training-kl-jakarta-11(apr-may)

Technical Training Programs

for Plastic Industries

Sheet Extrusion for Thermoforming 28 April 2011, Impiana KLCC Hotel, Kuala Lumpur, Malaysia

(Instructor: Mark Strachan, Global Thermoforming Technologies, USA)

Tooling and Part Design for Thin-Gauge Thermoforming

29 April 2011, Impiana KLCC Hotel, Kuala Lumpur, Malaysia (Instructor: Mark Strachan, Global Thermoforming Technologies, USA)

Thin-Gauge Thermoforming Principles, Control & Troubleshooting 2-3 May 2011, Hotel Borobudur, Jakarta, Indonesia


Plastic Injection Molding Technology 2-4 May 2011, Hotel Borobudur, Jakarta, Indonesia

(Instructor: David Jeavons, Polybridge Training Ltd., UK)

Organized by Plastic Industry Academy @ TechnoBiz

TechnoBiz Communications Co., Ltd. 2521/27, Lardprao Road, Khlongchaokhunsingha

Wangthonglang, Bangkok 10310 Thailand Tel: 66-2-933 0077 Fax: 66-2-955 9971 Mobile: 66-81-988 6874

Email: [email protected] Web: www.plasticindustry-academy.com

Sheet Extrusion for Thermoforming 28 April 2011, Impiana KLCC Hotel, Kuala Lumpur, Malaysia


Program Content

1. Basic Thermoforming and why the quality of the extruded sheet is so essential; 2. Material Handling – It all starts here! ;

3. From the Extruder Feed Throat to the Head – Basic overview of the following components and their functions: (Feed Throat

/ Hopper Magnet / The Screw / The Barrel / Barrel Heating and cooling / Process Instruments – Pressure, Temperature);

4. From the Head to The Flat Sheet Die (The Head Adapter / The Screen Changer / The Choke Valve and proper set-up of this

valve / The Gear Pump / The Feed Block - The function of the Feed Block and various types available ; Co-Extrusion – The

makings of multilayer sheet / The Die - The various Die configurations : Deckling options , Die adjustments, Auto Die Lip

Adjusters / The Cooling Roll Stack - Roll Stack Configurations; Roll face and Diameter; The importance of knowing the Cooling

Roll Construction ; Roll Stack actuators and Controls); 5. The Pull Roll (Haul-Off) Unit; 6. The Cooling Rack and other

additional cooling methods 7. The Sheet Slitters; 8. The Sheet Gauge Scanners and monitoring systems; 9. Sheet Coating

options - Single and double sided coating systems; 10. Lamination for decoration and barriers; 11. Sheet Accumulators; 12.

The Winding Systems; 13. The Extrusion Control Systems – Basic to advance; 14. Safety; 15. Start-up and Shut Down

procedures; 16. Pre-Start Set-up procedures and checks; 17. Maintaining “Steady State” conditions; 18. Stringing up the Roll

Stand–the correct way to do it; 19. Process Parameters – Speeds, temps and pressures; 20. Troubleshooting & Maintenance

Program Language: ENGLISH Program Agenda: 09.00 am to 05.00 pm

Tooling and Part Design

for Thin-Gauge Thermoforming 29 April 2011, Impiana KLCC Hotel, Kuala Lumpur, Malaysia


Program Content

1. Thermoforming Boot Camp : To Design, you first have to understand the process (Understanding the polymers for

thermoforming / Additives / Coatings/ Barriers and other sheet properties / Basic Thin-Gage Thermoforming Processes –

Vacuum and Pressure Forming / Basic Thin-Gage Punching and Trimming Processes / Basic Thin-Gage parts Handling;

2. Thermoformed Part Design - Thin-Gage Sheet Options, Finished Part Functionality, Life Cycle of the Part, The Design Process,

