Improving an injection moulding machine’s cooling system is crucial for achieving efficient and high-quality production. Recently, a new customer approached us with a faulty injection moulding machine cooling system. Once we examined the machine, it was obvious to GM Diagnostics that the system in place needed to be replaced.
Their current cooling system was plagued with leaks and a massive reduction in flow rate down time was an issue. In general, the cooling system plays a vital role in controlling temperature of the mould during the injection moulding process. By optimising the cooling system, manufacturers can enhance productivity, reduce energy consumption, and enhance product quality.
Moulding Machine’s Cooling System
We put the customer in touch with Swegon Refrigeration who were able to supply them with a suitable cooler. All new 21/2” and 2” steel pipework complete with filtration and by-pass system was installed down 3 rows of the machine. Once the new cooler arrived that was installed and commissioned.
Luckily for us, we were able to install and fix the issues just in the nick of time, as 24 hours before the existing system sprung even more leaks. And although we managed a temporary repair for the new leaks, the need to get the new system up and running was evident.
Improving the Injection Moulding Machine’s Cooling System
One of the key aspects of improving the cooling system is optimising the design of cooling channels within the mould. The cooling channels facilitate the circulation of water, around the mould to extract heat and maintain the desired temperature. By strategically placing cooling channels in critical areas of the mould, heat can be efficiently dissipated, meaning faster cooling.
To enhance the cooling efficiency, a chiller unit can be employed to provide chilled water to the cooling channels. The chiller unit helps maintain a controlled cooling water temperature, ensuring effective heat transfer from the mould. By closely monitoring and adjusting the cooling water temperature, manufacturers can optimise the cooling process and achieve faster and more uniform cooling throughout the mould.
In larger-scale operations, a cooling tower can be integrated into the cooling system to dissipate the heat generated by the chiller unit. The cooling tower uses ambient air to cool the water, allowing for more efficient heat exchange. This setup can help reduce energy consumption by minimizing the load on the chiller unit, especially in warmer climates.
The Importance of Cooling Management
Cooling Time is another noteworthy consideration, which directly affects the cycle time of the injection moulding process. Manufacturers can streamline production by reducing unnecessary waiting times and increasing machine utilisation. This is by accurately determining the required cooling time for a specific mould and material combination
Proper control of the cooling circuit is essential for optimising the cooling system. It involves monitoring and adjusting parameters such as water flow rate and pressure to ensure consistent and sufficient cooling throughout the mould. Insufficient water flow can lead to hot spots and uneven cooling, resulting in quality issues.
Mould temperature control is another critical aspect of improving the cooling system. Advanced temperature control systems with precise temperature sensors and feedback mechanisms can help maintain the mould at the desired temperature. This level of control ensures consistent product quality and reduces the chances of defects caused by temperature variations.
GM Diagnostics Repair and Replacement Services
After all of this, GM Diagnostics were able to enhance production efficiency and product quality. These improvements contributed to increased productivity, improved product quality, and overall cost savings in the injection moulding process.
If you are in need of injection moulding machine services, get in touch. GM Diagnostics are able to carry out replacements, repairs and even help with maintenance services. So just fill out the contact form, by providing your enquiry and contact information.
