JC Moulding Completes Full Machinery Overhaul to Boost Efficiency and Cut Energy Costs

JC Moulding, a UK-based provider of injection moulding services, whose unique method and expertise provide injection moulded parts without the high tooling costs of legacy practices, announces a complete overhaul of machinery, replacing 25 injection moulding machines with new, energy-efficient technology to reduce running costs and support long-term competitiveness.

For years, JC Moulding operated with 25 second-hand injection moulding machines. While the company had built a reputation for reliability and quality over its 30+ years of operation, it began facing growing challenges:

• Increasing maintenance costs due to ageing and unreliable machines
• Thousands spent annually on spare parts
• Limited output capacity
• Rising concern over long-term energy costs and environmental impact

JC Moulding set out to explore the potential benefits of upgrading to modern, energy-efficient machinery. After conducting a real-time energy usage test on their existing 90-ton clamp force machine, the findings were compelling:

By switching to a new Haitian Mars 90-ton machine, the company could save approximately 75% of annual energy costs, equating to over £6,000 per machine per year.

Following a thorough due diligence process, including a site visit to Haitian’s German subsidiary, JC Moulding placed its first-ever order for a brand-new servo-hydraulic Mars moulding machine.

With a monthly energy saving, the potential efficiency gains were so substantial that it made the commercial decision an easy one; we were able to see these gains from day one. The efficiency gains, lower maintenance needs, and increased reliability led to all 25 machines being replaced.

Embracing new technology allowed JC Moulding to not only improve its bottom line but also transform the business for long-term sustainability and competitiveness. Its strategic investment in energy-efficient machinery has become a blueprint for modern manufacturing success, as well as transforming its own business.

Sustainability and circular design

With heightened environmental awareness, increasing regulations and pressure to reduce waste, the industry faces scrutiny like never before. At JC Moulding, this is seen as an opportunity, not a threat.

The philosophy is simple. Starting from part features all the way through to mouldability and material selection, the focus is on creating products that are fit for purpose and built to last. Circular design is not new; having end-of-life considerations central to the process is essential. True sustainability starts at the design stage, not as an afterthought.

Efficiency in manufacturing is a key principle bringing both environmental benefits and cost efficiencies. JC Moulding have recently installed its sixth closed-loop granulation cell, enabling zero waste for a large portion of part production. This investment demonstrates a commitment to reducing environmental impact while maintaining commercial viability. The purpose is to ensure sustainability and profitability work hand in hand, to the benefit of both customers and consumers.

Closed-loop regrind strategy

In line with this, the business focuses on both productivity and environmental objectives. One area of improvement is on site conversion of any waste that is generated to regrind. However, generating tonnes of reground material without any need or requirement takes up valuable storage space. To be successful, there is always the need to have part requirements in line with supply.

JC Moulding meet this challenge by testing the material and evaluating part performance on a case-by-case basis. On occasion, 100% reground material can be used, but JC Moulding is able to trial any mix to achieve the desired results. This reduces the need for virgin material, as well as closing the loop on the generated scrap.

Full process control

“As the plastic industry strives to meet sustainability and productivity challenges, I believe the industry must lead with innovation and continuous improvement,” said Chris Fall, Technical Director at JC Moulding. “We’re proud to be part of that movement, combining decades of injection moulding expertise with forward-thinking design and manufacturing. We like to think of ourselves as being the future of injection moulding”

One of the key distinguishing features is the process. JC Moulding controls everything, including part design, tool design, tool making, moulding, regrinding and assembly. This positions the company to achieve both sustainability and profitability while providing its customers with exceptional value and service.

Read more news from JC Moulding here.

JC Moulding Ltd
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