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How to use water chiller to achieve efficient and energy-saving injection molding cooling？

2025/04/11 By Topstar

Water Chiller 1

The role of the water chiller is to regulate the mold temperature during the injection molding process to prevent defects such as warping or long cycle times. In injection molding, the cooling process is as vital as the molding process. Efficient cooling ensures high-quality parts, faster production cycles, and significant energy savings; for manufacturers pursuing precision and energy saving, high-performance, high-efficiency water chillers are key to improving overall production efficiency.

Multi-compressor staged control of water chiller, energy saving, and improved efficiency.

Topstar water chillers use multi-compressor staged control, which can directly improve cooling efficiency and energy saving. In traditional refrigeration systems, one compressor is responsible for maintaining a constant cooling output regardless of how the demand changes throughout the day. This often leads to energy waste because the system will run at full capacity despite low cooling demand. Multi-compressor staged control can be activated and deactivated according to the cooling demand of the system. This staged control ensures that the chiller operates optimally and consumes only the energy required to meet the demand. While improving energy efficiency, it also extends the life of the equipment and avoids the continuous wear and tear caused by a single compressor running at full capacity.

Self-developed horizontal multi-stage centrifugal pump

In addition to the multi-compressor stage control, self-developed horizontal multi-stage centrifugal pumps are used in the chiller to improve cooling efficiency. The overall design includes multi-stage pressurization, large flow, and low-noise operation, which can improve the overall performance of the water chiller. These centrifugal pumps are responsible for circulating the coolant in the system to ensure adequate heat dissipation from the mold. The advantage of multi-stage centrifugal pumps is that they provide higher flow with lower energy consumption. The multi-stage design ensures that water is pumped constantly, especially in a large-scale injection molding production environment, to maintain a stable cooling effect. In addition to improving cooling efficiency, the centrifugal pump design also focuses on minimizing noise, allowing the water chiller to ensure a quieter and more comfortable workplace.

Small diameter parallel multi-channel coil design, faster cooling speed

The coil design of the water chiller is crucial to the heat exchange efficiency. The water chiller adopts a small diameter parallel multi-channel coil design. This efficient configuration can improve both cooling speed and pressure resistance. In this design, the coolant flows through multiple channels simultaneously, increasing the heat exchange surface area and allowing the system to cool the mold faster. The use of small diameter channels in the coil improves the flow dynamics of the coolant, ensuring a consistent temperature throughout the cooling process, resulting in faster cooling, shorter cycle times, higher production efficiency, and preventing defects such as mold warping or incomplete filling caused by temperature fluctuations. In addition to more rapid cooling, the multi-channel design also improves the system’s pressure resistance. This allows the chiller to withstand higher pressure in environments without compromising performance or safety.

Chiller Coil

Reduced weld points in the water chiller to enhance durability

The chiller’s body has been carefully designed to reduce 60% of weld points, which directly reduces the risk of weld corrosion and water leakage. Traditional chillers’ weld points are often susceptible to stress, corrosion, and damage, especially in environments with temperature fluctuations and high humidity.

The reduction in weld points also reduces the system failure rate and the need for frequent maintenance, thereby improving the overall efficiency of the chiller. At the same time, it also reduces the possibility of weak points, ensuring that the chiller can operate smoothly for a more extended period. In addition, this design improvement also improves the safety of the water chiller, reducing potential leak points, avoiding the loss of coolant and the decline in system efficiency, and ensuring that the system is more sealed and safe, thereby maintaining stable cooling performance.

Water Chiller 2-1

Added safety features

To ensure that the water chiller is safer during operation, Topstar uses door interlock circuit breakers to ensure safe operation at all times. The door interlock circuit breaker automatically cuts off the power when the access door is open, preventing the chiller from operating when the access door is open, thereby ensuring the safety of technicians and operators while the system is running. In addition to protecting the operator, this safety feature also helps maintain the integrity of the chiller’s cooling process. Opening the door while the chiller is running can cause temperature fluctuations and interrupt the cooling cycle, resulting in inefficiency and possible damage to the system. The interlock circuit breaker keeps the cooling process uninterrupted while the system runs, preventing this from happening.

Achieve efficient and energy-saving injection molding cooling

Topstar’s water chillers combine energy-saving design with practical functions directly affecting performance and efficiency. The chiller provides reliable, stable, and efficient cooling performance through multi-compressor staged control, self-developed horizontal multi-stage centrifugal pumps, multi-channel coils, and other designs. It allows more precise temperature control during molding, shortens cycle time, and improves overall productivity.

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