Injection Press Startup and Shutdown Checklist

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13 critical items still open - these are the highest-risk gaps.

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Safety and area before startup

Safety gates, interlocks and emergency stops tested and functionalCRITICALLockout tagout status confirmed with no locks left from maintenanceCRITICALGuards, nozzle shield and barrel covers in placeCRITICALFloor around the press clean, dry and free of resin pelletsHydraulic oil level, hoses and fittings checked for leaksCooling water supply on and manifold valves positioned correctlyHot surface and pinch point warnings visible and personal protective equipment wornCRITICAL

Material and dryer

Resin grade, color and lot match the work orderCRITICALDryer at set temperature with dew point checked for hygroscopic resinCRITICALDrying time met before material reaches the pressRegrind percentage within the approved limitLoader lines, hopper and magnet clean, no cross-contaminationResin lot recorded for traceability

Mold and tooling

Correct tool installed and tool number matches the setup sheetCRITICALClamp bolts or magnetic platen holding verifiedCRITICALWater lines connected to correct in and out ports with flow verifiedHot runner connected and temperature controller zones setMold protection and low-pressure close set before runningCRITICALParting line, vents and cavity surfaces clean and free of debrisMold lubricated on slides, leader pins and lifters per scheduleShot counter and PM status checked

Barrel heat and settings

Process sheet loaded or entered and matches the approved setupBarrel and nozzle temperatures set and soaked for the required timeCRITICALNozzle seats against the sprue bushing with correct contactPurge the barrel until clean, uniform melt is seenShot size, transfer position and cushion set for the toolEjector stroke and speed set and tested at low speedAutomation, robot or conveyor tested with the tool

First shots and release to production

Run first shots in semi-automatic and inspect for short shots or flashDimensional and visual first-piece inspection approved per control planCRITICALCycle time within standard and cushion stablePart weight recorded and within the set rangeSwitch to automatic only after stable parts are confirmedSetup and first-piece results recorded in the log or MES

Shutdown

Purge the barrel with the correct purge compound or resin, especially for temperature sensitive materialCRITICALLower barrel temperatures per procedure if the press will be idle for a long periodClose the hopper slide and clear material from throatApply mold rust preventive and close mold at low pressure if stored in the pressTurn off or reduce water flow to avoid condensation on the moldRecord shot count, scrap and issues on the shift reportLock out the press if maintenance work will followCRITICALClean the area and remove resin and scrap

Every item marked critical must be complete before production or shutdown is signed off. Adapt the list to your press type, tool and resin, and follow the manufacturer's manual and your site safety procedures.

Capture startup checklists against work orders

Optional: we can outline how to store completed checklists with the tool, press and work order in your system.

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How to use the checklist

Work through the groups in order at the beginning of each setup and again at shutdown. Tick each item as you confirm it and treat the critical items as hard stops: do not run the press with a failing interlock, with unverified lockout status, or with mold protection not set. Export the completed list to PDF or Excel to keep with the shift record. The list is a template, so remove items that do not apply and add steps specific to your presses and tools.

Use it at every tool change, not only at the start of the week
Keep a signed copy with the setup sheet for traceability
Review the list after any incident or tool damage

Why order matters

Safety checks come first because an interlock or lockout error can injure someone. Material checks follow, because wet or wrong resin causes defects that look like process problems. Mold checks protect an expensive tool before it closes, and barrel heat soak prevents cold slugs and screw damage. Only then do you take first shots, inspect, and release the press to automatic. Skipping ahead is what leads to broken tools and long troubleshooting sessions.

Purging and shutdown

How you shut down affects the next startup. Purging the barrel removes resin that could degrade, which is especially important for heat sensitive materials like PVC or acetal and for color or material changes. If the press will sit idle, lower temperatures per procedure and protect the mold surfaces from rust. Record shot counts, scrap and any issues, so maintenance and the next shift have the information.

Common mistakes

Typical errors are leaving mold protection disabled after a trial, starting production before barrel heat soak is complete, forgetting to recheck dryer dew point, and failing to record resin lot. Another is turning off cooling water while the mold is still hot, which can crack hot runner components or cause condensation. Build the checklist into your MES or shift report so it is completed and stored for every setup.

Frequently Asked Questions

How long should the barrel soak before starting?

It depends on barrel size and resin. Many shops allow at least 20 to 30 minutes after the setpoints are reached so the whole barrel and screw are uniformly heated. Follow the machine and resin supplier guidance.

Why set mold protection before running?

Mold protection detects obstructions, such as a stuck part, and stops closing at low force. It protects the cavity and parting surfaces from crush damage, which is costly to repair.

When should I purge the barrel?

Purge at resin or color changes, before shutting down heat sensitive materials, and when you see degraded melt or black specks. Use a purge compound or compatible resin recommended by the supplier.

Does this checklist replace my site safety procedures?

No. It is a general template. Always follow the machine manual, local regulations and your site lockout and safety procedures, and adapt the list to your equipment.

If you want completed setup and startup checklists captured against the work order and tool in your ERP or MES, Netray can help design that workflow.

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