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Agenda

The Molding Conference is the most established education event in injection molding because of the quality of our speakers and our schedule. The jam-packed two day schedule will cover the most current and cutting-edge technologies and techniques that are shaping the way injection molders are creating in shops across the country.

 

The Molding Conference schedule will cover a wide array of topics, such as:

  • Best Practices for Quality and Productivity

  • Establishing/Maintaining a Robust Process

  • Lights-Out Molding

  • Sustainable Molding

  • Digital Molding

  • Designing & Launching New Products

  • Material Handling

  • Equipment Maintenance

2022 Molding Conference Agenda
Tuesday, November 8th

November 8th

1:00 PM

General Session

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The Universal Process - A Whole New Way to Think About Process Development

This talk will explain how to break all the rules of process development, and wind up with a more robust, flexible, and universal process. Instead of defining a process as a static group of machine set points, a new approach is possible that uses dynamic variables. This approach delivers a more robust process that is transferable from mold-to-mold, machine-to-machine, and material-to-material – a universal process. This is a major departure from traditional thinking that has major…

Presented By:

Gene Altonen, iMFLUX

November 8th

1:30 PM

General Session

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Generate Your Own Material Processing Datasheets

Processors rely upon Material Process Datasheets supplied by the material suppliers. However, some of the suppliers do not have datasheets and/or the data provided is not correct. The data provided may not be based on any scientific experiments and may have been a pass down from a similar material datasheet. Molders tend to use the same material in several molds. The talk will focus on how a molder can start generating material-specific data for achieving…

Presented By:

Suhas Kulkarni, Fimmtech

November 8th

2:00 PM

General Session

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Process Engineering: Utilizing Knowledge and Critical Thinking to Solve Molding Defects

Ask any molder about a molding defect or pick up any process troubleshooting guide, and both will typically tell you various ways to react to a defect. This results in a Process Tweaking approach to troubleshooting through “button pushing”. On the contrary, Process Engineering involves solving the defect by critically thinking through the intrinsic interaction of the plastic material, mold design, part design, and the molding process. For example, the corrective action for a short…

Presented By:

David Rose, Beaumont Inc.

November 8th

3:00 PM

General Session

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Melt Preparation & Plastication

Properly preparing your material and understanding how it affects the injection molding process is vital to producing quality plastic parts. In this presentation, we will cover various aspects of melt preparation and plastication, including material data sheets, material drying, plastic melt temperature vs. barrel temperature, screw design and utilization, screw speed RPM vs circumferential speed, and back pressure optimization, and decompression. We will look at each one of these items using a systematic approach from the plastic’s point of view...

Presented By:

Jacque Gibson, RJG Inc.

November 8th

3:30 PM

General Session

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Best Practices in Establishing a Results Driven Training Program

The best companies invest in their employees by training them to become knowledgeable and committed workforce. They know a solid training program creates efficiency in operations, saves on material costs, and aids in safety protocols. And, what's more, training can be a valuable tool in recruiting, onboarding, and advancing.

But how to get started? How to choose a quality training program? Which is best, subscription-based, instructor-led, or a blend of the two?...

Presented By:

Kirby Johnson, Paulson Training

November 8th

5:00 PM

General Session

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Packaging Molder Slashes Cycle Time to Meet Customer Demand Amidst Capacity Constraints

Amid the pandemic, the need for companies to package products direct to the consumer for health and beauty products rose sharply with salons and spas closed. One molder saw an exponential increase in the demand for jars and lids to package beauty products faster than they could produce. Facing the need for additional capacity they turned to conformal cooling as the primary technology to rapidly increase capacity. This presentation will explore the use of conformal…

Presented By:

Jason Murphy, Next Chapter Manufacturing

November 8th

5:30 PM

General Session

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Applying Servo Technology to Application Challenges

Flexflow is our servo-driven valve gate system, that is equipped with an advanced control unit that can control and monitor the valve pin position during the injection process. there can be many application challenges during the injection process, such as weld lines, part warpage, tool deflection and tonnage reduction. By applying this advanced technology, production quality, amount of scrap and much more can be improved. This is all done through independent adjustment of each valve...

