TopChiller Injection Molding Chiller Manufacturer and Supplier China

Injection Molding Chiller-An Ultimate Buying Guide by TopChiller

An Injection Molding Chiller is used for lowering the temperature of injection molding applications.

An injection Molding Chiller is a refrigeration system, that can be utilized to provide cooling, heat transfer out of the mold temperature controller, hydraulic heat exchanger, and the feed throat of injection molding machines.

The main purpose of using an Injection Molding Chiller in injection molding applications is to keep protecting your injection molding application as it takes the very little cost of your equipment.

It provides consistent cooling to increase the production rate and efficiency of your application and also reduces scrap counts.

An Injection Molding Chiller can be water-based or air-based depending on its heat dissipation or condensation process.

Let’s begin!

What is an Injection Molding Chiller?

The term Injection molding is used for a forming process using a mold; different synthetic resins are used in this process.

The materials such as plastic are heated and melted, then sent to the mold to obtain a specific size and design.

During the process, a large amount of heat is produced that can badly affect your injection molding application.

Here Injection Molding Chiller is used and it plays a crucial role by efficiently removing unwanted heat from the system.

When the hot melted plastic is inserted into the mold cavity, an Injection Molding Chiller cools it and turns it into a solid-state by removing waste heat from the process.

Sometimes Injection Molding Chiller takes too much time to cool down your equipment brand products, but cutting its time too short can lead you to defective products.

It is an essential element for your injection molding equipment to prevent overheating and damage.

Injection Molding Chiller comes in vast ranges depending upon various specifications and sizing, you can choose the best one for your application with the help of this guide.

Injection Molding Chiller

What is the Working Principle of Injection Molding Chiller?

Most of the plastic parts used in our daily life are injection molded. An injection molding application heats the plastics.

When it becomes molten it is injected into a mold where it is cooled.

An Injection Molding Chiller reduces the cooling time and preserves the quality of your products. It transfers heat from one location (injection molding process) to another (outer air).

It commonly uses a water solution as a heat transfer medium, which requires the Injection Molding Chiller to have a pumping system and a reservoir.

An Injection Molding Chiller cools down the injection molding equipment which produces innovative products such as gearbox, barrels injection molding machines to save energy and improve the lifespan of the injection molding machine.

It provides cooling by using evaporation, compression, condensation, and expansion processes.

Working Principle of Injection Molding Chiller

What are the Major Parts of an Injection Molding Chiller?

The main components of an Injection Molding Chiller are given below:

• Compressor

It ensures the compression process of the refrigerant being used in it, through different processes by using a motor as a driving force.

• Condenser

It can be water/air-based. This unit is responsible to dissipate the unwanted heat from the system to outer air by using water/air as a medium.

• Evaporator

The evaporator in an Injection Molding Chiller is used to vaporize the coolant by giving it heat from the system to make it ready for further processes.

• Expansion Valve

An expansion Valve in an Injection Molding Chiller is used to amplify the volume of the high-pressure compressed gas to pick up heat in the evaporator.

• Water Boxes

They are used to regulate the flow of water through the system by segregating the inlets and outlets of the system.

• Power Panel

A power panel is used to power the system by using an electric power supply.

• Controller Unit

This unit is used to monitor and control the overall performance of the Injection Molding Chiller. This unit is capable of making alarms and adjustments when required.

Injection Molding Chiller Expansion Valve

What are the Features of an Injection Molding Chiller?

Some features of an Injection Molding Chiller are appended below:

• Superior reliability.
• Highly energy efficient.
• Long equipment lifespan.
• It has a feature of variable frequency drive (VFD).
• Clean energy & intelligent management.
• Solution for energy-saving equipment.
• It provides an easy interface with BMS through protocols.
• It uses an ozone-friendly refrigerant HFC134a, HFC407c.
• Highly reliable design with a top-class cop.
• It is equipped with an advanced “H-smart” microprocessor-based controller.
• It offers efficient lubrication even in the event of power failure.
• Its casing is made up of Galvanized Steel.
• It is painted with Powder Coated / Polyurethane paint.
• Its Anti-freeze safety and water flow switches put it first.
• Excellent safety controllers for compressors.
• It is 100% well tested.

Injection Molding Chiller Water Flow Switch

Why Cooling is required in the Injection Molding Cycle of an Injection Molding Chiller?

In injection molding application the plastic is melted in liquid and poured into a mold and then cooled very quickly to avoid wrapping, stress, and shrinkage of the product.

Due to the following reasons injection molding cycle requires an efficient and precisely controlled Injection Molding Chiller.

• To control the temperature of the cooling fluid.
• To control the rate of mold cooling, it means to regulate the cooling process of mold which may vary from process to process and time to time.
• Maintain quality of product, if the products cooled too rapidly it may cause shrinkage, and if not cooled. May cause the DE shaping of the product
• Speed up the production rate, means that without compromising on quality the production of your injection molding machine will increase.
• Mold temperature management.
• Control the problems which may cause by over and undercooling.
• To decrease product rejection rate.

What are the Advantages of using an Injection Molding Chiller for your Injection Molding Machine?

