Bringing Clarity to Barricades, Barriers, and the Evolution of the Longitudinal Channelizer

Posted by Tracy L Connors on

A graphic with two photos. One photo showing plastic barricades on a city street with chain link fence on a rainy day with a car turning onto the street. The other photo shows concrete barriers in the middle of the highway on a grey day. The images are surrounded by an orange frame.

For those outside the traffic control industry, the various types of temporary traffic control devices used in work zones are often a mystery. In this article, we break down the two primary categories: barriers and barricades, explaining their distinct roles in keeping work zones safe.

Understanding Traffic Barriers

Barriers are essential for protecting road workers by physically separating them from oncoming traffic. These robust devices, like the commonly seen concrete Jersey Barriers or steel-reinforced plastic barriers, are designed to redirect vehicles away from the work area. A key feature of these barriers is their ability to withstand impacts without allowing vehicles to break through the line, thus ensuring worker safety.

What Are Barricades?

Unlike barriers, barricades are primarily used to inform and guide drivers, channeling traffic away from active work zones. These lightweight devices, such as traffic drums and Type I barricades (commonly recognized as “sawhorses”), are designed to be non-threatening to vehicles in case of accidental impact. Typically, they feature white or orange colors with reflective materials to enhance visibility at night, making them effective channelizers in low-speed areas.

The Evolution of the Longitudinal Channelizer

In the 1990s, the industry witnessed the introduction of hollow plastic barriers, mimicking the look of traditional concrete barriers. However, testing quickly revealed that plastic barriers, even when filled with water, did not provide the necessary protection due to their lower weight and lack of strength compared to concrete. To meet safety standards, manufacturers began reinforcing these plastic barriers with steel—either internally with steel cables or externally with an exoskeleton. While this innovation passed safety tests, it introduced new challenges, such as increased deflection during impacts, requiring greater spacing from the work zone, which is often impractical.

Despite these limitations, the imposing appearance of plastic barriers proved highly effective in channeling traffic, leading to their evolution into what we now know as longitudinal channelizers. These devices are now widely used in various scenarios, from parking lots and pedestrian management to site security, often enhanced with chain link fencing for additional protection.

Conclusion

As the traffic control industry continues to evolve, the need for clear distinctions between barriers and barricades remains crucial for ensuring safety in work zones. Whether it’s protecting road workers or guiding drivers through complex construction areas, understanding the purpose and proper use of these devices is key. The development of longitudinal channelizers highlights the industry’s commitment to innovation, finding new ways to balance safety, practicality, and effectiveness in an ever-changing landscape. By staying informed about these advancements, both industry professionals and the general public can contribute to safer and more efficient roadways.

A visual representation of particle size and distribution in dry blended polyethylene versus particle size and distribution in compounded polyethylene

Color in Rotational Molding: How to Get the Perfect Hue in Polyethylene

Posted by Tracy L Connors on

How Does Polyethylene Get Its Color?

Ever wondered how colored polyethylene is made? It all comes down to adding pigments to the plastic. But here’s the kicker—polyethylene itself never actually changes color; it stays its original translucent white. The color you see comes from tiny particles of pigment suspended between the polyethylene molecules. Picture this: it’s like having tiny pebbles floating in a block of ice. When light hits your product, it bounces off these pigment particles, creating the vibrant color we see. The secret to a rich, even color lies in how well these pigments are spread out. The smaller the pigment particles, the more stunning the color. And guess what? The way you mix the pigments plays a huge role in this.

What Are the Best Ways to Mix Pigments with Polyethylene?

When you’re working with polyethylene for rotational molding, both the polyethylene and the pigments are usually in powder form. You have a few options for mixing them together. On the lower end, there’s paddle or ribbon mixing—affordable but basic. In the middle, you have high-intensity dry blending. And if you’re looking to go all out, there’s melt compounding, which is the premium option. As you move up the ladder from basic to premium, the pigment particles get smaller and spread more evenly, which means better-looking color and a product that retains its impact strength. This is important because adding pigments can sometimes weaken the plastic if not done correctly.

How Does Sunlight Affect Polyethylene Colors?

