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Internship at the plastic injection factory
Presentation · April 2024
DOI: 10.13140/RG.2.2.17014.82247
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In the name of God
University of Mazandaran
Facility of chemistry
Internship at the plastic injection factory
Professor :Dr,Nabavi
Student:Mehrshid norouzi zarmehri
April 2024
We will see in this presentation
Introduction
What is plastic injection molding?
How does the plastic injection molding process work?
Spark machining
BFD OF PLASTIC INJECTION FACTORY
Factors Affecting Success and Failure in Plastic Injection Factories
Quality control unit and laboratory
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Introduction
Plastic components are used in many industries. From automotive to home appliances and medical devices,
components in a variety of plastics are used to protect, enhance and build a huge range of products.
With its reliable, high-quality performance, injection molding is one of the most common processes used to
produce plastic components. Indeed, the compound annual growth rate (CAGR) of the injection molded
plastics market is expected to increase by 4.6% up to 2028.
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Injection moulding is major net shape processes for thermoplastic polymers. Over 30% of all the plastic parts
are manufactured by the injection moulding [Link] is one of the process that are greatly preferred in
manufacturing industry because it can produce complex-shape plastic products and having good dimensional
accuracy with short cycle times typical examples are automobile industry, casings and housings of products
such as computer monitor, mobile phone and which has a thin shell feature
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What is plastic injection molding?
Injection molding is a complex manufacturing process. Using a specialized hydraulic or electric machine, the process
melts, injects and sets plastic into the shape of a metal mold that’s fitted into the machine.
Plastic injection molding is the most widely used components manufacturing process for a variety of reasons, including:
Flexibility
Efficiency
Consistency
Cost-effectiveness
Quality
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How does the plastic injection molding process work?
The injection molding cycle includes many parameters which need to be tightly controlled to ensure the overall quality of the
plastic components produced. Understanding the process and parameters in some depth will help manufacturers to identify plastic
components producers who can provide the quality and consistency they need.
Step 1: selecting the right thermoplastic and mold
Step 2: feeding and melting the thermoplastic
Step 3: injecting the plastic into the mold
Step 4: holding and cooling time
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Step 1: selecting the right thermoplastic and mold
Before the actual process begins, it’s key that the right thermoplastics and plastic injection molds are
selected or created, as these are the essential elements that create and form the final components. Indeed,
to make the right selection, manufacturers need to consider how the thermoplastic and mold interact
together, as certain types of plastics might not be suitable for particular mold designs.
Acrylonitrile-Butadiene-Styrene (ABS) – with a smooth, rigid and tough finish, ABS is great for components that require tensile strength
and stability. Find out more in our guide PVC vs ABS.
Nylons (PA) – available in a range of types, different nylons offer various properties. Typically, nylons have good temperature and good
chemical resistance and can absorb moisture. Read more about nylons in Nylon 6 vs Nylon 6/6.
Polycarbonate (PC) – a high-performance plastic, PC is lightweight, has high impact strength and stability, alongside some good electrical
properties.
Polypropylene (PP) – with good fatigue and heat resistance, PP is semi-rigid, translucent and tough. Find out more in our guide PP vs PE.
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In order to reduce plastic injection waste, in the plastic injection factory, the remaining wastes and
channels are reused. These wastes are crushed in the shredder and re-mixed with the raw material in
the mixer.
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Step 2: feeding and melting the thermoplastic
Injection molding machines can be powered by either hydraulics or electricity. Increasingly, Essentra is replacing its
hydraulic machines with electric-powered injection molding machines, showing significant cost and energy savings.
To start the process, raw plastic pellets of the thermoplastic material are fed into the hopper at the top of the machine. This
could be virgin material, like plastic resin, or recycled plastic materials. As the screw turns, these plastic pellets are fed
gradually into the barrel of the machine. The turning of the screw and the heat from the barrel gradually warm and melt the
thermoplastic to melting point until it turns to a molten material.
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Step 3: injecting the plastic into the mold
Once the melted plastic reaches the end of the barrel, the gate (which controls the injection of plastic) closes and the screw
moves back. This draws through a set amount of plastic and builds up the pressure in the reciprocating screw ready for
injection. At the same time, the mold halves close together and are held under high pressure, known as clamp pressure.
