Tool and die makers in India | Plastic Mould Manufacturer
15/1 Rama Road
Kirti Nagar Delhi-110015 India
+91 8883912346
asia@hongyijig.com
Certified
ISO 9001:2015
FMCG
INJECTIONMOULD
- THIN WALL CONTAINERS
- FOOD CONTAINERS
- CAPS & ENCLOSURES
- FLIP TO CAPS
- CABLE TIES
- DOUBLE COLOUR MOULDS
- IMD MOULDS
- CABLE GLENDS
- MULTI CAVITY SOLUTIONS
- SPRAY CAPS
FMCG
INJECTION MOULD
- THIN WALL CONTAINERS
- FOOD CONTAINERS
- CAPS & ENCLOSURES
- FLIP TO CAPS
- CABLE TIES
- DOUBLE COLOUR MOULDS
- IMD MOULDS
- CABLE GLENDS
- MULTI CAVITY SOLUTIONS
- SPRAY CAPS
CASE STUDY
DOUBLE COLOR ROTATING MOULD
CASE STUDY
Efficient Moulds | Quality Production
The Solution for Double Color Rotating Mould
Challenge: A packaging company needed an injection mould that could produce high-quality oil bottle caps in large quantities, with 4 cavities and a rotating platter.
Solution: A mould manufacturer used a 2K injection moulding process, which used two different materials (polypropylene and thermoplastic elastomer) to produce the cap. The mould was designed with 4 cavities and a rotating platter to increase production output and reduce manufacturing time. The mould was made with high-quality materials and was easy to use and maintain, minimizing downtime and production losses.
Result: The mould produced high-quality caps in large quantities, meeting the packaging company’s demand. The rotating platter enabled the mould to produce four caps per cycle, reducing production time and increasing output.
Conclusion: The successful project demonstrated how advanced technology can be used to meet the growing demand for high-quality packaging products. The mould’s design and material selection played a crucial role in ensuring its success.
CASE STUDY
OIL CAP | 48 CAVITIES
Objective:
Design and manufacture an injection mould for oil caps with 48 cavities and Mastip hot runner system. The mould should have a cycle time of 8 seconds and be made of S136 tool steel and P20 mould housing steel. The tooling lead time should be 60 days to T-1. The customer is in the packaging business and supplies oil caps to an oil manufacturing client.
Design and Manufacturing:
The mould design was based on the customer’s existing oil cap sample. The 48-cavity mould was designed with a Mastip hot runner system for consistent and precise flow of molten plastic. The tooling was made of S136 tool steel and P20 mould housing steel. The tooling lead time was 60 days to T-1.
Results:
The injection mould was completed within the 60-day lead time and produced high-quality oil caps with a cycle time of 8 seconds. The Mastip hot runner system ensured consistent and precise flow of molten plastic into each cavity.
Conclusion:
The injection mould for oil caps with Mastip hot runner system was designed and manufactured to meet the customer’s specifications and requirements. The tooling lead time of 60 days to T-1 ensured timely delivery of the mould, allowing the customer to supply high-quality oil caps to their oil manufacturing client.
CASE STUDY
OIL CAP | 48 CAVITIES
Oil Packaging Cap Enclosures | Mastip Hot runner with Valve gate
The Solution for Multi cavities Injection moulds
CASE STUDY
AIR TIGHT FOOD CONTAINER
Objective:
Design and develop an entire family set of airtight food containers for DLJM JEE PEE Plus brand. The containers needed to have an air tight and leak-proof design to ensure the freshness and quality of the stored food. The mould material chosen was P-20, and the lead time for development was set at 3 months.
Design and Development:
We designed the entire family set of airtight food containers, including containers of different sizes and shapes. The designs were subjected to DFM and Moldflow analysis to ensure they were feasible and manufacturable. Once approved, we commenced the tool manufacturing process. The moulds were made of P-20, a popular choice for injection moulding due to its good machinability, polishability, and thermal conductivity.
CASE STUDY
FOOD CONTAINER
Air Tight Food Container| Yudo Hot runner with Valve gate
The Solution for Air Tight Containers Injection moulds
Results:
The entire family set of air tight food containers was successfully designed and developed within the 3-month lead time. The containers had an air tight and leak-proof design, ensuring the freshness and quality of the stored food. The moulds made of P-20 ensured high-quality production and long-lasting durability.
