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1. Product Information
Product name: NR nylon mould base bushing 868
Size: 90mm outer diameter, 36mm thickness
Mould base: Aluminum (inside), nylon (outside)
Production conditions:
a. 34 moulds are used per 8 hours, each of which comes with 8 cavities. The material utilization rate is not high and the deflashing workload is huge.
b. The monthly output of similar products are nearly 2,000,000 pieces, needing about 10 sets of Longchang260T machines.

2. Doush Scheme
Bushing 868, 16-nozzle cold runner, 16-cavity mould, SE 250T rubber injection molding machine

3. Design Requirements
Equipment: SE 250T rubber injection molding machine
Mould: 600mm×650mm, 16 cavities
Cold runner: 16 nozzles
Cycle time: 8 minutes
Output per shift (8 hours): 57 pieces
Net weight of product: 63g
Runner loss: 3.64g/m×16=58.24g/m
Material utilization rate: 94%
Output capacity: 57 moulds×16=912 pieces/shift (8 hours), 2736×26 days=71136 pieces/month, 71136×11 months =782496 pieces/year

4. Project Investment (95W)


a. BE 250T rubber injection molding machine (non-servo drive)	b. Cold runner mould=25W 15W=40W	c. Sliding plate system (mould shifting ejection)

5. Cold Runner
a. 16 nozzles
b. Integral cold runner plate in good balance
c. 2 sets of oil temperature control systems making for excellent temperature uniformity
d. The stuck material can be easily removed.
e. The cold runner has excellent versatility. The center distance is 120mm.

1. Integral cold runner plate2. Thermal baffle 3. Heating platen 4. Main runner 5. 1/4 runner6. 1/16 runner7. 16 nozzles8. Cooling oil circuit

6. Mould Shifting Procedures

a. Mould return b. Mould base fixing c. Filled up cavities d. Shifting e. Opening f. Porduct removal

7. Cycle Time Analysis

As shown in the figure, the whole cycle time for mould shifting is within 480s.

8. Production Cycle Analysis

Cost composition	Machine, 16-nozzle cold runner, 16-cavity mould	Current production conditions
Output/shift (8 hours)	57 moulds/shift (8 hours) ×16=912 pieces	34 moulds/shift (8 hours)×8=272 pieces
Labor cost equipment depreciation electricity cost	100 100 80=280 CNY/shift280/912=0.31 CNY/piece	100 100 80=280 CNY/shift280/272=1.06 CNY/piece
Runner loss	Each mould: 120g/mould×20 CNY/kg=2.4 CNYEach piece: 2.4/16=0.15 CNY	Each mould: 100g/mould×20 CNY/kg=2 CNYEach piece: 2/8=0.25 CNY
Mould and cold runner amortization	Each piece: 150,000 CNY/200,000 moulds/16=0.046 CNYEach piece: 250,000 CNY/500,000 moulds/16=0.031 CNY	Each piece: 50,000 CNY/100,000 moulds/8=0.062 CNY
Total cost	0.537 CNY/piece	1.37 CNY/piece
Conclusion: As each product can save 0.83 CNY, the costs of cold runner and mould can be recovered if 500,000 pieces of products are manufactured (within 183 days), and the investment can be recouped from the saved costs within 7 months.

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