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Maximizing Efficiency at PMM with Secondary Operations

Plastic Injection Molding Machine, Associate machining plastic part at the molding machine.

At PMM, we pride ourselves on our commitment to efficiency and quality in the plastic molding industry. One of the key strategies we employ is the utilization of secondary operations in assembling our customers' parts. Unlike traditional methods where secondary operations are performed separately, often leading to delays and increased costs, PMM integrates these operations directly at the molding machine, improving our production process. 


How PMM Utilizes Secondary Operations: 

Our technicians seamlessly integrate secondary operations into the production workflow. As parts are taken off the machines, our skilled technicians immediately commence secondary operations right there at the molding machine. By synchronizing these operations with the machine's cycle time for the next part, we optimize productivity and eliminate downtime. This proactive approach ensures that our technicians remain efficient, leading to faster delivery times for our customers. 


Examples of Secondary Operations Performed: 


Sonic Welding 

Sonic Welding Plastic Part on the Molding Machine

Sonic welding is a process used to join two pieces of material together through high-frequency ultrasonic vibrations. This process is commonly used for plastics but can also be used to join metals.  

How it works: The two materials to be joined are positioned together with a welding tool, usually called a horn, placed against them. Pressure is then applied to hold the materials firmly together. The welding tool generates ultrasonic vibrations at a frequency typically between 20kHz to 70 kHz. The vibrations are passed through the materials, causing them to soften and become pliable. As the softened materials are pressed together from the ultrasonic vibrations, they bond together. Bonding occurs due to a combination of molecular and frictional forces. After the vibrations are stopped, the material will cool, solidify, and form a strong bond. 

Sonic welding offers several advantages including speed, precision, and the ability to create strong, hermetic seals without the need for additional adhesives or fasteners. 



Plastic part assembly at the molding machine

Assembly is a several step process that brings together individual components or parts to create a finished product. 

How it works: The parts are first inspected and prepared for assembly. Fixtures may be used to align parts accurately during assembly, following a predetermined sequence. Components are assembled using methods such as fastening with screws, bolts, or adhesives, and, if necessary, welding or soldering. Inspection ensures alignment and functionality before packaging for shipping.  


Plastic Injection Molding Machine, associate machining plastic part.

Machining involves various techniques to refine or alter the workpiece's shape, surface finish, or properties.

How it works: First, the workpiece is securely set up using clamps or fixtures. Appropriate cutting tools are then selected based on material and desired outcomes, which can include drilling, milling, turning, grinding, and other techniques. Throughout the machining process, quality control measures are implemented to ensure dimensional accuracy and surface finish. After machining, additional processes such as deburring, polishing, or coating may be applied. The finished part undergoes cleaning and inspection before packaging and shipping. Each step is carefully executed to meet specifications and ensure the final product’s quality and functionality. 

Benefits of Secondary Operations: 


Increased Efficiency and Reduced Downtime: 

By capitalizing on machine downtime for secondary operations, PMM ensures continuous productivity, minimizing idle time and maximizing resource utilization. Our technicians remain actively engaged in value-added tasks, eliminating wasted time, and expediting the production process. This proactive approach not only enhances efficiency but also translates into faster turnaround times for our customers.

Streamlined Processes with Less Part Handling: 

By performing secondary operations at the molding machine in tandem with the machine’s run time, we minimize part handling. This streamlined approach enhances quality control, as each part is meticulously handled at a single station, reducing the risk of damage or contamination. Moreover, it allows PMM to maximize plant floor space, ultimately reducing costs and enhancing overall production efficiency and safety.

Cost Reduction through Efficiency: 

This streamlined process contributes to more efficient production processes, leading to lower labor costs and increased output. By integrating these operations at the molding machine, we minimize the need for additional technicians and reduce processing time. This not only improves cost-effectiveness but also enhances quality control, as defects can be identified and rectified promptly, minimizing the expenses associated with rework or scrap. 

Accelerated Production Time: 

Integrating secondary operations at the molding machine enables PMM to expedite part production by utilizing downtime effectively. Advanced scheduling ensures that resources are optimized, minimizing delays, and ensuring timely delivery of parts. 


In conclusion, the integration of secondary operations offers unparalleled efficiency, cost-effectiveness, and quality control. By embracing this innovative approach, PMM remains at the forefront of delivering exceptional solutions to our valued customers.

Learn more about PMM’s secondary molding capabilities at:


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