WORK INSTRUCTION FOR

Ref. No:
RESTARTING CK/PRD/WI/01
CLASSY KONTAINERS INJECTION MOULDING MACHINE
VIZAG Rev. No/date:
Page 1 of 1 00/01.01.2019

Objective: - When Machine stopped due to power “OFF”, restart the

machine after power is restored.

Applicable for: - Shift supervisor/engineer/operator

Requirement: - Injection moulding machine

1. Switch on the main switch of machine on electrical panel.

2. Switch on the barrel heater from main panel of machine.
3. Switch on the motor from control panel.
4. Change the machine mode to manual operation
5. Open the mould by pressing the mold opening button and check it
whether any article is inside the mould or not. If yes then eject out that
articles by pressing pneumatic and mechanical ejection system.
6. Retract the injection unit fully back by pressing respective button.
7. Remove the sprue runner from nozzle side.
8. Check whether refilling is completed are not by observing refilling
position on monitor.
9. If refilling is not completed refill the material in the barrel by manual
mode till its specified position.
10. Move the injection unit forward until the nozzle contacts the mould
sprue bush by pressing injection unit forward button.
11. Change the machine mode to semi mode to start the production.
12. Run the machine in fully auto mode in case of automatic mold.

Prepared by: Approved by:

 WORK INSTRUCTION Ref. No:
FOR CK/PRD/WI/03
CLASSY KONTAINERS RAW MATERIAL FEEDING 
VIZAG Rev. No/date:
Page 1 of 1 00/01.01.2019

Applicable for: - Workmen/Operator

Requirement – Hopper loader, RM drum, Raw material

 Take the information from concern person (Shift Eng./Operator) for

the following:

A. Material name, Material grade e.g., PPCP, LLDPE and Recipe no.
B. Master Batch name, Master Batch grade & Quantity.
C. Machine no. and product.

 Check the product wise recipe of material

 Take the material recipe which is in mixing condition from mixer
area to specified Injection moulding machine with respect to
product material combination.
 Put the mixed material in drum which is placed in machine.
 After feed the material in drum once check that material is suck by
hopper loader or not.
 After feeding of material close the drum by oven bag/ drum cap.
 Properly clean the bag for which there should not be any material
or mixed material.
 Put empty bags at its designated place.
 Feed the Masterbatch in masterbatch hopper loader manually and
close the cap of masterbatch.

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 WORK INSTRUCTIONS Ref. NO:
FOR CK/PRD/WI/04
CLASSY KONTAINERS
VIZAG
HOT RUNNER SYSTEM
Page 1 of 1 Rev. NO/date:
00/01.01.2019

Applicable for: - Operator / Supervisor / Engineer

Requirement: - Temperature controller,

 Connect the power supply to temperature controller from the machine

socket.
 Connect the power supply cable from temperature controller to mould.
 Switch ON the power supply of temperature controller from the
machine.
 Switch ON the temperature controller, “LED” monitor will display
 If there is no LED indicator, interchange the connector end between
mould and temp. controller & then continue the setting
 Set the temperature as per standard process parameter sheet.
 Gradually increase the temp. (50% to 70%) by knob/pressing the button.
 Wait until the actual temperature reaches the set temperature.
 Now hot runner mould is ready to start the production.

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 WORK INSTRUCTIONS
FOR Ref. No:
CLASSY KONTAINERS GRINDING OPERATION CK/PRD/WI/05
VIZAG Rev. NO/date:
00/01.01.2019
Page 1 of 1

Applicable for: – Workmen / Operator

Requirement: - Grinder / Rejected products

 Before the starting the grinding machine, be ensure about all blades
and bolts are tighten and free rotation of grinding blades,
If not
A) Tighten the bolts and blades
B) Clears the material from grinder to get free rotation.

 If ok, then switch ON motor.

