Laboratory Scale Root-Cause Analysis to Target Waste Reduction in Injection-Moulded Components
About TEP
Taylor Engineering & Plastics Ltd. (TEP) is a specialist UK injection moulder with capability in structural foam systems for a broad range of end-use environments. Founded in 1949, TEP expanded its moulding and painting capabilities through the 1960s and 70s and continues to invest in advanced injection moulding, ESF, DCPD, and finishing technologies.
Background
TEP experienced persistent paint blistering failures in painted structural foams, resulting in increased plastic waste, reprocessing, landfill use, and production inefficiencies. Addressing the root cause was critical to improving sustainability and operational efficiency.
Project
TEP partnered with CEAMS to conduct laboratory-scale root cause analysis. Controlled test coupons were produced and analysed using advanced diagnostics including TGA, DSC, GCMS, and Optical Microscopy at the Universities of Manchester and Liverpool. Production-line data logging was used to correlate chemistry with processing conditions.
Results
Comparative analysis across different conditioning points revealed chemical signatures linked to blister severity. The findings enabled targeted process and material interventions with potential to significantly reduce reject rates and material waste.
Impact
The project demonstrated the value of CEAMS collaboration, providing access to high-end analytical capabilities without disrupting production. The project reduced waste, shortened cycle times, de-risked R&D activity, and supported TEP’s long-term sustainability goals.