What Is The Process?
Injection Moulding – The raw plastic material is taken from a hopper into the extruder and is heated and forced through a nozzle to inject the plastic into the closed mould. Chilled water is passed through the cooling channels in the mould to cool the plastic and solidify it quickly.
The hydraulic motors force oil to close and lock the mould (tonnage) and open the Mould apart to release the completed product. Hot runners are electric elements that surround the plastic flow paths in the mould from the extruder to the mould cavity, these stop the plastic in the plastic runners from having to be removed when the finished part is ejected (Spru).
Full Turnkey Solutions
Aqua’s aim is to build a life-long relationship with our customers, becoming essentially a “one stop shop” for all your temperature control requirements, for now and the future. The three divisions of our business – Sales, Hire & Service – enable us to help clients every step of the way.
Our USP is our ability to offer clients a complete turnkey solution. We’ll work with you from initial site visit and system design to installation and commissioning. Our services include:
- Free design consultancy, including AutoCAD drawings, 3D modelling and energy calculations
- Mechanical and electrical installation – encompassing civil works, offloading & positioning, pipework installation, mains power and cabling, all CDM compliance, full project management and delivery
- Aftersales support – including preventive maintenance plans to maximise product lifespan and efficiency
Our business is built on our core values of technical excellence, care, integrity and a “can do” attitude. We train all our people to be specialists in what they do – innovative engineers dedicated to providing practical, effective and efficient solutions supported by second-to-none customer service.
Vinyl Presents Aims To Turn The Table On Overseas Vinyl Market
Portsmouth based Vinyl Presents are aiming to shake up the vinyl record market with their new state of the art manufacturing facility and an Aqua temperature control system is at the heart of the pressing process.
Aqua Cooling designed and installed their bespoke cooling system, as well as installing a steam heating system designed by others which works in-conjunction with the pressing machinery.
The process starts with the raw vinyl material being melted before being passed to the pressing plates that have metal stampers containing the music installed on each plate. The pressing plates are then heated with steam and squeeze the vinyl into shape and press the music onto the vinyl, chilled water quickly cools the plates so that the vinyl retains the required “record” shape. The excess vinyl is trimmed off and the records are automatically transported to cooling spindles ready for a night on the shelf before being hand sleeved and distributed to eagerly awaiting customers.
Typical Products Used In The Packaging, Plastics & Rubber Industry
Injection Moulding Cooling Considerations
- What is the temperature of the chilled water required?
- What water pressure do you require at the tools?
- What is your plastic throughput/hour?
- What type of plastic is being used?
- What is the hot runner size?
- Are the hot runners insulated?
- Is there an accumulator fitted?
- What is the hydraulic motor input power?
Why Is Cooling Required For Injection Mould Cooling Systems?
To cool the mould there are cooling pass-ways in the mould, cooling water flows around these pass ways to remove the heat from the product. This transfers the heat into the water requiring cooling. The hydraulic oil is pumped around the system at high pressure for all the robotic parts on the machine. The hydraulic oil heats up when the hydraulic pump runs caused by the machine cycling. The hydraulic oil passes through a heat exchanger with water passing through the secondary circuit removing the heat from the oil.
The hot runners add heat to the mould as they maintain the temperature of the plastic within the flow path of the mould. Some hot runners are insulated and some not, on intricate parts or very fast moulds these can be considerable in their added load.
Considerations: Free Cooling – Are tools changed regularly? If so glycol may not be wanted in the cooling circuit and therefore frost protection or free cooling must be separated – Are there accumulators? – Are the hot runners insulated?
How To Calculate The Cooling
Tools = Plastic through put x plastic factor / kcals = Cooling Duty in KW
Hydraulics = 400 kcals / 1 hour x hydraulic motor size / kcals = Cooling Duty in KW
Hot Runners = Internally Hot Runners KW Input X 0.65 = Cooling Duty in KW
Externally Hot Runners KW Input X 0.8 = Cooling Duty in KW
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Why Call Aqua?
Established in 2001, Aqua Group are a market leading force in the design and supply of innovative temperature control solutions. Our team has a vast product knowledge base and years of application experience and is focused on finding the most energy efficient and price competitive solution for your specific business needs.
Whether you’re an end user looking for a bespoke cooling system design or a trade customer trying to source a single chiller unit, our specialist engineers are on hand to help. Aqua Group’s core values – Technical Excellence, Can-do Attitude, Integrity and Care – are at the heart of everything we do, and we always strive to achieve the highest level of customer service experience.
For help with product selection and technical advice call our sales team today on 0333 004 4433.