Paulson Training Programs

P.O. Box 366

Chester, CT 06412
International Sales
Larry Mercugliano
Cell Phone: 860-388-3736
Home Office Phone: 860-415-4880
Email: Larrym@PaulsonTraining.com
www.paulsontraining.com

PRODUCT DETAILS CD PROGRAMS

BASIC INJECTION MOLDING MACHINE OPERATIONS

Basic Injection Molding Machine Operations is a two-lesson (3 hours of training) program designed for
use by entry-level injection molding personnel, new employees, and for employment screening. The
emphasis is on safety, efficiency, and teamwork

Detailed Lesson Descriptions

Lesson 1 – This lesson starts with an overview of the injection molding process, then covers basic
material handling do’s and don’ts, machine part identification and standard operator responsibilities
during the molding cycle. Emphasis is given to operating safety, protection of molds from damage and
proper plastic part handling.
Lesson 2 – This lesson explains molding machine operations. It also discusses regrinding, trimming
flash and degating plastic parts from runners. Employees are taught to identify common part defects
such as short shots, flash, warp, surface defects and color changes.

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 INJECTION MOLDING FUNDAMENTALS

New Training Program For Entry Level Personnel !

Goals of this course

• Orient new employees to the injection molding production floor and process

• Teach the value of safety, quality and teamwork

• Show correct operating procedures

• Eliminate careless and unsafe procedures

• Quickly identify common part defects

Recommended For: Entry Level Personnel, All Personnel

Injection Molding Fundamentals is a new two lesson 3-4 hour training program that teaches your
personnel the most important and fundamental aspects of the injection molding production floor and
molding process. Using state-of-the-art 3D animations, participants get a firm understanding of the
inside the injection molding process. The course also uses actual in-plant scenes so that employees
and prospective employees gain an understanding of typical production floor operations.

3 – 4 Hours of Training

Safety around the injection molding production floor and machinery is emphasized throughout these
lessons. The emphasis is on production efficiency, safety and teamwork. The course also extensively
covers the fast and accurate identification of part defects.

Give all your new employees a firm, common foundation from which to build their injection molding
knowledge and give your current employees refresher training with Injection Molding Fundamentals.
This course serves as excellent refresher training for veteran employees.

Lessons Included
Lesson 1: Parts of the Molding Machine and Operator Responsibilities

This lesson starts with an overview of the injection molding process, machine part identification and
standard operator responsibilities during the molding cycle, modes of operation of the machine and the
important aspects of material handling, Emphasis is given to operating safety, protection of molds from
damage, and proper plastic part handling.

Lesson 2: Identifying Part Defects and Safety

This lesson presents visual and animated 3D examples of all of the most common injection molded part
defects such as short shots, flash, warp, surface defects and color changes. It also discusses
secondary operations such as regrinding, trimming flash and de-gating plastic parts from runners.
Employees are taught to identify common part defects such as short shots, flash, warp, surface defects
and color changes.

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PRACTICAL INJECTION MOLDING

Practical Injection Molding is a comprehensive 15 CD-ROM program (over 40 hours of training) focused
on developing the skills and understanding your personnel need in your injection molding facility. In
addition to 15 interactive lessons, Practical Injection Molding features SkillBuilder, which is a
revolutionary new training platform for injection molders. SkillBuilder is an injection molding machine
simulator combined with interactive molding labs which allows your employees to gain real, hands on
molding experience before running the molding machines on your production floor. Combined, this
comprehensive interactive training series and SkillBuilder package is unmatched by any training
program in the plastics industry. Molders from around the world see dramatic results in productivity and
profitability from this program and rely on it as the foundation of their training and troubleshooting
program.

Practical Injection Molding contains four core modules and is recommended for anyone involved in the
injection molding process.

PIM Module 1 - Basic Injection Molding

The Basic Injection Molding module contains five CD-ROM lessons (over 20 hours of training). This
hands-on, interactive package is recommended for machine operators, material handlers, set-up
personnel and production supervisors. The Basic module focuses on the fundamentals of injection
molding technology, including basic knowledge that all personnel involved in the molding process must
understand to make informed decisions on the production floor.
Note: Price includes five CD lessons, comprehensive leader’s guide and five study guides.

Detailed Lesson Descriptions for Basic Injection Molding

Lesson 1 – Inside the Molding Machine – Shows and describes all major components of the injection
molding machine.
Lesson 2 – Inside the Mold – Construction and operation of two-plate, three-plate and
runnerless molds.
Lesson 3 – The Nature of Plastics – Characteristics, types, structure, size and processing behavior.
Lesson 4 – Machine Operating Controls – Part 1 - Purpose, operation and effects of the pressure
and fill rate controls.
Lesson 5 – Machine Operating Controls – Part 2 – Purpose, operation and effects of machine and
mold temperatures, timers, screw and clamp controls.

SkillBuilder For PIM Basic – Module 1

SkillBuilder is the molding lab portion of our training. It integrates a fully functional injection molding
machine simulator with fifteen structured lab lessons. This closes the loop on employee training by
allowing employees to immediately apply what they learn in the interactive lessons.
Detailed Lab Lesson Descriptions for SkillBuilder

Lab Lesson 1 – Understanding the Injection Molding Process – A review of the sequence of the
standard injection molding cycle with emphasis on timer operation.
Lab Lesson 2 – Setting Machine Controls – Learn how to operate the control panel of the molding
simulator and how to interpret SkillBuilder outputs like fill time, cycle time, melt temperature, part size
and part weight.
Lab Lesson 3 – Understanding Fill Rate Controls – Teaches the effects of setting SkillBuilder’s five
steps fill rate profile on cavity fill time and part characteristics.
Lab Lesson 4 – The Effects of Back Pressure – Examines how raising and lowering the back
pressure setting affects the melt temperature and the maximum allowable back pressure setting and the
effects of exceeding it.
Lab Lesson 5 – Setting the Injection Limit Timer – Learn the proper setting for the injection limit
timer, which shuts off the injection pressure if the VPT set point is not reached.

