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How does water quality affect the performance of the mould temperature controller?

2024/12/09 By Topstar

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A mould temperature controller maintains precise mould temperature so the injection molding machine can produce high-quality, defect-free products. It regulates mould temperature by delivering water or oil through cooling channels, ensuring stable and efficient production. However, the performance of a mould temperature controller also depends mainly on the water quality used in its system, as water contains higher concentrations of calcium and magnesium ions, which can easily clog water lines. In this guide, we will explore how water quality affects the efficiency, durability, and overall performance of a mould temperature controller and explain how Topstar solves this problem to prevent it from being affected by water quality.

Importance of Water Quality in Mould Temperature Controller

The water used in water-based mould temperature controllers acts as a heat transfer medium, absorbing heat from the mold and carrying it away to maintain optimal temperature levels. If water quality changes, it will affect the ability to accurately and efficiently regulate temperature. Poor water quality can cause problems such as scaling, corrosion, and clogging, which reduces heat transfer efficiency and increases energy consumption. Impurities in the water, including minerals, salts, and dissolved gases, accumulate in the mold temperature controller over time and form deposits on heat exchangers, pipes, and cooling channels, making it more difficult for the water to absorb and dissipate heat effectively. In addition, contaminated water can damage internal components, including pumps, valves, and sensors, leading to increased maintenance costs, frequent failures, and shortened equipment life.

Scaling and mineral deposits in mould temperature controller

Scaling occurs when water contains high concentrations of minerals such as calcium and magnesium, which crystallize and form hard deposits within the water channels of the mould temperature controller. This scaling forms an insulating barrier that hinders effective heat transfer, resulting in more energy consumption to maintain the required mould temperature. These scales restrict water flow, causing overheating, extended cycle times, and increased maintenance costs. Topstar’s pure water series mould temperature controllers come with a water tank, use pure water as the circulating medium, and have a closed circulation system to avoid the corrosion of metal ions on the mold and clog the mold by scale. Reduce the requirements for water quality, prevent mold rust, and ensure cleaner and more efficient operation.

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Solve corrosion protection with Teflon float

Corrosion is also a problem in the use of mould temperature controllers. When water contains dissolved gases such as oxygen or carbon dioxide, it corrodes internal components made of metals such as steel or copper, weakens pipes and heat exchangers, and causes system failures and production stoppages. To solve this problem, the closed-loop system design used by Topstar mold temperature controllers minimizes contact with air and reduces the risk of oxidation. In addition, using Teflon floats in these machines ensures high corrosion resistance, even when using poor-quality water containing oil, iron filings, or other contaminants. Topstar precisely manufactures Teflon floats using a zero-welding process, eliminating the possibility of leaks due to welding failures.

A comprehensive solution to the problem of poor water quality and pipe blockage

To better solve the problems of poor water quality and pipe blockage, Topstar has upgraded the copper heater on the water-type mould temperature controller. People know copper for its excellent ductility and thermal conductivity, which minimize the adhesion of water-borne particles and maintain the integrity of the heating element. As a result, you can increase the life span by 40% and the efficiency by 10%. You can also use it normally even when the water quality is poor.

Nickel-plated copper heater

In addition to the copper heater, Topstar also equipped the mold temperature controller with a standard 50 mesh high-precision filtration system, which further solves the problem of impurities in the water. It can capture larger particles and prevent debris from accumulating in the system. For environments with particularly poor water quality, we offer an optional 30μm filtration grade precision filter with a filtration pore size of approximately 0.03 mm – equivalent to the diameter of a human hair. This ultra-fine filtration prevents even the smallest particles from entering the system, preventing mould clogging and ensuring the water flow remains uninterrupted and clean.

High precision filter

No longer affected by poor water quality

Poor water quality will directly affect the mould temperature controller’s performance, efficiency, and life. Contamination can be prevented by adopting Teflon material floats, pure water circulation systems, closed-loop designs, and upgrading copper heaters and high-precision filtration systems, and maintenance needs can be minimized.

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