BUNG TEMPLATES – 32 AND 48 CAVITIES
Brazil
The challenge passed on by our Client involved finding a solution to replace mould that was in use at that time, but that had a very high cycle time and had a history of many breakdowns of delicate components. The injected plastic part included a Ø 0.25mm through hole – which requires an insert with this diameter in the mould. There was a very large waste with the injection channel, as the product did not offer a suitable region for the injection point if a conventional hot chamber was used.
Our experience acquired over the years has allowed us to improve manufacturing processes, enabling the production and repeatability of so-called critical/delicate components. For this project we proposed a totally different approach to the movement mechanisms of the slats during mold closing in production. In order to solve the problem with waste in the injection channel (raw material), we incorporated into the Project the injection system with MeltCube® – at the time, the largest system ever implemented in the world – reinforcing our tradition of applying the most modern solutions technologies for our Clients.
For injection of Batoque Product, we deliver to the Client 1 mold with 32 cavities and 1 mold with 48 cavities. We solved the issues related to the cycle (from 22 s dropped to 12 s) and the constant breakage of the pins that make the bung hole with diameters of 0.25mm and 0.28mm (the incidence of breakage of toupees was reduced by 93%). With this, the BTOMEC Molds reduced the consumption of raw material during injection, met the level of performance desired by the Client and, in addition, we maintained CP and CPK ≥ 1.33 in the product’s critical quotas.
COVER TEMPLATE – 48 CAVITIES
Argentina
To meet the demand and the specific need for the cap created by the Client, the main challenge of this project was to develop a mould with multiple cavities together with a system that closes the lid still inside the mould (IMC – In Mould Closing).
With our history of solutions that meet the needs of our Clients in various applications and segments, we apply our experience with IMC systems and in different configurations to this Project.
We deliver to the Client a 48-cavity flip-top Lid Mold with IMC (In-Mold Lid Closing System) system included.
The fact that the Mold has 48 cavities makes it very difficult to place the IMC system, however, with the expertise of our Project and Production Team, we made the delivery even further promoting our Client a 20% reduction in the cycle.
BI-COMPONENT MOULDS – 64+64 CAVITIES
Brazil
The Client needed a Bi-component mould for injection of a plastic part that would act as a barrier against the entry of oxygen into the toothpaste packaging. This problem was causing changes in the sensory characteristics of the product (flavor and taste) – that is, impairing the success of the product in the consumer market.
BTOMEC invested in its own machine for mold testing, with the possibility of three simultaneous injections, which gives our company differentiated experience and “know-how” in multicomponent molds. Thus, in order to offer the complete solution to the Client, 03 Molds were developed with SpinForm® technology with 64 + 64 cavities, eliminating the need to assemble the two components, to generate consistent productivity gains.
The company received the solution through 03 molds with 64 + 64 cavities (diameters 25/35/38 mm), totally interchangeable. Allowing for productivity gains and cost reduction with maintenance parts inventory.
COVER TEMPLATE – 6 CAVITIES
Brazil
The biggest challenge of this project was to unite the large diameter of the lid with the need to close it still in the mould (IMC – In Mould Closing).
All the experience acquired by our team over the years, in different mold configurations in different segments, allowed us to offer this Client the ideal solution for the Project’s challenge.
We deliver to the Client a mold with 06 cavities for a flip-top lid of Ø 100mm and IMC system.
The system worked perfectly with high production performance and quality, with a cycle below the Client’s expectations, generating significant gains in productivity.
Ø 35 SNAP FLIP TOP COVER TEMPLATE – 24 CAVITIES
Brazil
The challenge of this project was to develop a mould with multiple cavities together with the lid closing system (IMC – In Mould Closing), also considering lowering the cycle time.
With our history of solutions that meet the needs of our Clients in various applications and segments, we apply our experience with IMC systems and in different configurations to this Project.
We deliver to the Client a 24-cavity flip-top Lid Mold with IMC system (in-mold lid closure system) included as well as reducing the cycle time from 23 s to 12.46 s. In addition, our Project reduced the weight of the lid by 10%, allowing the Client to consume less raw material.