processes - cold injection molding

Ultradent's entry of its Umbrella cheek retractor took home the awards for Technical Sophistication and Achievement in Economics and Efficiency at PTXPO.

“We think our coworkers have a feel for how our operation is doing and strive to maintain a high level of engagement in operational efficiency and quality,” Porter says, noting that PlastiCert has a monthly “all coworker” meeting, which has become two meetings an hour apart as the business grows. In these meetings, leadership communicates revenue trends, areas of operational interest, new internal developments, and items of interest in the surrounding community. “We also pick a customer to tell workers more about how what we do for that customer contributes to its mission,” Porter says.

Mold maintenance is critical, and with this collection of content we’ve bundled some of the very best advice we’ve published on repairing, maintaining, evaluating and even hanging molds on injection molding machines.

The 2019 Plastics Technology Top Shops Survey shows that for its highest-rated respondents, injection molding is just one element in a growing suite of services and capabilities offered to customers.

After successfully introducing a combined conference for moldmakers and injection molders in 2022, Plastics Technology and MoldMaking Technology are once again joining forces for a tooling/molding two-for-one.

Discover how artifical intelligence is revolutionizing plastics processing. Hear from industry experts on the future impact of AI on your operations and envision a fully interconnected plant.

Five industry pros with more than 200 years of combined molding experience provide step-by-step best practices on mounting a mold in a horizontal injection molding machine.

Additive technology creates air pockets in film during orientation, cutting down on the amount of resin needed while boosting opacity, mechanical properties and recyclability.

Start by picking a target melt temperature, and double-check data sheets for the resin supplier’s recommendations. Now for the rest...

The Plastics Industry Association (PLASTICS) has released final figures for NPE2024: The Plastics Show (May 6-10; Orlando) that officially make it the largest ever NPE in several key metrics.

While prices moved up for three of the five commodity resins, there was potential for a flat trajectory for the rest of the third quarter.

Core Technology Molding turned to Mold-Masters E-Multi auxiliary injection unit to help it win a job and dramatically change its process.

Because of the wrinkle of the global pandemic, or perhaps in spite of it, Plastics Technology’s annual Top Shops survey received its best-ever response as injection molders seemed anxious to take a deep dive into operations that stayed open as essential businesses, while other segments of the broader economy faltered.

“The biggest challenge was the unknown,” explains Mark Murphy, president of molder and moldmaker PRD Inc. in Springville, Ind.—one of PT’s 23 newest Top Shops. “We had gone for so many years with growing sales and a growing economy. We knew this could probably be the event that brought it all to a halt.”

Since implementing RaaS, ICON has experienced significant improvements across various performance indicators, including a 20% increase in production, a 40% reduction in operational expenses and a 30% improvement in cycle-time efficiency, according to Kleitsch-Killam.

In a time where sustainability is no longer just a buzzword, the food and beverage packaging industry is required to be at the forefront of this innovation. By adopting circular packaging processes and solutions, producers can meet regulatory requirements while also satisfying consumer demand and enhancing brand reputation. Join Husky to learn more about the broader implications of the circular economy — as well as how leading brands are leveraging this opportunity to reduce costs, increase design flexibility and boost product differentiation. Agenda: The cost and operational benefits of embracing circularity Key materials in circular packaging — including rPET and emerging bioplastics How to design a circular food and beverage package Strategies for selecting sustainable closures to future-proof packaging solutions Optimization and streamlining of production processes for enhanced efficiency How Husky Technologies can enable your sustainable success

Processors with sustainability goals or mandates have a number of ways to reach their goals. Biopolymers are among them.

This month’s resin pricing report includes PT’s quarterly check-in on select engineering resins, including nylon 6 and 66.

Exhibitors and presenters at the plastics show emphasized 3D printing as a complement and aid to more traditional production processes.

Successfully starting or restarting an injection molding machine is less about ticking boxes on a rote checklist and more about individually assessing each processing scenario and its unique variables.

Founded in 2001, family-owned, Phoenix-based ICON Injection Molding caters to a range of industries, making parts for laboratory use, security devices, pool equipment and more. “With a dedication to ‘Excellence from Art to Part,’ we have grown organically to become a go-to provider of custom plastic injection molding,” says Nicole Kleitsch-Killam, chief administrative officer at ICON. “It also means that if a customer wants to order only 1,000 parts this month and 100,000 next month, we have to be able to react.”