The Design team – Who should be involved in the design process, “Design to thermoform”, NOT “Thermoform the design”, Hinges,

snaps and other design features; 3. Advanced Forming Options- to be considered by the designer – Coining, Vacuum Bleed, Pre-

Blow, 3rd Motion Plug Assist, Sheet Clamps – To Clamp or not to clamp?; 4.Tool design - Thin Gage Thermoforming Processes &

Related Tooling, Prototyping, Mold Materials – Prototypes, Mold Materials – Production, Mold Layout Options (in relation to

machinery), Part Shrinkage, Draw Ratio’s, Vent Holes and Slots, Radii and Chamfers, Undercuts and draft angles, Form Tools,

Punch Tools, Trim Tools, Stacking Tooling, Chamfers, Positive or negative, Sheet Clamps, Designing for Pressure Forming vs.

Vacuum Forming , Tool Coatings and finishing ; 5. Tooling Set-Up and Troubleshooting : Pre-Setup checklist – Machine and

tooling, Cost Saving Techniques Troubleshooting the thermoforming process – Is it the Tool, the Plastic Sheet, the Machinery or

the operator, Tool Maintenance, Quick Change Tooling Options

Program Language: ENGLISH Program Agenda: 09.00 am to 05.00 pm

Thin-Gauge Thermoforming

Principles, Control & Troubleshooting

2-3 May 2011, Hotel Borobudur, Jakarta, Indonesia (Instructor: Mark Strachan, Global Thermoforming Technologies, USA)

Program Content

1. Materials for Thermoforming: An overview of many materials and additives used in the thin-gage thermoforming industry -

a). Basic Chemistry – Why are the materials so different b). The base polymers c).The Additives and Coatings, c) Laminates,

d) Foamed sheet materials 2. Material Handling & Feeding the Sheet : An in-depth look at sheet transport methods and proper

set-up a). Handling of Material Roll Stock, b).Proper set-up of the in-feed section of thermoformers, c). Proper set-up of the pin

chains and chain rail width adjusters d).Handling the skeletal regrind e). Troubleshooting 3. Heating the Sheet : An in-depth look

at the requirements for efficient and proper heating of the sheet- a).Heating hardware, b).Set-up of Heater zones c).Heating

controllers d). Troubleshooting; 4. Forming the Part – Basics - A basic overview of the thermoforming process and the

components required to thermoform plastic parts; 5. Advanced Thermoforming Techniques: An in-depth look at the advanced

thermoforming techniques and how they help to save costs and increase your company’s profit margins a). Vacuum Bleed, b).

Pre-Billow Forming, c). Advanced tool design features, d). Advanced 3rd motion plug systems, e). Advanced Form air pressure

systems f). Troubleshooting; 6. Trimming the Part: A Brief but in-depth look at the many thermoformed part trimming

techniques – a). Trimming hardware, b). Trim basics, c). Trim Troubleshooting 7. Knife-like and Match Metal Trimming

Techniques – a). An in-depth look at the steel rule, forged and machined knife trimming process and tooling, b). Troubleshooting

of the knife like trimming technique c). An in-depth look at the matched metal ‘punch and die’ trimming technique

d).Troubleshooting of the match metal trim tooling; 8.Thermoforming Machinery Configurations: An overview of the various

types of thermoformers available in the industry today and the products that are best suited for each

Program Language: ENGLISH Program Agenda: 09.00 am to 05.00 pm (Each Day)

Plastic Injection Molding Technology

2-4 May 2011, Hotel Borobudur, Jakarta, Indonesia (Instructor: David Jeavons, Polybridge Training Ltd., UK)

Program Content

SESSION 1 (Injection Molding Fundamentals) - Advantages and Disadvantages of Injection Molding; Applications of

Injection Molding (What is possible with injection molded products); The Injection Molding Cycle (Clamping, Injection,

Ejection); Components & functions of an Injection Molding Machines (Injection Unit - Screw, Barrel, Nozzle, Screw Drive

