valid No Comments

Significant Energy Cost Savings With Portable Chillers

Standard fixed speed compressors on chillers use a hot gas bypass valve that bypasses hot discharge refrigerant gas back into the compressor to simulate 100% load. This keeps the compressor running at full speed at all times regardless of the actual load. As an example, this means that if you have a 10 TON chiller and have 10 machines that each require 1 TON of chilling, or 2 machines that require 5 TONs each, you will be running your chiller at 100% capacity, regardless of whether you have 8 of your 10 machines running (80% load) or 1 of your 2 machines running (50%) load. With this example, the chiller will be costing you a fixed amount on your energy bill regardless of how many of your machines are running.

Thermal Care introduced the first portable chillers with a variable speed compressor on their 10 TON and 20 TON portable chillers.  It allows the compressor to reduce the actual output from 100% down to 30% by reducing the speed of the compressor while utilizing hot gas bypass to bring the load from 30% all the way down to 0% without shutting off the compressor.  As shown in the graph below, the energy savings often result in less than a 1 year return on investment.

Key Features:

  • Touch Screen PLC with full diagnostics
  • Totally enclosed, air-over (TEAO) low-noise, energy-efficient fan(s)
  • Removable tools-free access door
  • Power 3-phase error alarm
  • Warranty – lifetime controller replacement ($175 after 5 years)

 

How do you calculator your cooling your process requirement?

Click the link below for a simple calculator to get a good estimate on your cooling tonnage.

https://www.thermalcare.com/plastics-chillers-calculator/

Want to estimate your annual energy savings (above 50 TONs)?

https://www.thermalcare.com/tc-central-calculator/

 

Hirate America partners with Thermal Care, one of the best process cooling equipment and systems for removing heat from industrial applications.

 

If you have a project that you would like to discuss, feel free to contact us below to schedule a free consultation.

valid No Comments

More on China Ban Causing FUD

With all this fear, uncertainty and doubt (FUD) on the China ban of plastic scrap materials, this topic continues to hit the headlines in the plastic recycling world.  China doesn’t want to continue taking in everyone’s waste. They are taking measures to clean up their environment and would like everyone else in the world to partake in being providers of clean recycling materials.  They recently stated a “0.5% contamination threshold for imports”.  The we shouldn’t be taking the easy solution road of putting waste into landfills as eventually there won’t be anymore land to fill with trash!  In term, we should be promoting recycling to the fullest and take care of the planet we live on and reduce waste.

Details on this topic can be found on the Plastics Recycling Resource How China fallout is shaking recycling in California.

 

The China ban FUD of plastic scrap materials has lead to a boom in plastic recycling opportunities here in California.  We have been getting more inquiries about plastic recycling technology solutions and businesses are trying to capitalize on this opportunity domestically.

 

 

Do you want to jump on the opportunity bandwagon or cheer on on the sidelines and pass up huge demands and opportunities along with making our world a better place live for our future children?

 

 

 

 

Hirate America has solutions to provide full turn key plastic recycling systems with a combination of Lindner Resource for shredders and wash lines and Next Generation Recycling (NGR) for all-in-one shredder + extruder + pelletizer.

 

 

If you have a project that you would like to discuss, feel free to contact us below to schedule a free consultation.

valid No Comments

China Ban of Plastic Scrap

Most of you are aware of the whole China ban on imports of certain plastic recyclables after 2017.  The Chinese government is making the changes in order to improve its environment, including air quality and pollution. The Chinese government still has not clarified specifics of what plastics will be banned and what will be accepted.

There’s so much uncertainty and chaos in this market and many recyclers are uncertain of what their company’s future will hold. The uncertainty on whether materials could make it into China created massive market instability.  Many plastic manufacturing companies are having trouble finding buyers for their plastic scrap and are forced to paying recyclers to haul their scrap away.

One of our customers sent containers full of plastic scrap material only to be turned away back to the US and were told that they can only take in plastics that were repelletized.

This in turn causes a domino effect to plastic manufacturing.  If the recyclers are no longer taking plastic scrap material then the manufacturing companies are not stuck holding the ball.

One customer spends over $100,000 USD to get rid of their scarp.

There is a now a big initiatives for companies to seek a solution to this issue rather than sitting around waiting for the import ban to be lifted.

What if these plastic manufacturing companies could turn this scrap into reusable pellets that can be put back into your process?

Hirate America has a solution to provided full turn key recycling systems.

We partner with Lindner Resource for wash lines and shredders that will clean and shred the plastic down to prepare the material for repelletization

Next Generation Recycling (NGR) to take in this cleaned and shredded material to reprocessed pellets.

If you have a project that you would like to discuss, feel free to contact us below to schedule a free consultation.

valid No Comments

PLASTEC WEST 2018 Event

Happy New Year and hope you enjoyed your holiday!  It’s that time of year again and the entire team of Hirate America (one-stop-shop for injection molding, blow molding, auxiliaries, extrusion and recycling equipment in the plastics industry), will be in booth #3911 at the PLASTEC West 2018 show in Anaheim, CA on February 6-8.

