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Injection Moulding

Blow Moulding

Blow Moulded Tank

Film Application

Pale Container Application

Extrusion Application

Woven Sack Application

Injection Moulding Applications

We Provides all types of injection moulded products solutions like cost, quality & properties etc. Bajaj also provides high efficiency and fast production, Injection Molding can handle extremely complex parts and uniformity. It helps to enhance the strength of the product, Flexibility of production is endless because of the wide range of material and color. It reduced waste and low labor costs. Bajaj Masterbatch provides customized products as per customer requirements.

NEED FOR INJECTION MOULDING

Wide Variety

This is most common plastic processing technique used for manufacturing a wide variety of plastic items ranging from smallest components like Caps, buttons, Electrical & Electronic parts, buttons, etc to large components like Car bumper , dash board, Home Appliances body , etc.

high production output

The process itself is extremely fast compared to other methods, and the high production output rate makes it even more efficient and cost-effective. Speed depends on the complexity and size of the mold but only about 15-120 seconds pass between each cycle time.

Strength

Strength is one of the key factors determined when designing a plastic injection molded part. The designer will ascertain if the part needs to be flexible or rigid based on it’s end application requirements .

High Quality and Sustainability

When looking for a high-volume injection molding process, it’s important to consider companies’ green manufacturing initiatives, as these signify a commitment to quality, sustainability, and optimal safety.

Lower Labour Cost

Labor costs are relatively low in plastic injection molding, in comparison with other types of molding. The ability to produce the parts at a very high level with a high output rate helps with its cost efficiency and effectiveness.

TYPES OF INJECTION MOULDING

Thin wall moulding

It is a technology that achieves a plastic part with a very thin wall. It is often used in test apparatuses, electronic items, Food containers , tubes, and other enclosures.

Gas assisted Injection molding

is used when any thick plastic injection-molded part is that it runs the risk of distortion as it cools. This method helps to solve this issue by shooting gas into a plastic material-filled injection mold, allows the plastic on the outside of the mold to maintain a smooth and finished appearance while the inside stays porous or hollow.

Micro Injection moulding

is a process of obtaining micro injection moulded parts that weighs less than 1/10th of a gram, here very high precision is involved in both tooling as well as production.

Injection compression Moulding

is a technique where the molten polymer is injected into a partially open mould , then the mould closes to compresses and distributes the melt through out the cavity , completing filling and packing stage. This process works on lower injection pressure providing lower moulded in stress and thin walled part production.

Co-Injection(Sandwich) Moulding

is a process in which 2 different but compatible polymer melts are injected sequentially into a cold mould , forming a skin / core structure . The possibility of using recycled material in the core can be regarded as one of the key advantage in this process.

Insert Moulding process

are mostly done in vertical injection machines with vertical / horizontal clamp unit. In this an insert is placed into the mould cavity before closing and the plastic is then injected around the insert so that the insert becomes a part of the final moulded product.

Foam Moulding Process

is a low pressure process inwhich an inert gas is introduced into molten polymer the purpose of reducing density and hence weight of the finished product. Moulded products have cellular cores surrounded by rigid, integral skins. Foaming agents such as Nitrogen, Carbon di oxide is introduced into the polymer melt stream, creating a homogenous mixture of polymer & gas.

Fusible core Injection moulding

is a specialized process used to manufacture components with cavities / undercuts .

Rapid Injection moulding

is a process to make prototype injection moulded parts in a thermoplastic resin in 2-5 weeks. These parts are used for full functional and fit testing.

2-Shot Injection Moulding

is a technology of producing a part with 2 different raw materials or colours in single operation.

Classification of Injections Moulding

Hand Moulding Machine

Vertical & Horizonatal type Injection Moulding Machine

Advantages of Using
Bajaj Injection Moulding Solutions

Complex Part Design

High Efficiency- Fast Production

Enhanced Strength

Flexibility- Material and Color

Reduced Waste

Low Labor Costs

Further Injection of material can be done by two ways as given below :

1. The Screw type Injection Moulding

The Screw type injection moulding machine which utilizes motorized screw to mix and push the molten plastic material inside the mould. Screw does dual function of melting (compresses , melt and convey) & pushing the material , hence called as reciprocating screw.

2. The Ram type injection moulding

The Ram type injection moulding machine which uses a hydraulically operated plunger to push the molten plastic material into the mould.

Clamping unit

They are placed at the back of the mould in the machine. Mould is clamped to platen of the machine. One platen is stationery which has injection unit at its back while the other one attached to clamping unit is movable. The main function of clamping unit is to keep mould closed when hot plastic material is injected into mould at high speed & pressures. In general, Clamping pressure has to be higher than the Injection pressure. There are 2 types of clamping units, namely

A) Direct Locking unit which utilize a high pressure hydraulic cylinder where clamping forces is focused in the centre providing even force distribution.

