Cable tie production

//Cable tie production

Cable tie production

By Bill Huang, updated in Dec of 2018

This article is about cable tie production. After reading this, you will have a general understanding of the various issues in this field.

Since 2005, we have been producing cable tie injection molding machines for 13 years. Over the past 10 years, we have helped many customers build their cable production plants.

Through continuous research and development, our machines are approved by time in practice. With a good reputation, we have a 70% market share in China’s cable tie injection molding machines.

Our turnkey ability for the entire production equipment is a guarantee of customer success.

Contents

2.5 x 100 cable tie in production.

K288F working with robot.

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1. Why does the cable tie production require special injection molding machines?  

# Characteristics of cable ties

The cable ties are long, narrow and thin, with various lengths, widths and strengths, requiring a certain tensile strength.

cable tie in different size

# The key to successful molding.

Inside of the mold cavities, the machine must get material from the head to the tail in a very short time, otherwise it begins to freeze off and build pressure.

Build the pressure

# Cable tie molding is a contradiction.

In order to fill the mold cavities, it requires a huge injection speed and injection pressure. And this huge force will all be transferred to the clamping unit. If the clamping force is not enough, the mold will be blown open.

injection pressure transit
the challenge1

# Most cable ties molds are long and narrow.

This requires a special design of the toggles and the whole clamping structure to concentrate the force on the central of the moving platen.

long-cable-tie-mold

If the toggles and the clamping units do not respond well to this challenge, they will quickly have problem due to the uneven force, for example, the broken of the column or the broken of the platen.

# Some customized machines that increase injection pressure and injection speed by simply raising pump and motor capacity.

On this way, it can achieve the first goal of filling the cavity or success molding. However, each injection and clamping will bring the impact on the toggles which transmit to the whole clamping unit. If the toggles and the clamping units do not prepare well to this huge clamping force, as we have discussed, they will quickly have problem (usually within six months to a year).

# Injection unit.

The injection unit, especially the screw and the nozzle, needs to be designed according to the characteristics of PA66 – with high fluidity in the molten state.

injection-unit

2. Several key technical data for cable tie production you need to pay attention to:

First of the all, temperature

Temperature refers to the temperature of the plastic (PA66) in the molten state.

Temperature = machine heating temperature × cycle time

temperature- cycle time-1

high temperature + short cycle time

temperature- cycle time-2

low temperature + long cycle time

temperature- cycle time-3

high temperature + long cycle time

The areas of points A and B are the same, but point C is much larger than A and B.

More areas mean higher temperatures and result in higher fluidity of the PA66, which is being heated in the barrel.

Here we may think A and B are under the same temperature, and C is much more than them.

Once the temperature is too high, the quality of the cable tie will be degraded and we will see the cable tie turn to yellow color.

The problem of yellow cable ties may be hidden by some additives. We will not expand this issue here.

There are the solutions: 

Behind the high temperature, the molten material is required to have higher fluidity (PA66):

# From materials, add its fluidity. You need to discuss with your PA66 supplier to obtain one PA66 with high fluidity, or at high temperatures, the quality will not be degraded.

# From the machine, increase the injection pressure and injection speed. We have discussed topic in the first part.

# From the mold cavities, the cavity quantity is closely related to the injection pressure and injection speed.

The quantity of cavities is less, the request for injection pressure and injection speed are reduced, but the production output will become less.

# From the cable tie size, you can modify the cable tie to be thicker, etc., but obviously, it will increase the weight of each cable tie, which will bring more cost.

Summary:temperature, fluidity of the material, injection pressure & injection speed of the machine, mold cavities, cable tie size are the key technical data for the cable tie production.

3. Three M – machine, mold and material in the cable tie production

From the above, we may know how these three roles work.

Each cable tie manufacturer will have its own triangle based on their actual situation.

A good role will help the other two. If all three roles are good, you will continue to improve.

4. The normal trajectory of the cable ties factory

Normally the cable tie factory bought machines, molds and materials. If the molding is successful, they will increase the number of cavities in order to reduce the cost. If unsuccessful, will decrease the mold cavities or buy another new big machine to try again.

# Keep trying these three roles (machines, molds, and materials) step by step.

# For them, all these three roles hasn’t fixed specially in the beginning.

# It is a very high possibility that they will make the mistake because they are facing the three parts in the same time. 

We have been in the cable tie field for the last 13 years. We started developing our injection molding machine from 2005 had helped lots of clients to establish their plant successfully.

We have developed a complete range of cable tie injection molding machines. (288 tons, 358 tons, 428 tons, 500 tons, 650 tons, 850 tons and 1,000 tons). And we still keep improving to develop the injection molding machine for the cable tie.

5. What can we do for you? – Our ability of turnkey project. 

Our turnkey ability of the complete project guarantee your success.

