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PBY Plastics, Inc. (Ontario CA) is an innovator in the custom molding of high performance plastic materials. Using a number of unique proprietary manufacturing processes PBY produces stock shapes, near net shapes and its new line of one piece molded PFA high purity molded tanks.
PBY Plastics has made significant investments in its proprietary high purity compression molding operations and processes. It now has the capability to handle high purity resins, and the compression molding of its one piece tanks, in a tightly controlled environment. Virtually every step of the process from raw material storage, mold tool resin loading, and the final step of molding the tanks, has been designed to produce the highest quality finished article for the most demanding of applications.
The PBY technology, equipment and systems allow it to produce high purity PFA molded tanks virtually free of contribution contamination, metals and particulate. In addition to improved cleanliness and purity the tanks have exceptional surface smoothness and low permeation characteristics. The new process allows PBY to compression mold a true one piece molded process tank that can effectively replace sheet fabricated tanks in a number of applications where ultra-high purity, cleanliness and leak free durability are the primary requirements.
PBY Plastics selected Teflon™ HP-PFA resin for its unique line of one piece molded process tanks. Teflon™ HP-PFA allowed PBY design engineers to move past traditional design boundaries by starting with a premium industry standard material that exhibits high purity, low metals and very low levels of environmental particulate and background contamination.
PBY compression molded one piece process tanks produced with Teflon™ HP-PFA exhibit extreme performance and World Class quality, and offer a value added alternative to sheet fabricated and welded tanks.
The Teflon™ HP-PFA one piece molded tanks are well suited for chemical and process applications that do not require a custom sheet fabricated tank or where a heavier walled tank is desirable.
The tanks are available in a range of standard sizes, through 25 liter, and are available in rectangle, square or round configurations.
Options and design possibilities include:
Please contact PBY Plastics for more information on their product line and manufacturing capabilities.
PBY Plastics, Inc.
2571 E. Lindsay Privado
Ontario, CA 91767
TEFLON™ PTFE granular molding powders are manufactured in an enclosed, positive pressure system using purified air and water. The packaging area is under positive pressure with “air-lock” doors, tile floors, enamel walls and flush-mounted lighting. The following storage and handling recommendations will help to preserve the high quality of these resins.
Teflon™ granular resins are not shipped refrigerated. However, when these resins are shipped in a truck with fine powder resins, the granular products may arrive at the customer’s plant below PTFE’s room temperature transition temperature of 19°C (66°F).
Chilled resin: When granular PTFE resins arrive in a refrigerated truck, the drums should not be opened immediately. Good practice is to let them sit in the sealed container for 24 to 48 hours at a temperature of 23°C-27°C (73°F-80°F). Granular PTFE resins stored by customers in a refrigerated area must be removed from cold storage to an area where they will have time to warm before the drums are opened.
While PTFE resins are not hygroscopic, powder which has been chilled and then exposed to a damp atmosphere will become wet from condensation. Moisture will cause the preform to crack during sintering.
It is important not to preform PTFE powder below the 19°C (66°F) transition temperature even when the relative humidity is below 50%. Preforming cold powder will result in cracked preforms because the resin expands 1.5% in volume as it goes through the room temperature transition. The easily damaged preform cracks because it cannot resist the forces of the large volume change. To avoid this type of cracking, it is important to preform all granular powders at 23°C (73°F) or higher.
Unchilled resin: Unchilled resin received by customers should be stored at a temperature of 23°C-27°C (73°F-80°F) in a clean, dry area.
The Importance of Cleanliness: The importance of cleanliness in processing PTFE resins can hardly be over-emphasized. PTFE readily attracts particulate contaminants because it is a highly electrostatic material. The high sintering temperature and the whiteness of the resin intensify the effects of contamination. The smallest speck of atmospheric dust, oil or other organic substance can be carbonized during sintering leaving clearly visible dark, white or clear spots in a contaminated molding. While such imperfections may not have important effects on physical properties, they are undesirable in appearance. Conditions and practices suitable for molding other plastics may not be adequate for PTFE resins.
