Carolina Color’s G2 product line reduces overall cost for sheet extruders and large part thermoforming molders with lower let down ratios, higher loadings of additives and lower production costs due to ease of use when compared to other colorant options.
The large part thermoforming business has grown dramatically in the past decade due to improved materials, processing and the ability to mold in color. With such growth, the market has become very competitive thus, sheet extruders and molders are constantly on the look out for ways to reduce costs while delivering products that are both aesthetically pleasing and meet performance expectations.
Many sheet extruders and large part molders have found that using highly-loaded colorant, be it in solid pellet or liquid form, can reduce cost. The fundamental idea is to add smaller quantities of more concentrated colorant to virgin resin in order to achieve the same end result, as opposed to using larger amounts of conventional colorant. There are numerous benefits to using color concentrates, including improved physical properties.
In 2008, Carolina Color patented a new color concentrate product that has revolutionized the colorant industry. The G2 product line is able to load pigments and additives to levels never considered, let alone achieved in a commercial product. The idea of a highly-loaded “super concentrate” has circulated in the industry for some time, but attempts have fallen short of performance expectations on many levels—until Carolina Color formulated G2. The advanced G2 pellets are exceptionally well-dispersed and effectively distribute in both large and small parts, improving physical and visual properties of thermoformed material. In addition, G2 delivers the cost-saving possibilities of using concentrated color.
By switching to G2 product line, sheet extruders and their large part thermoforming customers have seen reduced material needs, improved extruder efficiencies, more consistent sag rates, reduced scrap and improved cycle times, along with increased UV protection and improved gloss. Large part manufacturers, such as Port-A-Potty products, have been able to benefit from G2 in various ways.
Photo Caption: Port-A-Potty manufacturer’s G2 can achieve better sag rates than traditional color concentrate, without increasing cost.
Port-A-Potty customers are largely concerned with the bottom line price point, so manufacturers must be extremely cost conscious and look for ways to reduce production costs. However, in thermoforming Port-A Potty panels, manufacturers must meet challenging requirements, with a focus on achieving the proper sag rate across their entire color pallet in order to maximize cycle time efficiencies and minimize scrap generated when going from color to color. They also need to ensure that parts will remain strong and will not become damaged due to UV degradation or other external environmental conditions. While these requirements can usually cause an increase in cost during manufacturing, G2 achieves lower sag rates than traditional color concentrate and better resists damage from UV exposure, without increasing cost.
Sheet extruders and thermoformers that sell into the markets listed below, can also benefit from the switch to G2:
- Tractor hoods and Interior parts
- Earth moving equipment panels and interior parts
- Semi-truck panels
- Snowplow blades
- Golf cart and ATV panels
- Medical equipment
Photo Caption: Medical equipment thermoforming manufacturers can reduce production cost by switching to G2.
In addition to better material strength and performance, sheet extruders and thermoformers have been able to reduce production cost by switching to G2 for a number of reasons. Quantifiable improvements in extruder efficiencies have led to improvements in extruder throughput. Further, sheet made using G2 allows for panels with reduced warp, enabling the molder to produce parts quicker and of higher quality.
Carolina Color’s G2 product line has proven performance in diverse applications, including outdoor durables, packaging, industrial, non-automotive transportation, and much more. Convertors continue to be impressed by this game-changing technology. Whether it is injection, extrusion or blow molding, G2 continues to hit the mark.
Carolina Color Corporation — a successful, family-owned company since 1967 — serves colorant needs from ISO 9001:2008 certified locations in North Carolina and Ohio.