PLC for Injection Moulding Machine

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Servo Motor Retrofitting
Platen Threading / Recoiling

Yuken Proportional Valves

Servo Valve Repair Service
Variable Displacement Pumps
Board Repair Services
Gefran Linear Potentiometers / Scales

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Things to Know
Mainteance of Moulding Machines
Used Injection Moulding Machines

Products & Services

SSR, Heater Control

Relay Card
Recoil Spring
Used Molding Machines

A Guide to Injection Moulding

Hydraulic

Calculations for Injection

Moulding Machine

Old Moulding Machines

Auto Mould Clamp

Hydraulic Pump Power Calculation

Power Ph (kW) = Q . p / 612

Mould Clamps
Robot Interfacing

Ph = in KiloWatts
Q = Liters per Minute
p = Pressure in Kgf/cm2

Screw Barrel Repair

Platen Thread Repair

Electric Motor Power for Hydraulic Pump

Pe

= Ph /

Usually it would be around 60% of Hydraulic Pump Power,

Electronic Board Servicing

since Pump would not be operated at full load always and

Motor can take 50% over load for short duration.

Hydaulic Pumps and Repair Services

Hot Runner Controllers
PID Controllers

For Practical Purposes, Motor Capacity is not used as

above. For. Eg. If Hydraulic Pump power is 30kW then

Electrical Motor Required is 18.5kW. Some Manufacturers of Injection Moulding Machines claim Less
Connected Load. If less than required capacity is used then motor efficiency will reduce and increasing the
consumption.
Melt Pressure Calculation
Pm = Ph * Ah / Ab
Pm

= Melt Pressure inside the Barrel during Injection in Kgf/cm 2

Ph = Hydraulic Pressure in the Injection Cylinder in Kgf/cm 2

Ah = Area of Injection Piston in cm2
Ab = Area Screw Ring Plunger in cm2
Locking Tonnage required for Moulded Component
F = Pm * Ac * 1.1 / 1000
F = Locking Force in Tons (1000kgf )
Pm = Melt Pressure in the Mould Cavity Kgf / cm 2
Ac = Component Area perpendicular to Locking Force. cm 2
Note : Locking force shall be always more than the calculated force above.
Maximum Shot Wt. Calculation
W = As * L * 0.88
W = Shot weight of the Machine in grams
As = Area of Ring Plunger of Screw in cm2
L = Screw Stroke of the machine. cm
Relation of Power Consumption and Oil Viscosity
Increase in Oil Viscosity causes
Efficiency of the pump is reduced
Consumption of Power increases
Oil Viscosity increases with increase of dirt in the Oil.
If you think you are saving by using oil more than the specified time then you will
paying more electricity bills which is invisible.
Accumulator and Power Consumption

Accumulators are used for High Speed Injection. In some machines whole machine
is operated with Accumulator. But using of Accumulator is always consumes more
power, because of the charging of the Accumulator takes place at higher Pressure.
Usually Open Close operations takes place with a pressure of around 30 bar. If
Accumulator is used then, Accumulator is to be charged at more than 120 bar which
is very high compared to actual requirement so power consumption is high. Loading

the pump with high pressure always also wears out the pump faster and life of
Hydraulic Oil comes down drastically.

STARTING PLASTICS INJECTION MOULDING MANUFACTURING

PLANT

If you have reached this page then somehow you are associated with Injection Moulding of Plastics, if not
then you can still find some useful information about starting a business.
Starting any business need planning. Planning includes the following points to be studied and discussed
with experienced professionals, friends before actually starting a company.

Purpose of Starting

Experience in Injection Moulding

Financial background

Technical knowledge about Plastics Processing

Location of Plant very important

End Customers and Location

Products to be manufactured / Job Work

Type of Products to be made Commercial / Industrial / Automotive / Aerospace

Legal Status of the Company Proprietor / Partnership / LLP / Pvt. Ltd. / Ltd.

Number of Partners / Directors

It all starts with your knowledge and experience in the Plastics Processing Industry, especially Injection
Moulding. I restrict my discussion to starting a small Proprietorship / Partnership company doing Job work
or moulding commercial plastics components.
Now a days many people who are not associated with plastics are also starting Injection moulding plant, by
way of necessity / opportunity available.
Most people think about their budget first and decide about the size of the plant accordingly. For a new
comer starting Injection Moulding plant with little experience in the field, seems to be easier with smaller
machines initially. But you have to look at the over all project cost before deciding what capacity machine to
be purchased.
Let us assume that one has decided to start with 100Tons Injection Moulding Machine to manufacture
Commercial items like 20 liter Water Jar Cap or house hold items.

