SEKISUI DLJM Molding Pvt. Ltd. Industrial Report(Plastic Injection Molding)

Department of Mechanical & Automobile
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Summer Training Report
SEKISUI DLJM MOLDING PVT. LTD.
Working On Plastic Injection Molding Machine
Submitted in partial fulfillment of the requirements for the degree of
BACHELOR OF TECHNOLOGY
by
ABHIKANT YADAV
110106004
Department of Mechanical & Automobile Engineering
Sharda University, Greater Noida
June, 2014

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APPROVAL SHEET
Summer training report, entitled: (PLASTIC INJECTION MOLDING)
is approved for award of 12 credits.
Examiners
__________________
__________________
Coordinator
__________________
Head of Department
__________________
Date:

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CERTIFICATE
This is to certify that Mr. / Ms.___________________________ has partially completed /
completed / not completed the Industrial Training in our Organization / Industry during 1st
June, 2014 to 15th July, 2014. He / She was trained in the field of ______________
____________________________________________________ __________. His / Her
overall performance during the period was Excellent / Very Good / Good / Average / Poor.
Manager/Guide

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ACKNOWLEDGEMENT
I would like to place on record my deep sense of gratitude to Mr. V.P. SINGH, HR
DEPARTMENT, SEKISUI DJLM MOLDING Pvt. Ltd., GREATER NOIDA, for his
generous guidance, help and useful suggestions.
I express my sincere gratitude to Mr.U.K.GUPTA, Dept. of Mechanical and Automotive
Engineering, Sharda University, Greater Noida, for his stimulating guidance, continuous
encouragement and supervision throughout the course of present work.
I also wish to extend my thanks to Mr. VINEET KUMAR, etc. and other colleagues for
attending my seminars and for their insightful comments and constructive suggestions to
improve the quality of this research work.
I am extremely thankful to Prof. BHARAT B.GUPTA, Head, Dept. of Mechanical and
Automotive Engineering, Sharda University, Greater Noida, for providing me infrastructural
facilities to work in, without which this work would not have been possible.
Signature of the student

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CONTENTS
ACKNOWLEDGEMENTS i
ABSTRACT ii
LIST OF TABLES iv
LIST OF FIGURES v
ABBREVIATIONS vi
NOTATIONS vii
INTRODUCTION 1
Industry 2
Purpose 2

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Abstract
Injection molded components are consistently designed to minimize the design and
manufacturing information content of the enterprise system. The resulting designs, however,
are extremely complex and frequently exhibit coupling between multiple qualities attributes.
Axiomatic design principles were applied to the injection molding process to add control
parameters that enable the spatial and dynamic decoupling of multiple quality attributes in the
molded part. There are three major benefits of the process redesign effort. First, closed loop
pressure control has enabled tight coupling between the mass and momentum equations. This
tight coupling allows the direct input and controllability of the melt pressure. Second, the use
of multiple melt actuators provides for the decoupling of melt pressures between different
locations in the mold cavity.
Such decoupling can then be used to maintain functional independence of multiple
Qualities attributes. Third, the heat equation has been decoupled from the mass and
momentum equations.

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Introduction
The purpose of the joint venture is to expand business with vehicle manufacturers in India
and be the foremost competitor by using the advantage of Sekisui Chemical and Sekisui
Techno Molding products, technology, and design. JV is focused on to build up a business
base in India centered on Japanese vehicle manufacturers by adding Japanese manufacturers
trust for Sekisui Techno Molding's quality and technology.
The fusion of the products Sekisui Techno Molding has that contribute to lighter weight
(metal substitute products and foam mold products) and its insert molding, and mold design
technology will exploit a technological synergy for market establishment.
From aesthetic to functional, from outer parts exposed to harsh environments to pleasing
interiors, from engine and transmission parts exposed to heat and water, to chrome grilles
enhancing the value of automobile, we make a wide variety of moulded plastic auto parts.
Sekisui DLJM Molding Pvt., Ltd. is a joint venture of Sekisui Chemical Co., Ltd. and Dipty
Lal Judge Mal Pvt. Ltd. and was established in August 2011.The purpose of the joint venture
is to expand business with vehicle manufacturers in India and be the foremost competitor by
using the advantage of Sekisui Chemical and Techno Molding products, technology, and
design. JV is focused on to build up a business base in India centered on Japanese vehicle
manufacturers by adding Japanese manufacturers trust for Techno Molding's quality and
technology. The fusion of the products Techno Molding has that contribute to lighter weight
(metal substitute products and foam mold products) and its insert molding, and mold design
technology will exploit a technological synergy for market establishment.
We have two plants located in Tapukara ( Bhiwadi), Rajasthan & Greater Noida, U.P. with
approx. 650 employee strength.Soon we are going to start a new plant in Chennai, Tamil
Nadu.
Sekisui DLJM turnover for Financial Year April 2013 - March 2014 was approx INR 700
million. Projected turnover Financial Year April 2014 - March 2015 INR 1500 million.