Opening the Drum: Before opening a drum of “Teflon” PTFE granular resin carefully clean the outside of the lid to remove contaminants picked up during shipping and storage. Granular PTFE resin is packed in a drum lined with a loose polyethylene bag. The bag is twisted and tied at its top. Before removing the tie, the outer surface of the bag should be vacuum cleaned to remove particles of contamination. Remove the tie, untwist the bag and fold the bag over the rim of the drum to protect the powder from contaminants trapped between the outside of the bag and inside of the drum. Promptly remove the amount of resin needed (into a clean container with a lid), close and twist the bag, and retie. Replace the drum lid until more resin is needed.
It is important to vacuum the inside of the drum and the outer surfaces of the bag liner when the entire drum is to be dumped into the mold cavity at one time (see footnote A). This will prevent loose particles trapped between the liner and the inside of the drum from falling into the mold cavity along with the resin.
Preforming: Preforming normally is carried out at temperatures between 23°C-27°C (73°F-80°F). Storing the powder before use in a room maintained at 23°C-27°C (73°F-80°F) and below 50% relative humidity helps avoid moisture condensation and also minimizes the tendency of the powder to form lumps in hot weather. Improved product quality, uniformity and reduced scrap losses justify the investment in such facilities.
An ideal arrangement for the molder consists of a room at 23°C-27°C (73°F-80°F) for temperature conditioning, weighing and preforming the powders. The room should be separated from the sintering operation and from the processing of other plastics. It should have a separate filtered air supply maintaining a slight positive pressure inside the room. Cleanliness conditions and practices suitable for molding other plastics are usually not adequate for PTFE resins. Operators should wear clean, lint-free coveralls and maintain a high standard of cleanliness.
Lumps: Granular PTFE resins may compact and form lumps during shipment. Soft lumps usually can be broken up sufficiently with a clean scoop to permit filling of mold cavities over 25mm (1 inch) wide. In rare instances screening through a clean, coarse (8 to 10 mesh) screen may be advisable. Remember: it is difficult to screen the resin and avoid contamination.
Harder lumps should be placed in a clean, covered container, chilled to about 10°C (50°F) and shaken vigorously. Be sure to allow the container and the resin to warm to the 23°C-27°C (73°F-80°F) range before removing the container’s lid.
Footnote (A): We do not recommend or encourage dumping an entire bag of resin into the mold cavity at one time. This practice will produce moldings with non-uniform density and can cause cracking. We recommend loading powder evenly into the cavity (no matter how large the mold) with a clean scoop.
PTFE COMPOUNDS, INC., backed by more than 30 years’ experience in the industry, was formed to meet the demanding need for quality and consistency in compounded materials, not only within lots, but from lot to lot as well. Their large capacity blending equipment enables them to offer billet quantities up to 1200 pounds. They provide a homogenous filled compound that ensures uniformity and stripe free skived sheet. Two examples which show the strength of their innovation are TUFFSHEET and PCI Bearing Compound 213.
TUFFSHEET is a new proprietary blend of DuPont Kevlar® and Teflon®, which combines the properties of these materials into a durable low wear composite with reduced deformation and creep resistance. TUFFSHEET is suitable for a wide range of applications such as bushings, dry bearings, thrust washers, dry air compressor rings, gaskets, o-rings, rollers, and wear strips. TUFFSHEET product is available as a low flow compression molding powder, as skived sheet, rolled slit strips, wear-strip (with or without adhesive backing), and CNC machined parts made to customer specifications.
PCI Bearing Compound 213 is a white molding grade compound containing a white mineral filler blended with Teflon® PTFE. Both the filler and PTFE used in the compound are approved by the FDA for use in food contact applications.
Please contact PTFE Compounds for more information on their product line and manufacturing capabilities.
PTFE Compounds, Inc.
Upper Chesapeake Corporate Center
220 Chesapeake Boulevard
Elkton, MD 2192
Ametek has developed a patented cooler/absorber for stripping aggressive gases (HCI, SO2, etc.) from chemical or refinery process streams. The versatile design functions like a column with the tubing acting as temperature-controlled packing that can add as well as remove heat. The new design uses clusters of small-diameter tubing made from Ametek’s “Q” resin, a patented thermally conductive compound based on Teflon® PFA fluoroplastic resin and graphite.
