Case Study: How a Mold Upender Transformed a Factory’s Production Process

Introduction

TBefore adopting mold flippers, the injection molding process involved heavy labor, requiring 5 to 6 workers per mold. This complex handling and coordination added approximately 30% additional time to each mold setup.

Furthermore, safety and cleanliness were major concerns, with a 10% annual accident rate during mold operations.

To address these issues, the factory implemented the FHOPE mold flipper. This equipment has transformed the production process by cutting mold setup times by up to 50% and significantly boosting overall efficiency. It also improved safety, reducing accident rates by nearly 80%. The FHOPE mold flipper supports molds weighing up to 100 tons and can handle molds up to 2 meters in diameter, enhancing productivity and operational safety in the factory.

The function of the mold flipper:

Enhanced Features of the Mold Flipper

High Weight Capacity: Accommodates molds weighing from 1 to 100 tons, designed to operate efficiently with molds up to 2 meters in diameter. It is also capable of handling molds with a surface area of up to 15 square meters.

Automatic Upending: Operates on chains and motors, flipping molds automatically, capable of handling up to 30 cycles per hour. It features a quick flip time of approximately 90 seconds per cycle.

Stable Support: Ensures balance and safety during flipping, using solid copper sleeve bearings for durability without extra lubrication, supporting a radial force of up to 5000 kg. The system has a lifespan of over 10,000 flips without maintenance.

Accurate Positioning: Features a precise positioning system for exact placement with less than 0.1% positioning error. Includes a feedback mechanism that adjusts for deviations in less than 0.5 seconds.

Ease of Operation: Includes a user-friendly control panel and an optional remote control for safe, flexible operation, with a response time of under 2 seconds. The control panel is designed to withstand over 500,000 presses.

Detailed Impact on Production Using the Mold Flipper

Versatility: Adapts to various mold sizes and shapes, increasing production flexibility. This has enabled the factory to expand its product range by 30%, and reduced the time for mold setup changes by 50%.

Increased Efficiency: The mold flipper reduces mold preparation time by 40%, enhancing overall production speed. This results in a 25% increase in mold throughput per shift.

Reduced Manpower: Automation reduces the need for manual labor by 70%, allowing workers to be reallocated to higher-value tasks, thereby improving productivity per employee by 50%.

Enhanced Safety: Stable support and accurate positioning minimize accidents by 90%, making the workplace safer and reducing injury-related downtime by 95%.

Conclusion:

By introducing a mold upender from FHOPE, the manufacturing factory has successfully changed the production process of mold processing.