On November 25, 2025, the six-cavity injection mould numbered KS-TK25-072 by K-SHOW Moulding Co., Ltd. completed the final acceptance and was loaded for dispatch to Ashgabat, the capital of Turkmenistan. The mould is designed for the production of polypropylene (PP) daily-use packaging caps. It features six cavities, with dimensions of 600 mm × 450 mm × 420 mm and a total weight of approximately 1.1 tonnes. The mould is constructed using a combination of P20 pre-hardened steel and H13 hot work steel. The cavity surfaces are nitrided, achieving a hardness of HRC 52-54, with an expected lifespan of no less than 500,000 cycles.
1. Project Background
In July 2025, the Turkmenistan client confirmed the assignment of the KS-TK25-072 project to K-SHOW after an online factory audit and two rounds of video conferences. The technical agreement signed by both parties stipulated a moulding cycle of ≤18 seconds, a product weight deviation of ≤0.15 grams, and automatic gate separation without post-processing. The client plans to match this mould with their existing 120-tonne injection machine, targeting a monthly production capacity of approximately 800,000 pieces.
2. Design Highlights
- Runner System: A semi-hot-to-cold runner system is adopted, with a main runner diameter of Φ16 mm, a trapezoidal cross-section of 7 mm × 5 mm for the sub-runner, and a hidden gate of Φ1.2 mm for automatic shearing.
- Cooling System: Eight sets of φ10 mm cooling channels are designed on the cavity side, and six sets of φ8 mm cooling channels on the core side, with a total cooling area of approximately 0.42 square meters. According to Moldflow analysis, the product ejection temperature can be reduced to below 65 °C.
- Ejection System: A composite structure of ejector pins and stripper plates is used, with twelve ejector pins of Φ2.0 mm specification arranged at the root of the product’s strengthening ribs to ensure balanced ejection.
- Venting System: A 0.02 mm shallow groove is opened on the parting surface, in combination with three breathable steel inserts, to reduce the risk of short shots and burn marks.
3. Manufacturing and Inspection
The Mould Department organized production in accordance with the “K-SHOW Plastic Injection Mould Enterprise Standard” QB/KS 05-2024:
- CNC: Rough machining of the cavity leaves a margin of 0.25 mm. Finish machining uses an HSK-A63 tool holder, with a speed of 18000 rpm and a feed rate of 8000 mm/min, controlling dimensional tolerances within ±0.02 mm.
- EDM: Deep bone positions are completed in one go using a Φ0.3 mm electrode, with a surface roughness of Ra≤0.8 μm.
- Assembly: The clearance between guide pins and bushings is 0.015 mm, and the compression amount of the reset spring is 25%, ensuring smooth opening and closing of the mould.
- Trial Moulding: Two rounds of trial moulding were conducted on October 18 and 25, 2025, using the client-specified PP material Moplen HP648T with a melt index of 20 g/10 min. The measured moulding cycle was 16.8 seconds, the product dimensions were in accordance with the drawings, the weight deviation was 0.08 grams, the gate separated automatically, and there were no defects such as whitening or shrink marks.
4. Quality Control
The Quality Assurance Department implemented full-process control over structure, dimensions, appearance, and packaging based on the “Export Mould Inspection Checklist”:
- Dimensions: Hexagon three-coordinate measurements were taken at thirty-two critical locations, all of which were within the tolerance band.
- Surface: The cavity was polished to a #600 sandpaper grade, with no scratches or rust spots.
- Identification: The client’s name, mould number, and weight were engraved on the sides of the mould for easy warehouse management by the client.
- Rust Prevention: Shell Ensis SX 32 rust preventive oil was sprayed on. The inner layer was covered with a VCI bag, and the outer layer was reinforced with plywood boxes and steel edges to meet the protection requirements for one month of sea transportation.
5. Logistics and Delivery
This dispatch employs a multimodal transport of “road-rail-sea”:
- At 08:30 on November 25, the mould was loaded onto a vehicle with the license plate Zhejiang B7×××, heading for Ningbo Beilun Port.
- It is scheduled to be shipped on November 27, with the voyage CMA CGM TURKMENISTAN EXPRESS, on the route Ningbo—Abbas Port—Turkmenbashi.
- The total transportation time is approximately twenty-two days, and the client can collect the goods at Turkmenbashi Port with the bill of lading number.
The accompanying documents include: commercial invoice, packing list, certificate of origin, fumigation certificate, mould certificate, and the PDF version of the trial moulding report, which have been sent to the client via email in advance for customs clearance.
6. Follow-up Support
The K-SHOW Customer Service Department has established a special file for KS-TK25-072, assigned after-sales engineers for online response, and provided mould spare parts, operation and maintenance videos, as well as remote debugging guidance for the first mass production. Clients can also submit work orders through the “Service Portal” on the company’s official website to obtain technical responses within 48 hours.
The successful delivery of this order to Turkmenistan once again validates K-SHOW’s capabilities in the design, manufacturing, and delivery of multi-cavity injection moulds. The company will continue to uphold the core values of “precision, trustworthiness, and win-win” and provide continuous and stable precision mould solutions for global clients.
