10 Benefits of Plastic Injection Moulding for Manufacturing

Plastic injection moulding is a widely used manufacturing process in companies that manufacture plastic parts with precision and consistency. In this process, molten plastic is injected into a mould cavity using an advanced injection moulding machine. It has numerous advantages, particularly its ability to support high-volume production, complex designs, and cost-effective mass production.

Let's explore all the major benefits in greater detail!

Top 10 Benefits of Plastic Injection Moulding Process

The growing adoption of plastic injection moulding across industries is driven by its efficiency, scalability, and reliability. From consumer goods to industrial components, this manufacturing technology enables businesses to produce consistent and high-quality outputs. 

1. High Accuracy and Precision

One of the primary advantages of the plastic injection moulding process is that it offers extremely high levels of accuracy and precision. The process allows the molten plastic to flow under controlled pressure and speed of injection, enabling manufacturers to produce components with very narrow dimensional tolerances.

Since the molten material is injected within a sealed mould cavity, manufacturers can repeatedly produce similar components without any dimensional variation. The use of advanced complex moulds with multiple cavities, threads, and undercuts also enables greater precision. This level of control is difficult to achieve through CNC machining or sheet metal fabrication, especially at scale.

2. Wide Range of Injection Moulding Materials

Another benefit of the injection moulding process is that it supports a wide range of injection moulding materials. Companies have the option to select from a number of plastic materials, such as Polypropylene, Polyethylene, PVC, PET, and ABS.

In addition to plastic materials, injection moulding supports rubber injection moulding, liquid silicone rubber, and other elastomeric materials with similar mechanical properties, such as flexibility, resilience, and heat resistance. This versatility allows manufacturers to switch materials without altering the core injection moulding process.

3. Cost-Effective Manufacturing

Injection moulding is recognised as a low-cost method for manufacturing high-volume plastic products. After the initial investment of developing the tooling and custom mould, the cost per unit will decrease with increased production.

Automated control of the mouldings and labour, and decreased rework reduce production costs. When compared with a variety of other manufacturing processes, injection moulding is an economical method for mass production of plastic products.

4. Low Material Wastage

Due to the efficient utilisation of raw materials, the plastic injection moulding process generates small amounts of material waste. Most of the excess molten material produced during the moulding process can usually be recycled and reused.

Through proper design of the gate and runner systems, the material can be evenly distributed throughout the mould, thus minimising defective parts resulting from trapped air or improper filling. Through the reduction of waste and recycling of materials, injection moulding is a sustainable manufacturing option with lower overall production costs.

5. Design Flexibility

Injection moulding provides an unparalleled amount of design flexibility, enabling manufacturers to produce components with complex geometries and uniform wall thicknesses. Manufacturers can incorporate features into their moulded parts, such as insert moulding, ribs, textures, and logos, directly into the mould.

Manufacturers can choose to use aluminium moulds for smaller production runs, or steel moulds or hardened steel moulds for long-term, high-volume applications. The design flexibility afforded by the injection moulding process enables manufacturers to produce plastic products in desired shapes that meet both functional and aesthetic requirements.

6. Consistent Output Quality

One of the distinguishing features of the plastic injection moulding process is the consistency of the quality of the outputs. Every step of the injection moulding cycle, from clamping to injection to cooling and ejection, is strictly regulated.

Quality monitoring systems track key parameters such as shot nozzle temperature, injection pressure, and cooling time. As a result, each batch of moulded plastic components manufactured will retain the exact same physical and dimensional characteristics even during prolonged production runs.

7. Reduced Labour Costs

Modern injection moulding machines are largely automated. The majority of the steps involved in the manufacturing process, once the moulding machine has been set up and the raw materials have been fed into the heated barrel, the system operates continuously with minimal human involvement.

This automation ensures continuous movement of the raw materials and strict control over all aspects of the manufacturing process. As a result, labour dependency and potential for human error are greatly minimised, and the efficiency of the manufacturing process is greatly enhanced in high-volume manufacturing environments.

8. Minimal Post-Processing Requirements

As a direct result of the high degree of precision achieved through the plastic injection moulding process, moulded plastic components typically do not require any post-manufacturing processing. Smooth tooling surfaces and accurate mould design eliminate the need for sanding, trimming, or polishing.

Components are released from the ejector mould using ejector pins, ready for immediate use. This reduces additional processing time and further contributes to lower moulding costs.

