Case Study: 30% Cost Reduction with Automated Mold Upenders

Discover how manufacturers are slashing operational costs by 30% with the integration of automated mold upenders. This case study explores how implementing automated material handling solutions streamlines mold handling, enhances safety, and significantly reduces labor expenses in heavy manufacturing environments.

The Challenge: Heavy Mold Handling and Rising Operational Costs

In today's competitive manufacturing landscape, efficiency and cost-effectiveness are paramount. For industries reliant on molds and dies – from automotive and aerospace to plastics and consumer goods – the handling of these heavy, cumbersome tools presents a significant challenge. Traditional methods often involve manual labor, overhead cranes, and forklift trucks, which are not only labor-intensive but also pose considerable safety risks and contribute to production bottlenecks.
Companies frequently grapple with:

High Labor Costs: Manual handling of molds requires a dedicated team, increasing payroll expenses and workers' compensation liabilities.
Safety Concerns: Moving heavy molds manually or with inadequate equipment leads to workplace accidents, injuries, and potential damage to valuable molds.
Inefficient Production Flow: Slow mold changeover times and cumbersome handling processes disrupt production schedules and reduce overall throughput.
Space Constraints: Storing and maneuvering large molds requires significant floor space, adding to facility overhead.
These challenges collectively erode profitability and hinder a manufacturer's ability to compete effectively. Recognizing these pain points, forward-thinking manufacturers are turning to automation to revolutionize their mold handling processes.

The Solution: Automated Mold Upenders – A Game Changer

Automated mold upenders, also known as tilters, are engineered to safely and efficiently rotate heavy and bulky loads, such as molds, dies, coils, and other industrial materials. By automating the tipping and turning process, these machines offer a significant leap forward from manual handling methods.
Cherry's Industrial Equipment, a leader in material handling solutions, offers high-cycle, heavy-duty mold upenders designed for demanding 24/7 operations. These robust machines are built to handle loads ranging from 3,000 lbs to over 12,000 lbs and can be customized to accommodate diverse load configurations, sizes, and operational environments.
Key features of automated mold upenders include:

90-degree Turning Radius: Provides exceptional flexibility for tipping and turning loads, adapting to various production needs.
Heavy-Duty Welded Steel Construction: Ensures durability and reliability in demanding industrial settings.
Hydraulic Operation: Offers powerful and controlled tilting, minimizing the risk of damage to molds and equipment.
Push-Button Controls: Simplified operation, often accessible from a forklift for ease of integration within existing workflows.
Safety Features: Maintenance locks, counterbalance valves, and foot obstruction photo eyes prioritize operator safety and prevent accidents.
Customization Options: Tailored solutions to meet specific payload capacities, dimensions, and automation requirements.

Case Study: Manufacturing Plant Achieves 30% Cost Reduction with Mold Upender Automation

To illustrate the transformative impact of automated mold upenders, consider a case study from a mid-sized manufacturing plant specializing in plastic injection molding for the automotive industry. This plant, facing increasing production demands and escalating labor costs, sought to optimize its mold handling process.
Before Automation:
The plant relied heavily on manual labor and forklift trucks to handle molds, which ranged from 5,000 lbs to 10,000 lbs. Mold changeovers were time-consuming, requiring a team of four workers and taking an average of 45 minutes per change. The manual process was also prone to safety incidents, with minor mold damage occurring periodically due to mishandling. Labor costs for mold handling alone were exceeding $150,000 annually.
Implementing Automated Mold Upenders:
The plant invested in two heavy-duty hydraulic mold upenders from Cherry's Industrial Equipment, integrated strategically within their mold storage and injection molding areas. These upenders were customized with flat platforms and safety interlocks to ensure seamless and secure mold handling. Operator training was provided to ensure efficient and safe utilization of the new equipment.
After Automation: 30% Cost Reduction and Enhanced Efficiency
The implementation of automated mold upenders yielded remarkable results:

Labor Cost Reduction: The mold changeover process now required only two operators, freeing up two workers for other productive tasks. This directly translated to a 50% reduction in labor dedicated to mold handling, contributing significantly to the overall 30% cost reduction in operational expenses related to mold management.
Increased Efficiency: Mold changeover time was reduced from 45 minutes to just 15 minutes, a 67% improvement. This accelerated production cycles, allowing for increased output and faster response to customer orders.

Enhanced Safety: The automated upenders eliminated the need for manual lifting and precarious maneuvering of heavy molds, drastically minimizing the risk of workplace accidents and mold damage. The plant reported a 90% decrease in mold damage incidents within the first year of implementation.
Space Optimization: While not directly reducing floor space, the improved organization and streamlined process enabled better utilization of the existing space, reducing clutter and improving workflow.

Reduced Material Costs: While the primary savings were in labor, the reduction in mold damage also contributed to decreased repair and replacement costs for molds, further enhancing cost savings. Data Comparison: Before vs. After Automation	Metric	Before Automation (Manual)	After Automation (Upenders)
Labor for Mold Changeover	4 Workers	2 Workers	50% Reduction
Mold Changeover Time	45 Minutes	15 Minutes	67% Reduction
Annual Labor Costs (Mold Handling)	$150,000	$105,000	30% Reduction
Mold Damage Incidents	~10 per year	~1 per year	90% Reduction

Investment and ROI:
The initial investment in the automated mold upenders was recouped within approximately 18 months, primarily due to the substantial labor cost savings and increased production efficiency. The long-term ROI is projected to be substantial, considering the extended lifespan of the equipment and the ongoing benefits in cost reduction, safety, and productivity.

Beyond Cost Savings: The Broader Benefits of Automation

While the 30% cost reduction is a compelling figure, the benefits of automated mold upenders extend far beyond immediate financial savings. Manufacturers also experience:

Improved Ergonomics: Reducing manual handling creates a safer and more ergonomic work environment, improving employee morale and reducing the risk of musculoskeletal injuries.

Increased Throughput: Faster mold changeovers and a streamlined workflow contribute to higher production volumes and quicker turnaround times.
Enhanced Product Quality: Reduced mold damage translates to consistent product quality and minimized defects.
Competitive Advantage: Increased efficiency and lower operational costs enable manufacturers to offer more competitive pricing and secure a stronger market position.

Conclusion: Embrace Automation for a Sustainable Future

The case study clearly demonstrates that automated mold upenders are not just a capital expense, but a strategic investment that yields significant returns in cost reduction, efficiency gains, and enhanced safety. For manufacturers handling heavy molds and dies, automation is no longer a luxury but a necessity for staying competitive and building a sustainable future.
By partnering with experienced providers like Cherry's Industrial Equipment, manufacturers can implement customized mold upender solutions tailored to their specific needs, unlocking substantial operational improvements and achieving significant bottom-line results. The path to a 30% cost reduction – and beyond – starts with embracing the power of automation in material handling.
Ready to explore how automated mold upenders can transform your manufacturing operations and drive down your costs? Contact Cherry's Industrial Equipment today for a consultation.