1 Melt-Phase Forming …a breakthrough in plastic technology.

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Presentation transcript:

1 Melt-Phase Forming …a breakthrough in plastic technology

2 About PBM Plastics Located in Newport News, Virginia 50,000 Square Foot Facility Operation is 24 hours a day/ 7 days a week Supply all major retailers in North America with private label drop-in baby bottle liners Work with all major markets: Consumer, Industrial, Medical, Food and Beverage Develop custom applications

3 Melt Phase Overview Billet Forming Low Scrap / Costs No Secondary Trim 100% Utilization Billet Forming Low Scrap / Costs No Secondary Trim 100% Utilization Melt Phase Radiant Heating Convert To Melt Complete Stress Relief Melt Phase Radiant Heating Convert To Melt Complete Stress Relief Forming Deep Draw Thin Wall Material Independent Forming Deep Draw Thin Wall Material Independent Melt-Phase Basics Melt-Phase Technology - Endlessly Adaptable

4 Melt-Phase Basics Web Sheet Utilization Melt-Phase Web Typical Thermoforming Web Melt-Phase Forming has 70% more sheet utilization than traditional thermoforming = Lower unit cost

5 Melt-Phase Basics Billet Forming Low Scrap / Costs No Secondary Trim 100% Utilization Billet Forming Low Scrap / Costs No Secondary Trim 100% Utilization Melt Phase Radiant Heating Convert To Melt Complete Stress Relief Melt Phase Radiant Heating Convert To Melt Complete Stress Relief Forming Deep Draw Thin Wall Material Independent Forming Deep Draw Thin Wall Material Independent VALUE CREATION Rapid Development

6 Melt-Phase Basics Billet Forming Low Scrap / Costs No Secondary Trim 100% Utilization Billet Forming Low Scrap / Costs No Secondary Trim 100% Utilization Melt Phase Radiant Heating Convert To Melt Complete Stress Relief Melt Phase Radiant Heating Convert To Melt Complete Stress Relief Forming Deep Draw Thin Wall Material Independent Forming Deep Draw Thin Wall Material Independent VALUE CREATION Rapid Development Low Scrap

7 Melt-Phase Basics Billet Forming Low Scrap / Costs No Secondary Trim 100% Utilization Billet Forming Low Scrap / Costs No Secondary Trim 100% Utilization Melt Phase Radiant Heating Convert To Melt Complete Stress Relief Melt Phase Radiant Heating Convert To Melt Complete Stress Relief Forming Deep Draw Thin Wall Material Independent Forming Deep Draw Thin Wall Material Independent VALUE CREATION Rapid Development Low Scrap High Strength

8 Melt-Phase Basics Billet Forming Low Scrap / Costs No Secondary Trim 100% Utilization Billet Forming Low Scrap / Costs No Secondary Trim 100% Utilization Melt Phase Radiant Heating Convert To Melt Complete Stress Relief Melt Phase Radiant Heating Convert To Melt Complete Stress Relief Forming Deep Draw Thin Wall Material Independent Forming Deep Draw Thin Wall Material Independent VALUE CREATION Rapid Development Low Scrap High Strength Low Stress

9 Melt-Phase Basics Billet Forming Low Scrap / Costs No Secondary Trim 100% Utilization Billet Forming Low Scrap / Costs No Secondary Trim 100% Utilization Melt Phase Radiant Heating Convert To Melt Complete Stress Relief Melt Phase Radiant Heating Convert To Melt Complete Stress Relief Forming Deep Draw Thin Wall Material Independent Forming Deep Draw Thin Wall Material Independent VALUE CREATION Rapid Development Low Scrap High Strength Low Stress High Yield

10 Melt-Phase Basics Billet Forming Low Scrap / Costs No Secondary Trim 100% Utilization Billet Forming Low Scrap / Costs No Secondary Trim 100% Utilization Melt Phase Radiant Heating Convert To Melt Complete Stress Relief Melt Phase Radiant Heating Convert To Melt Complete Stress Relief Forming Deep Draw Thin Wall Material Independent Forming Deep Draw Thin Wall Material Independent VALUE CREATION Rapid Development Low Scrap High Strength Low Stress High Yield Low Tooling Cost