PROJECT REQUIREMENT AND COST

Sl.No.

Plant Requirements

Details

Plant Size in Square Feet

400 600 Sq.ft

Amount of Rent per Month @ 20 per sq.ft

8000 12000 minimum

If rental Premises Cost of Advance

10 Months of rent is norm

Cost of Machine assuming Used Machine

6.0 to 8.0 Lakhs depends on age and

condition of the machine,.

A Frame with 2tons Chain Pulley Block

50000/-

Power Required for Machine

Approx 35hp

Cooling Water Pump Power

1hp

Cooling Tower and Piping

60000/-

Mould clamps and Tools

30000/-

10

Hydraulic Oil for Machine about 200liters

25000/-

11

Machine loading and unloading erection

25000/-

12

Machine Transportation if not in the same city

5000 15000/-

13

Electrical fittings, wiring in the Building

14

Accessories like Scrap Grinder, Oven

15

If own products then cost of Mould

16

Working Capital considering 6 months rent, wages, and other

30000/If required
3.0 lakhs

expenses
17

Number of employees assuming accounts work to be taken

6 for 24 hours operation

care by owner./ consultant

18

Registration with Sales Tax

19

Stationery Printing

10000/7000/-

20

Office Furniture

25000/Rs. 13,97,000/-

TOTAL INVESTMENT

Monthly Expenses
Description

Details

Electricity Bill

15,000/-

Wages and staff welfare

40,000/-

Miscellaneous Expenses

5000/-

Telephone / Mobile Expenses

1000/-

Transportation Expenses

To be determined

Interest on Investment @ 18% per annum

20475/-

Insurance for Equipment

To be determined
Total Monthly Expenses

81475/-

**** assuming accounts related work is carried by owner. Otherwise you may have to pay another Rs
1000/- Per month for filing sales tax returns.

How To Start Injection Moulding Company

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STARTING PLASTICS INJECTION MOULDING MANUFACTURING

PLANT

If you have reached this page then somehow you are associated with Injection Moulding of Plastics, if not
then you can still find some useful information about starting a business.
Starting any business need planning. Planning includes the following points to be studied and discussed
with experienced professionals, friends before actually starting a company.

Purpose of Starting

Experience in Injection Moulding

Financial background

Technical knowledge about Plastics Processing

Location of Plant very important

End Customers and Location

Products to be manufactured / Job Work

Type of Products to be made Commercial / Industrial / Automotive / Aerospace

Legal Status of the Company Proprietor / Partnership / LLP / Pvt. Ltd. / Ltd.

Number of Partners / Directors

It all starts with your knowledge and experience in the Plastics Processing Industry, especially Injection
Moulding. I restrict my discussion to starting a small Proprietorship / Partnership company doing Job work
or moulding commercial plastics components.

Now a days many people who are not associated with plastics are also starting Injection moulding plant, by
way of necessity / opportunity available.
Most people think about their budget first and decide about the size of the plant accordingly. For a new
comer starting Injection Moulding plant with little experience in the field, seems to be easier with smaller
machines initially. But you have to look at the over all project cost before deciding what capacity machine to
be purchased.
Let us assume that one has decided to start with 100Tons Injection Moulding Machine to manufacture
Commercial items like 20 liter Water Jar Cap or house hold items.

PROJECT REQUIREMENT AND COST

Sl.No.

Plant Requirements

Details

Plant Size in Square Feet

400 600 Sq.ft

Amount of Rent per Month @ 20 per sq.ft

8000 12000 minimum

If rental Premises Cost of Advance

10 Months of rent is norm

Cost of Machine assuming Used Machine

6.0 to 8.0 Lakhs depends on age and

condition of the machine,.

