Metals have been around for a very long time, drastically longer than Performance Plastic materials.
The history of Performance Plastic materials is the opposite of the history of metals. Metals are thought to have begun with the use of copper about 11,000 years ago. Gold, silver, iron, lead, and even some brass began to be used before the first known appearance of bronze in the 5th millennium BCE.
Artifacts made of smelted iron have been found dating from about 3000 BC in Egypt and Mesopotamia. In those times, iron was a ceremonial metal; it was far too expensive to be used in everyday life. Metals are commonly very stiff, tough and strong. However, they are also generally quite heavy. Also, the cost to heat metal to production temperatures is extremely high, over 5 times that of Performance Plastic materials. When metals corrode they get smaller, and many can decompose to yield rust.
Performance Plastics
In comparison, plastics only were first made in the early 1900’s. The world’s first known fully synthetic plastic was Bakelite (now days considered Phenolic), and was invented in New York in 1907 by Leo Baekeland who coined the term ‘plastics’. Since this date, thousands of chemists and material scientists have synthesized dozens of plastic base materials. Plastic materials are currently available in over 80 types, and each of these are molded or processed at slightly different temperatures. The wide range of performance plastic materials will allow you to choose the perfect material for your next application.
Some of The Advantages of New Performance Plastic Materials
New Higher Temperature Performance Plastics Material
New Performance Plastic materials like Victrex 450g PEEK and Sabic Ultem 1000 have much higher use temperatures over previous performance plastic materials. The Ultem 1000 unfilled has a continual use temperature above 400 degrees F, while the newer Victrex 450g PEEK materials work well at 480 degrees F on a continuous basis. In addition to the higher temperatures, they are still food grade materials.
Most performance plastic materials can typically be molded in a temperature range of 400 to 600 degree F. While steel starts to melt at 2,500 degrees F. This is five times the temperature, meaning it takes 5 times the energy to convert steel instead of plastic. Lower temperatures equates to lower costs of production.
New Lower Weight Performance Plastics Materials
The average plastic weighs just 20% of the average metal product. Many plastics have exceptional weight to strength ratios, meaning that for the weight of the product they are very strong. This low weight means much less raw materials and less impact on the environment if using plastics over metals. This results in lower cost to manufacture parts from plastics over metal.
For instance, new UV grades of HDPE or High Density Polyethylene are very light, with a density of just .96, so light it floats in water. And yet, this new UV grade of HDPE is a workhorse in the plastic market, and is used to replace wood and metals in outdoor furniture.
New Detectable Performance Plastic Materials For Food Contact Approved
Most Performance Plastic materials were engineered to be food contact compliant, and in most cases FDA approved for food contact. With the increase in food recalls, finding the proper materials to ensure that our foods are safe is imperative. Materials like Acetal Copolymer, Acetal Homopolymer, Nylon, Ultem 1000 and Victrex 450g PEEK are all FDA approved for direct food contact.
Which Performance Plastic Will Work The Best
Here are some new performance plastic material grades that include additives to make these materials detectable during food processing. These newly released detectable products include: Tecaform AH UD (copolymer acetal base), Tecapeek UD Blue (PEEK based) and Hydex 4101 UD Blue PBT – Polyester base). Each of these new performance plastic materials comes in Blue color to be detected by color sensors during food processing. The “UD” portion allows these materials to be detected by X-Ray and Metal Detection scanners in food processing production lines. Using these new detectable performance plastic materials in food processing plants can help to eliminate food contamination issues and massive food recalls.
Recent Rising Costs Of Transportation
Changes in transportation rules and regulations since 2018 have made shipping raw materials significantly more expensive. Weight, size restrictions and surcharges for longer packages have more than doubled in the last year.
This has made one of the most expensive components of materials reaching the marketplace is transportation costs, and over the last several years the costs of moving materials across the country has skyrocketed. Metals are heavy, and this weight makes many items very expensive to transport.
