Venture Plastics Improves Molding Quality, Productivity And Profitability Through Decoupled Molding
7/7/2011
Venture Plastics, Inc. --- a full-service, ISO/TS-16949 certified custom thermoplastic injection molder with processing facilities in Newton Falls, Ohio and El Paso, Texas --- has implemented a decoupled molding program aimed at enhancing the stability of its processing system to achieve molded parts with reduced-or-no defects.
The initiative is based on the Decoupled III Process, a program developed by RJG, Inc. to optimize the injection molding process by using process data (such as temperature, flow rate, pressure, cooling rate and time) to identify and correct viscosity variations inherent in polymers that are the root-cause of product defects.
"Adding decoupled molding to any plastics processing operations is a challenging undertaking ," stated Jim Smith, V.P. Operations, Venture Plastics. "It is a significant financial investment, requires extensive training for the staff, and demands consistent effort by the engineering department to fine tune all of the essential components. The payoff, however, is dramatic. We can now provide customers unsurpassed process repeatability."
James Monroe, Manufacturing Engineer, Venture Plastics, elaborates: The RJG Decoupled III Process enables us to maintain consistency in the three stages of molding: fill, pack and hold. To give you an example of how important that is, on one part alone --- an automotive instrument bracket --- we have been able to reduce cycle time by 2%, reduce scrap by 1.5%, reduce part weight by 4%, and have achieved a total part cost saving of 12.5%. We are pleased and our customer certainly is too!"
Decoupled molding, which focuses on the behavior of the material, not process set points, is based on sensors that are strategically located inside the mold for the purpose of enabling engineers to control cavity pressure, viscosity, and melt temperature --- thereby also controlling dimensions and limiting variations in the part being molded.
Since its founding, 40 years ago, Venture Plastics has grown dramatically and today provides manufacturing services that include injection molding and structural foam molding, over-molding, insert molding, and gas-assist molding --- all backed by engineering and design support and project management. Value-added processes include a wide variety of assembly, painting and decorating, and packaging expertise. Between its two facilities Venture Plastics offers a wide range of injection molding machines (55 ton to 725 ton), giving it the capability of serving a diversified customer base that includes, but is not limited to, the major markets of industrial/consumer, major appliance, truck/agriculture, automotive, fuel delivery, and communications.
For more information on Venture Plastics: Bryon Osborne, V.P.- Sales & Marketing, VENTURE PLASTICS, INC. P.O. Box 249 4000 Warren Road Newton Falls, Ohio 44444 Phone: 330.872.5774 Fax: 330.872.3597. E-mail: bosborne@VenturePlastics.com
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