Recently, the Unom team has visited many clients - both large companies and small factories. The deeper we talked, the more we discovered a phenomenon: regardless of the size, the pain points we encountered were surprisingly similar. And the most concerning core issue is——How to improve the yield rate? How to shorten the production cycle? How to reduce energy consumption?
We have compiled the professional content that Mr. Yao gave at the customer site and explained it clearly in three levels.
01Which of the three injection pain points do you have?
01
Pain point one: Drying materials takes a lot of time and electricity, and it's always difficult to fully dry them
nylon
PCThe
POMDrying for 4-8 hours is the norm. What's more troublesome is that the drying bucket can only blow dry the surface, and the internal moisture and volatile substances cannot be discharged at all. As soon as I got on the machine, bubbles, silver wire, and flowers all arrived - the yield rate dropped sharply.
02
Transparent parts have bubbles, silver wires, and fogging
Materials like PC will produce gas during the melting process. If trapped in the screw and unable to escape, there is a high probability of yellowing and black spots.
moldThe exhaust groove can only exhaust the air in the mold cavity and is powerless against the air in the material - the yield rate of transparent parts is particularly low.
03
Recycled materials, modified materials, and powder containing materials are difficult to produce
The moisture content of the recycled material is high, the volatile compounds in the modified material are high, and the carbon powder containing fuel will cause dust and corrosion of the mold when it is dried. Either ordinary machines cannot be used, or they will be scrapped if used - the yield rate of low-cost materials is almost impossible to guarantee.
Automatic discharge outlet for raw material steam
02Mr. Yao said: The root of low yield lies in "qi"
Mr. Yao repeatedly emphasized during communication with customers that there are many product defects——Bubbles, silver threads, floral patterns, yellowing, black spots, floating fibers——The root cause is not in the mold, not in the material,And in the 'qi'.
Unom has installed an exhaust port in the middle of the screw. When the material reached this position, the volume suddenly increased by more than ten times. Under high temperature and pressure conditions, the gas and material naturally separate - as the material moves forward, the gas is actively discharged from the exhaust port.
This explains why:
The gas in PC will not be trapped in the screw,The probability of yellowing black spots is greatly reduced.
Transparent parts have no bubbles, silver wires, or fogging,Because the gas was extracted halfway.
Returned materials and powder containing materials can also be processed,Because impurities and volatile substances do not enter the mold.
Drain the air, and the yield rate will have a foundation. There are many defects that don't need to be adjusted for half a day, they will naturally disappear.
03The yield rate has stabilized, but the cycle is shrinking like this
Mr. Yao continued to explain three logics, which are to shorten the cycle while ensuring the yield rate:
Firstly, the temperature is low and the cooling is fast.
Unom molding temperature is lower than ordinary machines10-20 degreesThe cooling time is naturally shortened, and the the first mock examination is one second faster, which is hundreds of seconds in a day. The yield rate does not decrease, and the cycle is shortened.
Secondly, if there is no gas in the material, injection molding can be accelerated.
Many products require high-speed injection molding, such as nylon and fiberglass, PPS and fiberglass. Ordinary machines are limited by the exhaust of molds and cannot keep up with the speed increase. Unom has already expelled the gas from the material in advance, so there is no need to rely on mold exhaust and it can be injected directly at high speed. High speed does not trap gas, and the yield rate is more stable.
Thirdly, the holding time is significantly shortened.
There is no residual gas in the material, filling is smoother, and the holding time can naturally be shortened.
Founder Yao said, "Taking these dimensions into account, the production cycle of the vast majority of products can be shortened by more than 10%. This is not a theory, but has been verified by a large number of customer cases.On the premise of stable yield rate, the cycle is shorter. ”
04The yield rate has increased, resulting in lower electricity costs
The yield rate has increased, the cycle has shortened, and the energy consumption has naturally decreased:
No need to dry materials:Save the electricity cost of the drying bucket (tens of thousands of kilowatt hours per year), save drying time, and save manual material inspection.
Low temperature molding:Lower heating power and reduced cooling water usage.
Less waste:Each the first mock examination is a good product, which does not waste electricity and materials.
Yield rate → production cycle → energy consumption,Optimizing all three dimensions simultaneously is the true way to reduce costs and increase efficiency.
05Make injection molding simpler, starting from exhaust
What Unom does is actually very simple: exhaust the gas in advance and let the material enter the mold cleanly.
thus:
1. Increase the yield rate (significant reduction in bubbles, material flowers, yellowing, and black spots)
2. Production cycle down (low temperature, fast injection molding, short holding pressure)
3. Reduce energy consumption (no drying, low temperature, less waste)
This is what Unom saidMake injection molding simpler——It's not a slogan, it's about solving a series of problems together from the root of exhaust.
If you are also struggling with yield, long lead times, or high electricity bills, welcome to the Xiangshan factory for a trial mold. Bring your materials, machine a dozen, and see how much the yield can be improved and how much the cycle can be shortened.
Unom - Exhaust the gas, increase the yield rate, shorten the cycle, and reduce energy consumption.