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Lab Lesson 6 – The Maximum Injection Pressure Settings – Discusses how to set the maximum
injection pressure setting so the fill rate control never lacks the pressure it needs to fill the cavity
according to the fill rate profile.
Lab Lesson 7 – Setting the Holding Timer – Examines how the holding timer determines the length
of time the holding (second stage) pressure stays on. Lesson 7 also examines the effects of the
holding time on gate sealing and molded part weight and dimensions.
Lab Lesson 8 – Setting the Holding Pressure – Focuses on how to set various holding pressures to
determine the effect on the molded part weight and length.
Lab Lesson 9 – Mold Closed Time and Mold Open Time vs. Melt Temperature – Learn the effects
of mold closed and open time on the melt temperature. Set the mold-closed time to the minimum
required to make a good part.
Lab Lesson 10 – The Effects of Barrel Zone Temperatures on the Melt Temperature – Vary the
temperature setting of each barrel zone temperature, one at a time, to determine how each zone affects
the melt temperature. Learn how to match the actual melt temperature to the front zone barrel setting;
a good molding practice.
Lab Lesson 11 – Some Effects on Mold Temperature – Set different core and cavity mold
temperatures to determine the effect on peak cavity pressure and part dimensions.
Lab Lesson 12 – The Effects of Screw RPM – Learn by setting various screw rpms, the effects on the
melt temperature and the plasticating time (the time required to convey the next shot of plastic ahead of
the screw.)
Lab Lesson 13 – The Effect of the Screw Back Position – Examines the effects of the screw back
setting on the cushion size and on the melt temperature. Students can change the screw back position
to increase and decrease the cushion size.
Lab Lesson 14 – Effects of Clamp Force – Learn how the molding conditions affect the amount of
clamp force required and how to set the clamp force to the minimum required to produce a good part.
Lab Lesson 15 – Achieving and Controlling the Melt Temperature – Use knowledge gained in
previous lessons to accurately achieve a desired melt temperature. Learn the front zone barrel
temperature and the melt temperature often don’t match and examine the various machine controls
available to alter the melt temperature.

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PIM Module 2 – Expert Series
Course and Lesson Descriptions

Practical Injection Molding – Expert Series is a 5-CD (approximately 5 hours of training) program that
builds on the knowledge gained from the PIM – Basic module. Emphasis of this course is on building
an in-depth understanding of the molding process for those wanting to be at the expert molding level.

Lesson Descriptions:

Lesson 1: Inside the Injection Molded Part

This lesson describes the structure of plastic molecules and the different internal structures than can
develop in molded parts - crystalline, amorphous and oriented. A part's internal structure affects
finished part properties.

Lesson 2: Plastic Flow: Understanding How Flow Affects the Molding Process
This lesson explains how the various types of plastics flow, orient, and change their viscosity.
Molecular orientation is discussed including its effects on part directional properties and frictional heat
generation.

Lesson 3: The Effects of Temperature, Pressure, Flow & Cooling on the Molded Part
This lesson shows that although a typical molding machine has from 15 to 30 separate controls, the
plastic knows only the four primary plastic processing conditions -- pressure, temperature, flow rate,
and cooling rate.

Lesson 4: The Requirements to Control Molded Part Quality

This lesson continues our discussion of the four primary plastic processing conditions. Here we
examine the effects of cavity pressure on molded part properties. The internal part stresses caused by
pressure and cooling are explained.

Lesson 5: The Expert Use of Molding Machine Controls

This lesson teaches the practical application of the information presented in the previous lessons. The
effects of machine controls on plastic behavior is analyzed to show how control changes affect finished
part properties.

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PIM Module 3 – Optimizing Machine Control Settings

Optimizing Machine Control Settings is a 4-lesson program (6 hours of training) that is recommended
for machine operators, supervisors, lead persons, set-up personnel and foremen. The course provides
your injection molding production floor personnel with hands-on, immediately useful training. Optimizing
Machine Control Settings emphasizes specific rules, procedures and detailed explanations for
controlling the plastic during molding, setting up the machine for optimum cycles, and overall safe,
efficient machine operation.

Detailed Lesson Descriptions for Optimizing Machine Control Settings

Lesson 1 – Setting Up for an Efficient Molding Run - This lesson teaches methods to optimize your
injection molding operations by examining efficient pre-start, safety and machine control set-up
procedures.
Lesson 2 – Optimizing Screw Control Settings - This lesson details rules and procedures for
optimizing the machine controls that affect the reciprocating screw. These controls include: back
pressure, screw rpm and timers. Specific procedures for optimizing these screw control settings are
given.
Lesson 3 – Setting the Injection Controls for Maximum Productivity - This lesson teaches the rules
and procedures for setting and maintaining the injection control settings for maximum productivity. We
discuss how changing processing conditions affects molded part properties. Some of these processing
conditions include: fill rate profiles, transfer set points, packing & holding controls, and mold open &
closed timers.
Lesson 4 – Maintaining Peak Efficiency & Solving Process Problems - This lesson discusses how
to maintain peak-molding efficiency by monitoring specified controls and operating parameters. The
lesson also describes how to correct the most common processing problems encountered during
routine production.

Skillbuilder for PIM Optimizing Machine Control Settings

The 7 SkillBuilder lessons designed to accompany Paulson’s 4 CD Optimizing Molding Machine

Controls Settings course are designed to simulate the molding floor environment. Users operate a
virtual molding machine control panel that allows them to make machine adjustments and cycle the
machine, just like on the molding floor. The combination Of Skillbuilder with PIM Optimizing provides
approximately 14 hours of training.

The 7 lessons in this course challenge users to solve difficult molding problems that would be costly,
time-consuming and difficult to replicate on the molding floor. After all, how many molders have a spare
molding machine lying around and workers with free time to run experiments on it? Using SkillBuilder,
valuable molding techniques are learned that translate to the production floor, making your production
personnel more knowledgeable and more productive. Employees learn how to mold without tying up
valuable machine time or damaging expensive equipment and tools.

Detailed SkillBuilder lab lesson descriptions

Lesson 1 - Optimizing Melt Temperature Molding an Amorphous Material. Molding a cell phone
cover in polystyrene, an amorphous material, the goal of this lesson is to create and maintain a melt
temperature of 430°F. The available molding machine controls are the barrel heaters, screw rpm and
the backpressure.
Lesson 2 - Optimizing Melt Temperature Molding a Crystalline Material. Molding a cell phone cover
in polypropylene, a crystalline material, the goal of this lesson is to create and maintain a melt
temperature of 400°F. The available molding machine controls are the barrel heaters, screw rpm and
the backpressure.
Lesson 3 - Optimizing Fill Time to achieve the Fastest Fill Possible. The goal in this lesson is to fill
the mold as fast as possible while still molding a good part. In general, good molding practice dictates
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that the mold should be filled as fast as is practical. The plastic type is ABS and the available machine
controls are the clamp tonnage, the fill rates and the holding pressure.
Lesson 4 - Optimizing Part Dimensions Molding an Amorphous Material. Part dimensions are
often critical in injection molding. This lesson teaches some techniques for tightly controlling part
dimensions while molding an amorphous plastic like polycarbonate. Available machine controls are the
mold temperature; fill rates and the holding pressure.
Lesson 5 - Optimizing Part Dimensions Molding a Crystalline Material. Crystalline materials like
polypropylene can be more difficult to keep to tight dimensions. This lesson teaches some techniques
for tightly controlling part dimensions while molding a crystalline like polypropylene. Available machine
controls are the mold temperature; fill rates and the holding pressure.
Lesson 6 - Optimizing Part Weight to Achieve Minimum Plastic Usage. Reducing part weight to the
minimum that makes a good part saves money by using less make a good part. Molding a bracket in
polystyrene, the student will have the holding material. In this lesson molding techniques are explored
that reduce plastic usage, but still pressure and the mold temperature as available machine controls.
Lesson 7 - Optimizing Mold and Melt Temperature to achieve the most Efficient Cycle Time.
Achieving the lowest possible cycle time can often be the difference between making and losing money
on a molding job. Understanding energy balance is important. The less heat you put in the plastic the
less you have to take out. Molding a cover in polyethylene the student has the barrel heaters, screw
rpm, backpressure, mold temperature and cooling time controls available.