Presented By:

Sam Michael, Oerlikon HRSflow

November 8th

6:00 PM

General Session

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Maximizing PCR Content with Co-injection Solutions – Real Life Examples

Mold-Masters Co-Injection, formerly Kortec, addresses the challenges molders face incorporating recycled material in their products and discusses how its co-injection technology has expanded the range of environmentally friendly solutions allowing molders to introduce new, lower cost, product options. Examples of applications with PCR content fully encapsulated in a virgin skin will be presented to showcase the real-world sustainability and economics of today's high-performance co-injection solutions.

Presented By:

Cheryl Sayer, Mold-Masters

November 8th

6:30 PM

General Session

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Using System and Hot Runner Balance in the Mold Qualification Process

System balance plays an important role in the optimization of an injection molding process and can be the limiting factor in the production of high-quality parts from every cavity. In this presentation, Husky will present the process fundamentals of system and hot runner balance and its impact on mold qualification. They will look at the factors that enable well-designed balanced hot runners as well as the causes of unbalanced systems. Attendees will learn about the…

Presented By:

Sheldon Alexander, Husky

November 8th

7:30 PM

General Session

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New Horizons in Automation: 6-Axis Robotics for Injection Molders

Injection molding manufacturers are showing increasing interest in adding 6-axis automation to their processes as labor shortages and a demand for more sophisticated machine cells address the need to stay competitive. Manufacturers may want to look at how six-axis robot technology can help them with continuous improvement of quality, consistency and repeatability.

These manufacturing companies should consider six-axis robots for a range of tasks including part assembly, vision inspection, laser marking, de-gating cutters, labeling, packaging and more...

Presented By:

Bob Shingledecker, Absolute Robot

November 8th

8:00 PM

General Session

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“Value Added” and the Top Entry Robot: Do More than Pick & Place Molded Parts for Superior ROI

Injection Molders have an opportunity to collaborate with a top entry robot supplier for new robot projects to automate the beside-the-press work cell. Optimize the work cell throughput and efficiency to maximize its ROI via reduced direct labor content, lower labor costs and fewer labor management challenges.

This presentation will offer lots of smart, simple, value-added application examples to streamline your beside-the-press work cells.

Primary Topics Include:
• Tote Loading / Box Loading
• Sorting
• Part Labeling
• Insert Loading
• Inspection

Presented By:

Joe Varone, Wittmann Battenfeld

November 8th

8:30 PM

General Session

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Presentation by SEPRO America

What does the future of injection molding look like? Automation, of course, will continue to be critical to compensate for the lack of skilled labor and increase overall efficiency and profitability. However, molding machines and the robots that are essential to automating the process likely will be similar to what we see today. What will change dramatically, will be the robot controls. They will do more, taking advantage of communication and interconnectivity to improve quality…

Presented By:

Jim Healy, Sepro

November 8th

9:00 PM

General Session

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What It Takes to Install a New Machine - Including Prep, Commissioning & Training

• The 5 phases of a project (initiate, plan, execute, monitor, and close) relative to a machine installation
• The standard process we have created at KraussMaffei that aligns with the 5 phases
• The criticality of the project manager to communicate with the plant team and engage them during the planning and execution phases of an installation.

Presented By:

John Fini, KraussMaffei

2022 Molding Conference
Wednesday, November 9th

November 9th

1:00 PM

General Session

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Controlled Viscosity Molding of Complex Polymers

Molders’ limited understanding of plastic behavior derives from only understanding its performance in conventional machines, utilizing pressure to attain flowable viscosities through shear. Since polymer melt is non-Newtonian, applying injection pressure increases viscosity five to 25 times before shearing. This dictates the machine’s and mold’s robustness; what polymers can be molded; and part cost. Controlled Viscosity Molding (CVM) applies the laws of physics differently, processing any resin with 10-20% of the power of conventional machines...

