, caulks, mastics and thick coatings up to 10,000,000 cps • Transfers shear sensitive latex and starch with ease • Suction capability - over 80% vacuum

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April 2011

Watson-Marlow

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masosine.com 800-282-8823 Adhesives & Sealants Industry

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A CLOSER LOOK For products that are not very free-flowing, the application of air pressure to the headspace of the mixer may be necessary to help move the material out of the vessel and on to the next production operation. The mixer and vessel must be rated for the level of internal pressure required for this method of discharge. Another option available on change-can mixers is the platen-style discharge system for efficient transfer of viscous mixtures. With the mix vessel positioned beneath the discharge system, a platen is lowered hydraulically into the vessel. A specially fitted O-ring rides against the vessel wall, literally wiping it clean. Product is forced out through a valve in the bottom of the vessel or through a port on top of the platen. A discharge system eliminates wasted hours of scraping heavy or sticky materials from the vessel.

POWDER INDUCTION

An operator uses a SLIM hose and wand attachment to induct fumed silica from its original sack and into an adhesive product being batched on a multi-shaft mixer.

If the starting viscosity is fairly low, a powder induction system (available on some rotor/stator assemblies) could be of benefit. Specially designed rotors, such as the Ross Solids/Liquid Injection Manifold (SLIM), generate vacuum conditions strong enough to draw powders right into the high-shear zone within the stator. Powders that are difficult to wet out are introduced sublevel, dispersed instantly and do not get a chance to float on top of the batch or form agglomerates (fish eyes). This technique is very operator-friendly and helps to prevent lightweight powders from becoming airborne. Attaching a hose and wand device to the powder inlet of the SLIM allows the operator to simply draw powders straight from within the bulk container. Powders can also be loaded into a hopper and, as soon as the rotor reaches operating speed, the hopper valve is opened to allow the flow of solids into the shear-intense region within the rotor/stator assembly. Powders are quickly drawn into the batch via the powerful vacuum generated by the ported rotor (see Figure 3). Fumed silica, talc, calcium carbonate, titanium dioxide, carbon black, carboxymethyl cellulose, clay powders, flour, starches, gums, pectin and resins are materials commonly inducted through the SLIM system.

EASE OF CLEANING To improve mixer cleanability, consider: • A CIP-ready mixer with rotary spray nozzles • High polish on the product contact parts (150-grit or higher) • A “slinger” on the high-speed disperser shaft to combat Weissenberg Effect (the tendency of some viscoelastic fluids to flow in a direction normal to the direction of shear; manifested by behavior such as the climbing of a fluid up a rotating rod) • Flush-tank discharge valve

LIMITATIONS AND EVALUATION Mixers operating with multiple agitators are exceptionally versatile, but they still have limitations in their range of viscosity if one considers the entire spectrum of adhesives and sealants that are currently produced in the industry. The mixers’ versatility mainly results from their independently controlled drives. The agitators can be engaged in any combination and at any speed for any interval during the mixing cycle. Although this sounds complex, multi-shaft mixers are actually engineered to be comparatively simple, effective and economical. When the batch material becomes too viscous to flow freely to the agitators, shifting to a different style of mixer is recom-

See us at ASC booth 302. 32

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ASI01104Dynasol.indd 1

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Figure 3. Batch SLIM Mixer with Hopper Attachment

mended. For example, the anchor in a multi-shaft mixer may start carving a path through a highly viscous batch as agitation close to the axis of rotation becomes increasingly limited. In these situations, the logical design alternative is a system consisting of agitators that move through all the points in the batch. This is the forte of double planetary mixers and kneaders, which are both also widely used in the industry. Adhesives and sealants are characterized by properties that are largely process-dependent, and the mixing operation is at the heart of processing. Products with identical formulations that have been batched in different mixing systems can very easily result in dissimilar yield, quality and physical attributes. Process engineers are encouraged to exercise ample diligence in evaluating mixing solutions that best achieve their specific process objectives. A trusted manufacturer that offers long-term experience, rental and testing resources will make for a very strategic partner whether you are selecting a mixer for a new product, scaling up, correcting a mixing problem or optimizing an existing process. For more information, contact the author at Charles Ross & Son Company, P.O. Box 12308, Hauppauge, NY 11788 or phone (631) 234-0500.

April 2011

See us at ASC booths 201 & 203.

CONSULTING BY “DR. DAVE” Adhesives and Sealants-Technology, Applications and Markets

Dr. Dave Dunn writes the monthly “Questions and Answers” column in Adhesives & Sealants Industry magazine, and is a unique source of both technical and management consulting for the adhesives and sealants industry. Technical Consulting • Formulation advice • Sourcing information • New developments • Application development • Application troubleshooting • Problem solving Market Research • Opportunity analysis • Customer surveys • Mergers and acquisitions • New developments • Market analysis • Industry structure • Competitive intelligence • Key trends

Technology Focus • Anaerobics • Cyanoacrylates • Reactive acrylics • Epoxies • Hot melts • Gasketing Market Focus • Industrial • Automotive OEM • Automotive aftermarket • Medical • Construction Management Consulting Innovation can be planned and managed to meet the strategic goals of a company. We have concentrated on integrating the R&D functions of companies into their strategic plans and putting systems in place to continuously measure the effectiveness of investments in R&D.