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ELECTRIC INJECTION MOLDING COURSE

Electric molding machines now account for over 50% of new machine sales. There are several reasons
for their popularity; more precise control, lower electricity consumption and potentially faster
cycles are among the reasons. But along with these and other advantages are potential
problems. These machines require an understanding of this new technology by the operating
personnel to gain the benefits and avoid very expensive mistakes. In short, they require more
knowledgeable personnel at all levels.

Now available, Paulson offers a new three-lesson Electric Injection Molding Machine course. This new
course integrates into the Paulson 15 lesson Practical Injection Molding training course.
Molders who already have the 15 lesson course and are interested in Electric molding
machines will want to integrate this new course into their training program. Others may just
want to start out with just the All-Electric course.

The All-Electric Molding Machine Course

Lesson 1 :: Electric Machine Design, Cycle & Parts

• The parts of the Electric molding machine

• How Electric molding machines work
• Comparing the operation of the Electric and the Hydraulic molding machine
• Operation of the ball screw drive
• The molding cycle
• Instruments and controls used on these machines
• Typical operating conditions

Lesson 2 :: The Effects of Each Control

• Safety around these machines

• Machine modes of operation: manual, semi-automatic and automatic
• Explanation and effects of the injection controls: injection rates and
pressures, vpt settings, back pressure, shot size, cushion, control
change ramps, decompression and others.

Lesson 3 :: Optimizing Electric Machine Settings

• Clamp settings: control of clamp distance and speed, clamp force, safety concerns.
• Ejector control
• Optimizing the machine control settings

• Process recordings

• Procedures for utilizing the advantages of the Electric machine.

As always, every Paulson course includes student workbooks so that the student has a permanent
record of what has been learned and to add or make notes as he or she is taking the course.

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SimTech™ Injection Molding Machine Simulator

Background – The Paulson Injection Molding Simulator, the world’s first software program that
simulates the complete injection molding process from hopper to finished part. Over 7000
programming and research hours were spent on its development. The result is a complete
mathematical representation of the effect of each molding machine control, the subsequent effects
on the plastic as it flows, the shear heating, the packing process and the cooling of the part.

SimTech 2003 is the forefront of applied molding process simulation. The simulator can evaluate
changes in the molding process that would take hours or even days to do on an actual molding
machine. Molders, resin suppliers, machine builders, researchers can quickly evaluate ideas that will
lead to improved personnel capability, higher productivity, and better mold and machine performance.

SimTech 2003 Calculates:

• cavity pressures
• melt temperatures
• screw run time
• cavity fill time
• fill pressure loss
• packing pressure loss
• cycle time
• percent full at VPT
• cushion size
• shot volume
• part weight
• part dimensions
• area under the cavity pressure curve
• average part temperature at ejection
• cavity discharge (if any)
• flash (if any)
• short shot (if any)
The User can:
• graph plastic pressures and temperatures inside the mold.
• change any mold, machine, plastic or control variable and re-run the cycle to compare results.
• run up to four cycles in a row to compare results

Who Should Use SimTech 2003?

Process Engineers and Molding Technicians – Molders can simulate the molding of production parts
to find optimum cycles and determine the effects of any control change.
Part and Mold Designers – Designers can change any machine control, part size, part thickness, gate
size and number of cavities to quickly determine the effects of the change on molded parts or on the
process.
Plastic Technical Service Personnel- Tech service personnel can learn the effects of any machine
control or mold design change. They can simulate the molding of a customer’s part to trouble shoot,
correct problems or recommend plastic changes.
Researchers – Anyone doing molding research can quickly determine the effects of any machine or
mold design change, resin change, or process change on the plastic behavior in the mold.
Students – Anyone learning the molding process should have practice running a molding machine.
The molding simulator allows the user the “practice” molding safely.

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Features and Benefits of SimTech

Features:
• The program has the capability to simulate all types of machines: Fill rate controlled, decoupled II
molding, and two-injection stage molding machines. (presently only fill rate controlled machines are
used)
• The program includes all the machine and mold operating controls found on both older and modern
molding machines.
• User can mold the geometric representation of his part and change the runner, gate and gate
location.
• User can select the number of cavities.
• User can change machine barrel, screw and clamp specifications or add a new molding machine
• User can change plastics or add a new plastic
• Outputs shows shot size, part dimensions, several likely part or molding problems, fill time, melt
temperature, cushion size, part weight, cycle time cavity pressure etc.
• Output includes graphs of plastic pressures in the runner, gate and cavity
• Output includes melt temperature and plastic temperatures during cooling.
• Up to four cycles at a time can run and then shown and graphed.

Benefits:
• SimTech 2003 Optimizer operates just like an actual molding machine. All the machine controls
are active. Personnel can learn the effects of every machine control.
• The program calculates the plastic behavior inside the cavities and shows cavity pressures,
temperatures and molded part dimensions.
• The user can change any process, mold, machine or plastic variable and then compare the results.
• The program graphically shows the pressure and temperatures in the cavities during the cycle.

Applications:
• Molding production improvement – find the best machine settings for improved cycle
times.
• Increase the number of molding experts through simulation training.
• Improve mold and part design personnel by giving them molding experience.
• Conduct resin evaluations under realistic molding simulation conditions.
• Reduce tech service time by improving the capabilities of employees and customers.

Frequently Asked Questions

What size computer do I need to run this simulation program?
The program size is just under 2 megabits. The computer speed should be 500 megs/sec or faster.

Can anyone run this injection molding simulation program?

Yes, however, SimTech 2003 is a fully operational molding machine simulator. Therefore the user must
know how a molding machine works and understand at least the basic machine controls. Molding
experience and/or the Paulson Basic and Advanced Injection Molding courses provide that knowledge.
Can the SimTech 2003 develop expert molders?

Just as flight simulators are the most effective and least expensive way to train pilots, molding
simulators do the same for molders. Simulation is the fastest way to provide “hands on” molding
experience. Users get actual molding practice that can then be directly applied on the production floor.

Can SimTech simulate my molding machines, molds and plastic?

