On-Site Testing: 10 Cable Tie Molds – 70 Key Videos

In a collaborative project with a client, we used a 358-ton injection molding machine and 10 molds to conduct a comprehensive production line setup and testing.

This experience was meticulously documented in 70 videos. Below is a complete summary of this project.

Part 1: Project Background and Overview

In this project, we provided the client with equipment and molds while conducting on-site testing with materials supplied by the client.

The client brought 10 bags of PA6 resin, each weighing 50 kilograms, for testing purposes.

However, the complexity of the materials added additional challenges to the process:

  • Material Characteristics Vary by Region: Each country’s resin manufacturers tailor material properties to local market needs, which added difficulty to our adjustments.
  • Import Duty Costs: The client incurred customs duties of approximately 3,000–4,000 RMB for importing the materials.
  • Time and Material Constraints: Completing the tasks within limited material supplies and testing time required significant efficiency.

Thanks to our extensive familiarity with cable tie production and the practical expertise of our team, we swiftly made adjustments to overcome these challenges.

Part 2: The Testing Process and Solutions

During the testing process, we faced the following major issues:

  1. Insufficient Mold Temperature
    • On the first day, a substantial amount of material was consumed merely to raise the mold temperature.
    • By the second day, we integrated a mold temperature controller, effectively resolving this issue.
  2. Nozzle Blockage
  3. Material Purging
    • Old materials needed to be purged before stop production.

Throughout the process, our engineers leveraged their rich experience to optimize injection parameters and refine mold settings.

A adjustment to the masterbatch for complete the task. The final tensile strength of the cable ties exceeded expectations, earning high praise from the client.

Comprehensive Summary of Cable Tie Production Testing

Part 3: Client Collaboration and Insights

A distinctive aspect of this project was the deep involvement of the client. They actively provided locally sourced materials and closely observed the performance of both the equipment and the final products.

This collaboration allowed the client to gain a clearer understanding of cable tie production, particularly the critical balance between machinery, molds, and materials. Achieving stability in these three areas is essential for optimal production outcomes.

Comprehensive Summary of Cable Tie Production Testing-1

Part 4: Key Insights and Summary

Taking this opportunity, I identified two key stages of cable tie production, which are easier to explain with video:

  1. Burning Money Stage
    • This is the transitional phase from the first shot to fully qualified products. Even with experienced operators and ideal conditions, this stage typically takes 1.5 to 2 hours. The resource waste during this time is significant, requiring careful management to minimize losses.
  2. Printing Money Stage
    • Once production stabilizes, the equipment runs efficiently, and cable ties can be produced continuously at minimal cost. This stage represents the core of profitability.

Efforts to improve production efficiency often focus on the printing money stage, such as increasing mold cavity numbers, which enhances output but may extend the burning money stage.

Managing the burning money stage is equally important, especially when dealing with small-batch, multi-specification orders. Failure to address this can directly impact production costs and profitability.

Conclusion

The testing and adjustments have been consolidated into 70 short videos, most of which are under 1 minute, totaling just over an hour of content. 

These videos provide invaluable insights for newcomers to the field and serve as a foundational training resource for staff development.

This project demonstrates the importance of meticulous testing, effective collaboration, and a deep understanding of production dynamics.

It is our hope that these resources will benefit more individuals and businesses navigating the complexities of cable tie production.

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