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How do you reduce waste with an efficient injection molding machine?

2024/06/26 By Topstar

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In the manufacturing industry, there is waste to varying degrees every day. The cause of the waste may be poor production technology, failure of equipment parts, and other problems. An efficient injection molding machine can minimize material waste, energy consumption, and production time, achieved through a series of technologies in the injection molding industry. This guide will teach users and consumers how to use them to reduce waste.

Advanced technologies for efficient injection molding machines

First, incorporating advanced technologies into efficient injection molding machines is a key driver for reducing waste. These technologies improve machine performance, increase precision, and provide better control over the molding process.

Automatic compensation for mold opening position

The high-efficiency injection molding machines of Tosda are equipped with robots as standard, which have the function of automatic compensation for the mold opening position of the robot. The robot can accurately grasp and place parts during high-speed mold opening operation, making production more stable and efficient. Precise grasping can reduce the waste of time and materials. At the same time, the host computer system also integrates auxiliary machines such as mould temperature controller, hopper dryer, and dehumidifier.

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Using double-shot cylinders with linear guides

The double-shot cylinder can accurately position and inject different materials into the mold. This ensures that the materials are placed precisely where needed, reducing the possibility of overflow, underflow, and other defects that lead to material waste. At the same time, it is possible to produce multiple material parts in one molding cycle, so there is no need to assemble separate components. Multiple molding cycles reduce the waste generated and the associated gates, runners, and defective parts.

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The linear guide can accurately control the movement of the injection unit, thereby achieving accurate material placement and consistent part quality. This high level of precision minimizes defects caused by misaligned or inaccurate injections, which reduces waste. Additionally, the smooth motion provided by linear guides reduces mechanical wear on machine components, which extends machine life and reduces the frequency of part replacement. This reduces waste generated by worn parts and improves overall machine efficiency.

Efficient injection molding machine optimize material use

One of the main ways to reduce injection molding waste is to optimize material use. They are equipped with self-developed control systems, KEBA controllers, PHASE servo motors, and DELTA servo drives to ensure that the exact amount of material is used for each part, thereby minimizing overage and waste. This optimization is facilitated by advanced features such as shot volume control and automatic material feeding systems, ensuring consistent and accurate material delivery. In addition, machines equipped with PHASE servo motors can be controlled accurately and stably through electric means, ensuring accurate and repeatable injection cycles to reduce material waste.

KEBA controller

Efficient injection molding machine shorten cycle time

Cycle time is the duration of the entire injection molding process and is a critical factor in reducing waste. Efficient injection molding machines use high-speed injection devices, electroplated screw groups, and temperature control at the feed port to quickly fill the molten plastic into the mold while increasing productivity and applying a more comprehensive range of rubber materials. Servo motors and drives also provide precise and fast motion for components such as injection and clamping. Both ensure quick and accurate performance at each stage of the injection molding process, helping to shorten cycle times.

Make a sound production plan

In addition to their technical characteristics, daily production planning is also the key to reducing waste. Material requirements can be accurately predicted based on past historical data. This minimizes excess inventory and reduces the risk of material degradation and waste. At the same time, it is necessary to select raw materials that are suitable for the product characteristics. Work with relevant material suppliers to ensure raw materials’ high quality and consistency to minimize scrap and waste. Moreover, real-time monitoring systems track key parameters and detect abnormalities.

Help you reduce waste

Reducing waste in injection molding requires advanced technology, optimized processes, and skilled operators. They provide the required technology and capabilities to minimize material waste, energy consumption, and production time. As an injection molding machine manufacturer, helping you and different manufacturers reduce waste and increase costs is also what we are most willing to see.

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