Injection Moulding
Blow Moulding
Blow Moulded Tank
Film Application
Pale Container Application
Extrusion Application
Woven Sack Application
Injection Moulding Applications
We Provide all types of injection moulded products solutions like cost, quality & properties etc. Bajaj also provides high efficiency and fast production, Injection Molding can handle extremely complex parts and uniformity. It helps to enhance the strength of the product, Flexibility of production is endless because of the wide range of material and color. It reduced waste and low labor costs. Bajaj Masterbatch provides customized products as per customer requirements.
NEED FOR INJECTION MOULDING
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Wide Variety
This is most common plastic processing technique used for manufacturing a wide variety of plastic items ranging from smallest components like Caps, buttons, Electrical & Electronic parts, buttons, etc to large components like Car bumper , dash board, Home Appliances body , etc.
High production output
The process itself is extremely fast compared to other methods, and the high production output rate makes it even more efficient and cost-effective. Speed depends on the complexity and size of the mold but only about 15-120 seconds pass between each cycle time.
Strength
Strength is one of the key factors determined when designing a plastic injection molded part. The designer will ascertain if the part needs to be flexible or rigid based on it’s end application requirements .
High Quality and Sustainability
When looking for a high-volume injection molding process, it’s important to consider companies’ green manufacturing initiatives, as these signify a commitment to quality, sustainability, and optimal safety.
Lower Labour Cost
Labor costs are relatively low in plastic injection molding, in comparison with other types of molding. The ability to produce the parts at a very high level with a high output rate helps with its cost efficiency and effectiveness.
TYPES OF INJECTION MOULDING
Thin wall moulding
It is a technology that achieves a plastic part with a very thin wall. It is often used in test apparatuses, electronic items, Food containers , tubes, and other enclosures.
Gas assisted Injection molding
is used when any thick plastic injection-molded part is that it runs the risk of distortion as it cools. This method helps to solve this issue by shooting gas into a plastic material-filled injection mold, allows the plastic on the outside of the mold to maintain a smooth and finished appearance while the inside stays porous or hollow.
Micro Injection moulding
is a process of obtaining micro injection moulded parts that weighs less than 1/10th of a gram, here very high precision is involved in both tooling as well as production.
Injection compression Moulding
is a technique where the molten polymer is injected into a partially open mould , then the mould closes to compresses and distributes the melt through out the cavity , completing filling and packing stage. This process works on lower injection pressure providing lower moulded in stress and thin walled part production.
Co-Injection(Sandwich) Moulding
is a process in which 2 different but compatible polymer melts are injected sequentially into a cold mould , forming a skin / core structure . The possibility of using recycled material in the core can be regarded as one of the key advantage in this process.
Insert Moulding process
are mostly done in vertical injection machines with vertical / horizontal clamp unit. In this an insert is placed into the mould cavity before closing and the plastic is then injected around the insert so that the insert becomes a part of the final moulded product.
Foam Moulding Process
is a low pressure process inwhich an inert gas is introduced into molten polymer the purpose of reducing density and hence weight of the finished product. Moulded products have cellular cores surrounded by rigid, integral skins. Foaming agents such as Nitrogen, Carbon di oxide is introduced into the polymer melt stream, creating a homogenous mixture of polymer & gas.
Fusible core Injection moulding
is a specialized process used to manufacture components with cavities / undercuts .
Rapid Injection moulding
is a process to make prototype injection moulded parts in a thermoplastic resin in 2-5 weeks. These parts are used for full functional and fit testing.
2-Shot Injection Moulding
is a technology of producing a part with 2 different raw materials or colours in single operation.
Classification of Injections Moulding
Hand Moulding Machine
Vertical & Horizonatal type Injection Moulding Machine
Advantages of Using
Bajaj Injection Moulding Solutions
Complex Part Design
High Efficiency- Fast Production
Enhanced Strength
Flexibility- Material and Color
Reduced Waste
Low Labor Costs
Further Injection of material can be done by two ways as given below :
1. The Screw type Injection Moulding
2. The Ram type injection moulding
Clamping unit
They are placed at the back of the mould in the machine. Mould is clamped to platen of the machine. One platen is stationery which has injection unit at its back while the other one attached to clamping unit is movable. The main function of clamping unit is to keep mould closed when hot plastic material is injected into mould at high speed & pressures. In general, Clamping pressure has to be higher than the Injection pressure. There are 2 types of clamping units, namely
A) Direct Locking unit which utilize a high pressure hydraulic cylinder where clamping forces is focused in the centre providing even force distribution.