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SEKISUI DLJM is a part of Sekisui Chemical Group founded in 1947. Since its founding, the
Sekisui Chemical Group has delivered a wide range of products and services to enrich
people's lives and the social infrastructure.
In 1947, Established Sekisui Sangyo Co., Ltd. in order to run a general plastic business. But
in a short span of time, changed the company name to Sekisui Chemical Co., Ltd. and opened
the Nara Plant with plastic automatic injection molding tagged to be the first in Japan. 1950s
was the decade of achievement in term of new plants & award winning product
developments. In 1954 SEKISUI became listed on the Tokyo Stock Exchange.
In 1960s SEKISUI group continued its success saga by set up Sekisui Plastics Corporation in
the U.S., the very first plant by a Japanese manufacturer in this part of world.
1970s was the period of honor & new activities. In 1970, exhibited the “Sekisui Heim (Heim
M1)" modular house at the International Good Living Show in Tokyo. SEKISUI Group
started the medical project in the Central Research Laboratory in 1979. SEKISUI Group
awarded the Deming Prize, the highest honor for quality management, including production,
sales and service in November 1979.
In 1980s not only started sales of "Two-U Home", a wooden structured modular house
nationwide but also established SEKISUI AMERICA CORPORATION in the U.S.
1990s was the decade of Figures. In September 1996, The Company’s capital exceeded 100
billion yen and in March 1997 SEKISUI Group celebrated the 50th anniversary of the
company's founding.
In the 2000s SEKISUI Group achieved the first zero emission plants and started the company
division organization. Established & acquired more companies to expend the wings in US &
Europe.
In 2010s The Group rores its success. Established a joint venture company SEKISUI DLJM
MOLDING in India for a vehicle components molding business.
We have number of group of companies 235 and number of employee is 22000.
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Outline of SEKISUI
Name SEKISUI CHEMICAL CO., LTD.
Establishment March 3, 1947
Paid-up Capital 100,000 million yen
President Naofumi Negishi
Number of Employees 23,017 (for the term ended March 2014; on a consolidated basis)
Net Sales 1,110,851 million yen (for the term ended March 2014; on a consolidated basis)
Operating Income 82,541 million yen(for the term ended March 2014; on a consolidated basis)
Ordinary Income 83,310 million yen(for the term ended March 2014; on a consolidated basis)
Net Income 41,190 million yen (for the term ended March 2014; on a consolidated basis)
Corporate
Headquarters
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Osaka Head Office
2-4-4 Nishitemma, Kita-ku, Osaka 530-8565 Japan
Tel: +81-6-6365-4122
Tokyo Head Office
2-3-17 Toranomon, Minato-ku, Tokyo 105-8450 Japan
Tel: +81-3-5521-0521

