At Mora, expertise in thermoplastic injection moulding goes hand in hand with extensive know-how in the decoration of injected parts. To give you a detailed insight into this business, we have gathered the testimony of Vincent COLLARD, Technical Director of the Mora Group.
Mr COLLARD, before highlighting the decoration business, could you briefly introduce yourself.
I’m Vincent COLLARD, Technical Director of the Mora Group. I am responsible for the development team based in Chambost-Allières, which works for all our sites in France, Portugal and Romania.
My career as a mechanical engineer, which began at the UTC in Compiègne, gave me a wealth of experience as a project manager for car manufacturers and in the field of solar energy for large power plants. In 2016, after several years at Mora as project manager, I took over as the group’s technical director.
What does decoration mean to Mora ?
« At Mora, the injection of thermoplastic parts is at the heart of our business. Decoration, or finishing, enhances this expertise by adding visual elements to injected parts. We apply decoration mainly using pad printing.
This technique uses a specific ink pad, designed to take ink from a mask of defined shape, then apply it precisely to the injected part.
This method ensures that the decorations are durable and robust.
Although other technologies, such as inkjet printing, exist, they are not as suitable in terms of durability and resistance over time. Pad printing therefore remains our preferred method for offering our customers durable finishes.
Who and why use pad printing for decoration ?
We use pad printing for a wide range of customers and applications. This technology enables us to decorate injected parts with great precision, meeting the requirements of a wide range of industries.
We work with customers in a wide range of sectors, including the medical sector. Pad printing can, for example, reveal graduations on syringes and Covid diagnostic control logos (positive/negative) on medical devices. This technology ensures that these markings remain visible and legible over the long term.
The versatility of pad printing means that brand logos can often be printed on a multitude of products, including DIY tools, household electrical boxes, perfume bottles and caps, and air conditioning units for vehicle interiors. Each part benefits from a precise and durable decoration, reinforcing the visual identity and perceived quality of our customers’ products.
How long has Mora mastered this expertise ?
« We’ve been pad printing for over 20 years. Over the years, technologies and machines have evolved, and we have constantly updated our equipment to stay at the forefront of innovation. Our multi-head machines, capable of applying different colours, have been complemented by sophisticated automatic lines.
These improvements allow us to integrate decoration perfectly with our core business of plastic injection moulding, offering complete, high-quality solutions. ».
Can you give us a concrete description of the pad printing decoration process ?
«We are currently working on a major project involving automatic pad printing for the CrossJet element. This project is a perfect example of our ability to integrate advanced automation into our decoration processes.
The decoration for this project involves pad printing around a window and printing an arrow and a number. These markings are used to guide the user ergonomically when handling the product, making it easier to apply the medication..
On this product, two elements require particular attention: the cap and the cover.
This project has enabled us to take a significant step forward in terms of automation. Thanks to these improvements, we are now able to respond to even higher volumes. For example, we can switch from a 2-cavity rotary mould to a 4+4 cavity mould to increase our production capacity. We are able to adapt our processes to customer requirements.
Why use automated lines and processes for decoration ?
We strive to develop optimised processes adapted to our customers’ requirements, while maintaining high synthetic yield rates (SRR). The OEE is a crucial indicator that assesses our ability to produce finished products over the course of a production day. It takes into account factors such as cycle time, machine downtime and time spent on quality. Our objective is to achieve an OEE of 90%.
This indicator is particularly important in interconnected processes, such as those involving pad printing and plastic injection moulding. As pad printing is directly linked to the injection moulding machine, it is essential that these two processes work in harmony. A problem on the pad printing line must not disrupt production upstream of the injection moulding machine
To avoid such interruptions, we have set up buffer systems. If a problem occurs on the pad printing line, the injection moulding machine continues to produce parts, which are stored in a buffer. When the pad printing machine is operational again, it can retrieve the stored parts and resume the process without interruption.
Having processes that run smoothly is essential if we are not to slow down the business. Through automation and rigorous process management, we ensure continuous, efficient production that meets our customers’ requirements while optimising our production capacity.
What are the practical benefits of automating pad printing ?
Automated pad printing lines minimise product handling, which is crucial for guaranteeing the cleanliness and integrity of decorations, particularly in the medical sector.
In our process, the cap comes out of the injection moulding machine, is picked up by a robot and placed directly on the mandrel. The robot then decorates the cap using pad printing and places it on a conveyor belt. The part is not handled until the end of the process, when it is placed in a cardboard box, which reduces the risk of contamination by human hands.
Our automated system makes it possible to produce two-colour pad printing in a single pass, considerably reducing the risk of quality defects that could occur if two passes were necessary
To validate the quality of each piece, we use 100% camera control. This final step ensures that all decorations meet our quality standards before the pieces are packed and dispatched.
Why trust Mora for the manufacture and decoration of injected parts?
At Mora, we stand out from our competitors who focus solely on pad printing thanks to our complete mastery of the manufacture of injected parts. This integrated expertise enables us to offer significant advantages:
We have the ability to automate the decoration process immediately after injection, which translates into high output rates and reduced costs. By avoiding the additional costs associated with transporting and handling parts, we can offer competitively priced products while maintaining superior quality.
Less handling of parts means less risk of impact and contamination. By minimising these human interventions, we can guarantee better part integrity, which is crucial for demanding sectors such as the medical sector.
Camera inspection is now an essential part of our process. Each part is inspected and qualified as soon as it leaves the production line. This ensures accurate and consistent pad printing, guaranteeing compliance with specifications in terms of template, dimensions and absence of defects such as run-outs. This rigour enables us to aim for zero defects
By integrating pad printing into our injection moulding process, we guarantee not only the decoration but also the overall quality of the part.
C Each stage is designed to optimise cycle time and part quality, strengthening our competitive position in the market.
