INPUTS

Project
Part Number
Production Temparature
L W T
Cost Covert
Product Size in mm
Product Volume cm
Conversion
Projected Area in cm Cooling Time FlatParts Factors
Plastic Material
Calculated Plasticising
Weight of the product based on Cooling Time Round
Parts capacity
in Grams material

Maximum wall thickness

No of Cavity /
Production time
Mold Cooling
Minimum Wall Thickness
Average wall thickness
Machine
Shot Weight Cooling
Production quantity required
Parts per Year

Production Hours
Barrel
Capacity

Coolant
Mold Heating Quantity

Mold WeightScrew Speeds

Gate Freeze
Injection Rate
d Component: Productivity / Component Cost Calculator. GB
Part Name; Cap Project U56 Cap
Scenario ID Prototype Machine Demag 300t M/c 13
Part Number; Date 12/07/06
Drawing Number: Issue/Rev. Gross hourly output: 3600.00 exc scrap & eff.%
Mould cost: 100,000 Material uPVC Nett Hourly output: 2,352.24 parts
Cycles per hour 225 cycles/ hour
Impressions: 16 Cavities Nett Daily output: 28,226.88 parts
Total mat'l throughput 79.2 Kg / hour
NU Cycle time; 16 Sec Gross Weekly output: 216,000 parts
Copy to Machine efficiency 66 % Nett Weekly output: 141,134 parts
Logbook Scrap Allowance 1 % Nett Monthly output:4Wks 564,538 parts
Profit Margin 10 % Nett production Per Shif 18,818 8 Hour shif
Amortisation Gross annual output: 2,592,000 parts
Period (mould) 3 Year(s) Nett annual output: 1,693,613 scrap allowance 1%

Overhead costs per part 0.637690 pence

Days per week 5.0 Days Tool cost per part. 1.968179 pence
p each Hours per day 12.00 hours Machine cost per part 0.680203 pence
p each Weeks per Year 12 Weeks Material cost per part. 1.232000 pence
p each Overhead Costs 15.00 per hour M'batch cost per part 0.000000 pence
Regrind Cost 450.00 per tonne Regrind cost per part 0.297000 pence
Regrind addition 30% %
Masterbatch cost 0.00 per Kg Total Nett cost per part 4.518072 pence each
p each M'batch addition 0.00 %
Material Cost 800.00 per tonne Nett Cost per 1000 45.18 per thousand
Machine Cost 16.00 per hour LOSS of -590.04 per week

OSS Part weight.

Sprue weight.
22
0
grammes
grammes
LOSS per 1000 parts
LOSS per part
-4.18
-0.004181
Shif Duration 8 Hours LOSS OF -7,080.52 is Being made
Comparison of AGREED PRICE with your NETT PRODUCTION COSTS. Selling Price Inc.profit Margin 49.70 per '000 @ Margin 10%
Agreed / Target Price 41.00 per 1000 Gross material usage; annually 57.02 Tonnes
Nett Production cost 45.18 per 1000 Virgin Matrial 39.92 Tonnes
Actual profit: -9.25% Regrind Material 17.11 Tonnes @ 30%
Virgin Material cost 31,933.44
our information in the yellow boxes. Regrind Material cost 7,698.24 @ Regrind % of 30%

CT, WARRANTY OR GUARANTEE, OF ANY TYPE, IS GIVEN OR IMPLIED. THE RESULTS OF CALCULATION ARE FOR GUIDANCE ONLY. All worksheets comprising "
POLYBRIDGE Training Ltd

OUTPUT Note: This document is for guidance only. No guarantee or contract is implied or given . MyDocuments/RAPRA/Output Calculator
INJECTION MOULDING CALCULATIONS
0A

Output / Costing Logbook

Drawing Number:
MENU Mould cost:

Impressions:
Copy OUTPUT to
Logbook
Cycle time;
Machine efficiency
Scrap Allowance
Profit Margin
Amortisation
Period (mould)
Print Logbook

Days per week

Clear Logbook Hours per day
Weeks per Year
Overhead Costs
Regrind Cost
Regrind addition
Masterbatch cost
M'batch addition
Material Cost
Machine Cost
Part weight.
Sprue weight.
Shif Duration

Agreed / Target Price

Nett Production cost
Actual profit:

Page 5 of 58
 Cooling Time Calculator FLAT Componen
Type your data in the yellow boxes.