 Set free the grinder in rotation condition for some times.
 Check the previous grinded material inside the grinder to get free
from rotation.
 If same type of material and color to be grinded as previously used
then feed the component in hopper of same material.
 If different type of colored material and color to be grinded, then after
free rotation.
 Switch OFF motor.
 Remove the previous material.
 Loosen the Allen bolts by using Allen key.
 Open the front cover clean the blades and grinder by compressed air.
 Close the front cover & tighten the Allen bolts by using Allen key.
 Switch ON motor.
 Feed the material into the hopper one by one so that grinder could not
chock.
 After grinding pack all types of material into woven sacks bags.
 Weight the bags and write the color and weight on bags.
 Enter the Quantity of grinded material into the grinding report under
receive column.

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 WORK INSTRUCTION Ref .No:
CLASSY KONTAINERS CK/PRD/WI/02
FOR
VIZAG MIXING OPERATION Rev.NO/date:
Page 1 of 1 00/01.01.2019

Applicable for: - Workmen / Operator

Requirement: - Mixer, Raw material

 As per Quality Plan (Product wise Raw material Combination) take

material near to mixing machine.
 Clean the bag with cloth & open the bag by removing the stretch (do
not cut the bag with blade knife).
 Empty the mixer drum if material is inside.
 Put the PPCP material into the mixer drum (4 Bag once).
 If regrinding material available of that material, then add % of
regarding according to the quality plan.
 Add LLDPE as per defined in Quality Plan.
 Mix the material as per set up time (5 Minute).
 Open the mixer drum shutter.
 Take out the mixed material from drum into the clean bag by opening
shutter of throat.
 Store the material as per recipe defined (Bag wise/Mc Wise /Product
wise)
 Close the shutter and go for next batch mixing.

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 Ref. NO:
WORK INSTRUCTION CK/PRD/WI/06
CLASSY KONTAINERS FOR
VIZAG
LOADING OF MOULD Rev. NO/date:
Page 1 of 2 00/01.01.2019

Applicable for: - Operator / Supervisor / Engineer

Requirement: - Mould, Crane, Machine, Mould Loading Tools/Safety
instruments

PROCEDURE TO START THE MACHINE WHEN THERE IS NO MOULD

(LOADING OF MOULD)

 Select the mould according to the daily production planning.

 Trace the mould location, where it is, may be in mould maintenance
area or near the machines.
 Verify the ejector system (hydraulic, pneumatic & mechanical) of the
mould.
 Check the locating ring which should match to the hole/bore of the
machine.
 Check the water and air nipples on the mould and if not fitted, bring
from the Tool room, and fixed to the mould.
 Check the mould height and it should be equal OR more than
machine minimum mould height.
 If mould height is lesser, add the required packing plate to the mould
or on machine moving platen fix the eye bolt to the tie bar of the
mould
 Take the chain & fix to eye bolt with the help of nut bolt.
 Bring the crane near to the mould & attach the mould chain securely
to the cane hook
 Switch ON power to machine
 Switch ON pump.

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 Ref. NO:
WORK INSTRUCTION CK/PRD/WI/06
FOR Rev. No/date:
CLASSY KONTAINERS
VIZAG
LOADING OF MOULD 00/01.01.2019
Page 2 of 2

PROCEDURE TO START THE MACHINE WHEN THERE IS NO MOULD

(Loading of Mould)
1. Switch ON pump
2. Extend the toggles once again fully and bring the moving platen towards the fixed
half .
3. Move the moving platen forward by operating MHA gear till the platen in flush /
touch with the mould
4. Switch OFF pump
5. Clamp the bolts to moving half mould to the moving platen.

For FERRMOATIK MILANCRON MC.

1. Place the Machine in the mould set mode of operation

1. Open the moving platen fully and pump switch off
2. Lift the mould & carefully position it between the platens. Ensure that the side
containing locating ring faces the fixed platen
3. Locate the mould by inserting the locating ring into the bore /hole provided in
fixed platen
4. Make the packing pieces from the maintenance room according to the plate
thickness of the mould
5. Take the Allen bolts, spanner, Allen keys and pope from the maintenance room
6. Clamp the bolts to the fixed half of mould to the stationary platen
7. Switch ON the pump
8. Close until the moving platen contacts the mould
9. If the mould is equipped the ejector, couple the ejector of the mould to the
machine ejection system
10. Clamp the bolts to the moving half mould to the moving platen
. Remove the crane hook from the chain
 Open the Chain from the eye bolts of the mould
 Open the eye bolt & mould lock patty from the mould
 Keep the chain, nut bolt & mould lock patty from the mould
 Keep the chain, nut bolt and mould lock patty from the mould
 Switch on the heating
 Fix the water & air nipples on both the sides of the mould by Allen keys &
spanner
 Connect the air pipes to the air nipples
 Keep the pipes spanner, Allen keys in maintenance room.