In this collection of articles, two of the industry’s foremost authorities on screw design — Jim Frankand and Mark Spalding — offer their sage advice on screw design...what works, what doesn’t, and what to look for when things start going wrong.

As Machine Design’s technical editor, Sharon Spielman produces content for the brand’s focus audience—design and multidisciplinary engineers. Her beat includes 3D printing/CAD; mechanical and motion systems, with an emphasis on pneumatics and linear motion; automation; robotics; and CNC machining.

“We listen to each others’ ideas to make the best choices and become closer as a team,” IEMSA’s Salazar says. “We also allow doubts and mistakes to happen—we let the learning process be part of our daily life—always taking care of the situation and solving the issues.”

Misa Ilkhechi, co-founder and vice president of product and partnerships at Formic, says, “Formic owns, programs, installs and maintains robotic systems from vendors like FANUC, Universal Robots and Yaskawa Motoman at its own cost, assuming the financial risk for customers…Put simply, if any of our systems don’t work or fail to hit the agreed-upon productivity metrics, we don’t get paid, so we’re literally invested in keeping them running well.”

Introduced by Zeiger and Spark Industries at the PTXPO, the nozzle is designed for maximum heat transfer and uniformity with a continuous taper for self cleaning.

Despite price increase nominations going into second quarter, it appeared there was potential for generally flat pricing with the exception of a major downward correction for PP.

Join KraussMaffei for an insightful webinar designed for industry professionals, engineers and anyone interested in the manufacturing processes of PVC pipes. This session will provide a comprehensive understanding of the technology behind the production of high-quality PVC pipes: from raw material preparation to final product testing. Agenda: Introduction to PVC extrusion: overview of the basic principles of PVC pipe extrusion — including the process of melting and shaping PVC resin into pipe forms Equipment and machinery: detailed explanation of the key equipment involved — such as extruders, dies and cooling systems — and their roles in the extrusion process Process parameters: insight into the critical process parameters like temperature, pressure and cooling rates that influence the quality and consistency of the final PVC pipes Energy efficiency: examination of ways to save material and energy use when extruding PVC pipe products

Resin drying is a crucial, but often-misunderstood area. This collection includes details on why and what you need to dry, how to specify a dryer, and best practices.

Examining other key metrics more closely, we see that Top Shops had more active molds (398 vs. 219) that molded more total parts (73 million vs. 32 million) for more active customers (102 vs. 56). Ultimately, it is that ability to wring maximum production from every person, every square foot, every tool and every machine that is part of what characterizes a Top Shop.

PlastiCert’s Porter says his company’s location in a small, rural farming community in Minnesota situated between two large cities equates to a shallow talent pool. Its answer to that geographic challenge: “First and foremost, we have created a desirable and accommodating workplace environment, resulting in turnover being practically negligible,” Porter says. The company has also sought to raise its visibility in the community and  to partner with a nearby state university for a stream of interns.

She says the onsite staff training was an informative six-hour-long, hands-on course. “The cell includes a customized robotic machine operator (a 6-axis articulated FANUC robot arm), which was installed on our largest injection molding press, a 720-ton Nissei FV9100 that is over 20 years old,” she says. “It also includes a vertical conveyor that fully automates the process of loading, unloading and lowering the finished parts into the cooling bath for the final annealing process. This project consists of eight different parts, and programs for each size are set by Formic and maintained with software from Rockwell Automation.”

On the injection side, this firm deploys all-electric presses with integrated parts-handling robots and machine-monitoring systems that can run unattended. “We also mounted cameras strategically throughout our facility so remote operators can log in from their phones.”

Take a deep dive into all of the various aspects of part quoting to ensure you’ve got all the bases—as in costs—covered before preparing your customer’s quote for services.

The aim of this presentation is to guide you through the factors and the numbers that will help you determine if a robot is a smart investment for your application. Agenda:  Why are you considering automation? What problems are you trying to solve? How and why automation can help Crunch the numbers and determine the ROI

Fully 70% of Top Shops perform regular, formal business reviews, compared with 54% of others, with 83% of Top Shops applying business-metric goal setting vs. 42% of others. And 87% of Top Shops have regular management meetings, compared with just 63% of others.