11 Melt-Phase Basics Billet Forming Low Scrap / Costs No Secondary Trim 100% Utilization Billet Forming Low Scrap / Costs No Secondary Trim 100% Utilization Melt Phase Radiant Heating Convert To Melt Complete Stress Relief Melt Phase Radiant Heating Convert To Melt Complete Stress Relief Forming Deep Draw Thin Wall Material Independent Forming Deep Draw Thin Wall Material Independent PRODUCT BREAKTHROUGHS Deep Draw

12 Melt-Phase Basics Billet Forming Low Scrap / Costs No Secondary Trim 100% Utilization Billet Forming Low Scrap / Costs No Secondary Trim 100% Utilization Melt Phase Radiant Heating Convert To Melt Complete Stress Relief Melt Phase Radiant Heating Convert To Melt Complete Stress Relief Forming Deep Draw Thin Wall Material Independent Forming Deep Draw Thin Wall Material Independent PRODUCT BREAKTHROUGHS Deep Draw Liner Technology

13 Melt-Phase Basics Billet Forming Low Scrap / Costs No Secondary Trim 100% Utilization Billet Forming Low Scrap / Costs No Secondary Trim 100% Utilization Melt Phase Radiant Heating Convert To Melt Complete Stress Relief Melt Phase Radiant Heating Convert To Melt Complete Stress Relief Forming Deep Draw Thin Wall Material Independent Forming Deep Draw Thin Wall Material Independent PRODUCT BREAKTHROUGHS Deep Draw Liner Technology Retortable

14 Melt-Phase Basics Billet Forming Low Scrap / Costs No Secondary Trim 100% Utilization Billet Forming Low Scrap / Costs No Secondary Trim 100% Utilization Melt Phase Radiant Heating Convert To Melt Complete Stress Relief Melt Phase Radiant Heating Convert To Melt Complete Stress Relief Forming Deep Draw Thin Wall Material Independent Forming Deep Draw Thin Wall Material Independent PRODUCT BREAKTHROUGHS Deep Draw Liner Technology Retortable Clarity

15 Melt-Phase Basics Billet Forming Low Scrap / Costs No Secondary Trim 100% Utilization Billet Forming Low Scrap / Costs No Secondary Trim 100% Utilization Melt Phase Radiant Heating Convert To Melt Complete Stress Relief Melt Phase Radiant Heating Convert To Melt Complete Stress Relief Forming Deep Draw Thin Wall Material Independent Forming Deep Draw Thin Wall Material Independent PRODUCT BREAKTHROUGHS Deep Draw Liner Technology Retortable Clarity Polymer Independent

16 Melt-Phase Basics Billet Forming Low Scrap / Costs No Secondary Trim 100% Utilization Billet Forming Low Scrap / Costs No Secondary Trim 100% Utilization Melt Phase Radiant Heating Convert To Melt Complete Stress Relief Melt Phase Radiant Heating Convert To Melt Complete Stress Relief Forming Deep Draw Thin Wall Material Independent Forming Deep Draw Thin Wall Material Independent PRODUCT BREAKTHROUGHS Deep Draw Liner Technology Retortable Clarity Polymer Independent Multi-Layer

17 Melt-Phase Basics Billet Forming Low Scrap / Costs No Secondary Trim 100% Utilization Billet Forming Low Scrap / Costs No Secondary Trim 100% Utilization Melt Phase Radiant Heating Convert To Melt Complete Stress Relief Melt Phase Radiant Heating Convert To Melt Complete Stress Relief Forming Deep Draw Thin Wall Material Independent Forming Deep Draw Thin Wall Material Independent PRODUCT BREAKTHROUGHS Deep Draw Liner Technology Retortable Clarity Polymer Independent Multi-Layer Seamless

