Setting up Plastic Injection Molding in China

Plastic items such as toys, utensils, medical devices, water bottles, food containers, and other devices have become indispensable in our daily lives. Most other components and products used in various industrial, automotive, and construction sectors also involve many plastic parts.

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While plastic continues to be a popular material for numerous applications, the manufacturing process has improved over time. Most plastic components are made using plastic injection molding, and China is a preferred destination due to cost advantages.

The process involves heating the raw plastic material, injecting it into the mold, cooling the plastic, and creating the desired end product. The creation of mold prototypes is both a science and an art. Comprehensive technical expertise and utmost attention to detail are required to design, manufacture, and finish custom plastic parts. Minor errors can lead to repeating manufacturing procedures from scratch, extending lead times and increasing manufacturing costs.

To set up plastic injection molding in China, it is important to have fundamental knowledge of the plastic injection molding process and know how to select the right manufacturer in China.

Plastic Injection Molding Process

The first step in manufacturing plastic injection molding in China is to create the design of the mold. This task is undertaken by design engineers who use specialized design and computer skills to craft mold designs. Based on the product requirement, they also add elements of texturing such as logos, patterns, gloss finishes, matte finishes, layered textures, graphics, and gripping surfaces.

The next step is to transfer the design to a plastic injection molding machine, which then carves out the precise product using the design. These molds, when made out of high-strength steel, can withstand the stress of mass production.

Creating a digital model helps manufacturers determine the precise shape and scale of the mold. The design must achieve maximum precision, as even minor errors at this stage can impact the entire production and lead to product recalls. After finalizing the mold design, the next stage is selecting the material to be molded in the plastic injection molding machine.

The plastic injection molding machine comprises these basic components:

• The injection system feeds raw material (plastic) into the cylinder, heats and melts the plastic, and pushes the melted plastic into the cavity through the vertical passage (spure).
• The hydraulic system provides the force for the injection system.
• The mold system is where the mold is loaded and assembled.
• The clamping system gives the packing force for the mold.
• The control system enables the control of the heating and cooling system.

The process of plastic injection molding starts with gravity feeding of raw materials into the injection system of the molding machine. The raw material melts due to applied heat and pressure, and the material is then injected into the mold under high pressure. Once the material enters the cavity, pressure is maintained until the raw material cools and solidifies. When the temperature of the plastic part is lower than the distortion temperature of the material, the mold opens, and the plastic product is ejected.

The entire production process is known as the molding cycle, while the time lag between the injection of the melted raw material into the cavity and the opening up of the mold is referred to as the clamp close time.

The time taken for the injection cycle is the sum of clamp close time and the time needed to open the mold, eject the part, and close the mold.

The cycle of plastic injection molding includes these steps:

• The mold closes while the screw of the injection system begins moving forward to inject the material while heating the material.
• The melted plastic is injected into the cavity.
• As the screw moves forward continuously, the cavity is packed.
• The cavity cools as the gate freezes off.
• The screw retracts to get ready for injecting in the next cycle.
• The mold then opens, and the plasticized parts are ejected by the ejection system.
• The mold closes.
• The next injection cycle begins.

Commonly Used Plastic Injection Molding Materials

Polyethylene – A commonly used material for making many products such as grocery bags and water bottles.

Polyethylene Terephthalate or PET – Also used for plastic water bottles, plastic bags, and as polyester fiber in the apparel industry.

Polyvinyl Chloride or PVC – This material has many industrial applications, being cost-effective and durable.

Polyamide – Known commonly as nylon, polyamide is a flexible and highly durable material with wide-ranging applications in climbing equipment such as ropes and cords, clothing, and mechanical equipment.

Polypropylene – This type of plastic is typically used to make food containers.

Polystyrene – Polystyrene is commonly used to package other finished products and is also called Styrofoam.

Polyurethane – This flexible plastic is also available as a liquid and is used in adhesives, sealants, and varnishes.

Polycarbonate and acrylic – These highly durable, scratch-resistant, and transparent plastics find industrial usage in the construction industry.

How to Choose the Right Plastic Injection Molding Manufacturer?

