Plastics Technology

JAN 2019

Plastics Technology - Dedicated to improving Plastics Processing.

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50-ton overhead crane to take on extra-large tools, including bumper fascia molds. The first bay, adjacent to the administra- tive offices, features injection molding capabilities, with five KraussMaffei and Haitian presses ranging in clamp force from 320 to 2300 tons. Integrity has two 2300-ton KraussMaffei presses in this bay, including one capable of running up to four different materials at a time. Beyond mold trials, Integrity says its molding capabilities are intended to support customers in emergency production situations. At the back of the bay, Integrity has installed a complete material-handling and drying system from Novatec. The middle bay houses mold assembly operations, with 22 separate work cells. The final bay is designated for moldmaking, with eight large five-axis CNC machining centers, including Promac and DMG Mori models, as well as EDM machines from Makino. Of the more than 170 full-time employees, between 35 and 40 are moldmakers; and the company is on track to build 130 new tools in 2018. Compared with Integrity's other operations globally, McLaughlin notes that the new site in Querétaro is roughly twice the size of its factility in Tennessee and just a little smaller than all of its original Canadian factories put together. The Querétaro location puts it very near the geographic center of Mexico, with Mexico City 135 miles south; San Luis Potosi the same distance north; Guadalajara around 200 miles to the west; and Aguascalientes about 180 miles northwest. When Integrity first set up operations in Mexico, McLaughlin said the company identi- fied two primary obstacles: "The first challenge was human-resource availability—skilled help. The second was supply base. Supply base has stepped it up really well over time. We don't even really qualify that as a challenge anymore. Steel suppliers are here; hot-runner systems are here; mold texturing—they're all right here." The human-resource issue, "We saw a lot more opportunity coming, but we were at full capacity. It spawned the idea for this new plant." The middle of Integrity's three bays is dedicated to mold assembly with 22 separate work cells. Integrity offers its customers five injection molding machines, ranging in clamp tonnage from 320 to 2300 tons. Show here is a 2300-ton KraussMaffei machine. To support its molding operation, Integrity installed a complete Novatec material-handling and drying system. 40 JANUARY 2019 Plastics Technology Integrity Tool and Mold On-Site

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