One of Singapore's leading plastic manufacturers, Meiban, has positioned itself at the forefront of molding technology by the introduction of the patent-pending Sequential Mold Technology (SMT). This innovative and breakthrough concept allows the implementation of multiple molding layers on a single standard molding machine via the use of a portable intelligent control system, the Independent Tool Controller (ITC). Traditional approaches require Stack molding machines or Tandem molding machines. With cost savings in mind, the non-requirement of these expensive systems is already providing SMT a head-start in the race to reduce overheads and improve production efficiency in the manufacturing industry.

Process overheads in molding have always been due to the following key factors: cycle time, cavitation capacity and machine tonnage. Imagine a system that allows you to maximize your cycle time, double the cavitation, while maintain similar machine tonnage. That's Sequential Mold Technology!

Sequential Mold Technology is the use of 2 or more molding layers to alternately produce parts. A simplified molding process can be explain in the sequence of injection, cooling, part ejection, with cooling taking the bulk of the cycle time and commonly referred to as dead-time. In Sequential Molding, the cooling sequence of one molding layer is also the Injection sequence of the secondary molding layer.

A simplified flowchart is shown below:

By minimizing the dead-time, a single-layer molded part that requires 40 seconds can be produced on a Sequential mold that ejects part every 20-25 seconds alternately from its double molding layer. That.s cycle time reduction and cavitation increase at the same time!

The uniqueness of Sequential Mold Technology is enhanced by the Independent Tool Controller in that a standard molding machine can be easily converted into a technological marvel that can operate a sequential molding layer tool. Imagine a system that can operate on your 220 Ton machine today, your 350 Ton machine tomorrow, and your 850 Ton next week. That's the Independent Tool Controller!

The savings enable by Sequential Molding is not only limited to a multiple molding layer that increases cavitation capacity, but also the number of molding machines required to meet production requirement. If you traditionally require two 450 tons machines operating two 2-cavity molds, Sequential Mold Technology could have just one 450 tons machine operating a 2+2 cavity Sequential Mold.

Sequential Mold Technology is ideal for flat parts (for daylight maximization), and parts with long cooling cycle time. The longer your cooling cycle time is, the better the savings that can be achieved. For parts that have high cosmetic requirements, the Sequential Mold can be used to increase the cooling cycle time per part, without increasing the process cost.

The Independent Tool Controller is easy to install and compatible with most molding machines. It's 'Plug n Play' for machines with Euromap connectors. For non-euromap connector machines, a plug-in part can be created for ease of interface.

This article was written by member of Blitz Team.