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Injection Molding of Custom Polypropylene and Elastomer Lids for the Cookware Industry

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Our customer, a large kitchen products OEM, had the opportunity to land a huge promotional order. The deal called for delivering 3 million pieces of glass bakeware with plastic lids in a five month window. The bid called for 2 million 8x8 dishes and 1 million 9x13 dishes. However, only one single-cavity lid mold existed for each lid shape. Those molds could produce fewer than 700,000 pieces each in the available delivery window running 24/7, and that wouldn’t be the only demand for those lids in that timeframe. So, Port Erie delivered six brand new molds, the first three in less than eight weeks, and at least one more mold every two weeks until all the new molds were in production. And, we did this in the Thanksgiving – New Year’s timeframe. During the last 30 days, we were running 8 lid molds 24/7. In addition, we negotiated for 1 million pounds of resin at a fixed price in the face of a resin market that saw polypropylene rise by 23%.

Outcome:
3 million lids delivered ahead of schedule.

Highlights of an Injection Molding Project

Product Name
Lids For Glass Cookware
Product Description
These plastic lids are fitted tightly over glass cookware to lock-in freshness
Industry for Use
Cookware
Capabilities Applied/Processes
Primary:
Engineering
  • Process Design
  • Tooling Design
  • Mold Build
  • Material Sourcing
Injection Molding
Tooling Lead Time
6 Molds Completed in 12 Weeks.
  • First Mold Delivered in 6 Weeks, then two more 2 Weeks later.
Tooling Material Used
P-20 Steel
Mold Dimensions
18” Width x 24” Length
Equipment Used to Make Tooling
CNC Machining Centers
Overall Part Dimensions
8” Width x 8” Length
9” Width x 13” Length
Wall Thickness: 0.055”
Tightest Tolerances
Overall Dimensions: ± 0.020”
Wall Thickness: ± 0.005”
Material Used
Custom Polypropylene and Elastomer Compound
Volume
3,000,000
Standards Met
Customer Specifications, 2D CAD Drawing Specifications
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