Injection Moulding At Hillbrush

    From Concept Through To Production

    The Hillbrush Trade Moulding Division offers an injection moulding solution right the way through from initial design concept to production. We manufacture bespoke products to suit all our customer requirements. Bespoke options range from new product design to injection moulding to co-branding.

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    Hillbrush Trade Moulding

    Hillbrush is the largest UK manufacturer of hygienic cleaning products. Our plastic injection moulding machines use the latest technology and processes to deliver high speed, high quality, larger and high volume products. We create more than 2 million  products a year and serve a variety of industry sectors as well as our own hygienic range of brushes.

    Until 2011, Hillbrush had historically used external trade moulding companies to produce bespoke plastic parts and our hygiene range. As demand for our hygiene product range grew, so did the need for more flexibility and control over the moulding process and the materials being used for the hygienic range of products. Hillbrush expanded our trade moulding capabilities through acquisition and have since invested heavily to be one of the largest UK injection moulding manufacturers.

    We control all aspects of the moulding process, from sourcing FDA and EU Food Contact Approved plastics if required, to ensuring the best mix of plastics is used in composite products.

    Our state of the art moulding machines were purchased in 2014 and include an automated material feed system, an integrated cooling system and an overhead crane for quick mould changing. We have since invested in two 1000 tonne machines to keep up with high demand product lines.

    Our Capabilities

     

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    Facility

    Our modern Injection Moulding facility consists of eight of the latest injection moulding machines ranging from 90 tons to 1000 tons locking force. Each machine has an automatic material feed system which takes the polymer from an internal material silo. This is supported by two automatic dosing systems for colour and other additives such as anti-microbial and metal detectable. We have the capabilities to mould most thermal plastic materials, Polypropylene, Polyethylene, Polycarbonates, ABS, Nylon and Acetal, and also glass or mineral-filled polymers.

    Materials

    Materials used include; POM, PA66, PP, ABS, Polycarbonate, GPPS, HIPS and HDPE. Speak to a member of our team to learn more about the materials we use.

    Our Pledge To The Environment

    We constantly strive to reduce our carbon footprint, and with the predominant use of plastics in moulding we strive to recycle and reduce waste to minimise the impact on the environment.

    SO 9001 Certification

    Our ISO 9001 Certification means that we set out key quality management principles, emphasising the importance of strong customer focus, the motivation and implication of top management, the process approach and continual improvement. Hillbrush is passionate about providing the highest level of customer service and producing superior quality products. ISO 9001 compliments our company ethos and ensures our rigorous quality control processes are upheld.

    Design and Manufacture

    Our expert product design and development team can help you design your product using Solidworks or you can come to us with finished drawings and specifications. We are also able to provide quotations for mould tool design and manufacture and can project manage the entire process for you. This ensures that your custom product experience runs smoothly, is controlled and pleasurable, we pride ourselves on our customer service and communication. 

    Injection Moulding Information

    What is injection moulding?

    Plastic injection moulding is the process of melting plastic pellets (thermosetting/ thermoplastic polymers) that once malleable enough, are injected at pressure into a mould cavity, which fills and solidifies to produce the final product.

    diagram

    How does an injection mould work?

    1. Plastic pellets are mixed and fed into the hopper
    2. The screw turns and pulls the pellets through the barrel where the heaters melt them
    3. When there’s enough molten material, it is fed through the nozzle into the mould

    4. The injection unit controls speed of injection and the dwell pressure ensuring that each cavity is filled properly.
    5. Plastic enters the mould through a sprue, and moves through runners to each cavity. Runners should be the same distance to each cavity to ensure consistent filling.
    6. Once the product is cool enough, the clamping unit separates and the ejector pins push the product out. The sprue is cut off post-processing


    What is tonnage?

    A moulding machine’s tonnage refers to how much clamp force it can apply to keep the mould halves closed as molten plastic is forced into the cavity between them. The pressures needed to completely fill a mould with viscous plastic before it freezes solid are often very large. tens of thousands of pounds per square inch. Which is similar to the water pressure at the bottom of the Mariana trench (about 16,000 psi). So you need a very powerful clamp to keep the mould from opening up under that pressure. Larger, higher tonnage, machines can mould larger parts (or a larger number of parts).


    What is a mould block?

    A mould is a hollow metal block where molten plastic is injected to form a fixed shape. The plastic flows into the mould through asprue and fills cavities through runners and gates. Once the cooling process is complete, the mould is opened and the ejector rods help to eject the product from the mould.

    mould block

    Our Injection Moulding Machines

    We have a vast array of injection moulding machines that we use to their full potential, ensuring that every specification of the design can be produced. 

    All new state-of-the-art, energy efficient moulding machines have replaced the old machines. The moulding department at our new premises has an automated material feed system, all integrated cooling system and an overhead crane for quick mould changing. The department has been designed with the capability of considerably increasing the number of moulding machines.

    With the newest edition to our moulding fleet, our new state-of-the-art 1000 tonne press injection moulding machine allows us to push the boundaries of our capabilities. The new machine will allow us to continue our mission of developing and innovating the highest quality brushware, raising the benchmark even higher. Hillbrush is the UK’s largest manufacturer of brushware and hygienic cleaning tools, meaning our capabilities are constantly evolving to create solutions for challenges found in the workplace.

     

    - Hillbrush Injection Moulding Machine being installed at our facility

    Our moulding machines are highly regarded within the industry, and Hillbrush were finalists in Plastic & Rubber Weekly Magazine's Plastic Industry Awards. This award highlights companies who invest in the most energy efficient moulding machines. Our new equipment has reduced our power consumption by 50%.


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    Enquire With Hillbrush

    Enquire today to find out how Hillbrush can help you

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    Enquiry process

    Enquire today to find out how Hillbrush can help you with your bespoke moulding products. 

    Our enquiry process for trade moulding is as follows:

    1. Send us your requirements using the enquiry form at the top of this page or call us on 01747 860 494.

    2. A member of our Product Development Team will contact you to discuss your requirements and gather any additional information that we may need.

    3. You will need to provide a 3D CAD design and Product Specification Document which we use to produce an estimated cost of the mould tool and product.

    4. Mould and part costs would be offered for approval at which stage the order would be placed.

    5. The tooling is then manufactured and samples are produced for approval.

    6. Once product is approved a standard is set for production.

    7. Production is booked in and lead times are advised.

    If you have a specific trade moulding requirement and would like to send us an enquiry, please get in touch and we will be happy to help.