If your product is going to spend a lot of time outdoors, you’ll need to think about how sunlight will affect its color. This is where a lot of people make a mistake: they assume that if the base polyethylene has a good UV rating, it’ll also protect the pigment from fading. Not so! The UV additives in polyethylene are there to slow down the material’s degradation, not to protect the color. If you want that vibrant color to last, the pigment itself needs to be “light-stabilized.” So, be sure to let your pigment supplier know if your product will be out in the sun a lot—they can help you pick the right pigments.

How Is Color Added in Other Plastics Manufacturing Processes?

In processes like injection molding, blow molding, and extrusion, the material is melted in a heated barrel and then forced into the mold by a screw. The color is added into that barrel and mixed by the screw. Because there’s usually enough material in the barrel to make several products at once, changing colors means removing the old color, cleaning the barrel and screw, and then introducing the new color. It’s a bit of a hassle, which is why these molders prefer longer runs of each color before making a switch. But with rotational molding, it’s a different story. You put the dry material and pigment directly into the mold, which is then heated in an oven. Only the material inside the mold melts, so you can change colors with just a quick clean of the mold between runs. This makes it super easy to do small color batches without much downtime.

The Epic Origin Story of Our Molded Marvels

Posted by Tracy L Connors on

So you might be asking yourself, “Remcon Plastics? What have they BIN up to?” Well, first, thanks for asking! The Connors have been cooking up a new video series, and here is the first result of that collaboration. It’s called “Pete’s Product History.” Because knowing our dad, a product is never just a product. It’s a story.

In our first episode, we look at the Flat Bottom Bin with Replaceable Pallet (or FBP for those who like their BLTs ASAP). Our story begins with a challenge taken up by a young upstart who used critical thinking to transform the Meat and Poultry industry. It captures what we do best with the Remcon process: listen to our customers, observe their pain points, and develop durable innovations that delight generations. After that, we go to lunch.

So what are you waiting for? It’s like watching a blockbuster movie, but with fewer explosions and more plastic (popcorn not included, but highly recommended). Stay tuned because this is only the beginning. Our plant is full of stories that are being molded and shipped every day. Join us!

side by side comparison of the product spillage on an injection molded pallet vs a rotationally molded pallet

Why Rotationally Molded Pallets Are Superior to Injection Molded

Posted by Tracy L Connors on

When it comes to selecting the best pallets for your material handling needs, the choice between rotationally molded and injection molded pallets can be critical. While both types have their benefits, rotationally molded pallets often come out on top for specific applications. Here’s why rotationally molded pallets can be the superior choice.

Longevity: Built to Withstand the Test of Time

Robust and Durable

Rotationally molded pallets are known for their robustness. They are designed to withstand harsh conditions, including extreme cold temperatures and the impacts that are common with forklift handling. Unlike injection molded pallets, which can be more brittle and prone to cracking under stress, rotationally molded pallets maintain their structural integrity over long periods. This durability translates to a longer lifespan, meaning fewer replacements and lower costs in the long run.

Customization: Flexible and Cost-Effective

Easier and More Cost-Effective Molds

One of the biggest advantages of rotationally molded pallets is the ease and cost-effectiveness of creating molds. Engineering and manufacturing a rotational molding mold is significantly cheaper than an injection mold. This cost differential makes it more feasible to produce custom pallets tailored to specific needs in quantities as low as 1000 without breaking the bank. The low tooling costs also allow for customized deck configurations to be produced inexpensively.

Encapsulate Metal Reinforcement

Rotationally molded pallets have the benefit of being able to encapsulate metal reinforcement within the rotationally molded shell to add stiffness, particularly for specialized racking applications. Encapsulating the metal minimizes chances for rust and degradation in wet environments.

Custom Colors and Color Coding

Rotationally molded pallets offer exceptional flexibility in customization. Whether you need specific colors to align with your branding or to facilitate organization, rotational molding allows for short production runs of colors with no added expense. Additionally, it’s simpler to add or remove steel reinforcements, change the top deck configuration, or add features like a lip or roll cradle. This adaptability ensures that you get exactly the pallet you need for your application.

