The full stack of plastic manufacturing capability — injection moulding, in-house mould making, R&D and product development, colour compounding, and quality control — all operated under one roof in Lahore.
Injection moulding is APPL's primary manufacturing process. Molten polymer is injected under high pressure into a precision steel mould, cooled, and ejected as a finished part — in seconds. The process is capable of extraordinary dimensional consistency, complex geometries, and the surface quality that consumer-facing and engineering applications demand.
Our machine fleet spans 50T to 650T clamping force, covering everything from small precision components to large structural parts. Settings are locked and recorded for approved production parts, ensuring that repeat orders produce identical parts to the first approved sample.
We run single-cavity and multi-cavity tools, process a wide range of engineering polymers, and can accommodate insert moulding (brass inserts, metal components) and overmoulding (two-material parts) for appropriate applications.
Injection moulding / production floor
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Most injection moulders in Pakistan outsource tooling and pass the lead time and quality risk to their clients. APPL's in-house mould shop is a fundamental competitive advantage: we control the quality, lead time, and cost of tooling from the first cut of steel to final trial.
Our mould design process begins with a DFM review — checking your part geometry for wall thickness uniformity, draft angles, undercuts requiring side-actions, gate location, and cooling circuit design. Changes made at design stage are free. Changes after steel is cut are not.
Tooling types: single-cavity prototype moulds, multi-cavity production moulds (up to 16 cavity for small components), family moulds, and hot-runner moulds for high-volume applications requiring zero runner waste.
Mould shop / CNC machining
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Many clients come to us not with a finished design, but with a problem to solve or a product to create. Our R&D capability allows us to work from brief to production — supporting new product development projects where the part needs to be engineered from scratch.
R&D projects begin with an application review: understanding what the part needs to do, what forces and environments it will be subjected to, how it connects to other components, and the appearance and cost requirements. From this, we specify material, design the geometry, model it in 3D, review it with you, and then move to tooling and first samples.
We also support import substitution — replacing a part currently sourced internationally with a locally manufactured equivalent. We can work from the imported sample alone: measuring, modelling, advising on material match, and producing local samples for your evaluation.
R&D lab / product development
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We compound masterbatch colour on-site, meaning we control the formulation, consistency, and repeatability of every colour we produce. We match to Pantone references, RAL codes, NCS standards, and physical colour chips.
When you approve a colour at the sample stage, we retain a chip from that approved batch as the reference standard. Every subsequent production run is colour-checked against that reference before despatch — ensuring batch-to-batch colour consistency across repeat orders placed months apart.
Beyond standard colours, we develop functional compounds: UV-stabilised grades for outdoor applications, flame-retardant grades for electrical components, rubber-toughened grades for improved impact resistance, and glass-filled grades for enhanced stiffness.
Colour lab / masterbatch compounding
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Our QC process is integrated into production, not a final inspection checkbox. In-process checks are conducted at regular intervals during every production run, and critical dimensions are verified against approved drawing tolerances before any batch is cleared for packing.
Our on-site QC lab performs dimensional inspection using calibrated gauging equipment, hardness testing using Shore durometers, visual inspection against approved appearance standards, and material verification using certified supplier data.
Every approved production part has a locked process parameter sheet. When a repeat order is run, the same parameters are reloaded — ensuring moulding conditions are identical to those that produced the approved first article. Consistency is engineered in, not left to chance.
QC lab / inspection
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Don't see your material? Contact us — we process a wide range of engineering and specialty polymers.
Send us your drawing, CAD file, sample, or brief. Our engineering team reviews the part within 24 hours and responds with a quotation or specific DFM questions. Engineers review enquiries directly — not a sales layer.
Our quotation covers mould cost, per-part production price, lead times, and any DFM notes on the design. If the design has issues that would affect part quality or mould life, we flag them before you commit to tooling.
On order confirmation, mould design begins. We share the mould layout with you for approval before machining — giving you a final checkpoint on cavity layout, gate location, cooling arrangement, and ejection system.
The mould is machined in our workshop. Initial trials verify fill, cooling, and ejection before first samples are produced. Any mould corrections are implemented in-house — rapidly, without third-party delay.
First article samples are dimensionally checked and presented with a report. You evaluate fit, function, and appearance — approve for production or request modifications. We iterate until specification is met.
Production runs against locked parameters. In-process QC at intervals. Critical dimensions verified before packing. Parts despatched with any requested documentation — delivery note, material certificate, dimensional report.
Your mould is stored and maintained at APPL between orders. Repeat orders are processed against the same locked parameters — ensuring the 10,000th part matches the first approved sample.
| Process | Thermoplastic injection moulding |
| Machine tonnage range | 50T – 650T clamping force |
| Shot weight range | 1 g – 2,000 g per cycle |
| Standard tolerance | ±0.1 mm on critical features |
| Achievable tolerance | ±0.05 mm on small, simple features |
| Wall thickness range | 0.8 mm – 10 mm |
| Mould types | Single cavity, multi-cavity, family, hot runner, insert mould |
| Maximum cavitation | 16 cavities (small packaging components) |
| Surface finish options | As-moulded, polished (SPI A1–D3), textured (VDI 3400), custom grain |
| Colour | Any — in-house masterbatch; Pantone / RAL / chip matching |
| Secondary operations | Drilling, tapping, assembly, pad printing, ultrasonic welding |
| QC equipment | Calibrated gauges, Shore durometers, visual inspection standards |
| Documentation | Dimensional reports, material certificates, batch traceability |
| Minimum order qty | 500 pcs (sample) / 5,000 pcs (production) |
| Sample lead time | 3–7 weeks from mould order (complexity dependent) |
| Production lead time | 1–3 weeks (existing approved mould) |
| Quote turnaround | Within 24 hours of complete enquiry |
Send us your drawing, sample, or brief — or just describe what you need. We review it and respond within 24 hours with a clear quote and any questions needed before tooling begins.