Yes. SimTech accepts any screw and barrel dimensions, part and mold dimensions, and plastic PVT
and viscosity data.

How can SimTech help develop molding experts?

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Personnel can learn aqnd practice molding away from the production floor. They can make any change
to the machine, mold or plastic and test the results. Molding problems can be shown and solved using
SimTech. The results is to give molders the realistic experience they need to become experts.
The greatest difference between the top molding companies and all the rest is the capability and
number of experts they have available.

What are other uses for SimTech besides training?

SimTech can simulate your molding jobs. It can be used to find setup conditions that are then
transferred to the production machines. Molders can simulate molding conditions on production molds
that reduce cycle times or solve molding problems. The user can evaluate conditions that might be
harmful of actual machines.

Can I simulate multi-cavity molds on the simulator?

Yes

Can I change gate locations?

Yes, you can center gate or edge gate any mold you put in.

Can I simulate a hot runner mold as well as a conventional mold?

Yes

I’m in Plastic Technical Service, how could I use a simulation program?

You can simulate and troubleshoot a customer’s mold in your tech service office. Then you can
recommend molding conditions base on your results using the simulator.

Can I get printouts of the results of my molding simulation?

Yes, a complete printout is available using the “print” button.

Can I run a sequence of molding cycles to compare the effects of changes in control settings,
cavity design, or the plastic?
Yes. Up to 4 cycles can be run consecutively.

Can I load my exact part design such as an STL file in this program.
Yes. The part will be shown on the simulator screen. However, the program will run a geometric
representation of the part to allow a fast calculation.

Can I simulate multi-cavity molds?

Yes

Are all the molding machine control settings active including fill rates and fill to pressure (VPT)
transfer?
Yes. All of them are included in the software.

Can I use the simulator to do research on the effects of machine controls, cavity changes, or
plastic changes?
Yes, the most important benefit of this software program in the ability to quickly change any variable to
determine its effects without the problem of machine conditions changing between cycles or changing
over time
.
What improvements and updates will be available to users?
Paulson is establishing a user group in addition to its own internal development group. New features
and improvements will be continuously added and released yearly to customers.

Injection Molded Part Problems and Solutions

Injection Molded Part Problems and Solutions is an eleven program that discusses eleven common
molding problems and solutions to solve those problems. Topics covered include Voids, Sink Marks,
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Short Shots, Flash, Weld lines, Splay, Jetting, Burn Marks, Warp, Cracking, and Dimensional Control.
This program is recommended for set-up personnel, foremen, process engineers, production
supervisors and molding managers.

Detailed Lesson Descriptions for Injection Molded Part Problems and Solutions

Voids – Small holes in thick sections caused by plastic shrinkage.

Sink Marks – Small depressions in molded part surfaces opposite thick sections, caused by internal
stresses as the plastic cools.
Short Shots – Undersized molded parts due to incomplete cavity filling from too little plastic, poor
venting, mold or melt temperature problems, faulty part or mold design.
Flash – Thin ribbon of excess plastic formed when plastic is forced between parting lines in the mold.
Harmful to the mold and requires trimming operation for removal.
Weld lines (Knit Lines) – Lines where plastic streams meet during mold filling, causing unsightly
appearance and structural weakness.
Splay (Silver Streaks) – Surface defect that occurs when gas bubbles are dragged along the plastic
surface as it fills a cavity.
Jetting – Surface defect caused when a jet of resin “shoots” through the gate and cools as a long string
of plastic inside the cavity.
Burn Marks – Burned plastic edge caused by plastic igniting in the cavity and the air in the cavity
cannot escape and overheats.
Warp – Molded part distortions from uneven stresses in the part caused by faulty molding conditions
inside the cavities.
Cracks and Part Breakage - Weak molded parts susceptible to cracking and breaking, as a result of
incorrect molding conditions that can cause five different types of cracking problems.
Controlling Molded Part Dimensions – Off-spec parts caused by dimensional changes throughout the
part, in specific areas or directionally.

Specific SkillBuilder Lesson Descriptions For Injection Molded Part Problems and Solutions

The SkillBuilder lessons that accompany our "Injection Molding Problems and Solutions" CD training
are designed to take the student from the classroom to the production floor. Using our state of the art
molding machine simulation software, employee's can actually run a molding machine to improve their
problem solving skills. The combination of IMPP&S with Skillbuilder machine simulation lessons
provides approximately approximately18 hours of training.

The Problems and Solutions lessons teach the user the multiple causes and multiple solutions to six
common molding problems. Users adjust machine controls and mold parts, guided by feedback from
the simulator, to become expert molding problem solvers.

SkillBuilder provides the student with an opportunity to practice molding in a realistic environment
without creating machine downtime.

Lesson 1 - Solving a Burn mark Problem. Burn marks on a molded part are caused by trapped air in
the cavity. If the air in the cavity isn't adequately vented as the plastic fill the cavity it will be
compressed, heated and ignite, charring the plastic. This SkillBuilder lesson guides the participant
through some of the available molding techniques that will help eliminate a burn mark on a molded part.
SkillBuilder allows experimentation with solving burn mark problems that would be impossible or
excessively expensive using your parts and your molding machines.
Lesson 2 - Molding to Precise Dimensional Tolerances. Controlling part dimensions can be a
complicated molding problems because so many molding variables affect dimensions. Some of the
primary influences affecting the final dimensions of the molded parts are the mold temperature, holding
pressure and fill rates. This SkillBuilder lesson conducts experiments using those machine controls,
which affect final part dimensions to lead the participant to a greater understanding of precisely
controlling part dimensions. SkillBuilder allows experimentation that would be impossible or overly time
consuming using an actual molding machine.

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Lesson 3. Controlling Flash on a Molded Part. When flash occurs it means that the plastic pressure
in the cavity exceeded the clamp force, forcing open the mold parting line enough to allow plastic to flow
into the parting line. Flash can be eliminated by several different molding techniques. This SkillBuilder
lesson explores all the possible solutions for eliminating flash on a molded part including, high or low
melt and mold temperatures, high packing and holding pressures, unbalanced pressure distribution in
the mold, parting line damage or too deep of a vent channel.
Lesson 4 - Solving Sink marks on a Molded Part. Sink marks in a molded product are caused by
plastic shrinkage. The packing and holding phases of the molding cycle are designed to reduce and
control the amount of shrinkage by putting more molecules in the cavity. In thick sections, like where
walls and ribs and bosses meet, the plastic shrinks more. This is where you often see sink marks occur.
This SkillBuilder lesson challenges the student to solve this problem in a variety of different ways. Both
mold temperature and injection pressures are experimented with to demonstrate to the user more than
one possible solution to the problem.
Lesson 5 - Identifying and Solving Voids in Molded Parts. Voids in a molded product are caused by
the plastic shrinkage. Voids and sink marks are often interchangeable. In thick sections, if the wall of
the part is frozen very quickly, and the plastic inside the part is still shrinking, this shrinking material can
sometimes pull itself apart, and a vacuum void is created. Voids are easiest to spot on clear parts or if a
colored part is cut open. Vacuum voids often have little effect on the appearance and functionality of a
part. The solutions for voids and sink marks are often a trade off of one defect for the other. This
SkillBuilder lesson allows the molder to adjust machine controls to create, then solve each problem. In
this way, a deeper understanding of the problem is realized.
Lesson 6 - Minimizing Weld line Formation and Appearance. Weld lines are caused when two
plastic flow fronts are split, and then rejoin during cavity filling as when plastic flows around a boss, for
example. The strength of a weld line can be from 40% to about 95% the strength of the surrounding
plastic, depending on the type of plastic and the molding conditions, like melt temperature, mold
temperature, holding pressure and fill rates. The purpose of this SkillBuilder lesson is to show molding
techniques on how to reduce and even eliminate the visual appearance of weld lines on a molded
product.