Each step in the production of a finished good generally involves shipping to the next step. Raw material converted into base material, then base material converted into usable shape. Later this shape is turned into a component or part. Each time there is a conversion, there normally is shipping to the next processor. Metal weight can limit the amount of metal that can be moved at one time, where plastics can ship up to five times more product per truckload.
With performance plastics, often the conversion in small factories that can be located near final assembly of components limits the amount of shipping of plastic parts. Also, due to the light weight of plastics, trucks can hold up to five times the amount of plastic over metals for shipping. Many plastic parts are made very close to where they will be consumed, cutting logistics fees. This five times the weight also translates to five times higher cost to ship metals. This reduction of transportation costs moves more profit to the bottom line.
New Performance Plastic Materials Eliminate Need For Lubrication
Often, on large metal parts or assemblies, grease ports are added to make lubricating the metal parts easy. Metal on metal parts will wear out very quickly, and therefore require regular service and lubrication.
Newly released performance plastic materials have made lubrication obsolete. One such material is a new compounded Nylon material, called Nylatech PVM has FDA approved oil additives. This new Cast Nylon material runs well for extended periods without external lubrication. This material runs quieter and smoother than previously used metal parts due to a much lower coefficient of friction, and requires no regular maintenance.
Another new grade of Performance Plastic material that is rated as ‘self-lubricating’, and have excellent wear resistance is Lub-X UHMW, which now makes curves in bottling plants move smoother, quieter and require no lubrication. These long wearing and high strength materials outperform most other substrate for low cost, high performance, low weight and self lubrication.
Each of these plastic advantages yield cost savings and long product life. Along with these new areas of advantage, Performance Plastics are 100% recyclable, and can be reprocessed into high strength parts again and again. The plastic recycling industry is still in its infancy, and as it becomes more adept at recycling and reusing valuable plastic materials, our planet and our pocket books will benefit.
During the last year, the number and size of food recalls has been staggering. With several major food processors, specifically in the poultry market, recalling massive amounts of product due to contamination, perhaps a change in material is in order, simply changing to a Metal or X-ray detectable plastic material may end recalls for contamination. The cost to change to a metal detectable plastic or x-ray detectable plastic is extremely small in comparison to the cost of these recalls.
What is a detectable Plastic
There are numerous quality high performance plastic materials that are available in Blue, X-ray and Metal detectable versions. These materials are designed with food safety in mind. These materials can assist the food industry and the food processing supply chain in keeping our foods safe. Identifying contaminates in the processing of foods can be made significantly easier with these detectable materials. Food safety should be the priority within the food processing industry. By changing to metal detectable plastic and X-ray detectable plastics, this can become a reality.
Metal Detectable Plastic and X-Ray Detectable Plastics
Here is a recent Press Release detailing the recalls and a rather straight forward and easy solution using detectable plastic.
(Newswire.net — October 10, 2016) Anaheim, CA – Can ‘Blue’ fix food recalls? –The year 2016 has seen some staggering food recalls by large food processors. Massive recalls of chicken specifically seem to have happened multiple times. The part that is the most amazing is that the root cause of many of these kinds of recalls is preventable. The specific recalls listed below are all for possible plastic contamination in the food product.
These large food processors should be aware of some simple steps that can totally eliminate these kinds of contaminates from getting into their food products.
Penny Wise, Pound Foolish
Keeping Food Processing Safe
While using FDA approved plastic materials for conveyor parts and moving components is a standard practice in most food processing plants, many processors use the cheapest available approved materials. This means that many producers are using a natural (white) HDPE, Acetal or other white approved plastic material. While it is safe to use these plastics, occasionally one of these parts gets jammed, breaks or wears to the point where parts can crack and pieces can get into the food processing line.
It Is Plain To See
The first easy step would be to use the same quality FDA approved material, but to buy the Blue metal detectable plastic version of the same approved material. This minor color change in the material makes any contaminates very easy to see with the naked eye. Since there are no food products in these bright blue colors, as long as there are employees looking at the food line, these broken pieces are easy to detect.
