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How does a mould temperature controller contribute to reducing scrap rates?

2024/10/14 By Topstar

Injection molding waste(1)

The high scrap rate in the injection moulding process and the frequent occurrence of scrap will greatly affect the production efficiency and product quality of the entire workshop. Therefore, reducing the scrap rate can maintain profitability and improve production efficiency. Many factors can affect the occurrence of scrap rate in this injection moulding process, such as poor mould design or structure, changes in material quality, and inconsistent process parameters such as temperature, pressure, filling rate, etc. One of the essential factors is to ensure that the mould temperature remains within the optimal range throughout the injection moulding process, helping manufacturers improve product quality and reduce material waste. Therefore, we introduce how the Topstar mould temperature controller plays an important role in reducing the scrap rate of plastic manufacturers.

Maintaining the optimal mould temperature to prevent defects

Using mould temperature controllers is one of the most important ways to reduce scrap rates. They are to keep the mould at the optimal temperature. During the injection molding process, the temperature of the mold directly affects the quality of the final product. By accurately controlling the mould temperature, manufacturers can ensure that the plastic flows smoothly into the mold cavity and solidifies at the correct speed. This temperature consistency prevents common defects that would otherwise lead to increased scrap rates. If the temperature of the mold is inconsistent, it will usually result in parts that do not meet the required quality standards, resulting in increased scrap rates. By using mould temperature controllers, manufacturers can avoid these costly problems.

Mold defects

The temperature control of the mould temperature controller is not accurate

Large temperature fluctuations during the injection molding process will lead to inaccurate temperature control. This is because the mold temperature controller’s accuracy cannot meet the actual production requirements. Therefore, the Topstar mould temperature controller adopts the latest PID temperature control algorithm, which can effectively improve the temperature control efficiency by 10% and ensure the uniformity of temperature. At the same time, solid-state relays are also used for temperature control, with a response time of 0.1s.

mould temperature controller 1

In addition, the pilot version mould temperature controller includes 1MHz ultrasonic flow monitoring as standard, which monitors the media flow in real-time and detects bubbles larger than 2mm to ensure consistent liquid flow and stable, accurate temperature control. It also features a standard gas-liquid separation device, which quickly separates gas from the medium to prevent uneven mold heating. The above functions can avoid temperature mold fluctuations and reduce the defective rate by about 3%~5%.

Unstable water pressure affects the yield rate.

The mould temperature controller is a key device for improving the yield rate, but the water pressure may be unstable, and the water inlet pressure may be low during use. When the water pressure is insufficient, it is easy to dry burn the pipeline, resulting in inaccurate temperature control, which in turn affects the yield rate. Topstar’s mould temperature controller uses water pressure adaptive temperature regulation. The standard 120℃ water-type mould temperature controller is equipped with a pressure detector with a detection accuracy of 1%. The upper limit of the use temperature can be adjusted according to different water inlet pressures to ensure the normal use of the mould temperature controller when the water inlet pressure is low. In addition, the 160℃ and 180℃ mould temperature controllers use indirect cooling sealed circulation mode and micro-boosting pump water replenishment to reduce the requirements for water inlet pressure.

Water pressure adaptive temperature regulation

Solve the problem of mold rust

Residual medium inside the mold usually causes mold rust or pipeline blockage, reducing product yield. The mould temperature controller’s heat medium recovery technology completely replaces the residual medium in the mold with high-pressure gas, preventing mold damage and improving product yield. In addition, the water-type mould temperature controller comes with a water tank, uses pure water as the circulating medium, and a closed circulation system to prevent metal ions from corroding the mould and scale from clogging the mold. Lower the requirements for water quality and prevent the mold from rusting.

Support process control and reduce variability

Reducing variability is key to maintaining stable product quality and reducing scrap in any manufacturing process. Mould temperature controllers play a vital role in controlling one of the most critical process variables: temperature. By ensuring that mold temperature remains stable and consistent during each production process, manufacturers can reduce the variability that leads to defects and increased scrap rates.

Inconsistent mold temperature can lead to variations in part quality, such as differences in wall thickness, surface finish, or mechanical properties. These variations often result in scrapped parts because they need to meet the required specifications. Mould temperature controllers help eliminate these problems and maintain consistent temperatures throughout the injection molding process.

Solve different injection molding problems for you

Reducing scrap rates in injection molding can maintain profitability, improve efficiency, and reduce waste. Mould temperature controllers play a key role in achieving these goals, ensuring that the mold maintains an optimal temperature throughout the injection molding process. By preventing defects, improving product consistency, shortening cycle times, and reducing material waste, mould temperature controllers help manufacturers produce high-quality parts with less scrap.

 

 

 

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