Implementing Decoupled Molding

Implementing Decoupled Molding is a new 3-lesson (5 hours of training) training program on interactive
CD’s, with full motion digital video and photo-realistic 3-D animation that details the molding process
like you have never seen it before. This training course perfectly combines the decoupled molding
expertise of RJG with the proven quality of Paulson.

Decoupled molding is a system of molding techniques designed to achieve a high level of accuracy and
repeatability in the molding process, even as molding conditions like viscosity, naturally vary. Learn how
to establish a methodology for setting up a decoupled molding process and the basics of pressure chart
reading to identify problem areas.

Detailed lesson descriptions

Lesson 1- Introduction to Decoupled Molding. Explains the goals of the course and defines the
necessary terminology. Defines decoupled molding and decoupled molding techniques. Discusses the
effect of normal viscosity variations on peak cavity pressure, types of transducers and their best
applications.
Lesson 2 – Decoupled Molding Techniques. Discusses decoupled 2 and 3 in greater depth,
highlighting when to use each type, the objective, fill, pack and hold techniques. Teaches importance of
plastic flow and viscosity variations to the molding process. Explains difference between process
monitoring and process control and the best techniques for each.

Lesson 3 – Establishing a Decoupled Molding Process. Discusses processing strategies that utilize
consistent plastic properties to produce consistent part properties. Uses pressure chart analysis to
understand what is happening during the molding cycle and to spot the problem areas. Gives a
methodology for setting up a decoupled process from mold and machine considerations to setting
proper filling, packing and holding parameters.
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Hot Runner Molding Solutions

Developed in conjunction with leading manufacturers of Hot Runner Systems, this fully interactive 5-
lesson course (6-8 hours of training) uses full motion digital video and detailed 3-D animation and
graphics.

This technology takes the employee inside the hot runner system to examine the many hot runner
components including the manifold, nozzle and gate. Important start-up and steady-state operating
techniques, specifically for the hot runner system are demonstrated, including ways to optimize the
production run and how to work safely around a molding machine equipped with a hot runner system.

Detailed lesson descriptions

Lesson 1 – Components and Operation of a Hot Runner Manifold. This lesson introduces the hot
runner system and its various components including: the manifold, melt channel considerations and
various manifold heating methods.
Lesson 2 – Nozzle Tip and Gate Design, Components and Operation. Introduces the various nozzle
and gating styles available in hot runner systems today, including the open or “thermal” gate, hot tip
gate and valve gate methods. Also examines proper nozzle positioning in the manifold, as well as
various nozzle heating methods.
Lesson 3 – Nozzle and Manifold Temperature control & Common Hot Runner Applications . This
lesson discusses nozzle and manifold temperature control, including those control methods used
specifically in the nozzle tip and gate area. Explores ways hot runner systems are used with stack
molds and multi-material injection molding processes.
Lesson 4 - Start-up, Molding Optimization, Color change and Shutdown Procedures. Explains the
typical set-up, start-up, molding optimization and shutdown procedures for hot runner molding. It
reviews important color and material change procedures, as well as some safety tips for starting up and
shutting down a hot runner system. Setting up and following the proper start-up and shut-down
guidelines, will allow molders to accurately and safely start, operate and shutdown the hot runner
injection molding machine.
Lesson 5 – Troubleshooting Techniques, Solving Processing Problems and Safety. Teaches how
to troubleshoot the hot runner molding system and explore ways to identify and correct some of the
more common processing problems that may arise in a hot runner injection molding process. It also
discusses the recommended safety and maintenance procedures that should be followed when working
with injection molding machines and hot runner molds.

Statistical Process Control (SPC)

Statistical Process Control is a three-lesson program (5-6 hours of training) intended for set-up
personnel, foremen, process engineers, production supervisors, molding managers and quality
assurance personnel. Train new and current production personnel in Statistical Process Control (SPC)
procedures with a course specifically designed for plastics processing plants. This program will train
new personnel in SPC requirements, increase employee SPC skills and assist in maintaining correct
SPC procedures.

Detailed Lesson Descriptions for Statistical Process Control (SPC)

Lesson 1 - Measuring and Plotting Process Variations – This session describes the application of
Statistical Process Control methods to plastics processing. Lesson 1 is designed for operating
personnel who must understand how SPC works. Part measurements are used to develop distribution
curves and control charts. Explanations are provided for SPC terms including data collection,
distributions, data plotting and setting control limits.
Lesson 2 - Developing and Using Control Charts – This session continues the application of SPC by
showing how X-bar and R-charts are developed from part measurements. The technique for calculating
upper and lower control limits is illustrated step-by-step. Control charts are analyzed, along with the
rules for determining in-control and out-of-control situations. No advanced mathematical ability is
required.
Lesson 3 - Process Monitoring and Problem Solving – This session explains Cp and Cpk ratios,
which are valuable indicators of the capability of a process to conform to customer specifications. The
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pareto method of problem evaluation and the Ishikowa method of problem analysis are described to aid
in identifying the causes of problems.
Plastic Drying Technology (PDT)

Plastic Drying Technology is a two-lesson program (3 hours of training) intended for material handlers,
set-up personnel, foremen, process engineers, production supervisors, molding managers and quality
assurance personnel. This is a comprehensive training program that teaches the important, but often
neglected, topic of plastic drying. Three common drying systems are taught: hot air, desiccant, and
refrigerant-dehumidifying systems. Each are explained from their operational, control and maintenance
characteristics.

