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Plastic Spoons Case study: Injection Moulding

Factory Operations Visibility & Intelligence

In order to meet customer expectations by supplying a wide variety of packaging units, from 36 to 1000 spoons per package, a new production and packaging line needed to be built. DeSter wanted to achieve higher production capacity, lower cycle time and a high degree of operator friendliness with this new production line.

DeSter is a world leader when it comes to plastic cups, mugs, plates, and cutlery with more than 1,000 employees around the world.

A new plastic spoon line was built with the demands of the market in mind. The heart of the production line is a 400-ton injection molding machine with a 144 composite mold. For unloading the products from the mold, a 6-axis IRB 6600 robot is employed.

Batch instructions, cycle time, packaging volume
Mature (technology has been on the market for > 5 years)
Programming time, production time, and installation time are shortened during the introduction of new products.

The stacking height of the spoon frames has been raised from 50 to 125 so that packages in multiples of 125 can now be supplied.

Relative to existing lines, production capacity has also been increased and the cycle-time reduced by 1 second, a 10.5% reduction.

Packaging volume was reduced to approximately 35%, reducing logistics costs.

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Total Cost of Ownership - Lowered due to reduction in labor cost and IT management.
Predictive Maintenance - The solution enables predictive maintenance which helps reduce maintenance costs.
Real-time Tracking - The location of individuals and assets can be identified in near real-time.
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