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Capabilities

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Injection Moulding

Co-Injection Moulding


Pad Printing

Spray & Brush Painting


Ultrasonic Welding

Hot Stamping (Rivetting)

Toolroom

Plasma Treatment



Injection Moulding

Injection Molding is at the core of our process. We have more than 60 injection molding machines, mostly All-Electric and from Milacron, Fanuc, JSW, Toshiba, Demag etc. The machines range in capacity from 75 to 420 Tons. We have capabilities of molding with cold runner, semi-hot-runner and hot-runner molds.

We inject more than 5 million pieces in a day. On an average our molds have 24 cavities, but in some cases going upto 64 cavities too. Our injection molding process uses a high level of automation from material feeding upto robotic sprue handling.

Co-Injection Moulding

Co - Injection is an injection technology in which more than 1 polymers and/or colors are injected either into the same mold or by transferring the product between different molds. This technology reduces the more labor intensive decorative processes such as pad-printing or spraying. Co-injection molding with transfer of product can be done by using horizontal or vertical injection machines in tandem. The transfer of product can be manual or robotic.

Dream Plast has made significant investments in horizontal co-injection systems and is looking for adding few more vertical systems too.

Pad Printing

Pad printing (also called tampography) is a printing process that can transfer a 2-D image onto a 3-D object. This is accomplished using an indirect offset (gravure) printing process that involves an image being transferred from the cliché via a silicone pad onto a substrate.

Dream Plast uses semi & fully automatic Pad printing machines for printing on toys. We have more than 40 Pad Printing Machine Machines (ranging from 2 to 6 colours) from G.A.A.,Tosh, Tampo Print and Happy.

Spray & Brush Painting

It is a technique used to spray a coating on toys, using the principle of venturi. High pressure spray guns, which are hand-held, are used for painting detailed work such as lips, hair and fine art. It covers large surfaces and gives an even coat of liquid. The plastic part needs to be masked using hand-made copper masks made through a process of electroplating. Inks and Paints need to be conforming, thus requiring a strong chemical management system.

We have more than 20 spray booths with sufficient space to increase this capacity. We source our inks and paints from reputed and reliable companies from across the world.

Ultrasonic Welding

Ultrasonic welding is an industrial technique where high-frequency ultrasonic acoustic vibrations are locally applied to work pieces. The pieces are held together under pressure to create a solid-state weld. It is used for plastics, especially for joining dissimilar materials to make toys.

Dream Plast has over 30 Ultrasonic Welding Machines from Branson and Evergreen.

Hot Stamping (Rivetting)

Hot stamping machines are also known as riveting machines. These machines automatically set rivets to join materials. The advantage of a riveting machine comes with the fact that it offers greater consistency, productivity and reduces cost as compared to manual riveting and sonic welding.

Toolroom

Dream Plast has an in-house tool room at its Works I in Pune. Our tool room serves for mold maintenance activities (preventive and breakdown) as well as modifications. Our tool room includes machines such as laser welding, surface grinding, drilling and EDM.

Plasma Treatment

Plasma treatment is a surface modification technique that uses a low temperature plasma discharge to impart changes in the properties of a surface. The plasma is generated by the application of high voltage to an electrode that has a sharp tip. The plasma forms at the tip. A linear array of electrodes is often used to create a curtain of plasma. Plastics are passed through the plasma curtain in order to change the surface energy of the material. This surface preparation treatment is particularly useful before pad printing of PP & PA6 parts.

Dream Plast has invested in such equipment and sourced them from GS Industrietechnologie, Germany.