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Factory Overview

Terminal & Connector Processes

Terminal & Connectors

K.S Terminals Inc. is a global leader in the production of electrical cold-pressed electrical terminals. It was established in Changhua, Taiwan in 1973, leveraging high-precision mold design, stamping, and injection molding as its core technologies.

In 2002, KST became a publicly listed company on the Taiwan stock market. Its core business values have proven to be sustainable as KST continues to strive to build integral relationships with partners who share a common commitment to quality, research & development. At present, KST has five factories in Taiwan and one factory in Suzhou, China.

In 1988, KST established the Zhangbin factory and headquarters in the Changhua Binhai Industrial Zone. It is the main production base of KST, which is dedicated to manufacturing our electrical terminal and connector product lines. KST has many manufacturing processes, with varying degrees of automation for continuous stamping, welding, electroplating, assembly packaging, and warehousing. We also have a mold processing center dedicated to working with customers to design and develop their product tooling.

Customizable Automation

Our automation engineering team designs and produces automation equipment, including automatic feeding, assembly, CCD screening, inspection, counting and packaging, that allow us to yield products of consistent quality and quantity. Automation equipment and processes can be quickly integrated and configured to produce a wide range of products, promoting flexible production, and expedited shipping that meet customer delivery requirements.

From large wire terminals for power transmission to small electronic connectors for electric car charging guns, about 3.8 billion PCS and more than 20,000 types of connectors are produced and shipped from this factory every year.

More than 45 years of experience, advancement in production technology, complete certified standard laboratories, ensure product quality and safety, create KST brand awareness as global leader in the terminal and connector market.

Automation

Automation Workshop

ISO 14001

There are more than 300 automated assembly machines in the factory dedicated to various types of terminals and connectors. These assembly machines have been developed by our automation team and they have been designed to boot up quickly, be simple to maintain, and yet be highly flexible in usage.

Step 1

Raw Copper Materials

ISO 14001

Incoming Quality Control  (IQC), material inspected for visual appearance, hardness, conductivity, size and direction confirmation

Step 2

Stamping Press

Automated

A fully automatic mechanical feeder is used to place the copper material into the mold for stamping and forming at high speed. The size tolerance is maintained automatically via CCD Inspection.

At present, there are about 41 stamping presses. The annual production output for stamped products is about 1.5 billion pieces. Stamped products range in size from a minimum of 6 mm to a maximum of 150 mm.

Step 3

Annealing & Welding

Automated, CCD Inspected

An automatic annealing & welding machine is used to weld the terminal and automated CCD inspection is used to ensure 100% product yield.

Step 4

Electroplating

ISO 14001

KST’s electroplating factory is located in the National Industrial Environmental Zone. It supports fast, high-quality electroplating surface treatments. Production processes are in full compliance with government environmental regulations and emission standards.

Step 5

CCD Inspection

Automated

The finished product passes between vibrating plates, and the CCD Inspection machine can automatically detect the defective appearance of products.

The Automation Department engineer codes programs to detect abnormal quality products through PLC (programming logical controller) signals and automatically returns the materials to the defective products area.

Step 6

Terminal Assembly Machine

Automated, CCD Inspected

Automatic assembly equipment is used to insert the terminal into the insulating sheath, and CCD inspection/detection is used to ensure product tolerances and quality specifications are met.

Step 7

Terminal Reel Assembly

Automated, CCD Inspected

Automatic assembly equipment is used to place the assembled terminal onto the reel tape, and CCD inspection/detection is used to ensure product tolerances and quality specifications are met.

Step 8

Connector Assembly

Automated, CCD Inspected

Automatic assembly equipment is used to insert the terminal into the connector, and CCD inspection/detection is used to ensure product tolerances and quality specifications are met.

Step 9

Packaging

Manual & Automated

Fully automatic packaging machines can execute one-stop processes for picking, weighing, encapsulating, labeling, and barcode printing. It can not only significantly enhance packaging productivity and efficiency, but also ensure the stability and consistency of package quality.