Mould 1 2 3 4 5 6 7 8 9 10
TempC Polycarb. HDPE LDPE Nylon 6.6 PA66 40%gf ABS Polystyrene PVC Acrylic Polyprop.
10 0.1065 0.1015 0.0965 0.0895 0.0625 0.081 0.0890 0.0798 0.0685
20 0.1069 0.0949 0.0923 0.089 0.062 0.0814 0.0871 0.0705 0.0782 0.0674
30 0.1074 0.0883 0.0881 0.0885 0.0615 0.0818 0.0851 0.0712 0.0766 0.0664
40 0.1078 0.0817 0.0839 0.088 0.061 0.0822 0.0832 0.0718 0.075 0.0653
50 0.1083 0.0750 0.0797 0.0875 0.0605 0.0827 0.0813 0.0725 0.0734 0.0643
60 0.1087 0.0684 0.0755 0.0870 0.0600 0.0831 0.0794 0.0718 0.0632
70 0.1092 0.0618 0.0865 0.0595 0.0835 0.0774 0.0702 0.0621
80 0.1096 0.0552 0.0860 0.059 0.0775 0.0686 0.0611
90 0.1101 0.0486 0.0855 0.0585 0.0670 0.0600
100 0.1105 0.0420 0.0850 0.058
Mould 1 2 3 4 5 6 7 8 9 10
Wall Mould Melt Ejection
Thickness: 5 mm Temp: 100 deg C Temp: 285 deg C Temp:
This row shows general ranges Range 80/120 deg C Range 280/310 deg C Max

Diffusivity
43.6616007148 2.4660583728

Cooling Time = 87.95 seconds Material Number:

Cooling @ Centre = 107.67 seconds** 2.0143460135

HDT give you a guide to the maximum ejection temperature that you can use. Note it's only a guide and you may have to go significantly lower.
to avoid distortion on ejection. If the plastic is glass reinforced this temperature goes up. See your material suppliers data sheets to obtain MENU
Coolingtime Flat Parts Note: this document is for guidance only. no guarantee or contract is implied or given.
 more accurate figures of all do these temperatures.

** Cooling @ Centre; is the cooling time when the centre core of the moulding has reached ejection temperature
It's longer because cooling time has waited for mouldings' centre to reach ejection temp.

Coolingtime Flat Parts Note: this document is for guidance only. no guarantee or contract is implied or given.
ponents
11 Mould
Acetal TempC
10
0.0800 20
0.0762 30
0.0724 40
0.0685 50
0.0647 60
0.0609 70
0.0571 80
0.0533 90
0.0494 100
11 Mould

120 deg C
130 deg C

0.058

MENU
Coolingtime Flat Parts Note: this document is for guidance only. no guarantee or contract is implied or given.
Cooling Time Calculator
Type your data in the yellow boxes.

Mould 1 2 3 4 5 6
TempC Polycarb. HDPE LDPE Nylon 6.6 PA66 40%gf ABS
10 0.1065 0.1015 0.0965 0.0895 0.0625 0.081
20 0.1069 0.0949 0.0923 0.089 0.062 0.0814
30 0.1074 0.0883 0.0881 0.0885 0.0615 0.0818
40 0.1078 0.0817 0.0839 0.088 0.061 0.0822
50 0.1083 0.0750 0.0797 0.0875 0.0605 0.0827
60 0.1087 0.0684 0.0755 0.0870 0.0600 0.0831
70 0.1092 0.0618 0.0865 0.0595 0.0835
80 0.1096 0.0552 0.0860 0.059
90 0.1101 0.0486 0.0855 0.0585
100 0.1105 0.0420 0.0850 0.058

Part Mould
Diameter 11 mm Temp: 100 deg C
This row shows general ranges Range 70/120 deg C

Back to word document?

105.8693254

Cooling Time = 159.19 seconds

5.5 mm Radius
Cooling @ Centre = 247.86 seconds**

HDT give you a guide to the maximum ejection temperature that you can use. Note it's only a guide and you may have
to avoid distortion on ejection. If the plastic is glass reinforced this temperature goes up. See your material suppliers
more accurate figures of all do these temperatures.
** Cooling @ Centre; is the cooling time when the centre core of the moulding has reached ejection temperature
"cooling time" has waited for mouldings' surface to reach ejection temp.
 ROUND Components
7 8 9 10 11 Mould
Polystyrene PVC Acrylic Polyprop. Acetal TempC
0.0890 0.0798 0.0685 10
0.0871 0.0705 0.0782 0.0674 0.0800 20
0.0851 0.0712 0.0766 0.0664 0.0762 30
0.0832 0.0718 0.075 0.0653 0.0724 40
0.0813 0.0725 0.0734 0.0643 0.0685 50
0.0794 0.0718 0.0632 0.0647 60
0.0774 0.0702 0.0621 0.0609 70
0.0775 0.0686 0.0611 0.0571 80
0.0670 0.0600 0.0533 90 1
0.0494 100