18 Melt-Phase Basics Billet Forming Low Scrap / Costs No Secondary Trim 100% Utilization Billet Forming Low Scrap / Costs No Secondary Trim 100% Utilization Melt Phase Radiant Heating Convert To Melt Complete Stress Relief Melt Phase Radiant Heating Convert To Melt Complete Stress Relief Forming Deep Draw Thin Wall Material Independent Forming Deep Draw Thin Wall Material Independent PRODUCT BREAKTHROUGHS Deep Draw Liner Technology Retortable Clarity Polymer Independent Multi-Layer Seamless Sealable

19 Melt-Phase Basics Billet Forming Low Scrap / Costs No Secondary Trim 100% Utilization Billet Forming Low Scrap / Costs No Secondary Trim 100% Utilization Melt Phase Radiant Heating Convert To Melt Complete Stress Relief Melt Phase Radiant Heating Convert To Melt Complete Stress Relief Forming Deep Draw Thin Wall Material Independent Forming Deep Draw Thin Wall Material Independent PRODUCT BREAKTHROUGHS Deep Draw Liner Technology Retortable Clarity Polymer Independent Multi-Layer Seamless Sealable Collapsible

20 Melt-Phase Basics Billet Forming Low Scrap / Costs No Secondary Trim 100% Utilization Billet Forming Low Scrap / Costs No Secondary Trim 100% Utilization Melt Phase Radiant Heating Convert To Melt Complete Stress Relief Melt Phase Radiant Heating Convert To Melt Complete Stress Relief Forming Deep Draw Thin Wall Material Independent Forming Deep Draw Thin Wall Material Independent PRODUCT BREAKTHROUGHS Deep Draw Liner Technology Retortable Clarity Polymer Independent Multi-Layer Seamless Sealable Collapsible Flexible

21 Melt-Phase Basics Billet Forming Low Scrap / Costs No Secondary Trim 100% Utilization Billet Forming Low Scrap / Costs No Secondary Trim 100% Utilization Melt Phase Radiant Heating Convert To Melt Complete Stress Relief Melt Phase Radiant Heating Convert To Melt Complete Stress Relief Forming Deep Draw Thin Wall Material Independent Forming Deep Draw Thin Wall Material Independent PRODUCT BREAKTHROUGHS Deep Draw Liner Technology Retortable Clarity Polymer Independent Multi-Layer Seamless Sealable Collapsible Flexible Non-Geodesic

22 Landscape Matrix Collapsibility Draw 1:1 (Shallow)1:8 (Deep) Rigid Flexible Retort Autoclave Lower Cost In-Mold Welding Molded Wall Design Traditional Thermoforming Traditional Blow Molding Melt-Phase Forming Food Dispensing Oxygen/Water Barrier Medical Sterility Covers Cosmetic Delivery Non-Geodesic Collapsible Accordion Dispense Air/Liquid Bladders Medical Dispensing / Collecting Aerosol Liner Consumer Cleaner Dispensing Melt-Phase Forming extends the possibilities beyond conventional thermoforming and blowmolding Chemical Resistance Ultra High Heat No Stress Low Cost Retort Laboratory Disposables

23 Melt-Phase Blow Mold Thermoform Engineering Thermoplastics Cost Effective Low Stress Retort / Autoclave Deep Draw Ultra Thin Wall Seamless Chemical Resistant Capability Matrix Melt-Phase Forming creates new possibilities for products and plastics!

24 Melt-Phase Blow Mold Thermoform Engineering Thermoplastics Cost Effective Low Stress Retort / Autoclave Deep Draw Ultra Thin Wall Seamless Chemical Resistant Capability Matrix Melt-Phase Forming creates new possibilities for products and plastics!

25 Melt-Phase Blow Mold Thermoform Engineering Thermoplastics Cost Effective Low Stress Retort / Autoclave Deep Draw Ultra Thin Wall Seamless Chemical Resistant Capability Matrix Melt-Phase Forming creates new possibilities for products and plastics!

