Milacron Twin-Screw Extruders Key to New Company's Rapid Expansion

Flex-Hose Maker VarTek Expanding Capacity to Keep Pace with "Sold Out" Demand

August 29, 2005 - Tampa, Florida...VarTek, a leading producer of PVC flex hose and tubing for the spa industry, is enjoying the kind of immediate success that most start-up manufacturing operations can only dream about. Since opening its Tampa plant in January, VarTek has seen booming demand for its PVC flex hose and vinyl tubing products - so much so that it is adding two Cincinnati Milacron co-extrusion lines to the four it currently operates just to keep pace with demand.

"Our growth has been unbelievable," says VarTek President John G. Porter. "We are already sold out in terms of production capacity in our new facility, and are presently adding two production lines to meet demand."

VarTek took delivery of its fifth production line from Cincinnati Milacron Extrusion Systems in July, followed by another new line in September. When both new lines are operating, VarTek's plant will have 11 Milacron conical twin- and single-screw extruders. The plant exclusively runs Milacron extruder equipment.

VarTek uses Milacron's TC35 twin-screw machines to extrude rigid PVC for the reinforcement in flex hose. Hose reinforced with rigid PVC generally performs better than hose reinforced with metal wire, widely supplanting the metal product, Porter explains.

The TC35 (35 mm conical) twin-screw extruders are mated with Akron Milacron PAK 250 (2.5-inch) single-screw extruders on the VarTek production lines. A lone Akron Milacron PAK 450 (4.5-inch) single-screw extruder is used exclusively to produce flexible vinyl tubing used to plumb portable spas and irrigation systems.

"Milacron is where it all begins," says Porter about VarTek's success. "We use the very best, state-of-the-art equipment supplied by Milacron. We trademarked the saying, 'Only The Finest PVC Hose and Tubing' because we truly feel we offer the best products on the market. We are successful in large part due to Milacron's superb technical support, field service and engineers. Milacron's staff is incomparable in terms of support, whether it's a technical issue or simply getting a small part to us," says Porter, a veteran of the PVC manufacturing field who previously used Milacron equipment before forming VarTek.

Porter explains that Milacron's equipment allows VarTek to offer a superior product at a highly competitive price. "Manufacturing a better product that could still compete on price was our challenge," says Porter. "Our investment in the twin-screw machines and automation achieved both goals. The conical twin-screw machines produce an exceptional melt stream from powder PVC for the reinforcement."

The TC35 utilizes a three-section barrel, including a conical feed section. Because the feed zone offers more surface area, heat transmission from screws to material is faster and more uniform. As with all Milacron conical twins, screws can be removed from the rear of the machine without disturbing downstream equipment.

VarTek's co-extrusion lines use Milacron's PC-based XTREEM XP control to make two extruders operate seamlessly as one. The XTREEM XP control offers Ethernet networking for the factory floor and provides the full functionality of a Windows (XP personal computer, including the Microsoft Internet Explorer) suite of software and a host of other PC capabilities such as e-mail, CAD, imaging, and databases for documentation.

Milacron's microprocessor control technology has helped VarTek gain a competitive edge. "Our software advises the operator if any adjustments are needed," says Porter. "Our strategy has proven that advanced technology can simplify operations, make a superior product and still let us compete on price," he says.

"We have invested about $1.5 million in Milacron equipment and it was worth every penny," says Porter.

For more information from Cincinnati Milacron Extrusion Systems, phone 1-888-MILACRON (645-2276) or fax 1-800-282-8082. Visit Milacron's home page at www.milacron.com for a detailed look at solutions that build productivity through advanced technology.