# First of the all, molding success. At the beginning, in the triangle ( 3M – machine, mold and material ), we can assume two roles: machine and mold, and participate in the part of the material by providing suggestions of the formula. So, you can just focus on material issues. We have provided the two corners, and we together can easily build your triangle.

The assist we provided at the beginning is necessary for you to learn how to get used to our machines.

– Complete advices for the machine operation and daily management.

– Complete plan for the cable tie quality control system.

– Keep updating you with the newest information about the cable tie production.

We may provide the complete plan for your development.

# After the molding success, you will be interested in large machines, which will bring more production and lower costs, which will give you a more favorable position in the market. We have a full series of cable tie injection molding machine for you to choose, from 288 ton to 1000 ton.

With time and development, you will have your own experience in these three roles in triangles ( 3M – machine, mold and material) and you will have your own business model.

We are machine manufacturer, whose main field is the machines, not cable tie production.

By working with us, most of our customers will like our machines and the way we work together. They will continue to buy machines, including cable tie injection molding machines and universal injection molding machines from us. We have a long-term friendly relationship with them.

6. What facilities you need for the cable tie production?

  • Injection molding machine
  • Molds for cable tie : Under the machine, the different size of the cable tie decide different quantity in mold cavities. Normally the big machine allow more cavities.
  • Hopper dryer: Dryer the PA66 before production. PA66 is the plastic which absorbs moisture in the air. And this can’t be avoided during the packing, transport etc.
  • Auto Loader: Load the resin into the hopper reducing the worker’s job.
  • Crusher: Crush the sprue and the rejected cable tie, which pick out by the worker.
  • Mixer: Mix the material under the formula
  • Mold temperature machine: In the beginning of the production, the mold needs to be warmed up the temperature, so that it will save the time and material to reach the point of the success molding.
  • Packing machine: One station to realize vacuum, water injection and seal the poly bag – the cable tie packing bag.
  • Unload Robot: Strongly recommendation, will make the production stable. Less job for the workers.

7. How do we work? – three steps

# First, the successful molding.

The machine and the molds are all provided by us. The two corners of the triangle (3 M – machine, mold and , material ) have been fixed, and it is easy to fix the third corner- materials. The successful molding is guaranteed by us.

# Second, stable production.

From the purchase plan we provide to you, we have already considered this target. The facilities we provide are the guarantee.

The full complete instruction according to our more than one-decade experience will be provided to our client, in which we are advising what is the problem will appear and how to fix them.

# Third step is to shorten the cycle time in order to get the maximum return on investment.

We will try to reduce the cycle time in order to maximum your production output, meanwhile we will provide some professional advice. ( This step requests our visit to your plan )

From the moment when you become our client, we will keep talk about the cable tie production. During the cominucation we will share our experience, some of the information will be updated in our website, but some of them relate to the technological confidential issue, we will just talk directly to our client, not for the public.

8. How much is your investment and benefit in this buesiness?

# The investment in the beginning:

  • Facilities: machines, molds and plant

# Daily cost:

  • Electricity, high pressure gas and water
  • Worker salary: one operator each machine, or two machine, tear cable tie and packing (one or two people per machine)
  • Raw material (all the sprue and rejected cable tie may be reused according to our formula), this is will be your main daily cost.

# How to I calculate the PA66 consumed per machine per day?

For example: one shot of the cable tie 2.5 x 100mm, 160 pcs, the weight is 38 g (without sprue).

Our machine cycle time is around 12 second, so:

One hour is 60 mins x 60 second= 3600 seconds

3600 second / 12 second per shot = 300 shots

300 shot x 38g = 11400g = 11.4kg

One hour, the consume of PA66 is 11.4 kgs

One day 24 hours is 11.4 kgs / hour x 24 hours = 273.6 kgs per day.

So how many tons of PA66 do you need to keep, how long you can sell after production, all you may calculate now.

# Your benefits – your costs are calculated by weight, and your sales are calculated on a piece.

Let’s continue with the examples mentioned above. For example, a 2.5*100 cable tie is 100 per package, and the package is priced at $0.90 per package.

And these 100 pcs 2.5*100 cable tie is 27 g ( 38g / 140pcs  * 100 pcs ), and now you get the price of PA66 is USD 5800 / TON( equivalent to USD 0.0058/g ), so 27g is USD 0.157

So the difference is USD0.9 – USD0.157 = USD 0.743, including the benefits of the retailer or the whole seller, Your daily costs – worker salaries, electricity bills, machine maintenance, bank rents, etc.

First of the all, quality is the key point for any product. Without good quality, there is no any issue about the profit.

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By | 2019-01-04T11:16:38+08:00 December 19th, 2018|Categories: cable tie|2 Comments

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2 Comments

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