Melt Ejection
Temp: 295 deg C Temp: 130 deg C
Range 185/225 deg C MAX 115 deg C

Diffusivity 0.0494
2.341180611

Material Number: 11
Menu
1.503632854 MENU

ote it's only a guide and you may have to go significantly lower.
goes up. See your material suppliers data sheets to obtain

has reached ejection temperature It's shorter because

INJECTION MOULDING CALCULATIONS

Production Duration Calculator; How long will the production run be?

Existing Moulds' number of impressions Cavities

8
Existing Moulds' cycle time Sec
75
Existing production efficiency %
85
Quantity to be manufactured. Parts
50000 MENU
How many days per week you work Days
5
How many hours per day you work Hours
24

Hourly out put available:

Production time needed:
Production time needed:
Production time needed:
 Menu

MENU

326.4 Per hour

153.19 Hours

6.4 Days

1.3 Weeks
Cavity number Calculator
Number of parts to be produced 200000 Parts Resultant
Production times.
Number of weeks worked per annum 6 Weeks 442.71 Hours

Number of days worked per week 5 Days 18.4 Days

Number of hours worked per day 24 Hours 3.6892361111 Weeks

MachineEfficiency 85 %

Estimated cycle time 75 Sec MENU

Number of cavities required: 8

to meet this volume 7
INJECTION MOULDING CALCULATIONS

POLYMER No LOWER OPTIMUM MAXIMUM Screw Diameter

ABS 1 0.45 0.55 0.65
EVA 2 0.4 0.5 0.55
GPPS (CRYSTAL) 3 0.7 0.8 0.95 Polymer Number
HDPE 4 0.65 0.75 0.8
LDPE 5 0.6 0.7 0.75
LINEAR LDPE 6 0.6 0.7 0.75
HIPS 7 0.75 0.85 0.9
NYLON 6 8 0.3 0.4 0.5
NYLON 6:6 9 0.3 0.4 0.5
PBT 10 0.25 0.3 0.35 Lower speed
Poycarbonate 11 0.3 0.4 0.5
PEEK 12 0.25 0.3 0.4
PEI 13 0.3 0.4 0.5 Optimum
PETp 14 0.1 0.1 0.2
PES 15 0.15 0.15 0.25
PBT 16 0.25 0.3 0.4 Maximum
PMMA 17 0.25 0.35 0.4
POM copolymer 18 0.15 0.2 0.5
POM homopolymer 19 0.1 0.1 0.3
PP 20 0.65 0.75 0.8
PPO 21 0.3 0.4 0.5
PPS 22 0.15 0.2 0.2
PVC plasticised 23 0.125 0.15 0.3
PSU 24 0.125 0.15 0.2
SAN 25 0.3 0.4 0.45
Upvc 26 0.125 0.15 0.2
Screw speeds are given im Metres/ sec
If you want mm/sec multiply by 1000.
 50.0
mm

