Scientific Processing Level 1
Garrett MacKenzie: On-Site Trainer
This class is designed for new to intermediate plastic injection processors that will be regularly setting up presses and making adjustments on the production floor. It is also a great venue for managers/supervisors that are new to molding and need a better understanding of how the molding process works to better perform their oversight of employees. Unlike many other training programs, this training takes place on your production floor using YOUR presses, materials, equipment and processes. This helps to assure that training is plant specific, which increases the impact of the skill sets taught within your organization.
“Garrett was very knowledgeable, and helpful with questions…”
John A. , CH3 Solutions
“I would love to have you come back to do more training!”
Samuel S, CH3 Solutions
“Instructor was very thorough in the delivery of his training. I would very much recommend!”
Micheal H., CH3 Solutions
“Class was timed well, and the processor training was a success! Instructor was thorough and ‘easily understood’. “
Timothy M., North Georgia Molding
Steps to develop training are as follows:
- Processors take a 50 question skills assessment, which can be reviewed by clicking the following link: Plastic411: Plastic Injection Testing
- Assessment is used to identify processor level, and develop training that is specific to the weaknesses in your plant.
- Training plan is developed and applied to a timeline, which is then provided to client for approval.
- Training is scheduled based on customer needs. Weekends are not a problem, and encouraged.
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Here is an outline of CORE, Processing I:
Processors are taken through all functions on the controller, and all functions are explained to them in detail, including set up, use and troubleshooting: Clamp, ejection, injection, hold, recovery, SPC
- Velocity: speed- Overview of speed set points as they relate to velocity. The student is given an introduction to profiling velocities based on cavity type.
- Velocity: pressure– Overview of pressure as it relates to velocity
- Fill Time: Fill time is explained, including its relationship to speed and pressure
- Peak Pressure: Peak pressure is defined, and its relationship to speed/ pressure/ viscosity is discussed
- Switchover (cut-off): Switch over (cut-off) is defined. Its relationship to peak pressure/ hold pressure is outlined
- Screw/ Check Ring: Screw operation and function is outlined. Outline includes: screw rotate, screw rotate time, screw speed, worn components, back pressure, decompress after rotate, Recovery vs. cooling
- Cushion: Good practice is outlined, cushion vs. hold pressure, cushion vs. shot size
- Heat vs. flow front: The relationships between heat and plastic flow fronts is outlined
- Turbulent flow: Turbulent flow is defined, and its relationship to mold temperature is discussed
- Mold Heat vs. Barrel Heat: The relationship between mold heat and barrel heat is outlined. Different approaches for correcting dimensional and visual defects will be discussed
- Feed Zone: The feed zone is discussed, including potential problems that can occur related to feeding material and approaches to take for fixing and avoiding these issues
- Metering Zone: The metering zone is outlined, and potential issues such as poor feeding, feed throat bridging, etc are discussed. The student is then given information on how to prevent or resolve problems associated with this zone.
- Front Zone: The metering zone is outlined; potential issues such as splay, unmelt, color swirls, etc are discussed. The student is then given information on how to prevent or resolve problems associated with this zone.
- Nozzle: The nozzle is outlined and potential issues such as splay, contamination, sticking runners, etc are discussed. . The student is then given information on how to prevent or resolve problems associated with this zone.
- Barrel Temperature Profiling: Straight, Forward, Reverse and Metering temperature profiles are outlined, and the student is given examples of what materials and situations apply to each.
- Shear Heat: Shear heat is defined and the student is given scenarios that show when shear heat can be used as a tool, as well as problems that can result from having too much shear in a process.
- Heat vs. Viscosity: The relationships between the various heating methods and how they affect viscosity are reviewed. The student is given guidelines on using viscosity as an advantage, as well as the disadvantages that can be related to high or low viscosity. Methods of measuring melt temperature are outlined, as well as measuring back pressure effects.
- Heat vs. dimensional shrinkage: The class is introduced to the effects on dimensional shrinkage as it relates to barrel and mold temperature.
- Heat vs. Fill Time: Students learn the relationship between temperature and fill time.
- Heat vs. Peak Pressure: The relationship between melt temperature and Peak pressure is outlined and discussed.
- Heats- Sprue Bushing: Heated sprue bushings are outlined, including advantages and disadvantages
- Hold Pressure: Students are introduced to the use of hold pressure. Gate seal study, Ramping hold profiles and proper use of hold pressure are outlined
- Cooling: Cooling standards are outlined, including the relationship between cooling and screw rotate time. Uses of cooling for dimensional correction are discussed, as well as its use in cycle optimization.
- Setting up a new process
Students will be shown how to develop a process on a mold that is being run for the first time. This includes clamp and ejector set up. Decoupled molding procedures will be taught, as well as methods of establishing injection speed, temperatures, hold pressure, cooling time, etc. Students will be shown how to read and record process monitoring variables such as fill time, peak pressure, etc.
- Troubleshooting Defects: Students will be shown examples of the defects below, including different sub-categories within each defect (EX: Heat splay, moisture splay, splay from injection speed, etc.). Approaches for identifying which type of defect and how to make adjustments for correction will be given.
- Shorts/ unfill
- Flow lines
- Gate blush
- Cracking/ Stress
- Color Swirls
2 day Class Cost: $3800, up to 6 people*
Class will be 2 full days taught at your facility, using your presses, materials, processes, etc. Weekends are fine, and encouraged! Company will be responsible for flight, hotel and rental car.
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John Bozzelli: Scientific Molding Founder/ Consultant
“Garrett and I go back to 1997 where he was trained in Scientific Molding procedures. Smart and talented, he has used this methodology and strategy to widen his knowledge base and grow in capabilities. His initiative is shown in starting up plastic411.com and his work at KI “Green Initiatives”. Currently we are working together to incorporate plastics in green technologies.”
LinkedIn: March 26, 2009
“Garrett is the type of individual editors of business-to-business media are always looking for but rarely find: Someone with deep technical expertise who is able to write about a complex topic in a clear and engaging manner. He is a regular contributor to PlasticsToday and I always look forward to receiving his articles because I know that I will learn something new about plastics processing and that minimal editing will be required. His articles also are highly valued by our readers: They consistently receive blockbuster page views.”
LinkedIn, April 5, 2017
Matt Defosse: Editor: Plastics Today magazine
“Garrett is an expert in multiple facets of plastics processing, and kindly offered to share his expertise in a series of articles for our audience. The mission of our web portal, PlasticsToday.com, is to provide plastics processors with information they can use to run their companies more efficiently. With Garrett’s expert insight, I am sure we can meet that mission.”
LinkedIn: September 14, 2011
Mike Tolinski: Editor: Plastics Engineering magazine
“Garrett’s website is a great training-focused online resource of the type the industry needs, especially at a time when it’s becoming harder to find trained plastics technicians”
LinkedIn: November 22, 2011
Clare Goldsberry: Senior Editor: Plastics News/ Plastics Today
“Garrett is a go-getter with lots of good ideas that he’s bringing to the plastics industry. His experience and expertise is providing him with the know-how to bring technology information to those in the industry with a “need to know”
Linked In: September 14, 2011
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