Manufacturers change the shoulder mold, body forming tools, and capping station to match different lami tube specifications.
Adjustments depend on tube size, shape, laminate thickness, and cap compatibility. Automation increases efficiency. Quality checks prevent defects after changeover.
Key Takeaways
Changing mold parts is essential for producinglaminated tubesthat meet specific size and shape requirements. Always replace the shoulder mold and body forming tooling to match new designs.
Automation enhances the efficiency of mold changeovers. Smart systems monitor processes and reduce manual errors, leading to faster production and improved safety.
Conduct thorough quality checks after every tooling change. Visual inspections and pressure tests help ensure that the finished tubes are defect-free and maintain high standards.
Lami Tube Mold Components
Shoulder Mold
The shoulder mold shapes the top section of the lami tube. This mold determines the neck diameter, shoulder angle, and the opening for the plug. Manufacturers select the shoulder mold based on the tube size and shape. When switching between different lami tube specifications, they must replace the shoulder mold to match the new design. The shoulder mold also affects how the plug fits and seals the tube, which is important for maintaining the barrier layer.
Body Forming Tooling
Body forming tooling creates the main cylindrical section of the laminate tubes. This tooling controls the diameter, length, and wall thickness. Changes in laminate thickness or barrier layer require adjustments to the body forming tooling. For example, a thicker laminate or a different barrier layer may need a new set of molds to ensure proper molding and plug fit. The lami tube making machine uses these molds to produce tubes with consistent quality.
Uses eddy currents for sealing, specific to aluminum laminate tubes.
Aluminum laminate tubes only
Ultrasonic Sealing
Budget-friendly, slower method that can seal through contamination.
Various tube types, slower speed
Folding/Crimping
Used for aluminum tubes, various styles for different seal strengths.
Aluminum and metal tubes
Proper selection of capping and sealing parts improves leak resistance and shelf life. Manufacturers test tube seals using pressure and crush testing. The choice of seal materials, such as urethane and silicone, affects the reliability and durability of the barrier.
Mold Adjustments for Laminate Tubes
Mold adjustments ensure that the laminated tube making machine produces tubes with the correct specifications. When changing tube size, shape, or laminate thickness, manufacturers must replace or adjust the shoulder mold, body forming tooling, and plug components. Matching the plug and barrier layer to the tube design prevents leaks and maintains product quality. Mold changes allow the production of different laminated tube styles while preserving the integrity of the barrier layer.
Tooling Changeover Process
Identifying Required Tooling Changes
Manufacturers must identify which tooling and mold components need replacement before switching lami tube specifications. The lami tube making machine uses several production parts, including the shoulder mold, body forming tooling, and plug preparation units. Each part must match the new tube size, shape, and barrier requirements. The process begins with design validation. Engineers verify the design details and functions, ensuring the plug fits correctly and the mold avoids undercuts. They check the barrier layer of aluminum or plastic barrier laminate for compatibility with the new laminate tubes.
The typical sequence for changing mold parts and tooling includes:
Design validation for fit and function.
Mold base and cavity/core preparation to exact tolerances.
Cooling channels, venting, and ejection systems setup for uniform curing and demolding.
Alignment and machine setup, including clamp force and safety checks.
Dry run and initial test shots to identify defects and adjust tooling.
This step-by-step approach ensures the lami tube making machine produces tubes with an excellent barrier effect and consistent quality.
Preparing For Mold Change
Preparation for mold change involves several safety and efficiency measures. Workers must follow strict protocols to protect themselves and the environment. The table below outlines recommended safety protocols:
Safety Protocols
Description
Injection molding safety
Emphasize safety during the production of plastic molds.
Environmental protection
Follow laws and standards to prevent pollution.
Health training
Train workers on health concerns, including eye protection.
Moisture control
Use strong cleaning solutions to handle moisture problems.
Safety equipment
Equip the workshop with masks, glasses, and respirators.
Operators clean the mold and tooling surfaces to remove residue from previous web stock and curing process. They inspect the plug preparation area and ensure all demolding systems function properly. Technicians check the web alignment and adjust the laminating process for the new laminate tubes. Proper mold preparation and tooling setup reduce downtime and prevent defects in the laminated tube manufacturing process.
Automation and Smart Systems
Automation and smart systems play a key role in efficient tooling changeover. Lami tube making machine uses sensors and programmable controls to monitor mold temperature, curing, and demolding cycles. Automated plug preparation units adjust settings for different laminated tube specifications. Smart systems track web stock usage and optimize the molding process for each application.
Operators use digital interfaces to select tooling parameters and monitor curing progress. Automated demolding systems reduce manual labor and improve safety. These technologies help manufacturers produce tubes with reliable barrier layers and consistent plug fit. Automation also minimizes errors during mold preparation and tooling changes, leading to higher quality and faster production.
Tip: Smart systems can alert operators to potential issues with mold alignment or curing, allowing quick adjustments and preventing defects.
Quality Checks After Changeover
Quality checks are essential after every tooling changeover. Technicians perform visual inspections and pressure tests on the finished laminate tubes. They verify the plug fit and check for leaks in the barrier layer of aluminum or plastic barrier laminate. The curing process must produce tubes with uniform wall thickness and strong seals.
Operators test the demolding system to ensure smooth release of production parts. They inspect the web stock for proper alignment and application. Quality teams use crush testing and other methods to confirm the excellent barrier effect of the finished tubes. These checks guarantee that the lami tube making machine produces high-quality laminated tube products for every application.
Note: Consistent quality checks after tooling changes help manufacturers maintain product standards and customer satisfaction.
Manufacturers replace the shoulder mold and body forming tooling. These parts must match the new tube diameter and length.
Tip: Always check the mold alignment after changing sizes.
How Does Automation Help in Mold Changeover?
Automation speeds up mold changes. Smart systems adjust settings, monitor temperature, and reduce manual errors. This process improves safety and product consistency.
Why Are Quality Checks Important after Tooling Change?
Quality checks catch leaks, misalignments, or weak seals. Technicians use pressure tests and visual inspections to confirm tube integrity and barrier performance.
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