Buyer's Guide: Selecting a Qualified Injection Molding ...

29 Apr.,2024

 

Buyer's Guide: Selecting a Qualified Injection Molding ...

In cases where budget and delivery problems occurred in a plastic injection molding project, it’s often true that these problems could have been prevented during the partner selection process. These problems include:

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  • Compromised quality
  • Unpredictable lead and delivery times
  • Gaps in capability 

There are a number of qualities that plastic injection molding manufacturers can demonstrate to show that they are best qualified to avoid these problems.

Quality

Customers seeking a plastic injection molding partner can ask for a number of assurances about the quality of the work. Injection molding providers can prove their ability to meet quality standards by showing potential customers that they have:

  • Adequate traceability from resin raw material to the finished product
  • Quality certifications and protocols that are needed for your industry segment
  • The ability to track scrap to achieve a quality KPI
  • A robust molding process that is approved during the mold-building process
  • An excellent quality inspection lab (team)
  • Industry 4.0 technology that monitors the injection molding process on all machines live on the production floor
  • Demonstrated success in the market

Timeliness

A qualified partner should have a process for communicating timelines that involves an initial agreement between customer and manufacturer about timelines and expectations. Procurement challenges do occur, but advance planning reduces these challenges. In plastics, procurement of raw materials (resins and compounds) can take 6 to 16 weeks or more, depending on disruptions in the supply chain like weather-related disasters and global events.

Injection molders also meet expectations of timeliness through transparency in their forecast of the entire process and through supply chain management practices. Some specific ways they achieve on-time delivery include:

  • Providing mold design, fabrication, qualification, and production in-house: Providing these services in-house cuts down dramatically on the time that would be required to have the project transported and processed elsewhere.
  • Using Kanban (just-in-time) shipping technology to track and maintain inventory levels.
  • Using Quick Response Manufacturing (QRM) work cells: Studies have shown that the physical time of manufacturing the product is only 5-12% of the total lead time in a project. Using the

    Quick Response Manufacturing (QRM)

    system, manufacturers can optimally manage time, organizational structure, system dynamics, and time-based management principles in all parts of the organization. 
  • Using blanket purchase orders rather than waiting for a new P.O. in cases where purchases are recurring or when changes need to be made in dollar amounts, quantities, goods and services, and/or the maximum order. 

Capability

Does the partner you are considering have the production capabilities for your project? 

In short, your partner must have the equipment to perform the job, provide facilities that are modern and well maintained, and have a plant designed for efficient workflow with flexible manufacturing systems. They should perform process monitoring, scientific injection molding, and decoupled molding to ensure that the best manufacturing process is performed.

Your partner should have demonstrated success in designing and fabricating injection molds. They should be equipped with both horizontal and vertical molding presses, depending on your project needs. In addition, they should offer the highest level of standards for certification and decoupled molding processes. 

Finally, the financial health of the company is an essential indicator of capability. A potential partner should be able to demonstrate proven success in overseeing operations, such as forecasting into the next quarter, and conducting inventory forecasts. A financially healthy partner not only has all of the equipment, processes, and personnel to complete your job, but has the capacity to acquire assets that will make your job run with optimal quality and efficiency.

Case Study: Finding the Right Injection Molding Partner Solves 3 Key Challenges

“We were looking to find a partner that could support our company’s entry into the biopharmaceutical market and also a partner that met all of the technical requirements for manufacturing molded parts for that market.” — Pharmaceutical Executive

Technical Challenges

A pharmaceutical company was seeking a partner to support entry into the biopharmaceutical market. They engaged a procurement specialist to research vendors. “We were looking to find a partner that met all of the technical requirements for manufacturing molded parts for that market,” an executive reports.

This company had the following criteria:

  • Molded parts needed to be manufactured in an ISO Class & Clean Room.
  • The supplier needed to be certified for manufacturing to the ISO 13845 Medical Devices Standard.
  • The molding tools needed to be manufactured in the United States.

Design Challenges

The customer was seeking to stay with their total budget for three tools with multiple variations of the parts. This presented a significant budget hurdle, but Crescent Industries met the challenge by building injection molding tool sets with removable cavities that would utilize their Master Frame bases to house their tools during production runs. 

Timing Challenges

The supplier needed to support a schedule to design and fabricate tooling and produce initial injection-molded parts with a quick turnaround. The solution to this problem was 

  • Working with a partner that could design and fabricate in-house
  • Working with a partner that manufactured tools in the United States to avoid long transportation line times and the risk of shipping delays.

The Complete Buyer's Guide to Plastic Pallets

Plastic pallets have become the cornerstone of sustainable, green supply chain management (GSCM). Their efficiency, durability, and cost-effectiveness has earned them the support of environmentalists, distributors, and economists alike. Today, plastic pallets are manufactured by hundreds of companies worldwide. Unlike wood pallets, plastic pallets offer a wide range of styles, sizes, and features. To help you purchase the best plastic pallets for your business, here’s the complete buyer’s guide to plastic pallets.