9. Environmental Benefits

When compared to a variety of other manufacturing processes, plastic injection moulding is environmentally friendly. The lower material waste, recyclability of plastic resin, and the energy-efficient nature of modern injection moulding machines minimise the impact on the environment.

Advanced systems prevent issues such as too much shear heat, shear heat burning, and material degradation, which can otherwise result in inferior mechanical properties. Temperature regulation using an external temperature controller also ensures efficient energy use.

10. Faster Production Cycles

Injection moulding is well-known for its rapid production cycles. Through automated control of injection speeds and cooling times, manufacturers are able to complete each moulding cycle rapidly.

Faster cycle times provide manufacturers the ability to meet tight deadlines and produce moulded components in high-volume production environments while maintaining the consistent quality of the moulded components.

How to Purchase Plastic Injection Moulding Equipment for Your Factory

Investing in the right injection moulding machine is critical for long-term operational success. Here’s what you need to consider:

1. Understand the Plastic Components You Plan to Mould

Prior to investing in equipment, manufacturers should clearly outline the plastic components they plan to manufacture in the desired shape. Important factors include part size, plastic materials to be used, mould cavity dimensions, anticipated cycle time, and regulatory compliance requirements.

Without a clear identification of the components to be manufactured before purchasing the equipment, manufacturers may incur quality-related issues, damage to the equipment, or inefficiencies in the manufacturing process.

2. Choose the Right Type of Injection Moulding Machine

Plastic injection moulding machines are available in three configurations: hydraulic, electric, and hybrid. Each type affects the energy consumption, injection speed, and operational efficiency.

For instance, energy-efficient servo systems are particularly beneficial in applications requiring high precision, lower energy consumption, reduced noise, and consistent performance. This is especially true during frequent start-stop cycles and cooling phases.

3. Determine the Required Clamp Tonnage

Clamp tonnage can be determined using:

• Manufacturer or supplier recommendations.

• Simulation software.

• Manual calculation based on cavity pressure, surface area, and material.

Choosing the correct tonnage will help to avoid issues with moulded parts such as flash or insufficient filling.

4. Select the Appropriate Injection Unit

Manufacturers can select from multiple injection unit sizes for a single machine tonnage. The correct unit size will ensure consistent pressure, efficient flow of material, and a constant supply of molten plastic to the mould.

To Conclude

Plastic injection moulding is a highly efficient manufacturing process to produce plastic parts in high volumes. The plastic injection moulding process supports design flexibility, consistent quality, and low wastage. It also supports faster cycles, making it ideal for scalable manufacturing operations.

To enable such growth, Poonawalla Fincorp provides Business Loan solutions to manufacturing businesses. This funding allows you to invest in plastic injection moulding machines and expand production capabilities. Apply now for this loan to enjoy competitive rates, flexible repayment schedules, and fast disbursals.

Read Also: How Machinery Loans for MSMEs Are Useful to Grow the Business?

FAQs

Which loan is best for a manufacturing business?

For manufacturing businesses, a Business Loan is among the most common and preferred financing options. Business Loans can be used to finance the purchase of machinery, production expansion, and working capital management. It is particularly suitable for manufacturing companies with heavy expenditures.

Who is eligible for a Business Loan?

Qualification for a Business Loan is primarily dependent on business vintage, revenue, credit history, and financial health. Manufacturing companies that demonstrate a stable source of income and proper documentation are generally qualified to apply for a Business Loan.

Can I get a loan for a plastic injection moulding machine?

Yes, a Business Loan can be used to purchase a plastic injection moulding machine. This helps manufacturers add or upgrade equipment while preserving liquidity for raw materials, labour, and day-to-day operations.

Can a Business Loan be used for manufacturing expansion?

Yes, Business Loans can be used for the expansion of manufacturing, beyond machinery purchase. This may include the expansion of production capacity, the introduction of new product lines, or the expansion of facilities to cater to the increasing demand.

How does Poonawalla Fincorp support manufacturing businesses with Business Loans?

Poonawalla Fincorp provides Business Loan solutions that cater to manufacturing businesses. Our funds help manufacturing businesses with machinery investments, operational expansion, and working capital requirements.

We offer competitive interest rates, flexible repayment terms, minimal documentation, and fast disbursal to help your business scale easily.