Detailed Lesson Descriptions for Plastic Drying Technology

Lesson 1 – Principles of Drying – This lesson establishes the background and basics of drying, from
the effects of moisture on molded parts to the theories of dryer operation. Defined terms include
hygroscopic, relative humidity, dew point, weight percent, vapor pressure differential, closed loop and
open loop.
Lesson 2 – Dryer Operation, Control and Maintenance – This lesson deals with the functional
characteristics of three common drying approaches: hot air, desiccant and refrigerant dehumidifying
systems. The purpose of this instruction is to help personnel set up, operate and maintain their drying
equipment to avoid production problems caused by incomplete moisture removal.

Design of Experiments for Injection Molders (DOE)

Design of Experiments for Injection Molders (DOE) is a three-lesson program (3 to 4 hours of training),
which provides an overview of how to design and experiment in an injection molding facility. This
program is recommended for quality assurance personnel, supervisors, lead persons and molding
managers. This comprehensive package allows you to train your employees on the importance of DOE
practices and easy and efficiently data can be collected and used to troubleshoot an injection molding
process.

Detailed Lesson Descriptions for Design of Experiments for Injection Molding

Lesson 1 – Learning the Basics. This lesson introduces the basics of experimental design for the
injection molding process. It also discusses ways to organize and analyze data by using graphs such
as the Pareto chart, main effects plot and contour plot, which provide the basis for analysis of any
experiment.
Lesson 2 – Fractional Factorial Designs. Lesson 2 continues to discuss various terms and concepts
of the Design of Experiments methodology. Some of the concepts are explored in more detail that
includes the process diagram, factors and responses, the design matrix, the Pareto chart and the main
effects plot.
Lesson 3 – The Taguchi Design Method and Various Modeling Designs. This lesson describes
other experimental design types that should be considered when conducting design of experiments for
an injection molding process. These design types include: Taguchi, Box Behnken, Central Composite
Circumscribed, Central Composite Faced and D-Optimal designs.

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Injection Molding Machine Maintenance
(2 Lessons)
Course Summary:

This 2-CD course is a hands-on instructional program demonstrating the proper machine maintenance
procedures for all hydraulic injection molding machines.

This 3 to 4 hour interactive training course demonstrates and teaches the hands-on maintenance
techniques that provide increased reliability and uptime for your molding machines. The importance of
establishing a regular maintenance schedule, including tools and techniques is reinforced. All machine
systems, hydraulic, electrical, and mechanical are covered in this course Also highlighted is the
importance of safety in the workplace and performing on-going safety system checks.

Topics Covered:

Safety, Injection Unit Maintenance, Screw & Barrel Maintenance, Clamping Unit Maintenance,
Hydraulic System Maintenance, Electrical System Maintenance

Lesson 1:
This lesson describes the importance of safety when performing routine maintenance on your injection
molding machine, and includes demonstrations of safety practices such as lockout/tagout procedures
and working with various types of safety systems on an injection molding machine. This lesson also
examines the maintenance schedules and recommended procedures for the injection unit and screw &
barrel, as well as corrective maintenance procedures for the clamping unit.

Lesson 2:
This lesson continues to explore the general maintenance requirements for injection molding machines.
The lesson also describes recommended maintenance procedures and schedules for the hydraulic and
electrical systems of the injection molding machine.

This course is designed for: Machine Maintenance, Machine Operator, Shift Foreman, Mold Setter,
and Process Set-up personnel.
Efficient Mold Setting (EMS)

Efficient Mold Setting is a two-lesson program (3-4 hours of training) recommended for setup, mold
maintenance and machine operating personnel. This course is specifically designed to teach your
employees valuable skills for the mold setting and removal stages of the injection molding process.
Efficient Mold Setting is an excellent course for new employees as well as a great refresher course for
veteran molders.

Detailed Lesson Descriptions for Efficient Mold Setting

Lesson 1 – Mold Installation and Set-Up Procedures – Explains procedures for transporting,
installing and setting up injection molds. This lesson also describes in detail, the safety procedures
involved when working with molds, moving the mold from the storage area to the injection machine, the
installation of the mold between the platens and basic mold start-up and operating procedures.
Lesson 2 – Mold Troubleshooting, Removal and Storage – Discusses potential mold problems that
may occur during operation, as well as the procedures for machine shutdown, mold removal and mold
maintenance and proper storage.

Injection Molding Operating Methods and Economics

Injection Molding Operating Methods and Economics is a 1 CD-ROM program (1 to 2 hours of training)
that focuses on how to maximize production efficiency by focusing on solving common problems and
production errors. In addition, many tips and suggestions are offered to show injection molding facilities
various ways to reduce costs and operate in a more profitable manner.
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PLASTIC PART DESIGN FOR INJECTION MOLDING

Developed in conjunction with Glenn Beall, the leading expert on plastic part design, this interactive
video training course takes the designer through a coordinated step-by-step procedure that reduces the
complex subject of plastic part design for injection molding to a simple, easy to understand technique.
8 Lessons: 10-12 Hours

Plastic Part Design for Injection Molding:

• Demonstrates proven parts designing techniques

• Provides industry accepted plastic part design rules and details.

• Delivers important part design knowledge to improve part quality, eliminate mold revisions
and reduce costs.

Many injection molded parts suffer throughout their existence due to minor design defects. The use of
this course and the guidelines explained will allow the designer to spot design defects in the drawing
stage and save tens of thousands of dollars in molding problems and tooling revisions.

This course is recommended for: Part Design Personnel, Production Supervisors, Process Engineers,
Quality Control Personnel, Molding Managers.

Lessons Included:
Plastic Part Design for Injection Molding Lessons
• Lesson 1 – Designing the Nominal Wall

• Lesson 2 – Designing Three Dimensional Shapes

• Lesson 3 – Designing Projections off the Nominal Wall

• Lesson 4 – Designing Depressions in the Nominal Wall

• Lesson 5 – Designing Hollow Bosses

• Lesson 6 – Designing Molded Threads

• Lesson 7 – Designing Parts with Undercuts

• Lesson 8 – Summary

Understanding Materials for Profitable Molding

Understanding Materials for Profitable Molding is a series of individual lessons (each providing1 to 11/4
hours of training), which provide an overview of the properties and characteristics of an individual raw
material type. Each lesson describes the properties and molding characteristics that will improve the
processing of that material. Our series of materials will include the most common commodity and
engineering grade plastics. A thorough understanding of these principles means less material waste
and a significant cost savings.

Lessons Description for Understanding Materials for Profitable Molding

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Discussed in these lessons are the chemical and physical properties of the specific material under
discussion in each lesson, the recommended processing windows, startup and shutdown tips, and how
to solve typical molding problems on each of these materials.
All material training programs released follow the same format by discussing the chemical and physical
properties, the recommended processing windows, start up and showdown topics and how to solve
typical molding problems.

