More and more businesses are automating their operations wherever possible. Not only does automation generally increase efficiency and overall productivity, but it also frees up employees to focus on other more complex tasks. In order to support these automated systems, many businesses in a range of industries rely on high-quality conveyor systems to move products and materials throughout their facilities. With this high demand, conveyor system components must be up to the task of performing at high levels over long periods of time without breaking down.
But how is this achieved? It all starts with the quality of the parts themselves. In this sense, injection molders in particular play an essential role in the performance of these systems over the long-term.
What is Needed From Conveyor System Components?
Imagine what might happen if even one of the conveyor systems in a major distribution center failed to operate. The entire operation would be heavily impacted.
This is the case for every business that uses conveyor systems extensively: warehouses, mining operations, pharmaceutical manufacturing, automotive manufacturing, food processing, and so many more. Conveyor systems are verging on being ubiquitous in one way or another.
Which is exactly why conveyor system components need to deliver optimal functionality, precise dimensions, durability, and wear resistance in order to support reliable operations. If the parts fail, the system runs the risk of failing, and that could result in a noticeable disruption in operations.
How Injection Molders Optimize the Manufacturing of Conveyor System Components
So, how exactly do injection molders produce conveyor system components that deliver on functionality, precision, and long-term performance? As you might expect, there are a number of factors that come into play.
Complex Geometry and Flexible designs
Injection molding is one of the most versatile and precise manufacturing processes for high-quality plastic parts. This includes conveyor system components. Because molders have a high level of control over the molding process itself, they can create parts with intricate geometries and flexible designs.
This is particularly important in the production of conveyor system components. Oftentimes, these parts have specific shapes and features that optimize functionality. Injection molding experts also typically have engineering experts on their team who can help tweak part designs if needed.
Consistency and Precision
Injection molding is also an extremely consistent process, capable of producing thousands of identical parts without deviating from specifications. Conveyor system components that are produced with consistent quality, dimensions, and tolerances help ensure the performance of the conveyor system itself by delivering proper alignment and functioning for all related parts.
Material Selection
Conveyor systems often operate in diverse environments with varying temperatures, levels of abrasion, and exposure to chemicals. Injection molders have the expertise to select materials that will withstand specific environmental factors. For instance, a system that requires a high level of wear resistance would likely benefit from engineering-grade or high-performance materials like PEEK.
Choosing materials with the right combination of durability, chemical resistance, and wear and tear resistance help ensure the long-term performance of the conveyor system.
Cost Efficiency in Mass Production
Conveyor systems can be complex and include numerous components like rollers, guides, brackets, and chain links, all of which are produced in high quantities. Injection molding becomes most cost-effective in high-volume production due to the economies of scale. Once the initial tooling costs are covered, the cost-per-part decreases significantly as more parts are manufactured.
This is highly advantageous for the production of conveyor system components, where large quantities of standardized parts are required. Because manufacturers can produce these parts in high volumes, conveyor systems are more economically viable than they might be otherwise.
Fast Production Cycle
Finally, injection molding is an excellent manufacturing process when fast production cycles are required. Because conveyor systems are integral to a variety of production processes, they require parts to be readily available when repairs or replacements are needed. Injection molders can produce conveyor system components quickly, and thereby keep operations running smoothly.
Experience the Ensinger Difference in Your Conveyor System Components
Ensinger has provided bespoke injection molding solutions for customers in a wide range of industries since 1934. We specialize in working with high-performance materials, but we’re also well-versed in producing high-quality plastic components using general and engineering-grade polymers as well. Plus, our machining facility in North Carolina and our list of other services, including design and post-processing, means we have the capabilities to manufacture your most critical components.
Connect with us today to get started.