Conclusion:
We successfully designed and developed an entire family set of air tight food containers for DLJM’s JEE PEE Plus brand. The containers had an air tight and leak-proof design, ensuring the freshness and quality of the stored food. The use of P-20 as the mould material ensured high-quality production and durability.
CASE STUDY
THIN WALL FOOD CONTAINER
Objective:
Design and manufacture an injection mould for oil caps with 48 cavities and Mastip hot runner system. The mould should have a cycle time of 8 seconds and be made of S136 tool steel and P20 mould housing steel. The tooling lead time should be 60 days to T-1. The customer is in the packaging business and supplies oil caps to an oil manufacturing client.
Design and Manufacturing:
The mould design was based on the customer’s existing oil cap sample. The 48-cavity mould was designed with a Mastip hot runner system for consistent and precise flow of molten plastic. The tooling was made of S136 tool steel and P20 mould housing steel. The tooling lead time was 60 days to T-1.
Solution Provided:
Our team conducted a DFM study and Moldflow analysis to optimize manufacturing efficiency and ensure compatibility with materials and hot runner system. We used S136 tool steel for the core and cavity and P-20 for the mold housing, along with a Yudo hot runner system for faster and precise filling. The outcome was an 18% reduction in container weight with maintained strength and durability. The cycle time of 8 seconds was achieved, reducing the production time and costs for the client.
Conclusion:
Through a thorough analysis of the container design and material properties, coupled with advanced simulation and tooling techniques, we were able to successfully reduce the weight of the container and improve the cycle time of the mold, making our client more cost-competitive in the market. Our expertise in DFM, Moldflow analysis, and tool design helped us achieve this goal, ultimately resulting in a satisfied client and a successful project.
CASE STUDY
THIN WALL FOOD CONTAINER
Thin Wall Food Container
The Solution for Thin Wall Container Injection moulds
CASE STUDY
OIL CAP​
Introduction:
Our client, a packaging company specializing in oil bottles, approached us with a challenge to develop an oil bottle cap with a unique seal geometry that breaks equally from all sides while opening. We were tasked with creating an injection mould that can produce caps in large volumes.
Challenge:
To develop a cap with a seal that breaks equally from all sides, we reverse-engineered an existing cap design. We also needed to create an injection mould with an unscrewing mechanism to unscrew the thread shape in the cap during ejection.
CASE STUDY
OIL CAP
Oil Cap
The Solution for Unscrew Injection moulds
Solution:
We developed a 4-cavity injection mould using H-13 material, equipped with a Yudo hot runner system and unscrewing mechanism to ensure uniform unscrewing of the thread shape in the cap.
Results:
Our injection mould produced high-quality caps that met our client’s specifications. The unscrewing mechanism ensured uniform unscrewing, preserving the seal’s integrity, while the 4-cavity mould allowed for large-volume production.
Conclusion:
The project was challenging but successful, and our client was pleased with the results. Our technical expertise and the use of H-13 material, Yudo hot runner system, and unscrewing mechanism resulted in consistent, precise cap production.
CASE STUDY
TOOTHBRUSH
Introduction:
Our client, a toothbrush manufacturer, tasked us with developing a next-generation toothbrush that incorporated toothpaste and a toothpick into a single design. We presented design options to the client and developed a functional prototype.
Challenge:
The main challenge of this project was to develop a toothbrush that could dispense toothpaste through a spray mechanism while incorporating a toothpick into the design.
Solution:
We developed a toothbrush design with a spray mechanism on the back and a toothpick incorporated into the handle. The toothbrush used a 2K moulding process with transparent elastomer (BR003) and TPE materials. We developed 13 moulds for production, including the spray mechanism. Tool steel S136 was used for the moulds, and P20 for the mould housing.
Results:
Our toothbrush design was successful, with the toothpaste spray mechanism dispensing accurately and the toothpick incorporated seamlessly into the handle. The transparent elastomer and TPE materials provided a comfortable grip, and the core rotating moulds allowed for efficient production.
Conclusion:
This project was a challenge, but we were able to develop a next-generation toothbrush that met the client’s requirements. The 2K moulding process and core rotating moulds allowed for efficient production, while the use of high-quality materials ensured a comfortable grip. The functional prototype was successful, and our client was satisfied with the results.