Diversified Plastics, Inc. (DPI) has recently installed six all-electric vertical injection molding presses. These presses will join DPI’s existing assemblage of vertical presses and provide increased production capacity to meet growing demand from medical device and other original equipment manufacturers (OEMs).
“The addition of these presses has tripled our vertical-press capacity,” says Mark Gremmels, director of operations. “Delivering faster output, electric presses are more precise and repeatable for improved quality, which is vital for many medical, aerospace and industrial components.”
DPI uses vertical presses for over-molding and insert-molding, capabilities often required for medical device and technology manufacturing. The rotary table improves efficiency and production speed using a two-mold-back half system. While one part is molded, the operator can preload inserts into the second, B-side tool. After each part is molded, the table rotates for the removal of the finished part; then the next insert is loaded. These efficiencies can reduce cost and time to market.
One of the new presses, a Sumitomo all-electric 50-ton vertical clamp with vertical injection unit, was added to manufacture a complicated over-molded part. This component is used in a product that has realized skyrocketing sales because of its significance during the COVID-19 pandemic.
All-electric presses are more efficient, using less energy than hydraulic presses. Electric presses are equipped with servo motors that operate only when motion is needed. This results in saving nearly half the cost of electricity compared to a similarly sized hydraulic press.
“We sold an underutilized 500-ton horizontal hydraulic press that required 368 square foot of floor space. By placing three of our new Niigata 85-ton vertical presses in that spot, we increased the annual production for that space from 157,000 dollars to a potential of nearly 1.7 million dollars.”