Knowledge Hub
03/05/2024
Maintaining Injection Moulding Equipment
What Do We Mean by Injection Moulding Equipment?
Injection moulding equipment is used in the manufacturing process of creating plastic parts by injecting molten material into a mould.
The equipment consists primarily of an injection moulding machine which melts the plastic, injects it into the mould, and then cools and solidifies it to produce the desired shape.
However, injection moulding equipment can also be moulds or dies, raw materials, heating and cooling systems, and other components which are needed to create the final product.
Maintaining Different Types of Injection Moulding Equipment
Injection moulding machine: the machine in which the creation of the plastic parts is conducted. Should be properly calibrated, regularly cleaned, lubricated, and checked.
Material loaders: used to transfer plastic resin from storage containers to the hopper of the injection moulding machine.
Hopper dryers: used to dry and preheat plastic resin from storage containers to the hopper of the injection moulding machine. Requires regular cleaning to remove any residue or contaminants. This will ensure proper feeding of resin pellets into the machine.
Moulds: the tooling used to shape and form the plastic resin into the desired final product. Regular cleaning to prevent buildup of plastic residue and checks for proper alignment and fit with the machine.
Plastic resin pellets: store in a cool, dry place away from direct sunlight and moisture to prevent degradation. Use a desiccant dryer to remove any moisture before processing.
Barrel and screw: check for wear and tear on the screw, ensuring proper temperature control for the melting plastic.
Cooling systems: used to control the temperature of the mould and the plastic resin during the injection moulding process. Ensures proper cooling and solidification of the final product. Requires regular monitoring, as well as cleaning and maintenance.
Heater bands: regular inspection for any damage or wear.
Hydraulic system: regular inspection and maintenance of hydraulic fluid levels, filters, and hoses to prevent leaks or malfunction.
Secondary operation equipment: such as robots, conveyors, and trimmers used to handle, transport, and finish the final plastic products after they have been moulded.
Injection moulding auxiliary equipment: such as sprue pickers, granulators, and mould heaters used to support the main injection moulding machine and improve its efficiency and functionality.
Why is it Important to Maintain Injection Moulding Equipment?
Maintaining and updating injection moulding equipment is important for several reasons:
Improved efficiency: regular maintenance and updates can help to ensure that the equipment is running at optimum performance, reducing the risk of downtime and increasing productivity.
Safety: proper maintenance and updates can ensure that the equipment is in safe working condition, reducing the risk of accidents or injuries to operators.
Cost savings: regular maintenance can help to identify and address issues before they become major problems, reducing the likelihood of costly repairs or replacements.
Compliance: keeping equipment well-maintained and up to date with industry standards and regulations helps to ensure that the business remains in compliance with the relevant guidelines and requirements.
Extended equipment lifespan: proper maintenance helps to prolong the lifespan of injection moulding equipment, reducing the need for frequent replacements.
Reduced environmental impact: looking after injection moulding equipment can help to reduce energy consumption and waste generation, leading to a more environmentally friendly manufacturing process.
Key Principles When Maintaining Injection Moulding Equipment
Regular cleaning and maintenance: it is essential to regularly clean the moulding equipment to prevent the buildup of residue and to ensure smooth operation. This includes cleaning the mould cavity, screws, and other components. Regular maintenance should also be performed to check for wear and tear on parts and replace them as needed.
Lubrication: proper lubrication of moving parts is important to prevent wear and ensure smooth operation. Lubricants should be applied regularly according to the manufacturer’s recommendations.
Temperature control: maintaining proper temperature control is crucial for successful injection moulding. This includes monitoring and controlling the temperature of the mould, barrel, and other components to ensure optimum performance and product quality.
Monitoring and adjusting parameters: injection moulding equipment requires careful monitoring of parameters such as pressure, speed, and temperature.
Inspecting and replacing parts: regular inspections should be conducted to check for wear on components such as screws, barrels, nozzles, and moulds. Any damaged parts should be replaced to prevent malfunctions and to ensure high quality production.
Training and education: proper training of operators and maintenance personnel is essential for the effective maintenance of injection moulding equipment. Training should cover proper operating procedures, safety protocols, and maintenance techniques to ensure equipment longevity and optimum performance.
Software updates and upgrades: some injection moulding equipment may have software components that require regular updates and upgrades. It is important to stay current with the latest software versions to ensure smooth operation and to prevent potential issues.
Who Should Carry Out Maintenance of Injection Moulding Equipment?
Maintenance of injection moulding equipment should be carried out by trained and knowledgeable injection moulding technicians or maintenance personnel.
Injection moulding equipment is complex machinery that requires regular inspection, cleaning and repair to ensure optimum performance and prevent breakdowns.
Trained technicians can identify potential issues, troubleshoot problems, and perform necessary repairs in a safe and efficient manner.
Additionally, these skilled operatives have the knowledge and skills to follow proper maintenance procedures. They also use specialised tools and equipment to keep the equipment running smoothly.
