Wednesday, April 25, 2012

Import of Thermoformed Plastics


Import of Thermoformed Plastics
Thermoformed plastics are extremely important in our society.  Plastics that have been created through the thermoforming process are being assimilated into our homes and businesses.  Thousands of plastic products are aesthetically pleasing, have made life easier, and are more environmentally friendly.  The video that has been posted earlier, and that can be found on YouTube, shows many visually pleasing and practical items that have been designed.
Plastics are durable, light weight, and cost effective, and there continues to be new innovations that further our society, economy, and culture.  Plastic products have been and will continue to be part of our future.  They have made their mark, and are here to stay. 
When discussing plastics in general think of the futuristic advancements made by John Huntsman Sr.  He was “key in developing the first plastic egg carton.  In 1974, [the] Huntsman Container Corporation created the "clamshell" container for McDonald's Big Mac and developed other popular products, including the first plastic plates, bowls and fast-food containers.”[i]  His inventions as with the many others have made a huge impact on our society.   We have benefited greatly from these products and their demand is rapidly increasing.
Thermoformed plastics are also extremely sought after, having an astounding world market value.  Companies span across the globe with Beaverton, MI as the plastic thermoforming capital of the world.  The North American market alone encompasses over 10 billion dollars from the thin and heavy gauge plastics industries.[ii]  It has become a competitive and promising market with investors and entrepreneurs looking at the possibilities.  Markets are continually investing in the research and development of new products. 
One of the greatest examples of companies accessing this great technology is Lifetime Products.  “Lifetime Products Inc. is the world's leading manufacturer of blow-molded polyethylene folding chairs and tables, picnic tables, and home basketball equipment. [Who] also manufacture other consumer products, including sheds, trailers, kayaks and paddleboards, and lawn and garden items...”.[iii]  My friend, Mike Todd, is currently working on a patent for a new Kayak design; his innovation and others like him will be able to enhance many existing products that are made of different material.  They can be made lighter, stronger, and cheaper.
These plastics are also beneficial because they are recyclable.  “Most thermoforming companies recycle their scrap and waste plastic, either by compressing in a baling machine or by feeding into a granulator (grinder) and producing ground flake, for sale to reprocessing companies or re-use in their own facility. Frequently, scrap and waste plastic from the thermoforming process is converted back into extruded sheet for forming again”.[iv]  This process lessens the cost of waste and decreases the price of the products that are being made.
Plastics are more environmentally friendly compared to other similar products such as styrofoam.  “The production of one ton of styrofoam requires 685 gallons of oil, and emits 94,119 tons of CO2 and 2,055 tons of greenhouse gases.”[v]  We need to utilize plastic products and get rid of the old and obsolete.  Plastic products are the future and we need to see their importance.  These items, at times, have been taken for granted.  Many overlook the ease, environmental safety and aesthetics that they possess.  I am personally invested in the process and am hopeful to take part in this great market and benefit society.
           


[i]   http://en.wikipedia.org/wiki/Jon_Huntsman,_Sr.#Philanthropic_efforts
[ii] http://en.wikipedia.org/wiki/Thermoforming
[iii] http://en.wikipedia.org/wiki/Lifetime_Products
[iv] http://en.wikipedia.org/wiki/Thermoforming
[v] http://en.wikipedia.org/wiki/Styrofoam

Terrarium Art Products

Blog 6

This is a video of all the new products that we are making!  We just recently went to the reptile expo. in Denver, Co.  Here is a listing of most of our products.   We will be having our products at the Repticon Reptile Expo.in Davis county this Saturday and Sunday if any of you are interested.  To answer your questions, we do not create specific molds for individuals.  We only focus on our product line.  Enjoy!




