Effective maintenance is the bedrock of any efficient and profitable injection moulding operation. It encompasses a broad spectrum of preventative measures designed to extend equipment lifespan, protect valuable tooling, and ensure workforce safety. Crucially, it also helps to avoid unscheduled breakdowns that can disrupt production schedules. Nick Stockton, technical manager at
Sumitomo (SHI) Demag UK and Ireland, said: “There are numerous benefits to having well-maintained machines. As well as increasing efficiency and extending the lifespan of equipment, machines that are well maintained are also easier to service and diagnose issues when they arise. Additionally, because the machines are running at their optimal level, energy consumption is minimised.”
Sumitomo (SHI) Demag has a long history of supporting customers with time-based maintenance schedules. The company was the first in the UK injection moulding sector to introduce annual machine checks nearly three decades ago. In the early 2000s, it launched a rewards programme offering tangible business benefits, including discounted spare parts, guaranteed engineer availability, capped breakdown costs, and a free ‘ErgoCheck’ for the first year on every new machine. These initiatives were a first for the polymer processing industry.
The annual ErgoCheck test remains a mainstay, with more than 400 carried out each year in the UK and Ireland to ensure machines continue to operate in line with original manufacturer protocols. Following each check, customers receive a certificate and detailed condition and measurement reports. Should a machine fall short of factory settings, a comprehensive report and quotation are provided, outlining the steps required to restore performance.
Performance checksThis service has since evolved into activeCare, which offers enhanced value by combining performance checks with the replacement of key maintenance components. For a fixed price, activeCare covers a complete service — from lubrication and filter changes to battery replacement and checks on the toggle system, belt tension, screw concentricity, and dosing speed. All parts and labour are included, enabling customers to budget confidently for annual servicing.
Mr Stockton said: “Customers especially value being able to budget for these machine services each year knowing that there will be no financial service surprises.” Discounts are available for multiple machines serviced on the same day or within the same week.
All maintenance is delivered by specialist injection moulding engineers, whose technical expertise and sector familiarity ensure that no aspect is overlooked. Mr Stockton continued: “There are so many things we inspect for which can impede machine performance. From looking for cabinet hot points to checking the battery backups. All of which can help to break the cycle of reacting to emergency maintenance tasks.”
He pointed out that the most significant step users can take to ensure reliability and longevity is to follow the service tasks specified in the machine and user guides. While these tasks are often straightforward, they are easily missed without a dedicated maintenance person. Planned maintenance, Mr Stockton argues, has far less impact on production than the disruption caused by unscheduled downtime. One common pitfall is switching off backup batteries over the weekend — a move that offers negligible energy savings but can result in the need to reinstall the entire software programme.
Modern electric moulding machines now offer advanced data gathering capabilities, enabling service plans to be tailored to actual usage rather than fixed intervals. Parameters such as acceleration, deceleration, forces, and motor duty cycles are monitored via sensors, providing a detailed optimisation picture.
The next step, Mr Stockton said, is predictive maintenance: “The optimum time to change a part is just before it fails. With the latest injection moulding machines this is entirely possible, as there is now the pre-emptive technology that can alert users to what maintenance needs to be carried out and what parts need to be replaced in advance.”
Condition monitoring, including the use of thermographic equipment, is now part of the annual activeCare check. Rather than relying on guesswork, engineers provide quantifiable measurements to predict when equipment or parts are likely to fail. Mr Stockton added: “Being able to monitor, test and check all critical areas of machinery assets, using equipment that is calibrated to ISO 9001 and VDA 6.4 certification standards, helps instil confidence and provide early ‘red flag’ warning signs of potential problems.”
For injection moulders, the message is clear — proactive, data-driven maintenance is essential for operational reliability, safety, and profitability. With the latest technology, predictive maintenance is now within reach, helping processors to avoid costly downtime and maintain a competitive edge.