Hygiene: Keeping Your Operations Clean

Easier to Clean

For industries where hygiene is paramount, such as food and pharmaceuticals, rotationally molded pallets offer a significant advantage. These pallets are non-porous and easy to clean, preventing the buildup of contaminants. Stiffness in an injection molded pallet is gained by adding ribs to the underside of the deck. Unfortunately, these ribs create a criss-cross pattern of pockets that become a cleaning challenge. Rotationally molded pallets are a hollow closed shape which gain stiffness through increasing the distance between the top and bottom surfaces of the deck. Those surfaces are relatively smooth with no sharp pockets to collect dirt or mold, which is the reason rotationally molded pallets are used extensively in the food and pharmaceutical industry.

 

Conclusion

For certain applications, rotationally molded pallets are superior to injection molded pallets due to their customization capabilities, longevity, and hygiene benefits. The cost-effectiveness of mold production, combined with the flexibility to customize colors and features, makes rotationally molded pallets an excellent choice for businesses looking to optimize their material handling solutions. Their robust construction ensures a long lifespan, and their ease of cleaning makes them ideal for industries with stringent hygiene requirements.

Discover how our rotationally molded pallets can revolutionize your material handling process. Contact us now 800-360-3636 for a personalized consultation and see how we can tailor our solutions to meet your unique needs. Don’t miss out on the opportunity to enhance your operational efficiency and reduce costs!

 

If you’d like to learn more about how the rotational molding process works be sure to check out this informative post, aptly title:

What is the Rotational Molding Process?

 

Revitalize American Manufacturing with Remcon’s Innovative Solutions

Posted by Tracy L Connors on

 

Bringing Manufacturing Back to American Soil

We proudly join the movement to bring manufacturing back to American soil. At Remcon, we passionately support American businesses with durable products and innovative solutions to tackle everyday challenges. Our mission goes beyond just creating products; we seize every opportunity to support businesses that create new jobs in their communities.

Supporting U.S.-Based Innovation

We’re excited to see the Remcon Guardsafe® 36 Barricade in action at the new Intel chip plant in Ohio. This project represents a significant step toward securing the future of U.S.-based manufacturing and innovation.

Family-Owned Commitment to Excellence

As a family-owned business, Remcon strives to exceed customer expectations, proving that “Made in America” stands for excellence and reliability. Our commitment to quality and innovation means that every product we offer is designed to meet the highest standards and provide exceptional value to our customers.

Join Us in Building a Brighter Future

Join us in building a brighter future together. Whether you are a business looking for reliable solutions or an advocate for American manufacturing, Remcon is here to support you. Let’s work together to strengthen our communities and create a legacy of excellence that will last for generations.

REMCON PLASTICS, INC. WELCOMES JAMES CONNORS AS DIRECTOR of DESIGN

Posted by Grayson Hale on

Reading, PA — Remcon Plastics, Inc., a leading roto-molding company, is proud to announce the addition of James Connors as Director of Design. James is an Industrial Designer with over a decade of professional experience. Throughout his career, James has worked for and consulted with companies such as Peloton, CTRL-Labs, KitchenAid, Colgate-Palmolive, Bare and other New York based design firms. He has overseen the development process of a variety of successful products, including the award-winning Peloton Bootcamp Weights and the CTRL-Labs CTRL-kit. In his career, he has collaborated closely with engineering and graphic design marketing teams to ensure a cohesive brand identify. James has also taught several college classes on design, given workshops at Industrial Design conferences and has his own podcast about Industrial Design.

James is excited about joining the Remcon team, “Off and on since 2006, I have worked for Remcon at every level of the business, from the factory floor to the engineering department. The enthusiasm and tenacity of the current team makes me more excited than ever to join the business full-time. In my role, I hope to take what I have learned so far in my career to design thoughtfully developed products for our clients and provide Remcon with the cohesive brand identify it has earned.”

Please join us in welcoming James to our team. James’ creativity, passion and thoughtful design innovation will be invaluable to Remcon as we continue to grow and innovate. We are confidents James’ skills and experience will be a tremendous asset to our continued success.

About Remcon:

Remcon Plastics, Inc., is headquartered in Reading, Pennsylvania, and has been in business since 1982. Remcon is a Rotational Molding Company with a 40-year reputation for solutions you can trust.   Remcon offers a proprietary line of polyethylene material handling and traffic safety products.  Remcon specializes in working with the following industries: Meat & Poultry; Pharma & Nutraceutical; Produce & Food Processing; Chemical; Candy Making; Grain, Feed, Bakery, Traffic Safety Control, and Construction. To learn more, please visit https://www.remcon.com.

