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STANDARD OPERATING PROCEDURE

Injection Molding Machine, 20 TonModel: Boy 22S

Manufacturer: Boy Machines Inc.

Location: Technology Transfer Pilot Plant, 1598 Food Sciences Building

Publication Date: 03/04/2014

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Description and Uses

Injection molding is a process of injecting plastic materials into the mold to create a part. Injection molding can also be used in metals, glass and elastomers. The desired materials are fed into a hopper then into the barrel, where it is mixed and forced into a mold cavity. After it cools and hardens, the material is now formed into the configuration of the mold.

Power Specifications

Motor: Boy 22S VH, Machine #22134

Power: 5.5 kW

Voltage/Amperage: 220V/20.5A (motors); 220V/17.5A (heaters)

Hydraulic System Pressure: 160 bar

Potential Hazards and Safety Precautions

Electric Shock/High Voltage (220 V)

• Make certain to use the correct outlet that is specifically designed to fit the electrical cord plug.

• Make sure the area around the outlet, floor and your hands are completely dry when plugging or unplugging the electrical cord to/from the outlet.

Potential Hazards Safety Precautions Mechanical Pinch Points/Possible Entanglement of Extremities, Hair, Jewelry or Clothing

• Keep hands clear of moving parts at all times.

• This machine operates at high temperatures and with high-speed moving parts. Never place any body parts near the machine while it is in operation.

• Make sure to secure long hair and any loose clothing or jewelry before operating the machine.

Flying Debris/Potential Eye Damage

• Always use proper personal protective equipment at all times while operating the machine.

• Ensure that the vent fans are turned on while the machine is in operation.

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Required Personal Protective Equipment

Safety Goggles

Protective Footwear (no open-toed shoes)

Lab Coat

Tie Back Long Hair

Heat-resistant Gloves

No Loose Fitting Clothes

Long Pants and Long Sleeves

Hair Net

Training

Required Training

*Denotes courses offered online

Machine & Site-Specific Training

Fire Safety & Extinguisher Training*

Laboratory Safety: Core Concepts*

Recommended Training for Frequent Users

*Denotes courses offered online

Electrical Safety & Lockout/Tagout

Laboratory Safety: Spill Procedures

Shop Safety Fundamentals: Basic Procedures & Policies*

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Operation

Operation: Start-up

1. Turn the power knob (red arrow) clockwise to turn on. See Figure 1.

2. In the control panel, ensure that the knob is set to manual as indicated by the bright blue arrow (Figure 2).

3. Press the white button, as indicated by the red arrow (Figure 2), to turn on the hydraulic motor.

4. To set temperatures, push and twist the temperature control knob. The temperature control knob is indicated by a bright green arrow (Figure 1). The control knobs (#1, #2 and #3) are temperatures for the back extruder feed zone, front extruder metering zone, and injection nozzle zone, respectively. Note that the units for control knobs #1 and #2 are in °C and °F, respectively, while control knob #3 is a percentage of the temperature set by control knob #2. For example, if control knob #2 is at 200°C and control knob #3 is at 40%, then the temperature at the injection nozzle zone is set at 80°C.

5. Once the temperatures are set, wait for the actual temperature to reach the set temperatures. To determine whether the actual temperature has reached the set temperature, check the four lights above control knobs #1 and #2 (as shown in the red ellipse, Figure 1). When the light is on, this indicates from left to right that: the extruder zone is heating, the extruder zone is below the set temperature, the extruder zone is at the set temperature, and the extruder zone is higher than the set temperature, respectively.

Figure 1

#1#3 #2

Figure 2

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Operation: Purging of Old Materials

1. Fill the barrel with materials/ingredients through the hopper. To move the carriage forward and backward, press the button–Y40 and–Y41, as indicated by the green ellipse and the green solid rectangle (Figure 2), respectively. Ensure that the safety cover of the hood is completely closed before starting to extrude the materials (see Figure 3).

2. To purge old materials out of the barrel, fill the hopper with new materials then press–Y53 (red box, Figure 2) to fill the shoots. Then press–Y50 (red ellipse, Figure 2) to purge the materials out. Repeat this step until only new material comes out of the barrel.

3. Once the materials come out of the barrel, open the safety cover and carefully take out the old materials that has purged out of the barrel (see Figure 4). Please note that the material will be very hot. Ensure that you wear the required personal protection equipment when retrieving the purged materials. When the new material starts to come out of the barrel, close the safety cover of the barrel.

Operation: Injection Molding

1. Fill the hopper with material and press–Y53 (red box, Figure 2) to fill the shots. Close the mold by pressing–Y10 (bright blue box, Figure 2). Ensure that the mold is completely closed.

2. Move the carriage forward by pressing–Y40 (green ellipse, Figure 2). Inject the shots by pressing–Y50 (red ellipse, Figure 2). Continuously feed the hopper with new material. To refill the shoots, press–Y53 (red box, Figure 2).

3. To open the mold, press–Y11 (bright blue ellipse, Figure 2). Then eject the part by pressing–Y60 (yellow box, Figure 2). Press–Y10 (bright blue box, Figure 2) to close the mold.

4. Repeat steps 1-3 to continually injection mold more parts.

Operation: Shutdown

1. Press–Y41 (green box, Figure 2) to move the carriage backwards.

2. Perform clean-up procedures (instructions on next page).

3. Press the red button (green arrow, Figure 2) to turn off the hydraulic motor.

4. Turn the power knob (red arrow, Figure 1) counter clockwise to turn off machine.

5. Log your username and time used in the log book.

Figure 3

Safety Cover

Figure 4

Safety Cover

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Clean-up Procedures

Note: Before shutting down the machine, please refer to the purge procedures below.

1. Fill the barrel with purge material through the hopper. To move the carriage forward and backward, press the button–Y40 (green ellipse, Figure 2) and–Y41 (green box, Figure 2). Ensure that the safety cover of the hood is completely closed before starting to extrude the material (see Figure 3).

2. To purge the remaining material inside the barrel, fill the hopper with a purge material (this is an ingredient/material that is typically used to push out the remaining material inside the barrel). Then, press–Y53 (red box, Figure 2) to fill the shots. Then, press–Y50 (red ellipse, Figure 2) to purge the material out. Repeat this step until only new material comes out of the barrel.

3. Once the material comes out of the barrel, open the safety cover and carefully remove the remaining material that has purged out of the barrel (see Figure 4). Please note that the material will be very hot. Ensure that you wear the required personal protection equipment when retrieving the material out of the barrel.

4. When the purge material starts to come out of the barrel, close the safety cover of the barrel (see Figure 3).

5. Now, continue with the shutdown procedures described on the previous page.

Machine Care and Maintenance

• Inspect the machine after every use for any leakage or broken parts. Report any leak or broken parts to the pilot plant manager.

• All final inspections are performed by the pilot plant manager.

Accessories

None