Process Automation in the Plastic Injection Industry

Plastic injection is one of the most critical processes in the manufacturing industry, enabling large-scale production of components ranging from household items to specific parts for the automotive, electronics, and medical sectors.

In this context, thermoplastic material, usually in the form of pellets, is melted and injected into moulds designed to create products of various shapes, in a process that demands efficiency and precision.

With the rise in global competitiveness and the growing demand for quality, reliability, and sustainability, plastic injection companies have been heavily investing in automation and robotics to improve processes, reduce costs, and minimize waste.

The Essential Role of Automation

Automation and digitalization have already proven to be central to the modernization of production processes.

Nowadays, increasingly sophisticated injection machines incorporate sensors and advanced software that monitor and analyze data in real time, while collaborative robots work side by side with operators.

The integration of systems such as MES (Manufacturing Execution Systems) allows for strict control of the entire production chain, increasing visibility and responsiveness to market demands.

Integration of Automation Technologies

Automation in the plastics sector results from the convergence of various technologies that contribute to greater efficiency and flexibility in production.

Combining different technologies into complete, customized solutions for each application is the right path to achieving more efficient and precise processes in this sector.

Below, we present the automation technologies that have stood out the most in plastic industry processes.

Cartesian and Articulated Robots

Cartesian robots and articulated robotic arms are widely used in industrial machines to remove parts from moulds, insert components, or even transfer products to other operations (such as inspection and packaging).

This is how companies can significantly reduce cycle time, avoid damage, and minimize potential contamination.

Automatic Part Feeders

Automatic part feeding systems, such as the one integrated into the OLI Automatic Cell project developed by Selmatron, ensure a constant and flexible supply to the machines.

Adjusted to the needs of each process, these components dispense parts oriented in the correct position, making them easier to handle in the subsequent stages.

Machine Vision Systems

High-resolution cameras integrated into machine vision systems enable the automatic inspection of each part in fractions of a second, identifying various types of defects and imperfections.

Automating this inspection allows for the immediate categorization of non-conforming items as NOK and reinforces the traceability of the produced part batches.

The integration of such solutions is one of the most frequent choices during the development of special-purpose machines by Selmatron, thanks to the positive impact they have on quality control across various types of products.

Collaborative Robots

The evolution of collaborative robots (or cobots) allows them to operate in increasingly close harmony with human workers, without the need for physical barriers.

This technology not only enhances the flexibility and safety of the production line but also frees up operators for higher value-added tasks.

Responsible for significant increases in both efficiency and safety, these solutions are programmable via intuitive interfaces and can be reconfigured for new tasks in a short amount of time.

The Role of Robotics

The integration of robotics has been fundamental in automating plastic injection processes, bringing significant advancements in quality and flexibility. This is a technological evolution that encompasses both material handling and the automation of complex tasks, resulting in remarkable benefits for companies.

In the production and processing lines of companies, one can find industrial machinery robots in more than one stage:

• Component insertion: Robots are used to position metal inserts in the moulds before injection, ensuring precision and repeatability.
• Part removal and finishing: After moulding, robots perform part extraction, injection gate trimming, and sorting, as well as assembly and quality control tasks.
• In-Mould Labelling (IML): In-Mould Labelling technology allows labels or graphics to be applied directly inside the mould during injection, a process effectively carried out by specialized robots.
• Assembly tasks: Industrial systems with robots are equipped with specific accessories, such as high-precision grippers, and are programmed to carry out complex assembly operations according to the dimensions, shapes, and layout of the production line.
• Quality control: By combining industrial and collaborative robots with sensors and machine vision components, it is possible to detect imperfections and identify defects that compromise the quality of the final product. This is a preventive way of identifying non-conformities and ensuring robust quality control.

Selmatron already has proven experience and a high level of expertise in creating complete industrial solutions for each of the stages mentioned above.

On our Special Machines page, you can find images and case studies of solutions developed by our brand.

Main Benefits Achieved

Within the wide range of applications that can be automated, companies in the plastic injection industry can benefit from advantages such as:

• Increased productivity and quality: Automating repetitive and precise tasks, such as component insertion and removal of moulded parts, reduces cycle time and minimizes human error, ensuring greater consistency in production.
• Operational flexibility: Robots integrated into industrial machines, for example, can be easily reprogrammed for different tasks, allowing quick adaptation to new product lines or changes in part design.
• Improved workplace safety: By taking over potentially hazardous or difficult tasks, systems composed of automation components help reduce accidents and injuries among workers.
• Optimization of complex processes: The use of 6-axis robots enables the production of complex parts with metal inserts and imprint moulding, as well as the application of graphics during the injection process.
• Sustainability and Energy Efficiency: Automated processes allow for more precise control of energy and raw material consumption, contributing to waste reduction and a lower environmental impact.

Implementation Approaches

To maximize the benefits and mitigate the risks inherent in implementing a robotics system, as with other areas of automation, it is advisable to adopt a structured and planned approach:

• Gradual Planning
  Instead of a total and immediate transformation, many companies choose to automate the most critical stages first, spreading the investment and allowing the team to adapt to the new technologies.
• Strategic Partnerships
  Establishing partnerships with reliable automation and technology providers, such as Selmatron, facilitates the development of customized solutions and the implementation of innovation projects, thanks to technical expertise, know-how, and risk assessment.
• Application of Lean Methodologies
  Integrating lean manufacturing principles with automation enables the elimination of waste at all stages of the production process, promoting continuous improvement based on well-defined performance indicators (such as OEE – Overall Equipment Effectiveness).

The Future Has Already Begun

Harnessing industrial robotics to automate plastic injection processes is a competitive advantage in the sector, one that will become increasingly evident over the coming years.

This approach to modernization delivers significant gains in productivity, safety, and quality. Companies that adopt robotics will be able to automate repetitive processes and transform the way they operate, making themselves more competitive.

The trend is for the plastics industry to continue investing in technology to optimize its processes and meet the sector’s growing demands.

Ready to Take Your Production to the Next Level?

You can count on us to develop a project tailored to your business.

Our special custom-made machines are designed to meet the specific needs of your industrial processes.

Talk to Selmatron to share your business requirements and benefit from a specialized team in robotics and industrial automation, ready to meet your needs from start to finish.