I. Introduction
Did you know that plastic injection molding companies
produce a lot of waste? In fact, it is estimated that the industry generates
around 2.2 million tons of waste each year. That's a lot of garbage!
Fortunately, many companies are now working to reduce their waste production.
Plastic injection molding companies have the difficult task of reducing waste
while producing quality plastic products. This is not always an easy task, but
with careful planning and execution, it can be accomplished.
In this blog post, we'll take a look at some of the ways
plastic injection molding companies can reduce waste and help save the
environment. We will also talk about the benefits of reducing waste in this
industry. Stay tuned for more information!
II. Understanding the Sources of Waste
Material wastage
Materials used in the injection molding process are wasted
at different steps such as plastic waste due to non-conforming products or
product remains or remains due to grinding. The waste becomes more when
companies are doing custom plastic injection molding.
Energy consumption
The injection molding process consumes high electricity due
to the use of electrical resistances for heating (and also cooling) in
injection machines and also used in ventilation, drying, transporting solids
and liquids, mills, etc. Other than electricity, diesel oil is also consumed
which is used basically in heating boilers, internal transport, etc.
Defective products
Both in the preventive maintenance operations of machines
and facilities and in the cleaning of machines and accessories, many types of
waste can be produced such as empty containers of raw materials or solvents
Cloths or papers impregnated with oils, greases, , chemical products in
general, solvents, etc, the dirty oils, crap, metals and metal parts. Waste
from facility maintenance such as used batteries.
III. Material Optimization Techniques
Proper material selection
Recycling of plastic raw materials is a very large market
within the injection molding industry. In fact, injection molding manufacturers
save costs and waste by using millions or billions of tons of recycled plastic
each year.
Almost all injection molded plastic parts will have a
recycling code molded into the part. This code indicates the type of plastic
the part is made of. This helps recycling companies group the plastic parts
correctly in their processing.
Common recyclable thermoplastic materials include:
- Polypropylene (PP)
- Polyethylene (PE)
- Acrylonitrile Butadiene Styrene (ABS)
Recycling and reusing excess materials
In the plastic injection industry, reusing scrap materials
offers the dual advantage of minimizing waste and enhancing sustainability. The
process begins with meticulous segregation and sorting, followed by identifying
the specific plastic type through methods like burn tests. Maintaining
stringent quality control ensures that only suitable scraps are processed. By
adeptly blending recycled materials with virgin ones, and refining injection
parameters, manufacturers can not only reduce costs but also contribute
positively to the environment by recycling waste generation.
IV. Machine and Process Optimization
Regular maintenance and calibration
Updating the machinery, Regular maintenance and calibration
so that machinery complies with environmental rules and regulations as well as
using new processes that have less environmental impact, have less waste and
contribute to less emissions of carbon dioxide are further steps in the
environmental work.
Advanced technologies and automation
The injection molding industry uses a wide variety of
machines and processing. The absolute best injection molding machines invest
large amounts of capital to have the most modern machinery and software
available.
By using modern machinery and by automating the system,
manufacturers of custom plastic parts can save an immeasurable amount of
manufacturing time, produce plastic parts with almost zero scrap, and save 50
to 60 percent of the electricity needed compared to injection molding companies
using old technology.
Training operators for best practices
Only good machinery is not enough in the plastic molding
industry, technicians should be professional and should know what they are
doing. Proper training with the latest processes and methods should be given to
the operators for best practices.
V. Quality Control and Testing
Implementing rigorous quality checks
Of course! another important thing to assure here is
ecological plastic injection molding. The company should take all necessary
measures to prevent any type of contamination that may be caused by the
manufacturing process. All products should go through strict quality control to
make sure that they comply with all the environmental standards set by the
authorities.
Early detection of defects to reduce rework
Collecting information throughout the process, prototyping
before the actual process, quality testing at every step, and making the
manufacturing method agile are some of the methods which can help you to catch
defect before it actually happens. This not only reduces waste such s useless
product but also reduce the workload and increase efficiency.
Using simulation tools for mold design
As discussed above having tools that virtually show the
design and working of molds is the most help full technique to reduce waste and
make the final product efficient and excellent in the first attempt of
products. Presently the most useable simulation tool is 3D printing.
VI. Sustainable Practices in Plastic Injection Molding
Embracing green technologies
plastic injection molding companies are always trying to innovate new technologies
and trends in the industry which are sustainable and reduce waste extraction
from the process as if we use 3D printing before the actual process then there
will be fewer defects in final products.
Energy-efficient machinery
Another way plastic injection molding companies reduce waste
is by using energy-efficient machinery that emphasizes cleanliness, efficiency,
and the reduction of scrap and/or wasted human effort. When plastic injection
molding companies implement such machinery, the consumer can expect a higher
quality product at a lower cost. And injection molding manufacturers can still
gain additional profit from the increased efficiency.
Sustainable packaging and transportation
Sustainability does not end with the product. It is a
central part of everything we do, and that includes the choice of our packaging
materials and the transport. Packaging for plastic and product transportation
should be made of reusable material so you can use it for future deliveries or
returns. Transport has a major impact on our environment due to the CO2
emissions associated with it. Sustainable transport in injecting molding
industry reduces the environmental impact of transporting products.
VII. Conclusion
To conclude, plastic injection molding companies can reduce
waste in a number of ways. By taking steps to improve their manufacturing
processes and recycle their plastic waste, companies can save money, improve
the quality of their products, and help protect the environment. Contact TDL Mould company today to learn more about
how we can help your business reduce waste!
We hope you have found this blog post useful. If you have
any questions or comments, feel free to leave them below. We would love to hear
from you!