About the principal… Dr. Dave Dunn is President of F.L.D. Enterprises, which is located near Akron, Ohio, USA. He is a former Vice President and Director of Loctite Corporation and has consulted for many adhesives and sealants manufacturers and users in both North America and Europe. He is the author of several books and many articles, including the recent book Adhesives and Sealants-Technology, Applications and Markets, published by Rapra Technology Ltd. (www.polymer-books.com). F.L.D. Enterprises Inc. 242 Trails End Aurora OH 44202 Tel. 330-562-2930 FAX 330-247-1690 e-mail [email protected] web site www.fldenterprises.com

Adhesives & Sealants Industry

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YOUR PROCESS Two pieces of process equipment are receiving attention in the industry. By Steve Jakubiak, Director of Engineering & Manufacturing, Aaron Process Equipment

ccording to a July 2010 Wall Street Journal report, U.S. firms are beginning to step up their spending again, particularly when it comes to equipment. They’re doing so cautiously, however, “as they … worry that the [nation’s economic] recovery could still stumble.” An August 2010 follow-up article in the newspaper declared, “Firms Spend More—Carefully.” The piece noted that purchases of equipment reached their “fastest pace since the late 1990s. But much of the spending is aimed at replacing older equipment after recession-related postponements or to improve efficiency—not to raise production or boost hiring.” Industries that require process equipment but are clinging to such a cautionary approach to business may still be able to increase production while improving their efficiency and relevance in today’s economy. In particular, two pieces of process equipment are bringing about the best of both worlds for manufacturers of products such as silicones, sealers, inks, adhesives, resins and more: the double-arm mixer extruder and the ribbon blender.

A

300-gal mixer extruder with TriMax gearbox.

DOUBLE-ARM MIXER EXTRUDER When cost is a driving factor, a double-arm mixer provides businesses with an economical solution to their process equipment needs. By answering the myriad challenges encountered in today’s industrial mixing applications, a double-arm mixer affords users significant value. Constructed of high-quality materials, double-arm mixers are engineered to provide decades of service with minimal maintenance. With less frequent replacement required and fewer dollars spent on upkeep and repairs, business owners enjoy even greater cost savings over the long-term life of the equipment. The financial benefits of a double-arm mixer continue to add up when the equipment’s compact, space-saving design is taken into consideration. As the 34

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NR ribbon blender.

April 2011

Los Angeles Times reported in January, “Propelled by … the age-old imperative to save a buck, companies [are] shift[ing] into smaller offices spaces.” In fact, since the 1970s, American corporations have downsized from about 600 sq ft to just slightly over 200 sq ft per employee. Those figures equate to a 150-250% reduction in corporate space per employed individual. The downscaling tendency hasn’t run its course yet. “The space allocation could hit a mere 50 square feet by 2015,” notes one workplace trend expert. Businesses that have embraced this downscaling trend will be drawn to the double-arm mixer’s compact, space-saving design. They’ll also appreciate how quietly it operates, even under full load, thereby lowering the likelihood of noise distraction. Of course, versatility cannot be overlooked when it comes to getting the most mileage out of one’s money. Double-arm mixers flexibly adapt to a variety of mechanical options and construction materials. In doing so, they enable the cost-effective configuration of a heavy-duty mixing machine. Business owners should not assume that a decrease in functionality and/or quality is the tradeoff for a double-arm mixer’s affordability. The triple output shaft of the MXT transmission eliminates the need for secondary and supplemental gear cases. The double-arm mixer also comes standard with a multitude of options. Unlike similar industrial mixing equipment, double-arm mixer extruders feature a product deflector in the bowl that helps relieve pressure against the auger packing gland. They are also capable of heating or cooling in a looped arrangement housed directly within the bowl’s chassis and the sidewalls of the mixer. As a result, pinpoint control over the mixing environment’s temperature is possible. The double-arm mixer’s auger screw affords an array of capabilities as well. Its bidirectional operation enables convenient alteration between mixing and discharging of the bowl contents. This functionality significantly reduces the time needed to sequence the mixer through a product cycle. The equipment also provides adaptability, with fixed speed, hydraulic variable speed and variable frequency drives for a variety of mix applications. April 2011

RIBBON BLENDER In addition to providing the same economic benefits, versatility, problem solving capabilities, high-quality construction, long-lasting durability and low maintenance as double-arm mixers, ribbon blenders also offer their own set of process equipment benefits. The agitator design provides excellent mixing efficiency to minimize product cycle time and blend product consistently and evenly. Heavyduty construction enables pro duct density of 75 lbs/cu ft to be processed with a standard drive configuration. As such, expensive enhancements are unnecessary for most process equipment applications. The mixer body and agitator are both constructed of a high-durability brushed stainless steel alloy that is resistant to chemical corrosion and mechanical fatigue. The cover can also be easily removed and replaced using quick-release clamps. In addition, both the cover and feed hatch feature gaskets that won’t harden over time. A safeguard proximity switch is added to the unit for customer wiring, and the drive assembly is completely enclosed for safety and durability. In addition, a discharge valve guard is provided on all ribbon mixers (with optional discharge valve mechanisms also available). Like double-arm mixers, ribbon blenders provide reliable, quiet operation. A high-quality TEFC motor drives a shaft-mounted torque arm reducer using V-belts and sheaves. Noise reduction stems from the heavy-duty, selfaligning support bearings, which provide smoother rotation of the agitator and drive assembly components. Ribbon blenders also share their construction material with double-arm mixers. The split design packing glands are constructed of stainless steel and can be supplied with a variety of packing materials to minimize leakage and offer ease of maintenance. Finally, the ribbon blender’s agitator discharges product through a bottom opening for easy use. The product flow is regulated by a manually operated knife-gate valve, so the user maintains complete control over the process. For more information, contact Aaron Process Equipment, 735 E. Green St., Bensenville, IL 60106; phone (630) 350-2200; fax (630) 350-9047: e-mail sjakubiak@ aaronprocess.com, or visit www.aaronprocess.com.

Automated Metering and Dispensing Technology Our core Competence ÷Metering and dispensing of epoxies, silicones and polyurethanes ÷Dispensing under normal conditions and vacuum aided potting ÷Automated production lines for automotive, electronics, medical, and power generation industry Atlanta, GA Office: Phone (770) 218-0835 www.scheugenpflug-usa.com sales.usa@scheugenpflug-usa.com

The horsepower of the disperser is related to the blade diameter and the anticipated load that the blade will create at a given speed and resistance.

