
Agri-Industrial Plastics Expands Production
of EPA-Compliant, Non-Automotive Fuel Tanks
Second Multilayer Coex Blow Molding Machine from Kautex Delivers
Barrier Solution for ATV, Marine, and Lawn and Garden Markets
FAIRFIELD, Iowa, February 4, 2010 – Agri-Industrial Plastics Co. has strengthened its commitment to the non-automotive fuel tank market with the purchase of a new six-layer continuous co-extrusion blow molding machine from Bonn, Germany-based Kautex Maschinenbau GmbH. The new multilayer machine – the second unit purchased from Kautex in five years – effectively doubles Agri-Industrial’s fuel tank capacity to meet the growing U.S. demand in the lawn & garden, ATV, snowmobile, and marine markets.
Manufacturers of these small-engine fuel tanks made of HDPE have increasingly turned to multilayer technology, which has been recognized as the most effective barrier solution for meeting stringent permeation requirements set forth by the U.S. Environmental Protection Agency (EPA), according to Agri-Industrial. The company began production of non-automotive multilayer fuel tanks in 2005. The newest machine is currently being installed at the company’s 186,000-sq-ft plant in Fairfield and is expected to be in operation this spring, according to Geoff Ward, Agri-Industrial’s engineering manager.
“This investment further reinforces our view that multilayer technology is the superior approach in meeting today’s stringent evaporative emission standards,” said Ward. “It’s a proven technology that is cost competitive, is consistent in meeting emission standards, and has
processing and quality benefits.”
The new coex machine from Kautex has a CP450 six-layer head with a maximum output of 1,985 lb/hr of HDPE. It uses s single clamp and robotic parison transfer to optimize production efficiencies. The single-press machine has a large 59-in by 70-in platen which has the ability to accommodate two molds at a time. This affords greater flexibility for production of a wide range of fuel tanks. The unit is specifically designed for tank sizes ranging from 5-gal to 20-gal, although Agri-Industrial has trialed some as small as 3-gal and some larger than 50-gal.
The HDPE fuel tank is composed of two virgin layers, two adhesive layers, an EVOH barrier layer, and a regrind layer. Permeation levels for the multilayer tanks far exceed the current EPA standard, which limits fuel vapor emissions to 1.5 g/m2/day with CE10 fuel at 28 C.
The new coex machine will be used to manufacture fuel tanks for all-terrain vehicles, snowmobiles, golf carts, personal watercraft, and a variety of lawn and garden applications including riding mowers, tractors, and other commercial equipment.
Agri-Industrial was one of the first custom blow molders in the U.S. to adopt multilayer technology as a barrier solution to meet tougher environmental regulations. The company works closely with customers to develop and design highly intricate part geometries which are not only environmentally-compliant but also functional.
About Agri-Industrial Plastics Co.
Founded in 1978, Agri-Industrial Plastics Co. is a leading industrial blow molder of large parts including non-automotive fuel tanks for the recreational equipment, lawn and garden, agricultural, and watercraft industries. The custom blow molder serves a diverse customer base and offers unparalleled expertise in part design, mold design, engineering, part production, and assembly. Agri-Industrial’s 186,000-sq-ft manufacturing facility in Fairfield, Iowa, houses 20
monolayer accumulator-head industrial blow molding machines and two multilayer continuous co-extrusion machines specifically for non-automotive fuel tank production. Learn more by calling (641) 472-4188 or visit HYPERLINK "http://www.agriindustrialplastics.com" www.agriindustrialplastics.com
Press Contact:
Joseph Grande
413.684.2463
HYPERLINK "mailto:joe.grande@verizon.net" joe.grande@verizon.net
When Agri Industrial Plastics Company in Fairfield was looking to install a walk-in freezer to test polyethylene fuel tanks at temperatures to 40 below zero, engineering manager Geoff Ward was having little luck last fall.
"I was looking around for quite a while for someone who could provide a 40 below [zero] freezer and the answer ended up being right across the street," laughed Ward.
Leer Inc., a wholly owned subsidiary of Fairfield's Dexter Apache Holdings Inc. since January 2008, just happens to make walk-in coolers and freezers in addition to its better-known ice-merchandising units commonly seen at convenience stores.
When Dexter Apache president and CEO Pat Albregts mentioned Leer at an Iowa Association of Business and Industry event in Coralville late last year, Ward was in the audience and his problem was solved.
"Pat was ready and willing to accommodate our need," said Ward.
The 8-foot by 12-foot by 9 1/2 -foot tall freezer unit was recently installed in the Agri Industrial Plastics plant and should be put to regular use soon.