B) Toggle clamps which are mechanical clamping providing both high speed and high force at different points in the cycle when required.
Clamping Tonnage : Clamping unit is rated in terms of Tonnage which is the maximum force that the machine can provide to keep the mould closed during the mould process.
Clamping force = Projected Area X Injection Pressure
The projected area of the part can be found based on the geometry ( dimensions) of the part. The injection pressure varies with the flow or viscosity of the polymeric material. Too low a clamping force can lead a short part or unfilled parts while too high clamping force can open mould leading to flash or even damage mould sometimes.
Clamping force = Projected Area X Injection Pressure
The projected area of the part can be found based on the geometry ( dimensions) of the part. The injection pressure varies with the flow or viscosity of the polymeric material. Too low a clamping force can lead a short part or unfilled parts while too high clamping force can open mould leading to flash or even damage mould sometimes.
Bajaj Masterbatch Injection Moulding Applications
Injection Moulding Process Cycle
Product Solutions for Injection Moulding
Filler Masterbatch For
Mineral Filler Applications
Fillers Reduce Cost and Weight by and large but most of the people
think these are simply used to add bulk and lower cost, but also these mineral fillers make them easier to mold and shape while ensuring the stability of the compounds used in the injection moulding process. Due to volatile pricing trends of polymer resins , processors has to expedite the usage of fillers as a solution to reduce cost without compromising the quality of outcome (ie) finished products.
| Product | Description |
|---|---|
| Plast Stiff | "Cost Saving Of Polymer,Better Productivity,Less Machine
Wear & Tear,Energy Saving ,Less Wastage,Lower Total Cost." |
| Plast White | "Cost Saving Of Polymer, Increases Output, Better
Productivity, Less Machine Wear & Tear, Energy
Saving, Less Wastage, Lower Total Cost" |
| Plast Modifier | It Increases Mechanical Properties In Highly Filled Mineral And Recycled Polyolefins Specially Made For Woven Fabric/Sack, Jumbo Bags |
| Plast Fab | "Cost Saving Of Polymer,Better Productivity,Less Machine
Wear & Tear,Energy Saving ,Less Wastage, Lower Total Cost." |
| Plast Clear | "Act As Nucleating Agent,Cost Saving Of Polymer Better
Productivity,Less Machine Wear & Tear,Energy Saving ,Less Wastage,Lower Total Cost" |
White Masterbatch For
Injection Moulding Applications
White (TiO2) masterbatches are used in Injection moulding process as TiO2 provides opacity by reflecting the light which is possible, due to its ability to scatter light. This is performed by refraction and diffraction of light, as it passes through the titanium dioxide particles embedded in the white masterbatch . If there is enough light through the injection molded surface it will be reflected outward and the object will appear opaque. Besides this phenomenon, it also yields good aesthetic appeal
| Product | Description |
|---|---|
| Plast Ultra 40% | Gives excellent opacity, reinforcing brightness & delivering the best print appearance on the substrate |
| Plast Ultra 50% | Gives excellent opacity, reinforcing brightness & delivering the best print appearance on the substrate |
| Plast Ultra 60% | Gives excellent opacity, reinforcing brightness & delivering the best print appearance on the substrate |
| Plast Ultra 70% | Gives excellent opacity, reinforcing brightness & delivering the best print appearance on the substrate |
| Plast Ultra 75% | Gives excellent opacity, reinforcing brightness & delivering the best print appearance on the substrate |
Black For
Injection Moulding Applications
| Product | Description |
|---|---|
| Plast Black 40% | It is used for conductive application to discharge the surface electricity and earthing. Carbon Black is used as an additive |
| Plast Black 45% | It is used for conductive application to discharge the surface electricity and earthing. Carbon Black is used as an additive |
Additive Masterbatch For
Injection Moulding Applications
Additive masterbatch is incorporated in the injection moulding process to improve the performance of plastic products attributing the desired characteristics . For instance Optical brightener improves brightness & shining of molded plastic item , Nucleating / Clarifying agent improves the clarity & transparency of molded items , Antioxidant and UV additive masterbatches prevent deterioration due to heat , shear during processing and UV radiation ,oxidation in the end-user environment.
