As we move into 2021, we’re already seeing the expected rise in the need for plastic injection molding for medical devices. Plus, due to the COVID-19 pandemic, the demand for medical devices in general continues to grow. As the demand for plastic medical devices increases, so does the need for NSF Listed injection mold cleaners, rust preventatives, and greases.
Plastic on the Rise for Medical Injection Molding
Medical injection molding has an estimated growth rate of 6.5% over the next 10 years for an ever-expanding list of reasons, including unlimited design options, better regulatory compliance, and little to no manufacturing side effects. Along with sustainability and biocompatibility, plastic injection molding is likely to continue increasing for medical devices.
From all types of tubing to prosthetics and more, the versatility and ability to distribute to a global marketplace add to the benefits of the medical industry moving away from metal and toward plastic.
The Importance of NSF
Particularly with medical devices that absolutely must be clean, sterile and safe, using mold cleaners, rust preventatives, and greases listed by NSF is paramount to the plastic injection molding industry. In order to be NSF Listed, products are rigorously tested and must meet or exceed all standard requirements for certification. At Nanoplas, we have five such products that also improve run time and capacity while reducing downtime.
NSF-Listed Products from Nanoplas
Cera-Lube™ Nano Ceramic Grease has a high drop point and incredible wear characteristics that let customers apply a very thin amount that still lasts up to 10 times longer than other greases.
Safe-T-Clean™ is a high-performance cleaner and degreaser with a powerful spray pattern to break up tough build up and clean hard-to-reach areas.
Safe-T-Guard™ prevents corrosion from penetrating your machine. It’s a truly dry rust preventative, so it won’t break down grease and other already-present lubricants.
SYN LUBE™ High Performance Synthetic Grease is designed for the most difficult industrial applications. With antioxidants, extreme pressure and anti-wear additives, and excellent high temperature properties, SYN-LUBE™ meets the most stringent industrial requirements.
Zap-Ox™ is unmatched in its cleaning ability. No other cleaner can remove rust, oxidation, build-up, weld discoloration and other stains like Zap-Ox™.
Request a Free Sample
Try any of our NSF-listed injection mold rust preventatives, cleaners, and greases for free to see first-hand what our products can do to increase efficiency and reduce downtime. Request a Free Sample
Corrosion in plastic injection molds can be a costly headache if it isn’t handled properly. In fact, according to Grand View Research, the injection molded plastics market size in 2020 is $267 billion and is projected to grow 5% through 2027. Considering those figures, downtime caused by corrosion is a huge potential cost. Preventing corrosion in plastic injection molds before it happens, or fixing it before it requires a shutdown, is essential.
A Rust Preventative is Key to Fighting Corrosion
Using the right Nanoplas rust preventative is the best way to fight corrosion and keep your presses running. Corrosion is caused when water, condensations, off-gases and mineral deposits come into contact with the steel of the mold, creating a chemical reaction that ultimately leads to corrosion.
A rust preventative forms a protective barrier on the mold, blocking those substances from interacting with the mold and keeping your presses up and running.
Choosing the Right Rust Preventative
Because not all molds or processes are alike, it’s important to use the right Nanoplas rust preventative to ensure maximum efficiency and productivity. As always, you can request a free sample of our rust preventatives.
Dry rust preventatives go on completely dry and won’t break down grease. Easy to clean, Nanoplas dry rust preventatives are ideal for protection against corrosion and avoiding bleeding.
Mold Guard can be molded through at startup and also contains release properties.
Mold Guard Green features a green tint to give you a better visual on coverage, which helps cut down on superfluous use.
Safe-T-Guard Safe-T-Guard is NSF H-1 listed, goes on dry and will not break down grease and other lubricants that are already on the surface.
Semi-dry rust preventatives give you longer-lasting protection without bleed through, stopping corrosion before it starts.
The Defender’s green tint helps avoid overspray as you can better see the coverage. Its acid vapor neutralizer protects against corrosive materials, including PVC.
The Protector can be used on both warm and dry molds and protects for up to three years.
Get Your Free Sample of Nanoplas Rust Preventative
Request a free sample of a Nanoplas Rust Preventative or any of our products. If you have any additional questions as to what rust preventative may be best for your application, feel free to contact us to discuss.
When you encounter rust, oxidation, buildup, discoloration, and other stains in plastic injection molding, you know both your production and your output is going to be adversely affected. You need to halt production so you can properly clean the mold, which further decreases efficiency and output, which has already been impacted by more scrap or rejects.
Causes of Mold Buildup, Discoloration, Rust, and Oxidation
Mold rust, oxidation, and gas stains can be a result of a number of things, but the most frequent culprit is exposure to water or corrosive gases. Improper shutdown of a mold and incorrect drying of the material can also lead to mold oxidation and rust. If it’s a process-based issue, you might be dealing with a too-high melt temperature, too-long residence time, excessive shear rates, poor venting or low-flow areas in the injection barrel or hot-runner system.
Mold buildup usually comes from volatiles leaving the plastic and collecting on the mold surface. When this happens, the part will often have a rough surface. Buildup can also lead to flash and other part defects, all of which can increase scrap and decrease efficiency.
Discoloration is a problem because it creates inconsistency among the parts, potentially creating scrap. Discoloration in the barrel or the mold can transfer to the parts, leading to the problem. Most often, discoloration is caused by poor venting or a too-small mold gate, nozzle, spruce or runner size. Using too much grease or mold release can also lead to discoloration.
