In the world of manufacturing, companies often face complex challenges that require effective solutions. A recent implementation by Elevate Solutions Group demonstrates how choosing the right technology can make a significant difference in production processes.
Elevate Solutions Group specializes in producing contact lens sample kits for eye-care professionals who fit disposable contact lenses to patients. These kits demand precise color matching across all components to maintain a professional appearance and meet stringent quality standards. When Elevate decided to bring their manufacturing in-house, they needed a reliable solution to address their specific color matching requirements.
When Elevate Solutions Group decided to bring their manufacturing in-house in just 90 days, they needed to choose the right machines for their new 15,000-meters facility. Achieving consistent color across multiple injection molding machines producing a wide range of parts was a significant hurdle. In the medical industry, where precision is of utmost importance, even slight color deviations would be immediately noticeable, and thus unacceptable.
To address Elevate’s color matching needs, they chose our ColorSave 1000 gravimetric feeder, designed specifically for injection molding, extrusion, and blow molding machines. «The LIAD color delivery system was a great match for us», said Chip Hembree, head of manufacturing and product integration at Elevate Solutions Group. «It enables us to feed color masterbatch across a number of molding machines producing a wide range of parts. It is accurate to the 10th of a gram and has high repeatability, which results in consistent product color and reduced number of rejects regardless of the line and part being molded»
The ColorSave 1000’s advanced algorithms ensure homogenous feeding regardless of material density changes or other dynamic parameters. It also features a unique double hopper design. The external hopper acts as a protective shell for the internal weighing hopper, shielding it from external factors that could affect the weighing accuracy, such as operator contact or air drafts. This mechanical separation of the weighing chamber from the screw feeder, motor, and additive loader ensures precision that is unmatched in the industry.
One of the benefits Hembree notes, in particular, is regarding efficiency: «We have been able to feed expensive colors and additives at the lowest possible LDR and at the low end of the tolerance specification to save on masterbatch costs.»
Our system’s user-friendly design includes many features that enhance operational efficiency. It stores up to 1000 recipes and has automatic calibration, shortening setup times, while being very easy to maintain and clean. Another such feature was highlighted by Hembree: «The industry-first Smart Clean feature enables operators to switch colors quickly without physically accessing and opening the feeder to clean it out, resulting in significant savings in labor and production time.»
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