In a typical installation, 1860 tubes measuring 0.125 in. (3.2 mm) in diameter by up to 25 ft. (7.3 m) long are vertically disposed in a steel column lined with Teflon® PTFE fluoroplastic resin. Cooling water flows upward through the heat-conductive tubing. Gas and droplets of water or another absorbing medium flow downward through the column, outside the tubing. The gas dissolves in the absorbing medium, which collects on the outer tubing wall.
The heat of solution is absorbed through the wall by the cooling water.
Thanks to the chemical and heat resistance of Teflon®, the cooler/absorber can be used with a wide range of aggressive chemicals at temperatures up to 400°F (204°C)
Ametek says that its units take less space and cost less than conventional designs because “Q” resin has double the thermal conductivity of unfilled fluoropolymers.
Ametek reports that its cooler/absorber provides more resistance to thermal and mechanical shock and fouling, and requires less maintenance than traditional graphite units.
Teflon® PTFE and Teflon® PFA meet needs for broad chemical resistance. Teflon® PFA allows compounding for conductivity and extrusion as small diameter tubing.
Please contact Ametek for more information on their product line and manufacturing capabilities.
AMETEK Fluoropolymer Products specializes in highly corrosion resistant, high purity, and high temperature products to serve the chemical processing, metalworking, semiconductor, aerospace, and other industrial applications. Its core products are based on Fluoropolymers, silica and phenolic resins and are marketed under the following trade names: Fluoropolymer Heat Exchangers, Fluoropolymer Tubing, Fluoropolymer Pipe, Havaflex® Ablative Products, and Flexsil® Molten Metal Filters.
Ametek Fluoropolymer Products
455 Corporate Boulevard
Newark, DE 19702
Micro-Tek, of Cinnaminson, New Jersey, specializes in custom drawing, stranding and insulating, cutting and stripping of fine wire and cable .0009” (AWG #50) and larger. Chemours fluoropolymer resins (Teflon® PTFE, FEP, PFA , Tefzel® ETFE and ECCtreme®ECA) are extruded on various nonferrous, ferrous, plated, unplated, thermocouple and alloy wires in single end, concentric, roped and bunched configurations. Extruded walls as thin as .0035” and made with Teflon® PTFE are just one of the precision engineered products.
Micro-Tek was asked to meet a customer’s specification that required an ultra fine stranding for flexibility as well as thin wall insulation to meet dimensional constraints. (0.005” ± .0005”)
Micro-Tek drew, stranded and annealed silver plated OFHC copper to produce a soft #42/750 (0.0033”) strand. This strand provides a higher flexibility and flex life than a single strand.
Using Teflon® PFA fluoropolymer resin, Micro-Tek was able to achieve the customers desired OD. Using extruded PFA allows for a consistent, high quality product in a variety of colors. The PFA insulation’s excellent mechanical, electrical and thermal properties make this insulated strand ideal for a variety of applications and environments with tight dimensional constraints.
As a custom manufacturer, Micro-Tek Corp’s operation is designed to accommodate specific customer requirements. One product that demonstrates a broad range of Micro-Tek’s manufacturing capabilities is a 50 Ohm low noise micro-coaxial cable.
This product requires stranding the SPC before insulating it with Teflon® PTFE to the specified diameter. A low noise coating is applied to the insulated strand, which is then braided with a (95% coverage) SPC shield. Finally the cable is jacketed with Teflon® FEP to the customer’s required diameter.
Example of Thin Wall Ultra-Fine Stranding
Please contact us for more information on our product line and manufacturing capabilities.
Applied Plastics Corporation was founded in 1965 and has evolved into a full service fabric and belting OEM supporting a broad range of industries and end use applications
An ISO-9001 certified company.
1748 Woodmont Drive
Tuscumbia, AL 35674
Fluoroplastic materials offer a wide variety of desirable characteristics in industrial applications where wear resistance, sealing, filtration, and high temperature performance are required. When used as an additive, coating or in a compound, fluoropolymers contribute their unique PTFE or Melts based properties to the host material to which they are paired with, providing non-stick properties, improved lubricity, anti-drip and better wear resistance.
