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Undisclosed challenges and considerations that mould tool sellers face

In the ever-evolving landscape of sustainable manufacturing, Luxus stands at the forefront as a pioneer in recycled plastic compounding for nearly six decades. With a commitment to innovation and environmental responsibility, Luxus has become a trusted partner for companies looking to integrate recycled plastics into their manufacturing processes. However, there are critical aspects of the compounding process that often go unnoticed, particularly when it comes to the specifications of mould tools. In this blog post, we uncover the undisclosed challenges and considerations that mould tool sellers may not always share, shedding light on the intricacies of recycled plastic compounding. 

Hot Gates: Size Matters, but Shear Matters More 
One of the key considerations in mould design is the size of hot gates, which can significantly impact waste reduction. Smaller hot gates may seem like an eco-friendly choice, but there's a hidden trade-off: increased shear. Shear, in the context of plastic compounding, refers to the degradation of the polymer during processing. The finer the hot gates, the higher the shear forces, leading to potential issues such as physical imperfections like splashing and silvering marks. 

We understand the delicate balance between waste reduction and material integrity. With 59 years of experience, we can navigate these challenges and develop customized solutions that meet your specific needs. By knowing your requirements, we can specify materials and create grades that optimise performance while minimising the impact of shear forces. 

The Complex Conundrum of Melt Temperature 
Complex mouldings often demand higher melt temperatures, but this comes at a cost – reduced physical properties like impact strength. Some mould tool designers may specify running materials at hotter temperatures without fully considering the consequences. Luxus materials can be tailored to accommodate higher temperatures, but again, this requires collaboration and knowledge sharing. The more we know about your project's intricacies, the better equipped we are to design materials that strike the right balance between complexity and performance. 

Residence Time: A Crucial Factor in Degradation: 
Residence time in the barrel is another critical factor that can contribute to polymer degradation. Extended and high-heat residence times can lead to a mass of degradation issues. At Luxus, we strongly advise against prolonged exposure to high heat unless we are informed and can adjust our material formulations accordingly. Transparent communication about your manufacturing process allows us to optimize our compounds for your specific conditions, ensuring the longevity and quality of the final product. 

Knowledge is Power, Collaboration is Key 
In the world of recycled plastic compounding, knowledge is power, and collaboration is key. We invite manufacturers and mould tool designers to open a dialogue with us. By sharing your requirements, challenges, and specifications, we can work together to develop solutions that not only meet but exceed your expectations. The more we know, the more we can help you achieve your sustainability goals without compromising on quality or performance.  
Older Updates
Staff and Managing Director, Peter Atterby at Louth based plastics compounder and recycler Luxus, recently presented a cheque for £500 to St Andrew’s Hospice representative, Lucy Wood.
The Grimsby based charity cares for people with life limiting illnesses in North East Lincolnshire ( The funds were raised by staff thanks to a raffle held at the company’s 50th anniversary celebration at the Best Western Oaklands Hall Hotel in Laceby, Lincolnshire earlier this year.
Sarah Coggle, sales office manager, Luxus, explains: "We decided to do something for a local charity and St Andrew's Hospice was chosen by a colleague who has had some involvement with them. The charity was a popular choice and the raffle went down very well, especially the prize of a day off work.
"We'd also like to thank the local businesses who donated prizes. There were many good items on offer, including a meat voucher and a bike donated by J C Cook. We would also like to say thank you to our staff for their support. The hospice touches so many people's lives; it is such a vital facility."

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