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Our Vision
Through Our Excellent Customer Support for Mutual Growth We Provide New Value to
Customers to Help Them Become the Best.
Quality Policy
SEKISUI DLJM is a customer-centric organization and Quality is the driving force behind
our success. Our ultimate moto is to achieve the highest level of client satisfaction.SEKISUI
DLJM believes in continuous improvement act and actively involved various improvement
activities through TPM and Kaizen that are implemented throughout its plants.
Sekisui DLJM is committed to maintain market leadership and customer confidence by
supplying high quality of products and services, conforming to agreed specifications of
customer, at local competitive price. These shall be achieved by:-
Implementation and continual improvement of effectiveness of Quality Management System.
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Improving customer satisfaction levels by prompt dispatches and reduction of non-conformities.
Improving productivity by optimum utilization of machines and reducing inventories.
OUR PRINCIPLE
Sekisui Chemical Group’s Principle (“Our Principle”) comprises elements such as our
Company Creed, Mission Statement, Group Vision that expresses an ideal form aimed for by
the Group in the medium to long term, and our concrete Business Strategy (e.g. Medium-term
Management Plan) to realize the Group Vision. Based on Our Principle, it is our aim to create
social values as a unified group.
COMPANY CREED
The “3S Principle” (Service, Speed, Superiority)
Service
We enhance the well-being of the world community through our global business network.
Speed
We surge ever forward into new fields of development with the power and vitality of a
mighty waterfall.
Superiority
We obtain the trust of our customers through superior operational performance and the
highest quality standard.
The “3S Principle”
Our company badge comprises the three S’s of the company’s original name, adopted at the
time of its foundation, “SEKISUISANGYO” enclosed in a hexagonal shape resembling a
tortoise shell (the chemical
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symbol for benzene), symbolizing the Chinese character meaning “water.”
In November 1959, this mark was defined as the “3S Principle”and formally established as
the company creed.
“The difference between people living their lives in accordance with ideals and those simply
going where the currents and eddies of life take them becomes ever more apparent as the long
years of their lives pass. The same is true of business. Only when employees mass under a
common ideal arising from a basic policy of business management can the company
demonstrate its great power as a corporate community.”
It was in the spirit of this intent that the 3S Principle comprising Service, Speed and
Superiority was established as the motto of SEKISUI.
Origin of Company Name
SEKISUI means “pent-up water.” An expression used by Sun Tzu in his classic treatise.
Meaning of “SEKISUI”
“The battle of victor is determined in a fell swoop with tremendous force, just as a full body
of water (pent-up water or “SEKISUI”) let drop into a deep gorge.”
Adoption of this concept into corporate
activities:
The expansion of business activities will inevitably experience problems and challenges. To
overcome such difficulties, it is important both to gain a full understanding of and to analyze
one’s opponent’s circumstances, to consolidate one’s own structure and then to release the
power of pent-up waters to do battle and be victorious.
MISSION STATE MENT
Create social value while fulfilling stakeholder expectations
Sekisui Chemical Group will fulfill the stakeholder expectations of our “Customers,”
“Shareholders,” “Employees,” “Business Partners,” “Local Communities and the
Environment.”
Customers
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Shareholders Employees in
• Satisfy customer needs to the fullest extent
• Provide the best possible services to customers
•Established a culture that encourages employees to set their own goals and take on new
challenges.
•Assure the validity of the performance-based evaluation.
• Contribute to society and the environment with our products.
•Build harmony with local communities as a good corporate citizen.
•Strive for the sustained growth of corporate value.
•Ensure the clear and timely disclosure of information.
• Deepen relationships with business partners and associated companies
•Promote coexistence and co-prosperity through fair transactions.
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GROUP VISION
Sekisui Chemical Group will continue to develop the frontiers of “Creation
of Housing/Social Infrastructure” and “Chemical Solutions, ” utilizing its
prominent technology and quality, thereby contributing to people’s lives
around the world and the global environment.
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The Group Vision contains the intention of the Sekisui Chemical Group. All Group
employees will realize the intention and continue to be a business group that is trusted and
expected.
Prominent technology and quality.We provide quality that satisfies customers, including
technology accumulated over many years in the plastics processing and housing sectors, as
well as "hard" products and "soft" services and solutions.
Creation of Housing / Social Infrastructure
We offer housing and related materials, and infrastructure related to water and the
environment, which
make full use of advanced technology.
Chemical Solutions
We supply chemical products that anticipate the advanced needs of customers in the
industrial fields of
transport equipment, electronics, healthcare, etc.
Development of frontiers
We create new value while exploring and expanding business, in keeping with the
progressive spirit of
development that flows through the Sekisui Chemical Group.
People’s lives around the world
We contribute to improving the quality of people’s lives by responding to global markets and
taking part
in global activities.
Global environment
We seek to create an environment in which people of the next generation can enjoy true
peace of mind
through business that combines ecology and economy.
CORPORATE HISTORY
Mar. 1947 sekisui industry co., ltd. Formed as a general plastics company by former
employees of nippon chisso hiryo k.k. (currently
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Chisso corporation)
Jan. 1948 nara plant (currently nara control center) opened, started the first plastic automatic
injection molding business in japan
Jan. 1948 changed the name to sekisui chemical co., ltd.
Mar. 1953 listed on the osaka securities exchange (currently osaka securities exchange co.,
ltd.)
Jul. 1953 amagasaki plant opened, began manufacture of plastic tape
Sep. 1953 tokyo plant opened, began manufacture of molded plastic products
Apr. 1954 listed on the tokyo stock exchange (currently tokyo stock exchange group, inc.)