The ‘Buzz’ with Thermoformed Plastics


Blog Post 5

The ‘Buzz’ with Thermoformed Plastics


Plastic products created from the thermoforming process are being used around the world and are aiding in the medical, agricultural, ecological, automotive, energy, and entertainment world.  Plastics are becoming more widely used and it is quite exciting when you see what can be done.  My business has opened my eyes to some of the possibilities.  Anyone with discipline, hard work ethic, and a good idea, can make a business that can become a huge part of our society.  Thermoforming is mainly discussed more widely in the business world where equipment and new technology is a key to having success.    James Callari, a production specialist, emphasizes, when referring to thermoformed plastics, that “IT’S ALL ABOUT PRICE & PERFORMANCE ... QUALITY & DEPENDABILITY FOR THE LONG TERM.”[i]  Demands for similar items have become very competitive in recent years and the major theme that producers use in their plastic products is the importance of sustainability[ii].
            Annual conferences are held just for new technologies that thermoform and aid in its process.  New versions of software[iii] are being developed as well as parts that increase speed production.  In 2007 the main emphasis at the thermoforming conference was on equipment that aided in high-output machines for packaging, an automatic-cut-and-stack unit, and improved in-line systems for high-speed cup production.[iv]  These machines listed may not seem very important, but when hundreds of millions of products are being sold, a great deal of money is made as well.   For Example, the company Optiwind makes thermoformed wind turbines with annual sales in the range of $10 million to $15 million with more than 100 employees in the business.[v]  These products especially help our economy by generating sales and new employees.  The entire market is also worth noting.[vi]
Plastics are discussed greatly in the food world.  Tupperware, utensils, and measuring cups to bowls are examples that almost everyone uses in their home.  [vii]
Major discussions relate to their durability, flexibility, and safety.  These plastics have to be formed correctly to meet the regulations placed upon them before being sold to the public.  Dr. Crippa, a food protection specialist, has said that there is a series of technical requirements so that we are to avoid potential food hazards.  Such requirements involve the longevity of their shelf-life and their ability to prevent the contamination of food.  [viii]  People are happy with these plastic products because they are effective and because they meet all of the requirements that are enforced by the food and drug administration.  They have revolutionized how we package and store food.
The uses of thermoformed plastics are extremely unique and important in the medical field.  One plastic specialist, Joseph Grande, has mentioned that “A novel thermoforming process has emerged as a promising new method to produce highly technical micro parts such as polymer microchips for life-science.”[ix] 
Such applications involve scaffold in tissue engineering.  Scaffolds help aid in the regeneration and aids in the growth of various tissues. In the medical field “plastic scaffolds are used to relieve the impaired organ so as to expedite recovery or facilitate regeneration.”[x]  This has helped drastically reduce the cost and have been useful because they can be re-cycled and re-used.   
The new plastic pallet has now made its inroad into logistics because of its “durability, reusability, and weight.”[xii]  Cost is the central theme of discussion when discussion these products and its process.
Plastics are mainly discussed in the business world, but are making a big scene in the entertainment world as well.  One great example is plastics being used in film.  People still Thermoform the costumes from the storm troopers in Star Wars.  

[xiii]

I also am using thermoformed plastics in my business to sell advanced terrariums and vivariums.  The qualities of the products being made are astounding and many are gravitating to this fact; the monetary wealth is ever expanding and will continue to grow and be a huge discussion throughout society.   







[i]
James Callari, "'Productive' Is More Than a Name For This Efficient Thermoformer," Plastics Technology, 57, no. 2 (2011): 34-37, http://web.ebscohost.com.hal.weber.edu:2200/ehost/results?sid=c6ddcbe4-510c-4128-ba51-2ca4dffd5581@sessionmgr114&vid=2&hid=110&bquery=thermoforming&bdata=JmRiPWFwaCZ0eXBlPTAmc2l0ZT1laG9zdC1saXZl (accessed April 6, 2012).

James Callari, "Sustainability Is Not a Buzzword For Thin-Gauge Thermoformer," Plastics Technology, 57, no. 55 (2011): 56-56, http://web.ebscohost.com.hal.weber.edu:2200/ehost/detail?vid=15&hid=110&sid=c6ddcbe4-510c-4128-ba51-2ca4dffd5581@sessionmgr114&bdata=JnNpdGU9ZWhvc3QtbGl2ZQ==

Grande Joseph, "Thermoforming Innovations Displayed At SPE Annual Conference," Plastics Technology, 50, no. 11 (2004): 37-39, http://web.ebscohost.com.hal.weber.edu:2200/ehost/detail?vid=21&hid=110&sid=c6ddcbe4-510c-4128-ba51-2ca4dffd5581@sessionmgr114&bdata=JnNpdGU9ZWhvc3QtbGl2ZQ==

