How Polyfab elevates injection molded parts to the highest quality

        Cavity pressure sensor for automated assembly

        Polyfab Corp has also integrated Kistler sensors into its automated assembly system, with remarkable results
.
Burhop explained: “In automated assembly, the value of a part increases significantly each time it goes through the assembly process, and Kistler’s sensors ensure that suspect (defective) parts are separated
.
For example, we have achieved a full-scale production of a commercial printer cartridge.
Automated assembly
.

        The production process involved two injection molding machines, six robots and two 4-cavity molds
.
We installed a Kistler sensor in each mold cavity, and in the event of suspected undershot or defective parts, the system automatically separates these parts and prevents them from entering the assembly process
.
This approach has proven to bring a lot of benefits and value to our automated assembly needs
.
"

        Kistler's process monitoring system saves users valuable time, reduces costs and increases ROI

        Kistler process monitoring systems save users valuable time, reduce costs and increase ROI
.
“Reducing the re-validation process is the key to saving time and reducing costs in my opinion,” Burhop said
.
For example, we may need to validate a tool in another process for throughput reasons, or to help customers reduce risk.
Performance, thanks to Kistler's technology, replicating the entire process has become easier and more scientific in terms of acquiring data in the cavity and the actual pressure curve
.
"

        Polyfab deployed Kistler's process monitoring system in an automated production line for living hinged dispenser closures, successfully saving time, reducing costs and increasing ROI
.

        Kistler Product Sales Manager Bob Hendricks, who worked closely with Burhop, further explained the time benefits Kistler's process monitoring systems and sensors bring to customers
.
"The reference curve representing the quality of the part is valid on every injection molding machine, so when a part needs to be transferred from one injection molding machine to another, there is no need to re-validate the entire process each time,
" he said.

        Shorter installation times ensure optimized production

        According to Burhop, Kistler's systems and sensors are quick to install and easy to learn and use
.
Kistler contact terminals mounted in injection moulds have also proven to be of great benefit
.
Burhop said: “Kistler’s contact terminals significantly simplify the process of dismantling and repairing molds
.
At Polyfab, we focus on lean production and want to simplify the installation process and enable quick replacement
.
With Kistler’s multi-channel connectors, only one connection is enough.
Thanks to
this, Burhop and his team saved a lot of time, significantly reduced the injection failure rate, and thus reduced costs
.

        Burhop added: “I think Kistler’s piezoelectric sensor technology is easier to use than many sensors on the market today.
It’s
very easy to install a Kistler process monitoring system on an injection molding machine
.
Because the entire installation process is so streamlined, we only need to Extract a signal and you can start collecting data right away
.
”

        Kistler takes customer satisfaction very seriously

        Hendricks said that he is very happy to maintain a long-term and successful cooperation with Polyfab.
He emphasized: "Kistler attaches great importance to meeting customer needs and strives to achieve 100% customer satisfaction
.
Our goal is to help customers achieve zero-defect mass production, regardless of customer.
Wherever we are in the world, we provide customized professional advice and a variety of on-site technical support such as calibration services
.
”

        "We are very satisfied with Kistler's service and support," Burhop said.
"It's rare that something goes wrong, but every time, Kistler's support team responds quickly and provides an amazing service
.
During the deployment and installation of Kistler Our mold shop installed the sensor in the mold without a hitch
.
The installation process was very simple and almost completely transparent
.
”