REMCON PLASTICS, INC. WELCOMES JOHN W. EMMONS AS CHIEF OPERATING OFFICER

Posted by Grayson Hale on

Reading, PA — Remcon Plastics, Inc., a leading roto-molding company, is proud to announce the hiring of John Emmons as its new Chief Operating Officer. John brings over 40 years of experience in manufacturing and operations management with broad experience working in a Fortune 500 publicly-traded company, a family-owned/professionally managed business, and several private equity companies. Instead of retiring, he elected to join Remcon to help grow the people, processes, and products in a refreshing and positive environment.

Peter Connors, current President, who founded the business in 1982, is pleased to have John in this leadership role, “John has always been a believer that the most important role of a senior executive is to develop the employees and help them reach their full potential and in so doing create long term security and profitability for all involved. As the second generation of my family steps up to continue to grow the company, I could not think of a better person to help Remcon develop a more robust management process than John.”

Starting as a chemical engineer out of college, John quickly gravitated to manufacturing, believing that the greatest value is generated with the fusion of man and machine. Since then, John has lived in 7 states and managed plants in Germany and India. He has held positions in Engineering, Research and Development, Plant Management and Operations.

John is looking forward to his new role, “I am very excited about this opportunity to join Remcon – great people, super products, a solid business, and a genuine desire to build for the future. That’s a rare commodity today.”

Please join us in welcoming John to our team. We are confident that John’s extensive knowledge, skills, and experience will have a positive impact on Remcon operations and overall performance.  We are looking forward to his contributions in driving the company forward.

About Remcon:

Remcon Plastics, Inc., is headquartered in Reading, Pennsylvania, and has been in business since 1982. Remcon is a Rotational Molding Company with a 40-year reputation for solutions you can trust.   Remcon offers a proprietary line of polyethylene material handling products traffic safety products.  Remcon specializes in working with the following industries: Meat & Poultry; Pharma & Nutraceutical; Produce & Food Processing; Chemical; Candy Making; Grain, Feed, & Bakery, Traffic Safety and Control, and Construction. To learn more, please visit https://www.remcon.com.

TRACY L. CONNORS PROMOTED TO EXECUTIVE VICE PRESIDENT AND CEO of REMCON PLASTICS

Posted by Grayson Hale on

Reading, PA  Remcon Plastics, Inc., a leading roto-molding company, is proud to announce the promotion of Tracy Connors to the position of Executive Vice President and CEO. Tracy’s extensive background in film production was a springboard to managing Remcon team projects, maintaining important deadlines while juggling ever-changing priorities. Since joining the company in 2017, Tracy has been an integral part of Remcon Plastics. Tracy has successfully managed all areas of our OEM business while strengthening customer and strategic supplier relationships. Tracy has consistently demonstrated exceptional leadership skills, an unwavering commitment to excellence, and a deep understanding our company’s mission and values.

Peter Connors, current President, who founded the business in 1982, is pleased to have Tracy in this leadership role. “Tracy has made amazing strides in developing her leadership skills and understanding our business model. It’s important that our loyal workforce and customers can count on the stability of our family’s commitment to those who have helped us build an amazing company. I am confident this new generation will deliver fantastic results for all Remcon families, including our customers.”

Tracy will be responsible for leading Remcon Plastics to even greater success and growth, building on our strong foundation and expanding our reach in the industry. Tracy’s vision, strategic thinking, and innovative approach will be invaluable in driving our company forward.

Tracy is excited about her new role, “I am honored and humbled to have been appointed as the new CEO. As a family-owned business with a long history of excellence and innovation, I am excited to take on this new role and help drive the company forward. My top priority is to continue building on our brand’s reputation for excellence in both products and processes. To achieve this, we will be looking to integrate new technologies allowing us to operate more efficiently and continue to grow. I look forward to working with our talented team to build on our successes and continue to drive innovation across all aspects of our business.”

Tracy’s promotion is a testament to her hard work and dedication to our company’s success. Her commitment to creating a positive, supportive culture for Remcon employees and an unwavering customer-centric approach position Remcon for great things ahead. We are thrilled to have Tracy leading our company and look forward to a bright future under her leadership.