I Can See You
Speaking of detect, the big step up for detection of contaminates is to use a FDA approved plastic that is detectable by the X-ray or metal detection equipment already installed in these food processing lines. While these ‘metal detectable plastics’ cost more, they certainly cost less than one recent 4.5 million pound poultry recall.
The goal here is not to point the finger or call any company a ‘bad processor’, but rather to encourage these great food processors to use the ‘best practice’ types of materials to eliminate these monster food recalls.
In September 2016, Tyson Foods recalled 130,000 pounds of chicken nuggets for foreign materials in the product.
“According to Tyson Foods, the plastic material ranged in size from 21mm in length and 6.5mm in diameter and may have come from a round, hard plastic rod used to connect a plastic transfer belt. The firm said the products pass through a metal detector, but the plastic is not detectable to this technology,” the USDA recall announcement said.
Have You Considered Detectable Blue?
Blue Metal Detectable Plastics From Ensinger
Perhaps they could consider using a metal detectable plastic that is detectable by a standard metal detector. Industrial Plastic Supply has supplied this FDA approved Metal Detectable UHMW rod since early 2010. Currently, there are several FDA approved materials that are available in Blue; UHMW, Acetal, Nylon, Polyester and now PEEK. Some of these materials are also available in a ‘triple detection’ version, where it is detectable because of the vivid Blue color, and it is also Metal detectable and X-Ray detectable. One of these new versions is the Ultra-Detectable Polyester rod made by Ensinger® Plastics called Hydex® 4101 UD Blue (FDA Grade Polyester).
–In April and May of 2016, Pilgrim’s Pride had a recall totaling 5,550,904 pounds (yes 5.5 million pounds) of poultry do to possible foreign matter contamination.
The cost is staggering. To recall this quantity of food takes a small army of people to identify the possibly contaminated batches of food. Then notification is spread to all the possible distribution and wholesalers. The USDA is normally notified as one more step to notify the public.
Simple method to protect the safety of our food chain using detectable plastic materials
What is the cost to change to a more metal detectable plastic?
This depends on the type of plastic, and the detection method.
Let’s assume that the currently used material is an FDA approved grade of 1″ diameter Natural Acetal rod (a popular performance plastic used in food processing). And let’s assume this material would sell for approximately $2.00 – $2.50 per linear foot.
Changing to a Bright Blue FDA approved grade of Acetal Rod would cost about $3.50 – $4.00 per foot.
Upgrading to a Metal and X-ray detectable plastic that is FDA grade and Blue Acetal plastic rod would cost in the range of $8.25 – $9.00 per foot.
A recall of 100,000 pounds of poultry is, of course, significantly more expensive than upgrading the plastic materials in the food processing plant. Consider the upgrade an inexpensive insurance policy against these kinds of monster recalls, with a simple change to metal detectable plastic materials.
Metal Detectable Plastic and X-Ray Detectable Plastics Actually Saves Money
Contact us for more information on these Metal Detectable Plastic and X-Ray detectable plastic products. Blue Sheet and Rod are available in Acetal, Delrin®, Nylon, PBT – Polyester, and more. The special ‘triple detectable’ grades are currently produced in Acetal (Tecaform® UD Blue) and PBT – Polyester (Hydex® 4101 UD Blue). More materials are in final stages of development. Contact us for your special requirements.
Yes, UV Resistant Recycled Plastic Lumber lasts and lasts
What happens to your ‘blue recycled trash’ materials? A common question regarding recycling is, ‘Does It Work’?
The answer is ‘YES’ it certainly works.
One of the most recycled plastic materials is HDPE. This is the material that laundry detergent bottles, milk jugs, opaque vitamin bottles and many more common household containers are made from. The HDPE is a FDA and NSF approved resin, and is the go to material for cutting boards, margarine containers, food storage containers, and many of your milky colored drinking cups.
So, what happens to these items after you put them into your recycle bin?