Jun. 1956 central research laboratory (currently research & development institute )
established
Aug. 1960 shiga ritto plant opened, began manufacture of pvc pipe and pvc building
materials
Nov. 1960 shiga minakuchi plant opened, began manufacture of polyvinyl butyral and
interlayer film
Jul. 1962 musashi plant opened, began manufacture of plastic tape and pvc tape
Jan. 1964 tokuyama sekisui industry co., ltd. (currently a consolidated subsidiary) established
and began manufacture of pvc resins
Feb. 1971 entered the housing business with the launch of steel frame unit housing “heim”
Oct. 1971 naseki industry co., ltd. (currently kinki sekisui heim industry co., ltd.,
consolidated subsidiary) established and began
Manufacture of unit housing
Mar. 1972 3s (san-es) heim manufacturing co., ltd. (currently tokyo sekisui heim industry co.,
ltd., consolidated subsidiary)
Established and began manufacture of unit housing
May 1977 introduction of a new divisional head office system
Mar. 1982 launch of wooden frame unit housing “two-u home”
Apr. 1982 gunma plant opened, began manufacture of pvc pipe and exterior paneling for unit
construction housing
Dec. 1983 sekisui america corporation (currently a consolidated subsidiary) established
Jul. 1987 applied electronics research center (currently development center, r&d center)
established
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Sep. 1990 housing research & development institute (currently housing technology institute)
established in the housing division (currently
Housing company)
Apr. 1992 kyoto technology center (currently kyoto r&d laboratory) established
Aug. 1997 komatsu kasei co., ltd. (currently vantec co., ltd., consolidated subsidiary)
acquired to strengthen pipe business
Jan. 2000 hinomaru co., ltd. (currently a consolidated subsidiary) acquired to strengthen
operations in the kyushu region
Mar. 2000 seven divisions combined into three: housing division, urban infrastructure &
environmental products division, and high
Performance plastics division; new business headquarters established
Oct. 2000 housing sales system reorganized, with the Tokyo and Kinki regional sales
companies overseeing local regional sales networks
Mar. 2001 New “company” system introduced, renaming the Housing, Urban Infrastructure
& Environmental Products, and High
Performance Plastics Divisions as the Housing Company, Urban Infrastructure &
Environmental Products Company, and High
Performance Plastics Company
Apr. 2002 Head office functions reorganized into 7 departments
Apr. 2003 Chugoku region housing business sales structure reorganized, Sekisui Heim
Chugoku Co., Ltd., (currently Sekisui Heim
Chushikoku Co., Ltd., consolidated subsidiary) established
Apr. 2003 Youngbo Chemical Co., Ltd. (listed on the Korea Exchange, consolidated
subsidiary) acquired, strengthening global
competitiveness
Aug. 2004 Tohoku region housing business sales structure reorganized, Sekisui Heim
Tohoku Co., Ltd. (currently a consolidated
subsidiary) established
Jul. 2005 Kyushu region housing business sales structure reorganized, Sekisui Heim Kyushu
Co., Ltd. (currently a consolidated
subsidiary) established
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Oct. 2006 Daiichi Pure Chemicals Co., Ltd. (currently Sekisui Medical Co., Ltd., a
consolidated subsidiary) acquired to strengthen the
medical business of the High Performance Plastics Company
Jan. 2007 Head office functions reorganized into 6 departments, and CSR department
established
Jul. 2007 Tokyo, Chubu and Kinki region housing business sales structures reorganized,
Tokyo Sekisui Heim Co., Ltd., (currently a
consolidated subsidiary) Sekisui Heim Chubu Co., Ltd. (currently a consolidated subsidiary)
and Sekisui Heim Kinki Co., Ltd.
(currently a consolidated subsidiary) established
Apr. 2008 Introduction of the Executive Officer System
Aug. 2008 Chugoku and Shikoku region housing business sales structures reorganized,
Sekisui Heim Chushikoku Co., Ltd. (currently a
consolidated subsidiary) established Jul. 2009 Polyvinyl alcohol resin business acquired from
group companies of the Celanese Corporation chemical company of the United States, stable
raw material supply structure for the interlayer film for laminated glass business established.
Main Businesses
High Performance Plastics Company
Electronics
LCD fine particles, photosensitive materials, semiconductor materials, industrial tapes and
films, ITO film
Automobiles and Transportation
Interlayer film for laminated glass polyolefin foam, molded resin products for vehicle use
Building and Infrastructure
Functional resins for infrastructure, fire-resistant tapes and sheets, rainwater storage materials
Life Science
Diagnostic pharmaceuticals, testing equipment, pharmaceuticals, drug-discovery support
businesses, sanitary materials
Industry
Adhesives packaging tapes, packaging, agricultural films, plastic containers
More Urban Infrastructure & Environmental Products Company
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Public and private infrastructure (construction)
PVC pipes and fittings, polyethylene pipes and fittings, plastic valves, system piping
Pipeline rehabilitation materials and methods, reinforced plastic composite pipe, fiber-reinforced
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foamed urethane (FFU)
Building materials (rain gutters, flooring materials), insulation material, unit baths, water
storage tanks
Design, construction and maintenance management of pipeline and water treatment facilities
Functional materials and others
DC Plate, aircraft sheets, interior and exterior sheet for vehicle use
More Housing Company
Housing business
Sekisui Heim steel frame modular housing, Two-U Home wooden frame modular housing,
apartment, building lots, Overseas business
Refurbishing Business
Sekisui Fami S
Real Estate Business
Circulation of secondhand housing, apartment leasing & management
Residential Services Businesss
Elderly housing with supportive services, interior/exterior decoration
Other Businesses
Manufacture and sales of industrial, agricultural and construction materials, etc.
Products and services not included in the above
Injection molding
Injection molding is a manufacturing process for producing parts by injecting material into a
mold. Injection molding can be performed with a host of materials, including
metals, glasses, elastomers confections, and most commonly thermoplastic
and thermosetting polymers. Material for the part is fed into a heated barrel, mixed, and
forced into a mold cavity, where it cools and hardens to the configuration of the cavity. After
a product is designed, usually by an industrial designer or an engineer, molds are made by a
mould maker (or toolmaker) from metal, usually either steel or aluminum, and precision-machined
to form the features of the desired part. Advances in technology now also allow