 

 

Structural Styles

Rackable Pallets

Pallets with length-wise, structurally supportive runners are often referred to as “rackable” or “rack-compatible” pallets. Having skid runners instead of feet enables rackable pallets to span the width of industrial storage racks and shelving. Naturally, rackable pallets can also be stacked or rest directly on the floor. Rackable pallets tend to be among the strongest options on the market, but that strength generally comes with additional weight and material costs. They’re necessary for rack storage and ideal for warehouses, retail stores, and general product storage.

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Nestable Pallets

The nestability of many plastic pallets is a huge advantage over traditional wood pallets. Designed with concave, cupped feet, these pallets nest inside each other when empty. This nesting provides incredible space efficiency, which can save a lot of money on return shipping and storage. While a traditional wood pallet may require more than six inches of vertical space, a nestable pallet can often require less than an inch when nested inside another pallet. This means that while a dozen wood pallets may waste up to six feet of vertical space, that same space can be filled with more than 60 nestable pallets.

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Stackable Pallets

Many plastic pallet descriptions include the word “stackable.” What this means is that those pallets are designed with features that enable safe and secure stacking. The design of these features can range.  Nestable pallets are inherently stackable, due to their cupped feet. Other stackable designs may include a small lip or edge along the top of the pallet that matches a corresponding groove or slot along the bottom. More advanced plastic pallet designs may feature entire deck tops that interlock with the bottom runners of other pallets. Whatever design technology is used, the end results are pallets that securely stack together — helping to eliminate the clutter and risks associated with precarious stacks of wooden pallets.

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Export “One Way” Pallets

Lightweight pallets are often referred to as “one way” or “export” pallets. These minimalist plastic pallets are often inexpensive and lightweight, reducing the costs associated with packaging and freight. But don’t mistake their streamlined look with weakness. Plastic export pallets can generally hold loads equal to or heavier than traditional wood GMA pallets (4,600 lbs.), but plastic pallets often weigh much less. As an added benefit, the moisture and contaminant resistance of plastic pallets can also help reduce product spoilage and customs issues caused by infested wood pallets.

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Deck Styles

Closed Deck Pallets

Closed deck pallets are those with solid-surface tops. These decks provide a smooth surface for the bottom of the cargo, which can be ideal for sensitive products. They minimize surface abrasion and protect contents from sagging or falling through the pallet. Some closed deck pallets have structural or functional features built in. These features can include non-slip materials, drainage holes, strap restraints, etc.

 

Ventilated Deck Pallets

As a hybrid between closed and open deck pallets, ventilated deck pallets feature generally smooth top faces with a number of ventilation holes, slits, or grooves. These vents protect the bottom of contents while still allowing airflow and drainage around products. This helps manage the moisture, pressure, temperature, and gaseous exposure of contents. Ventilated deck pallets are popular with industries dealing with food processing, paper goods, textiles, building materials, and wet conditions.

 

Open Deck Pallets

Open deck pallets provide minimal touch points on the surface of the pallet. They generally rely on a web or grid based design to provide structural support, but they remain otherwise open from top to bottom. The absence of a solid deck reduces the weight and provides unparalleled visual access, tie down points, drainage, and ventilation. Open deck pallets are popularly used with exports, packaged goods, agricultural produce, and machinery.

 

Specialty Pallets

Plastic pallets serve every industry, but flat pallets aren’t always the best fit. Speciality pallets are made for a wide number of uses. They include standard, octagonal, and cubed drainage retention pallets, drum pallets, and concave pallets with cylindrical supports for rolled materials. Another innovative style of specialty pallets are sectional, interlocking pallets. Sold in individual sections, these plastic pallets connect to one another and allow users to build the perfect pallets for their specifications.

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Materials

There are three primary materials used in plastic pallets. While each have their own unique benefits (e.g. rigidity vs. impact resistance), they’re generally equally sufficient for most use cases. The differences outlined here will not be noticeable for most users, but they may be a factor for those seeking to push the performance limits of various pallets.

 

High Density Polypropylene (HDPP) Pallets

High Density Polypropylene (HDPP) is the most common resin used in plastic pallets. It is light, durable, widely available, and used in everything from milk jugs to furniture. Slightly less rigid than HDPE (see below), HDPP has incredible impact resistance. HDPP tends to be more cost-effective than HDPE. HDPP pallets are ideal for high volume, fast paced, and tough work environments.

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High Density Polyethylene (HDPE) Pallets

High Density Polyethylene (HDPE) is the most common plastic in the United States, and the second most popular option for plastic pallets. As a chemical compound, it is slightly more rigid than HDPP, which makes it stronger but also less impact resistant. It’s ideal for sensitive products and low-abuse environments, such as in the technology, glasswares, and beverage distribution sectors.

 

Polyolefin (PO) & Advanced Composite Material (ACM) Pallets

Polyolefin (PO) is sometimes referred to as Advanced Composite Material (ACM). Made from a composite of various plastics and cellulose, PO tends to be more cost effective than HDPP and more rigid than HDPE. However, the PO material has been known to bleed colors or gels when exposed to water, so they are generally not used in food processing or with unprotected consumer goods. PO pallets work well in dry conditions and one-way shipping.