26
From table

0.125 m/s mm/s 125

0.15 m/s mm/s 150
0.2 m/s mm/s 200

48 rpm

MENU
57 rpm

76 rpm

This sheet allows you to find

the Lower, Upper & Optimun
revs per minute for your
material & screw diameter

Menu
MOISTURE DRYING POLYMER DRYING TIME BULK DENSITY
% MAX TEMPC No Hours Litres (kg/dm)
ABS 1 2.5 0.63
ABS/PC 2 3 0.65
ASA 3 3 0.63
LCP 4 4 0.97
PA6 5 5 0.68
PA6 30%GF 6 5 0.94
PA6 40%GF 7 5 1.02
PA6 50%GF 8 5 1.1
PA6:6 & PA 6:10 9 5 0.68
PBT 10 3 0.78
PBT 15%GF 11 3 0.9
Poycarbonate 12 2.5 0.75
PEEK 13 3 0.79
PEI 14 4 0.78
PES 15 4 0.82
PET (Preforms) 16 6 0.85
PET(Normal Moulding) 17 4 0.85
PETG 18 6 0.8
PMMA 19 2.5 0.71
PP Talc 40% 20 3 0.7
PP Chalk 40% 21 3 0.77
PPE 22 2 0.64
PPS 23 3.5 0.81
PSU 24 3 0.75
SAN 25 2.5 0.65
SB 26 2 0.64
Screw speeds are given im Metres/ sec
If you want mm/sec multiply by 1000.
 DENSITY
g/cc & kg/m Dryer Volume
60.0
1.05
1.2
1.2 Polymer Number From the Table
6
1.62
1.13
1.54 Drying Time 5 Hours
1.68 Bulk Density 0.94 Litres
1.81 Density 1.54 g/cc
1.14
1.3 N of Cavites 96
1.48 Part weight 4 Grams
1.25 Sprue weight 12 Grams
1.32 Cycle Time 15 sec
1.3 Total Weight 396 grams
1.37
1.34 Dryer Maximum 98 kg
1.3 No of Shots 248 shots
1.27 Time in dryer 248.23 mins
1.19 DRYING TIME 5.00 Hours
Actual Drying time
4.137 Hours
1.21 OK
1.24 available Not Enough
1.06
1.05
1.25
Cell is Red; There is INSUFFICIENT
1.08
DRYING TIME Use a bigger Dryer
1.06

MENU
 Gate Size: Shear Rate
Polymer Shear Rate Density
1 ABS 1 50,000 0.89 Cavity Volume
2 Acrylic 2 40,000 1.07 No of Gates
3 Acetal 3 40,000 1.1 Fill Time
4 EVA 4 30,000 0.8 Gate Diameter
5 GP Polystyrene 5 40,000 0.967 Gate width

6 High Impact P.S 6 40,000 0.967 Gate Depth

7 LDPE 7 40,000 0.7 Material No
8 (PA) Nylon 6 8 60,000 0.95
9 Glass Filled PA6 9 30,000 1.15
10 (PA)Nylon 6:6 10 60,000 0.95
11 Glass Filled PA6:6 11 30,000 1.15
12 PBT 12 50,000 1.1
13 PET 13 50000 1.10
14 Polycarbonate 14 40,000 0.98
15 PES 15 50,000 1.2
16 PPO 16 35,000 0.9
17 PPS 17 50,000 1.45
18 Polypropylene 18 100,000 0.73
19 PSU 19 50,000 1.1
20 PUR 20 40,000 1.13 47450.0
21 PVC Flexible 21 20,000 1.2 4472.0
22 uPVC 22 20,000 1.12 37.2670807453
23 SAN 23 40,000 0.88

V24 Nov 2008

 260.9 cc Weight 300.00 g
1 Volume 260.9 cc
7 Sec Density 1.15
2 mm: Round Gates Round 0.02513 cm
5 mm: Square/

1 mm: rectangular 0.05 cm

11 Glass Filled PA6:6
30000

TOO HIGH!
Calculated Shear Rate Round Gates
47,450.0
Polymers' Maximum Shear Rate= 30,000.0
Calculated Shear Rate for
Square & Rectangular Gates 4,472.0
OK - WITHIN RANGE

Q for round gates

Q For Square 7 rect MENU Menu
Q
Maximum Barrel Capacity Calculator
1 ABS 0.89
"Bayblend" 2 ABS/PC 0.96
Cellulose Acetate. 3 CA 0.97
Liquid Crystal 4 LCP 1.38
Nylon 6 5 PA-6 0.95
Nylon 6 35 % glass 6 PA-6 35%GF 1.15
Nylon 6.6 7 PA-6.6 0.95
Nylon 6.6 35 % glass 8 PA-6.6 35%GF 1.15
Polyester 9 PBT 1.1
10 PBT 30% GF 1.4
Poycarbonate 11 PC 0.98
P'carb + 30% glass 12 PC 30%GF 1.22
"Xenoy" 13 PC/PBT 1
Polyether imide 14 PEI 1.2
Polyethersulphone 15 PES 1.2
16 PET 30%GF 1.48
"Noryl" 17 PPE/PA 0.92
Polyphenylenesulphide 18 PPS 1.45
Polysulphone 19 PSU 1.1
20 HDPE 0.72
21 LDPE 0.7
Acrylic "Diakon" 22 PMMA 1.07
23 PP 0.73
24 PP 20% TALC 0.87
Acetal "Delrin" 25 POM 1.1
26 HIPS 0.967
27 PS 0.967
28 uPVC 1.12
29 SAN 0.88
T'plastic rubber 30 TPE-A 0.83
31 TPE -S 1.08
 Screw Diameter 35 mm 8 grams
Material No: 8
Material Density. 1.15 Weight of Full Shot
Maximum Shot 140 & any Sprue

23
Cycle Tme

0 in Seconds

154.92
This is how much
plastic can be injected
in a single shot, in
Grammes

What's it for, & who'd use it?