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for 3D printing of injection molds for certain applications, using photopolymer plastics which
do not melt during the injection process. Injection molding is widely used for manufacturing
a variety of parts, from the smallest components to entire body panels of cars.
Parts to be injection moulded must be very carefully designed to facilitate the moulding
process; the material used for the part, the desired shape and features of the part, the material
of the mould, and the properties of the moulding machine must all be taken into account. The
versatility of injection moulding is facilitated by this breadth of design considerations and
possibilities.
APPLICATIONS
Injection molding is used to create many things such as wire spools, packaging, bottle caps,
automotive dashboards, pocket combs, some musical instruments (and parts of them), one-piece
chairs and small tables, storage containers, mechanical parts (including gears), and
most other plastic products available today. Injection molding is the most common modern
method of manufacturing parts; it is ideal for producing high volumes of the same object.
INJECTION MOLDING MACHINE
An Injection molding machine, also known as an injection press, is a machine for
manufacturing plastic products by the injection molding process. It consists of two main
parts, an injection unit and a clamping unit.
OPERATIONS
Injection molding machines can fasten the molds in either a horizontal or vertical position.
The majority of machines are horizontally oriented, but vertical machines are used in some
niche applications such as insert molding, allowing the machine to take advantage of gravity.
Some vertical machines also don't require the mold to be fastened. There are many ways to
fasten the tools to the platens, the most common being manual clamps (both halves are bolted
to the platens); however hydraulic clamps (chocks are used to hold the tool in place) and
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magnetic clamps are also used. The magnetic and hydraulic clamps are used where fast tool
changes are required.
The person designing the mold chooses whether the mold uses a cold runner system or a hot
runner system to carry the plastic from the injection unit to the cavities. A cold runner is a
simple channel carved into the mold. The plastic that fills the cold runner cools as the part
cools and is then ejected with the part as a sprue. A hot runner system is more complicated,
often using cartridge heaters to keep the plastic in the runners hot as the part cools. After the
part is ejected, the plastic remaining in a hot runner is injected into the next part.
FIGURE:- (A 1300 ton injection molding machine with robotic arm)
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Types of injection molding machine
Machines are classified primarily by the type of driving systems they use hydraulic,
mechanical, electric, or hybrid.
Hydraulic
Hydraulic presses have historically been the only option available to molders until Nissei
Plastic Industrial Co., LTD introduced the first all-electric injection molding machine in
1983.
Hydraulic machines, although not nearly as precise, are the predominant type in most of the
world, with the exception of Japan.
Mechanical
Mechanical type machines use the toggle system for building up tonnage on the clamp side of
the machine. Tonnage is required on all machines so that the clamp side of the machine does
not open (i.e. tool half mounted on the platen) due to the injection pressure. If the tool half
opens up it will create flash in the plastic product. Reliability of mechanical type of machines
is more as tonnage built during each cycle is the same as compared to hydraulic machines.
Electric
The electric press, also known as Electric Machine Technology (EMT), reduces operation
costs by cutting energy consumption and also addresses some of the environmental concerns
surrounding the hydraulic press. Electric presses have been shown to be quieter, faster, and
have a higher accuracy, however the machines are more expensive.
Hybrid injection (sometimes referred to as "Servo-Hydraulic") molding machines claim to
take advantage of the best features of both hydraulic and electric systems, but in actuality use
almost the same amount of electricity to operate as a standard hydraulic,
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A robotic arm is often used to remove the molded components; either by side or top entry, but
it is more common for parts to drop out of the mold, through a chute and into a container
Plastic Injection Molding
• Plastic Injection Molding is a manufacturing technique for making parts from
thermoplastic and thermoset materials
• In contrast to the extrusion (which makes continuous parts of constant cross section),
injection molding make discrete parts (with complex and variable cross section)
• Molten plastic is injected at high pressure into a mold, which is the inverse of the
desired shape.
• The mold is made from metal, usually either steel or aluminium
• widely used for manufacturing a variety of parts, from the smallest component to
entire body panels of cars.
• The key to success in injection molding are to have;
– Proper machine for good melting and injecting of the resin
– The proper resin to appropriate part performance
– A good mold for part definition and removal
Proper operation for efficient molding cycle (mold cycle depends on the design of the
mold and manufacturing parameters)
• The most commonly used thermoplastic materials are;
– polystyrene (low-cost, lacking the strength and longevity of other materials)
– ABS or acrylonitrile butadiene styrene (a co-polymer or mixture of
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compounds used for everything from Lego parts to electronics housings)
– nylon (chemically resistant, heat-resistant, tough and flexible - used for
combs)
– polypropylene (tough and flexible - used for containers

