Preventive Analysis of Polymer Leakage in Injection Molding Machines and Its Impact on Production Efficiency

2026-01-01T11:28:17+00:00

This study examines the causes and impacts of polymer leakage in a 500-ton injection molding machine, which frequently occurs at the nozzle and sprue bushing junction. Leakage is caused by seal wear, excessive injection pressure, and nozzle misalignment, which enlarges microgaps. Measurements show that at a pressure of 150 MPa and a temperature of 250°C, the leakage rate reaches 20–100 ml/h. Through Autodesk Moldflow simulations, the nozzle-sprue transition area was identified as the point of maximum pressure (152 MPa) with the highest leakage potential, thereby extending conventional maintenance diagnostics through simulation-based identification of critical stress zones rather than relying solely on routine visual inspection. After optimizing the design and process parameters including reducing the injection pressure to 140 MPa, using heat-resistant Viton seals up to 250°C, and readjusting the nozzle position the leakage rate decreased by 70% (from 60 ml/h to 18 ml/h). The output of this study is a leak prevention model based on visual inspection, direct measurement, and numerical simulation, which distinguishes this work from standard industrial troubleshooting by integrating predictive simulation with quantitative cost-saving analysis, enabling an increase in production efficiency by ± 5 percent and operational cost savings of approximately US$1,800 per year per machine.

Analysis of Layout Design Discrepancies Generated in the Proofreading Process for Product Quality Improvement in the Label & Packaging Manufacturing Industry: Evidence from XYZ Company

2026-01-01T11:26:29+00:00

PT XYZ Packaging Indonesia is a company that produces various types of packaging for the garment industry, such as labels, stickers, printed labels, and related accessories, with integrated services from concept to execution. This research analyzes design layout discrepancies in the proofreading process, including content shifts, color errors, text format, cutting lines, fonts, as well as barcode and style/PO mismatches, which impact increased rejections, potential customer complaints, and production losses. In the last three months, the company recorded an average proofreading defect of 15%, mainly due to content errors of 10%. Using the PDCA method, the research identified root causes such as the absence of visual inspection standards, inconsistent work instructions, high workload, and suboptimal digital proofing. Through PDCA, improvements were implemented including standard checklists, two-step verification, increased operator training, and integration of automatic preflight software which reduced proofreading errors to 0%. These results confirm that PDCA effectively improves design layout accuracy and reduces rejects, as well as highlighting the importance of prepress-based quality control in the label and packaging industry.

Review: Journal of Multidisciplinary in Social Sciences

Preventive Analysis of Polymer Leakage in Injection Molding Machines and Its Impact on Production Efficiency

Analysis of Layout Design Discrepancies Generated in the Proofreading Process for Product Quality Improvement in the Label & Packaging Manufacturing Industry: Evidence from XYZ Company