The session began with a spirited discussion of environmental trends. Though the awareness is only now increasing, Ken Lipovsky, cast polymer application specialist for Reichhold, noted the industry has used a similar mindset in past production. “For years, we’ve used recycled cola bottles and x-ray films for our resins, and they’ve been used in a variety of applications,” he said.

The panel discussed the differences in implementing the greener resins into manufacturing. “Larger molecules are used in the green resins, so they’re more resilient,” said Lipovsky. Tom Pelt, director of technical projects for Bradley Corporation, said color concerns must be addressed. “If you’re not careful, exotherming can cause stress cracking, and that can affect the color consistency,” he said.

When asked how the “green” nature of a product is determined, HK Research Corporation’s President Richard Higgins said there must be a component that’s a renewable resource. “Things such as soybean oil and fatty acids would be in there. The key is renewal sources,” he said. Additionally, it was clarified that a green resin isn’t LEED requirement; that’s determined by the end product itself.

More general manufacturing-related issues were also brought up. The panel discussed scrap elimination and why it occurs. Factors included excessive use of outdated or improper resins. “Most resins have a 90-day shelf life, and it’s possible that the drum of resin may have neared that lifespan when you receive it,” said Lipovsky. Pelt added that there may be problems with an equipment operator. “It may be painstaking to document those procedures, but it’s worth it to fix the problem. Plus, it becomes a training tool for new employees,” he said.

Finally, the discussion turned to mold issues related to curing. Jack Simmons, vice president of sales with ACS International, said that improper usage of resin (whether incorporating too much or letting it migrate too long) was a primary cause of curing problems. Higgins added that the combination of heavy gel coats and slow resins (leading to a short period when the gel is stronger than the matrix) was also a factor.

COMPOSITES 2010 Attendees lined up at registration on opening day

Attendees began flocking to COMPOSITES 2010 this morning like an Elvis impersonator on a jumpsuit sale. Attendees from around the world, a few tired from either jet lag, a few rounds of slot machines or both,  lined up to register at the Mandalay Bay Convention Center in Las Vegas.  Cast polymer and solid surface manufacturers also have the opportunity to participate in the International Countertop Expo (ICE), which co-located this year with the COMPOSITES 2010 show. “This is my first time here and I already love it,” says Ishmael Rahamut, managing director of Trinidad and Tobago-based Top Décor. “This is a great place for us to network and with ICE next door, I think it will be a great show.”

The first day of the convention will focus on education, including education sessions on lean manufacturing, closed molding and CCT (certified composites technician) tutorials.  In addition, there will be six new networking receptions designed to allow attendees to make the most of the three-day event. The new receptions will focus on emerging markets, pultrusion, infrastructure, building and construction, architecture and ICPA.

Later today, composite consultant Ray MacNeil will address attendees in the general session on the economic outlook of the composite industry and keynote speaker Mitt Romney, Republican presidential nominee in 2008 and former governor of Massachusetts, will focus on key business developments affecting the composites industry.

For up to the minute highlights of COMPOSITES 2010, follow Composites Manufacturing magazine on Twitter.

Ken Lipovsky of Reichhold will re-present the data and remind manufacturers what is necessary to meet the standard. “We got members to manufacture panels to submit for testing to determine the smoke and flame spread ratings,” he says. “In order to meet the Class A rating for both, it was determined that a certain amount of ATH had to be added to the formulation to meet the requirements.”

Products such as fireplace surrounds need to meet the rating in order to pass muster. Lipovsky will review the test data, which takes into account the thickness of parts, whether or not it they have gel coats and different ATH levels.

The technical panel will include speakers with subject areas of expertise, including gel coat, resin and peroxide suppliers. Lipovsky will also share questions and answers from readers of his Ask the Expert column that has appeared in industry magazines.

At Composites 2010, Bonnie Webster of Monroe Industries will talk about the company’s experience developing and marketing Robal Glass products, which combine recycled post-consumer, pre-landfill glass and bio-based resins. “I’m going to discuss the advantage of bringing in green products to your repertoire, how to market to your architects, designers, and kitchen and bath dealers using current terminology and trends instead of the term of cultured marble,” she says.

For instance, the term “cultured marble,” doesn’t communicate the benefits of environmentally friendly products like Robal Glass. Instead, Webster prefers the term “Engineered Composites.”

Architects concerned about LEED points are hot prospects for “green” products, but making these products requires changes to the manufacturing process, and many manufacturers are reluctant to change. “Our industry needs to go as green as possible, because everybody talks about styrene, but there are resins out there that don’t have styrene,” she says. “There are bio-based resins. I’ve got bio-based resins coming out of my ears that I’ve trialed.”