basics of injection moulding

8/19/2019 basics of injection moulding

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Things to Know• Mainteance of Moulding Machines

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A #uide to n!ection Moulding

$%draulicCalculations for Injection

Moulding Machine

Hydraulic Pump Power Calculation

Power Ph &'() * + , p - ./0

Ph * in Kilo(atts

+ * Liters per Minute

p * Pressure in Kgf-c10

2lectric Motor Power for $%draulic Pu1p

Pe * Ph - ɳ

Usuall% it would be around .34 of $%draulic Pu1p Power5

since Pu1p would not be operated at full load alwa%s and

Motor can ta'e 634 over load for short duration,

7or Practical Purposes5 Motor Capacit% is not used as

above, 7or, 2g, f $%draulic Pu1p power is 83'( then

PLC for Injection Moulding Machine

low price.

Servo Motor Retrofitting

Platen Threading / Recoiling

Yuken Proportional alve!

Servo alve Repair Service

aria"le #i!place$ent Pu$p!

%oard Repair Service!

&efran Linear Potentio$eter! / Scale!

SSR' (eater Control

Rela) Card

Recoil Spring

*!ed Molding Machine!

+ld Moulding Machine!

,uto Mould Cla$p

Mould Cla$p!

Ro"ot Interfacing

Screw %arrel Repair

Platen Thread Repair

-lectronic %oard Servicing

()daulic Pu$p! and Repair Service!

(ot Runner Controller!

PI# Controller!

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2lectrical Motor 9e:uired is /;,6'(, So1e Manufacturers of n!ection Moulding Machines clai1 Less

Connected Load, f less than re:uired capacit% is used then 1otor efficienc% will reduce and increasing the

consu1ption,

Melt Pressure Calculation

P1 * Ph < Ah - Ab

P1 * Melt Pressure inside the Barrel during n!ection in Kgf-c10

Ph * $%draulic Pressure in the n!ection C%linder in Kgf-c10

Ah * Area of n!ection Piston in c10

Ab * Area Screw 9ing Plunger in c10

Locking Tonnage required for Moulded Component

7 * P1 < Ac < /,/ - /333

7 * Loc'ing 7orce in Tons &/333'gf )

P1 * Melt Pressure in the Mould Cavit% Kgf - c10

Ac * Co1ponent Area perpendicular to Loc'ing 7orce, c10

=ote > Loc'ing force shall be alwa%s 1ore than the calculated force above,

Maximum hot !t" Calculation

( * As < L < 3,;;

( * Shot weight of the Machine in gra1s

As * Area of 9ing Plunger of Screw in c10

L * Screw Stro'e of the 1achine, c1

#elation of Power Consumption and $il %iscosity

ncrease in ?il @iscosit% causes

2fficienc% of the pu1p is reduced

Consu1ption of Power increases

?il @iscosit% increases with increase of dirt in the ?il,

f %ou thin' %ou are saving b% using oil 1ore than the specified ti1e then %ou will

pa%ing 1ore electricit% bills which is invisible,

Accumulator and Power Consumption

Accu1ulators are used for $igh Speed n!ection, n so1e 1achines whole 1achine

is operated with Accu1ulator, But using of Accu1ulator is alwa%s consu1es 1ore

power5 because of the charging of the Accu1ulator ta'es place at higher Pressure,

Usuall% ?pen Close operations ta'es place with a pressure of around 83 bar, f

Accu1ulator is used then5 Accu1ulator is to be charged at 1ore than /03 bar whichis ver% high co1pared to actual re:uire1ent so power consu1ption is high, Loading


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the pu1p with high pressure alwa%s also wears out the pu1p faster and life of

$%draulic ?il co1es down drasticall%,

TTI'( PL&TIC I')*CTI$' M$+L,I'( M&'+-&CT+#I'(PL&'T

f %ou have reached this page then so1ehow %ou are associated with n!ection Moulding of Plastics5 if not

then %ou can still find so1e useful infor1ation about starting a business,

Starting an% business need planning, Planning includes the following points to be studied and discussed

with eperienced professionals5 friends before actuall% starting a co1pan%,

Purpose of Starting

2perience in n!ection Moulding

7inancial bac'ground

Technical 'nowledge about Plastics Processing

Location of Plant ver% i1portant

2nd Custo1ers and Location

Products to be 1anufactured - Job (or'

