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Plastic Molding Machine Solutions for Faster Turnaround Times

2025/02/14 By Topstar

Plastic Molding Machine 80-1

Delays in the injection molding can disrupt the supply chain and increase costs. Due to manual adjustments, traditional plastic molding machines often struggle with inconsistent cycle times, material waste, and frequent downtime. These challenges are exacerbated when customers expect a 20% or more reduction in turnaround time while also keeping defect rates below 5%. Topstar’s TM Series plastic molding machine addresses these pain points head-on. With fully upgraded injection units, clamping mechanisms, and other systems, the TM Series ensures stable, high-speed production. For example, a manufacturer of automotive lamp housings that used traditional plastic molding machines reduced cycle time by 22% and achieved a 96% yield rate after switching to the TM Series.

How does the TM Series plastic molding machine improve speed and precision?

The TM Series’ performance core lies in its fully upgraded injection unit, designed to maximize injection speed, melt speed, and pressure. On the one hand, traditional injection molding machines often suffer from slow screw recovery or uneven melting, resulting in inconsistent fill rates and defects. The TM Series solves this problem with high-torque electroplated screws. In addition, the melt speed has been increased by 10% with the upgrade of the injection station. At the same time, it also has a dynamic pressure control function, which can automatically adjust the injection pressure according to the real-time resin viscosity and mold temperature. For example, when molding thin-walled automotive connectors, the machine increases pressure during filling to prevent cavitation. Then, it reduces pressure during the pressure-holding period to avoid overflow. This adaptability ensures that the cycle time remains stable despite high molding requirements.

Plastic Molding Machine 80-3

Self-developed control system: speed up the cycle of plastic molding machine

Without precision, speed is meaningless. Topstar’s TM series realizes the communication of the main machine, auxiliary machine, and automation through the self-developed control system, which can optimize each stage of the molding process. We will realize the linkage of a control interface with multiple devices based on the opening of the software system and learn the optimal control of injection molding factors such as temperature, speed, position, pressure, and time through system integration, the combination of injection molding machines and auxiliary machines, and sensor technology. At the same time, it also reduces the operator’s workload of fine-tuning and monitoring the main machine and auxiliary equipment, lowers labor costs, and improves production efficiency. Secondly, Topstar realizes the synchronous linkage of the robot and the mold opening process, shortens the molding cycle, and improves production efficiency through early arrival and precision compensation functions.

plastic molding machine 12-1

Adaptability and flexibility for different production

Another significant advantage of the TM Series plastic molding machine is its ability to handle various materials and part designs. It comes standard with a chrome-plated screw and temperature control of the feed port, which is suitable for a broader range of plastics and more stable production. Whether producing small components or more significant, complex parts, the machine’s flexibility enables manufacturers to customize the molding process to meet their needs. This flexibility is substantial in industries where product design and material types constantly change. The TM Series can quickly adapt to different requirements, allowing manufacturers to adjust parameters such as mold size, pressure, and cycle time according to the specific needs of each project. This level of customization ensures that manufacturers can meet various customer needs without investing in multiple machines or production settings.

Injection molding electroplating screw

Enhanced cooling and ejection: accelerate the post-molding stage

Many manufacturers ignore the impact of cooling and ejection on the overall cycle time. The TM Series plastic molding machine has a dedicated water chiller for injection molding and a cooling channel. The ejection system has also been upgraded, which increases the ejector thrust by 20%, is conducive to the demolding of connectors and plug-in products, and has broader applicability. The servo motor positions the ejector with micron-level accuracy to minimize component stress. For a toy manufacturer producing snap-on parts, this accuracy reduced ejection-related defects from 8% to 0.5%. Faster cooling and ejection also means the mold can be reopened faster, significantly reducing idle time between cycles.

Reduce Waste in Your Workflow

Material waste is a silent killer of productivity. Conventional injection molding machines often overcompensate for inconsistencies using excess resin, resulting in increased costs and longer cycle times. The TM Series monitors melt temperature, pressure, and flow rate via sensors, feeding data back to the control unit to fine-tune screw rotation and nozzle pressure. In one case study, a packaging manufacturer reduced resin waste by 18% after adopting a TM Series injection molding machine. The machine’s precise injection control ensures that each cavity in a 64-cavity mold receives the exact amount of resin, eliminating flooding. Combined with faster screw recovery time, this efficiency enables the machine to maintain shorter cycle times without sacrificing part integrity.

Achieve Faster Molding Cycles

The TM Series plastic molding machines offer a powerful solution for manufacturers looking to reduce turnaround time and increase production efficiency. With the ability to increase output, reduce cycle time, and improve molding stability, the TM Series sets new standards for the industry. Upgrades to the injection platform, automation system, and control functions contribute to faster and more efficient production while ensuring product quality.

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