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Home / How to solve the problem of low production efficiency: Topstar’s molding machine to improve overall efficiency by 15%

How to solve the problem of low production efficiency: Topstar’s molding machine to improve overall efficiency by 15%

2025/12/12 By le zhan

injection molding operations

Inefficient injection molding operations are often caused by delays between steps, resulting in lower overall efficiency. For example, a slow-responding dryer causes the molding machine to be idle; drifting mold temperature controllers result in scrap. As a result, operators waste two hours a day switching between five different control interfaces. This lack of equipment coordination is the core of low production efficiency, and many companies still report that their existing injection molding machines cannot operate synchronously with upstream and downstream equipment. On average, injection molders lose 12% to 18% of potential output due to these bottlenecks.

Topstar’s molding machines, with their integrated process design, enable a single control interface to link multiple devices, and through real-time communication feedback, achieve integrated control of the entire injection molding process, from material pretreatment and plasticizing to molding and demolding, ensuring seamless coordination between all equipment. This resulted in a 20% increase in servo power, a 20% increase in injection speed, and a 10% increase in screw speed, leading to a 15% improvement in overall injection molding efficiency.

Inefficiency in injection molding causes more than just slow production cycles

Most customers equate “inefficiency” with slow production cycles—but the real costs go far beyond the speed at which machines produce parts. Inefficient molding machines can have a ripple effect, hurting your profits in four ways, and outdated, isolated equipment cannot solve any of these problems.

First, there is unplanned downtime. Molding machines that cannot communicate with the dryer or mold temperature controller are often idle: if the dryer isn’t ready, the molding machine waits; if the mold overheats, the molding machine stops. Second, there’s a high scrap rate. When the molding machine is operating in a vacuum environment, even minor deviations can result in defective parts. Third, it leads to low labor efficiency. Operators spend 15% to 20% of their shifts switching between different control interfaces: adjusting the dryer on one screen, the injection molding machine on another, and the injection robot on a third.

What is the root cause? Traditional molding machines are independent tools, not part of an interconnected system. Topstar’s injection molding machines solve this problem by integrating disparate steps—material preparation, plasticizing, molding, and demolding—into a single, coordinated process.

How to solve the problem of low production efficiency？

Topstar’s Integrated Molding Machine Design

The key to Topstar’s 15% efficiency improvement lies in its integrated molding machine process design. Instead of treating the injection molding machine as a standalone unit, we’ve designed it as the “brain” of the entire injection molding unit, connecting all equipment (dryer, mold temperature controller, injection robot, etc.) through an intuitive control interface. Real-time communication ensures synchronized execution at each step, eliminating waiting times and errors that degrade efficiency.

We use a single control interface, allowing operators to adjust the injection molding machine, set dryer parameters, and more from a single point. There’s no longer a need to switch between five different systems. Furthermore, a unified communication language ensures that every device in the unit transmits data to the injection molding machine’s central controller. If the dryer detects that the material’s moisture content is 0.5% above the target value, it alerts the injection molding machine, which automatically adjusts the screw speed to compensate. If the robot lags, the injection molding machine pauses the next cycle rather than ejecting the part into an empty slot. Topstar’s tests show that this integrated design reduces unplanned downtime by 40% and labor inefficiency by 25%, the two main drivers of an overall 15% increase in efficiency.

Molding Machine

Performance Upgrades, Integration is Effective

Topstar molding machines also enhance their original performance through hardware upgrades, translating coordinated steps into faster, more reliable production. Three key improvements, working synergistically with the integrated system, achieve a 15% efficiency increase: 20% more servo power, 20% higher injection speed, and 10% higher screw speed. Each improvement targets critical aspects of the injection molding process without compromising part quality.

  1. 20% Increase in Servo Power: Faster, Smoother Movement

We use servo motors that provide 20% more torque for clamping and injection movements. This reduces mold closing time by 0.8 seconds and ejection time by 0.5 seconds. These small savings per cycle accumulate to produce an additional 120 parts per hour within a 45-second cycle.

  1. 20% Increased Injection Speed: Perfect Cavity Filling, Zero Scrap

Topstar’s injection units reach speeds of up to 350 mm/s, a 20% increase, ensuring fast and uniform cavity filling, crucial for thin-walled parts. Faster injection speeds reduce “short shots” and “shrinkage marks,” thus lowering scrap rates.

  1. 10% Increased Screw Speed: Faster Plasticization, No Degradation

Our 40 mm diameter screw speeds at 220 rpm, a 10% increase, accelerates resin melting without overheating. Faster plasticization reduces “dwell time” by 1.2 seconds, shortening cycle time and preventing material degradation. Overall, these upgrades and integrated systems together achieved a 15% efficiency improvement.

Topstar’s molding machine demonstrates high production efficiency in real-world applications

Case 1: Automotive Interior Clips

Problem: 45-second cycle time; 8% scrap rate; 12 operators working overtime to reach a weekly output of 100,000 pieces; monthly overtime pay/late fees reaching $14,000.

Solution: Topstar TMⅡ injection molding machine.

Result: Cycle time reduced to 39 seconds (13% speed increase); scrap rate reduced to 2%; 100,000 pieces per week achieved with only eight operators.

Case Study 2: PET Beverage Bottles

Challenges: 28-second cycle time, 5% scrap rate, and high energy costs.

Solution: Topstar TMⅡ injection molding machine (10% increase in screw speed, energy-saving servo system).

Results: Cycle time reduced to 24 seconds (14% speed increase); scrap rate reduced by 1.2%

Efficiency is not just about speed; it is also about control.

For customers, low production efficiency is not an “inevitable reality,” but rather a consequence of outdated, siloed equipment that cannot keep pace with modern manufacturing. Topstar molding machines solve this problem by transforming your injection molding unit into an interconnected, high-performance system, resulting in a 15% increase in overall efficiency and measurable cost savings.

 

Prev: Guide to PID control Mold temperature controller: Fix Low-Temperature Dead Zones in Cold Runner Injection Molding

Next: How to Solve Poor Plasticization in the Injection Molding Process？

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