About Remcon:

Remcon Plastics, Inc., headquartered in Reading, Pennsylvania, offers a proprietary line of polyethylene material handling and traffic safety products, specializing in the following industries: Meat & Poultry; Pharmaceutical; Food Processing; Grain, Feed, Bakery, Traffic Safety and Construction. To learn more, please visit https://www.remcon.com.

REMCON PLASTICS, INC. ANNOUNCES CREATION OF ECO-FRIENDLY STATE OF ART DRY BULK HOPPER

Posted by Remcon Plastics on

Reading, PA — Remcon Plastics, Inc., today, announced the launch of its state of the art, eco-friendly, dry bulk mass flow reusable polyethylene hopper. This heavy duty unit has been designed specifically for use with fine particles and low bulk density powders. The initial offering is a two-piece design featuring a 60° cone and a 45 cubic foot capacity. Molded from FDA approved virgin polyethylene the DBH-60/45 is sanitary for food and pharmaceutical applications yet rugged enough for the most demanding industrial challenges. Design features allow the DBH-60/45 to accommodate a variety of valves and discharge configurations. Utilizing a patent pending interlock system the hopper and base can be lifted by crane as one piece or can be set up in a manner where a crane can easily lift the hopper out of the base for sanitary discharge or in areas with limited headroom.

 

According to Remcon President & CEO, Peter Connors, “Over the past 39 years, Remcon innovations have become the industry standards in many market segments because of the cost savings generated by durability, ease of use and sustainability. We are confident that the new DBH-60/45 will continue that trend.”

Connors noted, “The key to our long term success has been the creation of long lasting products that far outperform single/limited use flexible packaging. The long service life that each of our products provide means significantly reduced stress on your budget and our environment”

The Remcon heavy duty Dry Bulk Hopper has application for products such as dry resins, powders, or other loose granular solids. The hoppers can hold nominal weight of 5,000 pounds. This newly designed container compliments the full line of material handling products offered by Remcon, which are FDA compliant for storage, in-process handling, and shipping.

Georgeann Vaclavik, Remcon’s Director of Marketing, noted, “We will be showcasing our new heavy-duty, dry bulk material handling containers during the International Powder and Bulk Solids Conference and Exhibition in Rosemont, IL the week of August 23, 2021. The Powder Show brings together the powder and bulk solids handling and dry processing sector for one event, affording us the opportunity to showcase these heavy duty mass-flow hoppers to companies looking for innovative, environmentally friendly material handling solutions.”

What is the Rotational Molding Process?

Posted by Remcon Plastics on

What is rotational molding used for?

Rotational molding (commonly referred to as rotomolding) is a manufacturing process that is ideal for making hollow parts.

What is the rotational molding process?

The rotational molding process allows you to form a plastic part by coating the inside of a hollow mold with plastic material. Plastic, usually in powder form, is placed inside a metal mold and falls to the bottom forming a pool. The mold is then put in an oven and heated until the plastic melts enough to become sticky and cling to the surface.

The mold begins rotating as it enters the oven like a rotisserie except you are rotating the part on two separate axes (think of it as a merry-go-round riding on a Ferris wheel). Because of gravity the plastic wants to slide to the lowest area of the mold. Since the mold is turning the plastic keeps sliding downhill and as the powder moves over the hot mold surface another layer of particles melts in to the wall that is forming. When all of the powder has dissolved in to the walls it is time to cool the part back down and remove it from the mold.

While the mold is rotating, the plastic, driven my gravity, slides to the lowest point. The biaxial rotation (merry-go-round on a Ferris wheel) ensures that every area of the mold passes through this low point and another layer plastic adheres to the mold surface. You continue to cook the part in this manner until all of the plastic has attached to the mold.

What are the steps involved in the rotational molding process?

There are four primary steps to the rotational molding process:

  • Charging the mold with the appropriate weight of the required raw material
  • Melting the material and spreading it around the mold
  • Cooling the part so that it returns to a solid state
  • Removing the part from the mold and performing any necessary trimming operations.

What materials are used for rotational molding?

90-95% of rotationally molded parts are made from polyethylene in a full range of densities. In addition, rotomolders have had success with PVC , Polypropylene, nylon, fluorocarbons (think Teflon), PFA.

Check out this video to watch the rotational molding process in action!