While prices moved up for three of the five commodity resins, there was potential for a flat trajectory for the rest of the third quarter.

Plastics Technology’s Tech Days is back! Every Tuesday in October, a series of five online presentations will be given by industry supplier around the following topics:  Injection Molding — New Technologies, Efficiencies Film Extrusion — New Technologies, Efficiencies Upstream/Downstream Operations Injection Molding — Sustainability Extrusion — Compounding Coming out of NPE2024, PT identified a variety of topics, technologies and trends that are driving and shaping the evolution of plastic products manufacturing — from recycling/recyclability and energy optimization to AI-based process control and automation implementation. PT Tech Days is designed to provide a robust, curated, accessible platform through which plastics professionals can explore these trends, have direct access to subject-matter experts and develop strategies for applying solutions in their operations.

Join Engel in exploring the future of battery molding technology. Discover advancements in thermoplastic composites for battery housings, innovative automation solutions and the latest in large-tonnage equipment designed for e-mobility — all with a focus on cost-efficient solutions. Agenda: Learn about cutting-edge thermoplastic composites for durable, sustainable and cost-efficient battery housings Explore advanced automation concepts for efficient and scalable production See the latest large-tonnage equipment and technology innovations for e-mobility solutions

Materials run by our survey entrants largely tracked along similar lines, with other shops running slightly more polyolefins than Top Shops (63% to 52%), while Top Shops processed more engineering resins (87% to 76%). Only in LSR and bioplastics was the gap noticeably wide, with 9% of Top Shops running LSR and 17% bioplastics, compared with 2% and 7%, respectively, for other plants.

Kleitsch-Killam adds, “We can also monitor our system via a handy app, but Formic is committed to identifying and fixing problems before they even arise.”

Spielman has more than three decades of experience as a writer and editor for a range of B2B brands, including those that cover machine design; electrical design and manufacturing; interconnection technology; food and beverage manufacturing; process heating and cooling; finishing; and package converting.

Mixed in among thought leaders from leading suppliers to injection molders and mold makers at the 2023 Molding and MoldMaking conferences will be molders and toolmakers themselves.

In this collection, which is part one of a series representing some of John’s finest work, we present you with five articles that we think you will refer to time and again as you look to solve problems, cut cycle times and improve the quality of the parts you mold.

In fact, average plant-floor employee age, plastics/manufacturing experience, turnover rate and hourly wages were nearly identical for all survey participants—41/40 yrs; 17/16 yrs; 17/16% ; and $17/$16—for Top Shops/Others in all those categories, respectively.

As for their fleets’ clamp-force ranges, Top Shops and other entrants tracked closely in the 0-100, 101-500, and 501-1000-ton ranges, but only 9% of Top Shops utilized machines over 1000 tons, vs. 15% of other entrants. Top Shops also offered more specialty injection molding technologies, outstripping other entrants in providing two-shot, gas/water-assist, in-mold label and insert molding.

technotrans says climate protection, energy efficiency and customization will be key discussion topics at PTXPO as it displays its protemp flow 6 ultrasonic eco and the teco cs 90t 9.1 TCUs.

When, how, what and why to automate — leading robotics suppliers and forward-thinking moldmakers will share their insights on automating manufacturing at collocated event.

Jim Goerges, president of Precision Tool Technologies Inc. (PTT) in Brainerd, Minn., another Top Shops honoree, says that even before the pandemic, the company had a goal of unattended machining through all 168 hr in a work week, investing in lights-out capable machines over the years to get there. “Our investment in the right automated machining technologies put us in a strong position to navigate the issues related to increased social distancing during the pandemic,” Goerges says.

“The biggest challenges were maintaining operations, assuring customers that we were taking steps to sustain their order flow, and keeping our coworkers safe,” says Craig Porter, president and owner of another Top Shop, PlastiCert in Lewiston, Minn.  “As a small manufacturer, keeping track of COVID legislation, mandates and programs around finances for the company and our employees was a full-time job for people that typically already wear multiple hats.”

August 29-30 in Minneapolis all things injection molding and moldmaking will be happening at the Hyatt Regency — check out who’s speaking on what topics today.

Gifted with extraordinary technical know how and an authoritative yet plain English writing style, in this collection of articles Fattori offers his insights on a variety of molding-related topics that are bound to make your days on the production floor go a little bit better.