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 WORK INSTRUTIONS FOR Ref. No:
CLASSY KONTAINERS Machine start up CK/PRD/WI/07
VIZAG Page 1 of 2 Rev. No/date:
00/01.01.2019

PART-1 PROCEDURE TO START THE MACHINE WHEN THERE IS NO MOULD

(LOADING OF MOULD)
 Switch on the pump
 Go to setting mode & using mould open switch open the moving platen
 Open the water inlet outlet valves
 Check whether there is leakage of water from the nipples or not?
 If there is a leakage, tight the nipples or use Teflon tape to the threading of
nipples and again fix nipples
 Close the inlet outlet valve if there no leakage.
 Set the distance i.e. opening distance required for the mould
 Switch ON pump / Select manual mode.
 Set the locking force (i.e. tonnage)
 If the new (required) material is same as the previous material in the Hooper don’t
change the material
 If new material required (material is different than the previous material)
Take empty bag
Take out all the material into the bag
Take out all the material from RM barrel.
Till the bag and keep the material om RM store with proper identification
Use Air & cotton waste to clean the area around the hopper and inside the
hopper and RM barrel.
Load the required material in barrel/hopper and switch on the hopper loader, if
required.
 To remove the material from barrel do purging, if necessarily, with new (required)
material
 After purging move the injection unit forward until the nozzle contacts the mould
 Set the parameter as per process setting chart
 Change to mode manual to semi auto mode.
 Start the production by filling 90% of short weight.
 Prepare 5 to 6 piece with short piece.
 Open the water inlet outlet valves.
 Now fill the 100% material to make final product without short piece.
 Change the mode semi-auto to auto mode if mould runs in fully auto.
 Take QA approval, if any defect found take proper corrective action.
 Continue production after QA approval till the planning.
 Prepared by: Approved by:

Ref. No:
CLASSY KONTAINERS WORK INSTRUTIONS FOR CK/PRD/WI/07
VIZAG Machine start up
Page 2 of 2 Rev. No/date:
00/01.01.2019

PART-2 PROCEDURE TO START THE MACHINE WHEN AFTER SHUT DOWN

1. Switch ON the main switch.

2. Ensure the presence of water supply to the machine.
3. Switch ON barrel heater, open the cooling water inlet and out let
of feed zone of barrel.
4. Switch ON the hot runner temperature controller if applicable.
5. Switch ON pump.
6. Open the mould in setting mode.
7. Switch OFF the pump.
8. Clean the machine mould and conveyor by cloth.
9. When barrel temp. Reaches set values and the cold start
protection phase expires, start the pump.
10. Ensure free axial movement of the screw by injecting and
retracting the screw.
11. Open the hopper side.
12. Dose and purge the material till the melt is free from any sign of
degradation.
13. Clean the material drool from nozzle.
14. Start the production in semi auto and take 6 to 8 short shot (90%
of full shot) without water.
15. After getting some full shots open the water inlet – outlet valves
of mould cooling.
16. Run the machine in fully auto mode in case of automatic mode.
17. Take the article and check for quality and correct if any defect is
found.
18. After some good articles ask the QA person to verify the
specification regarding the articles.
19. Continue the production till quantity mentioned in planning.