 

 

Sizes

Standard Truck Sized Pallets

The typical tractor trailer hauls an 8-foot wide trailer, which is the same width as a sea container. As such, pallets with either lengths or widths of 48 inches (or slightly less) are generally ideal for maximizing load space. The most commonly used sizes are:

  • 44″ x 44″
  • 48″ x 32″
  • 48″ x 40″ (GMA Size)
  • 48″ x 45″
  • 48″ x 48″

Plastic pallets can be invaluable to maximizing trailer and container space, as nearly all plastic pallets feature 4-way fork access. This enables pallets to be loaded from any side, often eliminating the need for space-wasting “chimney stacking” or “narrow:narrow” load configurations.

 

Extended Length Pallets

Extended length pallets are generally any that exceed 48 inches in any direction. These large pallets are often used to transport large machinery, furniture, and other pre-assembled items. While custom pallets can always be made, there are some more common extended length pallets, including:

  • 26″ x 52″
  • 52″ x 52″
  • 54″ x 48″
  • 60″ x 48″
  • 60″ x 60″

 

Small Pallets

On the opposite end of the spectrum, there is an almost endless array of small plastic pallets, which we define as any pallet with a length or width shorter than 32 inches. Small pallets are useful in optimizing space, perfect for smaller deliveries, and easy to navigate through smaller doorways, aisles, and rows. Like all plastic packaging products, small pallets can be highly customized and built-to-suit, making them ideal for product-specific uses. Frequently sold sizes include:

  • 24″ x 16″
  • 32″ x 24″
  • 32″ x 30″

 

Shop Plastic Pallets by Size

Rackable Pallet Sizes
Nestable Pallet Sizes
Stackable Pallet Sizes
One-Way Pallet Sizes

 

 

Weights

Load Weights

Plastic pallets provide exceptional strength. Even the lightweight models often exceed the load capacities of wood pallets. Lightweight plastic pallet options are often rated for static loads over 3,000 lbs., and the heavy duty pallet versions are capable of carrying loads in excess of:

Tare Weights

Pallet weight has a large impact on shipping costs, rack storage, and workplace ergonomics. Having the most efficiently weighted pallets in your fleet can save you money while also improving ease of use. Our export pallets are a great example of some of the lightest plastic pallets on the market. But even our most robust standard pallets are comparable in weight to standard wood pallets, with virtually all standard and small sizes weighing less than 50 lbs.

 

 

Additional Pallet Options and Features

RFID Technology

RFID transponders can be embedded in plastic pallets to provide tracking, identification, and security. RFID transponders are an ideal addition to any closed loop supply chain or return credit distribution system.

 

Detachable Runners

Want the efficiency of a nestable pallet with the options of a rackable pallet? Some plastic pallet models are available with detachable runners (“skids”). These runners can be easily removed and replaced, which also makes these hybrid pallets ideal for high-abuse racking operations.

 

Anti-Slip Top Decks

Sometimes the contents on top of the pallet need a little extra help staying put. That’s easily accomplished with built-in friction pads and textured decks.

 

Safety Rims

Want to make sure your goods don’t shift? Plastic pallets feature a number of subtle but effective rim styles. From complete, raised edges to small prongs, safety rims keep contents in place with also enabling the secure stacking of empty pallets.

 

Customized Imprinting, Labeling & Numbering

Plastic pallets provide a wide range of customizability. There are many hot stamping, printing, labeling, and engraving options available for everything from your branding to the pallet fleet number.

 

Metal Reinforcement Rods

Want to make a plastic pallet even stronger? Many styles are available with either built-in or optional metal reinforcement rods. These additional supports can increase dynamic load capacities and reduce bowing on pallets loaded with uneven weight distribution.

 

Stretch Wrap Traps

Built-in stretch wrap traps are available on many of our plastic pallets. The clever little slots hold stretch wrap in place, helping you get your wrapping started.

 

Top Caps

Using all three dimensions is an important way to reduce storage and transport costs. Top caps protect the contents of your pallet load while also providing a secure base for the stacking of the next loaded pallet.

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Sleeve Packs

Often paired with top-caps, sleeve packs provide walls for your pallets, turning a plastic pallet into a reusable, plastic gaylord-style bulk container. Sleeve packs are made from recyclable plastic (usually corrugated), and they collapse for easy storage and efficient returns.

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Fire Retardant

The polymers that comprise most plastic pallets are naturally more fire retardant than wood. Nevertheless, additional fire retardation treatments can be added to plastic pallets to ensure that they meet the demands and safety requirements of your organization.

 

UV Treatments

Many plastic pallet options feature UV protection either in the base product or as an add-on solution. This protects the color of the pallets when dealing with prolonged sun exposure.

 

FDA Compliant Materials

There are hundreds of styles of FDA compliant plastic pallets. Built with FDA approved resins (PP or PE) and colors, these plastic pallets are perfect for use in agricultural, food, beverage, and pharmaceutical industries.

Shop Our Complete Inventory of Plastic Pallets

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