Step 10

Labelling

Manual & Automated

Linked to the production order management system in ERP, the label printing system can fetch product specifications and customer shipping information from the synchronized database. It can print product labels for bags, boxes, cases, pallets, crates, and custom documents efficiently.

Step 11

Finished Product OQC

Automated

Products undergo Outgoing Quality Control (OQC) including optical inspection,  quantity confirmation,  as well as various electrical and performance testing.

Step 12

Continuous Improvement

ISO 14001

Continuous improvement is the ongoing improvement of products, services, or processes through incremental and breakthrough improvements. These efforts can seek “incremental” improvement over time or “breakthrough” improvement all at once.

Nylon Cable Production Process

Nylon Cable Tie

KST injection mold and cable tie product factory has an independent research team and a well-equipped laboratory that supports integrated capabilities for material analysis, product design, mold prototype design, mold processing, injection trial production, independent design capabilities, research and development team mentoring, as well as a fully equipped laboratory for verification and testing, that is also UL independent laboratory certified.

In 2008, KST started developing its cable tie product line. By 2010 KST had set up a nylon cable ties manufacturing facility. Today KST manufactures a comprehensive line of nylon cable ties, Mounting, Releasable, Heavy Duty, Markable, Plug, Push, Releasable Push Mount Cable Ties as well as Weather Resisteat UV Cable Ties.

Materials & Equipement

Plastic products are produced using quality engineered plastics and plastic injection materials from premium suppliers

In addition, we have invested in precision plastic extrusion and injection machines imported from Japan and Europe, ensuring the stability of production and quality. We have further automated the entire production line allowing us to achieve higher capacity. That means that we can achieve high customization even for an increasing number of small orders.

We use PA66 which is frequently used when high mechanical strength, rigidity, good stability under heat and/or chemical resistance are required.

Process

From injection mold production, continuous reel product production, carbon embedded injection production, all of our product lines have achieved a high degree of automation including 2.5D CCD quality inspection equipment, and undergo prescribed industry-standard environmental, strength, material, and electrical testing processes.

Nylon Cable Tie Features & Benefits

Innovations in cable tie material and production processes have led to improved structural and tensile strength. Currently, KST has developed the only cable tie product on the market made from PA66 material, that meets the pull force requirements set by the UL 62275 standard, which requires testing to -20 degrees for mounting and -40 degrees in operation.

Standard colors: Natural, black, grey, red, blue, yellow, green, orange, brown, purple, florescent yellow.
Certified: DNV, ABS, UL, ROHS
Material: PA66 (Nylon)
Flammability Rating: UL 94V-2
Max. operating temperature up to 120℃

Step 1

Raw Material

ISO 14001

Raw material Input Quality Control (IQC) includes dimensional check, visual inspection of raw materials, RV (Reduced Viscosity), MI (Melt Flow Index), examine and determine mechanical physical strength.

Step 2

Retrieve Mold and Raw Materials from storage

Materials and molds are managed by the ERP system and picked out of the warehouse via an integrated automated storage retrieval system.

Step 3

Material Drying

The central computer system automatically controls the raw material mixing, and temperature drying setting, to ensure the stability of the moisture content of the raw materials.  PA66 (Nylon) is often used because it provides high mechanical strength, rigidity, good stability under heat and chemical resistance.

Step 4

Pneumatic Pressure Delivery System

Each injection machine communicates with the central computer system to automatically monitor the required material that is delivered through the pneumatic conveyor delivery system.  By, design, it is scalable, transporting PA66 from a single source feeder to multiple destinations. 

Step 5

Injection Molding

The plastic pellets are heated, and after they are melted, they are injected into the molding. During the injection molding process, the plastic can be reinforced with embedded carbon for additional tensile strength.  KST has invested in high-speed molding machines from Japan and Europe to produce superior quality nylon cable tie products.

