Case Study – Improving the Modernization Process of Injection Molds in a Packaging Production Plant

In a factory producing plastic hearing aid packaging, injection molds are used, which are the basis of mass production technology for plastic products. This process involves heating the material and then forcing the plasticized material under high pressure into a mold, where it takes the appropriate shape. After molding is complete, the product is removed from the mold. Precise design and correct installation of molds and system components are key to ensuring trouble-free and efficient production. Read the case study of Pneumat. and learn how the hearing aid packaging production process was improved.

A client from the packaging industry asked us to modernize the production line in their facility. The solutions provided by the previous supplier turned out to be inconsistent with the applicable standards, which prevented the start of production and introduced numerous delays.

Situation at the start:

1. The plant produces plastic packaging.

2. Hearing aid packaging is manufactured using injection molds.

3. The injection molds were purchased from a Chinese manufacturer, but were dismantled upon delivery and were not suitable for immediate use after installation on the production line.

4. The quick connectors used were not standard, which prevented free connection of individual system elements.

5. After connecting the molds, the entire system was tested – the result was incomplete and low quality products.

6. The final product did not meet quality standards, and the process caused significant losses of granulate and solidification of the medium in the moulds.

Optimized process by Pneumat System:

After a detailed analysis of the problems in the plant, we modernized 16 machines with injection molds. We equipped about 50 dies and installed pneumatic hoses – almost 500 pieces. We implemented completely new connections of hoses with quick connectors, crimping hoses for injection molding machines with our unified quick connectors, which are compatible in size and type. Thanks to this, it is possible to freely switch between different injection molds and hoses. Quick connectors and their standardization allow for easy connection of different system elements, which was a key customer expectation.

We have also introduced innovative solutions supporting the effective process of blowing off finished packaging and its deionization. Thanks to this, the products are thoroughly cleaned of particles of processed material and other impurities. Deionization, i.e. neutralization of excessive electrostatic charges, prevents the attraction of dust and particles to the surface of the packaging, which ensures their higher quality and cleanliness.

Without modernization and optimization of the production line, it was impossible to start production. The system was inefficient, generated large losses of material, and the manufactured products were incomplete and did not meet quality standards. After implementing the necessary changes, we increased the efficiency of the process, shortened the production time and reduced its costs. Additionally, we enabled precise control of the quality of products. The optimized solutions also increased the level of safety in the plant, eliminating the risk resulting from leaky systems that could lead to failures, accidents and a threat to the health of employees.

Where can this solution be used?

If you are looking for effective ways to improve work in your plant, contact Pneumat System. We will be happy to visit your company and help optimize production processes to increase efficiency and effectiveness, we recommend!