The plastics industry is challenged to increase the use of recycled materials which most consumer companies are driving to meet. As more companies increase their usage of Post Consumer Recycled (PCR) resins and/or Post Industrial Recycled (PIR) resins, they now face the issue of maintaining consistent color quality of their extruded or molded products due to the inconsistent color of the recycled stream from lot to lot and within the same lot of material. Brand identity in the market is critical and maintaining the brand color of products or packaging on the retail shelve is becoming difficult with the use of these recycled materials.
PCR compounders are finding the economics challenging when trying to produce quality recycled materials when one of their main ingredients (PCR or PIR) is highly inconsistent in quality. Customers are demanding top quality of PCR compounds which causes significant production challenges to meet this level of quality.
Compounders only solution today to improve the color quality during production is to constantly monitor the product every 15 minutes or so, which requires constant trips to the quality lab and then relaying information back to the operator if they are in-specification or not. If the material is out of specification, then the operator manually adjust the tools at hand to attempt to bring the color back in spec, like adjusting the color feeder. Ultimately, the operator increases the use of expensive colorant to off-set the recycled material color deviation, this drives a processors raw material cost high who already operates within tight margins.
This inefficient process contributes to downtime in manufacturing and can also lead to high scrap rates. It is extremely difficult to make a profit in making PCR compounds due to these production inefficiencies. The outcome is higher prices for PCR based materials which makes it poor economic sense to add more recycled content to consumer products.
Furthermore, with todays skilled labor challenges, finding experienced and retaining trained line operators is very difficult.  Relying on these operators to make the proper quality adjustments during production can contribute to these inefficiencies in production. Especially during the second and third shifts where less supervision is present.
These challenges threaten profitability, increase waste, and jeopardize brand integrity. However, cutting-edge technologies are enabling manufacturers to overcome these obstacles, ensuring precision, efficiency, and sustainability in plastic operations.
Can AI emerging technology help compounders of recycled materials make brand colors consistent and provide operational efficiencies?
Yes, new technologies are emerging that incorporate both equipment automation and AI software to create a closed-loop system to allow compounders and other plastic processors to make real-time color adjustments, based on in-line, continuous color measurements during production without operator involvement.
These new technologies are similar to having your own color chemist and color lab on each plastic processing line working continuously, 24/7, to prevent downtime and scrap when running out-of-spec production.
These new technologies incorporate a high tech, fiber optic in-line color spectrophotometer designed for the harsh plant environment where heat, dust and light typically prevents any automation on the plant floor. These small, mounted color sensors actually measure the true L.a.b color values of the continuously produced plastic material and automatically compares to a saved color standard while calculating the delta E variation in color, all in real-time. Live data to make immediate adjustments to quality.
These technologies even incorporate light cancelling features which is critical to accurate color measurements since the sensor is not in contact with the material being measured. Also, these sensors self-calibrate after every measurement which is key in a production environment. Plus, temperature controlled cabinetry protects the sensitive electronics, optics and software from the high heats of a production floor.
If the color measurement exceeds a desired deviation threshold, then the AI software calculates a change in the color feed rate to bring the color back into specification. There are even technologies being introduced that utilize single pigment dispersions or mono pigments to adjust even minor changes in the color spectrum. For example, if your color being extruded is too blue, the AI technology will calculate a new color formulation to add trace amounts of yellow and white to compensate for the blue shade deviation. This is similar to how a hardware paint shop formulates new paint colors for your home but in real-time and on the production floor without the human involvement.
These technologies actually retrofit onto existing machines and can be engineered to size with the machines throughput rates. The hardware consists of a series of gravimetric color feeders that hold the individual mono pigments which is mounted near or on the throat of the extruder. The AI color correction software saves the color standard values and color formulations which is continuously being evaluated and adjusted based on dE color tolerances during production. The key is to make continuously, small adjustments during production to ensure that the color never falls out of specification.
Basically, you’re turning your existing equipment into smart machines allows you to make accurate color adjustments in real time, eliminating subjectivity and inefficiencies in the production process.
Real-time data is critical to making decisions, additionally, these systems time stamp every measurement which documents the entire production run. Production reports concerning color quality can now be saved and even provided to customers to verify the color quality of the material they purchased.
These new AI technologies are a significant leap forward in plastics extrusion technology, empowering manufacturers to meet the demands of a competitive market while advancing sustainability goals. These innovations not only address the challenges posed by recycled materials but also enhance operational efficiency, reduce waste, and ensure consistent quality.