Applied Plastics Corporation, of Tuscumbia AL, is an innovator in high performance coated fabrics and industrial belting products.
Under its Applon™ product line, Applied Plastics produces a number of premium PTFE impregnated products using genuine Chemours Teflon® coupled with proprietary manufacturing processes.
This proprietary PTFE impregnation process was developed by Applied Plastics in 1965 and allows for an even distribution of PTFE throughout the base material and offers superior performance to more traditional surface coating techniques.
Applied Plastics has made significant investments in proprietary fabric coating processes, specialized equipment and technology to support the production of high-temperature fabrics and belting.
In addition, all Applon™ products are manufactured with the latest aqueous fluoropolymer technology from DuPont.
Chemours Teflon® aqueous fluoropolymers are dispersions of PTFE particles in water, stabilized by non-ionic wetting agents. These aqueous dispersions offer a practical method for impregnating fabrics, belting and other base materials, with PTFE to impart many of the benefits of fluoropolymers into the finished product.
Applied Plastics selected Chemours Teflon® PTFE aqueous dispersion for its unique and high performance characteristics.
Chemours Teflon® PTFE aqueous dispersions have allowed Applied Plastics engineers to move past traditional design boundaries to produce extreme duty PTFE impregnated fabrics and belting that exhibit consistent quality, performance and durability.
Applon™ PTFE impregnated fabrics and belting are designed for continuous service temperatures up to 500°F and are available in any desired length, in thicknesses up to .125 inch and widths to 88 inches.
To request additional information, please contact:
Richard Stutts VP / General Manager
Applied Plastics Corporation was founded in 1965 and has evolved into a full service fabric and belting OEM supporting a broad range of industries and end use applications
An ISO-9001 certified company.
1748 Woodmont Drive
Tuscumbia, AL 35674
Rubadue Wire, of Greeley CO, has developed the first UL approved 300°C AWM (Appliance Wire Material) wire construction. The process development, material selection and final product testing were carried out through a close working relationship with DuPont engineers and Underwriters Laboratories.
On January 29, 2014 Rubadue Wire was awarded UL certification, and a style page, for its new high-temperature single conductor appliance wire (AWM Style 11540) based on DuPont’s unique high performance fluoroplastic material, DuPont™ ECCtreme® ECA-3000.
The Rubadue high-temperature wire product line is available in AWG sizes of 30AWG* – 8AWG, in a variety of standard colors.
Rubadue Wire has invested in proprietary wire coating processes, specialized equipment, and technology to support the production of high-temperature fluoroplastic wire and cable.
DuPont™ ECCtreme® is a new class of fluoroplastic resin (ECA).
Wire produced with ECA (epitaxial co-crystalline alloy) exhibits the same beneficial properties of typical DuPont fluoroplastics with the additional capability to maintain operational performance under elevated temperatures, and harsh environmental conditions, for extended periods of time.
The first of its kind, DuPont™ ECCtreme® ECA-3000 fluoroplastic resin is the material of choice for Rubadue’s high-temperature wire and cable product line.
Rubadue Wire selected DuPont™ ECCtreme® fluoroplastic resin due to its unique and differentiating high performance characteristics.
DuPont’s new ECA material has allowed Rubadue engineers to rewrite traditional fluoroplastic design boundaries to produce an extreme duty wire construction that was previously unattainable.
In addition to higher operational performance, wire coated with ECA material, exhibits improved functionality when exposed to temperatures above 280°C. This is due in part to the material undergoing a thermal and structural transformation known as epitaxial co-crystallization. The result of this transformation is a lower MFR (as low as 1), a higher melting point and improved mechanical and thermal properties.
To request additional information on high-temperature wire constructed with DuPont ECA material, please contact:
*Rubadue Wire has UL certification for ECA wire AWG size to 30AWG, but can produce high-temperature ECA wire down to AWG38 for applications that may require smaller conductor sizes.
**UL certification (E54681) lists DuPont ECA-3000 as having the highest Relative Thermal Index (RTI) of any melt processable plastic in the UL database.
