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.