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How a Reworked Screw Barrel Transformed Production Efficiency By 30%

Every percentage of efficiency counts — especially when downtime costs more than hardware. A customer approached Elegant Mark Engineering with a challenge: their Injection Moulding Machine was suffering from inconsistent melt flow, low shot weight accuracy, and rising cycle times. Output had dropped nearly 25%, and energy consumption had gone up.

After detailed inspection, our team found the cause — a worn-out screw and barrel, with uneven wear in the compression and metering zones. Instead of recommending a full replacement, we proposed a rework solution that balanced cost and performance.

  • Precision sleeving was done in the worn zones.
  • The screw profile was re-engineered for improved mixing and melt homogeneity.
  • Surface hardening and polishing enhanced wear resistance and flow.

“The result? Once reinstalled, the machine showed improved performance and consistency.”

Elegant Mark Engineering — Success Story

The result

Once reinstalled, the machine showed:

  • 30% higher production efficiency
  • Improved cycle consistency
  • Reduced power consumption
  • Stable part weight with zero process variation

The customer not only saved the cost of a new set but also gained renewed performance from an existing asset — proving that the right diagnosis and precision engineering can outperform replacement.

At Elegant Mark Engineering, every rework is more than repair — it’s an opportunity to re-engineer performance.

Tags: Rework Injection Moulding Screw & Barrel Efficiency

In most cases, performance loss is caused by gradual wear in the screw, barrel, or mating components. These changes are subtle but directly affect melt quality, pressure stability, and cycle repeatability over time.

Wear usually begins where metal-to-metal contact and abrasive melt flow are continuous—such as screw flights, barrel bore, non-return valves, and high-shear zones. These areas experience stress every cycle.

Progressive wear leads to inconsistent melt flow, variation in shot weight, longer cycle times, and higher rejection rates—often before visible damage is detected.

Yes. Process adjustments can temporarily compensate for worn components, but this often increases energy consumption and accelerates further damage instead of solving the root cause.

Designing with wear in mind allows engineers to select suitable steel grades, coatings, and geometries that improve service life and reduce long-term maintenance costs.

Key considerations include:
  • Where will wear concentrate?
  • Which surfaces rub every cycle?
  • What will fail first—polymer flow or steel surface?
  • Can the component be repaired?
  • Will it survive high-shot production volumes?

Not necessarily. In many cases, process instability caused by worn steel affects plastic flow long before catastrophic metal failure occurs.

Components designed for repair or rework significantly lower total ownership cost by reducing replacement frequency, downtime, and emergency maintenance.

Not always. Some wear is unavoidable. The goal is to control, predict, and document wear behaviour so it can be managed rather than becoming a surprise failure.

Clear documentation enables informed decision-making, planned maintenance, and realistic production expectations—leading to higher uptime and consistent output.