Efficient milk crate production with KraussMaffei injection moulding technology for the plastic packaging industry

In the plastic packaging industry market, efficiency and innovation are key to staying ahead. MCG Industries, a prominent player in South Africa’s plastic transport packaging sector, faced a significant challenge in optimising their milk crate production process.  

MCG Industries recognised the need to evolve its manufacturing capabilities to meet growing market demands while maintaining its commitment to quality and cost-effectiveness and needed to find a solution that would seamlessly integrate into their manufacturing processes. 

About MCG Industries: MCG Industries is a proudly South African company, with locations in Gauteng, Western Cape, and Namibia. Specialising in manufacturing injection moulded crates, various containers, pallets, and specialised products, catering to a wide range of markets for over 50 years. Their products serve industries such as beer, soft drinks, agriculture, dairy, bread, baked goods, meat, fish, and poultry. Additionally, they offer a selection of chairs and seats designed for schools, auditoriums, and stadiums. More about MCG Industries  

The Challenge 

MCG Industries sought to revolutionise its milk crate manufacturing process to address several critical requirements: 

• Implementation of an innovative 2-cavity mould system 

• Increase production output while simultaneously reducing costs 

• Maintain the highest standards of product quality 

• Invest in durable, long-lasting machinery 

• Ensure user-friendliness for operators 

To achieve these goals, the company needed to meet specific technical demands: 

• Utilise a 2-cavity mould design 

• Accommodate a shot weight of 2745 g 

• Achieve a cycle time of 28 seconds 

• Process PE-HD material, including regranulation 

Solution 

To address these challenges, MCG Industries decided to invest in three large MX 1000-17200 injection moulding machines from KraussMaffei. The MX 1000-17200 features: 

• Clamping force: 10,000 kN 

• Screw diameter: 150 mm 

• Handling: Falling 

The machines were customised with the following solutions:  

• HPS barrier screw: Enhances material homogenisation, ensuring high throughput and superior product quality. 

• Machine bed elevation by 600 mm: Facilitates the easy discharge of crates in all four directions within the clamping unit. 

• Performance-optimised media supply: Efficiently manages the mould’s water and oil needs. 

• Intensive operator training: Conducted in Munich to ensure seamless operation and maintenance. 

Implementation 

The implementation process involved close collaboration between MCG Industries, KraussMaffei, and the collaboration of 2 other key partners. Each partner played a crucial role in ensuring the successful deployment and integration of the solution to meet MCG’s stringent requirements. 

Key steps in the implementation included: 

1. Mould design and testing: A designed a mould with two cavities to meet the high output and quality standards. KraussMaffei tested the mould and machines to ensure they met the specified cycle time and output rates. 

1. Machine customisation: KraussMaffei customised the MX 1000-17200 machines to optimise the performance for MCG’s specific needs. This included elevating the machine bed and optimising the media supply system. 

1. Training and support: KraussMaffei provided comprehensive training for all MCG employees involved in the project. This training was essential for achieving the desired efficiency and ease of operation. 

Results 

The collaborative efforts led to significant improvements in MCG Industries’ milk crate production process: 

• Reduced cycle times: The target cycle time of 30 seconds was surpassed, achieving a stable process at 28 seconds. 

• Energy efficiency: Energy consumption was reduced by 20%, contributing to cost savings and environmental sustainability. 

• High throughput and quality: The advanced HPS barrier screw ensured high throughput with maximum material homogenisation, maintaining product quality. 

• User-friendliness: The elevated machine bed and optimised media supply facilitated easy crate discharge and overall user-friendly operations. 

MCG Industries operates three MX 1000-17200 machines at their Johannesburg location, enhancing efficiency and competitive advantage in the logistics and packaging industry and has optimised their manufacturing process for milk crates ensuring consistent quality and increased output. This implementation has improved production capabilities and reinforced their position as a leading provider of high-quality plastic transport packaging in the South African market, supporting future growth. 

Looking to improve your milk crate production and gain a competitive edge in the packaging sector?

Contact our KraussMaffei expert Matthias to explore innovative injection moulding solutions specifically tailored to your business needs in the packaging sector and milk crate production.