Step 6

Automatic CCD Inspection machine

The finished product passes between vibrating plates, and the CCD Inspection machine automatically detects visual imperfections. The Automation Department engineer codes programs to detect abnormalities in products through PLC (programming logical controller) signals and automatically returns a product that is below tolerance to the defective products area.

Step 7

Automatic Cutting

The finished product in the mold is cut and separated from the runner material through an automatic cutting machine, and automatically counted by the infrared sensor. Every 100 pieces is picked by the robot hand gripper and put into the automatic packaging machine.

Step 8

Automatic Water Spray

Nylon Cable Ties are bundled, automatically inserted into a plastic bag, and sprayed with water to allow the cable ties to continue to cure inside the packaging and ensure the stability of the moisture content of the finished product.

Step 9

Labelling

Linked to the production order management system in ERP, the label printing system can fetch product specifications and customer shipping information from the synchronized database. It can print product labels for bags, boxes, cases, pallets, crates, and custom documents efficiently.

Step 10

Finished Product is returned to Inventory

When the product attains the target moisture, Personnel will scan the ID bar code and the ERP system will transport the finished product into the automatic storage and retrieval system.

Step 11

Outgoing Quality Control (OQC)

Outgoing Quality Control (OQC) shipping inspection conducted to confirm product appearance, function, packaging, marking, and quantity. Cable ties are placed on a conveyor belt and carried to packaging operations for inspection. Here they are placed on weighing devices and then sensor counters to double-check that the packing quantity is correct. 

Step 12

Loading and Shipping

The unloading of incoming raw materials from containers and loading of outgoing finished products are synchronized to facilitate good logistical practices.

Plastic Injection Molding Processes

Plastic Injection Molding Plant

In 2010 KST set up a second plastic ejection plant to expand the design and development of our own injection molds for plastic products production. In addition to a comprehensive line of nylon cable ties, KST also manufactures insulated plastic connector sleeves, home appliance connectors, automotive connectors, green energy connectors, EV charging connectors, carbon insert injection molding, metal insert molding, cable wire insert molding, and other plastic injection mold products. At present, we have 29 plastic injection machine lines with an annual output of approximately 300 million pieces.

Plastic Injection Molding

We excel in product and mold development and welcome you to inquire about our services.

Materials & Equipement

KST injection mold and cable tie product factory has an independent research team and a well-equipped laboratory that supports integrated capabilities for material analysis, product design, mold prototype design, mold processing, injection trial production, independent design capabilities, research and development team mentoring, as well as a fully equipped laboratory for verification and testing, that is also UL independent laboratory certified.

Research and development

Plastic products are produced using quality engineered plastics and plastic injection materials from premium suppliers. In addition, we have invested in precision plastic extrusion and injection machines imported from Japan and Europe, ensuring the stability of production and quality.

Process

From injection mold production, continuous reel product production, carbon embedded injection production, all of our product lines have achieved a high degree of automation including 2.5D CCD quality inspection equipment, and undergo prescribed industry-standard environmental, strength, material, and electrical testing processes.

Plastic Injection Molding Features & Benefits:

Regardless of the industry, OEMs opt for the benefits of plastic injection molding. It’s is known for being able to produce consistent, affordable, complex products of high quality that can withstand any environment.

High Efficiency - Fast Production
Complex Part Design
Enhanced Strength
Increased flexibility - Material and Color
Reduced Waste
Can opt to use multiple types of plastics(overmold)
Product Development Timeline
High-Output Production and Consistency
Reduced weight

Plastic Injection, Insert Molding (IM), Liquid Injection Molding (LIM) Processes

Insert Molding (IM):

When a metal, plastic, or ceramic part needs to be embedded in plastic to improve product structure it is called Insert Plastic Injection Molding (IM). It is a unique process and one that K.S. TERMINALS INC. specializes in.