T%pe of Products to be 1ade Co11ercial - ndustrial - Auto1otive - Aerospace

Legal Status of the Co1pan% Proprietor - Partnership - LLP - Pvt, Ltd, - Ltd,

=u1ber of Partners - irectors

t all starts with %our 'nowledge and eperience in the Plastics Processing ndustr%5 especiall% n!ection

Moulding, restrict 1% discussion to starting a s1all Proprietorship - Partnership co1pan% doing Job wor'

or 1oulding co11ercial plastics co1ponents,

=ow a da%s 1an% people who are not associated with plastics are also starting n!ection 1oulding plant5 b%

wa% of necessit% - opportunit% available,

Most people thin' about their budget first and decide about the siDe of the plant accordingl%, 7or a new

co1er starting n!ection Moulding plant with little eperience in the field5 see1s to be easier with s1aller

1achines initiall%, But %ou have to loo' at the over all pro!ect cost before deciding what capacit% 1achine to

be purchased,

Let us assu1e that one has decided to start with /33Tons n!ection Moulding Machine to 1anufacture

Co11ercial ite1s li'e 03 liter (ater Jar Cap or house hold ite1s,

P#$)*CT #*.+I#*M*'T &', C$T


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Sl,=o, Plant 9e:uire1ents etails

/ Plant SiDe in S:uare 7eet E33 .33 S:,ft

0 A1ount of 9ent per Month F 03 per s:,ft ;333 /0333 1ini1u1

8 f rental Pre1ises Cost of Advance /3 Months of rent is nor1

E Cost of Machine assu1ing Used Machine .,3 to ;,3 La'hs depends on age and

condition of the 1achine5,

6 A 7ra1e with 0tons Chain Pulle% Bloc' 63333-G

. Power 9e:uired for Machine Appro 86hp

H Cooling (ater Pu1p Power /hp

; Cooling Tower and Piping .3333-G

I Mould cla1ps and Tools 83333-G

/3 $%draulic ?il for Machine about 033liters 06333-G

// Machine loading and unloading erection 06333-G

/0 Machine Transportation if not in the sa1e cit% 6333 /6333-G

/8 2lectrical fittings5 wiring in the Building 83333-G

/E Accessories li'e Scrap #rinder5 ?ven f re:uired

/6 f own products then cost of Mould

/. (or'ing Capital considering . 1onths rent5 wages5 and other

epenses

8,3 la'hs

/H =u1ber of e1plo%ees assu1ing accounts wor' to be ta'en

care b% owner,- consultant

. for 0E hours operation

/; 9egistration with Sales Ta /3333-G

/I Stationer% PrintingH333-G

03 ?ffice 7urniture06333-G

T?TAL =@2STM2=T9s, /85IH5333-G

Monthly *xpenses

escription etails

2lectricit% Bill /65333-G

(ages and staff welfare E35333-G

Miscellaneous 2penses 6333-G

Telephone - Mobile 2penses /333-G

Transportation 2penses To be deter1ined

nterest on nvest1ent F /;4 per annu1 03EH6-G

nsurance for 2:uip1ent To be deter1ined

Total Monthl% 2penses ;/EH6-G


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=ow a da%s 1an% people who are not associated with plastics are also starting n!ection 1oulding plant5 b%

wa% of necessit% - opportunit% available,

Most people thin' about their budget first and decide about the siDe of the plant accordingl%, 7or a new

co1er starting n!ection Moulding plant with little eperience in the field5 see1s to be easier with s1aller

1achines initiall%, But %ou have to loo' at the over all pro!ect cost before deciding what capacit% 1achine to

be purchased,

Let us assu1e that one has decided to start with /33Tons n!ection Moulding Machine to 1anufacture

