Challenge
A leading automotive supplier experienced inconsistent part dimensions and frequent heater failures in their 500-ton injection molding machines producing PP components.
Solution
We replaced their standard band heaters with custom ceramic band heaters featuring improved thermal distribution and high-temperature cartridge heaters for precise nozzle control.
Results
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25% reduction in energy consumption, 40% longer heater lifespan, and consistent part dimensions within ±0.1mm tolerance.
Injection Molding
Challenge
A medical tubing manufacturer faced material degradation and inconsistent wall thickness when extruding high-temperature engineering plastics like PEEK and PEI.
Solution
We designed a multi-zone heating system with high-precision cartridge heaters and temperature sensors for each zone, allowing exact temperature control along the entire barrel.
Results
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Eliminated material degradation issues, achieved wall thickness consistency of ±2%, and reduced scrap rate from 8% to less than 1%.
Medical Device Company
Extrusion
Challenge
A manufacturer of automotive rubber seals struggled with uneven vulcanization, resulting in inconsistent material properties and high rejection rates.
Solution
We implemented a custom platen heating system with strategically placed cartridge heaters and high-temperature sensors to ensure uniform temperature distribution across the entire mold surface.
Results
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Achieved consistent vulcanization across all molds, reduced rejection rate from 12% to 2%, and decreased cycle time by 15% through optimized heating profiles.
Rubber Seal Producer
Compression Molding