Non-Caustic Zap-Ox Removes Rust, Oxidation, Buildup, Discoloration, and More
If you need to shut down to work on any of these issues, the best option for cleaning is Zap-Ox (or the no-grit version, Zap-Ox NG). It’s non-caustic, so it is operator-friendly and will not corrode the metal, and a thin coat Zap-Ox pulls the stain or discoloration to the surface without scrubbing, removing it in just a few minutes.
See Zap-Ox in Action
No matter the cause, Zap-Ox can remove stains in plastic injection molding. To see how Zap-Ox can work for you (with no scrubbing required on most stains), request a free sample today.
Over-greasing in injection molding is one of the most common causes of creating scrap and, potentially, downtime. By developing a standard method of lubricating and using the appropriate lubricant that works best for your specific application, you could see significant scrap reduction and less downtime.
Over-greasing in Injection Molding Can Lead to Contamination
Lubricating a mold might seem intuitive at first, but it’s not as easy as simply smearing grease on the pins. If you apply too much grease, you could end up with molds bleeding grease for hours and producing only scrap. When too much lubricant gets into the mold cavity, parts can get contaminated and scrap becomes a problem.
Most often, you’ll notice over-greasing when a mold comes back from service, particularly on the moving components. Check all moving parts for signs of over-greasing when a part comes back from service.
How to Achieve Scrap Reduction
There are two things you can do to prevent generating scrap from over-greasing in injection molding and wasting time:
Work with your mold maintenance staff to create a standard lubrication method following manufacturer’s instructions.
Use the right Nanoplas grease, appropriate for your specific application to increase efficiency and decrease the chances for contamination and scrap. For example, Cera-Lube is a food-grade grease that is best for plastic injection molding, off-road and auto racing, steel mills, transportation, salt and fresh water and anywhere there’s exposure to heat, highly corrosive chemicals or water. SYN-LUBE is a high temperature, food-grade grease generally used for plastic injection molds and extreme industrial applications.
Ess Tec, a plastic injection molding company in Holland, MI is an excellent example of solving this problem. They were having issues with grease bleeding off ejector pins, leading to excessive scrap, but through a repeatable application process using Nanoplas Nano Ceramic Mold Grease, Ess Tec saw 87% scrap reduction.
Lubricant Application Process to Eliminate Over-greasing in Injection Molding
Clean and remove contaminants off all components before applying.
Apply a small amount with a brush or hand. Spread and wipe off all excess with hands.
Make sure you have a thin film on your wear surfaces.
Install components and work back and forth. Remove components to wipe off extra grease at the end of travel.
Get a FREE Sample of a Nanoplas Grease
Like Ess Tec’s experience shows, combining the right grease with the right application method can drastically reduce scrap and increase efficiency. Get a free sample of Cera-Lube or Syn-Lube and see the difference for yourself. If you’re unsure which lubricant best fits your application, contact us and we’ll make a recommendation.
Injection molders around the world are striving to make their operations more efficient, and more productive. One area that is often overlooked when it comes to gaining such advantages is mold maintenance.
While applying the cleaner, rust preventative, and grease, take the time to thoroughly inspect the mold. Doing so will give you the chance to identify problems or wear on the mold before they become significant issues. As part of your maintenance log, make a note of any concerns, address the ones you can, and track the progression of any issues you can’t fix.
When it comes time to get the mold back into production, products used to clean and prepare the mold should not be a problem or cause a delay. The Nanoplas line of products are formulated to mitigate this issue. They do not cause bleeding or startup scrap, so you can mold right through them and save time getting the production run moving.
Integrating a maintenance program as a core element into your production strategy may allow you to realize significant gains in productivity by reducing startup issues and downtime, making your operation more efficient and profitable. To learn more about how the Nanoplas family of products can play a role in that strategy, contact us today.
Undesired bleed out in injection molding can be caused by—and lead to—a number of problems. One of the most common injection molding defects caused by bleeding is splay, which is often the result of an over-lubricated mold
Syn-Lube™, which breaks down differently than other greases and helps eliminate bleeding, when applied properly, could be the solution to any issues you’re experiencing with splay.
What is Splay?
Silver or white streaks appearing on the surface of the part often indicate splay in injection molding. Several other defects, like scuffs, flow lines, surface scratches, delamination from contamination and flaking, can resemble splay, so it’s important to determine the cause of the streaks as the first step in troubleshooting.
When the cause is from bleeding, you’re probably looking at splay, potentially from a mold with too much lubricant or grease.
How Bleeding Can Cause Splay
If the splay shows up immediately after getting the mold from the tool room, it’s likely the result of too much grease being applied to the mold. When a mold is over-lubricated, grease from the lifters and ejector pins may bleed onto the surface of the part, which then leave the silver or white streaks indicative of splay.
Sometimes, grease can get trapped in the mold inserts, which also leads to bleeding out.
The proper application of any lubricant is essential. Even better: the proper application of Syn-Lube. Syn-Lube high-performance synthetic grease lasts 10 times longer than competitor products and also doesn’t break down like other greases.
Other greases turn to oil at higher temperatures, which can then lead to bleeding into mold cavities. Syn-Lube is a full synthetic, food-grade grease that can be applied very thinly and will not break down with heat like other greases.
If you’re having issues with splay caused by bleed out in injection molding, try Syn-Lube. Applied properly, it will last longer and resist breakdown into potential bleeding.
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