A Frame with 2tons Chain Pulley Block

50000/-

Power Required for Machine

Approx 35hp

Cooling Water Pump Power

1hp

Cooling Tower and Piping

60000/-

Mould clamps and Tools

30000/-

10

Hydraulic Oil for Machine about 200liters

25000/-

11

Machine loading and unloading erection

25000/-

12

Machine Transportation if not in the same city

5000 15000/-

13

Electrical fittings, wiring in the Building

14

Accessories like Scrap Grinder, Oven

15

If own products then cost of Mould

16

Working Capital considering 6 months rent, wages, and other

30000/If required
3.0 lakhs

expenses
17

Number of employees assuming accounts work to be taken

6 for 24 hours operation

care by owner./ consultant

18

Registration with Sales Tax

19

Stationery Printing

10000/7000/-

20

Office Furniture

25000/-

TOTAL INVESTMENT

Monthly Expenses

Rs. 13,97,000/-

Description

Details

Electricity Bill

15,000/-

Wages and staff welfare

40,000/-

Miscellaneous Expenses

5000/-

Telephone / Mobile Expenses

1000/-

Transportation Expenses

To be determined

Interest on Investment @ 18% per annum

20475/-

Insurance for Equipment

To be determined
Total Monthly Expenses

**** assuming accounts related work is carried by owner. Otherwise you may have to pay another Rs
1000/- Per month for filing sales tax returns.

Annual Expenses

Audit fees.

Filing of Income tax returns

Annual Sales tax assessment

Bonus for Employees

Festival / Pooja Expenses if any

Insurance for Equipment and plant

Statuary Requirements

License to be taken from local Panchayat / Muncipality / Corporation to run the Business.

Profession tax to be deducted from employees and paid to the corporation

Monthly Sales Taxes to paid before 20th of Every month after filing returns online.

81475/-

If Registered with Central Excise then Duties to be paid before 5 th of every month

if Registered with Service Tax then same to be paid before 5 th of every month.

TDS to be deducted and paid for payments made to sub-contractors, service providers.

Registration with ESI and PF to be made if no of employees are more than 15.

Filing Income Tax returns every year.

NOC from Pollution Control Board.

Working Capital Requirement

About six month's expenses to be the basis for working capital, so it is about 5,00,000/- in this case. This
amount needs to be kept aside and should not be used for buying equipments and machines
If the Machine is in good condition then it will not give any trouble otherwise spending for the machine
repairs will also to be accounted.

Billing and Revenues

Assuming 100 tons Injection moulding machine is being used for producing commercial plastic components, then
costing is done based on shift rate or based on weight of Materials converted in Kgs. Per shift 1000 to 1500 or
per Kg Rs. 10/- is now norm in the market.

Revenue Calculation
Shift Rate

1500/-

Per Day

4500/-

Per Month assuming 25 days of production

112500/-

So the revenues are just sufficient to pay the monthly expenses. If Owner is able to reduce the Employee
expenses, then that expense can be saved to survive. For this, Machine should run without any trouble for 25
days and there should be orders for the same. If any one fails then it will become loss.
To avoid this any one starting company should start with little higher capacity machine like 200 tons and above,
so that monthly revenues will be more and wages would be same so that income increases. Wages and
Electricity bills are most expenses should be paid monthly without fail.
For this reason we strongly recommend not to start with lower capacity machine. Adding second machine with in
one year will reduce the administration expenses like wages and increase the growth prospects.

Assumptions made in Project Report

Materials processed are PP, HDPE, LDPE. Etc which does not need preheating.

Location : Tamilnadu. Other places local taxes may wary like octori

Labour availability and cost low / medium.

Un-official expenses not taken into account

Some times accommodation to be provided for employees is not accounted.
If ABS, Nylon, Polycarbonate, etc then Cost of Pre-heating the material and its equipment cost also to be
considered in the project cost.
If doing job work for any Automotive Supplier then maintaining Quality standards like ISO9000, registering
with Central Excise is also to be done.

Service Tax Implications

If billing done to one single customer and if it exceeds 4.0 lakhs per annum then Registration with service
tax is mandatory and service tax to be charged, if customer is not an assessee of Central Excise. If not Job
work, then Sales Tax rate based on the components produced to be levied and the same to be paid to the
CTO (commercial Tax Officer ) every month by filing returns.

Other issues to be taken care

Safety during machine operation. Several instances are there where employees have lost
fingers / hands / life due to poor maintenance of shop floor and machines. Safety of the Mould is also
uptmost important. Many times operators use metal rods to remove the stuck components from the mould
which will damage the mould. Also clamping of the mould to be done propperly with right torque. Bolt
should enter the platen atleast 30mm.
Recently one of our customer who started a new company lost half of his hand even before company is up
and running. Safety issues needs to be seriously taken care of from the beginning of the operations.
Internal wiring to done with proper earthing to the Machines.
Several companies gutted completely due to short circuit, losses running into cores of rupees. Any
unexpected loss to a new company that too in the first year is too much to bear and should take extreme
care in maintaining the shop floor and employee safety.
It is always suggested to make detailed study before stepping into starting a new company. Decisions
should not be taken on assumptions / hypothetical thinking. Discussing with experienced professionals in
the filed is mandatory.