Those challenges, just like the virus, didn’t stop at the border. Aida Cecilia Mercado Salazar of Mexican Top Shop molder and moldmaker IEMSA in San Luis Potosi, said her company had to adapt to and embrace how the pandemic changed day-to-day life and work. “The first big challenge was to get used to the new normal,” Salazar says, citing the two most recognizable aspects of the pandemic: masks and uncertainty. “In the beginning, we were scared because we didn’t know how safe we actually were.” Ultimately, IEMSA, like so many of the molders we surveyed, never halted operations and came through the crisis even stronger. “We became a closer team, and because of that trust it was easier to overcome the challenges in the way.”

The workplace is not only safer, but employee satisfaction is up and there is a reduction in employee turnover. Kleitsch-Killam says ICON’s corporate management team tries to frame the use of automation as a “productivity enhancer” rather than a “person replacer,” but there was initial skepticism from some of their long-time employees. “Once they saw that nobody was getting laid off to ‘make room’ for this automation, however, they recognized how much easier and safer it made their job. Those working on the less-staffed overnight and weekend shifts, in particular, now see much more opportunity to take on skilled roles within the company than before.

Under Formic’s pay-for-productivity RaaS model, ICON pays for the operation of the robots when they are actively deployed. This hourly payment structure avoids a large CapEx spend and still reaps automation benefits.

Plastics Technology covers technical and business Information for Plastics Processors in Injection Molding, Extrusion, Blow Molding, Plastic Additives, Compounding, Plastic Materials, and Resin Pricing. About Us

Across the show, sustainability ruled in new materials technology, from polyolefins and engineering resins to biobased materials.

ICON and Formic collaborated to design and deploy a custom automated solution. Taking a technology-agnostic approach, Formic sourced hardware and software components from a range of suppliers, taking performance and suitability for ICON’s needs into consideration. The RaaS offering also adapts as needs evolve.

Looking more deeply into the numbers, while the Top Shops and the other respondents were very close in average fleet size, the presses on Top Shops’ floors had considerably less miles on them, boasting an average age of nine years compared with 14. The Top Shops ran horizontal machines exclusively, while 9% of the other facilities also had vertical presses in their plants. Top Shops operated slightly fewer hydraulic machines (62% vs. 71%) than other survey entrants; and far more all-electric presses (65% vs. 50%) and hybrid (50% vs. 26%) machines.

“We are very open and honest with our employees and communicate frequently on the state of our business and outlook,” Murphy says. “We have always had a great culture at PRD where everyone feels like family. For some it is just a job, but many feel ownership and accountability for our success. We try to provide clear production goals, learn from our mistakes and celebrate our successes.”

While the melting process does not provide perfect mixing, this study shows that mixing is indeed initiated during melting.

The new industrial event from the publisher of Plastics Technology will feature data, sourcing and technology updates for manufacturing businesses, including injection molders.

Mike Sepe has authored more than 25 ANTEC papers and more than 250 articles illustrating the importance of this interdisciplanary approach. In this collection, we present some of his best work during the years he has been contributing for Plastics Technology Magazine.

Join this webinar to explore the transformative benefits of retrofitting your existing injection molding machines (IMMs). Engel will guide you through upgrading your equipment to enhance monitoring, control and adaptability — all while integrating digital technologies. You'll learn about the latest trends in IMM retrofitting (including Euromap interfaces and plasticizing retrofits) and discover how to future-proof your machines for a competitive edge. With insights from industry experts, it'll walk you through the decision-making process, ensuring you make informed choices that drive your business forward. Agenda: Maximize the value of your current IMMs through strategic retrofitting Learn how to integrate digital technologies to enhance monitoring and control Explore the benefits of Euromap interfaces and plasticizing retrofits Understand how retrofitting can help meet new product demands and improve adaptability Discover how Engel can support your retrofitting needs, from free consultations to execution

Kleitsch-Killam says ICON initially reached out to a familiar conventional vendor, but the capital expenditure (CapEx) was too high and only covered the robotic unit—not any of the essential auxiliary equipment.

In this collection of content, we provide expert advice on welding from some of the leading authorities in the field, with tips on such matters as controls, as well as insights on how to solve common problems in welding.