Dispersers are used to rapidly break apart lumps of powdery material, uniformly distributing and wetting them into a liquid.

By Herman Hockmeyer, Hockmeyer Equipment Corp.

very year, new people join the various businesses that use mixing machines in their laboratories and manufacturing facilities. What seems obvious to many experienced personnel can be complicated and frustrating to these newcomers. The purpose of this guide is to present a fundamental explanation of the “what, how, when and why” about high-speed dispersers.

E

WHAT IS A DISPERSER? A disperser is a type of mixer that is used to rapidly break apart lumps of powdery material, uniformly distributing and wetting them in a liquid. It is also used to dissolve soluble solids in a liquid. Dispersers work on the principle of energy transfer. A disctype blade is mounted at the bottom end of the mixing shaft and rotated at a relatively high tip speed. (Tip speed is the speed at the outer tip or edge of the rotating disc. Tip speeds typical of dispersers are measured in feet per minute, calculated by multiplying the constant 3.14 times the diameter in feet of the disc times the revolutions per minute of the mixing shaft. The industry terminology for tip speed is peripheral velocity.) The solids and liquids are drawn into the rotating disc by the suction it creates. This suction usually results in a visible whirlpool from the top of the mixture down to the top of the disc. A similar whirlpool is created below the disc extending from the bottom of the tank to the underside of the disc. The whirlpools are actually two individual vortices, although common industry practice refers only to the visible upper one as the vortex. 36

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When the solid/liquid mixture enters the vortices and is sucked into the high-speed disc, the energy (horsepower used to drive the disc) is instantaneously transferred from the disc to the mixture. This intensively focused energy transfer creates tremendous and immediate velocity changes in the mixture as it progressively contacts the disc. Think of the mixture as a series of individual horizontal layers descending downward from the top and upward from the bottom on to the face of the rotating disc. As each layer comes into contact with the disc, it is instantaneously accelerated from the slow-moving vortex into the very high speed of the disc and projected outward away from the disc and toward the wall of the tank. The rapid tearing apart of layer upon layer of the mixture is shear force, commonly referred to as shear.

DISPERSER VS. AGITATOR Dispersers and agitators will both mix. Mixers are sometimes compared to pumps; the performance of a pump is usually measured in the horsepower required for its gallons per minute discharge capacity. A disperser is a high-powered, low-volume pump. Considering its substantially higher horsepower per gallon requirement, a disperser is an inefficient mixer. An agitator is a low-powered, high-volume pump; hence, it is an efficient mixer. A typical dispersion application (such as the dispersion of pigment to make paint) requires about 1 HP for every 10 gal. On the other hand, an agitator application, such as thinning the pigment dispersion with solvent, requires about 1 HP for every 100 gal. Although the April 2011

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HIGH-SPEED DISPERSION agitator is the more efficient pump, it does not create sufficient shear to disperse most solids into the liquids. Moderate-shear dispersers, which operate at about half the normal blade speed of high-shear dispersers, are sometimes used in place of agitators when some shear is required. The discs typically have larger teeth to promote better pumping and require about one-third of the horsepower of a high-shear disperser (but still three times more than an agitator). A disperser will generate the shear force necessary to rapidly de-lump powders in a liquid. This de-lumping process is called dispersion. The agitator is an efficient mixer, but it typically cannot generate sufficient shear to disperse powders, regardless of how long they are mixed. This is because the forces holding the agglomerates (lumps) together are stronger than the force of the mixer trying to pull them apart. Mixers can do an excellent job of holding dispersed (sheared) mixtures in suspension, but they typically cannot disperse (shear) the mixture.

DISPERSER LIMITATIONS The limitations of dispersers depend on product rheology. If the product being dispersed is too thick, it will not move freely to and from the blade from the wall of the tank. This could result in dead zones of undispersed materials in the tank. If the material is too thin, there may not be sufficient body to generate tearing between the layers of product as they consecutively contact the rotating disc. Tacky or “sticky” products may also hinder the ability of the blade to generate proper flow within the tank. Proper flow should resemble a doughnut, with the blade acting as the hole. Product should flow in a circumferential

A disc-type blade is mounted at the bottom end of the mixing shaft and rotated at a relatively high tip speed.

pattern around the tank wall while simultaneously rolling inward to contact the blade. This type of flow is sometimes referred to as a doughnut roll. If undispersed particles stick to the walls of the tank or the flow is insufficient to roll the entire dispersion into the blade, a thorough dispersion is unachievable. Without flow, there is no “go.” Adding supplementary agitation to help feed the disperser blade can extend the operating range of a disperser. This type of machine is typically called a dual- or triple-shaft mixer. It has both a shaft with a slow-moving sweeper blade that passes close to or scrapes the tank wall to promote mass flow, as well as one or more additional mixing shafts with disperser blades to generate high shear.

DISPERSER SELECTION Dispersers are available with single-, two- and variable-speed mixing shafts. Some are directly mounted on top of a tank and are fixed to operate with the blade in only the original mounting position. Other tank-mounted dispersers can raise and

See us at ASC booth 309.