Rubadue Wire was founded in 1977 and has evolved into a full service global wire and cable supplier supporting a broad range of industries and end use applications.
An ISO-9001 and ISO-14001 certified company.
1301 N. 17th Ave.
Greeley, CO, 80631
Savillex Corporation, of Eden Prairie MN, has developed a unique two-stage stretch blow molding process for its premium Purillex™ high purity PFA and FEP biopharmaceutical packaging product line. The process development, material selection and final product testing was carried out through a close working relationship with DuPont engineers and fluoroplastic materials scientists.
The final product is unlike any other PFA / FEP biopharmaceutical package currently on the market. Manufactured with genuine DuPont™ Teflon® fluoroplastic material, the high purity Purillex™ product line has undergone extensive material testing for organic and inorganic extractables and overall purity.
As a result of this comprehensive testing, the Purillex™ product was determined to have no measurable organic extractables and only ultratrace levels of inorganic extractables, thus making the Purillex™ line of packaging ideally positioned for biopharmaceutical applications.
A full copy of the analytical data report can be obtained directly from Savillex Corporation (firstname.lastname@example.org).
High purity extreme performance material. Purillex™ PFA and FEP bottles manufactured from from DuPont™ Teflon® fluoroplastics using a proprietary Savillex process are ideally suited for pharmaceutical storage, transportation and packaging due to their excellent chemical inertness, high purity, a wide service temperature range (-200°c +260°c), permeation resistance and mechanical durability.
Unique design characteristics. Savillex has designed the Purillex™ product line with not only high performance fluoroplastic materials but also with several novel design features that allow for complete drainage upon inversion, no fluid retention in the neck threads, non-drip during dispensing and no secondary sealing required.
In addition, the Purillex™ product line has a very smooth interior surface finish which significantly improves cleaning, washout and reduces carryover to subsequent processes*.
Purillex™ high purity biopharmaceutical packaging is manufactured exclusively with high performance genuine DuPont™ Teflon PFA and FEP fluoroplastic materials supplied by Fluorogistx of Greenville, DE.
These materials, along with significant DuPont technical and analytical resources, allowed Savillex to meet the challenges of developing a high purity packaging product for the storage, handling and transport of pharmaceutical and biotechnology liquid materials.
Savillex offers six high purity bottle sizes in the Purillex™ product line, ranging from 50 mL to 2000 mL.
10321 West 70th Street
Eden Prairie, MN 55344
Because of their temperature/chemical resistance, electrical performance and low flammability, fluoroplastics are the material of choice in vital electrical, sealing, and fluid handling systems in many aerospace and military applications.
Fluoropolymers are specified in many local area network, computer, and mobile telephony applications due to their outstanding electrical performance and fire/temperature resistance — vital for system critical equipment and devices. This has become increasingly important as more and more interactions in society become technology-dependent.
Click here to view a video on the uses of DuPont Melts in consumer electronics.
The semiconductor industry is almost entirely dependent on fluoroplastics as they are the only materials that can hold and transport the harsh chemicals used in the manufacturing process. Without them, electronic equipment such as personal computers, cellular phones, LCD, Plasma and LED displays could not be produced.
As relatively lightweight plastics with exceptional chemical resistance, fluoroplastics help aircraft and auto makers meet ever-increasing standards for weight, fuel economy and emissions. Their ability to withstand the harshest environments, from high-temperature sealing and electrical systems to fluid handling, is critical.
Inert, corrosion-resistant fluoroplastics preserve equipment and system integrity for the chemical processing industry. They not only help protect workers, but also provide valuable benefits to business, including higher productivity and less potential liability.
Fluoropolymers are used in power generation and pollution control systems. With low permeability and chemical and temperature resistance, they help protect people and avoid emissions to the environment, while also ensuring system reliability when used in applications from filters to wire insulation to process components.
Chemical and corrosion resistant fluoroplastics used in fluid handling or component carriage systems help ensure a process free of contaminants. Industries that depend on high-purity environments have also begun considering fluoroplastics as an alternative to traditional stainless steel in their operations.