Patent ID: 8066920

Claim:
A method for identifying quality control defects and correcting an additive package during a base material pelletizing process to produce higher quality base material pellets for use in injection molding semi-finished (SF) lenses for ophthalmic use, comprising the steps of: providing a mold having cavities of different thicknesses including a first mold cavity with a first height X corresponding to a thickness of a SF lens and a second mold cavity with a smaller height Y; simultaneously molding the same base material pellets into an X thickness product color chipper plate within the first cavity and a Y thickness resin stabilization chipper plate within the second cavity utilizing a cycle time and temperature profile corresponding to SF lens molding conditions; performing a quality comparison between the resin stabilization chipper plate as a measure of resin stabilization and the product color chipper plate as a measure of SF lens product color; and if the quality control comparison reveals defects, adjusting one of purity or concentration of an additive package based on the degree of stabilization plate deficiencies during a base material pelletizing process.