Sandretto supplies Injection Moulding Machines, robots and ancillary equipment to companies for use in the manufacture of everyday houseware and kitchenware. This includes products such as linen baskets, plastic jugs, plastic storage boxes etc.
Click on any of the following stories to read more about how Sandretto machines are used in this area.
Crystalware Limited
‘T EF’ SPECIFICATION SANDRETTO MOULDING MACHINES ENABLE CRYSTALWARE TO RAISE PRODUCTION AND REDUCE ENERGY CONSUMPTION
This Sandretto MEGA T EF 750 tonne is the fourth new injection machine to be installed during the last 12 months by Crystalware Limited of Redditch. Employed for producing the larger products in its own range of household and kitchen ware, the new machine has a particularly high rate of injection; this permits the filling of long flow path products having thin wall sections, typically Crystalware’s linen basket and the large container shown in the photograph.
Managing Director Graham Coggins speaks of how Crystalware has successfully reduced cycle times on this machine – down to 40 seconds on two products – and on the new Sandretto 550 tonne where a rectangular storage box cycles at 17 seconds “day in, day out”.
Sandretto has installed four new moulding machines during the last twelve months, two MEGA T EF 750 tonne units, one 550 tonne and one 380 tonne. Two replaced smaller machines and two are additions to the moulding shop which now comprises 15 injection machines and three blow-moulders.
This increased capacity is essential for Crystalware which is constantly broadening its range. “We are currently producing in excess of 10 million parts annually” states Graham Coggins.
‘FROM MANUFACTURER TO SERVICE PROVIDER’
Graham Coggins’ background is distribution and not manufacturing. This, he believes, has been instrumental in the company’s successful change from manufacturer to service provider. “In three years, for one of our major customers, we have steadily reduced our delivery times from 30 days to same day. We now guarantee to deliver an order placed at 7 am by 3 pm the same afternoon.
“Furthermore, such is the nature of our long-term planning, that tool changes are restricted to Fridays, never in the week.”
At Crystalware, machines run 24 hours per day; stock from a day’s production goes into a buffer store where, commencing at 4 am, it is shrink-wrapped and bar coded before transfer to the main warehouse – at 12 metres to the eaves, the tallest in Redditch. The company’s computer-based quality and quantity control is, states Graham Coggins, 99.8% accurate.
CONSTANT NEED TO RAISE THROUGHPUT
Crystalware has used recent developments in moulding techniques and improvements in polymers to increase the size of products in its range. Extremely busy supplying the major retail outlets, the company is constantly seeking higher throughput from its machines. For this reason, the MEGA T EF specification was seen as ideal for its needs.
The 25:1 high yield screw profile was specifically designed to give excellent melt quality and colour dispersion at lower barrel temperatures. Electric screw drive lowers screw recovery time and reduces the energy required to plasticise the charge. A full, accumulator-driven hydraulic system produces a number of advantages, a notably higher injection speed which can up to 2½ times that of a standard machines, faster platen movement, minimum energy consumption during the holding stage and multiple overlap of movement without loss of performance.
CONTROLLING COSTS
Crystalware’s records show that its Sandretto MEGA T EF moulding machines give a substantially increased all-round performance compared with a standard configured machine for the same installed power.
Long term costing is a further factor in controlling costs and, to that end, Crystalware has implemented a 5 year maintenance contract with Sandretto; all of its nine Sandretto machines, including those installed earlier, are covered by the contract and are serviced and maintained on a fixed monthly outlay.
“ We couldn’t function as a service provider without this facility” states Graham Coggins. “Sandretto drew up the schedule and, on the day stipulated – always a Friday – we hand a machine over to them. I have to say that I’m pleased we went to Sandretto; their back-up service is second to none.”
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BSR Technical Moulding Services
SANDRETTO PRODUCTION CELLS EXTEND MOULDING CAPACITY FOR BSR, TAMWORTH
CUSTOM MOULDER CAN NOW INTRODUCE PROPRIETARY LINE
Two Sandretto injection machines, complete with colour dosers, hopper loaders, conveyors and chiller units, have been installed by Tamworth moulder BSR Technical Moulding Services, primarily to meet the requirements of two new moulding contracts. The machines will, in addition, provide capacity for the introduction of the ‘Plasticon’ range of tube fittings.
The major contract requires the Nove 300 tonne to produce a new kitchen jug body in polypropylene whilst, alongside, the Nova 220 tonne moulds the matching lid. This is a fast-cycling operation, hence the need for the Dal Maschio colours dosing and complementary ancillary equipment, supplied and commissioned by Sandretto as a total package.
MACHINES OF HIGH RELIABILITY
“The factory runs from 6 am Monday until 3 pm Friday, non-stop” explains director Bill Jones. “This alone demands reliable machinery. Then, late last year, we made the decision to broaden our moulding business by the introduction of a proprietary line of high pressure pipe fittings. Choice of Sandretto, was influenced by our need for high performance and reliability.”
BSR was established 12 years ago as a family business by Bill Jones, using the Christian names of himself, his wife and daughter for the company name. It is run by two working directors – Bill, trained as a toolmaker, and Peter Lowe who is an experienced moulder.