System; Clamping Unit – Mechanical, Hydraulic, Tie Bar Less Clamping System; Drives – Hydraulic, Electric, Hybrids; Plastic Materials

- How they influence machine choice); Injection Molding Machine Types (Standard Injection Molding Machines, Fast Cycling

Machines, Plunger / Shooting Pot Machines, Multi-Component Machines, Micro Injection Molding Machines, Gas Assisted Molding

Machines, Water Assisted Molding machines, Multi-Station Injection Molding Machines, Low-Pressure Injection Molding Machines, In-

Mould Decoration / In-Mould Labelling Machines) ; Injection Control (Profiled / velocity-controlled filling, The feedback loop,

Charting and interpretation of pressure / velocity curves, Pressure limited velocity); Plastics Flow during Injection Molding (How

plastic Flows, Laminar flow and fountain flow, Orientation effects, Effects of temperature, pressure, and molecular weight);

Shrinkage and Volume Changes (Pressure-volume-temperature relationship, Amorphous and semi-crystalline materials, Cavity

pressure and mould shrinkage, Flow and temperature effects, Fiber fillers and their effects); Molding Strategies (Traditional

molding, Two-stage molding, Velocity to pressure transfer methods , Process monitoring, Initial mould tryout procedure)

SESSION 2 (Injection Mould Design) - Function of Injection Moulds; Mould Types (Single cavity, Multi cavity, 2 plate moulds,

3 plate moulds, Hot runner moulds); Mould Layout (Mould component parts (Bases), Selection of mould bases, Effects of part design

on mould design, Use of inserts and sub-inserts in construction, Balancing of forces in a mould’s component parts); Tolerances

achievable in Mould and Part Design (Tolerances of mould components and molded articles, Sensitivity of tolerances to molding

material and process); Mould Steels (Mould material selection criteria, Treatments to modify steel properties, Components

requiring treatment); Mould Strength (Miscellaneous calculations, Metal fatigue issues, Wear and undesired hobbing); Ejection

(Types of ejection, Actuation and interface to the molding machine, Cosmetic tradeoffs); Cooling (Basic cooling principles & its

importance to product quality, Serial and parallel cooling layouts, Machining cooling lines, Cooling across multiple mould

components: (inserts, core pins, etc.) ,Cooling differences with Amorphous & Crystalline plastics); Gating (Types of gating, Designing

the proper gate for the molding material, Balanced runner layout); Hot Runners (Types of standard systems, Selection and

advantages of using a hot runner system, Needle valve gate types: pneumatic, hydraulic & electric, Needle valve gates & cascade

gating); Venting (Importance of venting in injection molding, Designing for proper venting); New Moulds (Specifying the build,

Product take-out: cavity layout implications, Designing for easy maintenance, Measurements and start-up checks, Setting up a

maintenance system, Inspecting the new mould); Older Moulds (What to document before, and when the mould arrives, Establishing

cleaning / maintenance schedule, Spare parts inventory); CAE in Mould Design (Flow analysis for proper gate selection, Cooling

analysis for optimal cycle times, Emerging technologies for mould design)

SESSION 3 (Mould Maintenance and Mould Setting): Mould Maintenance (Problems associated with poor maintenance,

Storage, Corrosion, Cooling Media Conditioning & Filtration, Documentation & logging repair work, Spares itinerary); Mould Setting

Considerations (Die height requirements, Platen usage , Shot capacity, Ejector stroke, Daylight requirements, Projected area and

clamp force requirements) ; Set-up of an Injection Mould (Tool change preparation (Check list), Systematic set-up procedure,

Setting Toggle clamp, Setting Hydraulic Clamping system, Attachment methods; mould to machine, Ejection systems: Types, Tied /

coupled ejector/ Ejection Monitoring, Mould protection systems, Services (Coolant /Power / Signals /Air), Optimising mould

movements & actions for safety with speed, Handling systems, Takeout devices)

SESSION 4 (Optimization of Injection Moulding Process) - Establish customer acceptance levels; Mould trial procedures;