With IM, a part is placed in a mold cavity. Selected plastic material is injected directly around it resulting in a single part, with the insert(s) embedded in the plastic material. This process normally uses engineered plastics for improved durability, tensile strength, and weight reduction.

IM can be a highly efficient and simple alternative when compared to the assembly of individual parts using soldering, connectors, fasteners, or adhesives. It also leverages plastic capabilities and can reduce finished product costs by reducing the amount of expensive metal needed to create a part. Critical to this process, because we can use a standard single-shot injection machine for IM, tooling costs are lower than with a multi-shot process.

Plastic Injection Insert Mold

We excel in product and mold development and welcome you to inquire about our services.

IM bonds numerous components together with thermoplastic. A benefit of this process, when coupled with automation, is reduced assembly and labor costs. For example, a stamped metal insert can be used to create a perforated IM part, which effectively creates an insulated multi-path circuit.

IM can be used to eliminate fasteners and connectors. By introducing the bonded strength of resin and metal inserts, IM yields smaller, lighter, more durable components.

Engineers welcome the flexibility and possibilities that IM provides. For example, a complex stamped metal or formed part can be used in IM. The external resin provides insulation while the internal metal part provides a dedicated multi-path electric circuit.

IM components reduce the possibility for parts to loosen, become misaligned and/or become electrically disconnected. An overall benefit of thermoplastic resin is improved shock and vibration durability.

Materials:

Inserted metals including frame die castings, plated copper pins, sockets, and wire embedded into Engineering plastic or Thermo Plastic Rubber (TPR).

Plastic Injection Insert Molding (IM) Benefits:

Lower assembly and labor costs
Reduced size and weight
Improved reliability
Increased engineering flexibility

Applications

TPR + Metal Frame (3C Mechanical Parts)

ABS + Aluminum Die Casting (Sports/ Medical Parts)

Engineering Plastic + Plated Pin + Wire (Electrical Connectors)

Engineering Plastic + Copper Pin/Contact (Precision Electronic Components)

Liquid Injection Molding (LIM)

Liquid injection molding (LIM) utilizes liquid silicone rubber (LSR) or similar elastomeric material and is the preferred process for manufacturing solid silicone rubber products for its excellent durability and flexibility characteristics. Some of the common products produced by LIM are:

  • Seals and sealing membranes
  • Electrical and electronic components, such as connectors and cables
  • Medical and sterile devices
  • Kitchen goods
  • Watersports
  • Gas masks
  • Military Gear
  • Waterproof device cases
  • Infant care products
Liquid Injection Molding Injection Machine

Due to Liquid Silicone Rubber characteristics (LSR), liquid injection molding requires a streamlined and consistent mechanical mixing process rather than a labor-intensive one. The closed-loop process leverages a pump and mixing unit to mix and dispense the liquid material into a molding press. Once the curing stage is complete, the press opens, and the product is manually or robotically removed.

Liquid injection molding is one of the most cost-effective and versatile manufacturing methods currently available. It can be applied towards any industry or market, including:

  • Aerospace and aviation
  • Automotive
  • Electronics
  • Food and beverage
  • Medical and dental

Materials

Shin Etsu / Dow Corning/ GE Silicones

Liquid Injection Molding (LIM)

Liquid injection molding (LIM) utilizes liquid silicone rubber (LSR) or similar elastomeric material and is the preferred process for manufacturing solid silicone rubber products for its excellent durability and flexibility characteristics. Some of the common products produced by LIM are:

  • Seals and sealing membranes
  • Electrical and electronic components, such as connectors and cables
  • Medical and sterile devices
  • Kitchen goods
  • Watersports
  • Gas masks
  • Military Gear
  • Waterproof device cases
  • Infant care products
Liquid Injection Molding Injection Machine

Due to Liquid Silicone Rubber characteristics (LSR), liquid injection molding requires a streamlined and consistent mechanical mixing process rather than a labor-intensive one. The closed-loop process leverages a pump and mixing unit to mix and dispense the liquid material into a molding press. Once the curing stage is complete, the press opens, and the product is manually or robotically removed.