| Product | Description |
|---|---|
| Plast Anti Microbial | It is an active agent that when included in the processing of a material will inhibit the life or growth of microbes. |
| Plast Anti Oxidant | Prevents loss of physical and mechanical properties in polymers . Prevents gas fading of plastics when subjected to atmospheric pollutants. |
| Plast PPA | They improve the melt process ability and handling of high molecular weight polymers to improve the appearance of the final product. |
| Plast Desiccant | Prevents degradation of the polymer, corrosion of the metal parts inside the extruder which shortens its durability |
| Plast Slip | Slip additives are products which can be added to polymers to control friction. Excellent printability , faster winding & unwinding of films. |
| Plast Antislip | Useful for preventing slippage of bags including big woven sacks slipping over each other while stacking and transportation |
| Plast Bright | They are used to mask the inherent yellowness, impart robust colour strength in plastic products & recycled material as well. |
| Plast Antiblock | Reduces adhesion effect, lubricative function & coefficient of friction, It does not affect optical properties, Improves scratch resistance & aethetics. |
| Plast Antistat | Prevents damage to microelectronics, prevents dust and reduces explosion risk due to static discharge in vicinity of flammable materials |
Color Masterbatch For
Injection Moulding Applications
Colour masterbatches facilitates value addition of Injection moulded items in various applications. From Industrial to consumer items, plastic processors rely on cutting-edge colour technology in a desired form, shape , surface aesthetics and so on. Thermal and colour flexibility are two major constituents that make colour masterbatch a perfect solution for plastic products.
| Product | Description |
|---|---|
| Plast Red | Bajaj Plast Red colour masterbatch series is used for giving different Red colour shades to the plastic products using Ral and Pantone. |
| Plast Green | Bajaj Plast Green colour masterbatch series is used for giving different Green colour shades to the plastic products using Ral and Pantone. |
| Plast Blue | Bajaj Plast Blue colour masterbatch series is used for giving different Blue colour shades to the plastic products using Ral and Pantone. |
| Plast Yellow | Bajaj Plast Yellow colour masterbatch series is used for giving different Yellow colour shades to the plastic products using Ral and Pantone. |
| Plast Orange | Bajaj Plast Orange colour masterbatch series is used for giving different Orange colour shades to the plastic products using Ral and Pantone. |
| Plast Violet | Bajaj Plast Violet colour masterbatch series is used for giving different Violet colour shades to the plastic products using Ral and Pantone. |
| Plast Grey | Bajaj Plast Grey colour masterbatch series is used for giving different Grey colour shades to the plastic products using Ral and Pantone. |
| Plast Brown | Bajaj Plast Brown colour masterbatch series is used for giving different Brown colour shades to the plastic products using Ral and Pantone. |
Injection Moulding Product Types
| Product Name | Category | Features | Download TDS |
|---|---|---|---|
| Filler Materbatch | Plast stiff | Cost Saving of Polymer,Better Productivity,Less Machine
Wear & Tear,Energy Saving ,Less Wastage,LOWER TOTAL COST. | Download TDS |
| Plast Modifier | Improves Whiteness ,Excellent Gloss, Shine & Luster, Improves Dispersion ,Minimize Denier Variation ,Increase Strength ,Increase Elongation ,Increase Output | Download TDS | |
| Plast White | cost saving of polymer, increases output, better
productivity, less machine wear & tear, energy saving, less wastage, lower total cost | Download TDS | |
| Plast clear | Act as Nucleating Agent,Cost Saving of Polymer Better Productivity,Less Machine Wear & Tear,Energy Saving ,Less Wastage,LOWER TOTAL COST | Download TDS | |
| Plast Fab | Cost Saving of Polymer,Better Productivity,Less Machine
Wear & Tear,Energy Saving ,Less Wastage,LOWER TOTAL COST. | Download TDS | |
| White Masterbatch | |||
