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The liberalisation of the Indian economy has given
many Indian manufacturers an increasing access to global markets.
The product range of these manufacturers has been on the rise. Moulders
are also reaping the benefits of this situation. However, along
with the benefits, is also associated a practical difficulty, namely
Downtime between product change over.
Downtime plays a major role in deciding the production run size,
especially, when it comes to mould change activity. Hence, even
if one can manage resin changeover sequence, flexibility of switchover
from one product to another is restricted by mould changeover downtime.
Molders thus find it very difficult to produce small products batches.
This can result in a sizeably extra inventory stock or 'dead' capital.
Concept
Quick mold change (QMC) is a very good solution to such a problem.
Internationally, QMC has been in use in various forms for quite
some time. Mostly, these systems call for mold or machine modifications.
Instead, molders will always be happier if the QMC can adapt to
the existing molds and machines. This will simplify the implementation
procedure throughout the production line and is made possible with
the help of a Magnetic Quick Mold Change (MQMC). The MQMC can be
made to order, to suit any size of machine or mould.
How does it work?
The Pressmag clamping system comprises two magnetic platens, one
at the injection side (fixed platen) and one on the ejector side
(moving platen). They are operated by an electronic control and
power supply unit. The QMC is retrofittable on to any existing machine.
Benefits
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Mould clamping/declamping time is virtually eliminated when using
magnetic platens. This can drastically bring down mould
changeover time. |
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The need for tools for changing moulds is also eliminated because
an electrical spanner is now used for changing moulds,
thus removing the total stress from the mould change activity. |
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TBeing a completely tailor-made system, user can order the platen
to match their own specifications. |
Payback
Typically, for example:
A 600T machine mould clam+declamp time = approximately 2 hours.
The time QMC needs = approximately (maximum) 10 minutes - a saving
of 110 minutes per mould changeover.
Considering, 12 mould changeovers per month, 144 per year, this
accounts for a saving of 144 x 110 = 15,840 mins (approx. 40 shifts)
of spare capacity per year.
Considering, a 1.5 kg shot wt. per minute, this means an additional
capacity of 16 tonnes per annum.
(An approximately pay-back period between 18 to 24 months).
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