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 Ref. No:
WORK INSTRUCTIONS TO STOP CK/PRD/WI/08
CLASSY KONTAINERS THE INJECTION MOULDING
VIZAG
MACHINE Rev. No/Date:
Page 1 of 1 00/01.01.2019

1. Close the Hopper from its neck by pulling the strip between barrel
and hopper
2. Close the water supply to the mould
3. Take out the material (remaining from barrel) by taking shot.
4. Change the mode auto to manual
5. Retract the screw by 30 mm to 40 mm
6. Switch off the barrel heating
7. Retract the injection unit fully back
8. Open the mould fully back
9. Check the cavity & core and assure there are no components /
articles inside the mould
10.In case of long shutdown clean the mould clean the mould
11.Clean the mould and apply anti corrosive spray or compound on
core, cavity & splits
12.Close the mould
13.Switch off the pump
14.Switch off the power to the machine

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 Ref. No:
WORK INSTRUCTIONS FOR
CLASSY KONTAINERS PARAMETER SETTING OF INJECTION CK/PRD/WI/10
VIZAG
MOULDING Rev. No/Date:
Page 1 of 2 00/01.01.2019

Sr. No. Problem Remedies

1. Short Moulding A Check the barrel heater

B Increase Injection pressure & velocity
C Increase barrel temperature
D Increase holding time & pressure

2 Stretching of rim A Increase hold on time

B Increase cooling time
C Check air time
D Polish the mould

3 Wall thickness variation A Check barrel heater

B Increase barrel heating
C Center the mould
D Check for mould problem

4 Buldging A Check chiller temperature & pressure

B Set air timer
C Increase cooling time

5 Bottom up & down A Set air time

B Check chiller temperature & pressure

6 Excessive flash moulding A Reduce barrel temperature

B Reduce injection pressure
C Increase tonnage
D Check the mould problem

7 Oily containers A Clean conveyor belt

B Arrest oil leakage

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 Ref. No:
WORK INSTRUCTIONS FOR
CLASSY KONTAINERS PARAMETER SETTING OF INJECTION CK/PRD/WI/10
VIZAG
MOULDING Rev. No/Date:
Page 2 of 2 00/01.01.2019

8 Scratches A Reduce packing in the mould

B Polish the mould

9 Shrinkage A Increase injection pressure

B Decrease injection speed
C Decrease barrel temperature

10 Air vents A Check mould air vent

11 Black spots A Check material

B Check grinding material
C Check the barrel temperature
D Clean the nozzle

12 Colour dispersion A Increase barrel heating

B Control the screw rotation
& . Increase the back pressure
C Mix master batch properly
D Increase mixing time

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 Ref. No:
CLASSY KONTAINERS WORK INSTRUCTIONS FOR CK/PRD/WI/09
VIZAG UNLOADING OF MOULD
Page 1 of 1 Rev. No/Date:
00/01.01.2019

 Keep the crane ready near the machine.

 Keep the chain, nut bolt mould lack patty, eyebolt, pipe spanner Allen keys and tool box
near the machine
 Close the hopper from its neck by pulling the strip between barrel & hopper
 Close the water supply to the mould
 Take 10 to 15 shots to warm up the mould
 Retract the injection unit fully back by pressing respective button
 Feed the natural material required into yhe hoppers to clean the barrel if necessary
 Purge out the barrel with natural material like LLDPE if necessary
 Remove the spruce runner by using girmit.
 Switch OFF heater.
 Set the machine to setting mode
 Remove the water inlet/ outlet pipes & air pipes
 Open the mould fully back
 Spray the mould protection spray / anti corrosive compound on the cavity ,core & spilt
 Close the mould in locking tonnage.
 Switch off the pump
 Fix the mould patty on the top of the mould & eye bolt to the mould patty
 Attach the chain to eye bolt with the help of nut bolt
 Bring the Crain over the mould & attach the mould chain securely to the Crain hook
 Lift the Crain up so that the chain is slightly tightened
 Open the clamp of mould from the platens by means of pipe, spanner /Allen keys
 Remove the ejector coupling if presence
 Switch ON the pump ad go for setting.
 Switch OFF the pump
 Lift the mould up by crane & slowly take out mould out of the machine tie bars
 Blow the compressed air through the cooling channel of the mould to remove the water
 Placed the mould near the machine or mould maintenance area
 Open the chain from the Crain hook
 Take out the chain from the eye bolt take out the bolt & nut
 Remove the eye bolt from the mould lock patty
 Place the chain Nut bolt Eye bolt Mould lock patty, pipe spanner, Allen keys and tool
box in maintenance room.

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