Product category:
Materials processing and testing
News Release from: GI Plastek
Edited by the Engineeringtalk Editorial
Team on 31 December 2002
Expansion for reaction injection
moulding
GI Plastek has completed the scheduled phase two expansion of its reaction injection moulding (RIM) facility in DeWitt, Iowa.
GI Plastek has completed the scheduled phase two expansion of its reaction injection moulding (RIM) facility in DeWitt, Iowa, with two custom-built urethane RIM presses installed, approved and operational Capital investment supporting this progress totalled more than $3 million
This article was originally published on Engineeringtalk on 23 Nov 2001 at 8.00am (UK)
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To date, GI Plastek has spent more than $6 million in development of this "greenfield" plant.
According to GI Plastek president, Randy Herman: "Our entire presence in the Midwest has been built upon encouragement from our customers in the markets of agriculture, construction, offroad, specialty and recreational vehicles, many of whom are within close proximity to the Iowa region.
Completion of Phase Two is further indication of how we are keeping our commitment to those companies by providing the skilled custom plastics processing, finishing and assembly they require, in a geographic area that benefits them from quicker turnarounds, reliable service and reduced freight".
The processing equipment features a new 600t RIM press with a 14 x 9ft platen and a capacity of more than 100lb per shot - one of the largest and most sophisticated presses of its type in the USA.
Also a 300t unit with a 10 x 6ft platen will be supported by the same injection unit.
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Each press is equipped to use ProTek In-Mold Composite Systems, a unique technology available only from GI Plastek, integrating the company's pioneering expertise in in-mould coating and in-mould composites with design and engineering functions, custom tooling and material selection, advanced techniques in reaction injection moulding and the most advanced coatings.
The addition to the two RIM presses intended for production of neat (unfilled) urethane RIM material systems, complements the existing capacity of two RIM presses constructed to process Metton DCPD material.
Those presses, added during phase one of DeWitt's development shortly after construction of the 35,000 square feet facility during the second half of 2001, include a 6 x 11ft platen 154t unit plus a 5 x 7ft platen machine with 117t hydraulic clamp pressure.
Both offer up to a 50lb maximum shot size.
The style of these clamps allows for large, deep draw moulds to be handled efficiently.
GI Plastek's new DeWitt operation is colocated with an established Class A paint and finishing facility.
Phase Three, expected during 2003, will further supplement the company's capabilities with equipment to process reinforced (filled) urethane materials.
During that phase it is anticipated that the physical facility in DeWitt will grow to approximately 10,000m2 to support production.
Phase four timing will be driven by the marketplace and will integrate RIM processes with thermoplastic injection molding technology.
GI Plastek also injection moulds from its facilities in Marysville, Ohio and Wolfeboro, New Hampshire.
GI Plastek's investment in its RIM business is further supported by the recent staff addition of Steve Ettore who joined GI Plastek as the Director of Business Development RIM Division.
Ettore provides more than 19 years experience in the field of reaction injection moulding, including formulations development, technical service, program management, applications development and commercialisation.
According to Wayne Donohue, Vice President and General Manager for GI Plastek's RIM Business "Phase two expansion in DeWitt is indicative of GI Plastek's significant ongoing investments in technology and human resources for the benefit of our entire RIM business.
Because of the impressive size of the new equipment in DeWitt we can accommodate projects that would otherwise be too large for our Newburyport, RIM production centre.
This enables us to focus Newburyport as a hub for R and D, including further development of our proprietary ProTek systems, as well as production for regional RIM applications along the eastern portion of the US".
Donohue also points out that: "GI Plastek's ability to accommodate innovative material technologies has been underscored by the fact that the company has employed its ProTek system in moulding a Bayer grade of high-density structural foam RIM polyurethane believed to be the first commercial application of a soy-based RIM formulation".
The part, an access door for a John Deere Harvester Works combine replaces a component previously moulded with a RIM system derived from standard petrochemical sources.
The new composite is extremely strong, but weighs significantly less than a steel or SMC alternative.
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