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Improving injection molding performance at North American sites with Topstar’s water chiller solutions

2025/03/10 By Topstar

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Injection molding plants across North America often face high energy costs when using water chillers. Some traditional water chillers are inefficient, resulting in a surge in operating expenses. In addition, hard water in some parts of North America (such as the Great Lakes) causes scale accumulation that results in a 20%-30% drop in heat transfer efficiency, severe pipe corrosion, and a lack of remote monitoring and inaccurate temperature control that results in temperature deviations, with downtime repairs taking an average of 4-8 hours. Topstar has designed innovative water chiller solutions specifically to address these challenges. Our systems combine precise temperature control, strong safety mechanisms, and energy-saving innovations to improve productivity in industrial environments across North America.

How do Topstar’s water chiller improve temperature stability and injection molding performance?

Continuous cooling is essential for defect-free injection molding. Topstar’s water chiller systems use fully computerized temperature controllers to keep water temperatures within a tight range of 5–35°C (±0.5°C). This eliminates thermal fluctuations that can cause warping, dents, or incomplete filling of molded parts.

The intuitive touchscreen interface allows operators to set parameters in 30 seconds and monitor cooling performance in real-time. Unlike outdated manual systems, our automated controls adapt to ambient temperature changes, material changes, or production speeds – ensuring repeatable results across shifts. The entire control system integrates seamlessly with the injection molding machine’s control system, enabling remote monitoring and data logging, further improving the reliability of the injection molding process. Operators benefit from real-time alerts and historical data, which aids in rapid troubleshooting and continuous process improvement. By consistently achieving and maintaining optimal temperatures, manufacturers can reduce downtime caused by thermal fluctuations.

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Simplified Operations with Thermostat Technology

At the heart of Topstar’s water chiller solutions is an advanced, fully computerized thermostat, which sets these systems apart from traditional cooling equipment. The computerized thermostat is programmed to maintain water temperatures between 5°C and 35°C. In injection molding, the ability to fine-tune temperature settings ensures that molten plastic cools at the correct rate, which is critical to producing parts with optimal structural integrity and surface finish. Another key benefit of a computerized thermostat is its role in energy management. The water chiller can minimize unnecessary power consumption by operating at peak efficiency without compromising performance. This is particularly beneficial in large injection molding operations, and the advanced programming capabilities of the thermostat allow for the integration of energy-saving modes that adjust cooling intensity based on real-time production requirements.

Imported high-quality compressors and pumps for improved efficiency

The high-efficiency, safe, and durable performance benefits are attributed to using imported high-quality compressors and pumps. These key components are the power source of the water chiller, ensuring that the unit operates quietly, safely, and with minimal energy consumption. The high-quality compressors used in Topstar water chillers provide stable performance even under heavy-duty operating conditions. With compression power ranging from 5HP to 50HP, these compressors operate at peak efficiency while maintaining low noise levels. In addition to the compressors, Topstar water chillers’ pumps ensure that cooling water is evenly distributed throughout the injection molding equipment. The superior design of these pumps allows them to operate with minimal vibration and noise, further contributing to a safer and more comfortable working environment. In addition, the energy-saving operation of these pumps helps reduce the water chiller’s overall power consumption.

Efficiency improvement

304 Stainless Steel Insulated Tanks in water chiller

The 304 stainless steel insulated tanks built into Topstar’s chillers extend the system’s life and simplify maintenance. The insulated tanks withstand harsh chemicals, UV exposure, and extreme temperatures (-20°C to 50°C). Their smooth interior surface prevents scale buildup and reduces cleaning time by 40% compared to galvanized tanks.

Insulated tanks maintain a stable water temperature throughout the cooling cycle. By reducing heat loss and protecting the water from external temperature fluctuations, the tanks help ensure that the cooling process remains efficient and consistent. From a maintenance perspective, the tanks’ 304 stainless steel construction offers significant advantages, as stainless steel is resistant to rust and corrosion and has a smooth, non-porous surface that is easy to clean and disinfect.

Built-in safety features for increased safety

Unplanned downtime in production costs North American plastics manufacturers hundreds of dollars per minute on average. In the chiller design provided by Topstar, in addition to current overload protection and voltage control, the system is equipped with an electronic time-delay safety device to prevent sudden power surges or drops from affecting performance. The current overload protection stops operation during power surges, and the electronic time-delay safety device (adjustable from 3-10 minutes) ensures stable restart after power failure. If a fault occurs, the chiller will immediately sound an alarm and display the cause of the fault, allowing the operator to take corrective measures quickly. This active fault detection system minimizes downtime and resolves problems before they affect the injection molding process. The chiller protects valuable equipment and the entire production line by maintaining a high level of process safety.

Production line safety

Comprehensively improve overall operational performance.

Topstar Technology’s water chiller solutions have demonstrated their ability to improve the injection molding performance of North American factories by providing precise temperature control, powerful safety features, and significant energy savings. By integrating intelligent temperature control, comprehensive protection systems, durable 304 stainless steel water tanks, and imported high-quality compressors and pumps, Topstar can comprehensively improve the efficiency and operational performance of the North American injection molding industry.

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