Get your complimentary expo admission by visiting:
www.plastecwest.com/special and use promo code SPECIAL
We hope that you have a chance to stop by our booth and meet the team and see what new products we have for 2018.

Looking forward to seeing you there!

Our latest product line brochure, which showcases all the products we represent along with some real case studies can be downloaded on our website Hirate America.   Please let us know and we’ll be happy to send you a hard copy as well.

In the meantime if you have any questions, or need assistance with your application, please do not hesitate to contact us. We’ll be more than happy to provide our expertise.

Again, thank you for considering Hirate America and we look forward to the opportunity of serving you.

If you have a project that you would like to discuss, feel free to contact us below to schedule a free consultation.

valid No Comments

Press Release: 1,000th NGR Plastics Recycling System

1,000th Plastics Recycling System: A New Milestone for NGR

For more than 15 years the globally known SIGMA Plastics Group has put its trust in recycling machines from Next Generation Recycling (NGR), the plastics recycling machine manufacturer from Upper Austria. In December, NGR’s machine number 1,000 was delivered to a Sigma plant New Jersey.

Founded in 1996, NGR is an internationally operating company that specializes in manufacturing plastic recycling machines. From its headquarters in Feldkirchen/Donau, Austria, the company has expanded its global reach and now has several customer centers in the US and Asia. During the past two decades, more than 1,000 machines have rolled off its assembly lines, including over 100 machines this year. And NGR marked this milestone together with its valued customer, the SIGMA Plastics Group.

SIGMA is the largest privately owned film extrusion company in North America, with more than 5,000 employees and an annual processing volume of over two billion pounds. Its product range includes packaging film, stretch film, merchandise bags, garbage bags and garment bags. In December, the 1,000th recycling machine produced by NGR was delivered to SIGMA Group – and with it NGR celebrated a major milestone.

Efficiency and service excellence

SIGMA Group currently has over 40 NGR recycling machines in use. When a company of this size forges such a steady business relationship with a supplier, clearly there are good reasons. Mr. Alfred Teo, CEO of SIGMA, explains: “We count on solutions from NGR because each system efficiently recycles all of our plastic waste and because we can rely on their excellent service. The NGR support team works actively with all of our plants to ensure that our machines are running smoothly.”

Picture capture: on the left Mr. Josef Hochreiter, CEO Next Generation Recyclingmaschinen (NGR), on the right Mr. Alfred S. Teo, CEO von SIGMA 

 

Many of our customers have had a great experiences with their NGR machines with little issues, they are workhorses.  The S:GRAN is a patented technology and has an integrated shredder/extruder combination.

S:GRAN high output range 500-1980 lbs/h (LDPE)

  • ONE-STEP technology
    * In a single process step, the slow-turning shredder blades grind up the plastic waste and the shredded material is then fed continuously to the extruder.
  • Process bulky plastic scrap including purgings
    * Large, thick or bulky waste can be processed without pre-shredding as long as pieces fit into the hopper opening.
  • One-button automatic On/Off control
    * Convenient start-up and shut-down
    * Restart after unplanned shutdown in less than two minutes with full hopper and full extruder
    * The control system provides for smooth start-up of equipment components 
  • DUMP and RUN operation
    * The material level in the chute is constantly measured and the feed is regulated accordingly
    * Conveyor can be loaded intermittently – the rest is handled by the NGR control unit

All of our customers have decreased waste and significantly increased efficiencies and savings within 1~2 years.  Hirate America is partnered with Next Generation Recycling (NGR)

If you have a project that you would like to discuss, feel free to contact us below to schedule a free consultation.

valid No Comments

5 Reasons Why You Want to Upgrade To A Hybrid Injection Molding Machine

Hybrid injection molding machines have been on the market for a couple of decades now, and have proven themselves to be the standard choice in many facilities.
Hybrid injection molding machines are different compared to standard hydraulic injection molding machines in that they use a servo motor coupled to a hydraulic pump to circulate the oil used to provide the hydraulic pressure which actuates the components of the machine. The use of a servo pump allows for continuous adjustments to the actual power requirements, low emissions, less noise, and energy savings.

1. Energy Savings.

Compared to standard hydraulic machines, hybrid injection molding machines typically provide 40% to 60% in energy savings. This is because the servo pump only runs when hydraulic pressure is needed, where as a standard hydraulic machine runs the pump continuously. Because there is no need for movement during the cooling stage of the process, the longer the cooling time, the more energy savings you will see.

Hybrid machines that utilize toggle clamping mechanisms are more energy efficient than the direct ram style clamping units that many manufacturers use. Toggle mechanisms are more energy efficient in creating the clamping tonnage, and locking the mold halves together to maintain pressure.

