Our plastic injection department

Located in our manufacturing plant in Botevgrad, Bulgaria, our plastic injection department is responsible for the design, validation, manufacturing, and continuous improvement of all injection-molded plastic components used in APS thermal printers and printing mechanisms. The department ensures dimensional accuracy, material integrity, process stability, and regulatory compliance across all molded parts.

1. Process governance & quality system integration

The department operates within the company’s integrated management system, including:

  • Documented molding processes, work instructions, and control plans.
  • Risk-based process management and change control.
  • Traceability of materials, molds, and production lots.
  • Compliance with customer, regulatory, and internal requirements.
  • Support for internal and external audits.

2. Mold & tooling engineering

Plastic injection engineering manages tooling throughout its lifecycle, including:

  • Mold design review and DFM/DFA collaboration with engineering and R&D.
  • Tool qualification, acceptance, and validation.
  • Preventive maintenance and tool life monitoring.
  • Tool change management and revision control.
  • Spare part management and tooling risk mitigation.

3. Injection molding process control

The department ensures stable and repeatable molding processes through:

  • Definition of validated process windows (temperature, pressure, cycle time).
  • Setup and optimization of molding parameters.
  • Use of scientific molding principles where applicable.
  • In-process monitoring and SPC for critical parameters.
  • Reaction plans for out-of-control conditions.

4. Material management & traceability

Material control is maintained through:

  • Approved material specifications and supplier qualification.
  • Lot-level traceability from raw resin to finished parts.
  • Moisture control, drying, and handling procedures.
  • Material change evaluation and validation.
  • Control of regrind and recycled materials.

Special attention is given to materials impacting thermal stability, wear resistance, dimensional consistency, and compliance.

5. Product validation & quality assurance

The department supports product conformity through:

  • First Article Inspection (FAI) and PPAP activities.
  • Dimensional, visual, and functional inspection.
  • Cosmetic and surface quality standards.
  • Ongoing conformance testing and audit sampling.
  • Non-conformance management and containment.
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6. Medical & automotive safety-critical controls

For regulated medical & automotive applications, the department ensures:

  • Validated molding processes and documented evidence.
  • Enhanced traceability and record retention.
  • Contamination control and clean handling where required.
  • Risk-based controls aligned with product use and safety.

7. Environmental management & sustainability

The plastic injection department supports environmental objectives by:

  • Monitoring and reducing energy consumption and material waste.
  • Scrap reduction and controlled use of recycled materials.
  • Compliance with environmental regulations and customer requirements.
  • Spill prevention, waste segregation, and proper disposal.
  • Continuous improvement initiatives for environmental performance.

8. Maintenance, equipment & automation

The department ensures equipment capability through:

  • Preventive and predictive maintenance of molding machines.
  • Qualification and calibration of process-monitoring sensors.
  • Automation for part handling, inspection, and packaging.
  • Downtime analysis and OEE improvement.

9. Continuous improvement & competence

The department drives improvement through:

  • Root cause analysis (5-Why, Ishikawa) and CAPA.
  • Lean manufacturing and waste reduction initiatives.
  • Operator training and certification programs.
  • Standardization of best practices across product families.

A Reliable Partner for Plastic Injection Manufacturing Excellence

Our Strengths

  • Sustainability and waste reduction focus
  • Scientific molding and process control
  • Strong tooling and material expertise
  • Integrated quality and validation

Your Benefits

  • Cost-efficient and scalable production
  • Support for medical and automotive safety requirements
  • Reliable performance and dimensional stability
  • High-precision molded parts with consistent quality



Discover the other departments in our manufacturing plant in Botevgrad, Bulgaria

ENGINEERING

Turning innovation into reliable, manufacturable, and high-performance printing solutions.

METROLOGY

Precision measurements supporting quality assurance, process control, and reliable industrial performance.

QUALITY

Quality, compliance, and operational excellence at every stage.

SUPPLY CHAIN

Smart sourcing and reliable material flow across global supply chain and operations.

LOGISTICS

Secure storage, precise handling, and reliable delivery flows.

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Contact APS today to learn more about our thermal printers and how we can create a custom solution to meet your specific requirements.

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