On the non-people or robotic side, 52% of Top Shops increased automation in 2020, compared with 35% of the rest of the shops surveyed. Those investments add to an already sizable fleet of robots for top shops, fully 96% of whom said their facilities used automation, compared with 68% of others.

Thousands of people visit our Supplier Guide every day to source equipment and materials. Get in front of them with a free company profile.

The impetus for ICON to explore automation arose when the company was faced with a specific project that required operators to repeatedly retrieve 300°F hot plastic parts and place them in a cooling bath. According to Kleitsch-Killam, the project required that operators stand on their feet for the entire workday to complete the task. “This repetitive manual process led to concerns about both worker safety and operational inefficiencies,” she says.

Learn about sustainable scrap reprocessing—this resource offers a deep dive into everything from granulator types and options, to service tips, videos and technical articles.

Say “manufacturing automation” and thoughts immediately go to the shop floor and specialized production equipment, robotics and material handling systems. But there is another realm of possible automation — the front office.

Where the gap between the groups widens further is the volume of resins processed, with Top Shops nearly doubling the other entrants’ poundage, running an average of 22.3 million lb of material in 2020 vs. 12.5 million lb average for the others. In addition to more material, our honorees processed more kinds of resins. Top Shops ran an average of 43 different material categories, compared to 18 for the remaining survey participants.

As Formic grows, it is creating a library of automation solutions that can do everyday tasks, Ilkhechi explains, “so that even as we customize solutions, we don’t have to continuously reinvent the wheel.” At the same time, Formic is creating a platform where the company purchases hardware in bulk, which solves supply chain issues and reduces the cost and access to hardware for its customers and for other sub-component and system integrators that sit between Formic and the hardware, he says. “As Formic builds its knowledge and hardware base, it will be able to lower subscription costs and continue to democratize automation for U.S. manufacturers.”

Across all process types, sustainability was a big theme at NPE2024. But there was plenty to see in automation and artificial intelligence as well.

Second quarter started with price hikes in PE and the four volume engineering resins, but relatively stable pricing was largely expected by the quarter’s end.

On the equipment side, the average fleet size for Top Shops and the other respondents registered at 21 and 20 injection molding machines, respectively. So, we are looking at basically the same amount of workers utilizing the same amount of machines in the same amount of space for the two groups, but there are also some key differences.

“Automation seemed out of reach, financially, until our CEO asked Jeff Galindo, our executive operations specialist, to find a solution,” she explained. “An industry friend introduced him to Formic, and he was blown away. With no upfront CapEx and a low $10/hour rate, Formic’s ‘Robotics-as-a-Service’ model just seemed too good to be true. We were even more impressed to learn that Formic would manage the maintenance, upkeep and programming of the system.”

At the start of 2021, as it does every year, Plastics Technology asked injection molders to look back on the year prior and take stock of their operations. The only difference this time: COVID-19.

Multiple speakers at Molding 2023 will address the ways simulation can impact material substitution decisions, process profitability and simplification of mold design.

In terms of physical space, individual employees and machine fleet, the two groups in this year’s benchmarking survey were virtually indistinguishable. The average floor space of a Top Shops entrant was 88,184 ft2, with the rest averaging 79,614 ft2. Total employees at Top Shops averaged 95 vs. 98 at other entrants, with workers directly involved in plant-floor operations coming in at 73 for Top Shops and 78 at all others.

This Knowledge Center provides an overview of the considerations needed to understand the purchase, operation, and maintenance of a process cooling system.

Sustainability continues to dominate new additives technology, but upping performance is also evident. Most of the new additives have been targeted to commodity resins and particularly polyolefins.

Join Wittmann for an engaging webinar on the transformative impact of manufacturing execution systems (MES) in the plastic injection molding industry. Discover how MES enhances production efficiency, quality control and real-time monitoring while also reducing downtime. It will explore the integration of MES with existing systems, emphasizing compliance and traceability for automotive and medical sectors. Learn about the latest advancements in IoT and AI technologies and how they drive innovation and continuous improvement in MES. Agenda: Overview of MES benefits What is MES? Definition, role and brief history Historical perspective and evolution Longevity and analytics Connectivity: importance, standards and integration Advantages of MES: efficiency, real-time data, traceability and cost savings Emerging technologies: IoT and AI in MES

Meetings may be the bane of many in the business world, and certainly the running butt of a slew of jokes, but the communication, goal setting and goal measuring that well-designed and organized meetings facilitate are very much a part of Top Shops’ winning strategies.

