Precision & Innovation in Geyser Mould Manufacturing – Our Collaboration with Sujata

In today’s fast-evolving home appliance industry, brands must ensure high-quality, efficient, and durable products to stay ahead of the competition. One of the most critical aspects of appliance manufacturing is precision mold engineering, which directly impacts product quality, cost efficiency, and production speed.

At Hongyi JIG, we take pride in delivering best-in-class mold manufacturing solutions that help industry leaders streamline production, reduce defects, and enhance performance.

One such successful collaboration was with Sujata, a well-established home appliance brand, where we developed a high-performance geyser mold that met their rigorous quality and efficiency standards.

This case study explores our approach, engineering solutions, and the impact of our mold design on Sujata’s manufacturing success.

About Sujata – A Legacy of Innovation & Quality

Sujata has been a trusted name in the Indian home appliance market for decades, known for its high-quality, innovative, and durable products. Their appliances, including mixers, grinders, juicers, and geysers, are recognized for cutting-edge technology and long-lasting performance.

When Sujata decided to expand its geyser product line, they faced challenges in mold manufacturing that required a high-precision, durable, and efficient molding solution. They needed a partner with deep expertise in mold engineering, and that’s where we stepped in.

HIGHLIGHTS

Project Size: 2

Injection Type: Cold Runner/Hot Runner

Tool Steel: Mould Base: C-45, AB Plates | Core Cavity: Domestic 73H

Cavitation Plan: Single Cavity?

Lead Time: 45 Days

Product Design – Where Engineering Meets User Needs

Product design is an iterative process that balances engineering feasibility with user functionality. Our design approach focused on:

? Refining product concepts to meet Sujata’s aesthetic and functional expectations.

? Enhancing ergonomics for easy installation and maintenance.

? Ensuring structural integrity to withstand prolonged exposure to hot water and pressure.

We used advanced CAD modeling to simulate every aspect of the mold, ensuring it met all technical and functional requirements.?

DFM & Mould Flow Analysis – Eliminating Defects Before Production

Design for Manufacturability (DFM) was a crucial phase in our project. It helped us:

? Identify potential manufacturing issues before production.

? Optimize wall thickness, draft angles, and parting lines to improve manufacturability.

? Ensure uniform cooling, reducing the chances of warpage.

Alongside DFM, Mold Flow Analysis played a key role in:

? Simulating material flow to predict how molten plastic would fill the mold.

? Optimizing gate locations for better flow balance.

? Preventing air traps and sink marks, ensuring a defect-free final product.

By integrating DFM and Mold Flow Analysis, we significantly reduced material wastage, minimized production errors, and improved efficiency.

Tooling – High-Precision Manufacturing

The tooling phase is where design meets reality. Our focus remained on ensuring engineering precision and robust tool manufacturing.

We ensured:

?? Perfect alignment & fitment for seamless assembly.

?? High-precision CNC machining for accuracy.

?? Durable materials for long-term mold performance.

Our tooling approach leveraged:

? CAD-driven NC machining for extreme accuracy.

? Hot runner systems to improve material flow and reduce waste.

? Stringent quality control to ensure consistency across all units.

Each tool component was meticulously engineered to withstand continuous production cycles, reducing the need for frequent maintenance.

Our rigorous testing and validation process ensured that each mold met Sujata’s high standards before final delivery.

Trial Sample – Testing for Perfection

Before moving into mass production, we conducted a trial sample run to analyze the mold's real-world performance. This trial phase allowed us to:

? Verify the dimensional accuracy of the geyser components.

? Assess the part’s surface finish and texture.

? Ensure optimal mold ejection without deformation.

Our testing team made minor optimizations based on trial results, ensuring the final mold met all technical requirements before full-scale production.

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Challenges in Fitment – Overcoming Precision Barriers

One of the key challenges in geyser mould manufacturing is achieving perfect fitment of components. The geyser body consists of multiple interlocking parts, and even a 0.1mm deviation can impact:

?? Water-tight sealing – Preventing leaks and ensuring longevity.

?? Structural integrity – Maintaining the geyser’s pressure resistance.

?? Aesthetic alignment – Ensuring seamless joint lines.

To overcome these challenges, we:

? Refined core-cavity alignment to eliminate mismatch issues. ? Used high-precision machining for micron-level accuracy. ? Integrated real-time quality checks to maintain 100% fitment accuracy.

These enhancements resulted in a leak-proof, highly durable, and perfectly aligned geyser mold.

The Results – Transforming Sujata’s Manufacturing Process

Our high-precision geyser mold helped Sujata achieve:

?? 25% Faster Production Cycles – Optimized cooling & mold flow reduced cycle time.

?? 30% Longer Mold Lifespan – High-quality materials and robust engineering.

?? 20% Less Material Wastage – Improved efficiency & defect prevention.

?? 100% Fitment Accuracy – Perfectly aligned components reduced post-processing.

By implementing advanced design principles, precision tooling, and cutting-edge analysis, we transformed Sujata’s manufacturing capabilities, enabling faster production, lower costs, and superior product quality.

Shaping the Future of Appliance Manufacturing

This project with Sujata demonstrates how advanced engineering, precision tooling, and expert problem-solving can create high-quality, durable, and efficient products.

As we move forward, we continue to push the boundaries of mold manufacturing, helping big brands like Sujata lead their industries with confidence.

?? Looking for precision-engineered molds for your next project? Let’s connect and create something remarkable together!

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