In the fast-paced world of manufacturing, efficiency is paramount. Every second shaved off a cycle time translates directly to higher profits and a competitive edge.
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When it comes to injection moulding, tooling design is often the foundation upon which everything rests.
Supercharging production
One SyBridge client, a manufacturer of plastic dosing scoops, faced a common challenge: production couldn’t keep up with demand. They were running four 175-ton injection moulding machines 24/7. Each existing 12-cavity tool had a 9.5-second cycle time and produced 110,000 parts per day, but it simply wasn’t enough.
Phase 1
SyBridge engineers evaluated the customer’s existing equipment, systems, and output needs, then designed a new 12-cavity tool using solutions for filling and cooling the component. Upon installation, they realised a 5.0-second cycle time, a 47% reduction from their previous 9.5-second cycle time. This translated into an 88% increase in daily production with the same machine, producing 207,000 parts per day.
Phase 2
Building on this "success", SyBridge engineered another tool, this time with 16 cavities; as before, the cycle time was at 5-seconds, and the higher-cavitation tool was still able to run in the same 175-ton presses. This powerhouse pushed daily production even further, reaching 275,000 parts – a 150% increase from the original tool.
The proof is in the ROI
The manufacturer not only met demand but was also able to get ahead of it, opening up opportunities for new sales growth. SyBridge tooling solutions delivered production gains that the customer was able to recoup their tooling investment in less than 6 months. The customer was also able to better schedule planned maintenance, extending the life of the tools and leading to additional long-term financial benefits.