Carclo Technical Plastics (CTP) provides custom injection-molded components and assemblies, as well as two-shot molding, insert molding, clean room capabilities, optics, and a full complement of secondary and decorating techniques. The company has manufacturing facilities in the US, UK, China, and the Czech Republic. At its 24,000 square foot Export, PA site, CTP operates 14 injection molding machines ranging in tonnage from 110 to 250 tons that generate mostly disposable medical components.
CTP manufacturing manager Jim Ritenour says the Export facility has been operating Mold-Vac gas and air vacuum systems from CAE Services (Batavia, IL) for many years. Mold-Vac units eliminate molding problems caused as a direct result of gas and air entrapment inside molds. Exclusive to Mold-Vac is its blowback control that cleans vented pins after every cycle. Mold-Vac provides precise microprocessor control for both vacuum and blowback timing functions.
Ritenour says, “The Mold-Vac units here have been of tremendous help over the years. Approximately 10 years ago, when we experienced both air and gas entrapment causing bubbles in parts, we initially installed the Mold-Vac 2,000 models. After perhaps three years, we upgraded to the Mold-Vac 10,000 system. Our fill rates are extremely fast generating millions and millions of parts. The Mold-Vac 10,000 upgrades do an appreciably better job of exhausting all the gas out of the mold cavities. Today, we are using seven Mold-Vac machines and plan to purchase several more.” CTP’s UK facility is using three Mold-Vac units.
Using the Mold-Vac System 1,000, Ritenour says his shop floor technicians performed preventative maintenance every four to six weeks. “When we replaced those units with Mold-Vac 10,000 machines, we were able to extend preventative maintenance to nearly eight weeks. That is a big deal considering preventative maintenance involves shutting down the system, tearing down, inspecting, cleaning, and reassembling the tool – a full eight-hour shift. Being able to operate tools longer helps us adhere to tight production schedules and remain competitive,” Ritenour adds.
As a matter of fact, CTP conducted a Six Sigma project focused on mold maintenance approximately two years ago. In going through that process, Ritenour says his team was able to streamline mold maintenance. “We not only eliminated existing problems, but the study results determined that using the Mold-Vac systems helped our overall mold maintenance processes,” Ritenour adds.
In addition, he says that using the Mold-Vac 10,000 units have improved mold venting. “Now, when we disassemble the molds, there is not as much residue build-up in the mold. So we know the Mold-Vac devices are doing a good job of keeping the molds free of unwanted build-up. We know that residue build up in the vent pins impacts part quality and mold maintenance. Using Mold-Vac units helps us fill tools much faster which results in faster cycle times.”
Because the Mold-Vac units are vital to CTP’s operations, Ritenour and his team design the company’s tools with the Mold-Vac units in place as part of tool specifications. He says the Mold-Vac systems are easy to install and operate. No special technicians are necessary.
Turn the Mold-Vac off?
Ritenour said he and his team wanted to see what would happen if they turned the Mold-Vac units off. “After we tried that, we discovered that we could run the tools for only three weeks without preventative maintenance. Residue quickly built up in the vents and vent pins causing us to revert to preventative maintenance much more often. We wasted a lot of critical production time as direct result of eliminating the vacuum system. The expensive downtime for frequent preventative maintenance can have serious consequences in terms of meeting production schedules. For any manufacturer who might question investing in a quality vacuum system such as Mold-Vac, I would say there is nothing lost in trying out a unit. From our experience using them, we have definitely improved cycle and run times. And, in today’s competitive global marketplace, the Mold-Vac units help us retain product quality and, ultimately, customer satisfaction.”
What’s more, Mold-Vac units are part of CTP’s lean manufacturing processes. “US companies that want to retain customers here have to hone talents and abilities in the most efficient methods possible,” says Ritenour. “Practicing lean manufacturing prevents customers from going abroad for products and services. While it can be challenging to work in a leaner manufacturing environment, the results are often worth the effort.”
Ritenour says the greatest benefits of using the Mold-Vac units are the extended preventative maintenance by up to three weeks and elimination of gas and air entrapment issues. “We are very satisfied with the Mold-Vac systems that we have purchased over the years. I have thoroughly enjoyed working with Mark Solberg of CAE Services. He and his team have been nothing but professional, congenial, and very helpful. They deliver a high-quality product and provide follow up expertise whenever necessary.”