Your local recycling center sorts through your clean recyclables and segregates the materials by the type of plastic. HDPE has the recycle code of #2, and this can be found on the bottom of many of your plastic items. The other plastic items are sorted out based on the recycle number and type of material. This allows for better and more efficient reprocessing of these resins into new and re-purposed items.
The reprocessing of plastic scrap or discarded post consumer products generated a large quantity of plastic material. The HDPE recycling market is a fast growing area of the recycled plastic sector. The other common plastic that is recycled is PET, which has the code of #1, and this is the very clear water bottles and soda bottle material.
Once the discarded containers and other HDPE scraps are collected, they are sent to a recycle plant. This is where the containers are cleaned, sent to the grinder, and converted into small pieces that can be used in the manufacture of new products. This reprocessing of post consumer goods into a usable plastic lumber is the first step in the recycling process. Much later, after the very long life of the HDPE recycled lumber is over, it can be again reprocessed into another recycled HDPE product, maybe even another piece of HDPE plastic lumber. The cycle of using an already produced plastic product, and then reusing, recycling or re-purposing this material is as environmentally responsible as any consumer can be. This ‘closed loop’ recycling eliminates the use of other natural resources, and cuts the impact on our planet.
In a recent press release, HDPE recycled content from milk jugs, laundry detergent bottles, shampoo bottles and other post consumer content are gathered. Then it is ground to usable sizes, and then reprocessed into Recycled HDPE Plastic Lumber. The only additive are the colorant and a UV stabilizer or UV resistant additive. The material is sent threw an extruded or molding process, and the result is a plastic boards that look like real wood, but will out last any wood product by 5 – 10 times, and not require the maintenance that we know is required with wood lumber. The premium recycled HDPE plastic lumber, made by Bedford Technologies, has a 50 year warranty.
That’s a long time, our UV Resistant Recycled Plastic Lumber will last.
Plastic lumber does not rot, splinter, require paint or sealants annually, nor any other regular maintenance. Perhaps a semi-regular washing down is all that would be needed to have this material continue to look like new.
What are popular items that are made from this recycled HDPE plastic lumber? The limit to uses is only limited by your imagination. Some of the most common HDPE plastic lumber products are: outdoor decks, outdoor furniture, docks for lakes and marinas, trellises, walkways, playground components, parking bumpers, sign posts and many more. All of these items outperform the lumber products previous used for these applications.
Call us for more information on the available sizes and colors of recycles HDPE plastic lumber, 866-832-9315.
People in the plastics industry have known for over 50 years that Tuffak Polycarbonate Sheets are tough. This clear plastic sheet material is commonly used to replace window glazing. The best known property for this polycarbonate sheet material is that it is break resistant, or in many cases, considered unbreakable. This is a great benefit for areas where window glass is broken easily.
Recently some cities have passed ordinances to change out the plywood window coverings on abandoned homes, and they are installing clear polycarbonate sheets instead. This is a very attractive replacement, and is a big step in fighting the blight of abandoned homes.
Polycarbonate is produced under several trade names, including Plaskolite Tuffak® GP, Covestro Makrolon®, SABIC Lexan®, Cyrolon®, Zelux® and many more. These materials are available in sheets, plate, slab, bar and rod.
Read more on this material below.
Excerpt from AZCentral, The Arizona Republic:
Property owners and banks in Phoenix had begun outfitting windows with sheets of polycarbonate, a thin, nearly indestructible plastic that mirrors the appearance of glass.
And last month, the city became among the first in the U.S. to make polycarbonate windows a matter of municipal law.
Phoenix now requires all window and door openings visible from the street to be secured with the material if the structure has been unoccupied for more than 90 days. The 90-day provision is also new, replacing the previous deadline of 180 days. The measures were the result of an abandoned buildings task force that Gallego spearheaded.
No one likes living next to abandoned buildings with boarded up doors or windows. So the city of Durham started replacing the plywood eyesores with a clear, durable plastic.