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lower the blade by several feet (to better control the vortex) without exiting the tank. Another design, perhaps the most popular, places the disperser on top of a hydraulic lift (similar to those used at gas stations to lift automobiles) that is mounted to the floor. The lift enables the operator to raise the blade completely out of the mixing vessel and change to another vessel. This technique uses small portable tanks (up to 500 gal) that can be rolled away on wheels or picked up with a fork truck. Larger stationary tanks are often centered within the arc of rotation from the center of the hoist to the center of the mixing shaft. The bridge containing the mixing shaft at one end and the motor at the other is then rotated from one tank to the next. Choosing the best configuration of available designs is a combination of functional need and economic justification. An experienced process engineer or consultant familiar with dispersers is a good investment. The size of a disperser is generally thought of in terms of horsepower. However, some dispersers are dimensionally very large but use relatively small amounts of horsepower. (These are exceptions to the rule.) The horsepower of the disperser is related to the blade diameter and the anticipated load that the

blade will create at a given speed and resistance. The resistance is a function of the rheology of the dispersion, as well as its viscosity and density. As the blade diameter increases, however, the horsepower increases disproportionately. For example, if a 12 in. diameter blade were to draw 20 HP in a non-Newtonian system (viscosity changes with shear), doubling the blade diameter could increase the horsepower demand by a factor of five. That means a 24 in. diameter blade of the same design, working in the same product, would require 100 HP. The larger blade would also pump considerably more, so it would lend itself to working in a much larger tank (perhaps five times the volume) and producing a much greater amount of finished product in the same time period. Horsepower requirements are interrelated with blade diameter, tank diameter, batch size, rheology, viscosity and density. Variations outside recommended operating parameters usually result in compromises in performance such as poor particle separation, extended dispersion times and a decrease in quality of the finished product. The ideal tank for most dispersers is slightly taller than it is wide. Dished or bowl-shaped bottoms aid in preventing solids from accumulating in sharp corners associated with flat bottoms. Dished bottoms drain to the center, where a discharge valve can be installed. Flush bottom ball valves welded into the center of the dished bottoms further enhance the ease of discharge and cleaning.

DISPERSER BLADES The blade is sized based on the flow characteristics of the product and the desired degree of dispersion. The thicker

G

orman-Rupp positive displacement rotary gear pumps are versatile enough to handle virtually any liquid or pumping application. They are manufactured with unique features and flexible seal designs that enable them to perform better and last longer than other gear pumps.

X-465

April 2011

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HIGH-SPEED DISPERSION the product, the larger the blade diameter must be in comparison to the tank diameter. Conversely, the thinner the product, the smaller the blade diameter must be in comparison to the tank diameter. This comparison is called the blade-to-tank ratio. Thick products such as heavy, flowable pastes may require a ratio of .5:1. Moderate products like paint require a .33:1 ratio, and thin products like stains can work with

up to a .125:1 ratio. For example, if the blade-to-tank ratio is .33:1, and the tank diameter is 6 ft, the blade diameter would be 2 ft. Once the batch formula has been process optimized, the typical time required to reach maximum dispersion should range from 20-30 minutes after the last ingredients have been added. Longer times do not usually result in better dispersions; in some cases, they

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can be detrimental because of the higher batch temperatures generated by the high-shear disperser blade. As the blade begins to wear, increasingly longer batch times are required to get to the optimized dispersion standard. Sawtooth disperser blades should be replaced once the blade tips are worn to half their original height. High-shear disperser blades are available in a range of styles and sizes, and can be generally categorized into two groups: open saw tooth and ring type. Both categories work well when used under the proper operating conditions. The open saw tooth blade is the most popular because of its low cost, ease of cleaning and general utility. It is available in a range of tooth designs. As the teeth increase in size and become more aggressive in shape, the pumping ability of the blade increases. However, as pumping (turbulent flow) increases, shear decreases. A high-pumping saw blade still generates significant shear compared to a low-shear paddle blade agitator. This aspect is an important consideration when determining exactly what is to be achieved in the finished product. The ring-type blade is a powerful tool for optimizing disperser performance. It is more expensive to purchase and consumes more horsepower than the saw blade. It typically runs at higher tip speeds (5700+ fpm) and performs more like a rotor stator. Instead of solely depending on the face of the disc and the configuration of the saw tooth for shear and flow, much of the ring blade’s work is achieved hydraulically as centrifugal force presses the product between the contoured rings, which creates velocity differentials and a high-pressure zone. The product then instantaneously discharges into the lowpressure area outside the rings, creating a film-splitting Venturi effect. Additional heat is created as a by-product of the higher shear. In some cases, however, this higher shear level eliminates or greatly reduces any subsequent milling that may have previously been required.

ADDITIONAL CONSIDERATIONS Formulating for a disperser is an important part of reaching optimum dispersion. Optimizing a formula can sometimes rely on how and when ingredients are added, since basic recipe changes may not be acceptable. In most 40

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April 2011

instances, the rapid addition of about half the total amount of powders into the liquid vehicle is acceptable, although careful observation of each initial formula is prudent to ensure powders are not floating on top of the batch for more than a few seconds. Adding dry powders too rapidly can “choke” the blade and may result in an incomplete, unstable dispersion. The second half of the powders should be added progressively more slowly until the final percentage completes the formula. The blade speed should be adjustable from a minimum of half the final tip speed at the beginning of the powder addition to the maximum of the final tip speed as the batch thickens and flow slows. This procedure helps prevent splashing and overvortexing, which are inefficient for dispersion and can cause excessive air entrapment in the dispersion. Assuming the rules of tank size, horsepower, blade size, etc. have been followed, most dispersions are completed within 20-30 minutes after the last of the powders have been properly added. Continuing the dispersion process beyond that time is usually unproductive and can actually cause harm to some ingredients if the temperature continues to rise. Typically, dispersers perform best when the flow pattern is doughnut-shaped and the blade tips are traveling at about 5000 ft/min in a medium viscosity (1500 to 5000 centipoises). Lower tip speed may be acceptable at higher viscosities and higher tip speeds may be acceptable at lower viscosities to achieve the same shear rate and stress. Optimum performance requires the following criteria: • A clean tank

• Correct blade-to-tank ratio • Proper formulation • Suitable blade in good condition • Highest appropriate blade tip speed • Correct tank geometry (length compared to width) • Sufficient horsepower • Proper raw material addition technique • Proper rheology

SAFETY MEASURES The disperser is a very fast and powerful machine. Serious and fatal accidents can occur in a split second of carelessness. It is important that operators read the operation and safety instructions supplied by the manufacturer. If these instructions are not available, call the manufacturer and request additional copies. Be certain that all operators are properly trained on the disperser’s use and drilled on the potential dangers involved. Do not operate the machine unless all of the appropriate safety features are in place and functioning properly. On hoistmounted units that raise and lower the blade, these features include but are not limited to the mixing shaft guard, the tank holder with a limit switch, and a limit switch on the lift to prevent the machine from operating with the blade or shaft within reach of the operator. For additional information, contact Hockmeyer Equipment Corp. at 6 Kitty Hawk Lane, Elizabeth City, NC 27909; phone (252) 338-4705; fax (252) 338-6540; e-mail [email protected]; or visit www.hockmeyer.com.

