Services
For over four decades, we have been improving manufacturers’ capacity to deliver the highest quality injection molded products on the market today through consulting, training and process optimization.
Plastic Injection Molding Consulting
Our consulting services help injection mold manufacturers navigate complexities, capitalize on opportunities, and achieve objectives more effectively. We’ll identify and analyze problems, challenges, and inefficiencies to propose actionable solutions to address the issues.
- Technical Staff Evaluation
- Process Evaluation
- New Program Launch Support
- Tool Evaluation
- Machine Evaluation
- Processing Validation & Support
- Project Management Support
- Tool Trial or Transfer Support
Process Optimization Training
Adopting new technology is essential, but empowering your team to use it effectively drives transformation. Our high-impact training services teach proven process and machine validation techniques with analytics. We focus on processing theory from the “Plastics Point Of View,” applying it to everyday processes with a hands-on approach. Trainees learn to troubleshoot and optimize injection molding machines efficiently. This methodology is effective and easy to follow.
- Material Analysis
- Melt Temperature Analysis
- Mold Temperature Analysis
- Venting Analysis
- Fill Analysis
- Cavity Balance Study
- Value Gate Sequence Analysis
- Machine Performance Capability Study:
- Injection Speed Linearity
- Pack & Hold Pressure
- Dynamic Check Ring
- In-Mold Rheology
Process Validation & Optimization
Setting up and sustaining robust processes that meet the quality standards set by your customer can be a challenging experience. ZIPPS has a proven protocol to streamline processes. This process can be duplicated on other machines once the product is approved on one machine. Offerings include:
- Process Optimization
- Machine Optimization
- Rigorous Machine & Mold Testing:
- Injection Speed Linearity
- Load Sensitivity
- Dynamic Check Ring
- 30/30 Melt
- Hydraulic Response
- Hold Pressure Analysis
- Hot Runner Manifold Design
- Clamp & Robot Optimization
- Troubleshooting Process Issues
- Launch Assistance for New Molds
- Cavity Pressure Control Process Support
- Establishing Alarm Limits for Automated Part Containment
Success by Numbers:
Chrysler Defroster Nozzle Mold 401F
Customers Who Trust ZIPPS
“Smiths Medical has been using ZIPPS for an array of services since 2006. They crafted a specialized schedule and technical training plan unique to my process technician needs based on staff knowledge, product, machine types, materials used, etc. The training was executed over a 7-week period and showed results immediately.”
James Lipps • Senior Plastics Engineer • Smiths Medical
“ZIPPS work on MPC’s molding optimization yielded substantial cost reductions from decreased cycle time and reduced part weights throughout various jobs in the plant.”
Marty Bondar • Plant Engineering Supervisor • MPC Inc.
“I have been in the automotive Quality Profession for 48 years and have met a few professionals in my time. Mike Zalipski is a true example of that. He is an expert scientific injection molding guru. His analytical abilities are top shelf, you won’t find anyone better. Mike and I have worked on several projects together, mostly under duress. He always shows up with energy, knowledge, and relentless drive to succeed. I would be proud to work with Mike Zalipski on any future projects.”
Robin McCormick • BMW QMT, Plant Spartanburg, SC
“When our training was complete with ZIPPS, we were able to reduce part weight and decrease cycle time with the Decoupled 3 molding technique with approximately $750,000 in total savings on two individual tools. We currently have over 180 tools in house with 45 more on the way, there is no telling how much money could be saved on just reducing part weight alone.”
Jeff Clayburn • Process Manager • Plastech
“Working with ZIPPS has truly been an investment in our company that has paid us back huge dividends. I would highly recommend ZIPPS to any Injection Molding Company needing help in launching new molds, assisting in start-up of transfer molds, Rigorous Machine Testing, educating Process Engineers & technicians or process improvement.”
Noel Somasundram • Sr. Quality Director • IAC Group
“ZIPPS teams’ proactive approach to Scientific Injection Molding and overall knowledge of manufacturing, processing, and various plastic materials, along with tool performance & testing has enabled us to reduce cycle times, part weights, and increase through-put efficiencies while improving overall part quality.”
Noel Somasundram • Sr. Quality Director • IAC Group
“The training ZIPPS has provided has been a positive and rewarding experience for each person involved, regardless of position. Other benefits included cycle time savings, scrap reductions, tooling modifications and improved material utilization.”
Cindy Forbes • Operations & Continuous Improvement Manager • Lear Corporation
“I would recommend ZIPPS for any molding company, they are very knowledgeable and are hands on individuals who can apply what they teach and not just talk.”
Jeff Clayburn • Process Manager • Plastech
“We strive to make our molding operation world class, and ZIPPS is an integral resource in helping us achieve this status. ZIPPS’ knowledge and passion for molding gave us a great tool in our arsenal to become a world class injection molder.”
Marty Bondar • Plant Engineering Supervisor • MPC Inc.
“I have worked closely with Mike and his staff on DOEs which has shown to be extremely beneficial in identifying and solving quality issues while improving productivity. Other benefits included cycle time savings, scrap reductions, tooling modifications, and improved machine utilization. They have always responded quickly to our needs and have been extremely professional to work with. I’ve had excellent support from ZIPPS.”
Agustin Zarate • Purchasing/SQE • FCA
“ZIPPS has assisted me in successfully implementing cavity pressure here at Smiths Medical. We started with a simple three gang body plate which was outfitted with sensors years ago but never utilized. With this mold we were able to prove with data to my management team the part weight savings, cycle time savings, and part containment abilities of cavity pressure and scientific molding.”
James Lipps • Senior Plastics Engineer • Smiths Medical
“ZIPPS ability to effectively train has significantly increased our employees’ knowledge level which enables us to maintain our processes at a much higher level of efficiency.”
Noel Somasundram • Sr. Quality Director • IAC Group