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Step 4: holding and cooling time
Once most of the plastic is injected into the mold, it is held under pressure for a set period. This is known as ‘holding
time’ and can range from milliseconds to minutes depending on the type of thermoplastic and complexity of the part.
This holding time is key to ensuring that the plastic packs out the tool and is formed correctly.
After the holding phase, the screw draws back, releasing pressure and allowing the part to cool in the mold and the
plastic solidifies. This is known as ‘cooling time’, it can also range from a few seconds to some minutes and ensures that
the component sets correctly before being ejected and finished on the production line.
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ejection and finishing processes
After the holding and cooling times have passed and the part is mostly formed, ejector pins or plates
eject the parts from the tool. These drop into a compartment or onto a conveyor belt at the bottom of
the machine. In some cases, finishing processes such as polishing, dying or removing excess plastic
(known as spurs) may be required, which can be completed by other machinery or operators. Once
these processes are complete, the components will be ready to be packed up and distributed to
manufacturers.
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Spark machining
Spark machining is a non-traditional machining method that uses electric sparks to remove material from the workpiece.
This method is used for making injection molding dies, as it can create complex and precise shapes with high hardness and
low conductivity. Spark machining consists of four main components: electrode, workpiece, power supply and dielectric
fluid. The electrode and workpiece are two poles that have a small and controlled distance from each other. The power
supply creates an electric current with low voltage and high ampere between the two poles. The dielectric fluid provides a
suitable environment for generating sparks and also cools the workpiece and cleans the chips from its surface. The sparks
create small holes in the workpiece that shape it. The electrode is made in the shape of the desired workpiece and transfers
its shape to the workpiece by advancing into it
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This method has some advantages for making injection molding dies, such as:
• Ability to create complex and precise shapes with high hardness and low conductivity
• No direct contact between the electrode and the workpiece and therefore no stress and deformation in the workpiece
• No need for high cutting force and sharp and resistant tools
• Reduced costs and time for making dies
This method also has some challenges, such as:
• Creating thermal changes and residual stresses in the workpiece
• Material loss from the electrode and need for replacement
• Need for precise control of the distance between the electrode and the workpiece and the electric current
• Need to use electrically conductive materials for the electrode and the workpiec
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In this slide we can see film of Spark machining
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BFD OF PLASTIC INJECTION FACTORY
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Quality control unit and laboratory
In this slide we see the list of lab tests:
1- Melt Flow Rate (MFR) test
2- Density measurement test
3- Vicat Softening Temperature (VST) test
4- Tensile strength measurement test
5- Ash content measurement test
6- Product and container interaction test (traceability of raw materials and product)
7- Print stability test method
8- Migration measurement test
9- Volatile matter measurement test
10- Dimensional change measurement test
11- Water absorption measurement test
12- Leakage measurement test
13- Layer number determination test
14- Print quality test
15- Burning test to determine pH
16- Acid resistance
17- Thermal resistance
18- Low temperature resistance
19- Chemical migration or extraction test
20- Heavy metals test (cadmium, chromium, lead and mercury)
21- Volumetric deviation
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Ash content measurement test
Translate this sentence as well, as in the previous instruction, that first you have to place the
crucible and its lid inside the furnace with a temperature of 950 degrees for 10 minutes, then take it
out and place it in the desiccator (the desiccator prevents the crucible from absorbing moisture and
dust), then weigh it on the scale and record its mass. Cut some of the completely dry and clean
product sample, crush it and place it inside the crucible, and also record the weight of the crucible
and the sample inside it. The amount of the initial sample is determined from the table that is in the
national standard 1-10237, so that the less the amount of possible ash, the more initial sample you
should choose. Usually for ash between 1 and 10 percent, 5 grams of sample and for the amount of
10 to 25 percent ash, 2 grams of sample is enough.