Shots

19.37 In
Barrel

Residence

7.4 Time
Minutes
MENU

CROSS CHECK: Practical check gave 66g using HIPS; 30mm Diameter screw, & a 95mm max screw stroke ( ARBURG 221-55-250)
 Quantity S.I. Unit is ... Conversion
Force N (newton) 1kgf = 9.80665 N
Strength N/mm 1kgf/cm = 0.098 N/mm
Impact Strength kJ/m 1kgf/cm/cm = 981 N/m/m
mJ/mm 0.981mJ/mm

Pressure bar (bar) 1 atm (=1kgf/cm) - 0.981 bar

1torr (=1mm Hg)
pa (pascal) 1Pa = 1n/m; 1bar =10 Pa
Work J (joule) 1kgf . M
1 N.m
Quantity of Heat J (joule) 1kcal
Power W (wat) 1kgf.m/sec = 9.81 N.m/sec
1hp (=75kgf . m/sec)
Temperature K (kelvin) 0C = 273.15K; 100C = 373.15K
Also C (celsius) Freezing Boiling
Nb 10 bar = 1mPa (megapascals)

1kW= 1000 Watts 1 bar of an electric fire

1cc of water = 1 gram 1000cc of water = 1 kilogram which also = 1 Litre : this is the basis of the system
 googol 10 100 "every atom in the universe"!

10N T tera 10 12 1 trillion

0.1N G giga 10 9 1 billion

1kJ/m m mega 10 6 1 million

1mJ/mm k kilo 10 3 1000

1N.mm/mm h hecto 10 2 100

1bar = da deca 10 Base Unit; metre: Litre.

=1.333mbar d deci 10 -1 0.1

c cent 10 -2 0.001

=9.81J m milli 10 -3 0.0001

=1J micro 10 -6 1 millionth

=4.19kJ n nano 10 -9 1 billionth

=9.81W p pico 10 -12 1 trillionth

=0.736kW f femto 10 -15 one thousanth of a trillionth

a atto 10 -18 one millionth of a trillionth

means "almost equal to"

Convert temps

e basis of the system

MENU
 1 ABS 0.89
"Bayblend" 2 ABS/PC 0.96
Cellulose Acetate. 3 CA 0.97
Liquid Crystal 4 LCP 1.38
Nylon 6 5 PA-6 0.95
Nylon 6 35 % glass 6 PA-6 35%GF 1.15
Nylon 6.6 7 PA-6.6 0.95
Nylon 6.6 35 % glass 8 PA-6.6 35%GF 1.15
Polyester 9 PBT 1.1
10 PBT 30% GF 1.4
Poycarbonate 11 PC 0.98
P'carb + 30% glass 12 PC 30%GF 1.22
"Xenoy" 13 PC/PBT 1
Polyether imide 14 PEI 1.2
Polyethersulphone 15 PES 1.2
16 PET 30%GF 1.48
"Noryl" 17 PPE/PA 0.92
Polyphenylenesulphide 18 PPS 1.45
Polysulphone 19 PSU 1.1
20 HDPE 0.72
21 LDPE 0.7
Acrylic "Diakon" 22 PMMA 1.07
23 PP 0.73
24 PP 20% TALC 0.87
Acetal "Delrin" 25 POM 1.1
26 HIPS 0.967
27 PS 0.967
28 uPVC 1.12
29 SAN 0.88
T'plastic rubber 30 TPE-A 0.83
31 TPE -S 1.08

Calculated Shot Weight is..=

Shotweight Note: This document is for guidance only. No guarantee or contract is implied or given.
 Note these densities are correct for the plastics molten state.

"If you know how heavy the part or parts are, and the machines screw diameter,
you can use this to find out the shot weight for your machine".

What's it for & Who'd use it

Screw Diameter 38 mm Screw gives 1.27

Material No: 28
Material Dens. 1.12

Total weight 234 g

*1 You should find screw diameter stamped on the machines' I.D. plate.

*2 If there are no parts to weigh use the estimated weight used to price the part.

Menu
MENU

Weight is..= 184.2 mm

Cross Checked:Arburg 221-55-250 30mm diam screw; HIPS; 65g total weight; Actual shot was 95mm.

Shotweight Note: This document is for guidance only. No guarantee or contract is implied or given.
 g/mm

ed to price the part.

