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Megasheet

New UHMW, PP, HDPE Compression Molding Sheet Press

Röchling Engineered Plastics recently installed a new compression molding sheet press that is capable of producing a single sheet of UHMW, HDPE or PP that is an 8 feet by 20 feet. The largest molded polyolefin sheet available anywhere in the world is available in thicknesses from 1/2" - 4".

Nicknamed the "Megasheet", it can be used as one huge sheet or cut as needed to achieve yields and sizes that have never been available in these products before. UHMW, HDPE and PP pressed sheets are most commonly available in the market as 48" x 96" and 48" x 120" sheets. For many applications these sizes are ideal, but there are numerous existing applications that can be perfected with the Megasheet, and at the same time present cost savings by eliminating many labor-intensive steps. Additionally, large or unique parts that can present terrible yields from standard sheet sizes can usually be cut or machined from the Megasheet while greatly reducing material waste. That translates into big savings for the fabricator.

New applications are sure to develop quickly in a variety of industries as engineers learn that this product is available. Welding of these materials can be successfully achieved with the right equipment and expertise. Prior limitations with the thicknesses and concerns about joint strength have now been virtually eliminated.

For example, these sizes are available in the market today as compression molded sheets:

48" x 96"

48" x 120"

48" x 240" (very limited thicknesses only)

60" x 120"

48" x 144"

60" x 96"

With the Megasheet, these unique sizes are now available:

96" x 96"

96" x 120"

96" x 240"

80" x 96"

80" x 80"

UHMW-PE (Ultra High Molecular Weight Polyethylene) is generally known for its outstanding impact and abrasion resistance, accompanied with an extraordinary low coefficient of friction. Unit material handling (conveyor) and bulk material handling are the largest segments for this unique polymer, however UHMW-PE is used in a vast range of industries. The benefits of the Megasheet for existing and new applications are endless. For example, many truck bed liners can now be installed as a one-piece section eliminating the costs to weld the sheets and omitting the risk of a weld breaking. Marine dock fenders are typically oversize lengths, such as 15 or 20 ft. Extruded boards were previously used to accomplish these lengths, but they can be susceptible to warping and bowing. Boards cut from the 20’ long Megasheet are stress-relieved due to the technology and design of this large compression molding sheet press. Large chute and hopper linings can now be designed with fewer seams and joints, helping solve material flow problems.

HDPE (High Density Polyethylene) is such a highly versatile plastic that it is used to some extent in just about every major market segment. Extruded sheet is available up to 1-1/2” thick but the compression molded Megasheet can be manufactured as thick as 4”. One benefit is actually in the HDPE pipe market. Manhole covers and flanges can now be fabricated as large as 8 feet in diameter without the labor-intensive task of welding thick sheets together.

Polypropylene is also extruded up to 1-1/2” thick but is now available in the 8 ft. x 20 ft. Megasheet as thick as 4”. Large blocks used in applications such as pump parts can now be configured with near-perfect yields from the big sheet.

Lew Carter, General Manager for Röchling Engineered Plastics stated, "This advancement is unprecedented in our industry and provides endless opportunities for the market place. We urge you to reconsider the way you are doing business today and to think outside the box as to how this sheet and its yield capabilities can improve your bottom line. We are fully equipped to cut the sheet to any size required to meet your demands."

Röchling's Megasheet is produced in standard and premium grades of Polystone®M (UHMW), Polystone®G (HDPE) and Polystone®P (Polypropylene). It is available through exclusive distributors located throughout North and South America.

For more information, contact Tim Brown, Marketing Manager, Röchling Engineered Plastics, P.O. Box 2729, Gastonia, NC, 28053, 800-541-4419, Fax: 704-922-7814, E-mail: rep@roechling.com, Web: www.roechling.com.

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