How RJG eDart Transformed PCI’s Injection Moulding Operation

In 2010, PCI embarked on a 2-year journey to incorporate RJG eDart compatibility on all presses. Additionally, in 2011, PCI adjusted specifications for all new presses to be delivered with E-Dart systems hardwired and mounted directly on the press.

PCI targets very high press utilization rates. High utilization requires flexibility from an agile fleet of presses and a solid foundation in scientific molding. E-Dart systems brought additional control and flexibility to map and control highly-tuned processes with in-mold pressure sensors. As PCI continued to convert presses with eDart systems and molds with pressure sensors, we quickly reached a critical mass where a plant-wide conversion became inevitable. Closed-loop process control was now ingrained into our operating culture.

PCI has always focused on scientific molding process development. RJG enhanced that approach with a second level of process control via decoupled molding. Traditionally, our process optimization sequence was designed to develop a set of press parameters that would net a robust process window.  RJG’s eDart systems enabled machine control based upon the plastic pressure in the mold.  As a closed-loop system, our machines could now compensate for plastic pressure fluctuation due to changes in viscosity from resin formulation. Maintaining and controlling plastic pressure is a vital element of molding a consistent product.  Producing a consistent product drives significant value in both quality control and flexibility since the process is mapped to the mold versus a specific molding machine. Our engineers and technicians could now monitor, control, and contain the same process across multiple runs with multiple machines and lots of material.

The primary benefit to PCI customers is quality, or in other words, remarkably consistent product.  By coupling press and eDart control, we can deploy a robust, closed-loop molding process that maintains consistent plastic pressure and limits variation in the part. This high level of control includes the ability to reject products based upon press and eDart alarm limits.  The net result is extremely consistent quality parts in the box for shipment, as well as less scrap material for recycling.

PCI’s customers also benefit from on-time delivery. RJG’s eDart systems allow us to map processes to the mold versus the press. As a result, PCI can deploy these processes across a more comprehensive array of presses while maintaining the same process control level. This consistency results in more presses that are available to satisfy the needs of our ever-changing customer demand forecasts.

Implementing the RJG eDart system has led to transformational change in managing part consistency across different material lots with reduced scrap and processing time. PCI molds products in well over 100 different resin types, with most engineering-based resins with varying filler contents. By nature, these resins have a wide range of viscosity due to both resin formation and filler content. Scientific molding already limits some of the impacts of viscosity variation. Still, the RJG eDart system enables PCI to monitor and control in-mold plastic pressure variation within the molding cycle. This advanced level of process control means that plastic pressure is controlled on every cycle. Maintaining consistent plastic pressure is a crucial element of delivering a consistent product.

Taking a leadership role in innovation and technology across all PCI areas is core to our DNA. As a result, process control is at the heart of our engineers’ mission, who rely on RJG in many ways. For starters, RJG eDart process mapping is a requirement for all new mold qualifications at PCI.  An RJG trainer visits PCI every quarter to refresh training and to audit our processors. Our engineers often take these opportunities to further develop their knowledge of in-mold pressure sensing and control.  They can independently specify the placement of pressure sensors on new mold designs, but RJG does offer assistance for challenging applications. Finally, our engineers can also rely upon a shot-to-shot history that is saved within the eDart system for troubleshooting and root cause identification.

We have found RJG dDart technology to apply to all sizes of parts. The technology is beneficial for large parts that are molded in commodity resins with high shrinkage rates. It is also beneficial for small, more critical components in highly-filled engineering resins. As a golden rule, PCI designs every mold for in-mold pressure sensing. Our customers require a consistent product, and closed-loop processing via eDart control is the solution.

RJG has a tremendous training infrastructure, and it is critical to a molder’s success with their products. The RJG systems are not a simple flip of the switch, and it solves all of your problems, but rather a technological tool that can provide dramatic results for the molder when utilized to its maximum.

To be most effective with RJG, it requires that the human talent on the production floor understand its capabilities. We use online, in-house, and remote in-person training offered by RJG. The online options are great introductory classes for our entry-level molding technicians. The remote in-person training is designed for the top-level Master Molder candidates and hands-on at the RJG training facilities. The in-house option is one we helped create with our RJG trainer to allow for incremental advancement through different stages of RJG comprehension.

The trainer spends 3-4 days onsite at our facility multiple times per year, helping teach and train our technicians on RJG and scientific molding principles. This is a very valuable opportunity for our production personnel and is something that everyone looks forward to.