Shotweight Note: This document is for guidance only. No guarantee or contract is implied or given.
INJECTION MOULDING CALCULATIONS

Mould weight

Enter the moulds

dimensions in the
yellow boxes.

98 cm

89 cm

80 cm

Mould weight =
5497 kg
5.4970 Tonnes
nb; the weights given make no allowance for spaces such as the ejector "box" or other steels such as Stainless, which is 20% heavier.
this means the results tend to be on the higher side to account for other metals, and more importantly SAFETY!
 Round Moulds.

Enter the moulds

dimensions in the
yellow boxes.

Round

Moulds
Diameter

89 cm
Menu 44.5
MENU

Mould weight =
9313.13
9.3131
ainless, which is 20% heavier. nb; the weights given make no allowance for spaces such as the ejector "box" or other steels such as St
this means the results tend to be on the higher side to account for other metals, and more importantly SA
 Enter the moulds
dimensions in the
yellow boxes.

Menu
"Height"

190 cm

9313.13 kg
9.3131 Tonnes
jector "box" or other steels such as Stainless, which is 20% heavier.
other metals, and more importantly SAFETY!
 Mould Heater Capacity
what's it for & who'd use it

Enter Mould weight here

90
Enter ambient temperature here
23
Enter moulds' operating temp here
200
Energy required to reach operating Temp:
So you need a Temp Controller of more than 2.07
Enter your data in the Yellow Boxes 0.112

2.07 Kilowatts= 1784.16 kCal

2.07 Kilowatts= 1.56 HP
2.07 Kilowatts= 7136.64 kJoule
2.07 Kilowatts= 7136.64 BTU
MENU
kG

kWatts

MENU
 TEMPERATURE CONVERTER

Enter your Centigrade temperautre here C

32
MENU 32 C Equals F
89.6

Enter your Fahrenheit temperautre here F

300
300 F Equals C
150.1
Enter your data in the Yellow Boxes
Flow Viscosity Chart.

A p p a r e n t V is c o s it y (b a r * s )
"Is your Injection Speed correct"?

Sample Set Actual Actual Injection Apparent

Injection Injection Injection Rate Viscosity
Number Speed Pressure Time (S-1) (bar*sec)
1 5 132 1.57 0.64 207.24
2 10 130 0.81 1.23 105.30 Flow Visc
3 15 135 0.57 1.75 76.95
250.00
4 20 138 0.45 2.22 62.10
200.00
5 25 150 0.38 2.63 57.00
150.00
6 30 151 0.33 3.03 49.83 100.00
7 35 152 0.3 3.33 45.60 50.00

8 40 152 0.28 3.57 42.56 0.00

0.64 1.23 1.75 2.22
9 45 152 0.28 3.57 42.56 Injec
10 50 152 0.28 3.57 42.56 Sample No: 1 2 3 4

Procedure.
Step 1 Decide on the 10 steps of Injection Speed you will use for the test.

Note: Avoid very fast speeds that may cause flash, and very slow spees that could be difficult to eject, or become lodged
You may wish to make some preliminary trials if you don't have much practical experience with this mould.

Step 2 Record both Injection Time & Injection Pressure generated at these speeds.

Step 3 Enter the results in the chart above

Step 4 Look at your graph & use the speed at which the curve "levels out".
 Flow Viscosity

0.00

0.00

0.00

0.00

0.00

0.00
0.64 1.23 1.75 2.22 2.63 3.03 3.33 3.57 3.57 3.57
Injection Rate (s-1)
le No: 1 2 3 4 5 6 7 8 9 10

ficult to eject, or become lodged in the fixed half. MENU

erience with this mould.
 Gate "Freeze" Chart.
Holding Weight Weight Weight Weight Weight Average
Time 1 2 3 4 5 Weight 3
1 1.9 1.9

Part weight; g
2 2 2
3 2.2 2.2 2.5
4 2.5 2.5
5 2.6 2.6 2
6 2.65 2.65
7 2.65 2.65
8 2.65 2.65 1.5
9 2.65 2.65
10 2.65 2.65
1

0.5

Material grade Makrolon Rx1805

0
Mould temp 70
0 2 4 6 8 10 12
Material Temp 330
Hold pressure 80 Holding Times; sec.

When the curve levels out, that when the gate has solidified
Date 2-Nov-03 MENU & that's your "FREEZE" time.
MENU Time
If you haven't used all 10 holding times, you may have
to change the Scale to give better curves. 13 Seconds
 120

Plasticising Capacity "can the machine melt enough plastic to keep up with th

Enter your Cycle time here in SECONDS.