Liquid injection molding is one of the most cost-effective and versatile manufacturing methods currently available. It can be applied towards any industry or market, including:

  • Aerospace and aviation
  • Automotive
  • Electronics
  • Food and beverage
  • Medical and dental

Materials

Shin Etsu / Dow Corning/ GE Silicones

Liquid Injection Molding (LIM) Benefits:

When implemented correctly, LIM consistently produces high-quality molded components in large quantities. However, it is not always the most optimal choice. For example, it is important to consider whether silicone would be the best material to choose. Silicone tends to react with certain environmental and chemical conditions, such as pressurized steam at temperatures above 150°C, which breaks down the material’s siloxane polymer and degrades its material properties.

ADVANTAGES & APPLICATIONS:

Low viscosity and lower injection pressure, good for silicon molding

Step 1

Raw Material

Dupont, Vydyne PA66

Raw material Input Quality Control (IQC) includes dimensional check, visual inspection of raw materials, RV (Reduced Viscosity), MI (Melt Flow Index), examine and determine mechanical physical strength.

Step 2

Retrieve Mold and Raw Materials from storage

ERP, ASRS

Materials and molds are managed by the ERP system and picked out of the warehouse via an integrated automated storage retrieval system.

Step 3

Material Drying

Fanuc, Wittmann Battenfeld, JWS, Lian Fa, Multiplas

Raw material mixing, and temperature drying settings are controlled locally at each injection molding machine. 

Step 4.1

Injection Molding

The plastic injection machine dehumidifier and dryer communicate with each other. The plastic pellets are heated, and after they are melted, they are injected into the molding:

Step 4.2

Insert Molding (IM)

Insert Molding (IM) – When a metal, plastic or ceramic part needs to be embedded in plastic to improve product structure it is called Insert Plastic Injection Molding (IM).

Step 4.3

Liquid Injection Molding (LIM)

Liquid Injection Molding (LIM) – is a manufacturing process commonly used to make silicone parts (LSR) that need to withstand extreme conditions.

Step 4.4

Continuous Strip Molding (CSM)

Continuous strip molding (or reel-to-reel molding) is used to efficiently manufacture and assemble terminals and connectors by combining metal terminals and plastic components and connectors. The process uses a feed reel and a take-up reel: a continuous metal “carrier” strip is precisely indexed off the feed reel, passes through an injection mold and onto the take-up reel. The molded parts are delivered to customers still on the take-up reel and placed directly in automated production equipment for hands-off operations that add more components, install covers or form electrical connections, etc.

Step 5

Automatic CCD Inspection machine

The finished product passes between vibrating plates, and the CCD Inspection machine can automatically detect the defective appearance of products.

The Automation Department engineer codes programs to detect abnormal quality products through PLC (programming logical controller) signals and automatically returns the materials to the defective products area.

Step 6

Product moisture

Plastic products are placed in the return chamber to control temperature and humidity. The amount of time the product remains in the chamber is monitored and managed by the ERP system, which maintains the standard rate of plastic moisture absorption.

Step 7

Finished Product is returned to Inventory

When the product attains the target moisture, Personnel will scan the ID bar code and the ERP system will transport the finished product into the automatic storage and retrieval system.

Step 8

Packaging

Pass the separated finished product through an automatic packaging machine to perform automated counting, sealing, labeling, and batch number printing, and the process is complete.

Step 9

Outgoing Quality Control (OQC)

Cable ties are placed on a conveyor belt and carried to packaging operations. Here they are placed on weighing devices and then sensor counters to double check that the packing quantity is correct and to simplify the manual counting process.

Step 10

Loading and Shipping

Synchronization of incoming raw materials and outgoing finished product loading facilitates good logistical practice.