The production of plastics began in 1869 when John Wesley Hyatt developed celluloid. The plastics industry, however, is almost entirely a 20th-century phenomenon. Its growth, developments, applications, and impact on society and the economy took place in the past 100 years; barely a heartbeat in the history of civilization and materials fabrication. As brief as the history of the industry is, its development was shaped by myriad influences throughout the 1900s. Here is our list of the 100 events that shaped the plastics industry into what it is today.
1) World War II (1939-1945): This is the demarcation point between the early thermoset-dominated materials and fabrication era of plastics and the thermoplastics age that developed from it. The buildup in materials technology and processing for the war laid the foundation for advances in formulations and applications that continue to this day. Rarely has one manufacturing culture changed as rapidly as did plastics in the post-war years.
2) The Global Economy: Buildup of international trade created exposure to and markets for a range of plastics goods and relevant process technologies. The cross-pollination of ideas and applications in markets worldwide made plastics one of the most dynamic and innovative businesses of the century.
3) Oil Shocks of the 1970s: Embargos and reduced output orchestrated by OPEC focused attention in developed countries on the tenuous link between prosperity and energy supply, and on the need to use fuel and other resources more efficiently. Oil shortages helped to promote plastics use in lightweighting and other resource-conservation roles.
4) Computer Automation: This set the stage for innumerable developments that have had far-reaching impact on the design, economy, versatility, and application of plastics.
5) The Internet: A decade ago most plastics firms had barely heard of this; now they're figuring how best to capitalize on the opportunities it offers for business and communication. Use of the Internet as a sales and information tool can only grow and change how the industry does business.
6) Development of Bakelite phenol-formaldehyde synthetic resin; first synthetic resin and brand name
7) Invention of the injection molding machine; need we say more?
8) Hermann Staudinger's work on macromolecule theory; basis for most resin developments, including polyamide
9) Use of Ziegler-Natta catalysts in polyolefin polymerization; spawned formulation revolution that's still underway
10) Auto industry's use of plastics in car production; impact on demand, technology, and productivity is huge
11) Development of polyamide; resin that launched consumer awareness of how plastics can improve life
12) Invention of polyethylene; technical curiosity and wartime mainstay became a cornerstone of consumer goods and the disposable society
13) Plasticization of polyvinyl chloride; by making PVC functional it created huge demand worldwide
14) Development of polypropylene; a key commodity resin that finds new and wider use every decade
15) Development of polystyrene; a mainstay of applications and formulation technologies
16) Development of polyurethane; applications are almost too numerable to mention
17) Invention of the reciprocating screw; an ingenious device without which injection molding as now known is inconceivable
18) Commercialization of the single-screw extruder; basic to most processes
19) Development of blown film extrusion; makes possible diverse flexible applications
20) Development of the pet beverage bottle; brought an entirely new dimension to, and awareness of, plastics packaging
21) Growth of compounding; makes possible infinite range of tailored grades
22) Development of acrylonitrile-butadiene-styrene; among the first of the popular engineering resins
23) Development of polycarbonate; raised resin performance and applications potential to new levels
24) Polymerization of methacrylate; led to development of Plexiglas brand; World War II use helped spawn contact lens business
25) Cast film and sheet; high-speed process raises capabilities of flexible web production
26) Container blow molding; created major volume markets for diverse resins
27) Window profile extrusion; early success in assault by plastics on traditional construction materials
28) Neck-ring calibration during blow molding; major productivity and quality gain for high-volume market
29) Development of form/fill/seal packaging lines; online process demonstrates plastics production flexibility
30) PVC blow molding; created huge market that continues to be strong in many parts of the world
31) Film orientation; mono or biaxial orientation expands properties and applications of numerous products
32) Development of synthetic elastomer; crucial to expanding the versatility of various grades of plastics
33) Counterrotating twin-screw extrusion; a boon to output and quality
34) Blow molded fuel tanks; created a huge market for plastics and for recyclate
35) Coextrusion technology; makes possible applications ranging from barrier packaging to use of recyclate
36) Acceptance of HDPE as milk container; in the U.S., especially, this solidified HDPE as a major commodity resin
37) Development of low-density polyethylene; broadened appeal, reach, and economics of PE, especially in film
38) Development of linear LDPE; another giant leap for pe technology once all the wrinkles were ironed out of the process
39) Polyolefins Renaissance: Upgrading PE and PP via catalysis; single-site, metallocene, and enhanced Ziegler-Natta are among catalysts remaking polyolefins
40) PVC use in blood bags; many view this as one of the best proofs of vinyl's benefit
41) Extrusion of vinyl siding; huge market that reinforced PVC's place in construction
42) Inline compounding; a critical route for economical production of tailored products for processors with sufficient expertise
43) Inline bagmaking; key breakthrough in the productivity and economy of the market
44) Online film and sheet quality control; dramatically increased efficiency and economy of webs
45) Grooved-feed extruder barrel; major benefit to throughput
