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ProFLOW Case Study

Current Customer

ISSUES: Include 0 ProFlow 1000 product

  • Current molded products uses high fill pressures to fill the parts resulting in a significant scrap rate for short shots exceeding 15%.
  • Belling also occurs during ejection and flash.
  • Material is a flame retardant low flow Polypropylene. Machine is a 950 ton Milacron. The tool is a single cavity cold runner tool. The part requires several gates to fill the part. Part weighs 5 lbs.

SOLUTION: Include a 7.5% addition of ProFLOW 1000 to mold the product

  • 17% Reduction in peak pressure observed.
  • 10% reduction in fill time observed.
  • 50 % reduction in pack time
  • 20% overall reduction in cycle time achieved.
  • Product released from cores with much more consistency.
  • Elimination of belling and short shots.

ProFLOW 1000 Return on Investment

  1. Addition of 7.5% ProFLOW resulted in a cycle savings of 13 seconds. You can produce 53 parts per hour at the original 68 second cycle time. At the new cycle time of 55 seconds you can produce 65 parts per hour. This is an additional 12 parts per hour – over 240 more parts per day. This equates to 1680 parts per week or 87,400 parts per year.
  2. If the current scrap rate is 15% and ProFLOW reduces the rate to 10%, this equates to 2 plus parts per hour or 40 more parts per day. This can be as much as 14,560 parts per year in scrap savings. With a material cost of $2.40/# and $12/part, this is a savings of $174,700 per year in scrap.
  3. Overall production would increase by 19%, allowing less machine time and labor time to be used to produce the same amount of production. This equates to over 1.5 additional part per hour at the new cycle and scrap rates. You could produce 450,000 parts in 41 weeks as opposed to 52 weeks. At the standard press rate, including profit and operator cost, of $109/hr. yYou would see an annual savings of $167,860 per year in reduced machine cost.
  4. Overall ROI
    a. Current Material Cost – New Material Cost = $270,000.00/ 450,000 parts
    b. Total savings From Above – $342,500/450,000 parts

    TOTAL ROI = $72,500.00/Year
    ***This is for one part. The process can be multiplied over several parts that are currently running and will show the same effects using ProFLOW 1000.