Plastics Technology - Dedicated to improving Plastics Processing.
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(riverdaleglobal.com), Perth Amboy, N.J., is devising a "local" satellite supply-and-service program that is intended to make the liquid-color option more appealing and convenient. Riverdale has two such satellite facilities running within a 200-mile radius of major customers, and expects its network of satellites to include three more by the end of 2015. With these satellite facilities, Riverdale can satisfy the just-in-time approach adopted by many companies that don't want lots of inventory on hand (see image p. 42). The facilities provide local support for equipment and color and can provide fast response for color "emer- gencies" with their local inventory and color matching and blending capability. Service technicians can help customers maintain the proper inventory with more frequent deliveries that help reduce color stock levels. Riverdale ofers free delivery plus automatic pickup of empty containers as part of its "return for refll" program that bolsters sustainability. Since its entry into liquid color in 2011, Plastics Color Corp. (PCC), Calumet City, Ill. (plasticscolor.com), has expanded its liquid- color production with a plant on each coast. Mark Hass, product manager for PCC's Liquosol liquid-color line, estimates the current annual growth of liquid colorants could be in the 5-10% range. Why all this activity? Hass and others see lower cost as the key factor convincing most processors to make the transition to liquid color, particularly in view of recent years' economic constraints and price volatility in commodity resins. Liquid masterbatches are highly concentrated so that less is needed to achieve brilliant, vibrant color, especially in translu- cent and transparent polymers. Hass says liquid color can lower costs by 10% to 40% compared with solid masterbatch, depending on the application. He points out that typical addition levels for liquid colorants are 0.5% to 1% for opaque colors and less for tints, vs. 3% to 4% for most solid concentrates. At Riverdale, president Paul Maguire points out that the cost savings extend beyond the colorant's purchase price. "You can run at cooler temperatures; you can speed up cycle time; your color changeover time is much reduced; liquid colorants take up less foorspace; and there are cost savings on reusable containers." He adds that the company's gravimetric delivery systems, from sister company Maguire Products, Aston, Pa. (maguire.com), provide precise metering that ensures correct letdown ratios so that color is never wasted. Use of gravimetric instead of conventional volumetric metering nearly always reduces color usage by 10%, Maguire says. Gary Fielding, marketing director at PolyOne Corp.'s ColorMatrix Group, Berea, Ohio (colormatrix.com), says liquid color continues to gain market share in injection molding. "The ability to change colors quickly can help reduce waste and changeover time. For molders with niche applications and shorter production runs, the ability to order smaller quantities helps them to manage inventory and keep working capital costs down." Maguire says liquid colorants have been used mainly in house- wares and toys. Within the last fve years, the company has seen a dramatic increase in demand for liquid colors in packaging, with major brand owners such as Procter and Gamble, Unilever, and Colgate requiring that its processors have liquid-color capabilities. Both Maguire and Hass note increased interest in liquid additives generally—ranging from slip and mold- release agents to antioxidants and UV stabilizers—that can either be formulated with the liquid color or fed separately. Says Maguire, "Whereas with a solid masterbatch, typical use levels are 3-4%, with liquid colorants and additives, use levels are closer to 0.2-0.3% because of the easier dispersion. We want people to know that these liquid additives are available and that if they opt to use them, they can expect improvements in processing such as faster cycle times, improved surface aesthetics, and easier assembly of parts." In any event, suppliers say processors should realize that liquid color is not a product but a system, and they should consider metering equipment and delivery, inventory, and cleanliness issues. Says Clariant's Prusak, "We recognize liquid color is not for everyone, and since Clariant ofers both solid and liquid, we are unbiased. Our objective is to help customers select the right solution for their particular needs." GETTING THE WORD OUT Clariant recently launched an initiative to build awareness and accep- tance of liquid color and additive masterbatches among North American processors, product designers, and brand owners. Late last year, the company launched HiFormer, a new global brand that encom- passes its high-performance liquid color and additive concentrates, dosing/handling equipment, expertise, and service. Raymond Sloan, director of liquid colorants at Clariant, says liquid masterbatches can be used in many of the same applications as "Many of the bigger players have moved in this direction, and this is trickling down to smaller molders." Personal-care packaging is yet another promising area for liquid color with custom molders such as Currier Plastics moving in that direction. (Photo: Clariant) @plastechmag 39 Plastics Technology Liquid Color