2. Longer Hydraulic Oil and Machine Life.

Hybrid machines also run the hydraulic oil at a lower temperature because there is less circulation required. This leads to an extended lifespan of the oil, servo pump, and other mechanical components involved. Less maintenance means less downtime and more production with the hybrid injection molding machines.

3. Less Demand for Process Cooling Equipment.

When hydraulic oil runs at a lower temperature, it requires less cooling from your chiller or cooling tower. Today most injection molding machines come equipped with a water saver valve that adjusts the amount of water that flows through the heat exchanger to provide just the right amount of cooling so that you are not wasting money on excessive cooling. There are machines without a water saver valve so make sure your machine manufacturer adds this feature. Using less water from your tower or chiller reduces the heat load on your water system which will end up saving you money in the long run.

4. Faster Response and Closed Loop Process.

Servo motors have a faster response time than standard hydraulic pumps, which leads to faster cycles and decreased cycle times. They also offer more precise controls and a more consistent process due to the encoders that track each turn to the exact rotation position. This means higher quality parts and less scrap..

5. Faster ROI.

Although hybrid injection molding machines are slightly more expensive than standard hydraulic molding machines, all of the above benefits provide a very fast return on investment. Hybrid machines are also typically faster than standard hydraulic machines, so you will be able to make more parts in the same amount of time.

The case study below showcases an old Mitsubishi hydraulic injection molding machine that was retrofitted with a hybrid servo system.

Conclusion

Many of our customers have switched over to hybrid injection molding machines, or replaced their old standard hydraulic machines based on the benefits we talked about above, and all of our customers have noticed significant energy savings and increased production efficiencies. Hirate America is partnered with Hyundai Injection Molding Machines and LS Mtron Injection Molding Machines who manufactures hybrid injection molding machines in South Korea ranging from 80 to 3,300 tons.

If you have a project that you would like to discuss, feel free to contact us below to schedule a free consultation.

valid 1 Comment

5 Reasons Why Magnets & Metal Separators Will Provide A Quick ROI

We all want to believe that the resin we buy, whether it be virgin, re-pro, or regrind, will come free of any contaminants/metal, but experience tells us otherwise. Whether it be pieces of metal that broke off from the process of pelletizing, grinding, or just the accidentally dropped bolt, we have all found metal in our material at some point in time.

Before we jump into the 5 reasons why having a magnet or metal separator in your plastic process will absolutely provide a quick ROI, here’s how it works:

The video below showcases Sesotec Sesotec’s Protector metal separator in action, which ensures that your process will be free and clear from any metal contamination.  The metal separators are installed directly at the material inlet of the injection molding machines and we believe it is an important component in the protection of your molding machines and molds.

1. Damage to your Screw and or Barrel.

A piece of metal can cause minor scratches to your screw/barrel, or render it completely useless, which can cost anywhere from $5,000 to $20,000 dollars depending on the damage and size of your injection molding machine.

2. Damage to your mold and or hot runner system.

If you are getting small amounts of metal in your material that doesn’t get caught by your nozzle tip filters, it can clog up your hot runner tips, causing more frequent maintenance to be required, or cause a breakage in the tip/valve which can quickly become an expensive repair.

3. Down time.

Every time you have to clean out a filter, get maintenance done, or send out your equipment for repairs, you lose precious production time, which may cause problems in your production schedule.

4. Cost of Labor.

Whether it gets calculated or not, time spent by employees removing equipment or doing maintenance is an hourly cost, and time spent dealing with avoidable metal problems, is time not spent doing other necessary maintenance/work.

5. The effect on sales.

If the downtime causes a shortage on production, this could lead to problems or even the loss of a customer(s). There is also the level of confidence that any potential customer(s) will have when they see your process has a magnet & metal separator protecting your equipment or their molds.

From our experience, we have seen payback on magnets & metal separators to pay themselves off by catching metal contamination. We recently did a trial of a magnet at a custom molder who was using 100% virgin material, and within the first 3 weeks, they found a nail on the magnet. This saved them thousands of dollars of repairs and down time with just a several hundred dollar investment. They immediately invested in 10 magnets for their machines.

Conclusion

Magnets and metal separators protect your equipment, minimizes downtime, saves you money on repairs/labor, reduces scrap rates, and provides confidence to your customers.

They clearly increase productivity, consistency, and product quality. Magnets and Metal separators typically have a 1 to 6 month return on investment (ROI) because catching 1 piece of metal 1 time will typically pay off the unit by preventing repairs. Sesotec’s “easy-clean” magnets has a removable stainless steel sleeve over the magnet, which instantaneously removes metal from the magnet. There is also a clear glass opening so you can see if any metal is caught on the magnet without having to continuously checking for metal contaminates. Any metal caught will remain on the magnet or in the discharge bin, ready to be presented as evidence.

Having a magnet & metal separator is an insurance policy on your machines. Hirate America is partnered with Sesotec, a German based company (one of the most well-known respected in the industry). They provide many types of magnets, metal separators and optical sorting equipment to provide a solution for every process.

Please contact us if you have any projects you’d like to discuss with us.