26 Engineering Thermoplastics Cost Effective Low Stress Retort / Autoclave Deep Draw Ultra Thin Wall Seamless Melt-Phase Blow Mold Thermoform Chemical Resistant Capability Matrix Melt-Phase Forming Creates New Opportunities In Traditional Markets Key Markets Medical Industrial Consumer Food Beverage

27 Engineering Thermoplastics Cost Effective Low Stress Retort / Autoclave Deep Draw Ultra Thin Wall Seamless Melt-Phase Blow Mold Thermoform Sample Applications Bladder System Dispensing Liner Disposable Mixing Liner Sterile Barrier Cover Medical Bag Test tube Replacement Liquid Delivery Chemical Resistant Capability Matrix Melt-Phase Forming Creates New Opportunities In Traditional Markets Key Markets Medical Industrial Consumer Food Beverage

28 Anatomy of a Liner Bladders Dispensers Spraying Disposables Flexible Body Seamless Clear Gasket Flange Sealable – cap or lidstock Deep Draw Melt-Phase Technology offers a wide range of liner and container solutions

29 Anatomy of a Liner Bladders Dispensers Spraying Disposables Integrates easily into devices Flexible Body Seamless Clear Gasket Flange Sealable – cap or lidstock Deep Draw Melt-Phase Technology offers a wide range of liner and container solutions

30 Anatomy of a Liner Bladders Dispensers Spraying Disposables Integrates easily into devices Eliminates cleaning Flexible Body Seamless Clear Gasket Flange Sealable – cap or lidstock Deep Draw Melt-Phase Technology offers a wide range of liner and container solutions

31 Anatomy of a Liner Bladders Dispensers Spraying Disposables Integrates easily into devices Eliminates cleaning Improves content evacuation Flexible Body Seamless Clear Gasket Flange Sealable – cap or lidstock Deep Draw Melt-Phase Technology offers a wide range of liner and container solutions

32 Anatomy of a Liner Bladders Dispensers Spraying Disposables Integrates easily into devices Eliminates cleaning Improves content evacuation Reduces packaging costs Flexible Body Seamless Clear Gasket Flange Sealable – cap or lidstock Deep Draw Melt-Phase Technology offers a wide range of liner and container solutions

33 Anatomy of a Liner Bladders Dispensers Spraying Disposables Integrates easily into devices Eliminates cleaning Improves content evacuation Reduces packaging costs Creates NEW revenue stream Flexible Body Seamless Clear Gasket Flange Sealable – cap or lidstock Deep Draw Melt-Phase Technology offers a wide range of liner and container solutions

34 Anatomy of a Container Rigid Body Barrier – Up to 7 Layers Clear or Opaque Rigid Flange Retortable or Autoclavable Cup Food Can Beverage Can Beaker / Flask Test Tube Melt-Phase Technology offers a wide range of liner and container solutions

35 Anatomy of a Container Rigid Body Barrier – Up to 7 Layers Clear or Opaque Rigid Flange Retortable or Autoclavable Cup Food Can Beverage Can Beaker / Flask Test Tube Withstands heat and chemicals Melt-Phase Technology offers a wide range of liner and container solutions

36 Anatomy of a Container Rigid Body Barrier – Up to 7 Layers Clear or Opaque Rigid Flange Retortable or Autoclavable Cup Food Can Beverage Can Beaker / Flask Test Tube Withstands heat and chemicals Ultra strong, deep draw walls Melt-Phase Technology offers a wide range of liner and container solutions

37 Anatomy of a Container Rigid Body Barrier – Up to 7 Layers Clear or Opaque Rigid Flange Retortable or Autoclavable Cup Food Can Beverage Can Beaker / Flask Test Tube Withstands heat and chemicals Ultra strong, deep draw walls Cost effective with ETP Melt-Phase Technology offers a wide range of liner and container solutions

