Poland Moulding: Softeners Removed, Cycle Time Cut

Case Study from Hydropath Poland

Injection moulding cycle time and cooling channel scale

Injection moulding cycle time was stretching at a Polish plant because scale and biofilm in the mould cooling channels were cutting heat transfer. Rotometers needed cleaning every month, operating costs were rising, and the ion exchange softeners already in place were not solving it. In July 2017 two HydroFLOW® P120 units and one S38 were fitted to the cooling circuits and the heat exchanger, on 114 mm and 30 mm pipe. Scale and biofilm stopped bonding to the channels, cycle time came down, the monthly rotometer cleaning stopped and the softeners were removed, leaving the plant with faster cycles and less equipment.

The Challenges

• Injection moulding cycle time was stretched by scale and biofilm in the cooling channels
• Reduced heat transfer was lengthening cycles and pushing up operating costs
• Rotometers needed cleaning every month
• Ion exchange softeners were in place but not resolving the problem

The Solution

• Units installed: two HydroFLOW® P120 and one S38(now called Pearl Plus)
• Installation point: cooling circuits and heat exchanger
• Pipe size: 114 mm and 30 mm
• Installed: July 2017
• Previous treatment: ion exchange softeners, since removed

The two P120 units and the S38(now called Pearl Plus) were fitted to the cooling circuits and the heat exchanger. The signal disrupts the conditions that bond scale and biofilm to surfaces. With the channels kept clean, the ion exchange softeners could be removed, and injection moulding cycle time fell as heat transfer in the cooling channels recovered.