Tool not working in an optimum manner? It may well need a dose of Green Validation from Bozilla Corporation.
Bozilla Corporation has created a unique system designed to make your mold Green. The Green Validation System.
Going "Green" means a more efficient molding process which benefits the environment and your bottom line.
A typical scenario entails a processor contacting Bozilla because they want to bring a tool back to life and/or make a tool more efficient. We would ask them to send us everything about the tool, including CAD drawings, 3D part and tool drawings, process conditions, tool conditions, machine process settings and anything else they can provide.
The suggestions are outlined and a quote is provided. Up until this point, there is no up-front cost to the processor. The processor then determines which suggestions can be practically implemented and Bozilla provides a cost estimate. Should the customer accept the quotation, and provide a purchase order, the work can begin immediately.
Examples of tools Bozilla has worked on include those that may have been sidelined because they were cut wrong, perhaps the hot runner system, cold runner system, or the combination of both, do not work as expected, cycle times are too long or are simply known to be inefficient.
The type of work performed in the initial stage is analytical in nature, where Bozilla models the current design and conditions in a virtual world using Autodesk Moldflow Insight.
Initially, we would identify areas of the process which can be optimized, make those changes and continue to further optimize the process. Once the process has been deemed as efficient as possible (based on the tool design, materials and any other constraints), it would be reviewed and discussed with the customer where they would accept as many changes as possible, which may or may not include tool modifications (such as adding cooling lines).
It is not always obvious that a tool is underperforming unless a thorough finite element analysis is performed. This is due to the nature of tooling where you are unable to see anything occurring within the tool during the process. You can see how everything is set up before the process and you can see the part at the end of the process, but nothing in between.
Bozilla's tool optimization techniques incorporate "cutting-edge" techniques that are used to determine if tools can be optimized so that they can be brought back to life in their most efficient state. These are proprietary techniques developed using the FEA software in collaboration with empirical data acquired over the years.
Each potential issue is identified accordingly and suggested changes will be provided in order to create a streamlined, lean running tool that in turn will be green and profitable.
Some examples are adding cooling lines, balancing cooling circuits, optimizing cycle time, optimizing gate freeze time, optimize feed system design, and possibly optimizing part design (if the tool can be modified to permit these modifications). Once these deficiencies have been determined, they are discussed with the customer and the customer approves as many changes as possible.
At this time, the analysis is rerun with all approved changes and final results based on those changes are provided as an overall solution package.
This system was created due to repeated processor requests to help find a solution to make their current tools more efficient or to find a means by which to make tools that have been shelved usable again.
If a tool is not efficient or not even running, there are costs involved that are lost. This system has been proven to recapture those costs and put that money back into your pocket.
Benefits include:
· Reduce energy consumption
· Correctly match the tool with the molding machine (use the smallest machine necessary)
· Reduce cycle times
· Use less material
· Thinner walled parts
· Less feed system waste
· Select materials more suitable for the application
· Can be recycled
· Easier to process yet meet part requirements
· Create less greenhouse gases
· Create parts which can be recycled and can last longer
· Reduce waste
· Create less scrap
· Less material consumption
· Use tools which have been shelved or sidelined
Contact Bozilla Corporation for your FEA and injection molding troubleshooting needs and please visit our website at www.BozillaCorporation.com.