There are many advantages of an Injection Molding Chiller. Some of its advantages for your injection molding application are as follow:

1. An Injection Molding Chiller reduces the scrap count by providing a consistent and reliable supply of the proper temperature to the injection molding process which means less scrap.
2. It offers better heat transfer rates for your application and is easy to install.
3. Less Maintenance and Downtime are required for this cooling system because an Injection Molding Chiller uses a closed water loop.

The use of better quality water will result in better heat transfer rates, less required maintenance, and decreased downtime.

4. An Injection Molding Chiller can produce much colder water (or water/glycol solution) than any of the other cooling systems by giving you certain advantages under some circumstances.
5. Highly reliable components for long time use.

What are the Applications of Injection Molding Chiller?

An Injection Molding Chiller is widely used in large industries for cooling purposes. An Injection Molding machine reduces the cooling time to improve the quality of the products.

Some industrial applications of an Injection Molding Chiller are listed below:

• Plastic injection molding applications
• Chemical & Pharmaceuticals  industries
• Engineering & Industrial applications
• Commercial & Institutional applications
• Hospitals & Hospitality
• Telecommunications
• Laser Technology
• Welding Engineering
• Aeronautical Testing Facility
• Defence Laboratory Testing facility
• Computer Chip Manufacturing
• Medical Process
• Blow Mold Machines
• Injection Molding Machines
• Plastics Processing
• Electroplating Industry
• Factory Furnaces
• Laboratory Equipment
• Food and Beverage Industry
• Food Process Industry
• Anodizing Plants
• Dye and Pigment Manufacturing
• Plasma Spray Machines
• Induction Hardening Machine
• Foundries

Applications of Injection Molding Chiller

How to Choose between the Air Condensed and Water Condensed Injection Molding Chiller?

For selection between air condensed and water condensed Injection Molding Chiller keep the following points in your mind.

• In the areas where sufficient water supply is not available air condensed Injection Molding Chiller is used.
• At places, where a cheaper and efficient cooling system is required, a water condensed Injection Molding Chiller is used.
• The water condenser is more energy-efficient than the air condenser in Injection Molding Chiller, so where energy efficiency is important water condensed Chiller may be used.
• Air condensed Injection Molding Chiller is used in applications where low maintenance is required.
• Water condensed is used where precise temperature control is required to be maintained.
• Air condensed Injection Molding Chiller may be used where less space and budget is available for installations.
• In the area where noise is of great concern, the water-cooled chiller is used.
• The air condensed Injection Molding Chiller is not used in the environmentally sensitive area, because Air condensed chiller throws heat directly into the environment.

What is the Rule of Thumb for Injection Molding Chiller Sizing?

Here are some tips to determine the size of a correct Injection Molding Chiller for your injection molding cooling application:

1. First of all, calculate the pounds of material per hour being processed. That may be a plastic material.
2. Then, determine how many kilograms per hour are required for each ton of cooling capacity.
3. Double-check if there is a water reservoir tank for the Injection Molding Chiller to determine closed-loop or open-loop for an Injection Molding Chiller.

As there is a water reservoir tank for regular extrusion or plastic extruder.

4. After that, size the cooling capacity of your equipment like the clamping force of the injection molding machine.
5. Now, confirm the water pressure and water flow rate required for an Injection Molding Chiller.
6. Combine the process and equipment cooling requirements, as for the injection molding machine; the Injection Molding Chiller needs to cool down the plastic mold only or together with the injection molding machine.

Injection Molding Chiller Water Tank

Why Insulation of Chilled Water Pipe is Necessary for your Injection Molding Chiller?

During the process, the chilled water is required to flow through pipes of an Injection Molding Chiller, which has a very low temperature.

The temperature outside the pipes may be too high that will cause the chilled water temperature to rise at higher rates.

As a result, it can reduce the efficiency of your Injection Molding Chiller, to reduce this effect the pipes in an Injection Molding Chiller are insulated by using a different insulating material.

This insulation also protects the pipes from contaminations, damage to the pipes, moisture, and condensation.  Fibre, plastic, foaming, and other materials are used for this purpose.

What should be the Quality of Water for your Injection Molding Chiller?

Mostly chilled water is used as a cooling agent in the process of injection molding, so you must know what should be the quality of water being used in an Injection Mo0lding chiller.

• The water used for Injection Molding Chiller must be treated to prevent the growth of bacteria and scaling.
• The low temperature of the water is preferred. It prevents the chiller to overwork.
• Always use soft water for your Injection Molding Chiller, if soft water is not available easily, the hard water may be treated to convert it into soft water.
• The water must be filtered before use this will remove all dust and dirt particles.

How to Reduce the Cooling Time of Injection Molding Chiller in Injection Molding Process?

The reduction in cooling time of an Injection Molding Chiller means, fast cooling and this is done to maintain the quality of your end product.

In the injection molding process on two points, heat transfer takes place

• Between plastic and mold
• Between mold and coolant.

To ensure optimum removal of heat between plastic and mold efficient coolant channels are very important.

To ensure the proper and quick cooling between mold and coolant, the coolant must be sufficiently cold.