Place the crucible and the sample on a direct flame (without a lid) until the whole sample starts to
burn and the smoke from it ends. After the smoke is over, place the lid on the crucible and enter it
into the furnace that is set at 950 degrees. Do not tighten the lid completely on the crucible and it is
better to have a little empty space (but not so much that the ash comes out of it), this is because the
gases in the crucible do not trap and create extra pressure.
Keep the crucible and the sample in the furnace for 30 minutes and then take out the crucible and
transfer it to the desiccator. Wait until it reaches room temperature and then weigh it.
Repeat the transfer to the furnace again until the difference in the mass of the crucibles is at most
0.5 milligrams.
Now calculate the amount of ash from the following formula, M0/M1 *100
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Ash content measurement test
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Quality control unit and laboratory
Volatile matter measurement test
To perform the volatility test, first dry the weighing container for 30 minutes in an oven at a temperature of 110 ± 1 degrees Celsius and
then place it in the desiccator for 15 minutes at room temperature of 20-30 degrees. (Immediately pour about 10 grams of the resin
sample under test into the dried weighing container and weigh it with an accuracy of 0.001 grams. (M1 In the next step, dry the sample
container for one hour in an oven at a temperature of 110 ± 1 degrees Celsius and then place it in the desiccator for 15 minutes at room
temperature of 20-30 degrees. Weigh the sample container again M2 which by using the formula [(M1-M2) / M1] × 100 the amount of
volatile matter is obtained.
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Quality control unit and laboratory
Dimensional change measurement test
In this method, first measure the dimensions of the containers under test from specific points (the points are
determined by the tester) (L0) (length, width and height for rectangular containers - diameter and height for round
containers) and then place them in a container of water at 100 degrees Celsius (boiling water) that is controlled by a
thermometer, for 30 minutes. And in the next step, pull the container under test out of the water and cool it for 15
minutes at room temperature (20-30) degrees Celsius and immediately measure the container under test from the
specified points (L1) which by using the following formula the percentage of dimensional changes is obtained
1 − 𝐿1 ÷ 𝐿0 × 100
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Quality control unit and laboratory
Water absorption test
To perform this test, first dry 3 samples for 24 ± 1 hours in an oven at a temperature of 50 ± 3 degrees Celsius and then
cool them in the desiccator and weigh them with an accuracy of 0.1 milligrams. (M1) In the next step, place the samples
in a container of boiling water for 30 ± 1 minutes, making sure that the samples do not touch each other or the container
(and then pull them out and cool them for one minute in distilled water that has room temperature and using a clean and
dry cloth or with the help of a smooth paper, take the water that covers their surface and weigh them immediately. The
difference in weight obtained shows the amount of absorption. (M1-M2)
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Quality control unit and laboratory
burning and pH determination test
In this method, prepare the sample in dimensions of 20 × 4 mm and then hold the sample with tweezers and ignite it
from the tip by a lighter inside the hood. When the sample catches fire, examine the ignition mode, flame color,
burning smell, smoke color and pH and record the results. Of course, to determine the pH of the product, you need to
insert small pieces of the product into the test tube and then place it on the flame until steam rises from it, then take the
pH paper inside the tube and wait a little, then read the pH using the guide on the pH paper package and report it
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Quality control unit and laboratory
film
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Quality control unit and laboratory
Acid resistance test
Generally, this test is used for volumetric containers. In this test, acetic acid 1% is used. Fill two containers under test
up to 80% of their volume with acetic acid 3% and place them upright at a temperature of 23 ± 2 degrees Celsius for
2 hours. After the conditions are over, empty the containers and examine them for color fading, twisting, deformation
and leakage
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Quality control unit and laboratory
Thermal resistance test
Place two containers on a paper and fill them completely with separate hot distilled water at a temperature of 95
± 5 degrees Celsius for polypropylene containers and 85 ± 5 degrees Celsius for polystyrene containers and
place them upright in an incubator at a temperature of 60 degrees Celsius for 30 minutes. After exiting the
incubator, examine the samples for any deformation, stain and leakage.