46) Development of cold-cure unsaturated polyester resin; start of the modern composites business
47) Development of laminated thermoplastic sheet; proved as far back as the 1920s the versatility and esthetics of plastics
48) Development of fluoropolymers; breakthrough in high-performance materials
49) Growth of electronics and telecommunications markets; practical only with plastics
50) Full automation of extrusion lines; definitely met the need for speed
51) Injection stretch blow molding; improves economy, quality, throughput of bottles and other containers
52) Barr Energy Transfer injection screw design; one of the most popular general-purpose designs ever
53) Hot-runner molding; not a process with flash, but that's the idea
54) PUR high-pressure technology and impingement mixing; this equipment opened the door to an array of applications
55) Process machinery for flexible PUR slabstock; among other things it helped to create the market for furniture foam
56) Robotics; they work round the clock, don't complain or file lawsuits, and do a better job than humans
57) All-electric injection machine; sets the standard for precision, energy savings, and cleanliness versus most hydraulics
58) All-electric blow molding machine; ditto, ditto, and ditto
59) Industry associations; ipso facto
60) Tupperware; PE kitchenware was one of the single biggest influences in alerting consumers to the benefits of plastics
61) Living-hinge design; inherent property of PP and PBT is textbook example of plastics' design flexibility
62) Calendering; process makes possible such applications as PVC floor covering
63) Development of epoxy; versatile material for molding, encapsulation, adhesives, and other markets
64) Universal masterbatch; not totally universal, of course, but enough to economically meet the needs of most processors
65) Twin-station blow molding machine; straightforward way to increase productivity, especially with large parts
66) Development of silicone; versatile material with diverse uses; critical to many medical applications
67) Development of thermoplastic elastomers; developments in formulation and applications technology mean they're not just for rubber replacement
68) Use of glass fiber in boats; this created, with thermoset polyester, one of the biggest of composites markets
69) Commercialization of pultrusion; helped to bring composites into more mundane products, like ladders and fishing rods
70) Development of cellulose acetate; major advance in safety over the highly combustible celluloid, and a component of early safety films
71) Development of Cellophane from viscous pulp; material was the first transparent film
72) Ultrasonic welding and vibration welding; processes advanced plastics joining
73) Tiebarless injection molding; an easy reach for many molders
74) Development of the Banbury Mixer; patented in 1916, this machine helped elevate early compounding technology
75) Chrysler specifies acrylic for auto taillights; application solidifies plastics' use in key end-use market
76) PUR slabstock sold as cooling insulation; important breakthrough for PUR and plastics generally in appliances
77) Commercialization by Dow of Saran PVDC food wrap; a major milestone in the use of plastics with food
78) General Motors specifies composites body for Corvette sports car; 1953 model is among first production cars to make use of the lightweight material
79) Structural foam molding; low-pressure process makes injection molding a viable option for fabrication of large parts
80) IBM in 1986 installs computer-integrated manufacturing at North Carolina injection molding plant; among first steps to "lights-out" production
81) Development of aramid fibers; high-strength materials expand performance capabilities of plastics
82) Rise of the "Green Movement" in Europe; environmental laws like Germany's "Green Dot" program challenge plastics designers with post-use considerations
83) Phaseout of chlorofluorocarbon blowing agents; controversial move forces foam industry to find alternatives
84) 3D blow molding: technique expands design capabilities of process
85) Organization of the K show; triennial expo, in Dόsseldorf, becomes world's largest plastics showcase and a truly global venue
86) Micromolding; recent advances extend miniature part capabilities
87) McDonald's fast-food chain bans EPS clamshells in U.S.; perception counts more than fact; score one for the "greens"
88) Development of nanocomposites; microscopic reinforcements have major potential in improving performance and efficiency
89) Modularity; whether in primary or auxiliary machines or other products, trend gives processors greater flexibility in machine specification, upgrading, and operation
90) Global Quality Standards: ISO, CE, QS, and others formalize quality procedures and give processors ways to qualify their capabilities to customers
91) End of the Cold War; reunification of Germany and restructuring of Eastern Europe creates opportunities and challenges for plastics throughout the continent
92) Southeast Asian Financial Crisis; 1997 crash ends double-digit growth for several countries and affects trade in other regions as well, a sign the global economy is real
93) Introduction of the euro in 1999; single currency for Europe could make many in the industry more competitive with currency fluctuations eliminated
94) Establishment of the IKV; Germany's leading institute for plastics processing contributes numerous technical innovations
95) Organization of the NPE; triennial event, second-largest plastics show in the world is North America's largest
96) Thermoformed blister pack for medical; debut from Becton Dickinson in 1942 moves plastics farther into this lucrative market
97) Commercialization of Filament Winding; composite process proves a boon to large vessels requiring high strength
98) Development of corona and plasma treatments; surface-modification techniques upgrade esthetics of film and molded parts
99) Retortable packaging; containers and pouches emerge as nonrefrigerated options to frozen foods
100)
Futures Pricing; technique for resin buying can protect processors from price
swings; puts hedge bets on resin prices