A Licence To Print Money

Our client, like many in the manufacturing industry, faced the challenge of boosting machinery performance without the significant expense of new equipment. To overcome this, they embarked on a series of R&D projects aimed at enhancing their existing machinery's capabilities. We collaborated closely, taking a comprehensive approach that tackled each problem in stages. These sub-projects not only delivered targeted improvements but also laid the foundation for future innovations.

Improving plastic injection moulding machines

A key focus was enhancing the efficiency of their plastic injection moulding machines. The goal was simple: increase the flow of pellets through the system to streamline production. The client designed and prototyped a 'collar follower' to integrate into the existing machinery, but the initial versions caused pellet contamination. This setback led to further iterations and material testing. After several adjustments, the final solution significantly improved performance, demonstrating the value of persistence in the R&D process.

Reducing manual intervention in paper rolling machines

Another critical project aimed to reduce the frequent manual intervention required for their paper rolling machines. Paper frequently stuck to the rollers, causing disruptions. To solve this, the client tested different materials and roller designs, refining prototypes until they found a solution that not only reduced maintenance but also increased the machine's overall efficiency. The result? Smoother production, less downtime and fewer manual fixes.

Lowering costs for paper printing machinery

Finally, the client sought to reduce the manufacturing costs of their paper printing machines without sacrificing performance. By exploring the existing structure, they developed a lighter, more efficient design. Rigorous testing ensured that safety and functionality were maintained, while production costs were significantly lowered - proving that innovation doesn’t have to come at a financial premium.