Reduced resin loss in the molding process

Abstract

The plastic injection process has gained significant growth in the industry due to the technical and economic benefits it offers compared to other material transformation processes. Today, products with specific requirements in mechanical behavior, weight reduction, wear resistance, electrical insulation, high dimensional stability, and chemical stability in aggressive environments are best produced using this process, displacing traditional materials such as bronze, aluminum, cast iron, and steel in industrial applications (Polished, 2004). This project is carried out in a company dedicated to the manufacture of automotive harnesses and light holders. In the molding area, there is a considerable difference between the inputs and outputs of raw materials (resin), leading to high waste costs. This project focuses on reducing these losses by identifying their main source and developing a preventive maintenance design for the tooling (TPM). As a result, significant improvements were achieved in the tooling conditions, with a monthly cavitation rate of 11%, resulting in an average reduction of 20% in resin loss per month, which corresponds to an approximate cost saving of $5,000 USD.