The city is working to reduce the number of abandoned houses by helping owners fix them up. But for houses that still need boarding up, the city has found that plastic not only improves the overall appearance of a neighborhood, it may reduce crime by discouraging squatters and making it easier for police to see inside vacant buildings.
“I can’t stress enough how the elimination of the boards has a tremendous positive impact on neighborhoods and communities,” said Faith Gardner, housing code administrator of the city’s department of neighborhood improvement services.
Read more here: https://www.newsobserver.com/news/local/counties/durham-county/article20778429.html#storylink=cpy
These communities have fought back against vandalism and crime, as well as enhanced the value of local homes by changing from Plywood to Clear Polycarbonate Sheets. Tuffak GP is a super tough glazing grade clear Polycarbonate Sheet material is the same kind of material that Police Officers use for face shields and banks are using for bullet resistant glazing.
The premier manufacturer of Polycarbonate Sheet in the USA is Tuffak® PG made by Plaskolite and made from Covestro® (formerly Bayer MaterialScience) resins, and they produce Tuffak® GP Polycarbonate Sheet. Polycarbonate is also available in rod and thick plate for machined parts.
Consider using Polycarbonate sheet for your next glazing material.
Why Do Performance Plastic Materials Get Unfairly Blamed?
Performance Plastic materials have been around for over a century now, and are used in almost every industry and application. The problem is that society has made the plastics industry the poster child for waste, trash and pollution. This is unfair, and factually incorrect.
Plastic materials are lighter, cost less to produce, use less electrical power to produce, and are safer for use. It is not new phenomenon that a material or product, once used, gets thrown away. This is the normal life cycle of many materials. Some inexpensive plastic materials used in consumer goods are made to throw away once the item has been purchased. Things like the indestructible packing we fight on kids toys, the cheap plastic ‘sporks’ from restaurants, the prolific plastic water bottles and of course, the plastic grocery bags. All of these materials are 100% recyclable, the hitch is that it requires a little effort to recycle.
Are Performance Plastic Materials The Cause?
On the positive side, the products that plastic currently replaces are much larger, heavier and generally cost more to produce, and use more energy to produce. This means, that the large amount of plastics that are not being properly disposed of, are replacing much larger quantities of materials that would not be recycled. I still remember times when I was a kid, and seeing tin cans in the lakes and rivers when out fishing. People polluting with their trash is not a new thing, now it is just a different group of materials.
Thermoplastic plastic materials are recyclable, and can be used over and over again. Generally, the recycled product would not be for a Food or Medical application. A common use of recycled plastic is with the collected milk jugs and detergent bottles, both made of HDPE, can be reground and turned into plastic lumber. The plastic lumber can be used to replace standard wood products for decks and outdoor furniture, and it will last for 15 – 20 years with no maintenance or painting. The cost savings and reduced use of natural resources for this one product can be staggering. The color doesn’t fade, it wood won’t split or crack, and it continues to look good for up to two decades.
Why Performance Plastic Materials Are Positive
Our recent article, “Plastic Material Bad Reputation – How did we get here?“, we discuss the factors that have lead to the ‘throw away’ society that we have become. Much of this bad reputation is for products that are designed as one use and then designed to be thrown away. So, if we are to change the bad reputation, companies need to change this design flaw, and start using materials for applications that can be reused easily.
If we can minimize the use of throw away plastics, and recycle the plastic material once we are done with it, we can help to limit plastic in land fills.
The blame for plastic pollution should be placed…on people. The plastic is not the cause of the problem, it is the litter-bug and irresponsible individuals that trash our planet. How do the plastic bottles and grocery bags end up in the ocean. They certainly don’t throw themselves in to the ocean, it is lack of responsibility and negligent behavior.
It really only takes a couple of seconds to throw something into a recycle bin. Even better would be to reuse the plastic bottles or plastic bags. Plastic materials are not the problem, empathetic people are the problem.
