Korean Journal of Chemical Engineering, Vol.39, No.12, 3179-3189, 2022
Objectives, challenges, and prospects of batch processes: Arising from injection molding applications
Injection molding, a polymer processing technique that converts thermoplastics into a variety of plastic products, is a complicated nonlinear dynamic process that interacts with a different group of variables, including the machine, the mold, the material, and the process parameters. As injection molding process operates sequentially in phases, we treat it as a batch process. The review paper discusses the batch nature of injection molding and identifies the three main objectives for future development of injection molding: higher efficiency, greater profitability, and longer sustainability. From the perspective of system engineering, our discussion centers on the primary challenges for the batch operation of injection molding systems: 1) Model development in face of product changes, 2) Control strategies in face of dynamic changes, 3) Data analysis and process monitoring, and 4) Safety assurance and quality improvement, and the current progress that has been made in addressing these challenges. In light of the advancement of new information technologies, this paper provides several opportunities and encourages further research that may break existing capability limits and develop the next generation of automation solutions to bring about a revolution in this area.
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