Co11ercial ite1s li'e 03 liter (ater Jar Cap or house hold ite1s,

P#$)*CT #*.+I#*M*'T &', C$T

Sl,=o, Plant 9e:uire1ents etails

/ Plant SiDe in S:uare 7eet E33 .33 S:,ft

0 A1ount of 9ent per Month F 03 per s:,ft ;333 /0333 1ini1u1

8 f rental Pre1ises Cost of Advance /3 Months of rent is nor1

E Cost of Machine assu1ing Used Machine .,3 to ;,3 La'hs depends on age and

condition of the 1achine5,

6 A 7ra1e with 0tons Chain Pulle% Bloc' 63333-G

. Power 9e:uired for Machine Appro 86hp

H Cooling (ater Pu1p Power /hp

; Cooling Tower and Piping .3333-G

I Mould cla1ps and Tools 83333-G

/3 $%draulic ?il for Machine about 033liters 06333-G

// Machine loading and unloading erection 06333-G

/0 Machine Transportation if not in the sa1e cit% 6333 /6333-G

/8 2lectrical fittings5 wiring in the Building 83333-G

/E Accessories li'e Scrap #rinder5 ?ven f re:uired

/6 f own products then cost of Mould

/. (or'ing Capital considering . 1onths rent5 wages5 and other

epenses

8,3 la'hs

/H =u1ber of e1plo%ees assu1ing accounts wor' to be ta'en

care b% owner,- consultant

. for 0E hours operation

/; 9egistration with Sales Ta /3333-G

/I Stationer% PrintingH333-G

03 ?ffice 7urniture06333-G

T?TAL =@2STM2=T9s, /85IH5333-G

Monthly *xpenses


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escription etails

2lectricit% Bill /65333-G

(ages and staff welfare E35333-G

Miscellaneous 2penses 6333-G

Telephone - Mobile 2penses /333-G

Transportation 2penses To be deter1ined

nterest on nvest1ent F /;4 per annu1 03EH6-G

nsurance for 2:uip1ent To be deter1ined

Total Monthl% 2penses ;/EH6-G


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f 9egistered with Central 2cise then uties to be paid before 6 th of ever% 1onth

if 9egistered with Service Ta then sa1e to be paid before 6th of ever% 1onth,

TS to be deducted and paid for pa%1ents 1ade to subGcontractors5 service providers,

9egistration with 2S and P7 to be 1ade if no of e1plo%ees are 1ore than /6,

7iling nco1e Ta returns ever% %ear,

=?C fro1 Pollution Control Board,

!orking Capital #equirement

About si 1onths epenses to be the basis for wor'ing capital5 so it is about 65335333-G in this case, This

a1ount needs to be 'ept aside and should not be used for bu%ing e:uip1ents and 1achines

f the Machine is in good condition then it will not give an% trouble otherwise spending for the 1achine

repairs will also to be accounted,

/illing and #e0enues

Assu1ing /33 tons n!ection 1oulding 1achine is being used for producing co11ercial plastic co1ponents5 then

costing is done based on shift rate or based on weight of Materials converted in Kgs, Per shift /333 to /633 or

per Kg 9s, /3-G is now nor1 in the 1ar'et,

#e0enue Calculation

Shift 9ate /633-G

Per a% E633-G

Per Month assu1ing 06 da%s of production //0633-G

So the revenues are !ust sufficient to pa% the 1onthl% epenses, f ?wner is able to reduce the 21plo%ee

epenses5 then that epense can be saved to survive, 7or this5 Machine should run without an% trouble for 06

da%s and there should be orders for the sa1e, f an% one fails then it will beco1e loss,

To avoid this an% one starting co1pan% should start with little higher capacit% 1achine li'e 033 tons and above5

so that 1onthl% revenues will be 1ore and wages would be sa1e so that inco1e increases, (ages and

2lectricit% bills are 1ost epenses should be paid 1onthl% without fail,

7or this reason we strongl% reco11end not to start with lower capacit% 1achine, Adding second 1achine with in

one %ear will reduce the ad1inistration epenses li'e wages and increase the growth prospects,

&ssumptions made in Project #eport

Materials processed are PP5 $P25 LP2, 2tc which does not need preheating,

Location > Ta1ilnadu, ?ther places local taes 1a% war% li'e octori


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Labour availabilit% and cost low - 1ediu1,

UnGofficial epenses not ta'en into account

So1e ti1es acco11odation to be provided for e1plo%ees is not accounted,

f ABS5 =%lon5 Pol%carbonate5 etc then Cost of PreGheating the 1aterial and its e:uip1ent cost also to be

considered in the pro!ect cost,

f doing !ob wor' for an% Auto1otive Supplier then 1aintaining +ualit% standards li'e S?I3335 registering

with Central 2cise is also to be done,

er0ice Tax Implications

f billing done to one single custo1er and if it eceeds E,3 la'hs per annu1 then 9egistration with service

ta is 1andator% and service ta to be charged5 if custo1er is not an assessee of Central 2cise, f not Job

wor'5 then Sales Ta rate based on the co1ponents produced to be levied and the sa1e to be paid to the

