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How to improve the yield of injection molded parts by using a water chiller?

2025/02/10 By Topstar

Water Chiller 1

Other auxiliary equipment is also needed to work to ensure a higher yield rate in the production of plastic parts, in addition to using high-efficiency injection molding machines. Injection molding machines generate very high temperatures when working, especially hydraulic injection molding machines, so in addition to mould temperature controllers, a water chiller is also needed to adjust the temperature. By cooling the hydraulic oil and molds to provide precise cooling, water chillers can significantly improve injection molded parts’ efficiency, quality, and durability, which is where water coolers come into play. In this article, we will explore how to use chillers to improve the yield rate of injection molded parts.

The role of water chiller in injection molding

The low-temperature cold water produced by the water chiller can cool the hydraulic oil and molds of the injection molding machine. With its assistance, it can cool quickly, improve efficiency, and enable the physical strength and internal stress of the injection molded parts to reach the optimal state, thereby improving the mechanical properties and durability of the product. At the same time, the cooling process can also significantly improve the product’s surface finish, avoid defects caused by overheating of the material, and thus improve product quality. Topstar’s chillers utilize a more efficient refrigeration circuit design, accelerating cooling and maintaining a stable, low-temperature environment during the injection molding process, enhancing product quality and production efficiency.

Using a water chiller to enhance hydraulic oil cooling in injection molding machines

Injection molding machines rely on hydraulic systems to generate the pressure required for the molding process. However, these systems create heat, leading to overheating and reduced efficiency if not appropriately managed. The cooling process provided by the chiller reduces the temperature and improves energy efficiency. When the system effectively cools the hydraulic oil, it reduces the overall energy consumption of the injection molding machine. By keeping the hydraulic oil at a constant temperature, the water cooler helps prevent thermal degradation of the oil, which can cause increased viscosity and reduced lubrication efficiency. This reduces wear on hydraulic components, extends their service life, and minimizes downtime. Topstar’s water chillers, with their advanced refrigeration circuits, ensure that cooling is both fast and consistent, providing a stable environment for hydraulic oil management.

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Better optimization of mold temperature

The mold is one of the most critical components in the injection molding process, directly affecting the final product’s quality, dimensional accuracy, and surface finish. Temperature control of the mold is vital. Overheating or uneven cooling can lead to defects, dimensional inaccuracies, and even compromised mechanical properties of the molded part. Water chillers are great for maintaining stable and controlled mold temperatures, ensuring consistent quality output. They provide a steady supply of low-temperature water circling through the mold’s cooling channels. This rapid cooling helps quickly and evenly solidify the molten material so that the resulting part will exhibit minimal internal stress and optimal physical properties. In addition, Topstar’s water chillers feature a fully computerized temperature control system that precisely adjusts the water temperature within a range of 5-35°C, ensuring the mold always maintains optimal performance.

Injection mold

Achieve Optimal Physical Properties of Injection Molded Parts

The cooling process in injection molding also directly impacts the final product’s physical strength and internal stress. Rapid or uneven cooling can lead to internal stresses that weaken the part and make it more susceptible to cracking or failure under load.

By using a water chiller, manufacturers can achieve a controlled, gradual cooling process, which helps minimize internal stress and improve the part’s mechanical properties. In addition, reducing stress inside the material can improve mechanical properties and increase the overall service life of the part. Parts produced under controlled cooling conditions are less likely to develop microcracks or defects over time, so their service life is extended. Ensure that the plastic is cooled evenly so that the parts have higher tensile strength, impact resistance, and overall durability.

Achieving Optimal Physical Properties of Injection Molded Parts

Realize real-time monitoring and scheduling advantages

The real-time monitoring and equipment control capabilities of injection molding equipment can bring high production quality and improve efficiency. In addition to precise temperature control, the self-developed control system used by Topstar’s Water Chille supports the injection molding machine to adjust the chiller and automatically adjust it to ensure optimal performance. At the same time, it supports real-time monitoring of equipment status and records operation and alarm logs. In addition, this scheduling function allows users to program the equipment to turn on and off a week in advance, providing operational flexibility rarely seen in traditional cooling systems.

Maximize production and quality

Providing precise and efficient cooling helps optimize the molding process to produce parts with excellent mechanical properties, perfect surface finish, and consistent dimensions. Topstar’s Water Chilles has advanced cooling and intelligent control systems, providing reliable and effective solutions for manufacturers wanting to increase production capacity.

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