30.0
Enter the number of IMPRESSIONS here
12

15.84
Enter your Part weight here in GRAMS.
11.0
Enter your Sprue weight here in GRAMS.
0.0
Enter your data in the Yellow Boxes
 0.132

plastic to keep up with this cycle"?

What's it for?

MENU

15.84 Kg / Hour
Cooling Water Flow Needed in our Mould (or Machine)
"how much water do we have supply to remove using this much heat and temperature drop"?
"Can our system deliver this much, and how big do we want the drop to be"?

what's it for & who'd use it

Enter hot plastics calculated heat content here.

or if its a machine , the figure from Machine cooling 5.50
Enter water Inlet temperature here.
17
MENU Enter water outlet temperature here.
19
Water flow needed to remove this much heat is =
39
Link To Mould Cooling Link to Machine Cooling
2365.00
8.68
520.93
Enter your data in the Yellow Boxes

5.5 Kilowatts= 33898.333 kCals

5.5 Kilowatts= 29.5625 HP
5.5 Kilowatts= 135593.33 kJoules
5.5 Kilowatts= 135593.33 BTUs
perature drop"?
nt the drop to be"?

5.50 Kwatts

17 C

19 C

39 LITRES PER MINUTE

2365.00 Litres (kg) per Hour

8.68 Gallons / Minute
520.93 Gallons/Hour
"how much energy can we remove using this flow and temperature drop"?
"Is it enough to keep up with our cycle"?

what's it for & who'd use it

Enter water flow in Litres per Minute:

60 l/min MENU

Enter water inlet Temp here:

25 C

Enter water outlet temp here

26 C

Cooling Capacity using these figures=

4.19 kWatts

Equivalent in kiloCalories 3600.00 kCal

Enter your data in the Yellow Boxes

4.19 Kilowatts= 3600 kCal
4.19 Kilowatts= 3.14 HP
4.19 Kilowatts= 14400 kJoule
4.19 Kilowatts= 14400 BTU
Cooling Capacity; Moulding Machin
Motor Rating in Kilowatts (KW)

45
Cooling capacity required is.

15.75
15.75 Kilowatts is equal to. 13545 Kilo calories
15.75 Kilowatts is equal to. 11.81 HP
15.75 Kilowatts is equal to. 54180 kJoules
15.75 Kilowatts is equal to. 54180 BTUs

For Pre 1990 machines use this figure

they are not as efficient. 22.5

This tells you how much heat needs to be removed from machine every hour, s
factory cooling sytem must be more than this, and don't forget this is just for t
individual machine! So you'd better do this calculation for all of the others and
add them all together!
ding Machines

45 kWatts

15.75 kWatts
MENU

Link to Water Cooling

kWatts

rom machine every hour, so the

on't forget this is just for this
ion for all of the others and
 Cooling :MOULDS.
Specific Heat "Have we got enough cooling to cool this amount of plastic every hour"?
Capacities (SHC) (kJ/kg.K)

1 Steel 0.46
2 Aluminium 0.88
3 Water 4.19 Throughput 4.82 Kg Hour
4 LDPE 2.5
5 HDPE 2 Material No 1
6 Polypropylene. 2 0.46 kJ/kg
7 Nylon 2 Mould t 25 c
8 Acrylic 1.5 MENU
9 Acetal Copolymer 1.5 Melt T 210 c
10 Reinforced Polyprop. 1.5

11 Polystyrene 1.5 To be cooled 0.17 kWatts Link to How much coolant

12 S.A.N. 1.5
13 S.B. 1.5 6.55 Kilowatts= 147.0 kCal Does the mould have a HOT RUNNER?
14 ABS 1.2 6.55 Kilowatts= 0.13 HP
15 Polycarbonate 1.2 6.55 Kilowatts= 587.9 kJoule No; of hot Tips?
16 uPVC 1.2 6.55 Kilowatts= 587.9 BTU Wattage if tip
17 Acetal Homopolymer 0.3 Manifold wattage
18 Plast,PVC. 0.3 More than one
19 Thermosets >2 Hot runner & Manifold ?
6.55
20 Rubbers. <1 Melt Combined 6.55
Cooling needed
for Hot Runner is.

NOTE: NO CONTRACT, GUARANTEE OF ANY TYPE IS GIVEN OR IMPLIED.

THE RESULTS OF THIS SHEET ARE FOR GUIDANCE ONLY.
 MENU

e a HOT RUNNER?