| Plast Ultra 40% | Improves specific properties such as Tensile strength, Elongation, bonding strength , Toughness, Heat sealing resistance , High temperature stability , Weatherability, Colour (whiteness) , surface finish ,etc | Download TDS | |
| Plast Ultra 50% | Improves specific properties such as Tensile strength, Elongation, bonding strength , Toughness, Heat sealing resistance , High temperature stability , Weatherability, Colour (whiteness) , surface finish ,etc | Download TDS | |
| Plast Ultra 60% | Improves specific properties such as Tensile strength, Elongation, bonding strength , Toughness, Heat sealing resistance , High temperature stability , Weatherability, Colour (whiteness) , surface finish ,etc | Download TDS | |
| Plast Ultra 70% | Improves specific properties such as Tensile strength, Elongation, bonding strength , Toughness, Heat sealing resistance , High temperature stability , Weatherability, Colour (whiteness) , surface finish ,etc | Download TDS | |
| Plast Ultra 75% | Improves specific properties such as Tensile strength, Elongation, bonding strength , Toughness, Heat sealing resistance , High temperature stability , Weatherability, Colour (whiteness) , surface finish ,etc | Download TDS | |
| Additive Masterbatch | |||
| Plast Anti Microbial | Inhibits bacterial and fungal growth on plastics by disrupting their cell membrane and also inhibiting enzymes and proteins vital for their function, Food grade – can be used in indirect food contact applications | Download TDS | |
| Plast Anti Oxidant | Prevents loss of physical and mechanical properties in polymers . Prevents gas fading of plastics when subjected to atmospheric pollutants. Contains high concentration of a combination of primary and secondary antioxidants and thus requires a low dosage. | Download TDS | |
| Plast PPA | PPA reduces line shutdowns for cleaning, allows lowering work temperature and saving energy, and the presence of gels in the final product diminishes. Another advantage is that PPA is also work as additives to improve cleanliness and facilitates to exit faster from a color in production. | Download TDS | |
| Plast Desiccant | Can achieve UL 94 V0, V1, V2 ratings as desired at different part thickness. It's ROHS compliant & safe to use., Reduce polymer melting, high thermal stability & yield best performance vis-a-vis cost incurred. Exhibit intermediate blooming resistance and good UV stability. | Download TDS | |
| Plast Slip | Excellent printability , faster winding & unwinding of films. We also offer PPA's comprising of non-migrating additives ,temperature independent & unaffected by corona treatment or lamination process. Can be offered as slow acting or fast acting with optimum thermal stability to suit the end application. | Download TDS | |
| Plast Antislip | It acts by increasing Coefficient of Friction (COF) on film surfaces. It does not contain any abrasive ingredients, minerals in it , hence no adverse effect on screw wear during extrusion process. Useful for preventing slippage of bags including big woven sacks slipping over each other while stacking and transportation. Also helps to increase stacking height without risk of slippage and resulting damage. | Download TDS | |
| Plast Bright | It Improves films, molded items & fibers with excellent brightness better than white MB in solo. It can be applied alone or in a variety of blends and combinations with processing, heat and light stabilizers as and when required. | Download TDS | |
| Plast Antiblock | Reduces adhesion effect, lubricative function & coefficient of friction. It does not affect optical properties.Improves scratch resistance & aethetics.Food grade compliant, Compatible with White, Black, Colour & other Additive Masterbatches such as Slip Additive , Anti static additive & Polymer Processing aid. | Download TDS | |
| Plast Antistat | Based on Amine Chemistry. Effective and long lasting performance than GMS. Can reduce surface resistivity of polymer surfaces up to 1010 - 1011 Ohm/Sq. Prevents damage to microelectronics, prevents dust, dirt accumulation and reduces explosion risk due to static discharge in vicinity of flammable materials eg. solvents. | Download TDS |
