Plastic injection molding machines rely on the force of a ram or a plunger to shape heated plastic granules into the desired form, from a tiny tab on aseptic packaging to a 5 gallon paint can or more. Custom designed molds determine the ultimate shape of the plastic, with significant investment and care taken to protect both design rights and mold condition.
Perfect alignment is required to ensure an even fit of the two halves of the mold receiving the plastic, as well as to avoid such flaws as flash, mold damage, and wear to the parting line. Dimensional defects to the final product can also occur when a machine is out of alignment. Although plastic injection machines include their own guides meant to keep mold aligned, if left for long without tune-ups the guides will begin to wear. This can lead to mold damage and the necessity of repair or replacement, which is extremely costly. Some molds can cost nearly as much as the machine itself, depending on the size and complexity of design.
Because molds are so valuable, the first source of concern when an injection machine goes awry is usually directed there. However, it’s possible that issues with production did not originate with the mold, and misdiagnosis can waste valuable production time while inspections are held.
A better place to begin troubleshooting is ensuring the machine is level. Checking the old leveling system may reveal inferior leveling feet or shims, which are best replaced with leveling wedges, depending on the size of the machine and the condition of existing supports. With leveling wedges, minimal time investment is required when re-leveling. After leveling the machine, technicians can then re-test for production issues if necessary, although a trial run may reveal full resolution of the issue.
Machine inspections should always include a thorough check of alignment. While tune-ups and re-greasing of sensitive parts is simply basic care, a level check should not be overlooked.
If your injection machine is functioning less than perfectly, be sure to check its level in advance of suspecting the mold. We are happy to offer leveling solutions to assist you in ensuring your machine runs flawlessly.