Low temperature resistance test:
Before performing the test, carefully check the containers for any cracks or breaks and then place them at a
temperature of -18 degrees Celsius for 4 hours. After the test conditions are over, remove them and examine
them for any cracks or breaks. Perform the test on three samples and if no cracks are observed in any of the three
samples, the sample is mechanically acceptable
𝑣 − 𝑣0
𝐷= × 100
𝑣0
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Quality control unit and laboratory
Raw material and product traceability
The purpose of this procedure is to trace the purchased raw materials and the products made from these materials at each stage of
production and distribution. The consumable raw materials (PS, PP, PE) are labeled upon arrival after laboratory approval, which
includes the date of arrival, the code based on the production batch, the production date and the grade. The bill of lading of the
purchased materials from the supplier is also coded according to the code that is in the identification card. The production supervisor
is obliged to inform the laboratory before starting to consume each batch of purchased raw materials until the end of the batch, and
according to this time interval, all the products that have been produced are identified, which raw material was used in the
production from which brand and supplier
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Other tests :
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Factors Affecting Success and Failure in Plastic Injection Factories
Plastic injection molding plays a vital role in manufacturing various plastic products. This research investigates
the key factors influencing the success or failure of plastic injection factories. By understanding these factors,
factories can enhance their production processes and deliver high-quality products.
Plastic injection factories face challenges related to material properties, process parameters, and tooling design.
Let’s explore the critical factors affecting their performance.
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Factors Affecting Success and Failure in Plastic Injection Factories
Success Factors
• Injection Pressure Control: Properly adjusting injection pressure
ensures consistent product quality.
• Material Properties: Viscosity and melting temperature impact mold
filling and part quality.
• Effective Gas Venting: Proper venting prevents gas entrapment
during injection.
• Tooling Design and Maintenance: Well-designed molds and regular
maintenance are essential.
• Injection Speed and Pressure: Balancing these parameters affects
part quality.
• Mold Temperature Control: Precise temperature management
ensures consistent dimensions.
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Factors Affecting Success and Failure in Plastic Injection Factories
Failure Factors
• Flow Lines: Improper flow patterns cause visible lines on part
surfaces.
• Material Overheating: Excessive material temperature degrades
properties.
• Inadequate Injection Speed: Incorrect speeds lead to incomplete
filling or flash.
• Poor Gate Design: Incorrect gate placement affects material flow.
• Material Contamination: Contaminated materials result in defects.
• Insufficient Cooling Time: Premature ejection causes warping
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By addressing these factors, plastic injection factories can enhance their processes and achieve better outcomes.
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Refrenses
1. **Abstract** ¹:
- Title: "Plastic Injection Process"
- Available from: [Hamiran Steel]([Link]
2. **Nouroozi, M.** (2024) ²:
- Title: "Internship Location"
- Location: Shahriar, Iran
3. **Plastic A.** ³:
- Title: "Amiran Plastic"
- Available from: [Amiran Plastp]([Link]
** .4Our Polymer** (2020) ⁴:
- Title: "Polymer"
- Available from: [Polymerma]([Link]
5. **Polymer Additives** (2023) ⁵:
- Title: "Polymer Additives"
- Available from: [Fardanews]([Link]
6. **Spark** (2020) :
- Title: "Spark"
- Not available online
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7. **Spark Machine Design** (2023) :
- Title: "Spark Machine Design"
- Not available online
8. **TUPE Y.** :
- Title: "Plastic Injection Theory"
- Not available online
9. **Nouroozi, M.** :
- Title: "Internship Film"
- Location: Iran
10. **Iran Standards** (2009) :
- Title: "Standard 11604"
- Location: Tehran, Iran
11. **Standard S.** (2013) :
- Title: "Standard 10237-1"
- Location: Tehran, Iran
12. **Iran A.** (2009) :
- Title: "Standard 11228"
- Location: Iran
13. **Reasons for Success** :
- Title: "Causes of Plastic Injection Problems and Troubleshooting"
- Available from: [Paniza Polymer]([Link]
** .14Reducing Production Costs** :
- Title: "Methods for Reducing Plastic Mold Making Costs"
- Available from: [Tikplast]([Link]
** .15Production Weaknesses** :
- Title: "Plastic Injection Process and Troubleshooting"
ADD A FOOTER - Available from: [B2Wall]([Link] 35
Thanks for attention
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