Support from

At creative we provide professional support to the customers to buy suitable machines and offer after sales
support through out the life of the machine. Some times we even say not to venture into based on the
market conditions prevailing. Some times we suggest to go for bigger capacity machines instead of smaller
machines.
So far we helped lot of new companies who have grown well and doing good business. We helped
companies to reduce the Electricity bills. We helped companies, who want to close by selling their
machines. Simply we are one point source for all your need for setting up , running an Injection Moulding
Plant.

2nd Feb 2016 - Updated this page.

After seeing overwelming response form the people who have visited this page in the
past one year, I decided to update this page with some feedback and observations
made by me during last year.

Most people who wanted to start business do not have clarity on what actually they
are wanted do and do not have any understanding about themselves. I have
compiled the following points which needs to be seriously addressed before starting
business.
1. Why do you want start Business ?
You have to identify reason behind the intention to start business. You shoud
have atleast 20 years plan to start business, if you dont have such plan, try to make
a plan right now.
2. Identify your Strengths and Weakneses and relate them to you area of business
whether they will be usefull or not. for eg. if you wanted to start a business in
plastics injection moulding, you have to ask yourself the following questions.
a. What type of exposure do you have in this field.
b. Whether it mathes with youreducation background
c. Whether you are the first person in your family to start business
d. Any family memebers will support you in the business on daily basis
c. Identify your financial strength and findout if it will not affect you and your
family in case if you loose entire amount of investment
d. how long you wanted to do this business ?
e. what is your age at the time of starting business, starting business after 50
years is not recommended right now unless your children will join your business at a
later time.
f. if you wanted start business with your friends or relatives as partners, then
identify their strengths and weaknessess as well. more than 80% partnerships split
after few years for various reasons.
g. have you studied any course in Plastics or worked in any plastics industry,
h. what is your confidence level on your knowledge on the type of business
are starting.
i. Visit any CIPET institute campus and findout more details about Plastics
Processing.

3. Prepare a detailed project report before spending any single rupee. Identify what
type of business you are going to start and then prepare the project report, you can
approach district Industries center for any help, they may have ready made reports
for some products, or take help from you elder friends or relatives. We can also offer
project reports Rs. 25,000/- each per product category.
4. If you identified a product to manufacure then identify the exisitng players in the
marketand findout their strengths and weaknessess and do a maker study for that
particular products, whether you will be able make the same product at lessor cost,
because if ant existing player finds competition then they will slash their prices
suddenly, because it is possible for them since they already recovered their
investment on business and it is affodable for them to operate with low margins.
I wanted to give one example on this. One young person from Nellore called me and
told that He wanted to start making of PVC fittings. I asked him whose is supplying
those products right now in your area ? he do not know that. Then I asked him why
he choose PVC products, he said because his friends told him he had chosen that
products, I asked again whether your friends are working in similar Industries, he
said no all of them are like him fresh from college completed education just now. This
is how things are going at the ground level. Colleges are not making any awareness
programs about careers for thier students. I have told him the name of an MP who is
the leader in this business and asked him whether he knows the MP, he said he do
not know. Without knowing anything about the product they wanted to start
business.
I have seen even experienced people who started business with friends and closed
down within first year with huge losses because every one has thier own interest in
life and without any long term perspective they are taking decisions.
5. Do not start business if you don't have habbit of reading news papers. Most people do not bother to
know about what is happening around them, always living in their own fascinating world. One example I
wanted share about this.
A group of friends started business, they are known to me, in a place near Chennai suburb. once they
identified the factory shed and moved that place and while unloading the machines local people ( goons )
affiliated to political parties, came and insisted that they will do the unloading and loading activities and not
allowed other persons doing it. After some discussion they left taking about Rs. 20000/- without doing
anything. These things are not tought in schools and colleges. you will come to know only when you read