Presented By:

Rick Fitzpatrick, X2F

November 9th

1:30 PM

General Session

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Digitalization - The New Reality in Injection Molding

The presentation will explain how digital tools are emerging into all areas of injection molding, to increase process consistency and allow for the production of higher quality parts, while at the same time reducing overall energy consumption and the environmental footprint of plastics production as envisioned in a truly circular economy. Several of the software tools available currently will be presented in greater detail to allow the operator to select the ones most applicable to their specific situation.

Presented By:

Joachim Kragl, ENGEL

November 9th

2:00 PM

General Session

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Introducing Nitrogen and Carbon Dioxide to Molding Machine

Nitrogen and Carbon dioxide are common gas, but they can improve the injection molding process. Sodick introduces two new systems to use these gases in order to reduce common issues in molding.

1. Low oxygen plasticizing system. Supplying 99.99% concentrated nitrogen gas at the feed throat, prevents contamination and mold deposit at venting. Sharing its mechanical features and its case study.
2. Inert gas dissolved molding. Mixing inert gas such as nitrogen or carbon dioxide…

Presented By:

Kohei Shinohara, Sodick Plustech

November 9th

3:00 PM

General Session

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PLA + Wood Flour: The New Generation of PLA Injection Molding

NISSEI has been developing and experimenting with PLA technologies for the past decade in order to contribute to reducing marine debris and materializing a sustainable society.

At the Molding 2021 last year, NISSEI introduced heat-resistant PLA molding technology and transparent thin-wall PLA molding technology.

As the next generation of our exploration of PLA’s potential, NISSEI developed a 2-color double-shot molding of PLA and wood flour.

Nagano Prefecture, where NISSEI Headquarters is located, is surrounded by forests…

Presented By:

Joe Kendzulak, Nissei

November 9th

3:30 PM

General Session

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Sustainable Products Start with Machine Technology

Recycled material is completely unpredictable, and often full of impurities. So how do you maintain a predictable process using unpredictable material? Machine technology is the answer. Let's take a deep dive into the reasons why recycled material in high percentages is tricky to handle and process, and then look at the solutions such as adaptive machine controls and mechanical features on a molding machine. Let’s understand the different grades of recycled material and what’s required…

Presented By:

Michael Sansoucy, Arburg

November 9th

5:00 PM

General Session

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Challenges in Molding Engineered Thermoplastic Polyurethanes (ETPU)

Let’s face it, it’s hard to find a super tough resin that predictably meets plastic part performance requirements. Most resins that are known for their toughness can let you down in other ways. We always trade away dimensional stability due to high, nonuniform shrinkage rates and high levels of moisture absorption- parts may warp, crack, shrink, or swell. Many high-impact thermoplastic blends may give up chemical resistance which leads to degradation under chemical attack…

Presented By:

Sat Nistala, Lubrizol

Mark McGinnis, Lubrizol

November 9th

5:30 PM

General Session

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Redefining Drying: Time to Dry to Moisture Level vs. Dewpoint

More information coming soon!

Presented By:

Mark Haynie, Novatec

November 9th

6:00 PM

General Session

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Optimizing Cooling Design Using Analysis to Minimize Cycle and Improve Part Quality

More information coming soon!