Formnext Chicago is an industrial additive manufacturing expo taking place April 8-10, 2025 at McCormick Place in Chicago, Illinois. Formnext Chicago is the second in a series of Formnext events in the U.S. being produced by Mesago Messe Frankfurt, AMT – The Association For Manufacturing Technology, and Gardner Business Media (our publisher).

While the major correction in PP prices was finally underway, generally stable pricing was anticipated for the other four commodity resins.

Now in its fifth year, this benchmarking survey of injection molders queries participants on demographic data, performance indicators, and business and process strategies. A selection of those performance metrics are then scored, with the highest scoring companies named Top Shops for 2021 based on their 2020 operations. The Top Shops display some stark contrasts with all other entrants, but in many ways they are quite similar.

While this is technically a survey of injection molders, in reality, nearly all of its participants are more accurately described as contract manufacturers. A purchase order for molding a single component dropped from the cavity with nothing else done to it—inspection, decoration, assembly, packaging—is most definitely not the business model for today’s molders. Fully 78% of Top Shops and 81% of other shops provide assembly for customers, with 70% of Top Shops and 60% of the remaining survey respondents offering customers collaborative design services. Where Top Shops go even further is in shipping/packaging/labeling, with 87% of our honorees providing those services, compared with 66% of others.

In this three-part collection, veteran molder and moldmaker Jim Fattori brings to bear his 40+ years of on-the-job experience and provides molders his “from the trenches” perspective on on the why, where and how of venting injection molds. Take the trial-and-error out of the molding venting process.

“While our operators faced persistent minor injuries such as burns, as well as a high risk of more serious injuries, our overnight and weekend shifts were marred by inconsistent staffing levels that led to disruptions.” She says as they grappled with the resulting high worker turnover, inconsistent output, longer lead times and higher prices for end customers, “We knew automation was the answer to both challenges.”

Plastics Technology’s 2020 Top Shops benchmarking survey reveals that the most effective molders are, not surprisingly, the most efficient, accomplishing more than their peers from a smaller manufacturing footprint.

“This collaboration with Formic has been a case study of sorts for us, reflecting the potential of RaaS and its impact on ICON's future,” she continues. “Right now, we’re focused on expansion to a new building on our premises, which ultimately means we’ve got room to amplify the role of robotics in what we do…We look forward to collaborating with Formic to determine what project or task to automate next.”

Markets served for both groups largely mirror each other, except for two sectors: medical/healthcare and building/construction. While 74% of the other respondents serve the building/construction market, only 35% of Top Shops generate business from it. And 74% of Top Shops have medical customers, vs. 54% of other survey respondents.

With a command center for remote login, Formic monitors its systems 24/7 to moderate temperatures, look for anomalies and find opportunities to improve usage and performance, according to Ilkhechi. “In addition, when a customer’s needs change, we can reprogram systems to accommodate new projects. And for customers with Formic Flex, we can even swap out their entire system—all at no cost to them,” he notes.

PRD’s Murphy says his company has thrown people and automation at the skills gap, which is “by far the biggest challenge. We have implemented automation where possible, increased wages, and gone out of our way to ensure our employees know how much we appreciate them,” including discretionary bonuses. “Unfortunately, I don’t hear anyone with a good answer to the predicament we find ourselves in. Everyone talks about the end of extra unemployment benefits, and while they do not help the situation, I am not convinced this well be the solution.”

Fully 83% of Top Shops and 80% of other shops experienced a skills gap in 2020, with all participants looking to address the issue, just in different ways. On the people side, Top Shops outstripped other respondents in flexible schedules, mentor programs, and outreach at local schools by 18, eight and 26 percentage points, respectively. As for partnering with area schools for open houses or staff recruitment, 64% of Top Shops took that step, while only 28% of the other respondents did so.

A nearly identical number of all survey participants said their facilities featured an in-house tool room (78% of Top Shops and 77% of all others), with both groups utilizing them in equal measure for mold building (rather than just repairs)—44% of Top Shops and 41% of other entrants. While 36% of Top Shops’ molds featured hot runners, only 22% of tools at the other facilities applied this technology. Only 9% of the Top Shops’ tools and 8% of the other entrants’ molds had more than 16 cavities.