Increased automation capabilities, growth for Plastikos

Erie, Pennsylvania – As Micro Mold and Plastikos continue to experience strong diversified sales growth, so too has the customer demand to diversify into new materials, technology, and manufacturing capability. Recently, Plastikos was awarded a program from a large global medical device OEM who develops enteral feeding systems (among other devices). The finished component consists of rigid substrate material that is over-molded with a flexible thermoplastic polyurethane (TPU). The TPU material acts as a sealant whenever the device is not in use.

The operation is heavily automated in order to support the yearly demand on the finished device. A high-speed robotic center was custom designed to properly load the rigid substrate into the second multi-cavity tool, unload the finished over-molded component, and monitor shot-to-shot consistency throughout the injection molding process. The tool is fully equipped with cavity pressure transducers that are integrated into the robotic work center. This way, individual cavities can be automatically sorted/scrapped in the event of a potential non-conformance.

Plastikos’ Manufacturing Manager, Rob Cooney, commented, “The real challenge was ensuring all elements of the supply chain were communicating effectively with one another. We needed to make sure that the robot would fit within the space limitations of the molding machine and complete all phases of loading, unloading, and detection sequence.”

During the past year, Plastikos invested more than $500,000 in automation and robotic centers throughout the facility. “We are continuing to look at ways to automate our manufacturing-related process such as: packaging, inspection, raw material, finished product handling, and so on. This new automated manufacturing cell should open the door to other exciting opportunities,” said Cooney.

Plastikos’ top management also built a sizable cleanroom assembly area within the company’s larger ISO 7 cleanroom. The company also recently purchased two additional medical molding machines in August 2015 that range from 88 tons to 220 tons of clamping force. Both machines are fully integrated with 3-axis robots and end-of-arm tooling capabilities, cavity pressure monitoring systems, advanced process monitoring software, integrated hot runner systems, and mold-protect vision systems, as well as integrated into Plastikos’ corporate IQMS ERP system. The medical division expansion was completed in June 2015 and is built to house eight molding machines with dedicated quality, tool room, mold vault, and office space.

Philip Katen, president of Plastikos commented, “We continue to see a growing need from our medical customer base to take on more advanced manufacturing and component assembly work that expands beyond our precision tool making and injection molding service offerings. Our cleanroom assembly area within our brand new medical expansion will likely be dedicated towards a range of secondary operations such as: ultrasonic welding, custom labeling, and other value-added operations.”

Source: Plastikos, Inc. & Micro Mold Co. Inc.