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– PVC (more common in extrusions as used for pipes, window frames, or as the
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insulation on wiring where it is rendered flexible by the inclusion of a high
proportion of plasticizer).
Injection Unit:
Purpose: to liquify the plastic materials and then inject the liquid into mold
– Resin is introduced through hopper
– Some machines can have several hoppers (to fed filler, colorants, other
additives)-Injection molding act as mixer
– However, due to limited size of barrel, mixing capability is poor
From hopper – hole (feed throat)
Barrel made of heavy steel cylinder to withstand the pressure and temperature involved in
melting the resin
2 types of system used in injection molding;
– Reciprocating screw- similar to extruder screw but with unique reciprocating
action
– Ram injector
• Design of screw- similar to an extrusion screw
• 3 sections;
– Feed section- to advance the resin
– Compression section- to melt the resin
– Metering section- to homogenize the resin and pump it forward
• The screw of injection molding machine is shorter than extruder, L/D ratios are 12:1
and 20:1
• Low L/D ratios suggest the mixing is less efficient in the injection molding machine
• The compression ratio (diameter of root at feed zone to the diameter of root at
metering zone) often in the range of 2:1 and 5:1
• Low compression ratio means less mechanical action is added during melting process.

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• Important measure of the size of an injection molding is weight of resin that can be
injected, called shot size
• Typical shot size range from 20g to 20 kg
• Since shot size depends on the density of the plastic, PS has been chosed as the
standard for rating the machine
Reciprocating Screw Injection Molding Machine:
• Resin is melt by mechanical shear and thermal energy from heaters
• The molten resin is conveyed to a space at the end of the screw- collects in a pool
• Here, the mold is closed
• The entire screw move forward and pushes the molten resin out through the end of
barrel
• To ensure the resin does not flow backward, a check valve or nonreturn valve is
attached to the end of screw
• Normally the screw will stay in the forward position, until resin began to harden in the
mold
• Retraction of the screw, create space at the end of the screw
• Cooling of the part in the mold, until it can be removed
While the part is cooling, the screw turns and melts additional resin
• Advantages
– More uniform melting
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– Improved mixing or additives and dispersion throughout the resin
– Lower injection pressure
– Fewer stresses in the part
– Faster total cycle
Ram Injection- Injection Molding Machine:
• In this type of injection molding, the resin is fed from a hopper into the barrel, and
heated through thermal energy from the heaters
• The molten resin is collect in a pool in a barrel celled injection chamber
• The molten resin is then push forward by the action of plunger (ram or piston)
• To five better mixing, the molten resin is pushed past a torpedo/spreader, impart shear
to the melt
Molds:
• Designing and making mold for injection molding is more complicated than making
extrusion die
• Mold Parts – mold is placed in between stationary plate and the moveable plate
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• The connection from the injection unit to the mold is through the nozzle
• The channel that run through the stationary plate of the mold is called the sprue
channel (material that is in the channel is called the sprue)
• The solid sprue is removed from the finished part assembly after the part is ejected
from the mold.
• Resin flow from the sprue through the runner (connecting channel) to the mold
cavities.
Assembly of various mold parts.
• Mold bases can be purchased as entire units, then the cavities are cut from A & B
plates.
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Runners:
• Distribution system for the resin from the sprue to the cavities
• Flow characteristics (viscosity), temperature and other factors are important in
determining the runner diameter and length
• If the diameter of the runner is too small or the length is too long,the resin can freeze
in the runner before the mold is completely full
• If the runner system is too large, excess material would be ejected and too much
regrind created
• If the resins have a high viscosity, larger runners are needed compared to low
viscosity resin
• The optimum flow of the resin through the runner system depends on the shape and
diameter of the channel
• Round channel give the best flow characteristics but difficult to machine
• Machining cost can be reduce by machining one side of the mold plates
• Better shape where the depth of the channel is at least two-thirds the size of the width
and the sides are tapered between 2 to 5º.
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Secondary Runners:
• Secondary runner channel are used for multicavity molds
• The flow into the secondary channel should be streamlined (angle in flow direction)
• The streamlined minimizes shear on the resin
Gates:
• The end of runner and the entry path into the cavity
• The gate shape can also affect the filling of the cavity, dimension and properties of the
parts
• Gate is the most restricted point in injection molding system, i.e. for reinforcement
and filler + polymer systems
Gate Design:
• Small rectangular opening at the end of the runner channel, connect to the edge of
cavity
• Edge gate can be below the parting line if the channel and part are also below the
parting line
• Or it can be symetricaly about the parting line, if the runner channel and part are at
both side of parting line
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Submarine Gate:
• Starts from the edge of the runner, and goes into the cavity edge at an angle
• It narrows to a point as it moves from the runner to the cavity
• The advantage; separation of the parts and the runner is automatic
• Disadvantage; gate cannot be used for some resins because of high shear
Tab Gate:
• By connecting the runner directly into the cavity with no reduction in runner cross-section
Used for very large parts where a reduction in flow would disturb the resin’s flow pattern and
might result inadequate flow into the cavity
Fan Gate:
• Made by reducing the thickness and not the diameter of the runner channel as it goes
