Overcoming the complexities of injection molding with Kistler
Continuous process monitoring and control of the entire production measuring chain is essential to meeting today's demanding industry requirements. By combining Kistler process monitoring systems and sensors, one can not only achieve optimized process efficiency and quality assurance, but also gain a competitive edge that raises the bar. This has proven true for Tessy. Passetti points out, “There has been a visible shift in the plastic molding market within the past five years. Customers are more educated and understand a lot more about the injection molding process than in the past and they are actively searching for more technological savvy solutions.
After reviewing Kistler's extensive product portfolio, Tessy decided to implement and combine several Kistler products in order to achieve a competitive edge. Jay Sklenka, Field Sales Engineer at Kistler, explains “Tessy has been using several Kistler products over the past five years; not just for injection molding but for assembly as well. This includes the Kistler ComoNeo, maXYmos, load cells, and pressure sensors. They are also using our amplifiers mounted on the injection molding machines to bring the pressure signals back into the machine controller.”
"From an assembly standpoint, we liked that Kistler pressure sensors allow us to detect the force that drives the components back and forth so we can make any necessary adjustments with reliable, visible, sustainable results."
Ben Passetti, Research & Development Engineer at Tessy Plastics
“We added ComoNeo from Kistler to give us a better understanding of how the component actually looks like to ensure they are fully formed and are able to move into the production stage with 100% zero-defect results. We also chose to implement the process monitoring system ComoNeo because prior to its implementation, we were struggling to understand what was happening in the mold itself to achieve accuracy and repeatability.” The result: control of the outcome throughout different stages of the value chain.
Quality assurance with reliable, repeatable, controllable results
Passetti describes how Kistler pressure sensors are utilized in their injection molding process: “In one of the first stages of the molding process for our medical components, the parts are inserted with the automation directly into the medical component. Here, we are monitoring the cavity pressure to ensure that parts are fully formed and to ensure that we do not overpack the mold using a visible envelope/reference curve over the injection profile so that we can monitor the fill.
When asked if he feels Kistler solutions have provided Tessy with useful tools to achieve success, Passetti exclaims, “Absolutely! We are using Kistler process monitoring systems and sensors for our documentation and providing invaluable information to our processes. Without it, we would likely struggle to meet the demands of today's market from a quality, efficiency, and cost-effectiveness standpoint. Kistler is probably the most advanced sensor company.”
Shaping the future with process monitoring systems and sensors of Kistler
Working together with Kistler has proven beneficial by drastically reducing scrap and improving Tessy's overall success rate. Looking back at the resulting reduced rate of return and increased ROI over the years, Passetti happily notes, “We are definitely satisfied with Kistler solutions. We at Tessy have been pushing the boundaries of facility size limitations for our machinery. We know that Kistler is continuously working to provide smaller systems and sensors to fit this need, especially on the micro-scale side, and we are happy with how much easier it allows for their integration into our machinery.”
Choosing to partner with Kistler in order to achieve continued success has inevitably paved the way for future success and process improvement at Tessy. Passetti concludes, “I would say, from my experience, that the growing market trend favors smart technology solutions like those offered by Kistler. At Tessy, our plan is to not only integrate more Kistler pressure sensors and systems into future molds but also to retro-fit our existing molds with Kistler sensors as well. There are very few companies in the U.S. that are using micro molding in combination with sensor technology. I believe that Tessy remains ahead of the competition in terms of sensor integration on a micro-scale and micro molding machinery thanks to Kistler technology.”