Materials programs available

Polycarbonate (PC)
Polypropylene (PP)
Polyethylene (PE, LDPE, HDPE, LLDPE, UHMWPE)
Nylon (PA)
ABS
Polystyrene (PS)
Acrylic (PMMA)
Acetyl (POM)
Polyester (PBT)
Thermoplastic Elastomers (TPE)

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 EXTRUSION
Extruder Operation and Control – Single Screw

Extruder Operation and Control – Single Screw is a nine-lesson program (11 hours of training)
recommended for extruder operators, material handlers, set-up personnel and production supervisors.
This program begins with the fundamentals of single screw technology and takes your employees
through the entire single screw process. Also included in this program is in-depth troubleshooting
information allowing your employees to become expert at troubleshooting your extruders.

Detailed Lesson Descriptions for Extruder Operation and Control – Single Screw

Lesson 1 – The Single Screw Extruder: Parts and Operation - Teaches extruder applications, the
raw material forms used in extrusion, how plastic travels through the extruder, the parts of the extruder
and how they operate.
Lesson 2 – The Structure of Plastic Raw Materials - Explains how a plastic is made (polymerization),
the difference between thermoplastic and thermoset, the effects of molecular weight and weight
distribution, the structure of polymers, and the physical characteristics and processing requirements of
amorphous and crystalline plastics.
Lesson 3 – The Characteristics of Plastics for Extrusion - Explains copolymers and blends/alloys,
the causes and effects of degradation, and the effects of additives on the plastic in the extrusion
process.
Lesson 4 – The Effects of Pressure, Temperature and Flow - Explains the characteristics and
practical effects of plastic flow in extrusion. Topics include how and why orientation occurs with plastic
flow, the interrelationship between flow and viscosity in a non-Newtonian fluid (plastics are non-
Newtonian), how viscosity is affected by temperature, pressure, and molecular length, and how plastic
flow behavior is measured.
Lesson 5 – Optimizing Extruder Controls – Part 1 - Describes variables within the extrusion process,
and discusses how these variables and control settings affect the process from the hopper through the
feed zone of the extruder. How plastic melts and flows in the extruder is also explained.
Lesson 6 – Optimizing Extruder Controls – Part 2 - Explains the effects of extruder control settings
on the plastic’s behavior as it travels through the compression and metering zones of the extruder.
Controls for the adapter zone and gear pump are also discussed.
Lesson 7 – Safety, Pre-Start and Start-Up Procedures - Teaches safety procedures in the extrusion
plant, and practical, hands-on, pre-start and start-up procedures.
Lesson 8 – Steady-State Operations, Shutdown and Maintenance Procedures Discusses steady-
state extrusion operation, and typical shut down procedures for leaving the extruder full of plastic,
running the barrel dry, and purging. Emergency shut down procedures are also explained. This lesson
describes routine post extrusion operations, such as maintenance, screw removal, and cleaning the
barrel, screw and die.
Lesson 9 – Troubleshooting for Extrusion - Teaches the basic guidelines and fundamental steps to
follow for successful troubleshooting of extrusion processing problems. Many of the most common
extrusion processing problems are analyzed and recommendations given.

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Davis Standard Plasticating Single Screw Extruder
(2 lessons)

Davis Standard Condensed Version:

In this 2 lesson (2 hour) course, we will discuss the individual components of the single screw extruder,

what they look like and how they operate. We will also take a look at how plastic travels through this

type of single screw extruder. In the second half of the course, we will discuss the control of plastic

melting, flow and pressure in the extruder. We will also examine the effects of temperature, pressure

and equipment design on the material and explore ways to optimize the extruder control settings.

Special effort is placed on learning the components of the Davis Standard Extruder.

Paulson’s Full Version:

To learn more about extruder operation and optimizing control settings, refer to the Paulson Training

Programs course called "Extruder Operation and Control-Single Screw". This 9-lesson course

discusses the basics of single screw extrusion and explains how to optimize control settings to increase

productivity.

The program includes an overview of the structure of plastic raw materials, how plastics flow and their

behavior in the single screw extruder. The course also explores ways of optimizing single screw

extruder controls and troubleshooting techniques as well as safety, start-up, operation, shutdown and

maintenance procedures of a single screw extruder.

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Compounding with the Twin Screw Extruder

Compounding with the Twin Screw Extruder is an eight-lesson training program (10 hours of training)
intended for twin-screw extruder operators, material handlers, set-up personnel and production
supervisors. Discussed are the components and operation of the twin-screw extruder used for
compounding, reactive extrusion and devolatilization processes. The course includes an overview of
the structure of plastic raw materials, how plastics flow and their behavior in the twin-screw extruder.
The program also explores ways of optimizing twin-screw extruder controls and troubleshooting
techniques as well as safety, start-up, operation, shutdown and maintenance procedures of a twin
screw extruder.

Detailed Lesson Descriptions for Compounding with the Twin Screw Extruder

Lesson 1 - The Twin Screw Extruder: Parts & Operation - discusses the individual components of the
compounding twin-screw extruder; what they look like and how they operate. Lesson 1 will also look
briefly at how plastic travels through the three commercially available twin-screw extruder designs.
Lesson 2 - The Structure & Properties of Plastic Raw Materials - explores the structure and
characteristics of plastics.
Lesson 3 - The Effects of Pressure, Temperature and Flow - takes a closer look at the
characteristics of plastics and examines plastic flow behavior in detail.
Lesson 4 - Plastic Behavior In The Twin Screw Extruder - discusses screw design elements and the
plastic behavior in the twin extruder. Lesson 4 also looks at how plastic flows through the counter-
rotating and co-rotating twin screw extruder, and the counter-rotating, tangential twin-screw extruder.
Lesson 5 - Optimizing Twin Screw Extruder Controls - explores twin-screw extrusion operating
conditions and variations, extruder and die head controls, and post-extrusion conditions. Also
examined in greater detail, the impact screw speed has on temperature in the intermeshing and
tangential (non-intermeshing) types of twin-screw extruders.
Lesson 6 - Safety, Pre-Start & Start-up Procedures - discusses twin-screw extruder safety, pre-start
and start-up procedures.
Lesson 7 - Steady-State Operation, Shutdown & Maintenance Procedures. Discusses twin-screw
extruder steady-state operation, shutdown and maintenance procedures.
Lesson 8 - Twin Screw Extruder Troubleshooting Reviews basic troubleshooting procedures for
compounding twin-screw extruders.

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Sheet Extrusion Technology

Sheet Extrusion Technology is a seven-lesson training program (9-11 hours of training) designed
specifically for the training needs of the sheet extrusion plant. Intended for set-up personnel, machine
operators, production supervisors, process engineers and extrusion technicians, this program is
designed to be used in conjunction with our nine-lesson single screw extrusion program. Personnel
from extruder operators through process engineers will find valuable information to help make their
work and the sheet extrusion process more efficient.