CT? &co11ercial Ta ?fficer ) ever% 1onth b% filing returns,

$ther issues to 1e taken care

Safet% during 1achine operation, Several instances are there where e1plo%ees have lost

fingers - hands - life due to poor 1aintenance of shop floor and 1achines, Safet% of the Mould is also

upt1ost i1portant, Man% ti1es operators use 1etal rods to re1ove the stuc' co1ponents fro1 the 1ould

which will da1age the 1ould, Also cla1ping of the 1ould to be done propperl% with right tor:ue, Bolt

should enter the platen atleast 8311,

9ecentl% one of our custo1er who started a new co1pan% lost half of his hand even before co1pan% is up

and running, Safet% issues needs to be seriousl% ta'en care of fro1 the beginning of the operations,

nternal wiring to done with proper earthing to the Machines,

Several co1panies gutted co1pletel% due to short circuit5 losses running into cores of rupees, An%

unepected loss to a new co1pan% that too in the first %ear is too 1uch to bear and should ta'e etre1e

care in 1aintaining the shop floor and e1plo%ee safet%,

t is alwa%s suggested to 1a'e detailed stud% before stepping into starting a new co1pan%, ecisions

should not be ta'en on assu1ptions - h%pothetical thin'ing, iscussing with eperienced professionals in

the filed is 1andator%,


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Support fro1

At creative we provide professional support to the custo1ers to bu% suitable 1achines and offer after sales

support through out the life of the 1achine, So1e ti1es we even sa% not to venture into based on the

1ar'et conditions prevailing, So1e ti1es we suggest to go for bigger capacit% 1achines instead of s1aller

1achines,

So far we helped lot of new co1panies who have grown well and doing good business, (e helped

co1panies to reduce the 2lectricit% bills, (e helped co1panies5 who want to close b% selling their

1achines, Si1pl% we are one point source for all %our need for setting up 5 running an n!ection Moulding

Plant,

0nd 7eb 03/. G Updated this page,

After seeing overwel1ing response for1 the people who have visited this page in the

past one %ear5 decided to update this page with so1e feedbac' and observations

1ade b% 1e during last %ear,


11/14

Most people who wanted to start business do not have clarit% on what actuall% the%

are wanted do and do not have an% understanding about the1selves, have

co1piled the following points which needs to be seriousl% addressed before starting

business,

/, (h% do %ou want start Business

ou have to identif% reason behind the intention to start business, ou shoud

have atleast 03 %ears plan to start business5 if %ou dont have such plan5 tr% to 1a'e

a plan right now,

0, dentif% %our Strengths and (ea'neses and relate the1 to %ou area of business

whether the% will be usefull or not, for eg, if %ou wanted to start a business in

plastics in!ection 1oulding5 %ou have to as' %ourself the following :uestions,

a, (hat t%pe of eposure do %ou have in this field,

b, (hether it 1athes with %oureducation bac'ground

c, (hether %ou are the first person in %our fa1il% to start business

d, An% fa1il% 1e1ebers will support %ou in the business on dail% basis

c, dentif% %our financial strength and findout if it will not affect %ou and %ourfa1il% in case if %ou loose entire a1ount of invest1ent

d, how long %ou wanted to do this business

e, what is %our age at the ti1e of starting business5 starting business after 63

%ears is not reco11ended right now unless %our children will !oin %our business at a

later ti1e,

f, if %ou wanted start business with %our friends or relatives as partners5 then

identif% their strengths and wea'nessess as well, 1ore than ;34 partnerships split

after few %ears for various reasons,

g, have %ou studied an% course in Plastics or wor'ed in an% plastics industr%5

h, what is %our confidence level on %our 'nowledge on the t%pe of business

are starting,

i, @isit an% CP2T institute ca1pus and findout 1ore details about Plastics

Processing,


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8, Prepare a detailed pro!ect report before spending an% single rupee, dentif% what

t%pe of business %ou are going to start and then prepare the pro!ect report5 %ou can

approach district ndustries center for an% help5 the% 1a% have read% 1ade reports

for so1e products5 or ta'e help fro1 %ou elder friends or relatives, (e can also offer pro!ect reports 9s, 065333-G each per product categor%,

