Production and Technology in India
Equipment
The park of the main production equipment is represented by injection moulding machines of the world leading manufacturers: Engel, Krauss Maffei, Husky with clamping force from 60 to 5500 tonnes. This equipment is used to produce injection moulded products: large-size containers, containers for solid waste, plastic pallets, crates, storage trays.
Production facilities also include extrusion lines using BubbleGuard® and Diamond® technologies, as well as honeycomb and solid sheet lines.
Uninterrupted operation is ensured by peripheral equipment from Piovan, Kuka, Jansen&Dieperlink, Motan
and
others.
Raw materials
For production we use high-quality domestic and imported raw materials (polypropylene, polyethylene and their mineral-filled compositions) from such manufacturers as Sabic, Sipchem, Chevron, Natpet, Tasnee and Borouge.
Quality control
- incoming raw material control;
- continuous production control;
- systematic quality control of manufactured products.
Control of raw materials and finished products is carried out by the factory laboratory.
We do everything to ensure that the company's products meet the world standards!
Technologies
The company has the most modern technologies for moulding and processing of plastics:
- Low-pressure moulding with structural foaming
- Extrusion (profile, flat-slot, extrusion with subsequent formation of the middle layer)
- Pneumatic-vacuum moulding
- TwinSheet thermoforming
In addition, there are options for additional processing of the finished product: rolling, welding, punching and printing.
Technologies
INJECTION MOULDING
The last decades have been a period of rapid development of plastic injection moulding technology. Advantages of this technology:
- low energy consumption during moulding due to relatively low processing temperatures;
- direct path from raw material to final product (one-step process operation, no rework required).
Injection moulded products include IBox containers, waste containers, plastic pallets, KLT containers, storage trays, some specialized products.
Injection moulding is a method of processing polymeric materials by injection moulding, mainly used for the manufacture of thermoplastic products.
Injection moulding is carried out at a pressure of 80-140 MPa on injection moulding machines of piston or screw type, which have a high degree of mechanization and automation.
In the injection moulding process, the injection moulding machine performs the following operations in sequence:
- heating of the material and its conversion into a viscous-fluid state;
- homogenisation of the melt;
- injection of a certain dose of melt into the mould cavity;
- holding the polymer in the mould until the product cools down and hardens;
- opening of the mould and removal of the finished product.
Injection moulding makes it possible to produce parts weighing from a few grams to dozens of kilograms.
EXTRUSION.
Flat and profile extrusion allows to produce cellular polypropylene sheets with thickness from 2-2.5 mm to 12 mm and web width up to 2000 mm.
Flat sheets are produced by feeding the melt from the flat-slit head onto the surface of the cooling calander. Calibration of geometrical parameters (first of all, thickness) of the finished sheet is made both by adjusting the head gap and by adjusting the rotation speeds of calander and receiving rolls.
Cellular polymer sheet is produced on extrusion lines equipped with profile heads. After the extrudate leaves the head, it enters the calibrating device of vacuum-forming plates, where, along with intensive cooling of the sheet, the final formation of the internal structure of the profile takes place.
Annealing furnaces are used to relieve internal stresses arising in the sheet structure. Immediately afterwards, the sheet is cooled with an intensive air stream, after which the side edges of the sheet are trimmed and finally the sheet is end trimmed with a guillotine knife.
Extrusion lines with BubbleGuard® and Diamond® technology are equipped with additional vacuum forming rolls. Extrusion is carried out through three/four flat-slot heads, after which the center sheets are vacuum-formed. This produces a center profile layer which is then welded to the outer layers. The finished polymer sheet has a cellular structure, which significantly enhances the physical and mechanical properties of the sheet and provides high stiffness and strength at a density lower than that of honeycomb sheet.
PNEUMATIC OR VACUUM FORMING
Main stages of the pneumatic-vacuum moulding process
2. Heating of the blank to the temperature corresponding to the highly elastic state (when processing amorphous thermoplastics) or to the melting point (when processing partially crystalline thermoplastics).
3. Positioning the heated workpiece over the mould.
4. Moulding the workpiece into a product under the effect of a pressure differential above and below the workpiece. The difference (differential) pressure can be created in various ways: vacuuming the volume under the moulded workpiece, creating excessive pneumatic pressure over the workpiece, impact on the workpiece by various mechanical pushers, etc.
5. Cooling of the finished product after the flat workpiece has taken the shape of the finished product under the influence of differential pressure.
The advantage of pneumo-vacuum forming, in comparison with other methods of plastics processing, is the possibility of using both inexpensive equipment and very cheap technological tooling when obtaining small series or single products, and fully automated and robotised technological lines for large-scale production.
When choosing a processing method, it should be taken into account that sheets and films are always more expensive than granulated raw materials. In addition, injection moulding can produce products with more complex configurations than pneumatic vacuum forming.