LM injected moulded trays

LM-injected moulded trays are custom-made packaging for component holders used every step of the way from storage and internal transfer between production stations to transport.

These trays are produced by injection moulding. This procedure requires high-level design and engineering to develop the tool or mould, produced from high-quality stainless steel. Our specialists and engineers cover this first step and pay close attention to every little corner, edge, and shape of the component, considering the details of the application – handling, transport, storage, etc.

Trays are produced by injecting various types of melted polymers in the mould at high temperatures and under extreme pressure. The injection parameters depend on the material and application of the trays.

Plastic injection is a good and cost-efficient process for personalized component packaging when large amounts of trays are required. Polymer injection is also preferable for very accurate geometries.

  • Customized trays for kit holders

    Kit holders

    They are developed to hold different components in a single place for an ergonomic assembly process.

    The kitting holders can be customized to pack the component pieces of a kit and protect them during storage and transport.

    Advantages:

    • High accuracy design – tailored cavities, product contour matching, high stability
    • Custom trays eliminate the need for any additional inlays or dunnage
    • Quick identification of any missing part/ parts
    • Compatible with automated systems – conveyor lines or robotic arms – for both packing for delivery and production assembly
    • They can be used as they are, without a larger container to hold them
    • Increased productivity – different parts necessary in a process are held together in one custom-designed tray
    • Space-efficient delivery of parts
    • Increased protection for goods and minimum damage
    • Excellent organization for the packed components, fitting any shape, sharp edges, wires or sensitive surfaces. The injection moulding process allows high flexibility in the design.
    • Can be washed and reused a large number of times, successfully replacing one-way packaging
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  • Customized trays for components packaging

    Component holders

    Industrial component holders are manufactured using injection moulding for delivering components to the assembly line. Components are packed in custom trays specifically designed for their shape and use.

    Advantages:

    • Trays can be stack-nested for return transport, which means less space and smaller logistic costs
    • Compatible with robotic arm systems for both loading and unloading segments due to their exact size and shape
    • Ideal for automated assembly lines
    • Precise fit for the packed components
    • Quick identification of the missing parts at delivery
    • Can be easily cleaned and prepared for following deliveries
    • High protection for sensitive pieces, as they do not touch
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  • Customized trays for components interior containers

    Component totes for KLT boxes/ single-units

    The main advantage of these crates is that they are designed to fit KLT boxes but also work as individual packaging.

    They are used with KLT totes when the application requires this.

    They are compatible with automated handling and assembly lines, with robotic arms for loading and unloading; they can be stacked without damaging the packed products during storage or shipping.

    They reduce the costs and waste with one-way packaging due to their reusability.

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  • Customized dunnage for metallic racks to fix the components

    Accessories for securing the components in racks

    Accessories are essential when it comes to packaging due to their multiple advantages:

    • The same container or packaging can be reused for various applications by simply placing/ removing the accessories as necessary
    • They enhance the safety of the goods and the container or rack used by neatly fixing the pieces inside. This guarantees fewer damaged products at delivery, more satisfied customers, lower costs with wasted goods and increased productivity both for the client and the supplier
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  • Detailed moulds for the most complex components

    • Plastic injection offers the technical possibility to manufacture high-precision parts with an incredible degree of detail
    • The high pressure used for injecting the trays forces the melted material firmly and evenly into the cavities, no matter how small, detailed or complex the geometry

    Incredible precision and performance

    • Injection moulding for trays is recommended for remarkably complex or small components, and if development or production is too time-consuming or difficult to obtain through thermoforming, milling or cutting
    • The injection tool may be used over and over again, for millions of cycles, over many years

    Effective usage of material

    • Plastic injection has a low rate of material scrap because the volume of plastic can be calculated with great accuracy
    • Some polymers offer the possibility to recycle scrap material, so zero material is wasted

    Cost efficiency with plastic injection

    • It is a known fact that plastic injection is more expensive than thermoforming, but for particular projects and with precise calculation of all factors, this might not be true
    • From the design phase, trays can be simplified and streamlined, reducing the cost of the mould, operator handling time, ergonomics, and productivity
    • Plastic injection is an automatic process where the trays are pushed outside the mould, after injection and cooling, without human intervention. This makes production more efficient than thermoformed trays, where each tray needs to be analyzed for undercutting or coring operations
    • Our specialists do all the math to ensure a precise answer as to what design route is less costly
    • LM-injected moulded trays are a 100% personalized solution in which each tray is designed for a particular component or purpose

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