This is the point where precise and very fast cooling is required to maintain the quality of your product.

Injection Molding Chiller Coolant

What is meant by Chilled Water Temperature Difference and Flow Rate in Injection Molding Chiller?

In a water-cooled Injection Molding Chiller, a cooling tower is used, this cooling tower lowers the temperature of the water.

This is going to be circulated into your Injection Molding Chiller to absorb heat from the injection molding process after absorbing the heat the temperature of the water is increased.

The temperature difference between chilled water and warm water is known as chilled water difference.

The term flow rate is the rate of flow of water or other coolant circulating through your Injection Molding Chiller and injection molding application to maintain the temperature of your process.

To monitor the flow rate a gauge is used, the flow rate must be maintained as prescribed, too much low flow rate will reduce cooling time, and too much high flow rate causes vibration Normally recommended flow rate is 12 ft /sec.

What are the Installation Requirements for an Injection Molding Chiller?

Prerequisite for Installation of your Injection Molding Chiller:

Your Injection Molding Chiller is required to be used in a closed room, the room should have the following characteristics.

• Ambient temperature 10 degrees Celsius(50 degrees Fahrenheit) to 40 degrees Celsius(104 degrees Fahrenheit)
• Cooling water temperature 28 to 33 degrees Celsius (82 to 91 degrees F). The water must be free of contaminants and other impurities.
• Make availability of all the tools and consumables required for installation of if injection mold chiller.
• Ensure availability of crane for offloading Injection Molding Chiller.
• Construct a platform for the Injection Molding Chiller installation in the production hall the plate form must be able to bear the load of your Injection Molding Chiller.
• The production hall must be completely ready and it should have sufficient height and width so that trucks can enter the hall.
• All the nuts and bolts are installed before placing the unit.

Injection Molding Chiller Installation

How to Maintain your Injection Molding Chiller for Higher Efficiency?

Maintenance of your Injection Molding Chiller is an essential element to get a high-quality product from your injection molding machine.

• All the water Channels must be cleaned for smooth flow of water in a water-cooled Injection Molding Chiller.
• The condenser coil must be cleaned in the monthly inspection.
• All the activities must be recorded in the logbook for future guidance.
• Inspect the earthling of your Injection Molding Chiller for resistance to the ground on an annual basis.
• Because the Injection Molding Chiller has to provide precise temperature control to the Injection molding machine to ensure a high-quality product, so get your equipment calibrated as mentioned in the manufacturing manual.
• Inspect the chiller panel security and tighten all the screws and nuts which became loose due to vibration.
• Carry out flushing and draining of the cooling tower.
• Check the system for any leakage or breakage.
• The oil filter must be cleaned if damaged then replace the filter.

Injection Molding Chiller Maintenances

FAQs of Injection Molding Chiller

When the Cooling Stage of an Injection Molding Chiller Starts?

The cooling stage in an injection molding machine starts at the finishing of the first step of injection.

It means that while your injection molding machine could be operating, it is in a cooling cycle.

What is the Cycle Sequence of an Injection Molding Application while Operating with an Injection Molding Chiller?

It operates in the following sequence:

1. Mold open.
2. Mold close.

How to Avoid Deforming during the Process of an Injection Molding Chiller?

Research the Heat distortion Temperature (HDT) of your chosen plastics, as they need to be cooled below their HDTs to avoid deformation on ejection.

How much Cooling Power do you need from an Injection Molding Chiller?

The sizes of Injection Molding Chiller are given in tons and tons do not refer to the weight of your chilling system.

It refers to the cooling power of an Injection Molding Chiller .you can determine the required cooling power by an Injection Molding Chiller.

What are the Benefits of Using Water Cooled Injection Moulding Chiller?

Water-based Injection Molding Chiller is more efficient and safe for your application as a continuous water supply provides constant cooling at a very less cost.

For the 160 grams of Injection Molding Machine, how much Tons of Cooling is required by a Water-Cooled Injection Molding Chiller?

In your injection molding machine hardly one or two units can be used for that you can buy 40 tons of water cooling towers that may help in the future if you plan for a bigger water tower.

What are the Steps to Install an Injection Molding Chiller?

• Unpack the equipment and check all the equipment as per the list. In case of any deficiency or damage supplier must inform about it.
• Place the Injection Molding Chiller on the foundation and tighten all the nuts and bolts as prescribed in the manufacture manual.
• Observe all the warnings and cautions prescribed in the manual and on the equipment during the installation of your Injection Molding Chiller.

Why Consistent Cooling Water is Essential for Mold Cycle in Injection Molding Chiller?

It is necessary during the molding cycle in an Injection Molding Chiller because the under-process material must be cured in the mold before ejection.

What is meant by Cold Slug in an Injection Molding Chiller?

A piece of small plastic drop that becomes cool and solid in the center of nozzle top during the cooling process

What is meant by the term Thermal Diffusivity in an Injection Molding Chiller?

In an Injection Molding Chiller the rate at which the higher temperature will be transmitted through the material being processed.

100% Quality Tested Injection Molding Chiller