The OptiMISER System
Plastic Blend Formulating & Optimizing
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. Therefore providing 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?
A: It’s generally to your advantage to combine the properties of two polymers, instead of trying to buy a specialty resin at a premium price. When you blend with low-cost commodity resins, you eliminate the need for specialty materials. Therefore, you generate an attractive return and the potential for a sustainable market advantage.
Q: Will The OptiMISER System enable me to create a blend tailored to my product and process needs at a lower cost, including testing, labor and capital 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 at a reduced cost. The results are improved processability, production rates, and product quality.
Q: Will your technology enable me to reduce the weight of my products?
A: Potentially! One OptiMISER System user achieved huge success in a high-volume application by altering the blend formulation. 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 proven product developed in 2002 with billions of pounds processed. We know first-hand that it does what we say it will do. Most importantly companies who license The OptiMISER System report enhanced product and production performance.
Q: Can you make high-quality products using The OptiMISER System blending technology?
A: Yes. The OptiMISER System can be used to enhance blend 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. With the knowledge of the properties and the vast range of resins available, the OptiMISER can generate recipes that meet your quality requirements.
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 raw materials provide critical performance data that are then entered into the OptiMISER formulation software. The software formulates blends based on your specifications and cost targets. You’ll see in the results screen that none of the blend options compromise your quality levels.
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. For additional information go to the Blending Basics page.
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 material testing services until you decide to bring 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 suppliers are broad and need to be accurately tested. In addition, the 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. Actually, the OptiMISER software allows for additional grades to be used.
Q: How many different components can I blend with your software?
A: With OptiMISER software, you can easily calculate blends containing ten or more 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.
Ease of Use
Q: It all seems complicated – maybe too complicated for my operators.
A: Absolutely not! The OptiMISER System was developed for easy use by shop floor operators. Simple, easy-to-use operator instructions and start-up assistance is available; little training is needed.