The company's six-layer fuel tanks for snowmobiles and all-terrain vehicles are filled with anti-freeze and dropped from a height of just over 4 feet to test impact for design and molding purposes.
The drop test in 40 below zero conditions has little to do with recreating weather conditions for snowmobile use. The test is more for detecting thin spots and sharp corners in the fuel tank construction.
"Every model [of snowmobile fuel tank] has to pass certification," said Ward. "The impact test is done more to validate design and processing or molding procedure."
In the past, testing was done by the snowmobile manufacturer or an independent lab, but Agri Industrial Plastics has been looking to add the convenience for its customers.
"We have been sending the tanks to an independent lab in Michigan, but that's not real timely and it is more costly," said Ward. "We've been looking at bringing this capability in house for quite some time. We're one of the few non-automotive suppliers providing this service around fuel tank lines. There is more and more of an expectation to be proactive about it."
Providing a walk-in freezer with refrigeration capabilities at 40 below zero was not a run-of-the-mill request for Dexter Apache's New Lisbon, Wis. company.
"Most frozen food applications are made for temperatures at zero or right above," said Albregts. "This refrigeration unit was made specifically to meet Agri's needs."
The actual box with 6-inch walls and ceiling was consistent with the walk-in freezers manufactured by Leer Inc. The Wisconsin company supplies coolers and freezers to a number of restaurant chains including Buffalo Wild Wings, Little Caesars and Culvers.
"Everything we do is designed for customers' needs," said Albregts. "In addition to restaurants, we sell to convenience stores, grocery and even stadiums. We had walk-in coolers and freezers in the new Dallas Cowboys football stadium."
Leer Inc. produces more than 80 percent of the ice-merchandising units in the United States commonly seen at convenience and grocery stores. The company has more than 380,000 of the ice dispensers currently in use.
The Agri Industrial Plastics move to add the fuel tank testing in house comes at a time when fuel tank production capacity will soon be doubled. The company added its first six-layer fuel tank production line in 2005 to meet Environmental Protection Agency regulations for 2008 model year snowmobiles and ATVs. The company will add a second multi-layer, blow-molding machine for fuel tank production at the end of October.
Ward said the walk-in freezer will be used to test tanks at the beginning of each production run. He expected about eight tanks to be tested weekly.
Agri's current customers include Arctic Cat, John Deere, Yamaha, Kubota and Toro. New EPA regulations for fuel tanks in lawn and garden equipment, water craft, golf carts and portable tanks will go into effect for the 2011 model year.
--------------------------------------------------
Agri-Industrial Plastics Company Continues to Expand Production Capacity with Additional 6-Layer Fuel Tank Machine
Fairfield, Iowa, June 15, 2009, – Agri-Industrial Plastics Company (AIP) will be accepting another 6-layer fuel tank machine in early August to compliment their current machine, doubling the production capacity of fuel tanks for ATV, snowmobile, watercraft, golf cart, lawn & garden and the small to medium sized engine market. Their new KBS241 will have a CP450 6-layer head with a maximum output of 1985 lbs per hour of HDPE. Using a single clamp and robotic parison transfer, it has today’s most sophisticated technology to optimize their production necessities. With this latest addition, AIP will have a total of 22 production blow molding machines.
AIP began manufacturing non automotive multilayer fuel tanks in 2005 to meet the more stringent permeation requirements enforced by the EPA in the United States. Since going down this path, their business has now required additional equipment to meet greater demand. The 6-layer plastic fuel tank has long been accepted as the favored way to meet permeation requirements as well as conform to the demanding form and function necessary in the automotive market.
About Agri-Industrial Plastics Company: Agri-Industrial Plastics Company (AIP) is a custom, large-part plastics blow molder founded in 1978. AIP serves a diversified customer base. AIP offers expertise in part design, mold design, part production, and assembly. Through each phase of the process, AIP provides the highest quality service and products to their customers. For more information, visit www.agriindustrialplastics.com or email sales@agriindustrialplastics.com.
About Kautex Machines, Inc.: Kautex Machines, Inc. is located in North Branch, NJ and was founded as Krupp Plastics & Rubber Machinery (USA), Inc. in 1985. The company is a wholly owned subsidiary of Kautex Machinenbau GmbH of Bonn, Germany. Kautex Machines, Inc. markets and services Kautex blow molding equipment manufactured in Germany, and China for industrial and packaging applications throughout the entire Americas. For more information, visit www.kautex-group.com or email kautexmachines@kautex-group.com.