Utilis multiduct for cable protection in critical infrastructure

Market: Infrastructure
Technique: Injection moulding
Material: HDPE recyclate
Application: Protection and orderly routing of cables and pipes

From existing moulds to reliable high-volume production

How can you adapt a large plastic product with existing moulds for reliable and scalable high-volume production?

HSV TMP advised PION Cable Protection about making the Utilis multiduct ready for production. The Utilis multiduct is a large, strong and circular plastic product that protects cables and piping in critical infrastructure. The product, which is manufactured at HSV TMP, is now in use across the world for applications including rail, energy, data centres, airports, seaports, telecoms and utility construction.

The challenge: making existing moulds suitable for series production

Before production could begin, a specific question first had to be answered. The moulds had not been developed by PION, and there was insufficient information about their technical condition. As large injection moulded products were involved, where dimensions, tolerances and a stable production process are essential, the specific question posed to HSV TMP was:

How can we prepare these large moulds for reliable production and make the Utilis suitable for high-volume injection moulding?

Optimising manufacturability and cost price
Looking beyond the plastic part to be produced.

To tackle the technical challenges at hand, we took a structured and integrated approach to deploying our knowledge of injection moulding technology and producing large plastic products. A technical inspection, mould maintenance and optimisation laid a firm foundation for high-volume production of the Utilis from recycled HDPE.

Technical inspection of large injection moulds. Each mould individually inspected and assessed.

During the inspection, we identified that the moulds required maintenance and that technical adaptations would be needed to use the moulds optimally with the machinery at HSV. The results of this inspection were transformed into a practical maintenance and optimisation proposal, including:

• technical assessment of each mould
• photos of relevant issues requiring attention
• required maintenance activities
• proposed modifications
• cost estimates
• technical explanation and discussion with PION

This transparent approach clarified in advance which steps were required to make the moulds suitable for reliable production. This reduced the technical risks and gave PION a clear picture of the required investment before production was scaled up.

Fully optimised production process

To prepare for high-volume production of the product, HSV TMP also optimised the entire production process, including:

• maximum process efficiency
• reproducible quality
• minimum cycle times
• optimal material use
• low Total Cost of Ownership

Thanks to our expertise in Design for Manufacturing (DfM), process management and automation, a production process was developed that not only delivers a high-quality product, but also lowers costs on a structural basis throughout the entire product life cycle.

Is your plastic product or mould ready for series production?

Let HSV TMP assess your product, mould and production requirements, and gain insight into manufacturability, technical points of attention and possible optimisations.

HDPE recyclate

Circular without affecting service life

It was decided to use HDPE recyclate from post-consumer waste. This means we use a circular material for a product with a very long lifespan: the expected service life is around 100 years. This combination is relevant for infrastructure projects, where sustainability plays an increasingly important role in material choices, procurement processes and project qualifications.

HDPE recyclate combines excellent mechanical properties with a considerably lower environmental impact. The material also lends itself to an efficient injection moulding process, which reduces production costs even further. Several benefits of HDPE recyclate:

• extremely strong and impact resistant
• moisture repellent
• high resistance to chemicals
• load class SN140 or higher
• fully recyclable after the use phase

Energy-efficient production at HSV

Not just the material is sustainable, but also the production process: HSV uses solar energy to produce the Utilis. Through energy-efficient production, by continually optimising processes and by using recycled raw materials where possible, we help clients realise their sustainability goals without affecting quality or performance.

LCA, EPD and ECI objective confirmation of the environmental performance of the Utilis

Alongside the technical performance of the product, assessments were carried out to objectively demonstrate its environmental performance throughout the life cycle. Various official processes were followed for the Utilis. The product has:

• LCA – Life Cycle Assessment
• EPD – Environmental Product Declaration
• ECI – Environmental Cost Indicator

The Utilis is now produced in an efficient, reproducible and cost-effective manner. This means PION benefits from a stable production partner and from a lower Total Cost of Ownership (TCO), high delivery reliability and consistent product quality.

Injection moulding of a large plastic product

The Utilis multiduct is not a standard injection moulded product.

The heaviest item weighs around 18.2 kg. With large plastic products like this, the machine capacity and mould construction are not the only important factors. Process management, dimensional stability and dimensional tolerances also play a crucial role. This is even more so if different product parts and accessories must fit together.

Production capacity that grows with international demand

Strategic collaboration to deliver innovative plastic solutions
What does this mean for your plastic product?

For clients, a successful partnership involves more than just producing plastic parts, and international growth requires more than just a good product.

The Utilis case study shows that an existing large plastic product can successfully be made production ready, provided that an integrated approach to the mould, material, machine, process and application is followed from the start. The result is a strategic partnership between the client and production partner, which leads to a high-quality technical solution that is also economically attractive.

Where HSV TMP supports organisations

With our specialist knowledge, HSV TMP can help organisations with questions related to:

• injection moulding of large plastic products
• preparing plastic products for production
• optimising existing injection moulds
• mould inspection, optimisation and maintenance
• product development and product design, optimisation of manufacturability
• high-volume production of plastic products
• upscaling of plastic production, production capacity and stock accumulation
• focus on lower Total Cost of Ownership
• consistent quality and delivery reliability
• sustainable and circular plastic solutions

By embarking on an intensive collaboration, from engineering to final product, a production process arises that grows with changing production volumes. This makes it possible to fulfil both regular deliveries from stock and larger project orders efficiently while anticipating future demand.

Collaboration: protecting critical infrastructure across the globe

PION has international ambitions, and products manufactured in the Netherlands are now used in projects across the world.

In this way, the partnership between PION and HSV TMP contributes to something that goes beyond plastic production: protecting critical infrastructure and keeping it operational across the globe.

More about the Utilis, developed for critical infrastructure

The Utilis multiduct is used across the globe for the orderly routing and protection of underground cables and piping where space is limited and reliability is essential. The compartmentalised duct is up to 24 times stronger than traditional plastic sheath tubes and is suitable for use in many different situations. The Utilis is produced in three variants: 4-compartment, 6-compartment and 9-compartment versions with a diameter of 110 mm.

Would you like to find out more about the possibilities for your plastic product?

Schedule a technical consultation with HSV TMP

Do you have an existing plastic product? Are you unsure whether your existing mould, material or production process are suitable for high-volume production? Or are you developing a new large plastic product and looking for a production partner from the engineering phase?

Our engineers can evaluate your product, mould, material choice and production process and discuss manufacturability, process optimisation and cost-efficient production. We can work with you to determine the steps required to move towards reliable, scalable high-volume production.

Discuss your plastic product with our specialists and discover how we can realise technical, production and cost benefits. Contact HSV TMP today for a technical consultation without obligation by calling +31 (0) 318 648 991.

From product idea to high-volume production. HSV TMP helps you prepare your large plastic product for production.