Case Studies in FMCG Injection Moulding

Fast-moving consumer goods (FMCG) manufacturers frequently employ the injection moulding technique. During this procedure, molten plastic is injected into a mould cavity, where it solidifies and adopts the mold's shape. The manufacturing process for items has changed significantly in recent years as a result of new technology and materials.

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The advent of automation is one of the main changes in injection moulding. Automated systems have the capacity to consistently produce large quantities of goods in a timely manner while reducing human error.

The adoption of sustainable materials is a further development in the sector. Many FMCG companies have responded to consumer concerns about the environmental effects of plastic products by looking into alternative materials. For instance, bioplastics are a sort of biodegradable, sustainable material derived from renewable resources that appeals to FMCG companies trying to lessen their environmental impact.

The advancements in injection moulding have also been influenced by improvements in simulation software and mould design. Complex mould designs are now easier to create thanks to computer-aided design (CAD) software, and engineers can also evaluate the operation of the moulds prior to production using simulation software. Due to this technology, FMCG companies can now produce high-quality goods with shorter lead times.

Following are the few Case studies on FMCG injection moulding that will explain you the major issues with the viable solutions:

1. Creating thin wall containers

We were successful in reducing the weight of the container and improving the cycle time of the mould thanks to a careful examination of the container design and material qualities combined with cutting-edge simulation and tooling processes, making our customer more cost-competitive in the market. We were able to accomplish this thanks to our skills in DFM, Moldflow analysis, and tool design, which eventually led to a happy client and a finished job.

2. Air tight Lids

For DLJM's JEE PEE Plus brand, we successfully designed and created a complete family set of airtight food containers. The containers' airtight and leak-proof construction guaranteed the food's quality and freshness while storing it. P-20 was used as the mould material to provide long-lasting, high-quality production.

3. Bottle caps and closures

The injection mould for oil caps with the Mastip hot runner system was created to adhere to the specifications and needs of the client. The customer was able to supply top-notch oil caps to their client who manufactures oil thanks to the tooling lead time of 60 days to T-1, which ensured prompt delivery of the mould.

4. Oral Care 

Although this project was difficult, we were able to create a cutting-edge toothbrush that satisfied the client's needs. High-quality materials were used to offer a comfortable grip while ensuring efficient production thanks to the 2K moulding technique and core rotating moulds. The working prototype worked well, and our client was pleased with the outcome.

5. Use of right Technology 

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Automation is one area where technology has had a significant impact, with the use of robots and other automated systems to handle tasks like part removal, sorting, and packaging. This reduces labour costs and increases productivity while also ensuring consistent product quality. Additionally, improvements in mould design software and simula- tions can also significantly improve efficiency, productivity, and product quality.

6. Lock the damage

Cable ties, usually referred to as zip ties, are a typical kind of fastener used to join cables, wires, and cords. They come in a variety of sizes and colours to suit various purposes and are produced from strong materials like nylon. The main manufacturing technique used to create cable ties is injection moulding. Plastic pellets are heated up in the process, and the molten material is then injected into a mould cavity where it cools and solidifies into the required shape. High numbers of cable ties may be manufactured with reliable quality and efficiency using injection moulding. Cable ties are suited for a wide range of applications in various industries since it also enables the manufacture of complicated forms and shapes.

What is Plastic Injection Molding?

Plastic Injection molding is one of the most common methods of mass producing plastic products. Examples include chairs, disposable cutleries, crates, toys, consumer electronics casing, lego bricks and many others.

Injection molding machine comprising of three main parts - the injection unit, plastic injection mold, and the clamp. The barrel heats up the plastic pellets (as shown below). These molten plastic will be moved forward within the barrel via a screw system. Once it's fully melted, it will be "injected" into the mold cavity and it will take shape. It will cooled and hardened to form the plastic part.

So, Why Should We Use Injection Molding For Mass Production?

Plastic Injection Molding automates the process for mass production. A single shot could lead to the production of many parts depending on your mold design. There are also many types of molds that can further increase the productivity of a single shot of the molten plastics, such as Stack Mold, Tandem Mold as well as Multi-cavitation Mold.

When we opt for mass production, we will definitely favor predictability, efficiency and less trouble-shooting. Plastic injection molding is undoubtably an established manufacturing method. Highly sophisticated, engineered plastic materials to advanced injection machines are readily available in the market, to fulfill different manufacturing requirements.

RELATED SERVICES: Plastic Injection Mold and Molding

Plastic Injection Molding Has Its Many Advantages

1. 1. Higher Efficiency

The use of injection molds for mass production is great for achieving higher efficiency. Once designed for a specific purpose based on a customers choice, molding process doesn't take long. This makes it a lot more effective in mass production and also a lot more efficient in output rate.

2. 2. It Has Enhanced Strength.

The use of additives such as fibre glass in plastic material is very common. These highly engineered compounded plastic materials carry characteristics of durability of its raw materials. And, there are  thousands of different types of materials in the market to suit different needs.

On top of that, the density of plastic just as it is being molded gives it greater strength. Strong and durable parts are very much needed in the market place, and plastic injection molding gives you the flexibility that not a lot of other molding processes can offer.

3. 3. Gives Products Detailed Features

The injection molds are a great way to give you mass-produce a good and detailed feature, and since they are subjected to high pressure. Thanks to this extreme and excessive-high pressure, it tends to provide great detail and design on all parts of your parts or products. Secondary processes can be saved such as texturing, and through 2K or 3K molding methods, you save a lot of labor costs on assembly and the finishings are a lot more impressive.

4. 4. Making Simultaneous Multiple Parts

Another major advantage when it comes to the use of plastic injection molding is that you can actually simultaneously manufacture different parts within the same mold. One shot of the molten plastic produces different parts to be assembled. Consistency in colors for different parts, is also a great determinant in designing the mold this way.

5. 5. Saves Cost.

Thanks to the automation in plastic injection molding processes, mass production most often leads to the lowering of manufacturing cost. Injection moldings are usually automated, and it is all done by machines, robots, and/or an operator for all the quality control and management. The automation helps with significant costs savings in the manufacturing process.

6. 6. It Is Cheaper than Plastic Machining, and More Lasting.

It is a lot cheaper as mentioned and give you the best without having to pay a large sum of money. As we know, the initial creation of mold can be very expensive but with mass production, each parts will cost significantly lower than say, a metal part. It is actually not economical to make low volume parts with plastic injection molding due to the high initial cost of making a mold.

7. 7. Global Usage.

Plastic injection molding is one of the most popular plastic producing processes around the globe. Anywhere you look, anywhere you are, you will see lots of products made through this process.

Conclusion

Plastic Injection molding method makes more sense for production on a larger scale. In fact, the high initial cost of the mold may not make sense for low volume production. There are also different types of plastic injection molds such as stack molds, tandem molds, as well as multi-shot injection molds which can offer more time-saving and increase in productivity.

Due to its many advantages, plastic injection molding is the most common choice for mass producing products nowadays.

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RELATED SERVICES: Multi-Shot Or Double-Shot Injection Moulding

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