E, f %ou identified a product to 1anufacure then identif% the eisitng pla%ers in the

1ar'etand findout their strengths and wea'nessess and do a 1a'er stud% for that

particular products5 whether %ou will be able 1a'e the sa1e product at lessor cost5

because if ant eisting pla%er finds co1petition then the% will slash their prices

suddenl%5 because it is possible for the1 since the% alread% recovered their

invest1ent on business and it is affodable for the1 to operate with low 1argins,

wanted to give one ea1ple on this, ?ne %oung person fro1 =ellore called 1e and

told that $e wanted to start 1a'ing of P@C fittings, as'ed hi1 whose is suppl%ing

those products right now in %our area he do not 'now that, Then as'ed hi1 wh%

he choose P@C products5 he said because his friends told hi1 he had chosen that

products5 as'ed again whether %our friends are wor'ing in si1ilar ndustries5 he

said no all of the1 are li'e hi1 fresh fro1 college co1pleted education !ust now, This

is how things are going at the ground level, Colleges are not 1a'ing an% awareness

progra1s about careers for thier students, have told hi1 the na1e of an MP who is

the leader in this business and as'ed hi1 whether he 'nows the MP5 he said he do

not 'now, (ithout 'nowing an%thing about the product the% wanted to start

business,

have seen even eperienced people who started business with friends and closed

down within first %ear with huge losses because ever% one has thier own interest in

life and without an% long ter1 perspective the% are ta'ing decisions,

6, o not start business if %ou dont have habbit of reading news papers, Most people do not bother to

'now about what is happening around the15 alwa%s living in their own fascinating world, ?ne ea1ple

wanted share about this,

A group of friends started business5 the% are 'nown to 1e5 in a place near Chennai suburb, once the%

identified the factor% shed and 1oved that place and while unloading the 1achines local people & goons )

affiliated to political parties5 ca1e and insisted that the% will do the unloading and loading activities and not

allowed other persons doing it, After so1e discussion the% left ta'ing about 9s, 03333-G without doing

an%thing, These things are not tought in schools and colleges, %ou will co1e to 'now onl% when %ou read


13/14

news papers and had chat with %our industr% people, n fact all of those people who started business there

were eperienced people and 'now the place ver% well and thier friends were also wor'ing in industries

there5 still the% 1ade a 1ista'e of selecting that place,

., Choose the right place of business, one fine ea1ple is recent floods in Chennai, al1ost ever% one got

affected due to floods, so1e business people doubl% affected, both thier 7actories and $o1es got

sub1ergd in (ater for 1ore than four da%s and da1aged properties etensivel% which is huge loss difficult

to recover if it happens first few %ears of starting business, 2ven the nsurance policies could help5 an

industir% friend of 1ine had an insurance polic% for 9s, 83 la'hs on 1achineries5 but he got onl% 9s,

.3333-G as co1pensation5 actual losses are 1ore than /3 la'hs, t is lesson for ever% one, %ou will co1e to

'now these things onl% when %ou read news papers, toda% %ou 1a% not need but in future %ou 1a% be

forced to 'now after loosing so1e 1one%, even people who not doing business and wor'ing T co1panies

suffered a lot for not reading news papers, the% purchased ho1es costing 1ore than a crore each in low

l%ing areas and toda% the% starting at a loss of 1ore than E3 la'hs on each ho1e, f the% 'now about their

surroundings5 losses would have been 1ini1ised,

H, isaster 1anage1ent, these are 'e%words for onl% big corporates but now it is 1ost co11on for ever%

one after seeing the Chennai 7loods, ou have to 'eep i1portant data at two different places to 'eep

business continut% and avoid loss of business due to loss of ?ffice e:uipe1ent due to natural cala1ities,

one ea1ple is the school wheere our son is stud%ing5 there was feet water in the school co1pound and

entire school docu1ents5 co1puters5 librar%5 students boo's etc got sub1erged in water, The% are now

as'ing students to produce the docu1ents which the% shoud have 'ept as part of disaster 1anage1etn

place, the school is big with 1ore than 0333 students studing there, =o person who is thin'ing to start a