B) Toggle clamps which are mechanical clamping providing both high speed and high force at different points in the cycle when required.

Clamping Tonnage : Clamping unit is rated in terms of Tonnage which is the maximum force that the machine can provide to keep the mould closed during the mould process.

Clamping force = Projected Area X Injection Pressure

The projected area of the part can be found based on the geometry ( dimensions) of the part. The injection pressure varies with the flow or viscosity of the polymeric material. Too low a clamping force can lead a short part or unfilled parts while too high clamping force can open mould leading to flash or even damage mould sometimes.

Bajaj Masterbatch Injection Moulding Applications

Injection Moulding Process Cycle

Product Solutions for Injection Moulding

Filler Masterbatch For
Injection Moulding Applications

ProductDescription
Plast Stiff "Cost Saving Of Polymer,Better Productivity,Less Machine Wear & Tear,Energy Saving ,Less Wastage,Lower Total Cost."
Plast White "Cost Saving Of Polymer, Increases Output, Better Productivity, Less Machine Wear & Tear, Energy Saving, Less Wastage, Lower Total Cost"
Plast Modifier It Increases Mechanical Properties In Highly Filled Mineral And Recycled Polyolefins Specially Made For Woven Fabric/Sack, Jumbo Bags
Plast Fab "Cost Saving Of Polymer,Better Productivity,Less Machine Wear & Tear,Energy Saving ,Less Wastage,Lower Total Cost."
Plast Clear "Act As Nucleating Agent,Cost Saving Of Polymer Better Productivity,Less Machine Wear & Tear,Energy Saving ,Less Wastage,Lower Total Cost"

White Masterbatch For
Injection Moulding Applications

ProductDescription
Plast Ultra 40% Gives excellent opacity, reinforcing brightness & delivering the best print appearance on the substrate
Plast Ultra 50% Gives excellent opacity, reinforcing brightness & delivering the best print appearance on the substrate
Plast Ultra 60% Gives excellent opacity, reinforcing brightness & delivering the best print appearance on the substrate
Plast Ultra 70% Gives excellent opacity, reinforcing brightness & delivering the best print appearance on the substrate
Plast Ultra 75% Gives excellent opacity, reinforcing brightness & delivering the best print appearance on the substrate

Black For
Injection Moulding Applications

ProductDescription
Plast Black 40% It is used for conductive application to discharge the surface electricity and earthing. Carbon Black is used as an additive
Plast Black 45% It is used for conductive application to discharge the surface electricity and earthing. Carbon Black is used as an additive

Additive Masterbatch For
Injection Moulding Applications

ProductDescription
Plast Anti MicrobialIt is an active agent that when included in the processing of a material will inhibit the life or growth of microbes.
Plast Anti Oxidant Prevents loss of physical and mechanical properties in polymers . Prevents gas fading of plastics when subjected to atmospheric pollutants.
Plast PPA They improve the melt process ability and handling of high molecular weight polymers to improve the appearance of the final product.
Plast Dessicant Prevents degradation of the polymer, corrosion of the metal parts inside the extruder which shortens its durability
Plast Slip Slip additives are products which can be added to polymers to control friction. Excellent printability , faster winding & unwinding of films.
Plast Antislip Useful for preventing slippage of bags including big woven sacks slipping over each other while stacking and transportation
Plast Bright They are used to mask the inherent yellowness, impart robust colour strength in plastic products & recycled material as well.
Plast Antiblock Reduces adhesion effect, lubricative function & coefficient of friction, It does not affect optical properties, Improves scratch resistance & aethetics.
Plast Antistat Prevents damage to microelectronics, prevents dust and reduces explosion risk due to static discharge in vicinity of flammable materials

Color Masterbatch For
Injection Moulding Applications

ProductDescription
Plast Red Bajaj Plast Red colour masterbatch series is used for giving different Red colour shades to the plastic products using Ral and Pantone.
Plast Green Bajaj Plast Green colour masterbatch series is used for giving different Green colour shades to the plastic products using Ral and Pantone.
Plast Blue Bajaj Plast Blue colour masterbatch series is used for giving different Blue colour shades to the plastic products using Ral and Pantone.
Plast Yellow Bajaj Plast Yellow colour masterbatch series is used for giving different Yellow colour shades to the plastic products using Ral and Pantone.
Plast Orange Bajaj Plast Orange colour masterbatch series is used for giving different Orange colour shades to the plastic products using Ral and Pantone.
Plast Violet Bajaj Plast Violet colour masterbatch series is used for giving different Violet colour shades to the plastic products using Ral and Pantone.
Plast Grey Bajaj Plast Grey colour masterbatch series is used for giving different Grey colour shades to the plastic products using Ral and Pantone.
Plast Brown Bajaj Plast Brown colour masterbatch series is used for giving different Brown colour shades to the plastic products using Ral and Pantone.

