The Research Road Less Travelled for Injection Moulding (IM) Process Development
8 minutes readKey Takeaways Software tools like Moldex, Sigmasoft, and mould flow simulation have significantly advanced IM process development by predicting defects and cycle time before mould manufacturing, though optimization through DOE-based software remains limited to few players. Process revalidation remains a major cost burden because machine parameter transparency is insufficient to mathematically predict process windows when […]
Four Challenges Faced While Working with Post-Consumer Resin (PCR)
7 minutes readKey Takeaways PCR is recycled resin derived from used consumer plastic products, but converting plastic waste into usable resin involves multiple stages including collection, segregation, cleaning, shredding, melting, and pelletizing. Collecting plastic waste at scale is a foundational challenge, requiring recycling centres, reverse vending machines, landfill collection, and consumer education on waste segregation to ensure […]
Three Ways FMCG Companies Can Start Becoming Sustainable
4 minutes readKey Takeaways Sustainability in FMCG means minimizing environmental impact through eco-friendly, recyclable, and reusable packaging while maintaining profitability and remaining competitive in an environmentally conscious market. Around 90% of FMCG packaging relies on virgin plastics derived from crude oil, making the shift toward recycled and reusable materials a critical step in reducing carbon emissions and […]
How Lateral Thinking Evolves an Organization’s Mindset
3 minutes readShare: Key Takeaways Cooling and hold time account for 50–75% of total cycle time, making cooling optimization the highest-impact lever in injection moulding productivity. Conventional straight-drilled channels often fail to cool complex geometries evenly, leading to hotspots, higher cycle times, and poor part quality. Conformal cooling channels follow the mould contours, positioning cooling closer to […]
Recycling Aerosol & Beverage Cans | Process, Benefits & Impact
5 minutes readKey Takeaways Cooling and hold time account for 50–75% of total cycle time, making cooling optimization the highest-impact lever in injection moulding productivity. Conventional straight-drilled channels often fail to cool complex geometries evenly, leading to hotspots, higher cycle times, and poor part quality. Conformal cooling channels follow the mould contours, positioning cooling closer to the […]
Part 3 Interesting Insights About Let Down Ratio in Post-Consumer Resin
4 minutes readKey Takeaways Let Down Ratio (LDR) is the percentage of master-batch added to base resin to achieve the desired colour intensity, uniformity, and appearance in moulded plastic parts. PCR has a natural grey, non-uniform base colour that makes bright shades like white, yellow, or blue appear pale and unappealing, making darker colours like black, dark […]
Optimal Clamping Force in Injection Moulding
4 minutes readKey Takeaways Cooling and hold time account for 50–75% of total cycle time, making cooling optimization the highest-impact lever in injection moulding productivity. Conventional straight-drilled channels often fail to cool complex geometries evenly, leading to hotspots, higher cycle times, and poor part quality. Conformal cooling channels follow the mould contours, positioning cooling closer to the […]
Mould Lifecycle Management (MLM): Commissioning: Step-by-Step Guide
5 minutes readKey Takeaways Commissioning transforms planning into production reality by converting design intent into a functional, validated, and production-ready mould aligned with market demands. A structured design review at the start ensures all stakeholders including the mould maker, R&D team, and suppliers are aligned on design, compatibility, and project-specific requirements before any build begins. Prototype trials […]
Corrective Maintenance in Mould Lifecycle Management
5 minutes readKey Takeaways Corrective maintenance is inevitable regardless of how well preventive maintenance is practiced, as every mould has a fatigue limit and unforeseen failures will occur over its lifecycle. Three corrective paths are available including repair for minor interventions, refurbishment for major overhauls, and replacement when the mould is near end of life or costs […]
Mould Decommissioning: Best Practices for Efficient Lifecycle Management
5 minutes readKey Takeaways Obsolete moulds silently increase costs by occupying valuable storage space, making timely decommissioning essential for operational and cost efficiency. A mould is ready for decommissioning when its life has elapsed, a product design change has eliminated demand, or it has remained unused in storage for an extended period. Three decommissioning methods are available […]