business thin's about these things at the ti1e of starting a business5 even a1 not an eception, t is all

eperience, Learn fro1 others 1ista'es is the best wa%,

;, (hat are the resources re:uired to run the business, dentif% the1 and findout diffiuclties in getting those

resources, Toda% &8rd 7eb 03/.)5 due to global recession we do not 'now what will happen to1orrow, ou

have to get bac' %our invest1ent within one %ear else %ou will loose %our Mone%, Technologi% is changing

faster than people can cope with, one ea1ple5 one of 1% relative is wor'ing in big M=C who has invested

about 9s, H333 crores in SAP 29P &trade 1ar' used here for illustration purpose onl%5 nothing to do with

the brand ) stand alone version which the% started few %ears bac' and co1pleted in 03/6, B% the ti1e the%

co1plete it5 technolog% has changed and now ever% industr% is 1oving towards Cloud s%ste1s5 1eans

their invest1ent beco1e outdated, ou have to identif% these things when %ou select 1achiner% and

e:uipe1ent, Chose 1achines which consu1e low power and have latest technolog%,


14/14

I, 7a1il% issues if an%, f %ou have patients at %our fa1il% and wants start business decide how would

balance both, 2speciall% if %our business 1a'es %ou to travel etensivel%,

/3, ou can not 1a'e profits if %ou do legite1ate business5 1eans if %ou follow rules strictl%5 pa% taes and

other statutor% obligations correctl% %ou end up loosing 1one%, Because %ou are forced to co1pete with

people who are not doing business legite1atel%, This is for people who are doing s1all business, Most

co1panies show less nu1ber of e1plo%ees to avoid pa%ing 2S5 P75 profession Ta etc, if the% ignore

these things5 then definetel% the% will incur losses because the% have not considered these things before

starting business, The% can not co1pete if the% do legite1atel%, ?ne ea1ple is Big corporates are

charged at 8E4 inco1e ta and their profit 1argins are about /64, The Big co1panies get about /0G/64

concessions so their effective inco1e ta would be in the range of 03G004, 1eans their profit 1argins are

actuall% the concessions given b% the #ovt, These concessions are not available to s1all business people,

n the last Budget Central #ovt, announced that the% will reduce nco1e ta rates and also reduce

concessions, 1eans Business people needs to run the show on real ter1s5 under loo1ing global recession

and increasing e1plo%ee costs, Means %ou 1a% be as'ed to reduce the price b% %our custo1er,

//, $u1an resources, The biggest proble1 now ever% business is now facing is getting right people, $ow

are %ou going to do that, Ma'e a detailed plan, 9ecentl% one of 1% custo1er scolder the wor'ers5 and

suddenl% 1ore than /3 wor'ers left the co1pan%5 at another co1pan% five of senoirs left the co1pan% due

to 1ishandling b% the ?wner, Tr% to understand how to deal with people,

/0, Accounts, Tr% to learn accounts and do not depend on others for this else %ou will end up loosing

1one%, Undertand what is Balance Sheet5 Profit Loss state1ent5 (hat is Capital 2penditure5 @at5 2cise5

Service Ta5 etc, in detail, ?ne of 1% custo1er lost 1ore than 9s, E3 La'hs due to lac' of 'nowedge about

Central 2cise rules, ou have to file 1onthl% Sales Ta returns5 2cise and Service Ta pa%1ents5 etc,

ou should have 'nowledge about these activities, Most of these things can be done online now,

/8, (or'ing 2perience, Alwa%s tr% to wor' in si1ilar industr% for a period of not less than four %ears

before starting the business, Learn various aspects of Business in the owners point of view,

/E, Ma'ing profits, o not thin' %ou can 1a'e profits right fro1 first 1onth, o not tr% to 1a'e a living out

of inco1e fro1 Business at least for first Two %ears,

/6, Love %ou Job, f %ou are starting business !ust to 1a'e 1one% then %ou will end up in frustration and

1ental tension, ou should love what %ou are going to do, t should be %our passion, ou have to be

prepared to spend sleepless nights5 and still should not loose confidence on %our self, f %ou are sensitive

person who can not control e1otions5 and not good at dealing with people then ? =?T STA9T

BUS=2SS,

/e positi0e2 Think positi0e" (ood Luck3

Documents

basics of injection moulding