Top 6 FAQs about Plastic Artificial Plants Injection Mold Maintenance
Do you know how plastic artificial plants come into shape? Did you notice any slight differences in the shape and appearance finish of the same batch of leaves? Or have you ever wondered why some wholesale artificial plants have a relatively long service life while others don’t? It’s all about injection mold design, building and maintenance. Plastic molding processing is an essential factor that affects product quality and longevity.
The injection mold material is steel and is generally composed of front mold / rear mold. Due to specificity, precision and vulnerability, the safety protection of injection mold is significant. Let’s get started looking at the key points of injection molding maintenance.
What is injection molding and its maintenance?
The so-called injection molding refers to the method of injecting the heated and molten material into the mold and obtaining molded products after cooling and solidifying. The specific process is that the granular or powdery plastic is fed from the hopper of the injection molding machine into the heated barrel, heated and plasticized into a molten state, and injected into a low-temperature, closed mold through the nozzle at the end of the barrel by the screw pressure. The cavity is cooled and hardened to maintain the shape given by the cavity, and a working cycle is completed after the mold is opened and the colloid is taken out.
Injection mold maintenance or tool maintenance means the cleaning and repairs required to keep the injection mold in the best working condition. The factory carries out regular maintenance over the life cycle of the molds and when things go wrong in service.
Why is injection mold maintenance important for manufacturing plastic artificial plants?
A great number of artificial plants, such as artificial boxwood hedges and outdoor UV-resistant plants are made from plastics. So the manufacturer will introduce injection molding machines for mass production of plastic artificial plants. In a word, proper maintenance of injection mold is vital to help manufacturers supply quality products and reduce downtime from potential mold-related issues.
Reducing wear and tear
The mold has to withstand thousands of impacts every day in the production process, and wear will occur over time. Mold abrasion will directly affect product quality.
Increasing service life
The advantage of regular maintenance is to extend the lifespan of the injection mold and ensure the quality of the plastic product. Statistics show that the injection mold service life can reach 800,000 times, while some well-maintained molds can even be extended by 2-3 times.
Ensuring delivery time
Carrying out maintenance ahead of time allows us to set targets during long production runs. By solving problems in advance before the scheduled tool operation, the faux plant supplier can avoid the delay caused by the downtime.
Lowering production costs
Mold occupies a large proportion of the production cost of injection molding artificial plant businesses. There’s no need for fake plant suppliers to invest in setting up new molds as long as they pay enough attention is paid to the maintenance.
The molds need regularly maintaining to avoid corrosion, surface finish reduction, etc., as well as high reject rates and energy waste.
How many types of injection mold maintenance are there?
Basically, we can divide injection mold maintenance of plastic artificial plants into five types or levels.
To maintain the equipment in good working conditions, the personnel will carry out maintenance and repair through systematic detection, inspection and correction of initial abnormalities.
Preventive maintenance is usually performed regularly according to the predetermined work guidelines to avoid equipment or functional machinery damage.
It is a fixed routine work to avoid machine damage or misoperation.
Maintenance to avoid failure, including testing, measurement, adjustment, parts replacement and cleaning.
Routine maintenance tasks are easy to do daily, weekly, monthly, quarterly or annually because they are small and simple in nature. Businesses that invest in routine maintenance can extend the service life of their assets, reduce emergency occurrences, and maintain more stable and regular operations of their production lines or facilities.
A maintenance inspection is a process of evaluating the condition of equipment or machine. As a critical element of the maintenance checklist, maintenance inspection aims to determine what tools, materials, and labor are required to keep them in good working order.
In addition to the mold complexity, general maintenance is usually needed depending on the cycle count or the mold running times. For instance, an artificial grass wholesale supplier will pay careful observation to molds with many moving parts. The supplier checks whether the final injected parts in the mold is damaged or defective.
Major maintenance refers to the adjustment, repair or replacement of components or modules that may affect the measurement accuracy. This method should be performed by skilled maintenance personnel when the mold meets the number of cycles required for maintenance, excessive wear or tool damage. If the mold cavity finish degrades, renovation is necessary. When everything is in place, the personnel will rebuild the mold and restore it to work under better conditions than the new conditions.
Where can we maintain injection molds?
Consistent routine maintenance is essential for long-term die performance. At Sunwing, we set up the Factory Technical Department to solve all kinds of technical problems and emergencies. The department has professional repair and maintenance staff.
The personnel loading and unloading the mold or debugging the injection molding machine conduct regular inspection and maintenance;
Mold professionals are responsible for solving problems involved in changes, improvements, repairs and others;
Technicians who deal with debugging injection molding machines can conduct simple repairs (slight scratches on the product and replacement of mouth sleeves, etc.).
When should we carry out plastic mold maintenance?
Considering the seamless connection of each production chain, most plastic artificial plants suppliers will conduct preventative tool maintenance (PM) at certain intervals. It starts with keeping a check on the tool and product to ensure that items do not wear out prematurely and that everything is ready to produce high-quality products for our customers on time.
We clean oil and rust on the mold surface and inspect the cooling water holes in case of unusual matters.
It is necessary to check the arc in the mold rubber sleeve and the moving parts for normality.
we maintain the molds that are in production normally once a week, including cleaning the mold, checking the mold ejector pins, waterways, switches, etc.
The molds after production must be well maintained and preserved. To prevent the injection mold from reacting with air, we will coat it with anti-rust oil before storage. Besides, we put them on the assigned shelf and then place the product right above the mold for easy reference.
How to maintain and repair injection molds?
- Product design. We will determine if the part is within our molding and material capabilities when we receive a customer’s product design file for a customized or new product.
- Disassemble the mold. A time-based mold disassembly level (based on cycles, hours, days or parts produced) should be established to optimize bench time.
- Clean and clear. Clean up the greasy dirt and impurities on the surface of mold parts.
- Weld the wear area. If there is wear, we will refurbish it by welding.
- Grind the weld. The mold needs polishing to maintain the surface finish.
- Mold match. Try to assemble the components layer by layer to make sure they fit together perfectly.
- Replace the spring. While the mold spring design allows maximum stress, we need to replace the spring at predetermined intervals.
- Assembly molds. This step is necessary to prevent the mold from leaking glue and causing the product to flash.
- Die proof. Before mass production of plastic artificial plants, we need to confirm that the final sample item is consistent with customer needs.
- Check product quality. We make sure that the sample is free from glue shortage, flash, hole breakage, etc.
With regard to color matching through the debugging and comparison of toner in different proportions, our customers may know about the three main points:
- Old products like artificial hedges can look more natural in color and improve the simulation degree;
- There are more colors for customers to choose from;
- We have purchased many new molds and need to bring out new colors to speed up new products launch.
Regular mold maintenance of plastic artificial plants is mainly to solve product quality problems such as burrs, foliage loophole, uneven thickness, etc. Rest assured of our professional commitment to product quality stability. Feel free to keep in touch with us!
- By: SUNWING
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