into the cavity
• Used for intermediate size, and when reinforcement in the resin cannot flow through
the edge gate
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Ring Gate:
• Used to make hollow cylinder parts
• The ring gate covers the entire top of the cylinder part so that the resin flow is
downward into the wall of the part
Cavities:
• Are actual molding locations
• Resin enter the cavities through gate, fills the cavities, and cools to form the solid.
The parts are ejected and finished
• Cavities are the heart of the molding process, and must be precisely prepared
• The shape of the cavities determines the shape of the part
Materials & Product Consideration:
• Almost all thermoplastic can be injection molded
• Resin with low melt viscosity is required; so that the flow through runner, gate, cavity
– easily done with minimum injection pressure
• Resin with injection molding grades have low molecular weight and narrow
molecular weight distribution
Shapes:
• Hollow parts can be created by allowing the moveable plate to protrude into the cavity
of the stationary plate
• Threads can be placed on the inside of a part by using a core pin that is inserted into
the cavity where the threads are desired
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• A hollow part with a hole on the side is even more complicated (the core pin is used)
• The core pin slide into position after the mold is closed
• The core pin seals against the surface of the moveable plate, prevent flow of resin into
the area
Infrastructure
In its endeavor to manufacture products at par with global standards, SEKISUI DLJM has
equipped all its manufacturing units with modern machines and technology for producing top
of the line Plastics Parts. A true customer-centric OEM Parts supplier, SEKISUI DLJM is
equipped with necessary resources and manpower to meet exacting demands of its clients.
Today, the company has two manufacturing units at Greater Noida and Tapukara. These
facilities are certified as per ISO/TS16949 system and also follow continuous improvement
concepts like Kaizen in order to exceed previous performance
We have 32 Injection Molding Machines Ranging from 100 T to 1000 T with Automatic Raw
Material Conveying System. We have Centralized Process Control for Machine Parameters,
chillers , assy lines all with 100 % power backup. We started a new paint shop from July
2013 which facilitate new design with advanced technology.
We also provide there Special pre-treatment line for :
Dust free parts
Better surface activation by additional surface conditioning mist spray
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We are soon going to start our new Injection Molding Plant in Chennai which is spread over
15000 sq.mtrs. where 10 Injection Molding Machines ( 200 T to 1000 T) at 1st stage & which
have Total Capacity of 40 Injection Molding Machine
Tool Room
Our design section not only develops Injection and Blow moulds in-house but also provides
Mould Flow Analysis.
We work on Pro-E, VISI CAD/CAM and are equipped to handle any design software. We
have been working in tandem with our customers in designing products as per their
specifications. Reverse engineering or proto tooling works are undertaken to support
customer’s need for changing part design. The design to moulded part turnaround time has
been exciting for many of our customers. Our tooling and design activities for local and
export markets have earned us a high level of customer satisfaction and trust evolving into
strong relationship.
Our state of the art in house Tool & Die manufacturing facility comprising of next generation
CNC machine and other machines like EDM, Die Spotting, Lathe, Milling Machine, Radial
Drilling Machine & Grinders from renowned companies like DMG, Haas, Kirloskar, HMT,
Cincinnati Milacron etc.
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Molding Shop
With the prime focus on Quality, Cost and timely delivery, SEKISUI DLJM accomplishes
these virtues through its meticulously planned Injection Moulding set-up. The plant has
centralized process control for all machine parameters. The Plastic materials processed range
from PP, ABS, PC, PC-ABS to PA6, PA66, PA46, including glass-filled or elastomer
composite grade Gas assisted injection molding at our facility helps us in maintaining the
aesthetic value of critical parts and reducing part weight and cost in otherwise thick sectioned
areas.
Paint Shop
The molded parts can be Painted, Plated or Assembled as per customer requirement. Our
painting line and flexible assembly lines cater to many thousand units per day. Millions of
parts including Chrome Plated Handles, Logos, Bezels and others are custom made at the
facility.
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Assembly
The molded and painted sub parts are assembled with other parts to make an assembly as per
customer requirement. Our flexible assembly lines cater to many thousand units per day.
Millions of parts including plastic parts, Logos, Bezels and others are custom made at the
facility.
Test Lab
The company is equipped with reputed brand of test equipment. A modern test lab with latest
equipments supports the company’s commitment to quality. Apart from regular quality and
performance tests, all critical products are tested on special testing equipments. The company
also implements modern analytical techniques and quality planning processes
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Products
The company manufactures premium quality plastic moulded auto parts. We are involved
with its customers, right from Product designing stage to Prototyping till the serial
production. The components are manufactured as per demands and specifications provided by
different companies and are in conformity with international norms and standards.
Two Wheelers Plastic Parts
With vast experience, we are now one of the major Two Wheeler Plastic Parts Manufacturers.
.
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.
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Technology
Possess more than 25 years of experience in Plastic Auto parts manufacturing.
Advanced Technology Input as a JV by Japan’s leading moulding group.
Offer complete solutions in Plastic Processing Technologies i.e. Injection.
Two state-of-the-art manufacturing units & one coming soon.
ISO / TS 16949 : 2009 certified plants .
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Engineering