See us at ASC booth 308. 26002 EPM_Kalama_ASI_outline-text.indd April 2011

ASI09094Emerald.indd 1

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8/6/09 2:28:49 Adhesives & Sealants Industry | PM41

8/11/09 9:04:16 AM

BLADEBASICS Dispersion blades are relatively inexpensive to replace and should be changed on a regular basis. By Tim DeLong, President, Quickblades Inc.

n these eco-conscious times, adhesives, sealants and coatings manufacturers are looking for ways to become more efficient and produce a smaller carbon footprint. A high-speed disperser is often used to disperse agglomerates into a liquid. If the agglomerates aren’t broken down to the desired size or grind, the product will be pumped over to a mill to finish off the process. This process has been the norm for many years; it takes time, but it works. What if the product could be finished in the high-speed disperser, however, and not have to go to a mill to be completed? Even if only one or two batches could be produced by the highspeed disperser, manufacturers would save time and electricity by skipping the milling process for these batches.

I

A NEW BLADE MAY BE THE ANSWER Using a new dispersion blade or a different style of blade can make the difference between long batch times and shorter, more efficient grind times. Several styles of blades are available to choose from, and not all batches require the same dispersion blade. When purchasing a new blade, ask questions about what style of blade should be used for your process. A different blade design might be more efficient and could possibly make a better product. Several guidelines can help determine the blade size required for a process: blades should be about one-third the diameter of the tank; standard dispersion blade tip speeds should be 42

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around 5,000 ft/min; and the disperser’s horsepower should be 1 HP per 10 gal of product. (These basic guidelines can be adjusted to your product line.) A dispersion blade should be replaced before it becomes worn or damaged. A blade that is damaged will be out of balance and could cause premature wear of the bearings and belts. A worn-out blade also takes longer to make your batch, thereby requiring more electricity and labor time.

BEST PRACTICES Check the teeth of a new impeller; the edges of a well-made dispersion blade look crisp, clean and squared off. These squared-off edges are designed to give the impeller the most efficient grind. Start a regimen of periodically checking the blade for signs of wear. As the blade begins to wear, the teeth start to round off. In time, the blade will eventually erode away until there are no teeth left. Such rounded corners decrease the effectiveness of the dispersion blade and precipitate the need for replacement. When installing a new impeller, run a standard batch of material and record the amps required to run the impeller. Check the amp draw of the machine in the same type of batch about once a week (or month, depending on the abrasiveness of your products). When a noticeable decrease in the amp draw for the same batch occurs, the impeller is losing its effectiveness and should be replaced. Every batch of material has a specific recipe that includes a dispersion time.

After installing a new impeller, check the batch several times during the dispersion phase and record how long it takes to bring the batch to spec. This recorded time is the guideline for how long it should take to make a batch properly. As the blade starts to wear, producing the desired results will take longer. The dispersion blade should be replaced when a proper dispersion can no longer be achieved in the expected amount of time.

BLADE OPTIMIZATION Dispersion blades are a relatively inexpensive replacement item and should be changed on a regular basis. Inspect the blade often for worn or damaged teeth, analyze the amp draw of similar batches of material on a periodic schedule, and check to make sure that batches are produced in the right amount of time. If the teeth are worn or damaged, the amps have dropped, or it is taking longer to make batches to spec, it is time change the blade. For more information, contact Quickblades Inc. at (877) 618-8304, fax (260) 359-2066, e-mail sales@ quickblades.net or visit www.quickblades.net.

April 2011

The Optimum Time to Sell Your Company By the latter part of 2011, middle-market deal pricing is expected to increase to above normal levels. By George Spilka, President, George Spilka and Associates

uring 2006 and the first half of 2007, the greatest market bubble in middle-market deal pricing in 50 years occurred; those pricing levels will probably not be seen again in our lifetime. During the second half of 2007 and the first half of 2008, deal pricing reverted to normal levels. However, as the business downturn started in the third quarter of 2008 and led to the Great Recession (my terminology for the period from the fourth quarter of 2008 to the start of the third quarter of 2009), deal pricing collapsed. In fact, 2009 was the first year the world economy contracted since the 1930s. While economic and market conditions were awful, they fortunately never deteriorated to the levels realized during the Great Depression. However, middle-market deals (transactions with values between $5 million and $250 million) were few; those deals that were completed were usually at deeply discounted prices. This pricing level continued until the start of the third quarter of 2010. At that time, deal activity and pricing started to improve.

D

CURRENT DEAL PRICING In early 2011, deal pricing began making strides to return to normal levels, and middle-market deal activity has greatly improved. However, many acquirers still believe they can “steal” companies, primarily due to the depressed earnings most April 2011

companies realized during the Great Recession. Many sellers are susceptible to accepting these discount prices, since the scars created by the Great Recession make them concerned they won’t be able to sell their companies. However, by the latter part of 2011, middle-market deal pricing is expected to increase to above normal levels. During 2011, as many acquirers use the depressed earnings realized by sellers during the two-year period ending June 30, 2010, as justification for a substandard offer, it is imperative for middle-market executives to understand that their company is a long-term asset whose sale price should not be impacted by short-term transient considerations. Furthermore, any serious acquirer does not anticipate earnings returning to 2009 and 2010 levels in the foreseeable future, or they would not be currently interested in buying companies. Middle-market executives must remember that the true and most significant determinant of a transaction price is a company’s expected future EBITDA/earnings (EBITDA) and the risk in achieving that EBITDA from the business foundation given an acquirer. This is an acquirer’s major consideration in determining a seller’s value. Any other factors they cite are merely used for negotiating leverage to justify an unwarranted discount price. Consequently, you should not entertain any discussions regarding your company’s earnings during the Adhesives & Sealants Industry

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THE OPTIMUM TIME TO SELL YOUR COMPANY two-year period ended June 30, 2010, as a factor in establishing a transaction price. They simply are not a consideration, and you should demand that they be treated accordingly.