The company built its reputation on the production of technical mouldings, the bulk of them in engineering thermoplastics such as acetals, polyesters and nylons, and has grown steadily, supplying the automotive, white goods, housewares and similar industries. In January this year, by now employing eight people, BSR moved to substantially larger premises, enabling it to increase both its production and its post-moulding capacities.
‘PLASTICON’ HIGH PRESSURE PIPE FITTINGS
Knowledge that it would shortly move to larger premises has also permitted BSR to broaden the base of its operation as a custom moulder by purchasing the ‘Plasticon’ range of high pressure tube fittings. The two new Sandrettos are consequently easing the load placed on the company’s four existing moulding machines by the demand for these fittings marketed from its Tamworth premises.
Capable of handling both liquids and compressed air, the range of imperial and metric connectors, adaptors and tees are moulded in nylon 66 and has been pressure tested up to 1000 psi. A major advantage of the ‘Plasticon’ fittings, also used in the dairy industry, is the positive sealing action achieved by only finger tightening. Bill Jones reports that quality approval to ISO TS 16949 has recently been achieved.
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TSR Plastics Limited
TSR PLASTICS RAISES THE ROOF TO INCREASE PRODUCTION
"Investment in more efficient manufacture is vital to withstand international competition and gain larger market share"
Carlo Tai, Managing Director TSR Plastics
When planning the current expansion of its Northamptonshire moulding factory, the third expansion in the 9 years it has occupied the site, TSR Plastics took the opportunity of literally raising the roof. "We can see an imminent need to install even larger injection machines in the near future" explains Managing Director Carlo Tai, "so we've raised the roof line by several metres, giving us the headroom for a 10 tonne gantry crane to lift the larger moulds we will soon be using, as well as upgrading the services, in particular the cooling water supply system.
"By constructing the new building around and over the existing structure, the impact on production was minimised. Furthermore, the new walls are over a metre outside the old walls, so the moulding shop is wider as well."
Specialists in the field of designing, manufacturing and marketing plastic ware for the garden and home - and most recently for the playroom with the Kiddyland range - TSR Plastics has spent almost £10 million in the last few years on new buildings, new plant, additional warehousing, a further 8 acres of land and the company's infrastructure.
REGULAR MACHINE REPLACEMENT THEORY
TSR's plant replacement programme is impressive; with the exception of one or two "classics" from the company's early yeas in Watford, none of the 30 machines is more than 5 years old. Two 200 tonne, two 270 tonne and one 550 tonne, all Sandrettos, are a part of a major investment programme over the last six months.
For the last 20 years, the company has built up what it describes as an excellent relationship with Sandretto and, with the obvious benefits in production control and maintenance, TSR Plastics has operated a policy of buying only Sandrettos. "We seek a high degree of reliability and a rapid response to any request for service back-up" explains Carlo Tai.
TSR Plastics Limited is a leading and independent UK manufacturer of plastic ware for the home and garden. Its b-line range is sold widely in the UK - in stores, DIY outlets and garden centres - and overseas. In order to fight international competition and gain a larger market share, constant reduction in unit costs is essential; investing in the latest technology is a necessary step towards achieving the goal. In recent years TSR has enjoyed substantial growth in export business, but the high value of the £-sterling is eroding margins, making investment in more efficient manufacture vital to maintaining profitability.
SELF-SUFFICIENT IN DESIGN - AND IT SHOWS
The 26-year old company, which moved to its present site at Finedon 9 years ago, is now totally self-sufficient in design and tool development, with tool repair and new tool manufacture lying within TSR's capability on site. The last few months has seen £1/4 million spent in setting up a new, fully functioning toolroom with CNC machines and EDM equipment under the reasonability of a new tooling manager.
With its own design team, TSR constantly updates its products and colourways; in both areas it can lay claim to have influenced the market. If the design requires larger machines, the company has always been prepared to invest, such as the Sandretto "Mega 750" machine to produce a large swing-top bin and the 55 litre linen hamper.
Examples of TSR innovation include the unique "Studio Drainer", several new colourways for its housewares, use of in-foil moulding with a traditional 'narrow-boat' design and the lion's foot pot supports for the garden market.
NEW WAREHOUSING MEETS NEW MARKET REQUIREMENTS
Introduction of the Kiddyland playroom range, which TSR moulds, assembles and packages on site, is dependent on the company maintaining stocks in all standard colours. Completion of Phase III of the warehouse expansion, with its high-reach/narrow-aisle stacker trucks, has provided the necessary space to hold stocks to meet customer demand. An 8 acre site close to the existing facility is to be developed under Phase IV. It will comprise a high bay warehouse for bulk raw material storage, enabling TSR to benefit from out-of-season raw material pricing, and for transport fleet servicing.
FLEXIBLE WORKING ENVIRONMENT
Complementary to the massive capital expansion programme is the manner in which the company has produced a working environment which recognises the social needs of its employees.
"In an industry with a history of long hours and inflexible structures" says Carlo Tai, "we have introduced flexibility at all levels. Shop-floor production staff are now contracted for 4 days in a week, absenteeism and high workforce turnover associated with long hours have dropped significantly and we are now able to recruit from a wider group of people whose social and family ties can be more easily satisfied with our new system.
"In the long run, we see the new shift system adding to the overall efficiency of the company. This, together with the new capital investment and further factory expansion, all contribute to placing TSR Plastics in a strong position to meet the demands of the millennium."
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