(cover story), "What's New at the Show in THERMOFORMING," Plastics Technology, 53, no. 9 (2011): 85-87, http://web.ebscohost.com.hal.weber.edu:2200/ehost/detail?vid=25&hid=110&sid=c6ddcbe4-510c-4128-ba51-2ca4dffd5581@sessionmgr114&bdata=JnNpdGU9ZWhvc3QtbGl2ZQ==

[v]
James Callari, " Thermoforming Helps Harvest the Wind," Plastics Technology, 57, no. 1 (2011): 48-48, http://web.ebscohost.com.hal.weber.edu:2200/ehost/detail?vid=23&hid=110&sid=c6ddcbe4-510c-4128-ba51-2ca4dffd5581@sessionmgr114&bdata=JnNpdGU9ZWhvc3QtbGl2ZQ==

[vi] Wikipedia, "Thermoforming." Accessed April 6, 2012. http://en.wikipedia.org/wiki/Thermoforming.
A. Crippa, T. H. D. Sydenstricker, and S. C. Amico, "Evaluation of Multilayer Thermoformed Films for Food Packaging," Polymer-Plastics Technology and Engineering, 47, no. 10 (2008): 991–995, http://web.ebscohost.com.hal.weber.edu:2200/ehost/results?sid=c6ddcbe4-510c-4128-ba51-2ca4dffd5581@sessionmgr114&vid=1&hid=110&bquery=thermoforming&bdata=JmRiPWFwaCZ0eXBlPTAmc2l0ZT1laG9zdC1saXZl (accessed April 6, 2012).

Grande Joseph, "Micro-Thermoforming Makes Its Debut," Plastics Technology, 51, no. 11 (2006): 37-41, http://web.ebscohost.com.hal.weber.edu:2200/ehost/detail?vid=42&hid=110&sid=c6ddcbe4-510c-4128-ba51-2ca4dffd5581@sessionmgr114&bdata=JnNpdGU9ZWhvc3QtbGl2ZQ==

[x]
S. Giselbrecht, "Microthermoforming as a novel technique for manufacturing scaffolds in tissue engineering," IEE Proceedings -- Nanobiotechnology, 151, no. 4 (2004): 151-157, http://web.ebscohost.com.hal.weber.edu:2200/ehost/detail?sid=c9d288fb-5fcc-40a4-88ca-d1402980c849@sessionmgr104&vid=1&hid=110&bdata=JnNpdGU9ZWhvc3QtbGl2ZQ==

Grande Joseph, "Plastic Pallets Gain Ground In an Eco-Conscious World," Plastics Technology, 54, no. 9 (2008): 58-75, http://web.ebscohost.com.hal.weber.edu:2200/ehost/detail?vid=17&hid=110&sid=c6ddcbe4-510c-4128-ba51-2ca4dffd5581@sessionmgr114&bdata=JnNpdGU9ZWhvc3QtbGl2ZQ==

Wednesday, March 7, 2012

Visual of Products


This is a video of the some of the products I make with explanations.  

 

This is a video of other products made world wide

 