Presented By:

Rick Carobus, EPS Flotek

November 9th

6:30 PM

General Session

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How Molders Can Implement an Easy-to-Follow Purge Program & Stop Wasting Money

When our experts talk to molders about their current purging situation, they usually fall into one of three categories:

1. Processors new to purging who don't know where to start
2. Processors that use purge but don't have standardized best practices
3. Processors using purge that aren't seeing the results they hoped for

Regardless of where your company falls, our purging expert will share easy steps to implement a more effective purge program to provide…

Presented By:

Jeremy Cooley, Asahi Kasei Asaclean Americas

November 9th

7:30 PM

General Session

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Challenges and Opportunities of Recycled Plastics

In today’s world recycling of plastics has become extremely important. In this paper, we review the importance and the various types of recycled plastics and how to design for recycling. Due to non-homogeneity of the recycled material, there are lots of manufacturing challenges. Inconsistency in viscosity is a major one. Moldex3D is able to measure the viscosity of few recycled compositions of recycled and virgin material blends and predict the viscosity for any combinations of the two…

Presented By:

Srikar Vallury, Moldex3D

November 9th

8:00 PM

General Session

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A Sustainable Step in Molding: How to Leverage Recycled Plastics for Injection Molding

Molding with recycled materials can add value to your business and help you reach your sustainability goals. But how can manufacturers integrate recycled plastics into their process in a practical and systematic way? Learn how Canon Virginia, Inc. approaches these challenges and helps other manufacturers take a more sustainable step forward.

Key takeaways:
• Business and technical values of molding with recycled materials
• Ways to successfully integrate recycled plastic into your molding process
• Challenges Canon Virginia faced and overcame when molding with recycled materials

Presented By:

Tim McNulty, Canon Virginia

Alex Battah, Canon Virginia

November 9th

8:30 PM

General Session

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Sustainable Technologies from JSW

This presentation will focus on the different aspects of reducing our carbon footprint.

Everything from our factories adopting the latest solar technologies. Just one plant utilizing the new solar power system is able to generate 610,000kwh / year, resulting in a CO2 reduction of 357 tons/year.

The different technologies, utilized for the different materials such as PLA's, PCR, pros and cons. solutions and challenges.

Part lightweight results in less material usage, which can be achieved…

Presented By:

Dale Bartholemew, JSW

November 9th

9:00 PM

General Session

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Additive Manufacturing's Place in Today's Molding Operations

In the modern manufacturing environment additive manufacturing and classic plastic injection molding are not mutually exclusive. That is why Mack Molding’s subsidiary, Mack Prototype, made significant investments in 3D printing technologies to support customers’ prototyping, bridge production and low volume production needs. Learn how additive manufacturing is allowing engineers to gain visibility into the production process earlier, improving DFM, allowing production parts to be created during the tool build and balancing production needs with unclear forecast volumes common with early programs...

Presented By:

Greg Cebular, Mack Molding

2022 Molding Conference - optional
Thursday, November 10th

*limited availability*

The Molding Conference is excited to partner with the Polymer Center of Excellence to offer a half-day workshop, featuring Suhas Kulkarni, Founder & President of Fimmtech. Fimmtech has developed several custom tools that help molders develop robust processes, and its seminars have trained hundreds of individuals. Kulkarni is an author of the best-selling book, Robust Process Development and Scientific Molding, published by Hanser Publications. 

The Workshop is optional to attend and costs $100 in addition to your Full Conference admission. The workshop will run from 9am-12pm with transportation and lunch included. Please allow 30 minutes of travel to and from the facility and book your travel arrangements accordingly.

Thurs. November 10

9:00am-12:00pm

Workshop

Cost: $100

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Melt Preparation Techniques—Settings and Techniques to Optimize the Melt in Your Process

The quality of the melt in injection molding is one of the first major contributors to achieving a robust and optimized molding process. The settings of the barrel zones, the screw rotation speeds, and the back pressures are all contributing factors that play major roles in the preparation of the melt. This in-person workshop hosted at the Polymers Center state-of-the-art training facility will focus on these techniques and demonstrate their impact on the ultimate quality of the melt.

Presented By:

Sushas Kulkarni, Founder & President, Fimmtech

Limited spots are available and it will sell out quick. Already registered and want to upgrade? Visit the Registration Resource Center or contact Brittany Belko, BBelko@gardnerweb.com