SHORT-TERM DEAL PRICING Due to a number of factors, the optimum time to sell a company should be the latter part of 2011 or 2012. Most companies’ earnings began to show some strength

during the second half of 2010. Earnings should continue to grow in 2011 and increase at an even higher rate during 2012. In addition, 2013 should be a very good earnings year, supported by a healthy economy. These earnings levels make it possible to realize a premium price. During 2011 and 2012, the capital gains tax will remain at a reduced level of 15%, compared to the prior rate of 20%. It is unlikely that the 15% rate will be extended

Project Acceleration Resources for Sustainable Manufacturing

beyond 2012. This 5% tax savings on the realized gain is a significant consideration when determining the timing of a sale. Cheap money, which is a byproduct of the excessive credit provided by the Federal Reserve, should contribute to strong acquisition prices during this period, while still enabling the acquirer to have a solid return on invested capital. As 2011 begins, the majority of banks are loosening the credit spigots. By the latter part of 2011, the availability of credit should return to normal levels. In addition, acquirers began to aggressively pursue deals around the end of 2010. These factors mandate that an owner interested in selling his company within the next seven years should seriously consider selling it during the latter part of 2011 or 2012.

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Beginning in 2014, the intermediate and long-term economic outlook gets pretty murky. It is not inconceivable that the economy could stay strong during 2014 and 2015. However, a number of factors provide warning signals that trouble could be on the horizon that might potentially affect these and/ or possibly later years. These factors could negatively impact middle-market deal pricing and activity, possibly significantly. For example, the condition of the credit markets, especially in Europe, could be an intermediate to long-term financial problem. In addition, major issues are impacting the Chinese economy and banking system, including the Chinese Central Bank increasing the “benchmark” lending rate and the reserve requirements for the commercial banks in an attempt to reduce an increasing inflation rate. These factors could potentially have a negative impact on the Chinese economy. Since the Chinese economy is one of the most dynamic and important economies in the world, any negative impact will likely have global consequences. The political and economic instability in the world at this time could provide the basis to produce an event that would have wide-ranging repercussions. Many global “hot spots” could erupt at any time. The impact of any of these events could produce fear and tremendous instability in the financial markets. I am not saying that intermediate and long-term economic and market conditions will definitely be bad. However, I am advising clients that I strongly prefer to consummate the sale of their company in the latter half of 2011 or 2012 due to the substantial risks facing the economy and acquisition April 2011

de!

to

market in 2014 and subsequent years. The risk factor is too great to delay a sale until 2014 in light of all the positive reasons why a sale should take place before the end of 2012.

bla r u o y e g chan

‡ Specially Designed Blade allows for

OBTAINING A PREMIUM PRICE

high efficiency grinding or dispersion For a middle-market seller to obtain a premium-priced deal with terms that fully insulate them from post-closing liability, it is imperawhich saves you time and energy tive they find an investment banker/acquisition consultant (IB) that ‡ Using QuickBlades decreases has certain capabilities and characteristics. Sellers should look for a the need to use a mill number of traits in their investment banker. The IB should realize—and actually relish—the fact that a sale ‡ We offer Laboratory & Production is not a win-win situation. In reality, it is actually much closer to a blades with several designs to choose from win-lose situation. This type of IB recognizes that negotiations are a psychological war between disparate interests with conflicting goals. ‡ Same day shipping most cases The seller wants the maximum attainable premium price while the much larger, sophisticated acquirer—who normally gets their way in middle-market acquisitions—expects a discounted price. These diametrically opposite interests are almost guaranteed to result in a psychological battle where the better prepared, more determined party will prevail. The IB should have compassion and concern for their clients and realize that most acquirers will try to steal a seller’s company. The right IB will be steadfast and resolute, concerned only with protecting and maximizing your realistic interests. If an acquirer won’t optimize your interests, the right IB will not consummate a deal under lesser terms. In addition, IBs should have the aggressiveness, determination, toughness, and the market and financial knowledge to force their will on large corporate acquirers or sophisticated private equity firms. If those traits are not present in the investment banker, you can be assured that a premium price will not be yours. asi04112Quickblades.indd 1 The IB should have executive and business skills that transcend Engineered Dispensing Solutions! 3/7/11 financial skills to fully understand your company, its strengths, market niche and potential. They also must have the ability to present and Albion Engineering, a recognized leader in articulate these facts clearly and persuasively to an acquirer. If they the manufacturing of precision dispensing tools, are to prevail, the investment banker has to understand your comhas been on the leading edge of tool design for pany better than the acquirer and understand your industry at least as almost 80 years. well. This knowledge base will intimidate an acquirer and convince Don’t settle for anything less than the best. them that they must buy your company at a realistic premium price. In addition to offering technical support, our full Finally, IBs should have the patience and confidence to wait, if line of products come with an Albion warranty and our necessary, to obtain a premium-priced, all-cash deal. In certain situcommitment to professional quality tools. ations, they must be willing to allow the power of their knowledge and personality traits to have the time necessary to wear down the For more information visit us at our website or acquirer and get them to agree to the deal and terms that are essential request our catalog. to the maximization of your interests.