Monday, March 5, 2012

About Me


Over the past year I have developed an interest in thermoforming plastic and have come to appreciate the versatility of the products that can be made.  I’ve seen the process from research and development to production and marketing. 
Thermoforming is a manufacturing process where a plastic sheet is heated to a pliable forming temperature, formed to a specific shape in a mold, and trimmed to create a usable product. The sheet, or "film" when referring to thinner gauges and certain material types, is heated in an oven to a high-enough temperature that it can be stretched into or onto a mold and cooled to a finished shape."  It is a relatively new concept that has had many applications.  Many of products on the current market are made through thermoforming.  Common examples are tables, sheds, chairs, and playground equipment.[i]
Mike Todd first introduced me to Thermoforming.  Mike has been good friend of my father for many years.  He works at Life-Time, a manufacturing plant, where he takes part in the entire thermoforming process.  I’ve come to realize he has a special talent and a very creative mind.  As he has come to understand the thermoforming process, and has been able to utilize it in his personal endeavors. 
With Mike’s innovation, my father’s business experience, and my cheap labor, we have created a business called Terrarium Art.  We specialize in creating a unique collection of terrarium and vivarium tanks using plastic that has been thermoformed.   Although we are still in the early stages of the business, we can see great potential in the products we make.  We have already gone to various shows to display our products and they have received great reception and interest.  One buyer even posted images of a tank on his blogThe Infinity Tank, the name of our vivarium, utilizes basic scientific methods, by having air vents at the top and bottom of the tank.  This allows constant airflow; basically causing a stovetop effect.  This also allows you to have a clear lens without condensation buildup.  The lens of the tank is made from polycarbonate; the same material bulletproof glass is made from.  The tanks are lightweight, specially designed for smaller reptiles, and they look sharp.  It also has a built-in waterfall creating a mechanical and biologic filtration system that helps maintain a clean tank.  It also includes easy access to the pump and has a port in the back to drain the water.  After creating the basic plastic shell, we utilize other materials to design the cages.  We have designed very realistic desert, tropical, and cave-like terrariums to fit whichever animal you wish to display. 
Over a decade ago my father began a similar business mainly specializing in terrarium décor.  He focused on making water dishes and other naturalistic decorative items that enhance tanks.  Instead of using plastics he used cement for all of his products.  He was very successful in his business until competition became overwhelming. Similar products could be mass produced in China and sold for less, so his business ceased to exist. 
The initial impetus for these endeavors has been my father’s interest in animals. I have grown up with a wide variety of animals and I was the only kid in the neighborhood to have a zoo in his own backyard.  Some of the animals we have had over the years include: bobcats, bengal cats, falcons, snakes, spiders, lizards, chickens, pigeons, quail, rabbits, mice, rats, ferrets, and dogs.  You can imagine with that kind of collection the chores that had to be done.  Even though others thought us odd, collecting animals as a hobby has had many advantages, including the people that we meet.  My father’s interest in animals led him to meet Mike Todd. 
Mike and my father are both falconers.  It has always been and always will be their hobby.  From that point on we came to see how smart and resourceful Mike really is.  Before we resurrected Terrarium Art, Mike and my Father created a business called High Tech Falconry.  They created and sold falconry supplies, which were made from thermoformed plastic.  Mike’s genius created hoods, hood holders, perches, wall perches, bathing pools and much more.  It was successful for several years, but as time has drawn out, it has become dormant with a few items being sold each year.  The market for falconry supplies isn’t exactly booming.
Thermoforming has so many different applications that can be utilized if one is innovative and makes that idea a reality.  For that reason, I have become fascinated with its process.  We have created a unique business like no other.





                                                      Kyle Tanner- The Cheap Labor 



                                              My Father Justin Tanner-The Businessman 







                                                                    Naturalistic decor 





                                                                   Thermal Former (exiting isn't it)




                                                                              Molds






[i] Wikipedia, "Thermoforming." Last modified January 25 2012 . Accessed February 20, 2012. http://en.wikipedia.org/wiki/Thermoforming.

History of Thermoforming



History and Expansion of Thermoforming!