UHMW (Ultra High Molecular Weight Polyethylene) and PTFE Sheet(PolyTetraFlouroEthylene) are very similar materials, and yet very different at the same time. They both possess certain characteristics that make them similar to each other. For instance, they both have a very low co-efficient of friction, which means they are great for sliding applications and are easy to machine.
Both of these materials are very resistant to chemicals such as chlorine and some acids and have great wear resistance. They have low to no water absorption. Both materials are FDA approved for handling food. PTFE and UHMW Polyethylene are both nearly impossible to bond (without treatment) and are susceptible to sagging under tensile load which is called ‘creep’. These both have very low coefficient of friction and work well for wear strips, slide pads and truck liners to make it easy to empty. These two materials are different in many ways also, and choosing between the two materials for a specific job is critical.
Below are a few examples of how these two materials are different.
1. UHMW is a polyolefin and PTFE is a fluoropolymer. Polyolefins are double bonded carbon while Fluoropolymers are carbon and fluorine bonded. UHMW is a monomer which is consisted of one atom that will bond with another to form a polymer. PTFE is a polymer which is made up of a repeating chain of monomers.
2. PTFE has a higher temperature range than UHMW. The PTFE has a continuous use temperature of 500 degrees F. UHMW is much lower with a continuous use temperature of 200 degrees F and a melting point of 271 degrees F. The UHMW starts to become become soft at higher temperatures while the PTFE is much more resistant and with a melting point of 621 degrees F.
3. UHMW has higher abrasion resistance than PTFE. Both have great impact and wear resistance but because of UHMW having a molecular weight between 2-6 million making it the best wear resistance material in the plastic family, it makes it ideal to take wear and impact over a wider range and longer period of time without losing its properties.
4. UHMW has a much lower density than PTFE. This makes UHMW able to float in water while Fluoropolymers are significantly heavier (almost twice the density of UHMW) and would sink.
5. PTFE has excellent electrical and thermal properties. The virgin grade of PTFE is a better insulator and exhibits better electrical properties which can be used in radio frequencies, cables and circuit boards while UHMW cannot.
6. UHMW is much less expensive than the Fluoropolymers. Especially recently, PTFE has become harder to come by, and during the last 18 months there has been a global shortage of a key raw material called fluorspar that is used to make all Fluoropolymer materials. The ability to take lots of wear and tear and requiring low long term maintenance makes UHMW more cost effective.
7. The standard color of PTFE is Natural, which is a dense white. The UHMW comes in Natural (a deep milky white) or Black. The UHMW can be produced in many colors, and minimums are rather low. To obtain PTFE in colors is much more difficult, and would also have large minimum orders.
Click here for data sheet comparisons for each material…
Both the UHMW and the PTFE are available as sheet, sheets, sheeting, slab, bar, strip, panels, film, round rod, rods and block. Contact us for assistance with these or other shapes.
PTFE Sheeting Properties
Specific Gravity D792 2.14 – 2.24
Tensile Strength Yield D638 2,500 – 6,000
Tensile Modulus D638 80,000
Izod Impact – Notched D256 3.0
Hardness – Rockwell D785 D50 – D65
Deflection Temp @ 264psi D648 150
Deflection Temp @ 66 psi D648 250
Co. Thermal Expansion D696 5.5X10-5
UHMW Sheeting Properties
Specific Gravity D792 .93 – .94
Tensile Strength Yield D638 6,800
Coefficient of Friction – Static D1894 .25
Izod Impact – Notched D256 No Break
Hardness – Rockwell D785 R64
Vicat Softening Temp D1525 260
Deflection Temp @ 66 psi D648 174
Co. Thermal Expansion D696 11.0X10-5
These are just some examples of plastic materials being similar, and yet having very different properties. The PTFE Sheet and UHMW Sheet may appear very similar in color and can be used for some of the same applications, but when needed for a specific use or property needed, one might be dramatically better than the other. As the old saying goes, “You should never judge a book by its cover” and the same is true with plastic. Review the properties and test prior to choosing a final material for your application.
Call us for further assistance at 866-832-9315, or click here to contact us with your questions.