9:18 AM

POTENTIAL OPPORTUNITIES The 18-month period ending June 30, 2007, was the most lucrative time to sell a middle-market company in the past 50 years. However, due to a number of economic, tax, financial and market reasons, the latter part of 2011 and 2012 should present a great opportunity to sell a middle-market company at a premium price. If you are to realize the premium price you deserve, your IB must have the commitment to protect and maximize your interests, as well as the determination, toughness, and strength of will to force an acquirer to price your company on its expected future EBITDA and the quality of its business foundation. For more information, contact George Spilka and Associates at 4284 Route 8, Suite 301, Allison Park, PA 15101; phone (412) 486-8189; fax (412) 486-3697; e-mail spilka@ georgespilka.com; or visit www.georgespilka.com.

Albion Engineering. Solving your dispensing tool needs. ALBION Engineering Co. 1250 N. Church St. Moorestown, NJ 08057-1102 856-235-6688 FAX TOLL-FREE: 800-841-7132 (USA, Canada, Puerto Rico & US Virgin Islands) INTERNATIONAL FAX: 001-856-235-9460 E-MAIL: [email protected] www.albioneng.com

April 2011

Adhesives & Sealants Industry ASI06071Albion.indd 1

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WHAT’S NEW RAW MATERIALS MOMENTIVE SILICONE

As part of its portfolio of specialty silicones for the solar industry, this company has introduced a one-component silicone, TSE3822. The new specialty product can be used for the frame sealing of polycrystalline modules. TSE3822 can

reportedly provide strong, primer-less adhesion to a range of photovoltaic substrates, including aluminum, plastics and glass. Web: www.momentive.com

WACKER

alkylphenol ethoxylates (APEOs). Reportedly offering excellent technical properties and an outstanding price-performance ratio, the material can be used for hard-to-bond floor coverings such as linoleum and polyvinyl chloride. Web: www.wacker.com

BINDERS

VINNAPAS® EAF 68 is a new generation of high-performance binders made without

EQUIPMENT NORDSON CORP. SLOT APPLICATORS

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The new TCHP TrueCoat slot applicators can provide stripe or full coating application accuracy in continuous web coating processes. According to the company, streak-free coverage and edge control make the TCHP particularly beneficial for labeling and tape applications. The compact, configurable design is ideal for coating a variety of substrates, including papers, foils, films and nonwoven materials. Web: www.nordson.com

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This company offers three sizes of its V-Blenders from stock. The blenders are most often used for the dry blending of free-flowing solids. The solids being blended in these units can vary in bulk density and in percentage of the total mixture. Materials being blended are constantly being split and intermixed as the shell rotates. Normal cycle times are typically about 15 minutes, but can be shorter depending on the blending difficulty. Phone: (800) 243-ROSS Web: www.mixers.com

P R O D U C T & L I T E R AT U R E

Showcase Leading the Way in 2K New catalog from Nordson EFD offers the complete line of TAH systems for meter mix and cartridge applications for two-component adhesives, including mixers, cartridges, dispensers, and valves. For a free copy, visit www.nordsonefd.com/ads/asi-1010.

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s r

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April 2011

SERVICES MARKETPLACE P R I VAT E L A B E L I N G S E R V I C E S D I S T R I B U T I O N S E RV I C E S Heigl Technologies ...................................................................................... 48

L A B O R AT O R Y & T E S T I N G S E R V I C E S Chemsultants International Network ............................................................ 48

M A N U FA C T U R I N G & P R O C E S S I N G S E R V I C E S

Incredible VOC Compliant Adhesives and Sealants From Ruscoe

ChemLink.................................................................................................... 48 Polymeric Systems, Inc. ............................................................................... 48 Resin Lab .................................................................................................... 48

P R I VAT E L A B E L I N G S E R V I C E S The Ruscoe Company .................................................................................. 47 This index is a feature maintained for the convenience of the advertiser. It is not part of the advertiser’s contract, and ASI assumes no responsibility for its accuracy.

W have consistently upgraded our formulas We t match customer requirements, while simulto t taneously meeting or exceeding governmental r regulations. We’re at the cutting edge of innovation and curW rently offer our customers a plethora of marketing r and a distribution options.

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Depending on volume, we can private label our D products or package p ackage a customer’s formula.

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The Ruscoe Company has been serving international industry indu with Pliobond adhesive and a host of other premium, p unparalleled adhesive and sealant p products since 1947.

C C compliant, Consider: VOC p ducts in your premium products c ame. company’s name. F additional For information, and a confidential ial review of your requirements,, oe. please E-Mail: Sales@Ruscoe. com or call Paul MIchalec, President, at 330.253.8148

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Be included in all 12 issues for one economical charge. Contact Peg Van Winkle at 614-760-4222 or [email protected] for more information regarding advertising in ASI 's Services Marketplace.

April 2011

Adhesives & Sealants Industry

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SERVICES MARKETPLACE M A N U FA C T U R I N G & P R O C E S S I N G S E R V I C E S

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If your company was mentioned in ASI, reprints of that article are a great sales tool!

Why Reprints? Distribute them at tradeshows. Mail them to your prospects. Use them in sales presentations.

Call Peg at 614-760-4222 or email: [email protected] 48

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April 2011

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ASK

AD INDEX

DR.DAVE

QUESTION: We manufacture two-part epoxy adhesives that are normally used by customers at ambient temperatures. We don’t completely understand why we always seem to get higher strengths if we cure them at higher temperatures. Is it a different type of curing?