8
315 w
1930 w

2
6.38 kWatts
 POLYBRIDGE TRAINING LTD, UNITED KINGDOM;
CONDITIONS OF BUSINESS FORMATION OF CONTRACT
1.1 All quotations are made and all orders are accepted subject to the following conditions. All other terms, conditions or warranties whatsoever are e
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 ns or warranties whatsoever are excluded from any contract between the parties unless expressly accepted by Polybridge Training Ltd in writing.
e withdrawn by Polybridge Training Ltd within such period at any time by written or oral notice. "Work" shall mean the work and services that Polybridge Training Ltd
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nce of these conditions where acceptance has not previously been communicated by the Client to Polybridge Training Ltd.

acceptance date.
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whole contract as repudiated by the Client or to suspend all further work on any contract or contracts between Polybridge Training Ltd and the Client without notice

ht to damages or to cancel the order for failure for any cause to meet any time stated for completion of Work.
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aims for death or personal injury due to negligence on the part of Polybridge Training Ltd shall not exceed 100,000 in any claim or group of claims and the Client agr

pts no liability arising from unauthorised use of such information or reports by a third party.
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ven to Polybridge Training Ltd, either directly or indirectly by the Client or by the Client's agents, servants, consultants or advisers, are accurate and sufficient for com
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d to be unable to pay its debts or compounds with creditors or in the event of a resolution being passed or proceedings commenced for its administration or liquidatio

or in any way interfered with by direction of government, war, industrial dispute, strike, breakdown of machinery or plant, accident, fire or by any other cause beyond

of the other party.

be subject to the jurisdiction of the English Courts only.

ation and demonstration purposes only. No liability is accepted from the use of such products and subsequent losses in respect to their use or interpretation of data f
 ining Ltd in writing.
and services that Polybridge Training Ltd agree to provide in the quotation.
et out that statement or representation in a document to be attached to the return copy of the quotation and in any such case Polybridge Training Ltd may accept or

e an adjustment to the contract price fairly reflecting such variation or addition.

bmit interim invoices in respect of each stage of Work completed for the Client.

aining Ltd and the Client without notice and to charge interest on any amount outstanding at the rate of 8% above the Bank of England base in force at the time the p

result in delay in completion.

her on condition that all costs and expenses incurred by Polybridge Training Ltd up to the time of cancellation and, where cancellation is at the insistence of the Client

at such death, injury, loss or damage is attributable to the negligent acts or omissions of Polybridge Training Ltd, its officers, employees, agents or sub-contractors to a
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aim or group of claims and the Client agrees to insure adequately to cover claims in excess of such amount.

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isers, are accurate and sufficient for completion of the Work. Examination or consideration by Polybridge Training Ltd of such drawings, information, advice or recomm
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menced for its administration or liquidation (other than for a voluntary winding up for the purposes of reconstruction or amalgamation) or if a Receiver or Manager is a

cident, fire or by any other cause beyond Polybridge Training Ltd's control Polybridge Training Ltd may at its option suspend performance or cancel its obligations und

ct to their use or interpretation of data from such programmes.

e Polybridge Training Ltd may accept or reject the same and/or submit a new quotation.

f England base in force at the time the payment was due.

cellation is at the insistence of the Client, all loss of profits and other loss or damage resulting to Polybridge Training Ltd by reason of such cancellation, will be paid for

mployees, agents or sub-contractors to a figure of 100,000 Sterling excluding VAT & expenses.
consequential loss, loss of profits, damage to property or wasted expenditure.

cuments, records, software or other information or extracts there from or copies thereof or use them in any way except in connection with the Work in respect of whi
tion with the preparation, filing, prosecution, assignment and recording of such applications are payable by the Client.

drawings, information, advice or recommendations shall in no way limit the Client's responsibility hereunder unless Polybridge Training Ltd specifically agrees in writi

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erformance or cancel its obligations under the contract without liability for any damage or consequential loss resulting there-from, such suspension or cancellation be
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nnection with the Work in respect of which they are issued.

ge Training Ltd specifically agrees in writing to accept responsibility.

ed to cancel the contract in whole or in part by notice in writing without prejudice to any other right or remedy accrued or accruing to that party.

from, such suspension or cancellation being without prejudice to Polybridge Training Ltd's right to recover all sums owing to it in respect of works performed and cost
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t in respect of works performed and costs incurred prior to the date of suspension or cancellation.
Compatibility Report for c Polybridge Calculator V25 Feb 09 Office
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