Mould Lifecycle Management (MLM) – Preventive Maintenance
7 minutes readKey Takeaways Maintenance is critical between commissioning and scrappage, ensuring mould performance, quality output, and longer lifecycle. Preventive maintenance (PM) reduces unexpected downtime and repair costs, helping avoid production delays and financial penalties. A structured PM schedule (daily, weekly, quarterly) ensures lubrication, inspection, cleaning, and deep checks are consistently performed. Understanding mould design, tools, and […]
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 […]
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
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 […]
What is Root Cause Analysis? A Guide for Manufacturing and Process Improvement
7 minutes readKey Takeaways RCA is about finding the correct cause of a problem, without it, corrective actions are directionless and defects are likely to recur. Correlation is not causation, the most common mistake in RCA is casually linking two correlated factors without validating a true cause-and-effect relationship. Key data is often missing or incomplete, making it […]