            “Thermoforming is considered as one of the oldest methods of forming useful articles of plastic.”[i]  It was first practiced, in some form, dating back to ancient time.  Some of the first recorded findings of thermoformed materials were found in common food containers and utensils.  Egyptians, Micronesians, Ancient Americans, and Romans used tortoise shells, (made of keratin), and tree bark (natural cellulosic) to form bowls and canoes.  The materials were heated it in hot oil or water and then re-shaped.[ii]
The next great advance in history occurred in the 19th Century with the creation of celluloid.   “Celluloid is the name of a class of compounds created from nitrocellulose and camphor, plus dyes and other agents. Generally regarded to be the first thermoplastic…The first celluloid as a bulk material for forming objects, were made in 1855 in Birmingham, England, by Alexander Parkes.  Parkes patented his discovery after realizing a solid residue remained after evaporation of the solvent from photographic collodion.”[iii] Collodion is a flammable, syrup like solution of nitrocellulose in a mixture of alcohol.
Progress continued following Parkes discovery. “In the 1870’s John Westley Hyatt, considered the father of modern plastics processing, and his mechanical engineering colleague Charles Burroughs, rolled thin, skived sheets of celluloid or cellulose nitrate into tubes, inserted the tubes into steel molds that contained the desired shapes, and heated the sheets with steam under pressure.  The steam softened the celluloid sheets and forced it against the mold shapes.  The molds were then cooled in water, rigidifying the plastic.  The molds were opened and the parts trimmed to size.
The main products they had created from plastic were small in size.”[iv]  They had items such as mirror cases, baby rattles, and shaped bottles.
 Through Hyatt and Burrogh’s engineering genius, creations were constantly being designed in plastic.  The United States first began creating bottles, relief maps, cigarette types, ice cube trays, and ping pong balls.  Europe formed polyvinyl chloride (PVC) used in Phillips refrigerators, and piano keys.  In 1938 an automatic thin-sheet roll-fed thermo-former was developed by Klaus B. Strauch Company which increased production speed to a never before seen high.  Not only were plastics used for common household products but also for military items.  During World War II, aircraft windscreens, machine gun turrets, and domes were being formed from plastics.  In 1948, in England, cast acrylic bathtubs were thermoformed by the Troman brothers, and in 1954 skin-packaged products were first shown at hardware manufacturer association trade shows.  Then in the 1970’s, the first thermoformed plastic concept car body was designed by Borg-Warner Inc.[v]
“Today heavy gauge plastics are used as cosmetic surfaces on permanent structures such as kiosks, automobiles, trucks, medical equipment, material handling equipment, spas, and shower enclosures, and electrical and electronic equipment.”[vi]  With the growth of education and corporate enterprise, new engineering technologies have been invented to aid in the thermoforming process.  “Although the basic forming process is very similar to what was invented many years ago, microprocessor and computer controls on more modern machinery allow for greatly increased process control and repeatability of same-job setups from one production run to the next, usually with the ability to save oven heater and process timing settings between jobs.”[vii]
Now the industry has become a powerhouse bringing profits in the hundreds of millions of dollars.  Huge companies such as: Mayfield plastics, Thermo-Fab, Universal-Plastics, and Lifetime have emerged.  The market continues to expand in part because of the versatility and variety of products made.  There are so many things can be done with the material.  Now, whenever you enter a Wal-Mart, Home Depot, Lowes or any other major retail store you will see Thermoformed plastic.  It has come along way since it’s the early creation of kitchen wear. 
 Tortoise Shell (made of Keratin)[viii]

  Alexander Parkes[ix] 
John Westley Hyatt[x]

 Plastic Relief Map[xi]



[i] Throne, James L. Hanser Gardner http://books.google.com/books?id=FIFlNYgV7poC Publications, "Understanding Thermoforming." Accessed February 20, 2012..

[ii] skytec plastics, "History of Thermoforming." Last modified October 03, 1999 . Accessed February 20, 2012. http://www.plasticwebsite.com.au/thermoforming_history.htm.

[iii] Wikipedia, "Celluloid." Last modified Februrary 15 2012. http://en.wikipedia.org/wiki/Celluloid

[iv] Throne, James L. Hanser Gardner Publications, "Understanding Thermoforming." Accessed February 20, 2012. http://books.google.com/books?id=FIFlNYgV7poC.

[v] Throne, James L. Hanser Gardner Publications, "Understanding Thermoforming." Accessed February 20, 2012. http://books.google.com/books?id=FIFlNYgV7poC.

[vi] Wikipedia, "Thermoforming." Last modified January 25 2012 . Accessed February 20, 2012. http://en.wikipedia.org/wiki/Thermoforming.

[vii] Ibid

[xi]Wikipedia, "Raised-relief map." Last modified January 5 2012. Accessed February 20, 2012. http://www.google.com/imgres?um=1&hl=en&sa=N&pwst=1&tbm=isch&tbnid=rrTXghbYvDLS3M:&imgrefurl=http://en.wikipedia.org/wiki/Raised-relief_map&docid=aXk5kNG1UEbQGM&imgurl=http://upload.wikimedia.org/wikipedia/commons/thumb/3/31/Tatry_Mapa_Plastyczna.JPG/350px.