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Topstar TS130 Injection Molding Machine | Injection Molding Solution for Artificial Plants

2026/08/24 By le zhan

Injection Molding Solution for Artificial Plants

The artificial plant industry experiences distinct seasonal production peaks. Traditional equipment has slow production speeds and limited per-machine capacity, making it difficult to fulfill large orders on time during peak seasons. If injection molding equipment suffers from low output per mold, slow part removal, or unstable continuous operation, factories quickly face capacity bottlenecks.

Topstar offers a dedicated solution for the artificial plant industry, which includes:

With this configuration, the comprehensive solution boosts production efficiency by approximately 100 percent; a single TS130 production unit can achieve the output previously required by two traditional machines.

The TS130 Injection Molding Machine Solves Seasonal Capacity Issues in Artificial Plant Production

The demand patterns for artificial plant production differ significantly from those of many traditional plastics manufacturing sectors. Artificial plant suppliers typically align production with the retail industry’s seasonal cycles.

Christmas-related artificial plants are a prime example.

Christmas tree foliage and decorative leaves must be produced before the peak season begins, so orders often concentrate in specific production periods. If production falls behind, factories risk shipping delays, missed on-time deliveries, and reduced capacity to accept additional orders.

For this reason, the primary production challenge is:

How many qualified parts can a single production unit produce within the limited peak-season production window?

TS130 Injection Molding Machine Solves the Problem of Limited Per-Cycle Output

The TS130 Injection Molding Machine Solves the Problem of Limited Output Per Cycle

Traditional single-cavity or low-output injection molding machine configurations can produce only a limited number of parts each time the mold opens. Even if the machine runs stably, per-cycle output limits total daily output.

If demand doubles, manufacturers typically have only two options:

Extend the operating hours of existing equipment or add more machines.

Therefore, Topsta approached the problem differently.

By using the TS130 injection molding machine in conjunction with a custom “one-to-four mold”, the mold can produce four artificial plants in a single molding cycle. The production unit no longer relies solely on increasing machine speed to achieve minor efficiency gains; instead, it increases the number of products produced per successful molding cycle.

TS130 Injection Molding Machine Solves the Problem of Limited Per-Cycle Output

The TS130 Injection Molding Machine Features a Dedicated, High-Power, Full-Servo Architecture

While four-cavity molds can increase potential output, they also place higher demands on injection molding machines. Compared to molds with fewer cavities, the equipment must not only maintain stable operation during repetitive, high-volume production but also ensure a continuous, stable supply of sufficient melt to multiple cavities.

Therefore, the TS130 injection molding machine—specifically designed for artificial plants—features two core design elements:

High-Power Drive Design

Full-Servo Control System

These two technologies address different stages of the production process and work together to solve production challenges.

High-Power Design Enables Faster Production Response

When facing peak-season orders, artificial plant manufacturers need equipment that responds quickly and runs continuously to avoid slowing molding cycles with sluggish machine movements. The TS130 artificial plant dedicated machine features a high-power design that delivers stronger motion and faster response times.

This supports high-demand operations, including coordinated mold opening, mold closing, injection, plasticizing, and ejection. It reduces unnecessary wait times while maintaining process stability.

The Full-Servo Control System Achieves a Balance Between Speed and Precision

High power alone cannot ensure production stability for artificial plants. Therefore, the TS130 machine, designed specifically for artificial plants, uses a fully servo-controlled system. This enables faster command response, more precise motion control, stable injection performance, and superior process repeatability. For artificial plant components, a stable servo control system helps the machine more consistently reproduce the required injection molding process curves during production.

Using a “One-Out-Four Mold” to Boost Production Capacity

The custom “one-out-four mold” is the most direct driver of increased production capacity in this solution.

The “one-out-four mold” contains four molding cavities, enabling the TS130 artificial plant dedicated machine to produce four parts in a single injection molding cycle.

This difference is easy to illustrate with a simple example.

Production ConfigurationParts Produced per Mold CycleRelative Single-Cycle Output
Single-cavity configuration11×
Two-cavity configuration22×
TS130 one-out-four configuration44×

However, this does not mean the factory’s total output will necessarily increase exactly fourfold, as actual production capacity depends on factors such as mold design, cooling time, cycle parameters, materials, robotic arm operations, and product geometry.

Using a “One-Out-Four Mold” to Boost Production Capacity

Integrating a Dedicated Cartesian Coordinate Robot to Achieve Stable Automated Part Removal

If the mold produces four parts per cycle but the injection molding robot cannot remove them quickly and reliably, part removal becomes the next bottleneck.

Therefore, we have integrated an artificial plant dedicated Cartesian coordinate robot into this solution.

Under Tpstar’s unified control system, the injection molding machine and Cartesian coordinate robot motion cycles are coordinated, with the Cartesian coordinate robot performing automated part removal after the mold opens.

The sequence of operations can be simplified as follows:

Injection → Cooling → Mold opening → Robot entry → Part removal → Robot exit → Mold closing

A dedicated Cartesian coordinate robot standardizes part removal, ensuring each cycle follows a more predictable rhythm. If the injection molding machine operates at high speed but manual part removal is slow, production potential cannot be fully realized.

Integrating a Dedicated Cartesian Coordinate Robot to Achieve Stable Automated Part Removal

Controlled Part Removal Achieved Through High-Precision Servo Positioning

Artificial plant leaves are typically thin or flexible. Rough handling or improper positioning during part removal can cause bending, tearing, or other damage. Dedicated Cartesian coordinate robots utilize high-precision servo positioning to approach the product at a controlled position and perform stable removal. This enables the robot to operate more gently while maintaining speed.

Building More Scalable Injection Molding Production for the Artificial Plant Industry

A key insight from this case study is that increasing production capacity does not necessarily require adding more equipment. In the artificial plant industry, Topstar boosts production capacity by optimizing the value generated per production cycle. In the artificial plant application case, production efficiency increased by about 100% while ensuring more stable operation, a higher yield rate, and lower labor costs. For manufacturers producing Christmas tree leaves and other artificial plant products, this injection molding solution precisely addresses the most pressing challenges during peak seasons.

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