Process parameters to measure process stability ; Process Parameter profiles: Why & when to use them (Injection,

Holding, Plasticizing, Back pressure) ; Tolerances for a stable process; Controlling check ring closure & opening; Basic

introduction to Design of Experiments / Taguchi® optimization methods

SESSION 5 (Troubleshooting of Injection Molding) - Troubleshooting Procedures and Logic (How to effectively approach,

analyze, and implement troubleshooting procedures); Exploring Root Causes (Explore the root causes of the various defects from

the perspective of the plastic material as it fills, compresses, and cools within the cavity); Surface Defects (Flow lines and jetting,

Splay (moisture or trapped air), Haze, blush, and poor gloss, Orange peel and surface ripples, Gate blush and gate splay, Stringing

witness, Gate vestige); Burning and Contamination Problems (Burn marks and black specks, Burn streaks, Contamination,

Discoloration or poor color match, Burning at the Gate); Physical Problems (Flash and short shots, Sink marks, Vacuum voids and

bubbles, Blisters and delamination) ; Geometry Maintenance Problems (Under- or over-sized dimensions, Poor dimensional

repeatability, Warpage and bowing, post moulding shrinkage) ; Structural Defects (Cracking, crazing, and brittleness, Weld lines,

Stuck parts and pin push marks, Long gates and plugged gates, Drag marks and moulded part damage)

SESSION 6 (Innovative & Tech Trends in Injection Molding) - Multi Layer “Sandwich” Molding; Over Molding; Gas

Injection Technology; Water Injection Technology; Injection Compression Molding; Long Fibre Molding; Micro Molding;

Introduction to Rapid Manufacturing Technologies (Fused Deposition Modeling, Selective Laser Sintering, Light curing resins,

Uses in mould construction)

Program Language: ENGLISH Program Agenda: 09.00 am to 05.00 pm (Each Day)

Program Instructors

Mr. Mark Strachan, Global Thermoforming Technologies Inc., USA Mark Strachan - President, Global Thermoforming Technologies Inc has been involved in the Thermoforming Packaging Industry for the past 29 years and has worked with many successful thermoforming machinery OEMS and Thermoforming companies around the world including Duracell, Gillette, Loctite, Oral-B, Colgate, PIMA, Mary-K, Nestle’, Kroger, Rich’s, Kodak, Mardec, Linpac, Dolphin, Huhtamaki to name a few. During this time, Mark has gained valuable experience in the Plastics Thermoforming and Extrusion Industry, and related machinery and materials handling issues. Due to increased request for assistance and his desire to impart this knowledge Mark formed Global Thermoforming Technologies Inc. He has since been presenting hands on training to thermoforming & sheet extrusion companies worldwide and for the Society of Plastic Engineers -SPE and Universities and training establishments such as Penn State College of Technology and the Royal

Melbourne Institute of Technology. Mark is the author and developer of many in-house thermoforming training programs which include hands-on and interactive computer based thermoforming training programs. Mark has worked extensively with Thermoforming companies to develop, patent and launch their products successfully in the market.

David Jevons, Polybridge Training Limited, UK David Jeavons, proprietor of Polybridge Training Ltd, UK has spent his whole working life in the

Injection Moulding Industry. Upon leaving Engineering college in 1969 he served a 4yr indentured

apprenticeship with GKN Sankey Ltd. Leaving thereafter to pursue a career in materials technology

and then research with RAPRA. After a period with 2 well known trade moulders he worked on

behalf of The Ford Motor Company. The late 1980's saw him as part of the PPITB as a technical

instructor, moving to become Technical Manager with NETSTAL UK Ltd, eventually leading to the

foundation of Polybridge in 1991. Since the mid 1990's he has been closely involved with ENGEL

UK Ltd, providing training and technical support on their behalf. Formed in 1991 Polybridge

Training Ltd has built a reputation for customer specific, bespoke training worldwide. Polybridge Training's clients include some

of the largest companies in the industry a few of which are listed as follows: Rapra, Engel, Netstal, Visteon, Sony, Hoover, Mikron,

IMI, Metalite, Glazpart, Rexam, FKI, Morgan Materials Technology, Braun, Gillette, Oral-B, Sims-Portex, Britax, Sumaria Industries

(Kenya), AWRE, M.O.D., PERA, Rhone Poulenc, ICI, EMS-Grilon, Ford, Precision Valve.

