Automotive Case Study

Customer Description

North American Tier 1 Injection Molder

The Program

Major Auto OEM

The Challenge

Identify cost savings for the injection molder by converting the colorant from precolored compounded resin to masterbatch colorant and natural resin, blended at the injection molding machine.

The Colors

Ebony, Light Cashmere, Light Gray, Cocoa

The Parts

IP Knee Bolster, Console Undercarriage, IP Glove Box Door Outer, Door Map Pocket, Door Trim Lower, Console Class A, IP Trim Panel Glove Box, Door Switch Plate, IP Side Panel

The Polymer/Specification

ABS

The Volume

894,000 lbs.

The Investment

$187,000 (Feeder/blenders and injection molding machine upgrades)

The Result

UCC successfully converted this program from precolored compounded resin to masterbatch and natural resin, blended at the injection molding machine. By doing so, the injection molder was able to store its natural resin in resin silos located on the exterior of the building (instead of storing 2000 lb. gaylord boxes of precolored compound in the warehouse). The molder has since added additional injection molding machines to the space that once housed precolored compound inventory.

The cost difference between precolored compound and masterbatch/natural resin resulted in an annual savings of $1,164,000. The molder received a return on its investment within two months of startup.