38 Anatomy of a Container Rigid Body Barrier – Up to 7 Layers Clear or Opaque Rigid Flange Retortable or Autoclavable Cup Food Can Beverage Can Beaker / Flask Test Tube Withstands heat and chemicals Ultra strong, deep draw walls Cost effective with ETP Replaces glass, metal, other Melt-Phase Technology offers a wide range of liner and container solutions

39 Product Families Accordion Melt-Phase Forming Recent Developments Melt-Phase Technology offers a wide range of liner and container solutions

40 Product Families Accordion Cone Melt-Phase Forming Recent Developments Melt-Phase Technology offers a wide range of liner and container solutions

41 Product Families Accordion Cone Ribbed Melt-Phase Forming Recent Developments Melt-Phase Technology offers a wide range of liner and container solutions

42 Product Families Accordion Cone Ribbed Beaker Melt-Phase Forming Recent Developments Melt-Phase Technology offers a wide range of liner and container solutions

43 Product Families Accordion Cone Ribbed Beaker Test Tubes Melt-Phase Forming Recent Developments Melt-Phase Technology offers a wide range of liner and container solutions

44 Product Families Accordion Cone Ribbed Beaker Test Tubes Sterilization Cover Melt-Phase Forming Recent Developments Melt-Phase Technology offers a wide range of liner and container solutions

45 Product Families Accordion Cone Ribbed Beaker Test Tubes Sterilization Cover Molded Flange Melt-Phase Forming Recent Developments Melt-Phase Technology offers a wide range of liner and container solutions

46 Product Families Accordion Cone Ribbed Beaker Test Tubes Sterilization Cover Molded Flange Inverted Draft Melt-Phase Forming Recent Developments Melt-Phase Technology offers a wide range of liner and container solutions

47 Product Families Accordion Cone Ribbed Beaker Test Tubes Sterilization Cover Molded Flange Inverted Draft Removable Capping Melt-Phase Forming Recent Developments Melt-Phase Technology offers a wide range of liner and container solutions

48 Product Families Accordion Cone Ribbed Beaker Test Tubes Sterilization Cover Molded Flange Inverted Draft Removable Capping Insta-Ready Dispensing Melt-Phase Forming Recent Developments Melt-Phase Technology offers a wide range of liner and container solutions

49 Product Families Accordion Cone Ribbed Beaker Test Tubes Outer Covers Sterilization Cover Molded Flange Inverted Draft Removable Capping Insta-Ready Dispensing Ultra-Ware High Heat & Autoclavable Melt-Phase Forming Recent Developments Melt-Phase Technology offers a wide range of liner and container solutions

50 Melt-Phase Forming Material Options Ultra High Heat Stretchable Impact Resistant Chemical Resistant Barrier Vibrant Colors Anti-Bacterial Recent Developments Melt-Phase Technology offers a wide range of liner and container solutions

51 Melt-Phase Forming Product Benefits Ultra-Thin Ultra Deep Draw High Impact Strength Seamless Flexible Bladders In-Mold Welding Heat Resistant Chemical Resistant Oxygen / Moisture Barrier Eliminate Assembly Air Tight Gasket Seal Recent Developments Melt-Phase Technology offers a wide range of liner and container solutions

52 RetortBarrierDispenseContainerDisposable Food Drink Consumer Industrial Medical Application Matrix Melt-Phase Technology - Endlessly Adaptable

53 Web Site Request FREE Samples Create with E-Designer News/Press Updates Award Updates Upcoming Tradeshows Melt-Phase Website Melt-Phase Technology offers a wide range of liner and container solutions

54 E-Designer Melt-Phase Website Create a Custom Design in 5 easy Steps Melt-Phase Technology offers a wide range of liner and container solutions Step 1: Choosing a Basic Parameter

55 E-Designer Melt-Phase Website Create a Custom Design in 5 easy Steps Melt-Phase Technology offers a wide range of liner and container solutions Step 1: Choosing a Basic Parameter Step 2: Selecting Detailed Information

