Q: What kind of polyethylene material savings potential is available with your technology?
A: OptiMISER® System users are reporting actual material cost savings from 10 to 30 percent. The impact of these savings for a typical plastics processor implies a reduction in cost of goods of around 5% to 15% The savings are sustainable, which presents exciting opportunities for improving earnings, expanding capabilities and increasing market share.
Q: Why focus my limited discretionary time on resins?
A: Resin cost is typically the single-largest cost element within a manufacturing environment and therefore provides the greatest opportunity for improving earnings and developing a competitive and sustainable market advantage.
Q: Why blend two or more materials? Why not just buy one material and reduce complexity in the plant environment?
A: It's frequently to your advantage to combine the properties of one polymer with those of another, instead of trying to buy a specialty or "boutique" resin (if available) at premium prices. When you begin blending with low-cost commodity resins, you not only eliminate the need for specialty materials, you generate an attractive return and the potential for a sustainable market advantage.
Q: So, The OptiMISER System will enable me to create a blend tailored to my product and process needs at a net lower cost, including the testing, manning and infrastructure needs that may be required?
A: Yes! The OptiMISER System can be used to optimize the materials to support the physical properties of your manufactured part and do so at a reduced cost. The results are greater processability, often improved production rates, and superior product quality.
Q: Will your technology enable me to reduce the weight of my products?
A: Potentially! It is not unusual to experience a compromise in the manufacturing environment due to one or more material properties not ideally suited to the process or the part design. One OptiMISER System user achieved huge success in a high-volume application by slightly altering the blend formulation for a specific product. That one change reduced the unit weight and improved the part quality.
Q: Your guarantee says that if I don't see any reduction in my costs after using The OptiMISER System for 90 days, you'll refund all of my license fees. How can you offer that kind of no-risk promise?
A: The OptiMISER System is not a new product - we used it for years before we founded Advanced Blending Technologies so we could offer it to other processors. We know first-hand that it does what we say it will do. And other companies who now license The OptiMISER System report the same kind of performance. It's a proven system, and once you've started it, you'll be glad you did.
Q: Can you make high-quality products using The OptiMISER System blending technology?
A: Yes. The OptiMISER System can be used to tailor formula properties to fit the specific needs of your product(s), improving quality and processability as well.
Q: So, you can make high-quality products using recycled, reprocessed or wide-spec resins using this technology?
A: The use of recycled, reprocessed or wide-spec polyethylene resins requires an understanding of the material properties. There is no difference between a recycled polyethylene molecule and a virgin polyethylene molecule having the same length. The length of the molecule — not whether or not it is virgin — determines its behavior. With our technology, using the vast range of PE resins available to produce highly replicable products to your standards will become routine.
Q: If I use multiple grades or forms of PE, how can I be assured that I won't sacrifice quality in the end product?
A: Our methods for characterizing the incoming raw materials provide critical performance data that are then entered into your customized OptiMISER formulation software. The software formulates blends based on your CTQ and cost targets. You'll see in your resulting screen display that none of the blends offered jeopardizes your quality levels. Your priorities — cost and/or performance — are your OptiMISER System's priorities.
Q: Can I just buy or access the optimization software as a separate service?
A: The success of the blend formulations optimized by the software depends completely on its access to accurate material characterization. It would be impossible to achieve one without the other.
Q: If I blend to a target melt index and density, isn't that sufficient to achieve the target performance I'm looking for in a product?
A: Unfortunately, blending for MI and density alone does not ensure processability or product performance. See for yourself in the Blending Basics section.
Q: What kind of issues am I likely to experience if melt index and density are my only blend inputs?
A: Examples include wide variations in your output rates and efficiencies, as well as unpredictable die swell, melt strength, shrinkage, impact strength and stress cracking resistance. Any one of the above could result in increased cost and/or product liability issues.
Q: What kind of equipment investment do I need to consider to take advantage of The OptiMISER System technology?
A: Minimal! Initially, you need not invest in the material test equipment Advanced Blending Technologies can provide the required material testing services until you decide to invest in bringing the testing in-house. Additional investments may be required if your blending capabilities require an upgrade.
Q: How do I know what type of blending equipment I need for my production needs?
A: Advanced Blending Technologies provides an in-plant evaluation of your total system needs: it's the first step of The OptiMISER System process. We evaluate for capacity, capability, and number of blend components.
Q: Why Test? Do I need the material characterization?
A: Yes. Most of the time the advertised specs from the broker or recycled material supplier are different from the actual specs (and material characteristics can vary from lot to lot). For The OptiMISER System to develop quality blend formulas we need accurate material properties.
Q: Will your blending technology restrict the type of polyethylene grade, form or quality I can use?
A: Not at all. OptiMISER System technology can accommodate multiple streams of material in varying forms or grades of quality. In fact, OptiMISER software even allows you to set parameters for specific material content as a percentage of the blend.
Q: We make a wide range of products. How many different components can I blend with your software?
A: With OptiMISER software, you can blend from two up to five different components. In fact, the manufacturer's blending capabilities are most often the limiting factor, not the software.
Q: If I choose to use wide-spec, recycled or reprocessed resin in my blend, how can I be sure of adequate supply?
A: Wide-spec, post-industrial and post-consumer resin streams are estimated at more than 15% of materials sold annually within the U.S. ABT can help you establish reliable material sources that will enable your company to increase earnings without jeopardizing product quality.
Q: How does The OptiMISER System "expand the universe of available materials" to my operation at lower cost?
A: Because our knowledge of material properties and resin behaviors is embedded in OptiMISER System software, it allows you to consider a wider band of resins by grade and type. This opens the door to resins that you may never have considered viable.
Ease of Use
Q: It all seems complicated - maybe too complicated for my operators.
A: Absolutely not! The OptiMISER System screen interface was developed for easy use by shop floor operators. Simple, easy-to-use operator instructions and start-up assistance; little training is needed.
To download The OptiMISER System brochure in PDF form, click here.