Cases

The challenge passed on by our Client involved finding a solution to replace mould that was in use at that time, but that had a very high cycle time and had a history of many breakdowns of delicate components. The injected plastic part included a Ø 0.25mm through hole – which requires an insert with this diameter in the mould. There was a very large waste with the injection channel, as the product did not offer a suitable region for the injection point if a conventional hot chamber was used.

Our experience acquired over the years has allowed us to improve manufacturing processes, enabling the production and repeatability of so-called critical/delicate components. For this project we proposed a totally different approach to the movement mechanisms of the slats during mold closing in production. In order to solve the problem with waste in the injection channel (raw material), we incorporated into the Project the injection system with MeltCube® – at the time, the largest system ever implemented in the world – reinforcing our tradition of applying the most modern solutions technologies for our Clients.

For injection of Batoque Product, we deliver to the Client 1 mold with 32 cavities and 1 mold with 48 cavities. We solved the issues related to the cycle (from 22 s dropped to 12 s) and the constant breakage of the pins that make the bung hole with diameters of 0.25mm and 0.28mm (the incidence of breakage of toupees was reduced by 93%). With this, the BTOMEC Molds reduced the consumption of raw material during injection, met the level of performance desired by the Client and, in addition, we maintained CP and CPK ≥ 1.33 in the product’s critical quotas.