Preventative Mold Maintenance & Tooling Services for Injection Molding
EXTENDED
TOOL LIFE
MAXIMIZING YOUR INVESTMENT
40%
REDUCTION IN DOWNTIME
WITH PREVENTATIVE MAINTENANCE
Precision
EXPERT MOLD REPAIR
AND REFURBISHMENT
Systematic Shot-Count Maintenance Solutions
Our comprehensive preventative maintenance programs are designed to maximize mold longevity and performance throughout the production lifecycle. We utilize a systematic shot-count based approach, scheduling critical maintenance at predetermined intervals based on production volume and mold complexity. This proactive strategy identifies potential issues before they cause production disruptions or quality problems, significantly extending tool life while maintaining consistent part quality and production efficiency.
Preventative Inspection Cycles
Regular mold inspections at predetermined shot-count intervals to identify wear, damage, or alignment issues before they impact production. Our technicians document all findings and provide detailed reports with recommended actions and timeline projections.
Scheduled Mold Maintenance
Customized maintenance schedules based on mold complexity, material abrasiveness, and production volume. Our programs include thorough cleaning, lubrication, component replacement, and surface treatments at optimal intervals to maximize tool lifespan.
Real-Time Shot Monitoring
Advanced tracking systems monitor actual shot counts and production conditions, automatically triggering maintenance alerts at predetermined intervals. This ensures timely maintenance based on actual production data rather than estimated schedules.
Expert Tooling Maintenance Process
Our systematic maintenance approach combines advanced inspection technologies with hands-on expertise to maximize tool performance and longevity. With over 50 years of experience maintaining injection molds, our technicians identify and address potential issues before they impact production, ensuring consistent part quality and minimizing costly downtime.
Expert Injection Mold Repair & Refurbishment
Our comprehensive mold repair and refurbishment services restore aging or damaged tooling to optimal condition, extending useful life and maintaining production quality. Our skilled technicians diagnose and address a wide range of issues from wear and corrosion to mechanical damage and alignment problems using precision machining techniques and specialized repair methods.
For molds nearing the end of their service life, our thorough refurbishment process can dramatically extend operational lifespan. We begin with a comprehensive evaluation to identify all wear points, damage, and potential failure areas. Components are then meticulously refurbished or replaced as needed, with special attention to critical areas like gates, runners, and cooling channels that directly impact part quality and cycle efficiency.
Beyond basic repairs, we also implement performance enhancements based on your specific production goals. Whether you need improved cooling efficiency, optimized material flow, or reduced cycle times, our engineering team can recommend and implement modifications that boost both quality and productivity. Every repaired or refurbished mold undergoes rigorous validation testing to ensure it meets both dimensional specifications and performance requirements.
Benefits of Professional Mold Repair
- Extended tool life with substantial cost savings
- Improved part quality and dimensional consistency
- Reduced production downtime and interruptions
- Optimized cycle times and production efficiency
- Enhanced cooling efficiency for better parts
- Elimination of flash, splay, and other defects
- Performance upgrades during repair process
- Detailed documentation for future maintenance
Common Mold Repair & Refurbishment Services
- Core and cavity reconditioning
- Gate and runner system repairs
- Ejector system refurbishment
- Insert replacement and repair
- Cooling channel optimization
- Venting improvements
- Surface polishing and refinishing
- Parting line and shutoff repairs
Tooling Performance Optimization
Engineering Solutions for Enhanced Tool Performance
Beyond routine maintenance and repairs, our engineering team specializes in optimizing mold performance to meet your specific production goals. We analyze your current tooling and processes to identify opportunities for improvement, whether you need faster cycle times, reduced material usage, or improved part quality.
Our optimization services address critical factors that impact production efficiency and part quality. We enhance cooling systems to achieve more uniform temperature distribution and faster cycle times. Our engineers design and implement modifications that optimize material flow, reducing pressure drops and improving fill patterns for more consistent parts with fewer defects.
For tools that have undergone multiple repairs or are nearing the end of their projected lifespan, we provide comprehensive performance evaluations with actionable recommendations. These may include strategic component replacements, surface treatments, or design modifications that significantly extend usable life while maintaining or improving production efficiency. Each optimization is implemented with precision machining techniques and validated through rigorous testing to ensure measurable performance improvements.
Frequently Asked Questions About Tooling & Maintenance
Get answers to common questions about our mold maintenance and tooling services. If you need additional information, our team is ready to assist with your specific requirements.
How often should injection molds be maintained?
The optimal maintenance frequency depends on several factors including material abrasiveness, part complexity, and production volume. As a general guideline, preventative maintenance should occur every 50,000 to 500,000 shots, with highly abrasive materials or complex geometries requiring more frequent attention. We recommend implementing a systematic shot-count based maintenance program customized to your specific tooling and production requirements.
What are the early warning signs that a mold needs maintenance?
Several indicators suggest maintenance is needed: dimensional changes in molded parts, increased flash or burrs, visible wear on cores or cavities, sticking parts or ejection issues, surface finish deterioration, increased cycle times needed for quality parts, and unexpected pressure changes during injection. Addressing these signs early through preventative maintenance can prevent more serious issues, reducing both repair costs and production downtime.
How does preventative maintenance reduce production costs?
Preventative maintenance provides substantial cost savings through several mechanisms: reducing unplanned downtime by up to 40%, extending total tool life by 30-50%, lowering scrap rates by maintaining consistent part quality, optimizing cycle times with properly functioning tools, minimizing emergency repair expenses, and reducing overall labor costs through planned maintenance rather than emergency interventions. The investment in preventative maintenance typically delivers a 3x to 5x return through improved production efficiency and extended tool life.
Can Norco maintain tools that were manufactured elsewhere?
Yes, we regularly maintain, repair, and optimize tooling that was manufactured by other toolmakers. Our experienced technicians can reverse engineer components when necessary and work from existing documentation when available. We perform a thorough initial assessment to understand the tool's design, construction, and current condition before developing a maintenance or repair plan. Our capabilities allow us to service virtually any injection mold regardless of its origin.
What is the typical ROI for a preventative maintenance program?
A well-implemented preventative maintenance program typically delivers a 300-500% return on investment through multiple cost-saving mechanisms. The most significant ROI factors include: extended tool life (30-50% longer service life), reduced unplanned downtime (typically 30-40% reduction), lower scrap rates (15-25% reduction), improved cycle times (5-15% improvement), and decreased repair costs by addressing issues before they require major interventions. For high-volume production or expensive tooling, the ROI can be even more substantial.
What documentation do you provide after maintenance or repairs?
Following each maintenance or repair service, we provide comprehensive documentation including: detailed condition reports with before and after comparisons, complete itemization of all work performed, measurement data confirming dimensional specifications, photographic documentation of key areas, recommendations for future maintenance intervals, process parameter adjustments if applicable, and replacement parts installed or recommended for future maintenance. This documentation creates a valuable historical record for your tooling and guides future maintenance planning.
Need more information about our tooling maintenance services?
Contact Our Tooling Team