ASK

ANSWER: It is difficult to give you an exact answer without the full details of the adhesive or what type of hardener you use for the epoxy. However, I can make some comments and generalizations about this type of adhesive. Compared to some other types of structural adhesives, such as cyanoacrylates or reactive acrylics, epoxies are highly crosslinked structures and tend to become highly viscous very early in their cure cycle. The result is that the molecules’ mobility becomes restricted, which limits their ability to collide and react. Is not unusual to see a lot of unreacted epoxy when curing is carried out at moderate It is common to temperatures. Heat has two effects: it lowers the viscosity have long heat cure and increases the reaction rate. A good way to observe this is cycles for very high to perform differential scanning strength epoxy calorimetry (DSC) on your cured adhesive. DSC measures adhesives. the energy absorbed or released as the adhesive is ramped up from low to high temperatures. In the case of the adhesive cured at ambient temperature, you will normally see an exothermic peak (heat released) during the scan as the remaining epoxy cures; the area under this peak gives you an estimate of the amount of unreacted epoxy in the sample. When an adhesive is fully cured at higher temperatures, this peak will not be observed. Heat-cured adhesives give the maximum adhesive strength and physical properties, plus enhanced heat and fluid resistance. It is common to have long heat cure cycles for very high strength epoxy adhesives.

DR.DAVE

Do You Have a Question for Dr. Dave?

Visit www.adhesivesmag.com and click on Ask Dr. Dave in the left-hand column.

Accumetric LLC

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Adhesive Packaging Specialties

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Albion Engineering Co.

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Applied Test Systems, Inc.

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Bayer MaterialScience LLC

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Conn & Co.

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Connolly Bove Lodge & Hutz LLP

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Dynasol, LLC

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Emerald Performance Materials

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41

Evonik Industries AG

www.evonik.com/adhesives-sealants

19

ExxonMobil Chemical Co.

www.escorez.com

15

F.L.D. Enterprises

[email protected]

33

Gabriel Performance Products

www.gabepro.com

22

Gorman-Rupp Company

www.GRpumps.com

39

Green Manufacturing Expo

www.GreenMfgExpo.com

44

Huntsman Polyurethanes

www.huntsman.com/pu/ace

21

Imass, Inc.

www.imass.com

30

Kraton Polymers

www.kraton.com

11

Masosine

www.masosine.com

31

Max Machinery Inc.

www.maxmachinery.com

Merlin Packaging Technologies Inc.

www.merlinpackaging.com

10

Mettler-Toledo Inc.

www.mt.com

40

NuSil Technology

www.nusil.com/asi

IFC

Poly-Clip Systems

www.polyclip.com

BC

PSTC

www.pstc.org

37

Quick Blades, Inc.

www.quickblades.net

45

Ross, Charles & Son Co.

www.mixers.com

17

Scheugenpflug USA

www.scheugenpflug-usa.com

35

Semco Packaging & Applications Systems

www.semcopackaging.com

Tech ManufactureXPO

www.TechManufactureXPO.com

IBC

Tech ManufactureXPO

www.TechManufactureXPO.com

cover

Tech ManufactureXPO

www.TechManufactureXPO.com

23-27

Univar USA Inc.

[email protected]

4

Wacker Silicones

www.wacker.com/knows-solutions

9

3

8

7

Dr. Dave Dunn is a former vice president and director of Loctite Corp. and has spent many years troubleshooting adhesive and sealant problems in the adhesives, sealants, specialty rubbers, and plastics fields. Questions for publication should be directed to him at 242 Trails End, Aurora, OH 44202; (330) 562-2930; FAX (330) 247-1690; e-mail [email protected]; or visit www.fldenterprises.com. Any views or opinions expressed in this column are those of the author and do not represent those of Adhesives & Sealants Industry, its staff, Editorial Advisory Board or BNP Media.

50

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www.adhesivesmag.com

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This index is a feature maintained for the convenience of the advertiser. It is not part of the advertiser’s contract, and ASI assumes no responsibility for its accuracy.

April 2011

FREE WEBINARS We d ne s d a y, M a y 4 Presented by:

10:00- 10:45am ET

11:15- 2:00pm ET

Automation: It’s not just for high volumes anymore

Lowering the Total Installed Cost of Assemblies in Today’s Manufacturing Environment

Kurt Greissinger, Industry Manager- Assembly & Handling Kurt Greissinger, Industry Manager for Assembly Products at Bosch Rexroth, takes on some common myths about automation and lean, and uses a variety of examples drawn from real-world applications to prove that automation makes a vital contribution to lean manufacturing solutions. At a time when companies are tearing out conveyor systems in the name of lean, he will describe the roles automation can play and the benefits it offers across multiple applications. Through this webinar, engineers and systems designers will gain new insight into the nuances of human interaction with automation and key ergonomic considerations in automated and semi-automated processes. • The Role of Automation in a Lean Manufacturing Environment • Humans vs. Robots • Ergonomic Considerations for Assembly • Considerations for Manual vs. Automated Tasks

11:15- 12:00pm ET

Michael Poth, Director of Global Marketing, Stanley Assembly Technologies Emhart Teknologies delivers engineered fasteners and systems that provide solutions to an array of extremely complex fastening challenges customers face today. Through optimal engineering and design the webinar will show you how the Emhart Family of companies use varied techniques to lower the total installed costs of assemblies. 2:30- 3:15pm ET

Reverse Engineering Featuring Paul Jr. Designs Julius Ndulue, Applications Engineer, FARO Paul Jr. & Vinnie – Paul Jr. Designs The purpose of this webinar is to demonstrate how to use a portable coordinate measuring machine (CMM) for the reverse engineering of parts. Paul Jr. and Vinnie of Paul Jr. Designs will be sharing their experiences using a CMM and how it has improved their reverse engineering processes.

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An educational virtual event covering trends in manufacturing from design to delivery.

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A Simple Suggestion to Help You Squeeze More Profit Out of Every Cartridge

Get Rid of the Cartridge Poly-clip introduces a low-cost alternative to expensive cans and pre-formed single-use cartridges. The Poly-clip foil-pack tube for lubricants, adhesives and sealants. And, because one roll of film makes thousands of tubes it offers a consistently better seal with lower equipment, materials and maintenance costs than vertical tube forming systems and heat seal closures.

Environmentally conscious consumers will appreciate the fact that an empty tube is less than 8% the size of an empty cartridge

Poly-Clip System

See us at ASC booth 306.

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