Partial view of mold sizes made in our New York factory. Shown here are molds from 275mm to 700mm.

Injection molding is the process used to produce most of today’s chocolate molds for automated production lines. It involves the manufacturing a tool or die from aluminum or other metal alloy which is then mounted into a steel bolster and then mounted into an injection molding press. The molding machine clamps the two halves of the die together with tremendous force, smallest typically being 300 tons to as much as 2000 tons. The polycarbonate, an engineering plastic resin, is then injected under very high pressure into the tool to form the chocolate mold. A bolster tool for a chocolate mold can weigh between 700lbs to 10,000 lbs depending on the mold size. In most cases the bolster must be removed by a crane/hoist system for each set of chocolate molds produced.

We have invested in master bolster tooling to produce molds for a wide range of standard chocolate molding lines. Recently we have aggressively invested in new master bolster tooling adding over a dozen new mold setups in the last few years alone. We continue to invest as the opportunities arise.

Partial view of standard carrier sizes made in our New York factory. Shown here are carriers from 275mm to 650mm

Mold carriers are available for many of the standard molding lines from 275mm series on up to the 600mm series. Mold carriers allow the use less costly vacuum form/thermoform molds on automatic or semiautomatic molding lines. Although we do not recommend their use for large production runs, they are useful for producing trial runs or sales samples. Since the vacuum form molds can be produced in a shorter period, they can also serve to form a bridge between the time of ordering injection molds and their actual completion. Thermoform/vacuum form molds can be used with or without carriers.