Program Organizer – Plastic Industry Academy @ TechnoBiz

Plastic Industry Academy (P.I.A) is a division of TechnoBiz Communications Co., Ltd., based in Bangkok. This academy is a educational and knowledge-based platform for plastic industries in Asia. It offers technical training programs, seminars and conferences and publishes bi-monthly magazine “Plastic Technology Asia” and also reference books of “Plastic Industry Process Improvement” series . For more information and upto date information on events, please visit www.plasticindustry-academy.com .

Plastic Industry Academy @ TechnoBiz

TechnoBiz Communciations Co., Ltd. 2521/27, Lardprao Road, Khlongchaokhunsingha

Wangthonglang, Bangkok 10310 Thailand Tel: 66-2-933 0077 Fax: 66-2-955 9971


Contact Person : Sirinthip, Program Coordinator

Registration Form We confirm to register following training programs (please select appropriately)

Training Program Date & Location

Registration Fee/Participant, US$

Before 28 Feb’11

Before 20 Mar’11

After 20 Mar’11

� Sheet Extrusion for Thermoforming 28 April 2011

(Kuala Lumpur) 500 US$ 600 US$ 700 US$

� Tooling and Part Design for Thin-Gauge Thermoforming

29 April 2011 (Kuala Lumpur)

550 US$ 650 US$ 750 US$

� Thin-Gauge Thermoforming Principles, Control & Troubleshooting

2-3 May 2011 (Jakarta)

850 US$ 950 US$ 1,200 US$

� Plastic Injection Molding Technology 2-4 May 2011

(Jakarta) 950 US$ 1,050 US$ 1,300 US$

Organization Name ……………………………………………………………………………...........................………………

Address …………………………………………………………………………………………………….................................

……………………………………………………………………………………………………………………………………

Tel ……………………………….Fax …………………………………... Email ……………………………….....................

Contact Person …………………………... Tel …………………………...…… Email ……………………….......................

Participant Names :

Participant 1: ……………………….…. Position ……………….……………… Email …………………….........................



Payment is required with registration. Group Discount: 3 or more than 3 delegates from the same organization for the same event, 10% discount on the

registration fee will be offered. If 5 delegates from the same organization for the same event, 6th person participation is FREE. Registration Fee includes

training documentation, refreshments and lunch during the program. Registration fee does not include Accommodation.

Payment Method

� Bank Transfer to Bangkok Bank, Ratchada-Latphrao Road Branch, A/C No: 177-0-70727-9

A/C Name: TechnoBiz Communications Co., Ltd., Swift Code: BKKBTHBK (Kindly make payment for all bank charges and fax /email bank slip )

� Credit Card � Visa � Master Card (5% bank fee for credit card processing will be applied)

Card Number ……………………………………………………………………………..

Cardholder Name …………………………………………………………………………

Last 3 digits on signature panel ……………………Card Expiry Date …………………

Signature of Cardholder ………………………………………………Date ……………

Please send completed registration form to

Plastic Industry Academy@ TechnoBiz, TechnoBiz Communications Co., Ltd.

2521/27, Lardprao Road, Khlongchaokhunsingha, Wangthonglang, Bangkok 10310 Thailand

Tel: 66-2-933 0077 Fax: 66-2-955 9971 Cell: 66-81-988 6874


Contact Person: Khun Sirinthip, Program Coordinator W

training-kl-jakarta-11(apr-may)

Documents