news papers and had chat with your industry people. In fact all of those people who started business there
were experienced people and know the place very well and thier friends were also working in industries
there, still they made a mistake of selecting that place.
6. Choose the right place of business. one fine example is recent floods in Chennai. almost every one got
affected due to floods. some business people doubly affected. both thier Factories and Homes got
submergd in Water for more than four days and damaged properties extensively which is huge loss difficult
to recover if it happens first few years of starting business. Even the Insurance policies could help, an
industiry friend of mine had an insurance policy for Rs. 30 lakhs on machineries, but he got only Rs.
60000/- as compensation, actual losses are more than 10 lakhs. It is lesson for every one. you will come to
know these things only when you read news papers. today you may not need but in future you may be
forced to know after loosing some money. even people who not doing business and working IT companies
suffered a lot for not reading news papers. they purchased homes costing more than a crore each in low
lying areas and today they starting at a loss of more than 40 lakhs on each home. If they know about their
surroundings, losses would have been minimised.
7. Disaster management. these are keywords for only big corporates but now it is most common for every
one after seeing the Chennai Floods. You have to keep important data at two different places to keep
business continuty and avoid loss of business due to loss of Office equipement due to natural calamities.
one example is the school wheere our son is studying, there was feet water in the school compound and
entire school documents, computers, library, students books etc got submerged in water. They are now
asking students to produce the documents which they shoud have kept as part of disaster managemetn
place. the school is big with more than 2000 students studing there. No person who is thinking to start a
business thinks about these things at the time of starting a business, even I am not an exception. It is all
experience. Learn from others mistakes is the best way.
8. What are the resources required to run the business. Identify them and findout diffiuclties in getting those
resources. Today (3rd Feb 2016), due to global recession we do not know what will happen tomorrow. You
have to get back your investment within one year else you will loose your Money. Technologiy is changing
faster than people can cope with. one example, one of my relative is working in big MNC who has invested
about Rs. 7000 crores in SAP ERP (trade mark used here for illustration purpose only, nothing to do with
the brand ) stand alone version which they started few years back and completed in 2015. By the time they
complete it, technology has changed and now every industry is moving towards Cloud systems, means
their investment become outdated. You have to identify these things when you select machinery and
equipement. Chose machines which consume low power and have latest technology.

9. Family issues if any. If you have patients at your family and wants start business decide how would
balance both. Especially if your business makes you to travel extensively.
10. You can not make profits if you do legitemate business, means if you follow rules strictly, pay taxes and
other statutory obligations correctly you end up loosing money. Because you are forced to compete with
people who are not doing business legitemately. This is for people who are doing small business. Most
companies show less number of employees to avoid paying ESI, PF, profession Tax etc. if they ignore
these things, then definetely they will incur losses because they have not considered these things before
starting business. They can not compete if they do legitemately. One example is Big corporates are
charged at 34% income tax and their profit margins are about 15%. The Big companies get about 12-15%
concessions so their effective income tax would be in the range of 20-22%. means their profit margins are
actually the concessions given by the Govt. These concessions are not available to small business people.
In the last Budget Central Govt. announced that they will reduce Income tax rates and also reduce
concessions. means Business people needs to run the show on real terms, under looming global recession
and increasing employee costs. Means you may be asked to reduce the price by your customer.
11. Human resources. The biggest problem now every business is now facing is getting right people. How
are you going to do that. Make a detailed plan. Recently one of my customer scolder the workers, and
suddenly more than 10 workers left the company, at another company five of senoirs left the company due
to mishandling by the Owner. Try to understand how to deal with people.
12. Accounts. Try to learn accounts and do not depend on others for this else you will end up loosing
money. Undertand what is Balance Sheet, Profit Loss statement, What is Capital Expenditure, Vat, Excise,
Service Tax, etc. in detail. One of my customer lost more than Rs. 40 Lakhs due to lack of knowedge about
Central Excise rules. You have to file monthly Sales Tax returns, Excise and Service Tax payments, etc.
You should have knowledge about these activities. Most of these things can be done online now.
13. Working Experience. Always try to work in similar industry for a period of not less than four years
before starting the business. Learn various aspects of Business in the owner's point of view.
14. Making profits. Do not think you can make profits right from first month. Do not try to make a living out
of income from Business at least for first Two years.
15. Love you Job. If you are starting business just to make money then you will end up in frustration and
mental tension. You should love what you are going to do. It should be your passion. You have to be
prepared to spend sleepless nights, and still should not loose confidence on your self. If you are sensitive
person who can not control emotions, and not good at dealing with people then DO NOT START

BUSINESS.

Be positive, Think positive. Good Luck!