Injection Moulding Product Types

Product NameCategoryFeaturesDownload TDS
Filler
Materbatch
Plast stiffCost Saving of Polymer,Better Productivity,Less Machine Wear & Tear,Energy Saving ,Less Wastage,LOWER TOTAL COST. Download TDS
Plast ModifierImproves Whiteness ,Excellent Gloss, Shine & Luster, Improves Dispersion ,Minimize Denier Variation ,Increase Strength ,Increase Elongation ,Increase Output Download TDS
Plast Whitecost saving of polymer, increases output, better productivity, less machine wear & tear, energy saving, less wastage, lower total cost Download TDS
Plast clearAct as Nucleating Agent,Cost Saving of Polymer Better Productivity,Less Machine Wear & Tear,Energy Saving ,Less Wastage,LOWER TOTAL COST Download TDS
Plast FabCost Saving of Polymer,Better Productivity,Less Machine Wear & Tear,Energy Saving ,Less Wastage,LOWER TOTAL COST. Download TDS
White
Masterbatch
Plast Ultra 40%Improves specific properties such as Tensile strength, Elongation, bonding strength , Toughness, Heat sealing resistance , High temperature stability , Weatherability, Colour (whiteness) , surface finish ,etc Download TDS
Plast Ultra 50%Improves specific properties such as Tensile strength, Elongation, bonding strength , Toughness, Heat sealing resistance , High temperature stability , Weatherability, Colour (whiteness) , surface finish ,etc Download TDS
Plast Ultra 60%Improves specific properties such as Tensile strength, Elongation, bonding strength , Toughness, Heat sealing resistance , High temperature stability , Weatherability, Colour (whiteness) , surface finish ,etc Download TDS
Plast Ultra 70%Improves specific properties such as Tensile strength, Elongation, bonding strength , Toughness, Heat sealing resistance , High temperature stability , Weatherability, Colour (whiteness) , surface finish ,etc Download TDS
Plast Ultra 75%Improves specific properties such as Tensile strength, Elongation, bonding strength , Toughness, Heat sealing resistance , High temperature stability , Weatherability, Colour (whiteness) , surface finish ,etc Download TDS
Additive
Masterbatch
Plast
Anti Microbial
Inhibits bacterial and fungal growth on plastics by disrupting their cell membrane and also inhibiting enzymes and proteins vital for their function, Food grade – can be used in indirect food contact applications Download TDS
Plast
Anti Oxidant
Prevents loss of physical and mechanical properties in polymers . Prevents gas fading of plastics when subjected to atmospheric pollutants. Contains high concentration of a combination of primary and secondary antioxidants and thus requires a low dosage. Download TDS
Plast PPA PPA reduces line shutdowns for cleaning, allows lowering work temperature and saving energy, and the presence of gels in the final product diminishes. Another advantage is that PPA is also work as additives to improve cleanliness and facilitates to exit faster from a color in production. Download TDS
Plast DessicantCan achieve UL 94 V0, V1, V2 ratings as desired at different part thickness. It's ROHS compliant & safe to use., Reduce polymer melting, high thermal stability & yield best performance vis-a-vis cost incurred. Exhibit intermediate blooming resistance and good UV stability. Download TDS
Plast SlipExcellent printability , faster winding & unwinding of films. We also offer PPA's comprising of non-migrating additives ,temperature independent & unaffected by corona treatment or lamination process. Can be offered as slow acting or fast acting with optimum thermal stability to suit the end application. Download TDS
Plast AntislipIt acts by increasing Coefficient of Friction (COF) on film surfaces. It does not contain any abrasive ingredients, minerals in it , hence no adverse effect on screw wear during extrusion process. Useful for preventing slippage of bags including big woven sacks slipping over each other while stacking and transportation. Also helps to increase stacking height without risk of slippage and resulting damage. Download TDS
Plast BrightIt Improves films, molded items & fibers with excellent brightness better than white MB in solo. It can be applied alone or in a variety of blends and combinations with processing, heat and light stabilizers as and when required. Download TDS
Plast AntiblockReduces adhesion effect, lubricative function & coefficient of friction. It does not affect optical properties.Improves scratch resistance & aethetics.Food grade compliant, Compatible with White, Black, Colour & other Additive Masterbatches such as Slip Additive , Anti static additive & Polymer Processing aid. Download TDS
Plast AntistatBased on Amine Chemistry. Effective and long lasting performance than GMS. Can reduce surface resistivity of polymer surfaces up to 1010 - 1011 Ohm/Sq. Prevents damage to microelectronics, prevents dust, dirt accumulation and reduces explosion risk due to static discharge in vicinity of flammable materials eg. solvents Download TDS

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