Cooling in the Plastics Industry: How Chillers Optimize the Injection Molding Process
The plastics manufacturing industry is one of the sectors most dependent on precise thermal control. Whether in injection molding, extrusion, or blow molding processes, the temperature of the mold and cooling fluid directly impacts the final product quality and line productivity.
The Thermal Challenge in Plastic Injection Molding
During the injection process, the molten polymer is injected into the mold at temperatures ranging from 180°C to 320°C, depending on the material. For the part to solidify correctly and be ejected without deformation, the mold must be cooled uniformly and in a controlled manner.
Common problems when cooling is inadequate:
- Warped or deformed parts
- Sink marks on the surface
- Excessively long cycle times
- Dimensional variation between parts
- Increased scrap rate
The Solution: Precision Industrial Chillers
Helioterm’s industrial chillers are specifically designed to meet the demands of the plastics industry. With temperature control of ±0.5°C, they ensure the thermal stability required for high-precision processes.
Recommended Technical Specifications
| Parameter | Typical Value |
|---|---|
| Temperature range | 5°C to 25°C |
| Control accuracy | ±0.5°C |
| Capacity | 1 to 100 TR |
| Refrigerant fluid | R-410A, R-32 |
| Voltage | 220/380/440V |
Success Story: Auto Parts Manufacturer
An auto parts manufacturer in São Paulo was facing quality issues with technical polypropylene parts. The cycle time was 45 seconds, and the scrap rate reached 8%.
Implemented solution:
- 2 Helioterm chillers of 15 TR each
- Distribution system with manifold
- Individual temperature controllers per machine
Results achieved:
- Cycle time reduced to 27 seconds (40% improvement)
- Scrap rate dropped to 1.2%
- ROI achieved in 8 months
- Energy savings of 25% compared to the previous system
Proper Sizing
To correctly size a chiller for injection molding machines, consider:
- Mold weight: Larger molds require higher cooling capacity
- Processed material: Each polymer has a specific processing temperature
- Desired cycle time: Faster cycles demand greater capacity
- Ambient temperature: Hotter environments require larger chillers
Helioterm offers free technical sizing for industrial cooling projects. Contact our engineering team.
Conclusion
Investing in quality cooling is not a cost, it’s an investment. Gains in productivity, quality, and scrap reduction pay off the equipment in a few months, while ensuring long-term operational competitiveness.
Helioterm has been manufacturing industrial chillers since 1970, with over 1,000 projects delivered to the Brazilian plastics industry.