The major reason for businesses to look for plastic injection molding manufacturers in China is the price, which can make a huge difference in the bottom line. However, apart from price, there are many factors to consider when choosing a plastic injection molding manufacturer in China:

• Reliability and Authenticity – The typical marketplace for most Amazon sellers and companies is Alibaba. Although this primary marketplace provides comprehensive listings of manufacturers, not every business is genuine. Many resellers or trading companies may pose as manufacturers. Choosing the wrong manufacturer based solely on low cost can be disastrous. Some companies that ordered injection molds from a manufacturer in China found that the mold was not a high-quality product, and the certification provided was fake. Poor-quality molds wear down quickly, leading to higher replacement costs. Checking the legitimacy of licenses, business registration, and quality certifications such as ISO is crucial.
• References – A genuine company will provide references of past and current customers, while a fake company will hesitate or give vague responses.
• Quality Systems – Verify if the manufacturer has stringent quality systems in place for manufacturing.
• Experience – It is important to check how long the company has been manufacturing plastic injection molds and if they possess in-depth knowledge of the field and process. Asking a few technical questions can help establish their knowledge and experience.
• Communication – Technical knowledge and communication are of utmost importance. The manufacturer needs to understand your product requirements, measurements or dimensions, material requirements, and be familiar with CAD drawings and the mold-making process to comprehend your specifications fully.
• Capability and Capacity – Evaluate if the factory’s capacity and capabilities match your production requirements. Ask if the manufacturer does the entire production in-house or subcontract to other vendors. Check the manufacturing plant’s size and whether it is equipped with state-of-the-art mold processing and injection molding workshops, measuring instruments, and product assembly services. Also, verify if the factory has other equipment such as CNC machining, milling/grinding, engraving machines, and wire cutting required for specific products.

Many manufacturers in China use CAE technology (Computer-aided engineering), which is one of the most effective ways to create mold design, manufacture plastic products, and ensure product processing. Compared to traditional mold design, CAE technology offers greater advantages in ensuring product quality, improving productivity, cost reduction, and reducing labor intensity.

Evaluating whether the manufacturer in China adopts CAE technology is crucial in choosing the right plastic injection molding manufacturer. Traditional injection molding involves testing several products, finding problems, rectifying the process, and possibly modifying mold design and plastic products. All of this increases production costs, extends the development cycle, and can result in poor-quality products.

CAE technology accurately predicts the injection molding process, including packing, melt filling, cooling, stress distribution, deformation, fiber orientation distribution, and product shrinkage, before processing in the mold. Designers can identify problems and rectify the mold design instead of waiting until the mold is made. This avoids mold rework, reduces costs, and has considerable economic and technical significance.

Benefits of Setting Up Plastic Injection Molding in China

Plastic injection molding in China is a flourishing and efficient manufacturing sector. With more than 15,000 plastic manufacturing companies existing in 2016, the total sales had reached $366 billion. In 2018, China manufactured 13.95 million tons of plastic parts and products. The steady growth in the industry is due to rising demand from downstream industries, including computer manufacturing, automobile, and household product manufacturing. The industry revenue in 2019 was estimated to be $43.8 billion.

China exports die-cast and high-end mold products worldwide to 190 countries, with exports from more than 700 manufacturers exceeding $1 million annually.

This indicates that Chinese plastic injection molding manufacturers are competitive in terms of price and can meet the quality standards of European and American markets.

In addition to CAE technology, many manufacturers have adopted advanced technologies such as robotization and automation in the plastics industry.

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Injection molding companies are increasingly investing in automated technologies to achieve precise plastic product development, boost product consistency, and achieve overall production and quality efficiency. With automated features, the production line is optimized, enabling the production of high volumes of customized engineering plastics over fewer cycles.

The adoption of robotic technology was expected to rise by 75 percent in 2019, with an expected ratio of 150 robots per 10,000 humans in 2020.

Here are some of the benefits of setting up plastic injection molding in China:

• Low Scrap Rates – Many manufacturers use efficient plastic injection molding production, optimizing the amount of plastic used to ensure minimal wastage and residual scrap.
• Cost-Effective – The greatest advantage with China is the ability to produce large numbers of plastic products with less investment. While labor costs are lower, sophisticated technology ensures precision products, fewer errors in finished products, and quicker timelines.
• Repeatable Process – As molds are reusable, identical products can be produced repeatedly, saving costs while maintaining quality.

Working with a China sourcing agent specializing in plastic injection molding can optimize these benefits. An agent with an office in China can communicate in Mandarin, visit factories for audits, and check samples. They can also negotiate the best deals and ensure the supplier in China understands your product requirements fully. The agent also coordinates with freight forwarders, making the sourcing process hassle-free.

Plastic injection molding methods in China have significantly improved. With the ability of Chinese manufacturers to produce high-quality products using the latest technology at lower costs, you can streamline your budget and ensure the best quality plastic products.

Sourcing Allies is a team of expert China sourcing agents that has helped Western customers manufacture and source products from low-cost regions since 2006.

For more on China sourcing, visit our website or write to us at info@sourcingallies.com.