Engineering
Single window contact point for all our customers available.
A well experienced product development team with deep understanding of the most intricate
products.
Various In house Testing facilities and a well equipped tool room with latest CAD software.
A True One Stop OEM Solution provider.
Clients of SEKISUI DLJM MOLDING PVT.LTD
HERO HONDA
YAMAHA
MARUTI SUZUKI
SUZUKI
DONALDSON
Corporate Social Responsibility
CSR: The Foundation of Management
As a Sekisui Group company, Sekisui DLJM Molding considers CSR to refer to contributing
to sustainable society through its businesses. We believe that promoting CSR management
increases the quality of corporate management.
Three Prominences:
First, we aim to be an environmental leader by contributing sustainable society and lessening
the environmental load of its business activities. Second, we pursue quality specified by
customers, through maximizing the quality of human resources, products, and systems. Third,
we encourage individual prominence and self-realization, providing opportunities for diverse
human resources in our workplace.
Three Attitudes of Sincerity:
We aim to continue being a company trusted by society through deploying compliance. Each
employee can be proud, not just for his or her own sake but for his or her family and society
at large, as they strives to put our management vision into practice. Also, we aim to increase
sensitivity to risks by running through PDCA cycle, and to advance CSR management
through communication with our stakeholders build on trust.
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Three attitudes and Prominences of sincerity of company:
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Why Us??
Possess more than 25 years of experience in Plastic Auto parts manufacturing.
Advanced Technology Input as a JV by Japan’s leading moulding group.
Offer complete solutions in Plastic Processing Technologies i.e. Injection.
Two state-of-the-art manufacturing units & one coming soon.
ISO / TS 16949 : 2009 certified plants .
Single window contact point for all our customers available.
A well experienced product development team with deep understanding of the most intricate
products.
Various In house Testing facilities and a well equipped tool room with latest CAD software.
A True One Stop OEM Solution provider
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Policy
SEKISUI has basically three main policy. There are given below :
1-Quality Policy.
2-Enviroment Policy.
3-Enviroment Policy.
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ENVIRONMENT
SEDM commitment to General environment. Rainwater harvesting (RWH) and recharging of
groundwater is emerging as a sustainable measure to cope with the increasing pressure on
scarce freshwater resources. It is imperative that RWH practices have to be promoted
globally for a secure water future of our societies and of the planet as a whole. Industry can
play a vital role in producing and propagating RWH systems and solutions in this critical and
challenging direction. SEKISUI DLJM takes pride in envisioning and enterprising in this
direction through its sincere and sustained efforts in contributing with its groundbreaking
environment conservation technology called CROSS-WAVE, brought from the
pioneers, Sekisui Techno Molding of Japan.
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Conclusion
On the whole, this internship was a useful experience. I have gained new knowledge, skills
and met many new people. I achieved several of my learning goals, however for some the
conditions did not permit. I got insight into professional practice. I learned the different facets
of working within an industrial machines. I experienced that financing, as in many industry
is an important factor for the progress of projects.
Related to my study I learned more about the injection molding and maintenance of mould
and the assembly of parts. There is still a lot to discover and to improve. The methods used at
the moment are still not standardized and a consistent method is in development.
In injection molding education is an important aspect of the conservation of the parts joining.
I have seen that local people can contribute to conservation, for example with their
knowledge. Furthermore I experienced that it is of importance that the education is objective
and that you have to be aware of the view of other people. Industrial education is not one
sided, but it is a way of sharing knowledge, ideas and opinions.
The internship was also good to find out what my strengths and weaknesses are. This helped
me to define what skills and knowledge I have to improve in the coming time. It would be
better that the knowledge level of the language is sufficient to contribute fully to projects.
After my master I think that I could start my working career. However I could perform
certain tasks in research better if I practice/know more the research methodologies applied in
cetacean studies. It would also be better if I can present and express myself more confidently.
At last this internship has given me new insights and motivation to pursue of my career.
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Refrences
1. www.google.com
2. www.wikipedia.com
3. www.sekisuidljm.com
4. www.sekisuichemical.com

Engineering
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SUMMER TRAINING EVALUATION
COURSE:
SEMESTER:
PROJECT TITLE:
STUDENT NAME:
ROLL NUMBER:
S.No. Description Total Marks Mark
Awarded
1. Training Diary with attendance 50
2. Training Report 100
3. Presentation 50
4. Viva
(For self arranged training 25
marks)
100
Total 300
EXAMINERS NAME INITIALS DATE
Internal
External

SEKISUI DLJM Molding Pvt. Ltd. Industrial Report(Plastic Injection Molding)

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