Detailed Lesson Descriptions for Sheet Extrusion Technology

Lesson 1 - Parts and Operation of the Sheet Extrusion Line - An overview of the machinery that
makes up the sheet line, and how it operates. Discussion includes roll stand designs and operation,
design and operation of the chill rolls, types of gauging systems, static discharge systems, design and
operation of trimmers, pull rolls, winders and cutters.
Lesson 2 - Parts of the Sheet Die - The first part of this lesson discusses sheet die construction, and
the parts of the sheet die including the manifold, heaters, restrictor bar, deckle bars, and types of die
lips including fixed lip, adjustable lip, and flexible lip. The second part of the lesson discusses plastic
flow behavior through the sheet die.
Lesson 3 - Controlling Plastic Flow in the Die - This lesson discusses the design and operation of
the T-type, the Coat hanger, and the Curved Manifold sheet die designs, as well as how the restrictor
bar and the die gap adjustment are used to control plastic flow through the sheet die. Feed block and
co-extrusion dies are also discussed.
Lesson 4 - Plastic Flow Behavior in the Sheet Extrusion Line and Process Control - Discusses
what happens to the plastic once it leaves the sheet die and travels through the downstream sheet line.
Orientation, die swell, the effects of roll speed and roll cooling, how cooling affects semi-crystalline
plastics, uniaxial and biaxial orientation, and annealing are all discussed. The lesson also discusses
the fundamentals of process control of the sheet line.
Lesson 5 - Prestart, Startup and Operation of the Sheet Line - This lesson discusses how to plan
and startup the sheet extrusion line safely and efficiently. Proper steady state operations, such as
monitoring the equipment and sheet product are also discussed.
Lesson 6 - Shutdown of the Sheet Line - This lesson discusses how to safely shut down the sheet
line. Emergency shutdown procedures are also discussed. The lesson finishes with a discussion on
safety in the sheet extrusion plant.
Lesson 7 - Troubleshooting for the Sheet Extruder. This lesson discusses common sheet defects,
such as surface lines and warp and their possible causes and solutions.

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Extrusion Blow Molding

Paulson’s Extrusion Blow Molding Technology program is a seven-lesson program (9-11 hours of
training) that teaches your personnel to understand the basics of blow molding technology, plastic
behavior and resolve common problem situations. Extrusion Blow Molding is intended for machine
operators, material handlers, set-up personnel and production supervisors. This seven lesson program
will also help your personnel recognize processing conditions that affect quality and evaluate and
improve operating procedures.

Detailed Lesson Descriptions for Extrusion Blow Molding

Lesson 1 - The Process and the Equipment - Describes the extrusion blow molding process, the
major components and the operation of extrusion blow molding machines (reciprocating screw,
accumulator, and continuous machine types). Also discussed are the general characteristics of die
heads: axial and radial die heads, as well as machine specifications.
Lesson 2 - Plastic Behavior in the Blow Molding Process - Teaches the blow molding process from
the plastics point of view; how the plastic molecules are affected by pressure, temperature, flow and
cooling. Discussed are the unique characteristics of plastics, the finished part properties, the influence
of die head design on plastic parison formation. An analysis of pressure and temperature changes
within the die head during flow is included as is how mold cooling affects blown part characteristics.
Lesson 3 - Machine Operating Controls - Contains an explanation of the process inputs that affect
the plastic behavior and finished part properties, including machine controls and outside influences. At
each step, the applicable machine controls are explained, showing how each one affects the blow
molding machine operation, and the plastic behavior.
Lesson 4 - Start-Up, Operation, and Shutdown Procedures - Described are typical start-up,
operation and shutdown procedures: setting machine controls, the basis for determining optimum
control settings, operation safely, efficient start-up, and shutdown. Information is included that provides
a basis for managers, supervisors, and operating personnel to evaluate and improve operating
procedures.
Lesson 5 - Processing Conditions that Affect Quality and Productivity - Explains blow molding
process variations and their effects on finished part properties; a step-by-step procedure to locate,
analyze and correct processing problems; and the most common causes of process variations. The
control adjustments that affect parison formation are discussed as are flow laws that describe plastics
behavior in the die head, and plastic behavior analysis leading to problem solving.

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Lesson 6 - Problems and Solutions - Part 1 - In this session the problem solving analysis methods
shown in session 5 are used to analyze and solve practical processing problems. Problem examples
include: parison swell variations; weld lines, doughnut formation, parison curl, and curtaining.
Lesson 7 - Problems and Solutions - Part 2 - This session continues the analysis of blow molding
problems. Problems discussed include melt fracture, rings in the parison, sag, holes, pinch-off
problems, thickness variations, parting line defects, venting problems, discoloration, streaks, and
others.

ITZ, General Hydraulics, Pneumatics, Electric and Mechanical Training

This series provides trainees a working understanding of electric, hydraulic, mechanical and pneumatic
systems. Each of the four programs has provisions for on line testing, tracking and certification. You
learn by seeing, then actually doing. Trainees create hydraulic, electric, etc. circuits and then test their
performance in a simulated run mode. The insertion of these interactive real world experiences keep
the trainee interested in the learning process. In this way the student builds experience in creating
circuits and mechanical designs, checking them, understanding applications and trouble shooting
problems. Realistic 3D graphics make hard to understand materials easy to comprehend. The series
provides both maintenance and production the information needed to keep machines running,
productivity and efficiency levels up, maintenance costs down and downtime at a minimum.

Abbreviated content description:

 All programs address reading schematics and mechanical drawings, including a basic
understanding of symbols and their meanings.

 All programs address building basic circuits or mechanical

devices, then running and trouble shooting them.

 The electric program addresses basic physics, how to work with varying types of power both
two and three phase, as well as some low voltage circuits. Some of the topics covered include
understanding energy conversions and requirements, polarity, grounding, power connections,
solenoids, designing power circuits, breakers, fuses, switches, etc. This program provides a
basis for creating, designing and maintaining electric systems.

 Mechanical training includes an understanding of basic physics, linear actuators, clutches,

brakes, clutch-brake combinations, bearings, drives and couplings. This program provides a
basis for creating, designing and maintaining mechanical devices.

 Hydraulics training covers fluid power physics, pumps, actuators, pressure control valves,
directional control valves, flow controls, fluid conditioning, check valves, accessory
components, fluid conductors, understanding schematic and basic system design. This
program provides a basis for creating, designing and maintaining hydraulic systems.

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  7/Pneumatics addresses an understanding of basic physics, compressors operations and
types, air dryers, air preparation, air distribution, direct control valves, actuators, miscellaneous
valves, accessories, air line conductors, vacuum and a understanding of schematics. This
program provides a basis for creating, designing and maintaining pneumatic systems.

For assistance call or email:

Larry Mercugliano
Paulson Training Programs
International Sales
Email: Larrym@PaulsonTraining.com
Home Office Phone: 860-388-3736

Last Update 9-12-07

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