What are the advantages of choosing China for your injection molding needs?

1. Negotiable, cost-effective pricing
2. Higher production and fast turnaround times
3. Manufactures polished, intricate products
4. Advanced plastic parts and machinery
5. Sell your products to local Chinese consumers
6. World-class production support

Overview

• Injection molding companies in China provide negotiable pricing, fast turnaround times, and the production of polished, intricate products.
• Partnering with them enables businesses to access a large Chinese consumer market with diverse tastes and preferences.
• Their valuable resources, equipment, and industry-specific work culture are available through partnerships with Chinese injection molding companies.

With its well-established reputation as a global manufacturing powerhouse, China provides a compelling proposition for businesses seeking cost-effective, high-quality, and efficient solutions for their injection molding needs.

This article highlights the advantages of choosing China for injection molding services, shedding light on how these can significantly enhance your manufacturing processes and overall competitiveness. Read on to discover more.

Negotiable, Cost-Effective Pricing

Many companies opt for China as their manufacturing hub for plastic injection molded products due to its cost advantages compared to other global regions. This can result in significant labor cost reductions, sometimes as much as 80%. The extent of these cost savings depends on the intricacy of the product design. Simpler designs often achieve higher labor cost reductions compared to highly complex products.

It’s also important to understand that pricing in China is often open to negotiation. For instance, if your company plans to manufacture a line of straightforward, standardized plastic components, you can tap into your Chinese plastic mold maker's cost efficiencies and engage in effective discussions to secure a competitive manufacturing agreement.

Higher Production and Fast Turnaround Times

In China, many injection molding companies are known for their large production capacities and efficient turnaround times. They can handle bulk orders and deliver them within a reasonable timeframe. This efficiency is due to not only affordable labor but also the ability to scale up the workforce when needed.

Most of the time, injection molding companies in the country commit to a four-week production timeline, highlighting their operational efficiency and commitment to on-time deliveries.

However, while low labor costs are attractive, some mold makers engage in unethical labor practices. That’s why it’s crucial to research and choose a partner you can rely on, like Richfields Corporation, ensuring they adhere to ethical labor standards in China.

Manufactures Polished, Intricate Products

When it comes to precision plastic injection molding, you can achieve highly polished and intricate products. Many companies in the country provide their clients with detailed and customized molds.

These molds are placed into specialized equipment that proceeds to make plastic products in bulk. This material is under high pressure, which makes it easier to create plastic parts with intricate details and designs.

Advanced Plastic Parts and Machinery

Chinese injection molders can blend or co-inject different types of advanced plastic materials in a single mold during the injection molding process. This allows them to cater to specific requirements regarding the choice of plastic materials, each with its unique texture and strength characteristics.

For example, a customer might require a plastic part with high impact resistance and a smooth, glossy finish. In such cases, the molder can co-inject the mold with two different types of advanced plastic materials. One may offer the desired strength and impact resistance, while the other provides the desired surface texture and appearance.

This flexibility in material selection and machinery allows manufacturers to create plastic components with tailored properties, meeting various performance and aesthetic criteria.

Sell Your Products to Local Chinese Consumers

China’s population of over 1.4 billion makes it one of the largest consumer markets in the world. Choosing to manufacture plastic products in China goes beyond efficient production—it is a smart move to enter this massive and dynamic marketplace.

It allows businesses to reach a wide range of potential customers with different tastes, preferences, and buying power. The diversity of the Chinese consumer market encompasses various demographics, from tech-savvy urban millennials to older residents in rural areas. This means companies can customize their products to suit specific customer profiles and regional differences.

World-Class Production Support

Beyond paying for manufacturing services, partnering with a Chinese injection molding company gives businesses access to valuable resources, equipment, and the industry-specific working culture. This exposure to their work ethics and culture specific to plastic manufacturing provides an advantage often overlooked.

Moreover, hiring them goes beyond just obtaining a third-party service. They become your business partner, offering outstanding product support and establishing a professional connection. This partnership entails a collaborative relationship where the Chinese company works with you to understand and fulfill your business needs.

Key Takeaway

Our team at Richfields Corporation provided you with the advantages of choosing China for injection molding services. These advantages make China an attractive and strategic choice for businesses looking to optimize their manufacturing processes and tap into new opportunities for growth.

If you’re seeking a top-tier injection molding company in China, your search ends here with Richfields Corporation! We specialize in delivering premium-quality and cost-effective injection molding products and services, catering to all your plastic mold-making requirements. For inquiries about our services, please feel free to contact us here. You may also explore our blogs here for deeper insights into our plastic injection molding processes.

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