56 E-Designer Melt-Phase Website Create a Custom Design in 5 easy Steps Melt-Phase Technology offers a wide range of liner and container solutions Step 1: Choosing a Basic Parameter Step 2: Selecting Detailed Information Step 3: Material Selection

57 E-Designer Melt-Phase Website Create a Custom Design in 5 easy Steps Melt-Phase Technology offers a wide range of liner and container solutions Step 1: Choosing a Basic Parameter Step 2: Selecting Detailed Information Step 3: Material Selection Step 4: Application Information

58 E-Designer Melt-Phase Website Create a Custom Design in 5 easy Steps Melt-Phase Technology offers a wide range of liner and container solutions Step 1: Choosing a Basic Parameter Step 2: Selecting Detailed Information Step 3: Material Selection Step 4: Application Information Step 5: Contact Information

59 Designing in Melt-Phase  Phase IConcept Development

60 Designing in Melt-Phase  Phase IConcept Development  Phase IIPrototype Creation

61 Designing in Melt-Phase  Phase IConcept Development  Phase IIPrototype Creation  Phase IIICommercialization

62 Awards Melt-Phase Forming Achievements SPE Award, 2002 – Food Container (baby bottle liner) Flexible Packaging Association Award (Silver), 2003 – (pumpmate liners) SPE Award, 2004 – Consumer Housewares (squeeze bottle liner) Participation in : Ameristar Awards (IOPP) – 2003 Clorox – Out-Packaging Competition, 2003 DuPont Packaging Awards – 2004 Ameristar Awards Melt-Phase Technology - Endlessly Adaptable

63 Modern Plastics – December 2004 Plastics Engineering – October 2004 Plastics Engineering – July 2004 Melt-Phase Forming Achievements Recent Articles

64 Melt-Phase creates new market opportunities Melt-Phase Summary Melt-Phase Technology - Endlessly Adaptable

65 Melt-Phase creates new market opportunities Melt-Phase develops new plastic resin channels Melt-Phase Summary Melt-Phase Technology - Endlessly Adaptable

66 Melt-Phase creates new market opportunities Melt-Phase develops new plastic resin channels Melt-Phase allows thermal transfer through thin walls Melt-Phase Summary Melt-Phase Technology - Endlessly Adaptable

67 Melt-Phase creates new market opportunities Melt-Phase develops new plastic resin channels Melt-Phase allows thermal transfer through thin walls Melt-Phase makes disposable/convenience an option Melt-Phase Summary Melt-Phase Technology - Endlessly Adaptable

68 Melt-Phase creates new market opportunities Melt-Phase develops new plastic resin channels Melt-Phase allows thermal transfer through thin walls Melt-Phase makes disposable/convenience an option Melt-Phase creates ETP products at a lower cost Melt-Phase Summary Melt-Phase Technology - Endlessly Adaptable

69 Melt-Phase creates new market opportunities Melt-Phase develops new plastic resin channels Melt-Phase allows thermal transfer through thin walls Melt-Phase makes disposable/convenience an option Melt-Phase creates ETP products at a lower cost Melt-Phase offers an unique solution previously unavailable –Deep Draw –Ultra Thinwall –Chemical Resistance –High Impact –Rigid Flange With Collapsible Body Melt-Phase Summary Melt-Phase Technology - Endlessly Adaptable

70 Sample Shapes Collapsible Funnel Liner (Polycarbonate) Elastomeric Sterile Guard (Polyurethane) Retort, Barrier 307 Cup (Polypropylene) Medical Beaker (Polyetherimide) Collapsible Accordion (PPO) Vibrant Cup (PC / ABS) Autoclavable Test Tube (PEI) Disposable Bottle Liner (LDPE) 16 oz Collapsible Liner (LDPE) Disposable Filtration Sleeve (LDPE) Impossible Products – NOW ARE POSSIBLE!

71 Contact Information